Chapter 28
Forklifts and Other Powered Industrial Trucks

Contents

Approved by Jean Myers
New 3/07

28.1 Policy
28.2 Scope
28.3 LBNL Support Organizations
28.4 Introduction
28.5 Training, Certification and Approval Requirements for PIT Operators

28.5.1 General Requirements
28.5.2 PIT Operator Certification

28.6 Forklift / PIT Manager
28.7 General Requirements for Forklift and Other PIT Operation
28.8 Maintenance and Inspection

28.8.1 General
28.8.2 Fork Extensions

28.9 Responsible Parties

28.9.1 Supervisors
28.9.2 PIT Operators
28.9.3 Facilities Division Rigging Supervisor
28.9.4 Facilities Division Transportation Group

28.10 Standards
28.11 Related LBNL/PUB-3000 Chapters
28.12 References

Appendix A. Powered Industrial Truck Operator Application
Appendix B. Powered Industrial Truck Application Instructions
Appendix C. Electric Forklift Daily Inspection Form
Appendix D. LP, Gas, or Diesel Forklift Daily Inspection Form

NOTE:
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. . . . . . . .	Denotes the end of changed text within a section.

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28.1 Policy

The purpose of the Powered Industrial Truck (PIT) Program at Berkeley Lab is to assure that forklifts and other PITs are operated safely and in conformance with all applicable standards. 

28.2 Scope

This policy applies to all Laboratory employees, casual and participating visitors, guests, and contractor employees using LBNL owned or leased PITs.

PITs include not only forklifts, but also tow motors, pushers, electric pallet movers, and electric stackers.
Manual pallet movers may require on-the-job training, but no formal license, and are not within the scope of this chapter.

Construction operations involving PITs are covered in the Construction Safety Chapter.

Note that High Value/High Consequence Lifts and Moves often involve the use of forklifts. The requirements for High Value/High Consequence Lifts and Moves are addressed in Chapter 27 and apply also to such moves involving the use of forklifts.

28.3 LBNL Support Organizations

• Industrial Safety Group - Environment, Health & Safety (EH&S) Division
• Transportations & Rigging Groups - Facilities Division

28.4 Introduction

Heavy material handling requiring the use of forklifts and other powered industrial trucks is a potentially hazardous activity.  To assure the safety of such operations, the Laboratory requires stringent controls for the use of such equipment, and the procurement, maintenance and inspection of such equipment is strictly controlled. 

28.5 Training, Certification and Approval Requirements for PIT Operators

28.5.1 General Requirements

Operation of forklifts and other powered industrial trucks is restricted to trained personnel who have completed LBNL required training and who have been certified for specific types of equipment in accordance with the requirements of this chapter.

In addition, all PIT use must be approved by the PIT manager for that particular PIT. The PIT manager is a qualified PIT operator who has been designated as the individual responsible for the safe operation of a specific PIT. Before operating any given PIT for the first time, discuss the proposed use with the PIT manager and obtain approval. The PIT manager will verify that the operator is familiar with the controls for that particular PIT, and that the PIT use will not conflict with other operations in the area.

PITs may also be operated by qualified service personnel who have been contracted to install, maintain or repair PITs.

28.5.2 PIT Operator Certification

To become initially certified, prospective PIT operators must do the following:

Complete a PIT application package (see Appendix A and Appendix B), which contains the following:

• Identification of the specific types of PITs to be operated by the employee.
• A copy of a current, valid driver’s license.  This is required because PITs frequently operate on Laboratory roads.
• Identification of a currently licensed LBNL PIT operator who will provide on-the-job training and close supervision of all use of the PIT during a learners permit period. 
• Signature of the licensed PIT operator to verify agreement to provide the OJT.
• Signature of the prospective PIT operator’s supervisor.  The signature verifies that the employee will be required to operate the identified PITs as part of the LBNL employment.  The certification is not valid for any other purpose.  The supervisor’s signature also ratifies the designation of the licensed PIT operator as a mentor and task supervisor during the learners permit period.
• A signature or certificate from Health Services, verifying that the employee meets minimal medical requirements.
• The operator must complete EHS0225 Powered Industrial Truck Operator Classroom Training.  Upon completion of this course, a learner’s permit is issued when needed, and the individual may operate PITs under the direct supervision of the experienced PIT operator identified on the application.  The learner’s permit will expire no later than 60 days from the date of issuance.
• When the prospective operator has acquired sufficient experience, he/she may contact the instructor to be examined on the operation of the PITs to be operated.  If the candidate is to be certified on several types of PITs, a separate examination will be conducted for each PIT.  Upon receipt of the examination certification from the instructor, the EH&S Training Office will record that the employee has completed EHS0224 Powered Industrial Truck Practical and will issue a permit to operate the specific PITs the employee was examined on.  The certification will be valid for no more than 3 years.
• The PIT certification must be renewed whenever the operator is observed to operate a PIT in an unsafe manner, or when the operator is involved in a PIT accident, but at least once very three years.  Note that the certification will be revoked or suspended by the PIT program manager in case of an accident or unsafe operation of the PIT.  At renewal, the operator must complete a medical questionnaire, which will be reviewed and must be approved by Health Services.  The employee will then be reevaluated on each type of PIT that is to be covered by the recertification.  There is no requirement to repeat the classroom training.

28.6 Forklift / PIT Manager

For each forklift and other PIT, a current employee must be identified as PIT manager to the Facilities Transportation Group. The following requirements apply:

• The PIT manager must have a valid certificate for the operation of the PITs in question.
• The PIT manager is responsible for controlling use of the PIT and limiting use of the PIT to qualified operators.  The PIT manager is the custodian of any keys or other mechanisms for limiting use of the PIT.
• The PIT manager is responsible for maintaining the records of the daily inspections that are required for all PITs.  See Appendix C and Appendix D.

PIT manager assignments must be kept current.  The Facilities Division will work with the respective Division ES&H Coordinator to update PIT manager assignments.  The Facilities Division will take out of service all PITS for which no PIT manager is identified until a PIT manager is identified.

28.7 General Requirements for Forklift and Other PIT Operation

The following rules apply to all use of forklifts and other PITs at the Lab:

• Do not operate any forklift or PIT unless you have the required operator certificate.
• Do not operate any forklift or PIT until the required daily inspection has been performed and documented.
• Estimate the weight of the rated load to assure that you do not exceed the rated load capacity of PITs.
• Always ensure the load is against the backrest.
• Follow all safety rules regarding speed, parking, loading, unloading, and moving loads. Operators should use extreme caution when operating on ramps, grades, or inclines.

• Always drive an unloaded forklift with the forks on the downhill side.
  Drive down forward and back up.

• Never turn a forklift sideways on a ramp.

• Check the floor loading limit before a PIT enters an area.  The floor must safely support the forklift, the load, and all materials that are already in the area.
• Drive material-moving equipment forward going up a ramp and backward going down a ramp. Note: Pallet jacks should not be used on ramps, unless the load is securely strapped to the pallet and the pallet is strapped to the pallet jack platform.
• Never allow traffic or personnel to pass under a raised load, nor allow a load to pass over personnel or traffic.
• Do not allow passengers to be carried on any PIT unless it is specifically equipped by the manufacturer to carry passengers.
• Never leave an elevated load unattended. Lower the forks to the floor, set the brake, and turn off the PIT before leaving the PIT unattended.
• Keep traffic lanes and loading areas clear and appropriately marked.
• Store materials in work rooms or designated storage areas only. Do not use hallways, fan lofts, or boiler and equipment rooms as storage areas.
• Do not allow exits, passageways, or access to equipment to become obstructed by either stored materials or materials and equipment in use.
• Arrange stored materials safely to prevent tipping, falling, collapsing, rolling, spreading, or any other unsafe motion.
• Modifications of PITs and addition of equipment to PITSs may only be performed by the PIT manufacturer or by qualified PIT mechanics with the approval of the manufacturer.
• Do not use front-end attachments other than factory-installed attachments; make sure that the truck is equipped with a plate that identifies the attachments, shows the approximate weight of the truck with attachments, and shows the lifting capacity of the truck with attachments at maximum lift elevation with the load laterally centered.
• All forklift trucks must carry fire extinguishers, usually 2-1/2lbs ABC, regardless of their location classification.
• Only trained operators shall replace LPG tanks on forklift trucks or charge batteries.  Battery changing may be performed only by trained and authorized PIT service personnel

28.8 Maintenance and Inspection

28.8.1 General

All forklifts and other PITs must be inspected daily before they are used.  The inspection must be documented on the daily inspection checklists shown in Appendix C and Appendix D, and the checklists must be kept on file by the PIT manager.

Because forklift trucks may become hazardous if maintenance is neglected or incomplete, all forklifts and other PITs must be routinely inspected and maintained by the Laboratory’s PIT maintenance contractor.  Contact the Facilities Transportation Group at ext. 5404 for any questions concerning routine inspection or maintenance, or to report conditions that require repair or emergency maintenance.

If PIT components have been overloaded or stressed beyond capacity, or when there are other reasons to believe that there might be damage to the lifting components, magnetic particle inspection for cracks must be made, primarily at the heel of the forks.  Contact the Transportation Group in the Facilities Division assistance when such issues are suspected.

28.8.2 Fork Extensions

Fork extensions are only appropriate for occasional use, and with rather light loads. Usually the right solution is a forklift with longer forks, but the Rigging and Transportation Groups in the Facilities Division do have extensions available for awkward but light-weight loads. When longer forks are needed on a regular basis, the truck should be equipped with standard forks of a longer length. Contact the Transportation Group in the Facilities Division to acquire a forklift with the proper length forks, or to have the forklift equipped with longer forks through the services of the PIT maintenance contractor.

Reliability and safety require that fork extensions be used properly. That requires determining the center of gravity and calculating the capacity of the forklift at the center of gravity for a specific lift. Each specific use of forklift extensions must be reviewed and approved by the LBNL Rigging Supervisor or by one of the certified forklift instructors.

Routine on-the-job inspections of the fork extensions must be made by the fork lift operator before each use.

Purchasing properly rated and certified forklift extensions is rarely cost-effective.  Rather than purchasing forklift extensions, contact the Facilities Rigging Group or Transportation Group for assistance with awkward loads that require use of extensions.  If extensions must be procured, contact the Facilities Division Crane and Elevator Office for assistance.

28.9 Responsible Parties

28.9.1 Supervisors

Supervisors must make certain that only those employees who are formally qualified by training and certification may operate a fork truck or other PIT.  Supervisors must enforce the use of safe lifting practices and maintain lifting equipment in good mechanical and operating condition.

28.9.2 PIT Operators

Employees may only operate those forklifts and PIT that they hold specific operator certification for.  They must adhere to all safety requirements pertaining to the use of PITs, including the requirement for daily inspections of forklifts and other PITs.

28.9.3 Facilities Division Rigging Supervisor

On request, the Facilities Division Rigging Supervisor will provide guidance and assistance with lifts; participate in the development and review of high-consequence/high-value moves/lifts; participate in pre-lift meetings; and review and approve the use of forklift extensions.

28.9.4 Facilities Division Transportation Group

The Facilities Division Transportation Group maintains an inventory of all forklifts and other PITs, and arranges for routine maintenance and repair of PITs. Contact this group to coordinate all procurement of forklift and other PIT equipment, service, repair, and modification.

28.10 Standards

• 29 CFR 1910.178 Powered Industrial Trucks
• ASME B56.1, Low Lift and High Lift Trucks (2004)
• ASME B56.6, Rough Terrain Forklift Trucks (2002)

28.11  Related LBNL/PUB-3000 Chapters

EH&S Training (Chapter 24)

28.12 References

NFPA No. 505-1969, National Fire Protection Association Powered Industrial Trucks 

Appendix A. Powered Industrial Truck Operator Application

	APPLICATION Powered Industrial Truck TRAINING AND CERTIFICATION   (circle one) Renewal?   Yes    No
Employee Information
Name (Last, First, MI):										Employee No.
Job Title			Drivers  License No.				Exp. Date
Division	Dept		Mail Stop				Phone Ext.			Last Certificate No.
Employee Signature							Date			Attach:    copy of old card (if applicable)                 copy of current drivers license
Employee will operate the following lift trucks (list trucks).  A separate evaluation is required for each truck type at the maximum rated capacity to be operated. Sit-on forklifts: ___ LP fueled    Max Rated Capacity ___ tons;       Transmission: ___ manual ___ automatic ___ Gas/diesel  Max Rated Capacity ___ tons,      Transmission: ___ manual ___ auto ___ Electric       Max Rated Capacity ___ tons,      Control: ___ standard ___ monotrol								Walk-behind equipment: ___ Electric pallet mover, Max Rated Capacity ___ tons ___ Electric stacker,         Max Rated Capacity ___ tons Other: ___ ElPar, 30 tons ___Special (describe)
On-The-Job Trainer: The following licensed PIT operator will provide on-the-job training until the operator is ready to be examined and certified, and he/she agrees to do so:
Name (Last, First, MI):				Employee No.						Signature
Supervisor Approval: This employee needs to operate the above equipment as part of his work duties and I authorize his training and certification as operator
Name (Last, First, MI):				Employee No.						Account No. for Applicant Use
Division	Dept			Mail Stop		Phone Ext.				Supervisor Signature
Medical Approval: This employee meets the medical criteria for operating forklifts and other powered industrial trucks
Date of Exam	Medical Approver (Type or Print Name)						Medical Approver Signature				Date
Trainer Information
Date of Lecture	Lecture Trainer (Type or Print Name)						Signature				Pass/No Pass
Date of Practical	Practical Examiner (Type or Print Name)						Signature				Pass/No Pass
		To be completed by Lecture & Practical Trainers			Restrictions: Void unless accompanied by a valid state driver’s license
PIT Operator Learner’s Permit					Name _______________________________ Qualified to Operate
					TYPE VEHICLE AND/OR EQUIPMENT				CAPACITY		Pass/Fail for Practical Examination
This individual is authorized to operate the Powered Industrial Trucks listed under the direct supervision of the following on-the-job trainer:					Sit-on forklifts: __ LP, __ manual __ automatic __ Gas/diesel. __ manual ___ auto __ Electric, __ std ___ monotrol Walk-behind equipment: __ Electric pallet mover __ Electric stacker Other: __ ElPar __ Special (describe) ___________ __________________________				__ tons __ tons __ tons __ tons __ tons 30 tons __ tons		__________________ __________________ __________________ __________________ __________________ __________________ __________________
OJT Trainer___________________
Lecture Trainer issuing this permit: ___________________________ Date: _______________________ This Learner’s Permit expires 90 days from date of issue.

Appendix B. Powered Industrial Truck Application Instructions

POWERED INDUSTRIAL TRUCK APPLICATION COMPLETION PROCESS (use ink)
Until all of the following steps are completed and requested information provided licenses will not be issued.

STEP 1.  Applicant indicates initial or renewal training on top of form.

STEP 2.  Applicant completes Employee Information, indicates what forklifts and/or powered industrial trucks are to be operated, provides a copy of current driver's license and signature to application.

STEP 3.  Applicant and Supervisor agree on a licensed PIT operator who will provide OJT, obtain agreement signature of this individual.

STEP 4.  Supervisor completes Supervisor Approval and provides signature.

STEP 5.  Medical Approval: All Forklift Applicants must obtain medical approval from Health Services (Bldg. 26).  Medical approval usually required a medical exam.  To schedule an appointment for an exam contact x6266.  If sufficient information is in the employee’s medical file, the exam may be waived.

STEPS 1-5 must be completed before proceeding on to remaining items

STEP 6.  Forklift Classroom Session (EHS0225)  The classroom trainer will sign the form if the employee attends the entire class and passes the written exam in class.  The classroom instructor will also issue a Learner’s Permit and will assign a practical trainer to the employee at that time.

STEP 7.  The EH&S Training Office credits the employee in the EH&S Training Database for having completed the classroom training for Powered industrial Truck Operators, EHS0225.

STEP 8.  Applicant receives On-The-Job training in PIT operation under the close supervision of the designated OJT trainer for a period not to exceed 90 days.  When ready, applicant contacts designated practical examiner and arranged for the practical examination.

STEP 9.  Forklift Practical Session  The practical examiner will examine the employee on each type of forklift or powered industrial truck to be operated.  Employees who fail the practical examination will have to repeat the examination until they pass.

STEP 10.  Practical examiner completes application, indicating which equipment applicant was examined on and whether applicant passed or failed.  Practical examiner forwards signed form to EH&S Training office.

STEP 11.  EH&S Training Office credits applicant on the training database for having completed the PIT Practical Session and processes the Berkeley Lab Powered Industrial Truck Permit.  The permit is a laminated card to be worn with the employee’s Laboratory badge.

Appendix C. Electric Forklift Daily Inspection Form

Appendix D. LP, Gas, or Diesel Forklift Daily Inspection Form

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