This is a grey area for many companies: does a pallet truck fall within the provisions of LOLER (Lifting Operations and Lifting Equipment Regulations 1998)? Technically speaking, it does lift loads off the floor. If so, it would require a ‘thorough examination’ by a ‘competent person’, typically a third party such as an insurance inspector or product specialist, subsequently incurring a cost and administrative burden. It therefore becomes important to define whether a pallet truck is lifting equipment, or not.
Fortunately, BITA Guidance Note GN28 (‘Thorough Examination And Safety Inspections Of Industrial Lift Trucks’) provides clarity with the following statement: “Low lift (pallet) trucks, that is non-stacking powered and manual trucks with forks or load platform that lift to not more than 300mm from the ground, do not require thorough examination under LOLER 98 regulation 9. They do, however, need periodic safety inspections as means of addressing PUWER regulation 6.”
David Goss, technical director at the UK Material Handling Association (UKMHA), says: “Unfortunately, periodic inspections under PUWER [Provision and Use of Work Equipment Regulations] are a little vague, although the onus is clearly on the employer [duty holder] to work out what is safe and explain why the company feels something is safe.” UKMHA was formed by the merger of BITA and FLTA.
He adds: “It’s reasonable to expect the periodic inspection of a pallet truck to take place every year, which could form part of routine maintenance. There is no reason why someone competent in maintenance cannot perform the inspection. However, any failures to carry out inspections under PUWER could result in HSE action, particularly if there is an incident. The duty holder must also keep a record of all inspections and show actions on any findings.”
For pallet trucks used in harsh environments, such as those involving poor-quality surfaces, Goss says it would be reasonable to expect shorter periods between inspections.
COMMON CHECKS
So what are the common issues that an annual inspection might reveal? According to Goss, the inspector should check for signs of oil leakage, how well the truck holds its raised height, and brake performance. It is also advisable to check the rollers and wheels for wear and damage, as well as the condition of the bearings. To get things right, however, companies must look beyond inspections alone, according to Goss.
“With pallet trucks, it’s not just about inspections and maintenance, it’s also about training, and who is trained to use which truck types,” he says. “For instance, pallet trucks are widely used on the tail-lifts of delivery vehicles, where drivers often don’t receive any training. It’s very easy to fall off the back of a truck with a 1t load landing on top, due to lack of training or poorly-maintained equipment. Even in a factory environment, it’s common to see pallet trucks lifting 1,000kg or more. If that loaded truck rolls with momentum across a surface, it can easily cause very serious crush injuries. So training isn’t to be taken lightly.”
Employers are obliged to provide adequate operator training for the purposes of health and safety, including: training in the methods which may be adopted when using work equipment; any risks which such use may entail; and precautions to be taken before, during and after operation. The degree of training needed, and the time it will take, will vary according to the type of equipment and the tasks required, but UKMHA recommends that basic training be provided by a trainer accredited by a member of ABA (Accrediting Bodies Association for Workplace Transport).
In the forklift industry, every truck has its own ABA category to ensure the correct areas are covered during any training set by the appropriate accrediting bodies. ABA identifies manual and semi-manual hand pallet trucks as category Z1, and low-lift, pedestrian-controlled, electric-powered pallet trucks as category A1. It is important that training should not just be on the equipment type (basic training), it should include specific job training (actual equipment, loads and working environment) with a period of familiarisation under supervision.
COMMODITY ITEMS?
Of course, some companies buy their pallet trucks from a catalogue or website, which means there is unlikely to be any support available regarding training or maintenance.
“As long as it’s appropriately marked, any pallet truck purchased from such sources should still be a perfectly usable, adequate product, but that doesn’t take away your obligation to make sure it’s maintained properly and your operators are trained,” concludes Goss. “The benefit of buying a renowned brand is that you get the manufacturer’s or distributor’s support. Whatever happens, the duty is on the employer, not the seller of the truck, to provide training, maintain the equipment and ensure its safe use. If you need help with that, make sure the vendor is capable of providing the right level of support.”
BOX: PROLONG PALLET TRUCK LIFESPAN
Parts supplier TVH offers tips to prolong the lifespan of pallet trucks. Top of the pile is checking the oil level every six months and topping up or replacing it every year. The oil should have a viscosity of 30cSt at 40°C, with a total volume of approximately 0.4 litres (ISO VG32). If other oil is used, the pallet truck may be hard to pump up, as it will likely be too thick.
Number two on the TVH list is lubrication. The company recommends lubricating the wheels, axles and grease fittings with long-life grease on a monthly basis and/or after each clean.
Regular cleaning of the wheels and the removal of any noticeable dirt before use is another tip for extending the lifecycle of pallet trucks, while using the pallet truck in a correct and safe way is further good practice. To move the pallet truck, always set the operating lever in the ‘drive’ position, as this ensures that the drawbar moves more easily and reduces the pressure in the hydraulic pump section. Adopting this routine protects the hydraulic seals and valve components, ensuring longer lifespan.
BOX: SIMPLE REPAIR GUIDANCE
According to manufacturer Jungheinrich, it is possible to use industrial pallet trucks for many years without problems, provided proper handling and regular maintenance. Any yet on occasion this type of equipment may develop issues, such as not lowering or manoeuvring as expected. However, rather than hiring a specialist repair technician, users can carry out simple repairs themselves, such as bleeding the hydraulic system to remove air or foreign bodies as part of a regular inspection.
To bleed the system, unload the pallet truck, move the fork handle to the lowering position, then pump vigorously several times. If this quick procedure is not sufficient, it is possible to release the air via the bleed screw on the hydraulic cylinder. If bleeding air does not improve the situation, the oil level is probably too low or contains contamination. Topping up the oil in line with the manufacturer’s specification, or draining and replacing the oil in the tank, should rectify matters.
Replacing the transport rollers is another potential in-house task, assuming the company has replacements of the appropriate size and load. Jungheinrich recommends selecting original parts for this purpose, as only these will be optimally compatible with the lift truck, ensuring trouble-free operation.
If the pallet truck still behaves sluggishly or remains difficult to manoeuvre during load transport, the fault will likely be a defective chassis, which will require a specialist.