1. Forklift Operator Training
OSHA 1910.178 Powered Industrial Trucks
Developed by HMTRI through cooperative agreement
# 2 U45 ES006177-14 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:
1.
2.
3.
4.
5.
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
2

3. OSHA 1910.178 Powered Industrial Trucks Operator Training
1910.178 (l)
1915.120 (a)
1917.1 (a)(2)(xiv)
1918.1 (b)(10)
1926.602 (d)

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.
4

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

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).
6

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.
7

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
8

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.
9

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
10

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.
11

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
12

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
13

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
14

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
15

16. Appendix A - Stability of Powered Industrial Trucks
•
•
•
•
•
•
•
Definitions
General
Basic Principles
Stability Triangle
Longitudinal Stability
Lateral Stability
Dynamic Stability
16

17. Stability Triangle - Figure 1
B
Vehicle Center of
Gravity (Unloaded)
A
C
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.
17

18. 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
(Line of Action)
This vehicle is unstable and
will continue to tip over
18

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.
19

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).
20

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.
21

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.
22

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

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.
24

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)
25

26. Class I - Electric Motor Rider Trucks
26

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

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

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

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

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.
31

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
32

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
33

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.
34

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.
35

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

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
37

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

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

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
40

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?
41
?

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?
42
?

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

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

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
45

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

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.
47

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.
48

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
49

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.
50

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!!!
51

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

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.
53

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
54

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
55

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

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
57

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.
58

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.
59

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

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
61