Powered Industrial Trucks OSHA Standard 29 CFR 1910.178 MIOSHA Part 21

1. Powered Industrial Trucks • OSHA Standard 29 CFR 1910.178 • MIOSHA Part 21

2. Powered Industrial Truck Operator Certification “The heaviest load you’ll ever carry is responsibility”

3. 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

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

5. Purpose of Training • Improved Awareness • Increased Efficiency • Additional Productivity • Reduction of Damaged Goods and Property • OSHA Requirements • Reduction in Risk of Employee Injuries

6. 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).

7. 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.

8. Powered Industrial Truck Classes* • The Industrial Truck Association (ITA) 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 these classifications refer to commonly-used vehicles and do not include all powered industrial trucks covered by the OSHA standard.

9. Class IElectric 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)

10. Class IElectric Motor Rider Trucks

11. Class IElectric Motor Rider Trucks • Counterbalanced Rider Type, Stand-Up

12. Class IIElectric 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)

13. Class IIElectric Motor Narrow Aisle Trucks

14. Class IIElectric Motor Narrow Aisle Trucks

15. Class IIIElectric 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

16. Class IIIElectric Motor Hand or Hand/Rider Trucks

17. Class IIIHand and Hand/Rider Trucks

18. Class IVInternal Combustion Engine Trucks - Cushion (Solid) Tires Fork, counterbalanced (cushion/solid tires)

19. Class IVInternal Combustion Engine Trucks - Cushion (Solid) Tires

20. Class VInternal Combustion Engine Trucks - Pneumatic Tires Fork, counterbalanced (pneumatic tires)

21. Class VInternal Combustion Engine Trucks (Pneumatic Tires)

22. Class VIElectric and Internal Combustion Engine Tractors Sit-down rider

23. Straight-mast forklift Extended-reach forklift Class VIIRough Terrain Forklift Trucks All rough terrain forklift trucks

24. Class VIIRough Terrain Straight Mast Forklifts

25. Class VIIRough Terrain Extended-Reach Forklifts

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

27. Forklift Fatalities by Age

28. Appendix AStability of Powered Industrial Trucks • Definitions • General • Basic Principles • Stability Triangle • Longitudinal Stability • Lateral Stability • Dynamic Stability

29. Stability Triangle - Figure 1 Vehicle Center of Gravity (Unloaded) B A Center of Gravity of Vehicle and Maximum Load (Theoretical) C 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.

30. Stability Triangle - Figure 2 Load CG Load CG Vertical Stability Line (Line of Action) Combined CG Combined CG Vertical Stability Line (Line of Action) Truck CG Truck CG This vehicle is unstable and will continue to tip over The vehicle is stable

31. How can a forklift tip over? Every object has a center of gravity. • If the center of gravity is near any edge of the forklift, it will tip over. • Size, weight, & position of the load, the amount of tilt ,& the speed, braking & cornering forces can shift the C.O.G.

32. It doesn’t take a heavy load Even a rated load can tip a forklift if • Not loaded with the heavy part against the backrest • The mast is raised and tilted forward • You turn a sharp corner too fast

33. VISUAL PRE-CHECK

34. Visual Pre-Check • PIT’s should be inspected before the start of each shift by walking around the entire lift. • Nameplate and Markings - Load Limits • Fire Extinguisher - Present and Charged • Fuel Level, Engine Oil Level • Radiator Water Level • Evidence of Any Damage - Bolts, Nuts, Guards, Chains, Hydraulic Hose Reel • Wheels/ Tires - Treads, Cuts, Gouges, Uneven Wear • Forks - Teeth Broken, Chipped, Worn, Positioning Latches in Working Condition

35. Visual Pre-Check • Anchor Pins and Chains - Worn, Loose, Bent • Fluid Leaks - Damp Spots, Fluid on Ground • Battery - Exposed Wires • Hoses - Securely Fastened • Fuel Tank - Securely Fastened • Seatbelts

36. OPERATIONALPRE-CHECK

37. Operational Pre-Check • Horn • Backup Alarm/Flashers • Lights • Foot Brake • Parking Brake • Deadman Seat Brake • Clutch/Gear Shift • Lift Mechanism • Tilting Mechanism • Slide Shifter • Steering/Seat Belt

38. Handling Loads • Before handling a load, determine: • Weight • Stacking • Security of the load • Contents • Obstructions • Pallet

39. Picking Up a Load • Be aware of nearby materials. • Square truck with the load resting location. • Stop when forks are about a 18” to 24” away. • Level forks and slowly drive forward until load is against the backrest. Avoid disturbing load. • Raise load so it is completely suspended. • Look over both shoulders. • Back out 18” to 24” and tilt mast back to stabilize load.

40. To Put Down a Load • Square truck and stop 18” to 24” away. • Level forks, drive the rest of the way in. • Lower load to a height of 4”, if possible. • Tilt the load forward to a level position. • Lower the load to its resting position. • Look over both shoulders, drive straight out.

41. Lifting Loads From a Stack • Approach slowly and squarely. • Stop about a foot from the load. • Raise mast to correct height. • Level forks and drive forward until load is flush against the backrest. • Raise forks just enough to clear. • Check overhead clearance before raising load. • Look over both shoulders and slowly back straight out. • Once clear, lower mast and tilt it back.

42. Forklift rules are much like traffic laws Like in traffic . . . Use common sense Show courtesy But, it is up to YOU to police yourself!! Look to rear prior to backing Sound horn at corners and intersections Obey all traffic rules, warning signs and aisle markings “Rules of the Road”

43. Traveling Rules • Look over both shoulders before backing. Blow Horn! • Use your horn and slow down at intersections and corners. • Look out for pedestrians! • Stay alert! Don’t drive while you are distracted or talking to someone.

44. More Traveling Rules • Drive in reverse if load obscures vision. • When on a ramp, keep the loaded end up whether you are going up or down the ramp. • If you must drive with an unstable load, SLOW DOWN! • Avoid excessive maneuvering.