Powered industrial truck compliance

EACH YEAR, improper operation of powered industrial trucks (PITs) causes property damage, injuries, and fatalities. Whether it is operator or pedestrian error, more than 100 employees lose their lives each year in an incident with these trucks, but better operator training and employee awareness could eliminate such incidents. Employers also face OSHA citations and monetary penalties for inappropriate PIT operation or failure to comply with other PIT regulations.

Distinguishing aspects of PITs

A PIT pushes, pulls, lifts, stacks, or otherwise moves materials. They are usually powered by an electric motor or an internal combustion engine. Different types of PITs operate in our industry, including fork-lifts, clamp trucks, wheel-loaders, cherry-pickers, man-lifts, powered platform jacks, and transfer carts.

Because this equipment moves substantial loads, it is extremely heavy and powerful. It is imperative that the equipment is appropriate for the job and is used properly by trained personnel.

Each PIT must clearly display the manufacturer's label, which shows its lifting capacity. PIT manufacturers provide a number of devices for safe operation. These devices, which may include lights, horns, back-up signals, seatbelts, and overhead guards, must be maintained in proper condition and may not be removed. If an after-market device is used with a PIT, you must have the manufacturer's written approval for safe use of the device. Most commonly, this addition involves some type of work platform.

Whether powered by electric motors or a gas or diesel engine, each type of PIT has unique safety requirements. Electric PITs run from current stored in banks of heavy deep-cycle batteries that you must recharge, usually once per shift. Sometimes, the PIT itself is plugged into a charger, but more commonly the batteries are exchanged for fully charged ones. Batteries are quite heavy and are lifted by a hoist or chain-pull and placed in a charging rack. The process is repeated with the fresh battery. Proper personal protective equipment must be worn while performing this task. Additionally, fire extinguishers, no smoking signs, and a method of neutralizing acid must be available.

Gasoline and diesel trucks have similar requirements, and those fueled by LPG have even more due to the high pressure and extreme cold. Internal combustion engines generate heat, particularly around the exhaust manifold and catalytic converter. Care must be taken to keep the engine clean and free of flammable debris like paper dust. Occasionally, an improperly tuned or aging engine will actually exhaust sparks.

PITs should always stay properly tuned. Plants using internal combustion engines should periodically check levels of carbon monoxide in the plant and at each PIT's exhaust. Some states require such air monitoring at specific time intervals.

Proper training of PIT operators is both essential to employee safety and is a regulatory requirement. OSHA adopted new PIT operator training provisions in December 1999. Trainees may only operate a truck under the direct supervision of a qualified person. They also may only operate in an area where they do not endanger others.

The required training consists of three basic elements: formal instruction, practical application, and an evaluation of demonstrable operating skills. Training must be equipment specific, and the certification must indicate which types of PITs the employee qualifies to operate. Operators may not work on another truck type, although similar, until they go through its formal training process. For instance, a lift-truck operator may not drive a clamp truck until also certified on it. Training must include all aspects of the safe operation of the unit, including load capacity, instruments and controls, vehicle stability, trailer loading, surface conditions, and more.

Proper inspection of each PIT prior to the shift's start is required and is included in operator training. The procedure must provide for hazard recognition and for removal of defective, safety-compromised PITs from service.

In previous articles, I've discussed the necessity of maintaining our focus on compliance issues that are often taken for granted. Safe operation of powered equipment and proper training of PIT operators can fall into this category. The process is so common that we often overlook the veiy clear regulatory mandates that can prevent a serious injury, OSHA citation, or significant penalty. We must take time to see that PIT operators are trained and that trainers have necessary qualifications. Working safely is just good business. P&P