Powered Industrial Trucks Safety
Photo: Oregon OSHA
Powered Industrial Truck Program Summary
Each department that owns or uses PITs must ensure that all operators are authorized by the department to use such equipment, and are trained and certified by Environmental Health & Safety. This program applies to all motorized material handling equipment being operated by Virginia Tech personnel regardless of location and includes:
- Sit down powered industrial trucks
- Stand up powered industrial trucks
- Low-lift pallet jacks (walk-behind)
- High-lift pallet jacks (walk-behind)
- High-lift order pickers
- High-lift reach riders
- Sit down rider tractors with forks
- Bobcats with forks
- Rough-terrain extended-reach powered industrial trucks
- Rough-terrain straight-mast powered industrial trucks
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Responsibilities
General roles and responsibilities for health and safety can be found in university Policy 1005.
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Training
Operator Training and Certification
The operator must complete the following prior to being authorized to operate a powered industrial truck (PIT) at Virginia Tech.
- The operator must complete Powered Industrial Truck training (available online). Training topics include:
- How forklifts operate differently from a car.
- The types of tires on forklifts.
- Forklift attachments and requirements, such as additional counter balances, personnel lift cages, and fork extenders.
- Basic engineering principles, such as the center of gravity, the stability triangle, and stability while lifting or moving.
- Safe operating principles, such as travel and speed, pedestrian right-of-way, parking, and the importance of seatbelts in a rollover.
- Daily inspection and maintenance.
- Other safety considerations, such as fire extinguishers, alarms, lights, and traffic signals.
- The operator must review and understand pertinent information in the operator's manual as specified by the manufacturer prior to attempting to operate the lift.
- Safe and proper use
- Pre-use inspection
- Limitations of the equipment (e.g. maximum capacity)
- Note: The supervisor, operator, and Environmental Health & Safety trainer will be required to sign off on the certification form that these areas have been addressed prior to observing and finalizing operator training and certification.
- Operators must receive training on the make and model of PIT to be used from their supervisor or designee, including how to properly inspect and operate the PIT under supervision.
- Reporting deficiencies if the PIT does not pass inspection
- Required fall protection systems associated with the PIT, if applicable
- Supervised operation to develop proficiency.
- Complete the Observation Form and schedule a time with EHS or your Departmental Safety Representative (if applicable) to have your operating skills reviewed.
- Your operator card will be sent to your supervisor or Designated Safety Rep through campus mail.
Certification
Certification will be given for each type of PIT that the operator will be using, and indicated on your operator card, such as:
- Sit down forklifts
- Stand up forklifts
- Low-lift pallet jacks (walk-behind)
- High-lift pallet jacks (walk-behind)
- High-lift order pickers
- High-lift reach riders
- Sit down rider tractors with forks
- Bobcats with forks
- Rough-terrain extended-reach forklifts
- Rough-terrain straight-mast forklifts
If a different type of PIT needs to be added to your certification, contact EHS or your Designated Safety Rep to complete the observation portion only of the process.
Certification is valid for 3 years. Note that online training is required every six years, and observations are scheduled every three years, in order to stay current.
Fall Protection
Where personal fall arrest systems are required to be used (i.e. high-lift order pickers) in conjunction with the lift, training will involve the proper donning, fit, and use of the full-body harness, as well as the location of the approved anchor point on the lift.
Retraining
Additional training by Environmental Health & Safety may be required under the following conditions:
- The forklift is operated unsafely.
- The operator is involved in an accident or near-miss involving a forklift.
- The operator evaluation indicates a need for additional training and/or practice.
- A different type of forklift is to be used.
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General Requirements
Maximum Capacity
Operators must be familiar with the lifting capacity of their PIT. It should be indicated on the PIT itself, and may be expressed as maximum lifting capacity based on load centers of 24", 36", or 48". The maximum capacity should never be exceeded. If a larger capacity lift is necessary, departments should make arrangements to have one available.
Seatbelts
Seatbelts are designed to keep the operator in a "safe zone" in the event of a tip-over. If the forklift came with a seatbelt installed, it must be used. If the forklift does not have a seatbelt installed, the manufacturer should be contacted for a retrofit kit.
Daily Inspection
PIT's should be inspected daily for general damage and defects which may affect the integrity or operation of the equipment. Report any defect to your supervisor and do not use the PIT until the proper repair has been completed. Repairs should be made by qualified technicians only. Inspect for:
- Damaged, loose, or missing parts;
- Adequate tire inflation;
- Check the fuel level or charge of the battery;
- Air, hydraulic, or fuel system leaks;
- Loose hoses or wires;
- Ensure the operating controls are working properly;
- Ensure all safety features, such as horns and lights are working properly;
- Inspect the fork "elbows" for weld cracks; and
- Check the battery fluid, hydraulic reservoir, and coolant levels, if applicable.
Operator's Manual
The operator's manual for the PIT should be available to operators at a central location or on the lift itself. Operators should take the time to review operating instructions and safety guidelines. Servicing and maintenance should be in accordance with the manufacturer's recommendations.
Traveling
In general, forklifts are not designed to travel at fast speeds. Walking pace or about five miles per hour is a good rule of thumb. The load should be kept as low to the ground as possible - about 6 inches off of the floor in areas with smooth, hard floors. More height is necessary when traveling in outdoor areas, such as construction sites, where the terrain is uneven. Operators should always look in the direction of travel and use "spotters" where visibility is poor due to the size of the load. Sound the horn at blind corners to warn on-coming traffic to proceed cautiously. Avoid potholes, bumps, and wet areas whenever possible, or proceed with extreme caution.
Fueling/Battery Charging
Fueling or battery charging of the lift should be conducted according to the manufacturer's recommendations. In general, no sparks or open flames in the area, and adequate ventilation must be available.
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Definitions
Center of gravity: The point on an object at which all of the object's weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.
Dynamic stability: The resistance of the PIT to overturn while traveling or moving.
Fulcrum: The PIT's axis of rotation when it tips over.
Lateral stability: The resistance of the PIT to overturn sideways.
Load center: The distance from the back of the forks to the center of the load being lifted.
Longitudinal stability: The resistance of the PIT to overturn forward or backward.
Powered industrial truck: Any mobile, power-propelled truck used to carry, push, pull, lift, stack, or tier materials. Examples include:
- Sit down powered industrial trucks
- Stand up powered industrial trucks
- Low-lift pallet jacks (walk-behind)
- High-lift pallet jacks (walk-behind)
- High-lift order pickers
- High-lift reach riders
- Sit down rider tractors with forks
- Bobcats with forks
- Rough-terrain extended-reach powered industrial trucks
- Rough-terrain straight-mast powered industrial trucks
Spotter: A person who aids the operator with visibility issues.
Stability triangle: The imaginary triangle between the PIT's two front tires and the pivot pin on the rear axle. The principle is that the PIT will not tip over as long as the vehicle's center of gravity remains inside of this triangle.
Track: The distance between wheels on the same axle.
Wheelbase: The distance between wheels on different axles.