Forklifts and Powered Industrial Trucks

EFFECTIVE DATE: 1/14/2011
LATEST CHANGE DATE: 12/01/2010
SUPERSEDES: 6/2002

1.0  Scope

This policy provides directive for the safe operation of fork trucks, tractors, platform lift trucks, motorized hand trucks, steer skid loaders, also know as Powered Industrial Trucks and meets the regulatory requirements of 29CFR1910.178.

2.0  Definitions

2.1. Operators
Any employee, who is selected to operate powered industrial trucks based on their ability to be successfully trained and who completes the required classroom and practical training.

2.2. Powered Industrial Truck
Any motorized vehicle used to move materials using forks, bucket, hoist, or platform. Powered industrial trucks are not used for transporting or positioning personnel unless an attachment, designed for and provided for approved by the manufacturer, is used. Powered Industrial Trucks used by UCAR staff must meet the design and construction requirements as established in ANSI B56.1, 1969; American Nationals Standard for Powered Industrial Trucks, Part II.

2.2.a. Modifications and additions to powered industrial trucks may happen only with prior written approval of the manufacturer or licensed professional engineer if the manufacturer is no longer in business.  Changes to capacity, operations or maintenance are recorded on instruction plates, tags or decals posted on the truck.

2.3 Unattended
A vehicle 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.

3.0  Responsibilities

3.1 Management
Assures assigned employees and supervisors are qualified, properly trained, and skilled in safe conduct, potential hazards, and emergency procedures for powered industrial trucks for use by employees.

3.2 Supervision
Assures operators are selected based on their ability to be trained, and their capability to perform assigned duties; assures that only trained drivers are allowed to operate powered industrial trucks and that the operator performs duties competently.

3.3 Employees
Conducts operations in safe manner compliant with UCAR/NCAR policies, procedures, and training. Attends and participates in required training. Recognizes and understands potential hazards of operations. Reports out of tolerance conditions to supervisors, and discontinues any unsafe operation.

3.4 Health, Environmental and Safety Services Office
Determines, designs, communicates, and administers the Powered Industrial Truck program. Monitors and audits compliance to policies, procedures, and regulations, and reports non-compliant conditions to supervision for correction. Writes, publishes, and up-dates generic safety policies and procedures. Provides generic safety training. Identifies potential hazards of operations and communicates to supervisor. Takes appropriate actions to abate unsafe conditions, practices or activities. Provides annual inspection checklists.

4.0  General Procedures

4.1 Inspection
Before operating any powered industrial truck, perform an inspection on the vehicle to determine that the vehicle is safe to operate. This inspection needs to be performed once each shift the vehicle is used. 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. An inspection checklist may be used as a guide to the inspection and to document the condition of the vehicle. Checklists for each powered industrial truck are provided annually by the Health, Environment and Safety Services Office.

4.2 Load Management
All loads must be within the rated capacity of the powered industrial truck. Use the vehicle load chart to determine the limitations of the vehicle. Loads must be properly centered to maintain the vehicle and load center of gravity to prevent tipping the vehicle or loosing the load. Loads that are top-heavy or awkward because of their shape may need to be secured to the vehicle mast, platform, forks or bucket. Load weight and center of gravity must be known or conservatively estimated before moving the load.

4.3 Operation

4.3.1 Select the powered industrial truck for the job, considering the environment (generally select an electric truck for indoor environments to avoid accumulation of carbon monoxide), size and shape of the object to be moved, and training of the operator.
4.3.2 Only individuals qualified by training and experience may operate powered industrial trucks. The operator is the only person allowed on the truck unless a passenger seat with seat belt is provided. The operator may not allow any one to stand or pass under a raised portion of the truck or stand between an operating vehicle and a fixed object, such as a wall, post or dock.
4.3.3 The operator's entire body must remain in the cab of the vehicle at all times the vehicle is in operation. A seat belt or other restraining method must be used.
4.3.4 When a powered industrial truck is left unattended, the forks/bucket or other attachment must be fully lowered, controls neutralized, power shut off, and brakes set. Wheels must be blocked if the truck is parked on an incline.
4.3.5 If the truck is used to load or unload materials from trucks or trailers, those brakes shall be set and wheel blocks shall be in place to prevent movement of trucks or trailers while loading or unloading. Fixed jacks may be necessary to support a semi-trailer 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.
4.3.6 When driving, look in the direction of travel, drive slowly and use the horn in locations where vision is blocked. Travel over grades slowly and carefully with the load uphill as fork lifts and skid-steer loaders have tipped over on grades as small as 3-4 degrees. The load must be carried as low as possible, and tilted back when traveling on grade.
4.3.7 Under all travel conditions the truck must be operated at speed that will permit it to be brought to a stop in a safe manner.
4.3.8 Stunt driving and horseplay are never permitted.
4.3.9 Fuel tanks may not be filled while the engine is running. Spilled oil or fuel shall be carefully cleaned up or completely evaporated and the fuel tank cap replaced before restarting engine.
4.3.10 Batteries for electric powered trucks are charged in designated locations that are equipped with flushing and neutralizing equipment, fire protection, and adequate ventilation for dispersal of vapors from gassing batteries.  The charging apparatus must be protected from damage by trucks. Adequate materials handling equipment must be available to handle batteries when removed for charging.  Procedures for handling battery acid must be developed before use.

5.0  Training

Initial training is required before an operator may operate a powerd industrial truck and consists of classroom training, conducted by an instructor or use of interactive computer training, practical demonstrations by an instructor, and practice in driving the vehicle and operating the forks/bucket or other accessories. Training may be provided by qualified UCAR staff or contracted instructors. The training programs must include elements required by 29CFR1910.178. Driving performance is assessed every 3 years. Retraining may be needed if the driver does not follow appropriate operations.

6.0  Miscellaneous

6.1 Record keeping
Records are retained of training provided to UCAR/NCAR employees, including copies of training materials, course outline, name and address of contracted person conducting training, and the performance evaluation for each operator.