ONLINE SELF-STUDY

Powered Industrial Trucks

OSHA Standard

This training course will cover the OSHA 1910.178

Powered Industrial Truck standard

Employer Responsibilities

The employer is responsible for providing employees

who will be operating powered industrial trucks as

function of their job the knowledge and skills to use

the equipment in a safe and productive manner.

The employer must:

Communicate hazards to employees

Comply with North Carolina and Federal Safety

Rules and Regulations

Operator Responsibilities

As an operator of a powered industrial truck, you

have several responsibilities:

Perform a daily inspection of the machine and

document the condition of the equipment

Safely operate the piece of equipment that you

have been assigned to use

Report any items that are in need of repair to your

supervisor and do not operate the machine until the

items have been corrected

Powered Industrial Truck

A mobile power-propelled truck used to carry, push,

pull, lift, stack, or tier materials. Powered industrial

trucks are classified by manufacturers according to

their individual characteristics.

PIT Types

The most common powered industrial truck is the sit

down rider type, but there are many different

pieces of equipment that are classified as powered

industrial trucks and are subject to the powered

industrial truck standard. This may range from a

motorized hand truck (class III) to a Bobcat type

machine with a fork attachment.

Center of Gravity

The point at which the load of the powered industrial

truck is concentrated.

If the center of gravity remains inside the triangle, the

truck will not tip over.

Support points A, B & C form stability triangle

Load Capacity

Each powered industrial truck should have a name plate secured to it. The name plate will give the load capacity of the truck

Do not exceed the rated load capacity

Exceeding the load capacity may cause the truck to tip causing harm to you and bystanders

Attachments

Powered industrial trucks serve a variety of purposes and there are many different attachments that may be added on and used safely. Each attachment requires training specific to that piece of equipment

Attachments may require specific operating conditions and/or PPE

Only use attachments that are designed for that specific powered industrial truck

Authorized Operator

To become an authorized operator you must

successfully complete a two section training program

consisting of:

Classroom – this course

Practical – demonstration of a working knowledge

of powered industrial trucks through safe operating

practices and evaluation.

After successful completion of both courses EHS will

issue you an Authorized Operator License

Authorized Operator, con’t.

As an authorized operator, you may only operate the

Powered Industrial Truck(s) that you have been

trained on and authorized to use. While many

powered industrial trucks look similar and have

similar controls, it is important to know the specifics

of each piece of equipment.

Seven Classes of Powered Industrial

Truck

Class I - Electric motor rider trucks

Class II - Electric motor narrow aisle trucks

Class III - Electric motor hand trucks or hand/rider trucks

Class IV - Internal combustion engine trucks (solid/cushion tires)

Class V - Internal combustion engine trucks (pneumatic tires)

Class VI - Electric and internal combustion engine tractors

Class VII - Rough terrain forklift trucks

Class One

Class I - Electric Powered Sit Down Rider

Class Two

Class II - Electric Motor Narrow Isle Truck

Class Three

Class III - Electric Motor Hand Trucks or Hand/Rider

Trucks

Class Four

Class IV - Internal Combustion Engine Trucks

(solid/cushion tires)

Class Five

Class V – Internal Combustion Trucks (pneumatic tires)

Class Six

Class VI - Electric and Internal Combustion Engine

Tractors

Class Seven

Class VII - Rough Terrain Forklift Trucks

Components of a PIT

Controls and Instruments

Fuel Gauge

Identifies how much fuel is currently on board the piece of equipment. The fuel gauge reading must be taken during the daily checks

Engine Temperature Gauge

Identifies the running temperature of the engine on the piece of equipment. The C on the gauge refers to the engine being cold and the H refers to the engine being hot

Ampere Gauge

Identifies the battery strength of the piece of equipment

Controls and Instruments, con’t.

Oil Pressure Gauge

Identifies the engine oil pressure

Engine Hour Meter

This meter records the total amount of hours that the engine has been used. This reading must be recorded on the daily inspection forms because it is used to schedule maintenance on the piece of equipment

Rear View Mirror

The mirror attached to the powered industrial truck that gives a visual representation of the area behind the driver

Safety Features

Seat Belt

keeps you secured to the truck in the event of an

accident. At UNC you are required to wear your

seatbelt

Overhead Guard

prevents the powered industrial truck from crushing

you in the event of a tip-over, but this guard is only

effective with the combined used of a seatbelt

Safety Features, con’t.

The flashing strobe light and horn should be used to

notify others when:

driving around a corner

visual obstruction is present

poor lighting conditions

lowering your load

Safety Features, con’t.

Auxiliary Seat Brake:

acts as an emergency brake

engage prior to stepping off the truck

may be located in the front next to the steering

column or in another position depending on piece of

equipment

Differences Between Powered

Industrial Trucks and Automobiles

There are several differences between driving a

powered industrial truck and driving an automobile.

Differences Between Powered

Industrial Trucks and Automobiles

Powered industrial trucks can weigh several times more than an automobile. The steering of the vehicle is usually from the back wheels as opposed to an automobile turning from the front. This gives the powered industrial truck a tighter turning radius than an automobile from the front, but a wider turning radius from the rear.

Powered industrial trucks also have a three point suspension system as opposed to the four point suspension of an automobile. This factor makes the powered industrial truck easier to tip over than an automobile.

Before and After Each Use

Before and after each use you are responsible for checking:

The overhead guard for any broken welds, missing bolts, or damaged areas

Hydraulic cylinders and lines. Make sure they are free from leaks and lines are in good condition showing no signs of cracking

The mast assembly for broken welds, cracks, or bends

All lift chains and rollers for excessive wear, damage, kinks, rusting, need for lubrication, squeaks and bends

Before and After, con’t.

Before and after each use you are responsible for checking:

Forks and carriage. Make sure that there are no cracks or bends in the metal. Make sure attachments being used are securely fastened

Steering mechanism for excessive motion

Brakes for proper function. If the pedal goes all the way to the floor when you apply the brake, that is an indication that the breaking system is not functioning properly. Make sure the emergency brake works. There should be no movement of the powered industrial truck when the emergency brake is engaged

Lights and horn to make sure they are functioning properly

The battery to make sure all caps are in place and that cables are free damage

If Any Problems Are Found

After completing the visual inspection, if any problems

are found:

Tag the equipment identifying that it is not to be

used

Report the problem to your supervisor

Types of Fuels

Diesel or Gasoline Refueling

To properly refuel a powered industrial truck the following steps should be taken:

All internal combustion engines must be turned off before refueling. Refueling should be in the open or in specifically designated areas, where adequate ventilation is provided

Smoking is prohibited when refueling or operating a powered industrial truck and signs must be posted to that effect

Proper PPE must be worn

Propane Refueling

Safely refueling a propane cylinder requires the following steps:

Turn the gas valve to the off position and let the engine run until it stalls

Turn off the ignition and the lights and set the emergency brake

Check the connections for damage

Remove empty tank and store it or secure the tank in a vehicle and bring it to the service station to be filled

Install the new or filled tank securely

Check the connection for leaks and damage

Proper PPE must be worn

Recharging

Battery-charging installations must be located in areas designated for that purpose. They must be capable of flushing and neutralizing spilled electrolyte. The charging apparatus needs to be protected from damage by trucks, adequate ventilation for dispersal of gases or vapors from gassing batteries. An overhead hoist, or equivalent equipment, must be used for handling batteries. Reinstalled batteries must be properly positioned and secured in the truck.

Recharging, con’t.

A carboy tilter or siphon must be used for handling electrolyte. Acid must always be poured into water. Water must NOT be poured into acid (it overheats and splatters)

During charging operations, vent caps must be removed to avoid electrolyte spray. Make sure that vent caps are functioning. Battery or compartment cover or covers must be open to dissipate heat

Precautions must be taken to prevent open flames, sparks, or electric arc in battery-charging areas and tools and other metallic objects must be kept away from the tops of uncovered batteries

Employees charging and changing batteries shall be authorized to do the work, trained in the proper handling, and required to wear protective clothing, including face shields, long sleeves, rubber boots, aprons, and gloves

Smoking is prohibited in the charging area. "No Smoking" signs must be posted

Transporting and Maneuvering

When maneuvering and transporting:

Give pedestrians the right of way

Activate strobe lights and utilize the horn when going around corners

Always pay attention to the path of travel

Never lift loads when the powered industrial truck is moving

Approach any potential obstacle slowly and with caution

Transporting and Maneuvering

When maneuvering and transporting:

Ensure that the loads are neatly stacked, stable, evenly distributed and secure

Space the forks under the load as far as possible. This will ensure that the load is evenly distributed

Approach the load with caution with the mast in a vertical position

Lift the forks only as high as needed to move the load. (2 to 6 inches)

Tilt the forks back for added stability

Transporting and Maneuvering

If the powered industrial truck is not loaded, drive

in reverse up the incline. Drive forward down the

incline

If the powered industrial truck is carrying a load

Drive forward up the incline. Drive in reverse down

the incline

Crossing Railway Tracks

There are areas where employees may need to cross railway tracks. This poses a unique hazard and caution must be exercised.

Always cross railway tracks on a diagonal

Park forklift at least 8 feet away from railway tracks

Obey any warning signs or alert systems

Refresher Training

In General, refresher training is required every three (3) years. However, refresher training will be required more frequently if:

An authorized operator is involved in an accident or near-miss incident

An operator is using the powered industrial truck in an un-safe manner

The written and/or practical evaluation is not completed successfully

If workplace conditions change

Different equipment will be used

Review

The following are key points to remember as an authorized operator:

Operate only the equipment that you are authorized to use

Familiarize yourself with the piece of equipment that you are going to use and follow all of its operating procedures

Inspect equipment thoroughly prior to use

Know your travel routes and overhead clearance levels

Do not allow any passengers

Stay within the safety cage of the powered industrial truck at all times

No matter how short or long the distance always fasten your seat belt

Post Test

In order to successfully complete the classroom section

of the powered industrial truck training you must

pass the post test.

After passing you must contact your supervisor to

arrange for the practical section of this training.