Powered industrial trucks rules

This rule applies to every type of powered industrial truck used for material or equipment handling within a marine terminal and does not apply to over‑the‑road vehicles. See Applicability in 1917.43(a) for the exact scope.

No — after October 3, 1983, modifications that might affect capacity or safety (for example adding counterweights) require the manufacturer's prior written approval or the written approval of a professional engineer experienced with the equipment (who has consulted with the manufacturer, if available). See 1917.43(b)(1).

• Capacity, operation, and maintenance plates/tags/decals must be changed to match the modified equipment.
• If you plan to add accessories (e.g., strobe lights) that could affect operation, the same approval process applies; OSHA has affirmed this in a letter allowing strobes only with appropriate approval and possible operator retraining (Strobe lights LOI).

Unauthorized personnel must not ride on powered industrial trucks; if riding is authorized, the employer must provide a safe place to ride. See 1917.43(b)(2).

• 'Safe place to ride' typically means a manufacturer‑approved seat or platform specifically designed for carrying personnel.
• If you use a platform to lift employees, follow the lifting‑employees rules in 1917.43(e)(6).

When left unattended, load‑engaging means must be fully lowered, controls neutralized, and brakes set. See 1917.43(b)(3).

• If the truck is out of the operator's view and farther than 25 feet, power must be shut off and wheels blocked or curbed on an incline per 1917.43(b).

Power must be shut off unless the truck is in view and within 25 feet (7.62 m) of the operator; wheels must be blocked or curbed if the truck is on an incline. See the general rule at 1917.43(b).

• This helps prevent unintended movement and runaway trucks when operators leave their machines.

No — powered industrial trucks must not be operated inside highway vehicles or railcars that have damage which could affect operational safety. See 1917.43(b)(4).

• Inspect the interior of the vehicle or railcar for structural damage, loose debris, or obstructions before operating the truck inside.

Powered industrial trucks must be marked with their rated capacities, visible to the operator, and vehicle weight (with and without counterweight) must also be similarly marked. See 1917.43(b)(5) and 1917.43(e)(5).

• Do not exceed rated capacities; if multiple trucks lift together, the load must not exceed the combined rated lifting capacity (1917.43(e)(5)(ii)).

Only stable and safely arranged loads within the truck's rated capacity may be handled. See 1917.43(b)(6).

• Secure or restrain shifting loads and use appropriate attachments per the manufacturer's recommendations (1917.43(e)(3)).

Employers must direct drivers to ascend and descend grades slowly and to slow down and sound the horn at cross‑aisles and other locations where visibility is obstructed. See 1917.43(b)(7) and 1917.43(b)(8).

• Train operators to keep speeds appropriate for load, surface conditions, and pedestrian traffic.

If the load obstructs the forward view, the employer must direct drivers to travel with the load trailing (i.e., travel in reverse). See 1917.43(b)(9).

• Use a spotter when necessary and ensure the operator has unobstructed sightlines when moving in either direction.

Steering knobs must not be used unless the truck is equipped with power steering. See 1917.43(b)(10).

• Steering knobs on non‑power‑steered trucks can reduce control and increase risk of injury.

A means must be provided to enable the operator to determine that the cargo has been engaged when the engagement point is hidden from view. See 1917.43(b)(11).

• Examples include mechanical indicators, remote sensors, or a reliable spotter; document the chosen method in procedures and train operators accordingly.

A safe means must be provided to protect the driver from sliding loads when cargo is being towed on pipe trucks or similar equipment. See 1917.43(b)(12).

• Use restraints, chocks, or guards designed to prevent loads from shifting onto the operator's path.

Only designated persons may perform maintenance and repair on powered industrial trucks. See 1917.43(c)(1).

• Designated persons should be trained and qualified for the tasks they perform and follow written procedures for safety-critical repairs.

Batteries on all powered trucks must be disconnected during repairs to the primary electrical system unless power is necessary for testing and repair; systems capable of storing residual energy must be safely discharged before work begins. See 1917.43(c)(2).

• Follow lockout/tagout and manufacturer guidance when disabling electrical energy sources.

Replacement parts that might affect operational safety must be equivalent in strength and performance to the original parts, and braking systems or other braking mechanisms must be operable and in safe condition. See 1917.43(c)(3) and 1917.43(c)(4).

• Use OEM parts or engineer‑approved equivalents and keep maintenance records showing inspections and repairs.

No — powered industrial trucks must be maintained in safe working order and safety devices must not be removed or made inoperative except as provided in the section; trucks with a fuel leak or any other safety defect must not be operated. See 1917.43(c)(5).

• If a device must be temporarily disabled for testing or repair, follow written procedures and restore the device immediately after work is completed.

Repairs to fuel and ignition systems that involve fire hazards must be conducted only in locations designated as safe for such repairs. See 1917.43(c)(6).

• Designated areas should have fire protection, ventilation, and appropriate hot work controls.

An 'approved' power‑operated industrial truck is one listed or approved for the intended use by a nationally recognized testing laboratory, and approved trucks used after February 15, 1972, must bear a label indicating testing laboratory approval; where the atmosphere is hazardous and Coast Guard rules at 33 CFR 126.15(e) do not apply, only trucks approved for such locations shall be used. See 1917.43(d)(1), 1917.43(d)(2), and 1917.43(d)(3).

• Use trucks certified for hazardous locations (e.g., explosion‑proof or intrinsically safe) when required.

When operators are exposed to overhead falling hazards, forklift trucks must be equipped with securely attached overhead guards sized to protect the operator during all truck operations (including forward tilt) and not obstruct the operator's view; openings in the top of the guard must not exceed six inches in either width or length unless no opening allows the smallest unit of cargo to fall through. See 1917.43(e)(1)(i)–(v).

• Overhead guards must be constructed so that failure of the mast tilting mechanism will not displace the guard (1917.43(e)(1)(iii)).

Yes — an overhead guard otherwise required may be removed only when it would prevent the truck from entering a work space and if the operator is not exposed to low overhead obstructions in the work space. See 1917.43(e)(1)(iv).

• Document the assessment showing no overhead falling hazard exists before removing the guard.

A vertical load backrest extension is required where necessary to protect the operator and prevent the load from hitting the mast when the mast is at maximum backward tilt. See 1917.43(e)(2).

• The load backrest extension must extend vertically from the fork carriage frame to contain raised loads.

Forks, fork extensions and other attachments must be secured so they cannot be accidentally dislodged and used only per the manufacturer's recommendations; counterweights must be affixed so they cannot be accidentally dislodged. See 1917.43(e)(3) and 1917.43(e)(4).

• If a manufacturer’s recommendation is not available, consult a qualified engineer before changing attachments or counterweights.

Employees may be elevated by forklift trucks only when a platform secured to the lifting carriage or forks meets specific requirements: it must have a railing complying with 1917.112(c), toeboards if objects could fall (1917.112(d)), an employee must be at the truck's controls, employees must be protected from moving truck parts, the platform floor must be skid resistant, means must be provided to shut off power when controls are elevated, and while elevated the truck may be moved only for minor placement adjustments. See 1917.43(e)(6).

• OSHA also makes clear that an operator must be physically able to perform operations without leaving controls while a load is suspended (Crane operator LOI).

Crawler‑type bulk cargo‑moving vehicles with seated operators who may contact projecting overheads must be equipped with operator's guards; guards and attachment points must resist a horizontal load at shoulder level equal to the drawbar pull without excessive deflection; and after July 26, 1999, these vehicles must have rollover protection designed to prevent operator crushing in a rollover. See 1917.43(f)(1)–(3).

• Ensure guard attachment points and ROPs are inspected and maintained per manufacturer's guidance and repair records.

Straddle trucks must have a permanent means of access to the operator's station (including necessary handholds), guards for main sprockets, chains, gears and revolving parts per the specified enclosures, personnel‑deflecting guards around the leading edges of wheels when used near employees, and adequate visibility features. See 1917.43(g)(1)–(3).

• Guarding details include enclosing the upper sprocket, enclosing the upper half of the lower sprocket, and enclosing the drive chain to a height of eight feet except for the lower half of the lower sprocket (1917.43(g)(2)(i)).

Reach stackers are considered powered industrial trucks and are therefore exempt from the 29 CFR 1917.50 certification requirement, but they remain subject to the powered industrial truck rules in 1917.43 and to operator training requirements referenced in 29 CFR 1910.178(l). See the OSHA memorandum on reach stackers (Reach stacker certification exemption LOI).

• Treat reach stackers like other powered industrial trucks for maintenance, markings, and safe operation per [1917.43].

No — OSHA has advised that Part 1917's specific requirements do not apply to designated waterfront facilities used solely for storage, handling, and transfer of liquids or gases; in that situation Part 1917 and most Part 1910 requirements for marine terminals do not apply. See the OSHA letter on Applicability to waterfront facilities.

• Confirm applicability for your operations with OSHA or legal counsel, since other federal or Coast Guard rules may apply.

You can install a strobe light only after obtaining the manufacturer's prior written approval or the written approval of a professional engineer experienced with the equipment (if the modification might affect capacity or safety), and operators may need refresher training if the change affects safe operation. See 1917.43(b)(1) and OSHA's guidance on adding strobe lights (Strobe lights LOI).

• Keep written approvals on file and document any required operator retraining per 29 CFR 1910.178(l).

Yes — but only if the total weight of the load does not exceed the combined rated lifting capacity of all trucks involved. See 1917.43(e)(5)(ii).

• Coordinate lifts with a plan, use communication or a spotter, and verify combined capacities before lifting.

When a truck has controls elevated with the lifting carriage, a means must be provided for employees on the platform to shut off power to the vehicle. See 1917.43(e)(6)(vi).

• This may be a remote kill switch on the platform wired to disable vehicle propulsion; ensure the device is regularly tested and documented.