1. Powered Industrial Truck (PIT) Training
Firelands College
                                                
Shaeff Electric Lift Truck E 3000 C

2. Agenda Importance of the PIT Training Program; OSHA’s PIT standard;
BGSU’s written PIT Program;
Truck related topics;
Workplace related topics;
Truck operations;
Traveling;
Loading and;
Inspection and maintenance.

3. 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 PIT’s when used for maintenance activities.
Excludes compressed air or nonflammable compressed gas-operated industrial trucks, farm moving or over-the-road hauling.

4. 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 % of the accidents are caused by inadequate training (OSHA).

5. 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 Department’s 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.
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6. 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.
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7. OSHA’s 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

8. BGSU’s 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.

9. BGSU’s Written PIT Program
Policy Statement
Forward
Objective
Applicability

10. BGSU’s Written PIT Program
Responsibilities
Occupational Safety and Health Specialist
Management
Supervisors
PIT Operators

11. BGSU’s 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.

12. BGSU’s 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

13. BGSU’s 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 PIT’s.

14. BGSU’s 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.

15. BGSU’s 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.

16. Truck Related Topics
Manufacturer’s operating instructions, warnings, and precautions.

17. Differences Between a PIT and an Automobile
Truck Related Topics
Differences Between a PIT and an Automobile
Forklift
Automobile
Narrow Wheel Track
Wide Wheel Track
Short Wheel Base
Long Wheel Base
High Structure
Low Structure
3-point suspension
4-point suspension
Center of gravity is higher and moves in a significant range w/loads
Center of gravity is low and moves in a narrow range
3 or 4 wheels, steers from the rear
4 wheels, steers from the front

18. Truck Related Topics
Stand Up Counterbalance

19. Truck Controls and Instrumentation
Truck Related Topics
Truck Controls and Instrumentation
Direction Control
Horn
Power Steering
Tilt Control
Key Switch
Service Panel

20. Truck Controls and Instrumentation
Truck Related Topics
Truck Controls and Instrumentation
Overhead Guard
Light
Mast
Front Wheel Drive
Battery Compartment
Brake Pedal

21. Truck Related Topics Control/ Instrument Location Effect or Function
Brake
Left Floor
Stop
Power Steering
Left Dashboard
For fast smooth maneuvering
Right Control
Right Dashboard
Controls direction and speed
Key Switch
Right Lower Dashboard
Turns on the lift
Battery Compartment
Side of Vehicle
Holds battery
Left Control
Controls tilt cylinders
Horn
Audible alert
Mechanical Emergency Disconnect

22. 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 truck’s capabilities and limitations.

23. 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 you’re operating.

24. Truck Related Topics Visibility Restrictions due to loading.
Look in the direction you’re traveling.
Watch for overhead obstacles.
Ensure adequate clearance.
Check blind spots to side and rear.

25. 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.

26. Truck Related Topics Vehicle capacity
Only handle loads within truck’s 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 load’s center of gravity can be from truck’s vertical load rest.
Max Capacity: lbs
Max Lift Height: 255 inches
(Located on Left Dashboard)

27. 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

28. 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.

29. Truck Related Topics

30. 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.

31. Truck Related Topics Vehicle stability During a tipover:
stay with vehicle and lean away from the direction of the fall
don’t jump downward while truck is tipping
Brace your feet
Hold on to the steering wheel
Keep load at lowest practical point

32. 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.

33. 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.

34. 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

35. Workplace Related Topics
Pedestrian Traffic
Transporting material across courtyard
THE DRIVER IS ALWAYS THE ONE RESPOSIBLE: NEVER THE PEDESTRIAN

36. Workplace Related Topics
Narrow Aisles and Other Restricted Places Where Vehicles Will Be Operated
One aisle in the service building

37. Workplace Related Topics
Composition of Loads to be Carried and Load Stability
Load Identification
Weight
Books
150 lbs
Furniture
200lbs-300lbs
Ramps/Staging
300lbs-500lbs
Dry Mats
400lbs

38. Workplace Related Topics
Load manipulation, stacking, and unstacking.

39. 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.

40. Workplace Related Topics
Ramps and other sloped surfaces that could affect the vehicle's stability.
None

41. Workplace Related Topics
Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.
None

42. 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.

43. 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.

45. 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.

49. 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.

51. 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.

52. 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.

53. 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.

54. 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.

55. 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.

56. 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.

57. 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.

59. 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.

60. 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.

62. 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.

63. 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.

64. 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.

66. 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.

70. 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.

71. 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.

74. 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.

75. Inspection and Maintenance
Inspection Form
See Tab 2

76. 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

77. What is Wrong With This Picture?
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88. What is Wrong With This Picture?
Exercise – Tab 3

89. Where to Get More Information
Occupational Safety and Health Administration.
Bowling Green State University Environmental Health and Safety