Powered Industrial Trucks -

Operator Training

1910.178 (l)

1915.120 (a)

1917.1 (a)(2)(xiv)

1918.1 (b)(10)

1926.602 (d)

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Powered Industrial Truck - Definition

• A mobile, power-propelled truck used to carry,

push, pull, lift, stack or tier materials.

• Excluded are vehicles used for earth moving and

over-the-road hauling.

• Commonly known as forklifts, pallet trucks, rider

trucks, forktrucks, or lifttrucks.

• Can be powered through electric or combustion

engines.

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Final Rule

• OSHA published the final rule for Powered

Industrial Truck Operator Training on

December 1, 1998.

• The effective date is March 1, 1999.

• It applies to all industries except agricultural

operations.

• OSHA estimates that the new rule will

prevent 11 deaths and 9,422 injuries per

year.

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The Certification Process

• Review Safe Operating Rules as published by

OSHA.

• Watch a video which demonstrates the safe

operation of Powered Industrial trucks.

• Complete a written exam.

• Complete a skill test on actual equipment.

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The certification is valid for one or three

years and will include the following:

• Certificate of Achievement • Powered Industrial Truck Operator’s Card

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The explicit purpose of forklift safety is to eliminate:

• Accidents and Injuries,

86 89

120

95

114

1992 1993 1994 1995 1996

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Forklift Fatalities by Age Group 1992 -1996

3%

10%

22%

21%

12%

5%

27%

Under 20

20 - 24

25 - 34

35 - 44

45 - 54

56 - 64

65 & over

Source: Bureau of Labor Statistics

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Industries Where Powered Industrial Truck Accidents Occurred

Industry

# Accidents

Investigated by

OSHA

Mining 4

Construction 25

Manufacturing 95

Tranportation, Communication, Utilities 22

Wholesale Trades 25

Retail Trades 18

Service 7

Public Administration 4

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Property Damage, which can be very

costly for your company

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Equipment Abuse and Damage.

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Class I - Electric Motor Rider

Trucks

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Class II - Electric Motor Narrow Aisle Trucks

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Class II - Narrow Aisle Trucks

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Class III - Electric Motor Hand or Hand/Rider Trucks

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Class III - Hand & Hand/Rider Trucks

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Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

Fork, counterbalanced (cushion/solid tires)

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Class IV - Internal Combustion Engine Trucks - Cushion (Solid)

Tires

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Class V - Internal Combustion Engine Trucks - Pneumatic Tires

Fork, counterbalanced (pneumatic tires)

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Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

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Class VI - Electric & Internal Combustion Engine Tractors

Sit-down Rider

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Class VII - Rough Terrain Forklift Trucks

– Straight-mast forklift – Extended-reach forklift

All rough terrain forklift trucks

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Rough Terrain Straight Mast

Forklifts

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Rough Terrain Extended-Reach

Forklifts

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Some Types of Powered Industrial Trucks Used in Maritime

– Container top handlers

– Container reach

stackers

– Straddle carriers

– Semi-tractors/ Utility

vehicles

– Sidehandlers

– Combination vacuum

lifts

– Yard tractors

The following types of vehicles are

covered by the OSHA standard if the

vehicles carry, push, pull, lift, or tier loads.

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Powered Industrial Trucks Used in Maritime

Container Handlers

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Powered Industrial Trucks Used in Maritime

Empty-Container Handler

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Powered Industrial Trucks Used in Maritime

Container Reach Stacker

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Powered Industrial Trucks Used in Maritime

Straddle Carriers

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OPERATING RULES

• Drivers will check the vehicle at least once per shift, and if it is found to be unsafe, the matter will be reported immediately to a supervisor. (#2)

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• Vehicles will not exceed authorized or safe speed . (#3)

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• NO RIDERS WILL BE PERMITTED ON VEHICLES,

unless a safety platform with guardrails is provided.

(#5)

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This is NOT a Safety Platform!

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• A loaded vehicle will not be moved until the load is

safe and secure. (#7)

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• When leaving a vehicle unattended, the power will be shut off, brakes set, the mast brought to the vertical position, and the load-engaging means left in the down position. (#8)

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• Vehicles will not be driven in and out of highway trucks and trailers at unloading docks until such trucks are securely blocked and brakes set.(#14)

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• Vehicles will not be operated on floors, sidewalk doors, or platforms that will not safely support the loaded vehicle. (#15)

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• The forks will always be carried as low as

possible, consistent with safe operations,

usually 4 inches off the floor. (#18)

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• Extreme care will be taken when tilting loads. Loads

may fall or forklifts can easily be turned over while

tilting moderate loads. (#19)

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• Employees will not place any part of their bodies

outside the running lines of an industrial truck or

between mast uprights or other parts of the truck

where shear or crushing hazards exist. (#21)

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• The width of one tire on the powered industrial truck will be the minimum distance maintained from the edge by the truck while it is on any elevated dock, platform, freight car or truck. (#24)

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• The driver will slow down and sound the horn at cross

aisles and other locations where vision is obstructed. If

the load being carried obstructs forward view, the

driver will be required to travel in reverse, with the load

trailing. (#28)

• Trucks will not be loaded in excess of their rated

capacity. The rated capacity of the truck must be

clearly visible by the operator. (#31)

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No truck will be operated with a leak in the fuel, oil

and hydraulic systems. (#33)

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A

B

C

Vehicle Center of

Gravity (Unloaded)

Center of Gravity

of Vehicle and

Maximum Load

(Theoretical)

Tilting forward with the load engaging means is prohibited except when

picking up a load. Elevated loads will not be tilted forward unless the load is being deposited onto a storage rack or equivalent. By tilting forward the fork lift can be overturned, due to the change in the trucks center of gravity. (#34)

Note: When the vehicle is loaded, the combined center of gravity shifts toward line B-C. Theoretically the maximum load will result in the center of gravity at the line B-C.

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• Special precautions will be taken in the

securing and handling of loads by trucks

equipped with attachments. Any attachment

changes the center of gravity and the

maximum capacity rating of the lift. (#36)

• The engine must remain running and the

operator at the controls, when a person is

elevated in a safe platform. (#37)

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• Forklift and electric pallet jack operators may not

smoke while operating this equipment. Sparks,

open flames or smoking are not allowed in an area

within 50 feet of any battery charging or refueling

operation. (#38)

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Remember, Always wear your

Seatbelt!

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