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Lototo

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Lockout/Tagout (LOTO) Safety Procedures =======================================

Date: 2025-09-04

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

To understand and implement proper Lockout/Tagout procedures to prevent unexpected machine start-up or release of hazardous energy during maintenance and servicing.

Introduction

Lockout/Tagout (LOTO) is a critical safety procedure designed to protect employees from the dangers of hazardous energy release. This toolbox talk will cover the essential steps and precautions for effective LOTO implementation.

Key Points

  • Importance of LOTO: LOTO procedures prevent accidental start-up of machinery or equipment during maintenance, protecting workers from serious injury or death.
  • Authorized vs. Affected Employees: It's important to distinguish between authorized employees (those who perform LOTO) and affected employees (those who work in the area). Only authorized employees can perform lockout/tagout procedures.
  • Energy Isolation: Identify all energy sources (electrical, mechanical, hydraulic, pneumatic, thermal, etc.) and ensure they are properly isolated before starting work.
  • Verification: After applying locks and tags, verify that the equipment is indeed de-energized by attempting to start it up (following proper safety protocols).

Hazard Identification

  • Unexpected machine start-up: Crushing injuries, amputations, electrocution.
  • Release of stored energy: Burns, lacerations, fractures.
  • Failure to properly identify energy sources: Exposure to hazardous energy, leading to injury or death.

Control Measures

  • Develop and implement a written LOTO program.: The program should outline specific procedures for each piece of equipment.
  • Identify all energy sources and isolating devices.: Clearly label all energy isolating devices (e.g., circuit breakers, valves).
  • Use standardized lockout/tagout devices.: Locks and tags should be durable, standardized, and clearly identify the employee who applied them.
  • Train all authorized and affected employees.: Training should cover the purpose and function of the LOTO program, as well as the specific procedures for each piece of equipment.

Personal Protective Equipment (PPE) Requirements

  • Eye Protection: Always wear eye protection and personal safety equipment. [1]

[2] [3] [4] [5] [6] [7] [8]

  • Gloves: Wear appropriate gloves to protect against electrical, thermal, or chemical hazards.
  • Safety Boots: Wear safety boots to protect feet from impacts and punctures.

Real-World Example or Case Study

A maintenance worker was seriously injured when a conveyor belt started up unexpectedly during cleaning. The LOTO procedures were not followed, and the worker had not verified that the equipment was de-energized. This resulted in crushing injuries to the worker's arm.

Group Discussion

Discuss the following questions:

  1. What are some potential energy sources we might encounter in our work area?
  2. What steps can we take to improve our LOTO procedures?
  3. How do we ensure that all employees understand the LOTO procedures?

Emergency Procedures

  1. Immediately shut down the equipment if safe to do so.
  2. Evacuate the area if there is a risk of explosion or further energy release.
  3. Report the incident to a supervisor and initiate an investigation.

Questions and Answers

  • Q: What do I do if I need to remove a lock that isn't mine?

A: Follow the established procedure for removing locks, which usually involves contacting a supervisor and verifying that it is safe to remove the lock.

  • Q: What if I'm unsure about the energy sources?

A: Never proceed if you are unsure. Consult with a qualified person to identify and isolate all energy sources.

Summary

Recap of main points:

  • LOTO is essential for preventing injuries during maintenance and servicing.
  • Always follow the written LOTO procedures.
  • Verify that the equipment is de-energized before starting work.

Action Items

Specific actions participants should take:

  1. Review the written LOTO program.
  2. Participate in LOTO training.
  3. Report any unsafe conditions or LOTO violations.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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8 source record(s)

Sources used for this answer

[1] TEREX TH528C (manufactured after 9/14/2002) - Operator's Manual (PN 236499)

Page 19

Open source document

Source excerpt

# ! GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. All 2-3

[2] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 4/28/2003 to 12/17/2003) - Operator's Manual (PN 236501)

Page 19

Open source document

Source excerpt

# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. FIRST AID 2-3

[3] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 2/26/2004 to 7/15/2004) - Operator's Manual (PN 236503)

Page 19

Open source document

Source excerpt

# TABLE OF CONTENTS (cont.) # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. / 0 AII 2-3

[4] TEREX TH636C / TH644C / TH842C / TH844C (manufactured before 4/28/2003) - Operator's Manual (PN 236500)

Page 19

Open source document

Source excerpt

# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. - Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. 0 AII 2-3

[5] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 12/18/2003 to 2/25/2004) - Operator's Manual (PN 236502)

Page 19

Open source document

Source excerpt

# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. FIRST Allo 2-3

[6] TEREX TH644C / TH842C / TH844C (manufactured after 7/15/2004) - Operator's Manual (PN 236504)

Page 19

Open source document

Source excerpt

# SECTION 2 - GENERAL SAFETY (cont.) # GENERAL SAFETY # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. 2-3

[7] TEREX TH528C (manufactured before 2/14/2001) - Operator's Manual (PN 236497)

Page 7

Open source document

Source excerpt

# GENERAL SAFETY (cont.) ! GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. / FURST AID 1-3

[8] TEREX TH1048C / TH1056C - Operator's Manual (PN 236506)

Page 19

Open source document

Source excerpt

# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. AII LEMIT 2-3

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