Getting a flat tire. Having a raised and tilted back load

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Powered Industrial Truck (PIT) Training

• Firelands College

Shaeff Electric Lift Truck E 3000 C
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Agenda

• Importance of the PIT Training Program
• OSHAs PIT standard
• BGSUs written PIT Program
• Truck related topics
• Workplace related topics
• Truck operations
• Traveling
• Loading and
• Inspection and maintenance.

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Importance of the PIT Training Program

• PIT Defined
• An industrial vehicle that carries, pushes,
  pulls, stacks or tiers loads.
• Includes fork trucks, tractors, platform lift
  trucks, motorized hand trucks, and other
  specialized industrial trucks powered by electric
  motors or internal combustion engines. Golf carts
  are considered PITs when used for maintenance
  activities.
• Excludes compressed air or nonflammable
  compressed gas-operated industrial trucks, farm
  moving or over-the-road hauling.

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Importance of the PIT Training Program

• Powered industrial truck accidents cause
  approximately 100 fatalities and 36,340 serious
  injuries in general industry and construction
  annually.
• Approximately 20-25 of the accidents are caused
  by inadequate training (OSHA).

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Importance of the PIT Training Program

• August 2003
• A 15-year-old forklift operator was at the
  controls of a forklift in a warehouse when the
  vehicle suddenly went into reverse, ran through
  the loading dock gates, flipped over and plunged
  four feet onto a concrete floor. The company was
  fined by the U.S. Labor Departments Wage and
  Hour Division because the operation is one of 17
  hazardous occupations banned for youth under the
  age of 18. OSHA is also investigating the
  incident.

Reference http//www.safteng.net
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Importance of the PIT Training Program

• August 2003
• A construction worker at a California campus was
  left in critical condition after he was pinned by
  a forklift. He was attempting to stabilize the
  forklifts load of more than 30 panes of glass.
  He suffered leg injuries, broken ribs, a broken
  shoulder, and severe lacerations to his face.

Reference http//www.safteng.net
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OSHAs PIT Standard

• Design and construction requirements
• Safe operation requirements
• Fire protection requirements
• Maintenance requirements including daily PIT
  inspections
• Operator training program including classroom,
  hands-on training and refresher training
• Operator evaluations every three years
• Operator certification
• Appendix A Stability information

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BGSUs Written PIT Program

• Initial classroom and hands-on training was
  offered in 1999 after the new standard went into
  effect.
• The training was given by an outside consultant
  who has since gone out of business.
• In order to provide a more cost effective, easily
  accessible training program, Environmental Health
  and Safety is working with departs and areas on
  campus to develop department specific PIT
  training sessions consisting of a combination of
  classroom and hands-on training.

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BGSUs Written PIT Program

• Policy Statement
• Forward
• Objective
• Applicability

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BGSUs Written PIT Program

• Responsibilities
• Occupational Safety and Health Specialist
• Management
• Supervisors
• PIT Operators

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BGSUs Written PIT Program

• PIT Operator Responsibilities include
• completely adhering to the requirements of this
  program and attending required training and
• performing powered industrial truck inspections
  for every eight-hour shift.
• Program Enforcement
• A violation of a University employee's
  responsibility must be reported to the employee's
  immediate supervisor for appropriate action.

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BGSUs Written PIT Program

• Work site specific information is located in Tab
  1 including
• Site Specific Operating Environment
• Site Specific Load Information
• Site Specific Controls and Instrumentation List

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BGSUs Written PIT Program

• Training
• Classroom Training
• Hands-On Training
• Training Certification
• All operators will be issued a BGSU PIT license
  that includes
• Name
• Date of training
• ID of person who performed the evaluation
• Only trained, certified operators can drive
  PITs.

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BGSUs Written PIT Program

• Re-Training is required when
• An operator has been observed to operate the
  vehicle in an unsafe manner or
• The operator has been involved in an accident or
  a near miss or
• The operator is assigned to a different truck or
• The conditions change in an area where the PIT is
  operated or
• A new truck is brought into use or
• The operator has received an evaluation that
  reveals that the operator is not operating the
  powered industrial truck safely.

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BGSUs Written PIT Program

• Operator Evaluations
• Must be completed once every three years.
• A sample form is located in Appendix G.
• Accident Reporting
• Immediately report PIT related accidents.
• Accident reporting must be completed using the
  BGSU Accident Investigation form and if needed
  the BGSU Injury/Illness Report if an operator is
  involved in PIT accident or near miss.

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Truck Related Topics

• Manufacturers operating instructions, warnings,
  and precautions.

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Truck Related Topics

• Differences Between a PIT and an Automobile

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Truck Related Topics
Stand Up Counterbalance
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Truck Related Topics

• Truck Controls and Instrumentation

Direction Control
Horn
Power Steering
Tilt Control
Key Switch
Service Panel
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Truck Related Topics

• Truck Controls and Instrumentation

Overhead Guard
Light
Mast
Front Wheel Drive
Battery Compartment
Brake Pedal
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Truck Related Topics
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Truck Related Topics

• Engine or motor operation
• Shaeff Electric Lift Truck E 3000 C is battery
  powered.
• Knowing how a truck is powered helps to
  understand the trucks capabilities and
  limitations.

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Truck Related Topics

• Steering and Maneuvering
• Rear-end steering.
• Many trucks do not have a standard steering
  wheel.
• Operator may need to steer in reverse.
• Operator may need to steer with one hand.
• Understand the controls for the type of truck
  youre operating.

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Truck Related Topics

• Visibility
• Restrictions due to loading.
• Look in the direction youre traveling.
• Watch for overhead obstacles.
• Ensure adequate clearance.
• Check blind spots to side and rear.

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Truck Related Topics

• Fork and attachment adaptation, operation, and
  use limitations
• Trucks can be equipped or modified to accept
  attachments for moving odd-shaped loads.
• Additions/modifications may affect stability,
  safe operation.
• Attachments can cause restrictions/limitations to
  operation.
• Operate trucks with attachments as being
  partially loaded.

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Truck Related Topics

• Vehicle capacity
• Only handle loads within trucks rated capacity.
• Capacity is found on name plate.
• Understand limitations for how much weight can be
  handled, how high the load can be raised, and how
  far the loads center of gravity can be from
  trucks vertical load rest.

Max Capacity 3000 lbs Max Lift Height 255
inches (Located on Left Dashboard)
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Truck Related Topics

• Vehicle stability
• Center of gravity shifts when load is raised
• Truck is less stable with raised load
• Moving an unstable truck can result in tipover

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Truck Related Topics

• Stability Triangle
• Operators must keep the center of gravity within
  the triangle that is formed by the three
  suspension points.   If the center of gravity
  goes out of this area by lifting a load that is
  too heavy, or by carrying a load too high and
  tilted forward, the lift will tip over.

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Truck Related Topics
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Truck Related Topics

• Conditions that combined with turning may cause a
  tip over include
• Hitting a pothole
• Carrying an off center load.
• Getting a flat tire.
• Having a raised and tilted back load.
• Being on a ramp.

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Truck Related Topics

• Vehicle stability
• During a tipover
• stay with vehicle and lean away from the
  direction of the fall
• dont jump downward while truck is tipping
• Brace your feet
• Hold on to the steering wheel
• Keep load at lowest practical point

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Truck Related Topics

• Refueling and/or charging and recharging of
  batteries
• Keep flames, sparks, arcs from fueling areas.
• Smoking is not allowed in fueling/charging areas.
• Keep tools and metallic objects from top of
  uncovered batteries.
• Inspect battery connections for damage.
• Immediately clean up electrolyte spills.
• PPE Face Shields, chemical gloves, apron,
  safety glasses.

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Truck Related Topics

• Any other operating instructions, warnings, or
  precautions listed in the operator's manual for
  the types of vehicle that the employee is being
  trained to operate.

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Workplace Related Topics

• Use
• Unloading trucks
• Lift objects to mezzanine (furniture etc)
• Lift to dry mats
• Transport material (ramps, staging)
• Surface conditions
• Water, snow, ice
• Effects on traction, stopping ability
• Uneven ground and/or potholes
• Effects on stability

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Workplace Related Topics

• Pedestrian Traffic
• Transporting material across courtyard
• THE DRIVER IS ALWAYS THE ONE RESPOSIBLE NEVER
  THE PEDESTRIAN

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Workplace Related Topics

• Narrow Aisles and Other Restricted Places Where
  Vehicles Will Be Operated
• One aisle in the service building

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Workplace Related Topics

• Composition of Loads to be Carried and Load
  Stability

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Workplace Related Topics

• Load manipulation, stacking, and unstacking.

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Workplace Related Topics

• Hazardous (classified) locations where the
  vehicle will be operated.
• Operation of PIT in closed environments can
  produce carbon monoxide build-up. Detectors
  should be installed in these areas.

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Workplace Related Topics

• Ramps and other sloped surfaces that could affect
  the vehicle's stability.
• None

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Workplace Related Topics

• Other unique or potentially hazardous
  environmental conditions in the workplace that
  could affect safe operation.
• None

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Truck Operations

• Trucks shall not be driven up to anyone standing
  in front of a bench or other fixed object.
• No person shall be allowed to stand or pass under
  the elevated portion of any truck, whether loaded
  or empty.

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Truck Operations

• Unauthorized personnel shall not be permitted to
  ride on powered industrial trucks.
• A safe place to ride shall be provided where
  riding of trucks is authorized.

44
Truck Operations

• No arms or legs should be placed between the
  uprights of the mast or outside the running lines
  of the truck.
• When a powered industrial truck is left
  unattended, load engaging means shall be fully
  lowered, controls shall be neutralized, power
  shall be shut off, and brakes set.

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Truck Operations

• Wheels shall be blocked if the truck is parked on
  an incline.
• A powered industrial truck is unattended when the
  operator is 25 ft. or more away from the vehicle
  which remains in his view, or whenever the
  operator leaves the vehicle and it is not in his
  view.

46
Truck Operations

• When the operator of an industrial truck is
  dismounted and within 25 ft. of the truck still
  in his view, the load engaging means shall be
  fully lowered, controls neutralized, and the
  brakes set to prevent movement.

47
Truck Operations

• A safe distance shall be maintained from the edge
  of ramps or platforms while on any elevated dock,
  or platform or freight car.
• Trucks shall not be used for opening or closing
  freight doors.

48
Truck Operations

• Brakes shall be set and wheel blocks shall be in
  place to prevent movement of trucks, trailers, or
  railroad cars while loading or unloading.
• Fixed jacks may be necessary to support a
  semitrailer during loading or unloading when the
  trailer is not coupled to a tractor.
• The flooring of trucks, trailers, and railroad
  cars shall be checked for breaks and weakness
  before they are driven onto.

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Truck Operations

• There shall be sufficient headroom under overhead
  installations, lights, pipes, sprinkler system,
  etc.

50
Truck Operations

• An overhead guard shall be used as protection
  against falling objects. It should be noted that
  an overhead guard is intended to offer protection
  from the impact of small packages, boxes, bagged
  material, etc., representative of the job
  application, but not to withstand the impact of a
  falling capacity load.

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Truck Operations

• A load backrest extension shall be used whenever
  necessary to minimize the possibility of the load
  or part of it from falling rearward.
• Only approved industrial trucks shall be used in
  hazardous locations.
• Fire aisles, access to stairways, and fire
  equipment shall be kept clear.

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Traveling

• All traffic regulations shall be observed,
  including authorized plant speed limits.
• A safe distance shall be maintained approximately
  three truck lengths from the truck ahead, and the
  truck shall be kept under control at all times.
• No passing.

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Traveling

• The right of way shall be yielded to ambulances,
  fire trucks, or other vehicles in emergency
  situations.
• Elevators shall be approached slowly, and then
  entered squarely after the elevator car is
  properly leveled. Once on the elevator, the
  controls shall be neutralized, power shut off,
  and the brakes set.
• Motorized hand trucks must enter elevator or
  other confined areas with load end forward.

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Traveling

• Other trucks traveling in the same direction at
  intersections, blind spots, or other dangerous
  locations shall not be passed.
• The driver shall be required to slow down and
  sound the horn at cross aisles and other
  locations where vision is obstructed and when
  approaching pedestrians.
• If the load being carried obstructs forward view,
  the driver shall be required to travel with the
  load trailing.

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Traveling

• Railroad tracks shall be crossed diagonally
  wherever possible. Parking closer than 8 feet
  from the center of railroad tracks is prohibited.
  
• Running over loose objects on the roadway surface
  shall be avoided.

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Traveling

• The driver shall be required to look in the
  direction of, and keep a clear view of the path
  of travel.
• Dockboard or bridgeplates, shall be properly
  secured before they are driven over.
• Dockboard or bridgeplates shall be driven over
  carefully and slowly and their rated capacity
  never exceeded.

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Traveling

• Grades shall be ascended or descended slowly.
• Stunt driving and horseplay shall not be
  permitted.
• The driver shall be required to slow down for wet
  and slippery floors.

58
Traveling

• When ascending or descending grades in excess of
  10 percent, loaded trucks shall be driven with
  the load upgrade.
• On all grades the load and load engaging means
  shall be tilted back if applicable, and raised
  only as far as necessary to clear the road
  surface.
• Under all travel conditions the truck shall be
  operated at a speed that will permit it to be
  brought to a stop in a safe manner.

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Traveling

• While negotiating turns, speed shall be reduced
  to a safe level by means of turning the hand
  steering wheel in a smooth, sweeping motion.
• Except when maneuvering at a very low speed, the
  hand steering wheel shall be turned at a
  moderate, even rate.

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Loading

• When approaching a load
• Make sure forks are spread as wide as possible.
• Make sure the truck is square to the load.
• Make sure the mast is vertical.

61
Loading

• Only stable or safely arranged loads shall be
  handled.
• Caution shall be exercised when handling
  off-center loads which cannot be centered.
• Only loads within the rated capacity of the truck
  shall be handled.
• The long or high (including multiple-tiered)
  loads which may affect capacity shall be
  adjusted.
• Keep the load close to the ground while driving.
• Raise the forks as much as you need to clear the
  road surface.

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Loading

• Trucks equipped with attachments shall be
  operated as partially loaded trucks when not
  handling a load.
• When lifting a load place forks under the load as
  far as possible the mast shall be carefully
  tilted backward to stabilize the load.
• Inspect load for stability, projections, and
  damaged pallets before lifting.
• Restack unstable loads and never place weight on
  back of a lift truck to increase capacity.

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Loading

• Extreme care shall be used when tilting the load
  forward or backward, particularly when high
  tiering.
• Tilting forward with load engaging means elevated
  shall be prohibited except to pick up a load.
• An elevated load shall not be tilted forward
  except when the load is in a deposit position
  over a rack or stack.
• When stacking or tiering, only enough backward
  tilt to stabilize the load shall be used.

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Loading

• Parking
• Lower forks.
• Set gear into neutral.
• Set the parking brake.
• Turn off the key.

65
Inspection and Maintenance

• If at any time a powered industrial truck is
  found to be in need of repair, defective, or in
  any way unsafe, the truck shall be taken out of
  service until it has been restored to safe
  operating condition.
• Fuel tanks shall not be filled while the engine
  is running. Spillage shall be avoided.

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Inspection and Maintenance

• Spillage of oil or fuel shall be carefully washed
  away or completely evaporated and the fuel tank
  cap replaced before restarting engine.
• No truck shall be operated with a leak in the
  fuel system until the leak has been corrected.

67
Inspection and Maintenance

• Open flames shall not be used for checking
  electrolyte level in storage batteries or
  gasoline level in fuel tanks.
• All repairs shall be made by authorized personnel.

68
Inspection and Maintenance

• No repairs shall be made in Class I, II, and III
  locations.
• Those repairs to the fuel and ignition systems of
  industrial trucks which involve fire hazards
  shall be conducted only in locations designated
  for such repairs.

69
Inspection and Maintenance

• Trucks in need of repairs to the electrical
  system shall have the battery disconnected prior
  to such repairs.
• All parts of any such industrial truck requiring
  replacement shall be replaced only by parts
  equivalent as to safety with those used in the
  original design.

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Inspection and Maintenance

• Industrial trucks shall not be altered so that
  the relative positions of the various parts are
  different from what they were when originally
  received from the manufacturer, nor shall they be
  altered either by the addition of extra parts not
  provided by the manufacturer or by the
  elimination of any parts.
• Additional counterweighting of fork trucks shall
  not be done unless approved by the truck
  manufacturer.

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Inspection and Maintenance

• Industrial trucks shall be examined before being
  placed in service, and shall not be placed in
  service if the examination shows any condition
  adversely affecting the safety of the vehicle.
• Such examination shall be made at least daily.
• Where industrial trucks are used on a
  round-the-clock basis, they shall be examined
  after each shift.
• Defects when found shall be immediately reported
  and corrected.

72
Inspection and Maintenance

• Water mufflers shall be filled daily or as
  frequently as is necessary to prevent depletion
  of the supply of water below 75 percent of the
  filled capacity.
• Vehicles with mufflers having screens or other
  parts that may become clogged shall not be
  operated while such screens or parts are clogged.
  
• Any vehicle that emits hazardous sparks or flames
  from the exhaust system shall immediately be
  removed from service, and not returned to service
  until the cause for the emission of such sparks
  and flames has been eliminated.

73
Inspection and Maintenance

• When the temperature of any part of any truck is
  found to be in excess of its normal operating
  temperature, thus creating a hazardous condition,
  the vehicle shall be removed from service and not
  returned to service until the cause for such
  overheating has been eliminated.

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Inspection and Maintenance

• Industrial trucks shall be kept in a clean
  condition, free of lint, excess oil, and grease.
• Noncombustible agents should be used for cleaning
  trucks.
• Low flash point (below 100 deg. F.) solvents
  shall not be used. High flash point (at or above
  100 deg. F.) solvents may be used.
• Precautions regarding toxicity, ventilation, and
  fire hazard shall be consonant with the agent or
  solvent used.

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Inspection and Maintenance

• Inspection Form
• See Tab 2

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Inspection and Maintenance
Pre-Inspection Checklist

• Overhead guard
• Hydraulic Cylinders
• Mast Assembly
• Lift Chains and Rollers
• Forks
• Tires
• Battery Check
• Hydraulic Fluid
• Gauges
• Steering
• Brakes
• Lights
• Horn
• Engine Oil and Coolant
• Windshield wipers

• Safety Seat
• Load Handling Attachments
• Seat Belts
• Safety Door
• Safety Switch
• Hand Guards
• Tow Hook
• Control Lever
• Safety Interlock
• Gripper Jaws
• Work Platform
• Propane Odor, Tank, Hose
• Transmission Fluid

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• Exercise Tab 3

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Where to Get More Information

• http//www.osha.gov. Occupational Safety and
  Health Administration.
• http//www.bgsu.edu/offices/envhs. Bowling Green
  State UniversityEnvironmental Health and
  Safety419-372-2171