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Occupational Health and Safety Program Powered Industrial Trucks Operator Training. 29 CFR 1910.178. For More Information Contact. Richard T. Owen, Safety Coordinator or Kentucky Occupational Safety and Health Program. Acknowledgment. - PowerPoint PPT Presentation
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Occupational Health and Safety Program
Powered Industrial Trucks Operator Training
29 CFR 1910.178 29 CFR 1910.178
For More Information Contact
Richard T. Owen, Safety Coordinator or Kentucky Occupational Safety and Health
Program.
AcknowledgmentOSHA’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.
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 and over-the-road hauling.
Commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lifttrucks.
Can be powered through electric or combustion engines.
Scope of OSHA 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.
Standard covers general industry, construction and shipyards.
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 20 - 25% of the accidents are, at least in part, caused by inadequate training.
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.
Operator TrainingThe 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).
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.
Training Agenda
Training shall consist of a combination of:Training shall consist of a combination of:
Formal instructionFormal instruction (e.g., lecture, discussion, interactive (e.g., lecture, discussion, interactive computer learning, written material), computer learning, written material),
Practical trainingPractical training (demonstrations and exercises (demonstrations and exercises performed by the trainee), and performed by the trainee), and
EvaluationEvaluation of the operator’s performance in the of the operator’s performance in the workplace by knowledge tests.workplace by knowledge tests.
Training Program Content
Operators shall receive training in the following topics: Truck-related topics, Workplace-related topics, The requirements of the standard.
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.
Refresher Training
Refresher training required when:
Unsafe operation, Accident or near-miss, Evaluation indicates need, Different type of equipment introduced, Workplace condition changes.
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 1910.178(i)(4)(iii)
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.
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.
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.
Unique Characteristics of Powered Industrial Trucks
Each type of powered industrial truck has its own unique characteristics and some inherent hazards.
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
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)
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)
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
Class V - Internal Combustion Engine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)
Class VII - Rough Terrain Forklift Trucks
Straight-mast forklift Extended-reach forklift
All rough terrain forklift trucks
A
B
C
Vehicle Center ofGravity (Unloaded)
Center of Gravityof Vehicle and Maximum Load(Theoretical)
Stability Triangle - Figure 1
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.
Load CG
Vertical StabilityLine(Line of Action)
Combined CG
Truck CG
Load CG
Combined CG
Vertical StabilityLine(Line of Action)
Truck CG
The vehicle is stable This vehicle is unstable and will continue to tip over
Stability Triangle - Figure 2
Inspecting the Vehicle
Daily before each shift. Defects, when found, must be immediately reported and
corrected.
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.
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.
Driving the Truck
Slow down for wet and slippery floors. Properly secure dock boards or bridge plates. Approach elevators slowly and squarely.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Hazardous Environment
Concentration levels of carbon monoxide gas created by forklifts do not exceed the levels specified in 29 CFR
1910.1000.
Operate in well ventilated areas.
In low lighted areas, forklift must have directional lighting.
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.
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.
Thank You For Your Participation
For additional assistance contact:Richard T. Owen
Education Cabinet Safety Coordinator601 East Main Street
Frankfort, Kentucky 40601502-564-7346