This document provides information and guidelines for powered industrial truck operator training and safety. It defines powered industrial trucks, details the OSHA final rule requiring operator training, and describes the certification process. It also outlines various classes of powered industrial trucks, operating rules to follow, and safety hazards to avoid like tilting loads, riding as a passenger, and smoking while operating equipment. The goal is to prevent accidents, injuries, property damage, and equipment abuse through proper operator training and adherence to safety standards.

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. 2
Powered Industrial
Truck - Definition
 A mobile, power-propelled truck used to carry,
push, pull, lift, stack or tier materials.
 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.

3. 3
Final Rule
 OSHA published the final rule for Powered
Industrial Truck Operator Training on
December 1, 1998.
 The effective date is March 1, 1999.
 It applies to all industries except agricultural
operations.
 OSHA estimates that the new rule will
prevent 11 deaths and 9,422 injuries per
year.

4. 4
The Certification Process
 Review Safe Operating Rules as published by
OSHA.
 Watch a video which demonstrates the safe
operation of Powered Industrial trucks.
 Complete a written exam.
 Complete a skill test on actual equipment.

5. 5
The certification is valid for three years and
will include the following:
• Certificate of Achievement
• Powered Industrial Truck Operator’s Card

6. 6
The explicit purpose of forklift safety is to eliminate:
 Accidents and Injuries,
86 89
120
95
114
1992 1993 1994 1995 1996

7. 7
Forklift Fatalities by Age Group
1992 -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

8. 8
Industries Where Powered Industrial Truck
Accidents Occurred

9. 9
Property Damage, which can be very
costly for your company

10. 10
Equipment Abuse and Damage.

11. 11
Class I - Electric Motor Rider Trucks

12. 12
Class II - Electric Motor Narrow Aisle Trucks

13. 13
Class II - Narrow Aisle Trucks

14. 14
Class III - Electric Motor Hand or
Hand/Rider Trucks

15. 15
Class III - Hand & Hand/Rider
Trucks

16. 16
Class IV - Internal Combustion
Engine Trucks - Cushion (Solid)
Tires
Fork, counterbalanced (cushion/solid tires)

17. 17
Class IV - Internal Combustion
Engine Trucks - Cushion (Solid)
Tires

18. 18
Class V - Internal Combustion
Engine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)

19. 19
Class V - Internal Combustion
Engine Trucks (Pneumatic Tires)

20. 20
Class VI - Electric & Internal
Combustion Engine Tractors
Sit-down rider

21. 21
Class VII - Rough Terrain Forklift
Trucks
 Straight-mast forklift  Extended-reach forklift
All rough terrain forklift trucks

22. 22
Rough Terrain Straight Mast
Forklifts

23. 23
Rough Terrain Extended-Reach
Forklifts

24. 24
Some Types of Powered Industrial
Trucks 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.

25. 25
Powered Industrial Trucks Used
in Maritime
Container Handlers

26. 26
Powered Industrial Trucks Used
in Maritime
Empty-Container Handler

27. 27
Powered Industrial Trucks Used
in Maritime
Container Reach Stacker

28. 28
Powered Industrial Trucks Used
in Maritime
Straddle Carriers

29. 29
OPERATING RULES
 Drivers will check the vehicle at least once per shift, and if it
is found to be unsafe, the matter will be reported
immediately to a supervisor. (#2)

30. 30
 Vehicles will not exceed
authorized or safe speed .
(#3)

31. 31
 NO RIDERS WILL BE PERMITTED ON VEHICLES,
unless a safety platform with guardrails is provided.
(#5)

32. 32
This is NOT a Safety Platform!

33. 33
 A loaded vehicle will not be moved until the load is
safe and secure. (#7)

34. 34
 When leaving a vehicle unattended, the power will be
shut off, brakes set, the mast brought to the vertical
position, and the load-engaging means left in the down
position. (#8)

35. 35
 Vehicles will not be driven in and out of highway
trucks and trailers at unloading docks until such
trucks are securely blocked and brakes set.(#14)

36. 36
 Vehicles will not be operated on floors, sidewalk
doors, or platforms that will not safely support the
loaded vehicle. (#15)

37. 37
 The forks will always be carried as low as
possible, consistent with safe operations,
usually 4 inches off the floor. (#18)

38. 38
 Extreme care will be taken when tilting loads. Loads
may fall or forklifts can easily be turned over while
tilting moderate loads. (#19)

39. 39
 Employees will not place any part of their bodies
outside the running lines of an industrial truck or
between mast uprights or other parts of the truck
where shear or crushing hazards exist. (#21)

40. 40
 The width of one tire on the powered industrial truck will be
the minimum distance maintained from the edge by the truck
while it is on any elevated dock, platform, freight car or truck.
(#24)

41. 41
 The driver will slow down and sound the horn at cross
aisles and other locations where vision is obstructed. If
the load being carried obstructs forward view, the
driver will be required to travel in reverse, with the
load trailing. (#28)
 Trucks will not be loaded in excess of their rated
capacity. The rated capacity of the truck must be
clearly visible by the operator. (#31)

42. 42
No truck will be operated with a leak in the fuel,
oil and hydraulic systems. (#33)

43. 43
A
B
C
Vehicle Center of
Gravity (Unloaded)
Center of Gravity
of Vehicle and
Maximum Load
(Theoretical)
Tilting forward with the load engaging means is prohibited except when
picking up a load. Elevated loads will not be tilted forward unless the load is
being deposited onto a storage rack or equivalent. By tilting forward the fork
lift can be overturned, due to the change in the trucks center of gravity. (#34)
Note: When the vehicle is loaded, the combined center of gravity shifts toward line B-C. Theoretically the
maximum load will result in the center of gravity at the line B-C.

44. 44
 Special precautions will be taken in the
securing and handling of loads by trucks
equipped with attachments. Any attachment
changes the center of gravity and the
maximum capacity rating of the lift. (#36)
 The engine must remain running and the
operator at the controls, when a person is
elevated in a safe platform. (#37)

45. 45
 Forklift and electric pallet jack operators may not
smoke while operating this equipment. Sparks,
open flames or smoking are not allowed in an area
within 50 feet of any battery charging or refueling
operation. (#38)

46. 46
Remember, Always wear your Seatbelt!

47. 47
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