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1910.178 (l)
1915.120 (a)
1917.1 (a)(2)(xiv)
1918.1 (b)(10)
1926.602 (d)
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Disclaimer
This presentation is intended as a resource forproviding training on OSHAs revised poweredindustrial truck operator standards. It is not asubstitute for any of the provisions of theOccupational Safety and Health Act of 1970, or
for any standards issued by the U.S.Department of Labors Occupational Safetyand Health Administration (OSHA). It is alsonot a substitute for a powered industrialtruck operator training program.
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Acknowledgment OSHAs 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.
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Powered IndustrialTruck - 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 andover-the-road hauling.
Commonly known as forklifts, pallet trucks, rider
trucks, forktrucks, or lifttrucks.
Can be powered through electric or combustionengines.
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Scope of Standard
The scope provisions of 1910.178(a), which arebased on ANSI B56.1 - 1969, remain in effect andcover: ... fork trucks, tractors, platform lift trucks, motorized
hand trucks, and other specialized industrial truckspowered by electric motors or internal combustion
engines. It does not apply to compressed air or nonflammablecompressed gas-operated industrial trucks, farmvehicles, nor vehicles intended primarily for earthmoving or over-the-road hauling.
This scope covers general industry, construction and
shipyards.
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Scope of Standard (continued)
For marine terminal and longshoringindustries, 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.
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Reasons for New Standard
Powered industrial truck accidents causeapproximately 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.
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Additional Reasons for NewStandard
Updated consensus standards have beenpublished.
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 outdatedstandard.
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Forklift Fatalities, 1992-1996
Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts
86 89
120
95
114
1992 1993 1994 1995 1996
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Forklift Fatalities by Age Group1992 -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 TruckAccidents Occurred
Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and
Mechanical Engineering Safety Standards.
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Nonfatal Occupational Injuries andIllnesses by Source, 1996
Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.
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Background
The previous OSHA standards, whilerequiring 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.
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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.
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Background (continued)
OSHA published a proposed ruling on March 14,1995 for General Industry, Shipyard, MarineTerminals, and Longshoring regulations, addingspecific training requirements.
On January 30, 1996, OSHA proposed a revisionof the construction standards, mandating thedevelopment of an operator training programbased on the prior knowledge and skills of thetrainee and requiring a periodic evaluation.
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Final Rule
OSHA published the final rule for PoweredIndustrial Truck Operator Training on December1, 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 11deaths and 9,422 injuries per year.
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Fatalities/Injuries Potentially Averted Annually byNew Standard
Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997
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Performance-Oriented
Requirements
The powered industrial truck operatortraining requirements are performance-
oriented to permit employers to tailor a
training program to the characteristics of
their workplaces and the particular types ofpowered industrial trucks operated.
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Revised Operator TrainingRequirements
General Industry:1910.178 is amended by revisingparagraph (l) and adding Appendix A.
Shipyard Employment:New section 1915.120 andAppendix A are added.
Marine Terminals:Section 1917.1 is amended byadding new paragraph (a)(2)(xiv) and Appendix A.
Longshoring:Section 1918.1 is amended by addingnew paragraph (b)(10) and Appendix A.
Construction:1926.602 is amended by adding newparagraph (d) and Appendix A.
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Operator Training Safe operations
The employer shall ensure that each poweredindustrial truck operator is competent to operate apowered industrial truck safely, as demonstrated bysuccessful completion of the training and evaluatiospecified in the OSHA standard.
Prior to permitting an employee to operate apowered industrial truck (except for trainingpurposes), the employer shall ensure that eachoperator has successfully completed the requiredtraining (or previously received appropriatetraining).
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Training Program Implementation
Trainees may operate a powered industrial
truck only:
Under direct supervision of a person who has
the knowledge, training, and experience totrain operators and evaluate their
competence; and,
Where such operation does not endanger the
trainee or other employees.
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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 exercisesperformed by the trainee), and
Evaluation of the operators performance in theworkplace
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Training Program Implementation(continued)
Training andevaluation shall beconducted by aperson with the
knowledge, trainingand experience totrain poweredindustrial truckoperators and
evaluate theircompetence.
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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 employers workplace.
Truck-related topics
Workplace-related topics
The requirements of the standard
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Training Program Content(continued)
Operating instructions,warnings and precautions
Differences fromautomobile
Controls andinstrumentation
Engine or motor operation
Steering and maneuvering
Visibility
Fork and attachmentadaptation, operation, use
Vehicle capacity and stability
Vehicle inspection andmaintenance that theoperator will be required toperform
Refueling/Charging/Recharging batteries
Operating limitations
Other instructions, etc.
Truck-related topics
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Training Program Content(continued)
Surface conditions
Composition and stabilityof loads
Load manipulation,
stacking, unstacking Pedestrian traffic
Narrow aisles andrestricted areas
Operating in hazardous
(classified) locations
Operating on ramps andsloped surfaces
Potentially hazardousenvironmental conditions
Operating in closedenvironments or other areaswhere poor ventilation ormaintenance could causecarbon monoxide or dieselexhaust buildup
Workplace-related topics
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Training Program Content (continued)
The requirements of the OSHA standard onpowered industrial trucks must also be
included in the initial operator training
program.
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Refresher Training and
Evaluation
Refresher training, including an evaluation of theeffectiveness of that training, shall be conducted toensure that the operator has the knowledge and skillsneeded 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
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Refresher Training and Evaluation(continued)
An evaluation of each powered industrialtruck operators performance must be
conducted:
After initial training,
After refresher training, and
At least once every three years
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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 requiredif the operator has been evaluated and found
competent to operate the truck safely.
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Certification
The employer shall certify that each operatorhas been trained and evaluated as requiredby the standard.
Certification shall include:
Name of operator
Date of training
Date of evaluation
Identity of person(s) performing the training or
evaluation
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Dates The employer shall ensure that operators of
powered industrial trucks are trained, asappropriate, by the dates shown in the followingtable.
If the employee washired:
The initial training andevaluation of that
employee must becompleted:
Before December 1, 1999 By December 1, 1999
After December 1, 1999
Before the employee is
assigned to operate apowered industrial truck.
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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.
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Appendix A - Stability of PoweredIndustrial Trucks
Definitions
General
Basic Principles
Stability Triangle
Longitudinal Stability
Lateral Stability
Dynamic Stability
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Load CG
Vertical
Stability
Line(Line of Action)
Combined CG
Truck CG
Load CG
Combined CG
Vertical
Stability
Line
(Line of Action)
Truck CG
The vehicle is stable This vehicle is unstable and
will continue to tip over
Stability Triangle - Figure 2
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Effective Powered Industrial TruckOperator Training Program
Four major areas of concern must beaddressed:
The general hazards that apply to the operation
of all or most powered industrial trucks;
The hazards associated with the operation ofparticular types of trucks;
The hazards of workplaces generally; and,
The hazards of the particular workplace where
the vehicle operates.
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T f P d I d i l
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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 platformtrucks, 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/sideloader lift trucks.
A single type of truck can only be described bycalling it by all of its characteristics, (e.g., a highlift, counterbalanced, sit down rider truck).
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Unique Characteristics of PoweredIndustrial Trucks
Each type of powered industrial truck has itsown 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.
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C t f F klift
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Components of a ForkliftTruck*
*One of the most common types of powered industrial trucks
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Classes of Commonly-Used Powered
Industrial Trucks*
The Industrial Truck Association has placed poweredindustrial 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/cushiontires)
Class V - Internal combustion engine trucks (pneumatictires)
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 notinclude all powered industrial trucks covered by the OSHA standard.
C
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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)
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Cl I El i M Rid
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Class I - Electric Motor Rider
Trucks
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Class I - Electric Motor Rider Trucks
Counterbalanced
Rider Type, Stand-Up
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Class II - Electric Motor Narrow AisleTrucks
High lift straddle Order picker
Reach type outrigger
Side loaders, turret trucks, swing mast andconvertible turret/stock pickers
Low lift pallet and platform (rider)
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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 orHand/Rider Trucks
Low lift platform Low lift walkie pallet
Reach type outrigger
High lift straddle High lift counterbalanced
Low lift walkie/rider pallet
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Class III - Electric Motor Hand orHand/Rider Trucks
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Class IV - Internal Combustion EngineTrucks - Cushion (Solid) Tires
Fork, counterbalanced (cushion/solid tires)
Class IV - Internal Combustion
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Class IV - Internal CombustionEngine Trucks - Cushion (Solid)Tires
Cl V I l C b i
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Class V - Internal CombustionEngine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)
Cl V I t l C b ti E i
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Class V - Internal Combustion EngineTrucks (Pneumatic Tires)
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Class VI - Electric & Internal CombustionEngine Tractors
Sit-down rider
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Rough Terrain Straight Mast Forklifts
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Some Types of Powered IndustrialTrucks 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 inMaritime
Container HandlersOSHAX.orgThe Unofficial Guide To the OSHA
Powered Industrial Trucks Used in
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Powered Industrial Trucks Used inMaritime
Empty-Container Handler
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Powered Industrial Trucks Used inMaritime
Container Reach Stacker
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Powered Industrial Trucks Used inMaritime
Straddle Carriers
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Powered Industrial Trucks Used inMaritime
Yard Tractor