Powered Industrial Trucks
29 CFR 1910.178
Disclaimer
• As a committee of a national organization, the
Safety, Health & Environmental Committee of
NPCA must reference federal standards.
However, users of this information are informed
that state and local agencies may have more
stringent standards than those cited here. It is
the users responsibility to ensure that the federal
standards referenced herein are applicable in
their locale. If more stringent standards apply
locally, you must adhere to those local
requirements.
Covered Topics
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Definitions
Injury/fatality statistics
Operator training requirements
Re-training/operator evaluations
Safety features
Inspections
Modifications/maintenance
Employer responsibilities
Definition of a Powered Industrial Truck
• 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, fork trucks, or lift trucks.
• Can be powered through electric or
combustion engines.
Injuries/Fatalities
• Over 36,000 serious
injuries annually.
• Approximately 100
fatalities annually.
• Most caused by lack
of training or
inadequate training.
Injury types
25%
Tipov er
18%
Struck by lift truck
14%
Struck by falling load
12%
Elev ated employee on truck
7%
Ran off loading dock
6%
Improper maintenance
0%
5%
10%
15%
20%
25%
30%
Training Requirements 29 CFR
1910.178
• Each employer shall ensure that operators are
competent to operate the powered industrial
truck safely.
• Training needs to include operating instructions,
warning labels, vehicle capacities, components
of the vehicle, material loading, etc.
• In addition, training should include worksite
conditions where the truck will be operated.
• Written test are recommended for operator
training.
Training Requirements 29 CFR
1910.178
Trainees May Operate a Powered
Industrial Truck Only:
• Where such operation does not endanger the
trainee or other employees
• Under direct supervision of a person who has
the knowledge, training and experience to
train operators and evaluate their competence
Training Requirements 29 CFR
1910.178
Training Components:
• 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.
Training Requirements 29 CFR
1910.178
Training Components Continued:
• Vehicle capacity and stability
• Vehicle inspection and maintenance that the
operator will be required to perform
• Refueling/charging/ recharging/changing
batteries
• Operating limitations
• Other instructions, etc
Training Requirements 29 CFR
1910.178
Training Components Continued:
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Surface conditions
Composition and stability of loads
Load manipulation, stacking, unstacking
Pedestrian traffic
Narrow aisles and restricted areas
Operating in hazardous (classified) locations
Training Requirements 29 CFR
1910.178
Training Components Continued:
• 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
Training Requirements 29 CFR
1910.178
• In addition to written
tests, hands on
(operating) tests
should be given.
Re-Training/Operator
Evaluations
• Re-training is required
anytime there is an
accident involving the
powered industrial truck.
• Operators assigned to a
different style of truck
need to be re-trained.
• Conditions in the
workplace changing
could require re-training
of the operator.
• Operator evaluations are
required to be done at
least once every 3 years.
Certification of Training
• The employer shall certify that each
operator has been trained and
evaluated as required by the standard.
• Certification shall include:
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Name of operator
Date of training
Date of evaluation
Identity of person(s) performing the
training or evaluation
Vehicle Components
Mast
Overhead
Guard
Lift cylinder &
Chain
Load backrest
extension
Counterweight
Carriage
Forks
Steer Axle
Drive Axle
Safety Features
• Seatbelts-should
always be worn while
operating the truck.
• Back up
beepers/horns.
• Capacity plates
Safety Features
• Center of gravity
• Stability triangle
• Lifting capacity
*The powered industrial truck operator needs to know these!
Safety Features
Stability Triangle
Stability of Lift Trucks
A lift truck has its own center of gravity.
When a lift truck picks up a load, a
combined center of gravity is produced
(indicated by the star).
Stability of Lift Trucks
• Moving the center of gravity outside of the
stability triangle:
1. Loss of steering
2. Loss of Traction
3. Unstable Load
4. Potential Tip Over
Stability of Lift Trucks
• Tipovers occur from:
• Overloading
• Load too high
• Mast tilted beyond
vertical
• Sharp turns
• Braking abruptly
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Pot holes
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Overhead obstructions
Wet, uneven surfaces
Ramps
Low tire pressure
&
Excessive speed
Safety Features
Inspections
• Daily inspections shall
be completed by the
operator prior to use
of the powered
industrial truck.
• Any deficiencies shall
be noted on the
inspection form and
repaired.
Modifications
• Modifications to the powered industrial
truck should be avoided whenever
possible.
• Altering of the truck in any way needs to
be approved in writing by the manufacturer
of the lift.
• Converting from gasoline to LP is allowed
as long as the conversion equipment is
approved 1910.178 (q)(12).
Maintenance
• A strict maintenance schedule on the
powered industrial truck is the key to
having a safe piece of equipment.
• Defective components should always be
repaired or replaced.
• The powered industrial truck should
always be clean and free of debris
(garbage).
Employer Responsibilities
• Employers are required to provide training
to operators of powered industrial trucks.
• A written training program is required.
• Operators need classroom as well as
hands on training.
• Evaluations need to be documented as
part of the training program.
Doing your part will help save
lives!
Disclaimer
• This publication is designed to provide accurate and
authoritative information in regard to the subject matter
covered; however, National Precast Concrete
Association acts as mediator without approving,
disapproving, or guaranteeing the validity or accuracy of
any data, claim or opinion appearing herein. Information
is provided and disseminated with the understanding that
National Precast Concrete Association is not engaged in
rendering engineering, legal, or any other professional
services. If engineering, legal, or other professional
assistance is required, the services of a competent
professional should be obtained. National Precast
Concrete Association does not assume and hereby
disclaims liability to any person for any loss or damage
caused by errors or omissions in the material contained
herein, regardless of whether such errors result from
negligence, accident, or any other cause whatsoever.
Powered Industrial Trucks
29 CFR 1910.178