Powered Industrial Truck Operator Training (OSHA Office of Training and Education)

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1. Slide 1

   Powered Industrial Trucks - Operator Training

   • 1910.178 (l)
   • 1915.120 (a)
   • 1917.1 (a)(2)(xiv)
   • 1918.1 (b)(10)
   • 1926.602 (d)
2. Slide 2

   Disclaimer

   • This presentation is intended as a resource for providing training on OSHA’s revised powered industrial truck operator standards. It is not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970, or for any standards issued by the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA). It is also not a substitute for a powered industrial truck operator training program.
3. Slide 3

   Acknowledgment

   • 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. Slide 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. Slide 5

   Scope of Standard

   • The scope provisions of 1910.178(a), which are based on ANSI B56.1 - 1969, 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.
6. Slide 6

   Scope of Standard (continued)

   • For marine terminal and longshoring industries, all powered industrial trucks are covered, no matter what specialized name they are given.
   • This includes, but is not limited to, straddle carriers, hustlers, toploaders, container reach stackers, and other vehicles that carry, push, pull, lift, or tier loads.
7. Slide 7

   Reasons for New Standard

   • Powered industrial truck accidents cause approximately 100 fatalities and 36,340 serious injuries in general industry and construction annually.
   • It is estimated that 20 - 25% of the accidents are, at least in part, caused by inadequate training.
8. Slide 8

   Additional Reasons for New Standard

   • Updated consensus standards have been published.
   • OSHA has been petitioned to improve the requirements for industrial truck training.
   • Advisory Committee on Construction Safety and Health has recommended improving the standard.
   • Resolutions have been introduced in the Senate and House urging OSHA to revise its outdated standard.
9. Slide 9

   Forklift Fatalities, 1992-1996

   • 1992
   • 1993
   • 1994
   • 1995
   • 1996
   • Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts
10. Slide 10

    Forklift Fatalities by Age Group 1992 -1996

    • 12%
    • 5%
    • 21%
    • Under 20
    • 3%
    • 20 - 24
    • 25 - 34
    • 10%
    • 35 - 44
    • 45 - 54
    • 56 - 64
    • 65 & over
    • 22%
    • 27%
    • Source: Bureau of Labor Statistics
11. Slide 11

    Industries Where Powered Industrial Truck

    • Accidents Occurred
    • Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and Mechanical Engineering Safety Standards.
12. Slide 12

    Nonfatal Occupational Injuries and Illnesses by Source, 1996

    • Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.
13. Slide 13

    Background

    • The previous OSHA standards, while requiring operator training, did not define the type of training or authorization required.
    • March 15, 1988 - Industrial Truck Association (ITA) petitioned OSHA for specific training requirements.
14. Slide 14

    Background (continued)

    • American National Standards Institute (ANSI), in cooperation with ASME, has revised its standard 4 times, including current lifttruck technology and specific training topics.
15. Slide 15

    Background (continued)

    • OSHA published a proposed ruling on March 14,
    • 1995 for General Industry, Shipyard, Marine Terminals, and Longshoring regulations, adding specific training requirements.
    • On January 30, 1996, OSHA proposed a revision of the construction standards, mandating the development of an operator training program based on the prior knowledge and skills of the trainee and requiring a periodic evaluation.
16. Slide 16

    Final Rule

    • OSHA published the final rule for Powered Industrial
    • Truck Operator Training on December 1, 1998.
    • The effective date is March 1, 1999. Start-up dates are included in paragraph (l)(7).
    • It applies to all industries except agricultural operations.
    • OSHA estimates that the new rule will prevent 11 deaths and 9,422 injuries per year.
17. Slide 17

    Fatalities/Injuries Potentially Averted Annually by New Standard

    • Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997
18. Slide 18

    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.
19. Slide 19

    Revised Operator Training Requirements

    • General Industry: 1910.178 is amended by revising paragraph (l) and adding Appendix A.
    • Shipyard Employment: New section 1915.120 and Appendix A are added.
    • Marine Terminals: Section 1917.1 is amended by adding new paragraph (a)(2)(xiv) and Appendix A.
    • Longshoring: Section 1918.1 is amended by adding new paragraph (b)(10) and Appendix A.
    • Construction: 1926.602 is amended by adding new paragraph (d) and Appendix A.
20. Slide 20

    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).
21. Slide 21

    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.
22. Slide 22

    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
23. Slide 23

    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.
24. Slide 24

    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
25. Slide 25

    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.
26. Slide 26

    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
27. Slide 27

    Training Program Content (continued)

    • The requirements of the OSHA standard on powered industrial trucks must also be included in the initial operator training program.
28. Slide 28

    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
29. Slide 29

    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
30. Slide 30

    Avoidance of Duplicative Training

    • If an operator has previously received training in a topic specified in this section, and the training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.
31. Slide 31

    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
32. Slide 32

    Dates

    • The employer shall ensure that operators of powered industrial trucks are trained, as appropriate, by the dates shown in the following table.
    • If the employee was hired:
    • The initial training and evaluation of that employee must be completed:
    • Before December 1, 1999
    • By December 1, 1999
    • After December 1, 1999
    • Before the employee is assigned to operate a powered industrial truck.
33. Slide 33

    Appendix A - Stability of Powered

    • Industrial Trucks
    • 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.
34. Slide 34

    Appendix A - Stability of Powered Industrial Trucks

    • Definitions
    • General
    • Basic Principles
    • Stability Triangle
    • Longitudinal Stability
    • Lateral Stability
    • Dynamic Stability
35. Slide 35

    Stability Triangle - Figure 1

    • Vehicle Center of Gravity (Unloaded)
    • Center of Gravity of Vehicle and Maximum Load (Theoretical)
    • 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.
36. Slide 36

    Stability Triangle - Figure 2

    • Load CG
    • Load CG
    • Vertical
    • Stability
    • Line
    • (Line of Action)
    • Combined CG
    • Combined CG
    • Truck CG
    • The vehicle is stable
    • Truck CG
    • Vertical
    • Stability
    • Line
    • This vehicle is unstable and will continue to tip over
37. Slide 37

    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.
38. Slide 38

    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).
39. Slide 39

    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.
40. Slide 40

    Components of a Forklift Truck*

    • *One of the most common types of powered industrial trucks
41. Slide 41

    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.
42. Slide 42

    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)
43. Slide 43

    Class I - Electric Motor Rider Trucks

44. Slide 44

    Class I - Electric Motor Rider Trucks

    • Counterbalanced Rider
    • Type, Stand-Up
45. Slide 45

    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)
46. Slide 46

    Class II - Electric Motor Narrow Aisle Trucks

47. Slide 47

    Class II - Narrow Aisle Trucks

48. Slide 48

    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
49. Slide 49

    Class III - Electric Motor Hand or Hand/Rider Trucks

50. Slide 50

    Class III - Hand & Hand/Rider

    • Trucks
51. Slide 51

    Class IV - Internal Combustion Engine

    • Trucks - Cushion (Solid) Tires
    • Fork, counterbalanced (cushion/solid tires)
52. Slide 52

    Class IV - Internal Combustion Engine

    • Trucks - Cushion (Solid) Tires
53. Slide 53

    Class V - Internal Combustion Engine

    • Trucks - Pneumatic Tires
    • Fork, counterbalanced (pneumatic tires)
54. Slide 54

    Class V - Internal Combustion Engine

    • Trucks (Pneumatic Tires)
55. Slide 55

    Class VI - Electric & Internal Combustion Engine Tractors

    • Sit-down rider
56. Slide 56

    Class VII - Rough Terrain Forklift Trucks

    • Straight-mast forklift
    • Extended-reach forklift
    • All rough terrain forklift trucks
57. Slide 57

    Rough Terrain Straight Mast Forklifts

58. Slide 58

    Rough Terrain Extended-Reach Forklifts

59. Slide 59

    Some Types of Powered Industrial Trucks Used in Maritime

    • The following types of vehicles are covered by the OSHA standard if the vehicles carry, push, pull, lift, or tier loads.
    • Container top handlers
    • Sidehandlers
    • Container reach stackers
    • Combination vacuum lifts
    • Straddle carriers
    • Yard tractors
    • Semi-tractors/ Utility
    • vehicles
60. Slide 60

    Powered Industrial Trucks Used in Maritime

    • Container Handlers
61. Slide 61

    Powered Industrial Trucks Used in Maritime

    • Empty-Container Handler
62. Slide 62

    Powered Industrial Trucks Used in Maritime

    • Container Reach Stacker
63. Slide 63

    Powered Industrial Trucks Used in Maritime

    • Straddle Carriers
64. Slide 64

    Powered Industrial Trucks Used in Maritime

    • Yard Tractor