1. Forklift Operator Training OSHA 1910.178 Powered Industrial Trucks
Adopted from the OSHA Forklift presentation for FEMA warehouse forklift operator training
The scope provisions of (a), which are based on ANSI B , remain in effect and cover:
... fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines.
It does not apply to compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, nor vehicles intended primarily for earth moving or over-the-road hauling.
This scope covers general industry, construction and shipyards.
Developed by HMTRI through cooperative agreement
# 2 U45 ES with NIEHS under the Worker Safety and Health Training Support Annex

2. Objectives of this training - At the end of this session, you should be able to:
Identify the hazards involved with Powered Industrial Trucks (PITs)
Explain the different types of PITs
Conduct a PIT visual inspection
Pass the written test
Demonstrate proficient operator skills on a forklift
Trainer Notes:
State and federal agencies are deploying in support of hurricane relief efforts
Environmental and occupational health hazards are a potential threat to deployed personnel
Hurricane Katrina left the Louisiana and Mississippi coastlines in ruin. Up to 1 million people are without power, safe food, and safe water.
Additional Training is required for specific operations involving, but not limited to:
Confined Spaces
Excavations
Heavy Equipment operators
Fall Protection
Work Zone Safety

3. OSHA 1910.178 Powered Industrial Trucks - Operator Training
(a)(2)(xiv)
(b)(10)
(d)
General Industry: is amended March 1, 1999) by revising paragraph (l) and adding Appendix A.
Shipyard Employment: New section and Appendix A are added.
Maritime and Construction Standards: [ (a), (a)(2)(xiv), (b)(10), (d)] refer back to (l).
Longshoring: Section is amended by adding new paragraph (b)(10) and Appendix A.
OSHA’s Office of Training and Education wishes to acknowledge the following for contributing some of the graphics used in this presentation:
Caterpillar Lift Trucks
Mason Contractors Association of America
Industrial Truck Association
State of Utah Labor Commission - Occupational Safety & Health Division
Steamship Trade Association of Baltimore
Taylor Machine Works, Inc.
UAW - Ford National Joint Committee on Health and Safety
Appearance of products does not imply endorsement by the U.S. Department of Labor.

4. Powered Industrial Truck - Definition
A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]
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.

5. Performance-Oriented Requirements
The powered industrial truck operator training requirements are performance-oriented to permit employers to tailor a training program to the characteristics of their workplaces and the particular types of powered industrial trucks operated.

6. Operator Training Safe operations
The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.
Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the required training (or previously received appropriate training).

7. Training Program Implementation
Trainees may operate a powered industrial truck only:
Under direct supervision of a person who has the knowledge, training, and experience to train operators and evaluate their competence; and,
Where such operation does not endanger the trainee or other employees.

8. Training Program Implementation (continued)
Training shall consist of a combination of:
Formal instruction (e.g., lecture, discussion, interactive computer learning, written material),
Practical training (demonstrations and exercises performed by the trainee), and
Evaluation of the operator’s performance in the workplace

9. Training Program Implementation (continued)
Training and evaluation shall be conducted by a person with the knowledge, training and experience to train powered industrial truck operators and evaluate their competence.

10. Training Program Content
Operators shall receive initial training in the following topics, except in topics which the employer can demonstrate are not applicable to safe operation in the employer’s workplace.
Truck-related topics
Workplace-related topics
The requirements of the standard

11. Training Program Content (continued)
Truck-related topics
Operating instructions, warnings and precautions
Differences from automobile
Controls and instrumentation
Engine or motor operation
Steering and maneuvering
Visibility
Fork and attachment adaptation, operation, use
Vehicle capacity and stability
Vehicle inspection and maintenance that the operator will be required to perform
Refueling/Charging/ Recharging batteries
Operating limitations
Other instructions, etc.

12. Training Program Content (continued)
Workplace-related topics
Surface conditions
Composition and stability of loads
Load manipulation, stacking, unstacking
Pedestrian traffic
Narrow aisles and restricted areas
Operating in hazardous (classified) locations
Operating on ramps and sloped surfaces
Potentially hazardous environmental conditions
Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup

13. Refresher Training and Evaluation
Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.
Refresher training required when:
Unsafe operation
Accident or near-miss
Evaluation indicates need
Different type of equipment introduced
Workplace condition changes

14. Refresher Training and Evaluation (continued)
An evaluation of each powered industrial truck operator’s performance must be conducted:
After initial training,
After refresher training, and
At least once every three years

15. Certification
The employer shall certify that each operator has been trained and evaluated as required by the standard.
Certification shall include:
Name of operator
Date of training
Date of evaluation
Identity of person(s) performing the training or evaluation

16. Appendix A - Stability of Powered Industrial Trucks
Definitions
General
Basic Principles
Stability Triangle
Longitudinal Stability
Lateral Stability
Dynamic Stability
Appendix A provides non-mandatory guidance to assist employers in implementing the standard.
This appendix does not add to, alter, or reduce the requirements of this section.

17. Stability Triangle - Figure 1
Vehicle Center of
Gravity (Unloaded) B A
Center of Gravity
of Vehicle and
Maximum Load
(Theoretical) C
Notes:
1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C. Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.
2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.

18. Stability Triangle - Figure 2
Load CG
Load CG
Vertical
Stability
Line
(Line of Action)
Combined CG
Combined CG
Vertical
Stability
Line
(Line of Action)
Truck CG
Truck CG
This vehicle is unstable and
will continue to tip over
The vehicle is stable

19. Effective Powered Industrial Truck Operator Training Program
Four major areas of concern must be addressed:
The general hazards that apply to the operation of all or most powered industrial trucks;
The hazards associated with the operation of particular types of trucks;
The hazards of workplaces generally; and,
The hazards of the particular workplace where the vehicle operates.

20. Types of Powered Industrial Trucks
There are many different types of powered industrial trucks covered by the OSHA standard.
Commonly used types include:
High lift trucks, counterbalanced trucks, cantilever trucks, rider trucks, forklift trucks, high lift trucks, high lift platform trucks, low lift trucks, motorized hand trucks, pallet trucks, straddle trucks, reach rider trucks, high lift order picker trucks, motorized hand/rider trucks, and counterbalanced front/side loader lift trucks.
A single type of truck can only be described by calling it by all of its characteristics, (e.g., a high lift, counterbalanced, sit down rider truck).

21. Unique Characteristics of Powered Industrial Trucks
Each type of powered industrial truck has its own unique characteristics and some inherent hazards.
To be effective, training must address the unique characteristics of the type of vehicle the employee is being trained to operate.

22. A PIT is a PIT NOT a CAR Controls are different from those of cars.
Steer very differently than cars.
Are used for different purposes than cars.
Steer from the rear, and have drive wheels in the front.
When turning, the rear end swings in a circle.
Front drive wheels support most of the load.
Less steering control when turning, especially if loaded.
Difficult to stop quickly and dangerous to swerve. 17

23. Components of a Forklift Truck*
*One of the most common types of powered industrial trucks

24. Classes of Commonly-Used Powered Industrial Trucks*
The Industrial Truck Association has placed powered industrial trucks into 7 classes.
Class I - Electric motor rider trucks
Class II - Electric motor narrow aisle trucks
Class III - Electric motor hand trucks or hand/rider trucks
Class IV - Internal combustion engine trucks (solid/cushion tires)
Class V - Internal combustion engine trucks (pneumatic tires)
Class VI - Electric and internal combustion engine tractors
Class VII - Rough terrain forklift trucks
* Note that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

25. Class I - Electric Motor Rider Trucks
Counterbalanced rider type, stand up
Three wheel electric trucks, sit-down
Counterbalanced rider type, cushion tires, sit-down (high and low platform)
Counterbalanced rider, pneumatic tire, sit-down (high and low platform)

26. Class I - Electric Motor Rider Trucks

27. Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires
Fork, counterbalanced (cushion/solid tires)

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

29. Class V - Internal Combustion Engine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)

30. Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

31. Pre-use Inspection
Must be done at least daily or at the beginning of each shift
Check the power-plant
Gas, Diesel or Propane Powered
Electric Powered
Check for damage and proper operation.
Additional information on checklists may be found at the following link: 16

32. Performance Data
Gross vehicle weight without a load will always exceed the vehicle’s rated lifting capacity
Gross vehicle weight will normally be about 2 times the vehicle’s rated capacity
Weight distribution varies depending on load weight and position 21

33. Load Stability NEVER EXCEED the rated load capacity of your PIT
Look for Impact or Capacity plate to find:
>machine working capacity
>gross vehicle weight
>rated load center
>capacity rating with attachment
>tire data
>attachment identification
>maximum lift height 22

34. Reduce your load if:
The load is too tall, wide, oddly shaped or if you are using attachments.
A high lift is involved or if the route is rough.
The load can’t be centered on the pallet or carried close to your drive wheels.
You have to make tight turns or travel on a ramp or slope. 23

35. To Keep the Load Stable:
Space your forks as far apart as possible.
Make sure the load won’t shift while traveling.
Secure loose or slippery items.
Transfer loads on broken pallets to sound pallets before picking them up.
Wrap or strap loads made up of individual items. 24

36. Load Capacity Attachments Batteries
When in doubt consult your supervisor 25

37. Stability in Practice
Your PIT and load become less stable in any of the following situations:
whenever the load is raised
when you are turning
on slopes, either front to back or side to side
when tilting the load forward or backward, or side to side
on rough or uneven surfaces 26

38. Center of Gravity and Stability Triangle
Drive Tires
Steering Axle 18

39. Center of Gravity Will Shift
STATIC FORCES
are affected by:
a) load characteristics
b) lift height
c) amount of tilt
d) tire condition
DYNAMIC FORCES
are affected by:
a) acceleration
b) travel speeds
c) braking
d) surface condition 19

40. Counterbalance
load is carried at front of vehicle and is offset or counterbalanced by the weight of the vehicle located behind the drive tires which act as a pivot point
internal combustion-engine, steer axle, transmission, counterweight, and frame
electric powered battery, control panel, motors and pumps, steer axle, counterweight, and frame 20

41. Some Questions to Help Judge a Load:
What is the rated load capacity of my truck?
Is this load well within the capacity limits?
Will the shape of this load affect my stability?
Will the load affect my visibility?
Do I need to split up the load?
Do I need to drive in reverse?
What hazards are along the route? ? 27

42. Some Questions to Help Judge a Load:
What turns will I have to negotiate?
Are there ramps, slopes, rough ground or obstacles?
What about the destination?
Can I get close enough?
Can I pull straight in?
Is the area free of overhead hazards like power lines, pipes or ventilation equipment? ? 28

43. Principles of Internal Combustion
Fuel Type
Engine Starting Conditions
Refueling
Changing an LP Tank
Gasoline 29

44. Principles of Electric Battery Power
Three Primary Voltage Types
Recharging a Battery
Trained Personnel ONLY
SOPs
PPE
Designated Areas ONLY 30

45. Maintenance of PITs If defective, take out of service
Repair by authorized personnel only
Repair parts as safe or safer than original
Do not alter from manufacturer’s design
Repair in designated location 31

46. Safe Parking Procedures
How and Where to Park?
Attended Parking
Unattended Parking
Parking on an incline 32

47. Lifting a Load
Level the forks and slowly drive forward until the load rests against the mast.
Do not slam a load into the carriage.
Lift the load high enough to clear whatever is under it.
Assess the stability of the load.
Tilt the mast back slightly to a traveling position. 33

48. Lifting a Load
If there is another load in front of yours, lift without tilting.
Reassess load stability.
Look over both shoulders to make sure it is safe to move in reverse.
If there are no obstacles to the rear, back out slowly about one foot to insure the load will clear.
Back away to completely clear the load.
Lower load to travel and reassess load stability. 34

49. Carrying the Load Keep your vehicle under control at all times
Keep forks close to floor
Maintain safe distance (3 vehicle lengths)
Examine surfaces - safety and strength
Safe speed - a brisk walking pace 35

50. Carrying the Load Stay within the vehicle lanes.
Look over both shoulders before you back up.
Stop before raising or lowering loads.
Tilt the load slightly back with forks low.
Drive at a slow, steady pace.
Observe speed limits and controlled
Slow down for turns, sound your horn and stay near the inside corner. 36

51. Carrying the Load
Slow down and sound your horn at intersections and places with limited view.
Drive in reverse if your vision is obstructed by your load.
Yield to pedestrians - always!!! 37

52. Carrying the Load Never travel or turn with the load elevated.
Never drive up to anyone standing in front of a fixed object. 38

53. Carrying the Load
Never allow anyone to stand on your fork or lift people without an approved platform.
Never allow anyone to walk or stand under your forks, whether the forks are loaded or empty.

54. Carrying the Load
Surfaces you should avoid or be very careful on or around include:
Loose objects, bumps or uneven floors
Rough surfaces
Wet, oily or icy surfaces
Railroad tracks and similar edges, which you should cross at a 45-degree angle whenever possible 39

55. Putting Down a Load
Square up and stop about 1 foot away from the loading area
Drive about 1/2 way into the unloading area
Lower the load, assess alignment, stability
Lower forks slightly
Look over both shoulders and back out slowly 40

56. Working with Stacks
The higher you go - the less stable your PIT and load 41

57. Working with Stacks Remember these stacking rules:
Set the top load squarely on the stack
Never raise or lower a load unless you fully stop
Never attempt to turn with your mast raised
Approach load straight on and back straight out
Make sure you have enough overhead clearance
Watch for electrical lines, pipes, fixtures, sprinklers 42

58. Traveling on Grades Stay well back from the edge
Never turn around on the slope
Drive with your load on the uphill side!!!
When loaded, drive up slopes with your load in front and drive down slopes in reverse.
When the forks are empty, back up a slope and drive down it forward. 43

59. Working on Docks DOCK WORK CHECK SHEET
Check to make sure that wheels are chocked!
Check the front support on a trailer to insure it won’t shift.
Check to make sure the train car or trailer brakes as set.
Check the dock locks.
Check the deck capacity.
Check combined vehicle and load weight.
Check dock plate condition and position. 44

60. Do not jump from the unit!
In Case of a Tip-over
Do not jump from the unit!
HOLD ON TIGHT
BRACE YOUR FEET
LEAN AWAY FROM THE TIP DIRECTION 45

61. Summary
Operating a Powered Industrial Truck is a highly skilled job that is dangerous if not done properly.
You need to know all about your PIT and its operation including:
design and function
controls and instruments
pre-use inspection
stability
capacity and visibility 46