1. Occupational Health and Safety Program Powered Industrial Trucks Operator Training
29 CFR

2. For More Information Contact
Richard T. Owen, Safety Coordinator
or Kentucky Occupational Safety and Health Program.

3. Acknowledgment
OSHA’s Office of Training and Education acknowledges 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. Examples

6. Standard covers general industry, construction and shipyards.
Scope of OSHA Standard
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.
Standard covers general industry, construction and shipyards.

7. Reasons for the Standard
Powered industrial truck accidents result in approximately 100 fatalities and 36,340 serious injuries in general industry and construction annually.
It is estimated that % of the accidents are, at least in part, caused by inadequate training.

8. 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.

9. Operator Training
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).

10. 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.

11. Training Agenda 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 by knowledge tests.

12. Training Program Content
Operators shall receive training in the following topics:
Truck-related topics,
Workplace-related topics,
The requirements of the standard.

13. Refresher Training
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.

14. Refresher training required when:
Unsafe operation,
Accident or near-miss,
Evaluation indicates need,
Different type of equipment introduced,
Workplace condition changes.

15. Evaluations
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.
29 CFR (i)(4)(iii)

16. 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.

17. Four Major Areas of Concern
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.
The hazards of the particular workplace where the vehicle operates.

18. 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.

19. Unique Characteristics of Powered Industrial Trucks
Each type of powered industrial truck has its own unique characteristics and some inherent hazards.

20. Components of a Forklift

21. 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

22. 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)

23. Class I - Electric Motor Rider Trucks

24. Class I - Electric Motor Rider Trucks
Counterbalanced Rider Type, Stand-Up

25. Class II - Electric Motor Narrow Aisle Trucks
High lift straddle
Order picker
Reach type outrigger
Side loaders, turret trucks, swing mast and convertible turret/stock pickers
Low lift pallet and platform (rider)

26. Class II - Electric Motor Narrow Aisle Trucks

27. Class II - Narrow Aisle Trucks

28. Class III - Electric Motor Hand or Hand/Rider Trucks
Low lift platform
Low lift walkie pallet
Reach type outrigger
High lift straddle
High lift counterbalanced
Low lift walkie/rider pallet

29. Class III - Electric Motor Hand or Hand/Rider Trucks

30. Class III - Hand & Hand/Rider Trucks

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

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

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

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

35. Class VI - Electric & Internal Combustion Engine Tractors
Sit-down rider

36. Class VII - Rough Terrain Forklift Trucks
Straight-mast forklift
Extended-reach forklift
All rough terrain forklift trucks

37. Rough Terrain Straight Mast Forklifts

38. Rough Terrain Extended-Reach Forklifts

39. Stability Triangle - Figure 1
Vehicle Center of
Gravity (Unloaded) B A
Center of Gravity
of Vehicle and
Maximum Load
(Theoretical) C
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.

40. 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

41. Inspecting the Vehicle
Daily before each shift.
Defects, when found, must be immediately reported and corrected.

42. Driving the Truck
Maintain a safe distance from the edge of ramps or platforms.
Assure sufficient head room.
Observe all traffic safety rules.
Yield right-of-way to pedestrians.
Slow down and sound the horn at cross aisles and areas of obstructed vision.

43. Driving the Truck
Look in the direction of, and keep a clear view of, path of travel.
Travel with the load trailing if the load being carried obstructs forward view.
Ascend or descent grades slowly.
Operate at a speed that will permit the forklift to be brought to a safe stop.

44. Driving the Truck Slow down for wet and slippery floors.
Properly secure dock boards or bridge plates.
Approach elevators slowly and squarely.

45. Driving the Truck Do not operate under the influence.
Do not drive forklifts up to anyone standing in front of a fixed object.
Do not run over loose objects.
Do not allow persons to stand or pass under the elevated forks-loaded or empty.
Do not allow any person to ride on the forklift.

46. Driving the Truck Do not use forklift for opening or closing doors.
Do not block exits or emergency equipment.
Do not participate in stunt driving or horseplay.
Do not push or tow other forklifts.

47. Load Handling Know the weight of the load prior to moving the load.
Do not stand on a forklift or add counterweights to compensate for an overload.
Do not operate an overloaded forklift.

48. Load Handling Approach to within a foot or so of the load.
Stop forklift and raise load slowly while inching forward.
Position load so load lines up squarely.
When load reaches desired height, tilt backward.
Lower the load slowly; when it is resting solidly and the forks are free, back away slowly.

49. Load Handling
The heavier the load, and the higher it is raised, the higher the forklift’s center of gravity, reducing stability.
When lifting a load, always check for any overhead obstruction.

50. Stacking Height
Stacking to the ceiling will block the sprinkler system (where installed) and may overload the floor.
Allow 18 inches clearance below sprinkler heads or piping.
Allow 24 inches clearance below roof if not equipped with sprinklers.
Never allow other workers to stand nearby when materials are stacked.
Do not stack materials in aisles or roadways.

51. Unattended Forklift Precautions
A forklift is left unattended when:
The unit remains in view of the operator, or
Operator leaves the unit and it is not in view.

52. Unattended Forklift Precautions
When a forklift is left unattended:
Fully lower front forks;
Neutralized controls;
Shut off power;
Set brakes;
Block wheels if the forklift is parked on an incline.

53. Operator Dismounted and Within 25 Inches of the Forklift
Remains in the view of the operator.
Front fork must be fully lowered.
Controls neutralized.
Brakes set.
If the load must remain elevated, the operator must remain on the forklift at the controls.

54. Hazardous Environment
Concentration levels of carbon monoxide gas created by forklifts do not exceed the levels specified in 29 CFR
Operate in well ventilated areas.
In low lighted areas, forklift must have directional lighting.

55. Refueling or Recharging Operations
Battery charging and installation must be located in areas designated for that purpose.
Facilities must be provided for:
Flushing and neutralizing spilled electrolyte;
Fire protection;
Protection from other forklifts;
Adequate ventilation for battery gasses.

56. Refueling or Recharging Operations
Reinstalled batteries must be properly positioned and secured in the forklift.
Forklift shall be properly positioned and brake applied before changing or charging battery.
Vent caps must be functioning.
No smoking.
No open flames, sparks or electric arcs in battery charging areas.
Keep tools and metallic objects away from uncovered batteries.

57. Thank You For Your Participation
For additional assistance contact:
Richard T. Owen
Education Cabinet Safety Coordinator
601 East Main Street
Frankfort, Kentucky