2.12 POWERED INDUSTRIAL TRUCK OPERATIONS PROGRAM
A powered industrial truck (PIT) operator has an important professional
responsibility. A PIT operator handles
an expensive piece of equipment that is a vital part of the University’s
material handling operation. The
operator also takes responsibility for expensive materials and the safety of
people in the vicinity every time a load is moved.
OSHA regulations state: “The
employer shall ensure that each powered industrial truck operator is competent
to operate a powered industrial truck safely…” (29 CFR 1910.178) This program provides guidelines
to outline the procedures for training and authorization to use powered
industrial trucks.
A. SCOPE
This program is applicable to all University employees whose duties
require them to operate or maintain (including repair or daily routine
maintenance, i.e., fluid levels, refueling, etc.) PITs, including those units powered
by electrical motors or internal combustion engines.
B. DEFINITIONS
Attachment - A device, other than conventional forks or load backrest
extensions, mounted permanently or temporarily on the PIT for handling the
load.
Counterbalanced Truck - A PIT equipped with load engaging means wherein all the
load during normal transporting is outside the area formed by the wheel
contacts.
Fork Height - The vertical distance from the floor to the load carrying
surface of the forks with mast vertical.
Free Fork Height - The attainable fork height before the stated overall
lowered height of the mast is exceeded by any standard part of the forks, mast
or carriage assemblies, when loaded.
Powered Industrial Truck (PIT) - A wheeled vehicle, primarily intended for the movement of
objects or materials and usually associated with manufacturing, processing or
warehousing, but not including vehicles intended primarily for earthmoving or
over-the-road hauling.
Lift - The vertical travel of the carriage with mast vertical.
Lift Speed - The average velocity in feet per minute when raising the
load carriage throughout its operating range, specified as empty and/or loaded.
Maximum Fork Height - The fork height attainable with the mast at the fully
elevated position.
Non-Telescoping Mast - A mast in which the support member or members providing
the guideways for vertical movement of the fork carriage do not move vertically
with respect to the PIT.
Overhead Guard - A framework fitted to a PIT over the head of a riding
operator.
Rated Capacity - The maximum weight, expressed in pounds, at a given load
center, that a PIT can safety transport and/or stack to a specified height when
equipped with a standard mast, carriage and forks. The rated capacity is based on the strength
of the various PIT components and the amount of counterweight.
Stability - A PIT’s resistance to overturning.
Telescoping Mast - A multiple mast wherein one member is stationary and the
other(s) movable vertically with respect to the stationary member and
supporting the fork carriage in its vertical movement. This mast permits maximum lifts substantially
greater than the overall lowered height.
Tilt - The amount by which the mast structure, forks and carriage
may be tipped beyond the vertical position, forward or backward.
Turning Radius (outside) - The radius of the arc (circle) described by the PIT when
driving slowly empty or loaded with the steering mechanism at the maximum
steering angle.
C. REFERENCES
OSHA Regulations 29 CFR 1910.178
ANSI Standard B56.1 Safety Standards for Powered Industrial Trucks
D. RESPONSIBILITIES
Supervisors: Supervisors must
ensure that PIT operators complete training as required in Section E of this
program. Supervisors are responsible for
ensuring that potential operators successfully complete a medical evaluation
from EOHS prior to operating a PIT and biennially thereafter. After attendance and successful completion of
the classroom portion of the PIT Training, supervisors will be responsible for
ensuring that Trainees only operate PITs under their supervision or the direct
oversight of a competent licensed PIT Operator. The PIT Trainee will operate
under this close supervision until such time as the Supervisor submits a
written statement to SRS acknowledging the Trainee’s competent skills have been
thoroughly demonstrated. Supervisors
shall ensure that no modifications or additions which may affect the capacity
and safe operation are made to the equipment without the manufacturer’s prior
written approval. If modifications are
made, all capacity, operation and maintenance instruction plates, tags or
decals shall be changed accordingly.
Employees: Only trained,
qualified and authorized personnel shall be permitted to operate a PIT. Every employee assigned to operate a forklift
truck will be required to successfully complete the University Training program
outlined in Section E. It is the
operator’s responsibility to read and understand all operating instructions,
warnings and precautions for the type of PIT being operated. If this information is unclear contact the
supervisor for clarification. Each PIT
shall be visually inspected by the operator at the beginning of each shift to
ensure that the vehicle is safe to operate.
Each operator will routinely check his/her vehicle to ensure that it has
adequate fuel, oil, hydraulic fluid, coolant and battery water. Additions of oil and hydraulic fluid will be
made only by authorized personnel, but operators are required to possess the
knowledge and capabilities to add coolant, battery water and refuel the
truck. All irregularities in the
operation of the forklift truck shall be immediately reported to the
supervisor. Adverse conditions affecting
the safe operation of the truck shall render the vehicle unfit for service
until such irregularities are corrected.
All other maintenance and repairs will be performed only by a qualified
maintenance mechanic.
E. TRAINING
OF OPERATORS
All PIT operators, who will operate a PIT as part of their job
requirements, will be required to successfully complete the Powered Industrial
Truck Classroom Training Program prior to operating a PIT in the performance of
their job functions. The Powered
Industrial Truck Classroom Training is coordinated by the Safety and Risk
Services Department. This program is
designed to teach the safe techniques of operating a PIT. Operators completing the Classroom training
will then be classified as Trainees.
Trainees will then be allowed to operate PITs under the direct
supervision of departmental personnel with knowledge, training and experience of
PIT operations and where such operation does not endanger the trainee or other
employees. Upon successful completion of
the on-the-job training program the department deems appropriate, the
supervisor will provide written certification to the SRS Department that the
operator is competent and fully qualified to operate the equipment. SRS will then perform an onsite evaluation
and, if appropriate, process the formal PIT Operator Permit. All operators must re-qualify for their PIT Operator
Permit as specified in Section F of this program. Supervisors must ensure that PIT operators
complete a medical evaluation in order to determine medical clearance to
operate a PIT, on a biennial basis.
Operators that have previously received training in PIT operations that
is appropriate to the PIT and working conditions to be encountered may be
exempted from the on-the-job training program.
Operators must satisfy all other aspects of this training program.
F. REFRESHER
TRAINING
All PIT operators must complete refresher training and an evaluation of
the effectiveness of that training to ensure that the operator has the
knowledge and skills needed to operate the PIT safely whenever:
Refresher training consists of completion of the PIT Classroom training
and an evaluation by the department supervisor of relevant topics as necessary.
G. CARE
AND USE
Turning a PIT will require more concentration than driving a car. Most PITs steer from the rear. The back end of the PIT swings wide and can
injure co-workers or damage products or equipment if the operator is not
careful. A typical PIT has a high center
of gravity and a short wheelbase. A PIT
has only three points of stability—two front wheels and the center of the rear
axle. An automobile has four points.
The vehicle’s counterweight is another key principle. The counterweight is designed to stabilize
the truck when a load is lifted. This is
referred to as longitudinal stability.
Here, the “see-saw” principle comes into play when a PIT carries its
payload outside of its supporting base.
Therefore, all loads must be placed as close to the back of the mast as
possible, not forward on the forks. Even
a light load could tip a PIT forward if it is placed near the front of the
forks.
Stopping a PIT is not as easy as stopping a car. A PIT has only two braking wheels and its
brakes are much small than a car’s. It
is also important to note that a typical auto weighs 3,000 to 4,500 lbs. An unloaded PIT can easily weigh twice as
much—and with a capacity load, three times as much. Consequently, a PIT cannot stop on a
dime. This is why so many pedestrians
are struck by PITs.
PITs are powered by batteries, propane or diesel. If you find a problem, never attempt to fix it yourself. Report any problems to your supervisor and let a qualified mechanic correct the problem.
Always perform a pre-use inspection.
Inspect the mast for cracks, roller tracks and chains for lubrication
(grease), for worn hydraulic lines, and hydraulic cylinders for leaks. If using pneumatic tires, check for proper
tire pressure. Once the truck has been
inspected for any visible damage, the PIT can be started. Apply the foot brake, shift gears to neutral,
turn the key, check all gauges and indicators, check controls, steering and
brakes for smooth operation. Start the
truck. Make sure that the area you
operate in has adequate ventilation so you won’t be overcome by carbon monoxide
poisoning.
Engage all loads squarely on the forks and center the weight of the load
between the forks. Only stable or safely
arranged loads shall be handled. Caution
shall be exercised when handling off-center loads which cannot be centered.
When carrying pallets, the forks should be spaced as wide as possible and
positioned evenly between the pallet stringers.
Do not bump or jar loads. Drive
the PIT forward under the load until the load touches the carriage. Tilt the mast backwards slightly, then lift
the load. DO NOT lift the load higher than necessary for safe traveling. There must always be sufficient headroom
under overhead installations, lights, pipes, sprinkler systems, etc.
If the load obstructs your vision, operate the truck slowly backwards and
look in the direction of travel. Sound
the horn at cross aisles and other locations where vision is obstructed. If possible use spotters to assist in the
movement of large loads.
During truck unloading, it is the PIT operator’s responsibility to ensure
that the brakes of highway trucks (tractor trailers, semis and/or “bobtails”)
are set and wheel chocks are placed under the rear wheels to prevent the truck
from rolling while they are being boarded by PITs. The flooring of trucks,
trailers, and railroad cars shall be checked for breaks and weakness before
they are driven onto.
PITs shall not be driven up to anyone standing in front of a bench or
other fixed object.
Carrying a passenger on a PIT truck is prohibited unless a passenger seat
is installed on the vehicle.
All personnel are prohibited from extending their arms and legs between
the uprights of the mast or outside the running lines of the truck.
When parking a PIT, or if a PIT is left unattended, i.e., the operator is
25 feet or more away from the vehicle or if the vehicle is out of his/her view,
the forks shall be fully lowered, controls in neutral, brakes set and power
shut off. On inclines or uneven
surfaces, wheel chocks will be used in addition to the forks being lowered to
the ground to prevent movement by the PIT.
PITs shall not be used to elevate personnel unless a safety platform, that
has been specifically designed and engineered for that purpose and specific PIT,
is firmly secured to the lifting carriage and forks. Such operations must be approved by SRS prior
to the work. Additionally, means shall be provided whereby personnel on the
platform can shut off power to the PIT.
A safe distance shall be maintained from the edge of ramps or platforms
while on any elevated dock, platform, or freight car. Trucks shall not be used for opening or
closing freight doors.
Only approved trucks shall be used in hazardous locations.
Fire aisles, access to stairways, and fire and other emergency equipment
shall be kept clear at all times.
When on grades, operators should travel in a straight line and avoid
turning.
Under all travel conditions, the PIT shall be operated at a speed that
will permit it to be brought to a stop in a safe manner.
Stunt driving and horseplay shall not be permitted.
The operator shall be required to slow down for wet and slippery
surfaces. Avoid driving on surfaces that
won’t support the PIT, such as sand.
Dockboards or bridgeplates shall be properly secured before they are
driven over. They also shall be driven
over slowly and carefully. Dockboards or
bridgeplates shall be kept dry and free of oil and grease and their rated
capacity shall never be exceeded.
H.
Smoking is prohibited during fueling or battery charging of a vehicle and
within 25 feet of this type of operation.
Working around batteries can be dangerous due to the acid content and
potentially explosive gases. Do not
smoke or let anyone else smoke in a battery charging area. Never use an open flame to check the
electrolyte level in batteries or the gasoline level in fuel tanks.
Fuel tanks shall not be filled or exchanged while the engine is
running. No PIT shall be operated with a
recognized leak in the fuel system.
Spillage of oil or fuel shall be carefully washed away or completely evaporated
and the fuel tank cap replaced before restarting the engine.
When checking fluid levels in batteries, personal protection (face and
hand protection) must be worn and an eyewash station should be readily
available.
In areas where electrolyte is added to batteries, an eyewash station must
be readily accessible.