Powered_Industrial_Trucks Training Module 30JAN2018.pptx

Baylor University
Environmental Health and Safety
Awareness Training Module

This section reviews the classes of commonly-used powered
industrial trucks. It also summarizes the major types of
power sources used in powered industrial trucks and
reviews safe practices for refueling and battery
charging/changing operations. Finally this section reviews
the major parts of a powered industrial truck, including
some of the potential hazards and possible solutions
associated with each.

• 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, fork trucks, or lift trucks.
• Can be powered through electric or combustion engines.

Powered industrial truck operators shall receive initial training in the following topics, except in topics which the
employer can demonstrate are not applicable to safe operation of the trucks in the employer’s workplace.
Truck-related Topics (29 CFR 1910.178(l)(3)(i)
• Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate.
• Differences between the truck and the automobile.
• Truck controls and instrumentation: where they are located, what they do, and how they work.
• Engine or motor operations.
• Steering and maneuvering.
• Visibility (including restrictions due to loading).
• Fork and attachment adaptation, operation, and use limitations.
• Vehicle capacity.
• Vehicle stability.
• Any vehicle inspection and maintenance that the operator will be required to perform.
• Refueling and/or charging and recharging of batteries.
• Operating limitations.
Workplace-related Topics (29 CFR 1910.178(l)(3)(ii)
• Surface conditions where the vehicle will be operated.
• Composition of loads to be carried and load stability.
• Load manipulation, stacking, and unstacking.
• Pedestrian traffic in the areas where the vehicle will be operated.
• Narrow aisles and other restricted places where the vehicle will be operated.
• Hazardous (classified) locations where the vehicle will be operated.
• Ramps and other sloped surfaces that could affect the vehicle’s stability.
• Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of dangerous fumes.
• Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

If an operator was previously trained in one of these topics, and the training is appropriate to the truck and working conditions encountered, additional
training on that topic is not required if the operator has been evaluated and found competent to operate the truck safely.
Trainees may operate a powered industrial truck only:
 Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence.
 Where such operation does not endanger the trainee or other employees.
Refresher training and evaluation (29 CFR 1910.178(l)(4)
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 in relevant topics shall be provided to the operator when:
 The operator has been observed to operate the vehicle in an unsafe manner.
 The operator has been involved in an accident or near-miss incident.
 The operator has received an evaluation that reveals that the operator is not operating the truck safely.
 The operator is assigned to drive a different type of truck.
 A condition in the workplace changes in a manner that could affect safe operation of the truck.
Each operator’s performance must be evaluated at least once every three years.
Certification
Employers must certify that each operator has been trained and evaluated in accordance with:
 Operator name.
 Training Date.
 Evaluation date.
 Name of person(s) performing the training and evaluation.

1. All faculty, staff, student employees must be certified to operate the equipment that they are tasked to use.
2. The operator’s manual for each piece of equipment must be readily available and reviewed prior to beginning
training and operation of the equipment.
3. A competent person designated by the department and approved by the university OSHA Manager will conduct the
initial and refresher training. An approved outside contractor may be utilized to conduct the training if that works
best for the department.
4. The training will consist of the following:
Complete the university computer based training program (all assigned modules).
Review the operator’s manual(s) for the equipment that will be utilized.
Department competent person and/or an approved outside contractor will conduct the hands-on training.
All training will be documented with copies of completion forwarded to the university OSHA Manager.
Refresher training will be conducted for all operator’s every three years or if necessity for training arises prior
to the three year timeframe.

• Powered industrial trucks shall be
examined before being placed in service
and shall not be placed in service if the
examination shows condition adversely
affecting the safety of the vehicle.
• Such examination shall be made at least
daily.
• Where powered industrial trucks are used
on a round-the-clock basis, they shall be
examined before each shift.
• Defects when found shall be immediately
reported and corrected.

Daily Inspection Checklist: Walking Pallet Truck
•The vehicle inspection
• Forks
• Battery
• Hand guards
•The operations inspection
• Check the drive operations
• Test the brakes
• Check the horn
• Inspect the load-handling attachment
operations

•KEY OFF Procedures The vehicle inspection
• Overhead guard
• Hydraulic cylinders
• Mast assembly
• Lift chains and rollers
• Forks
• Tires
• LPG tank and locator pin
• LPG tank hose
• Gas gauge
•Check the engine oil level
•Examine the battery
•Inspect the hydraulic fluid level
•Check the engine coolant level
•KEY ON Procedures
Test the standard equipment
• Front, tail, and brake lights
• Fuel gauge (if diesel)
• Windshield wiper
• Heater
•ENGINE RUNNING Procedures
Check the gauges
• Oil pressure indicator lamp
• Ammeter indicator lamp
• Ammeter
• Hour Meter
• Water Temperature Gauge
•Test the standard equipment
• Steering
• Brakes
• Horn
• Safety seat (if equipped)
•Check the operation of load-handling attachments
•Check the transmission fluid level

Lift Code 1: Low Lift Platform Lift Code 2: Low Lift Walkie Pallet Lift Code 3: Tractors Lift Code 4: Low Lift Walkie/Center Control Lift Code 5: Reach Type
Outrigger
Lift Code 6: High Lift Straddle Lift Code 6: Single Face Pallet Lift Code 6: High Lift Pallet Lift Code 7: High Lift Counterbalanced Lift Code 8: Low Lift
Walkie/Rider
Pallet and End Control

This training program is designed to assist you in becoming a trained and authorized lift truck
operator. The powered hand pallet truck is a critical piece of equipment to a company that needs
to move materials from point A to point B. It can move thousands of pounds of products in a
matter of minutes. The same job performed by manual labor could take hours or days. Imagine
in your area how difficult it would be to do the same amount of work without a lift truck.
Who can use a lift truck?
The Occupational Safety & Health Administration (OSHA) has very clear standards (29 CFR
1910.178(1)(6)) that employees must follow. The employer shall certify that each operator has
been trained and evaluated as required. Prior to the employer certifying the operator; the
operator must receive classroom type training, hands-on training, and an evaluation. Do not
operate a pallet truck unless you have been trained, authorized, and employer certified on the
specific class of lift truck. Once you are a certified pallet truck operator, you are responsible for
always following the safety procedures outlined in this training, the truck manufacturers
Owner's and Operator's Manual, and your companies policies and procedures.

Looking for Hazards
Making the workplace safe involves everyone. Keep an
eye open for hazards and report them immediately to
your supervisor. Safety hazards can be anywhere:
People: Untrained, indifferent (attitude), stepping into
the path, horseplay, and human error.
Materials: Unstackable, stacked too high, bulky,
blocked vision, unevenly distributed.
Equipment: Inadequate maintenance, design
difference, wrong for job, visibility restrictions, no
safety markings.
Environment: Congested areas, poor lighting, layout,
uneven floors, weather, slippery floors.

Operating Instructions, warnings and precautions
Prior to operating a pallet truck you should have reviewed
the Operator/Owner's Manual for that specific truck. The
manual provides specific information for the operation of
that specific pallet truck. There may also be specific
warnings or precautions for pallet truck operations. These
warning or precautions might be found in the operator's
and owner's manual(s), attachment manual(s), or posted on
the lift truck(s).
Differences between the lift truck and the automobile
A pallet truck is a mobile, powered propelled truck used to
carry, push, pull, and lift material. Pallet trucks are
significantly different from automobiles. Pallet trucks are
equipped with forks designed to move material weighing
several thousand pounds. Automobiles are not designed for
this purpose. Automobiles are not designed to carry heavy
loads at one end of the vehicle. Pallet truck steering is from
the rear while automobile steering, in most cases, is front
wheel drive.

Controls
The specific controls and instrumentation of your pallet truck should be discussed during the hands-on portion of the training and the specific trucks
Operator's and Owner's Manual.
Capacity
All pallet truck capacities are required to be identified by a securely fastened and legible nameplate. The nameplate contains vital information about the truck's capacity.
Generally, a pallet truck can lift a load up to six inches and may have a capacity as high as 8,000 pounds. If the pallet truck is modified in any way or has an attachment added,
you must have prior written approval from the lift truck manufacturer. The nameplate will show the maximum weight the pallet truck can lift.
Nameplate for electric trucks
MODEL - The model of the truck
SERIAL NO. - The frame number of the truck.
MAST - Not Applicable
BACK TILT - Not Applicable
ATTACH -The attachment that is approved for this truck
TYPE - The type of power needed to operate the truck as designed and safety rating.
VOLTAGE – This is the operating voltage of the truck.
BATTERY TYPE - This defines the minimum safety rating for the battery for this specific truck.
FRONT TREAD - In both metric and inches.
FRONT TREAD TIRE SIZE - The required tire size for both axles to meet the stability requirements as the truck was designed.
TRUCK WEIGHT W/O BATTERY - The approximate weight of the truck without the battery including attachment weight. In both metric and pounds.
BATTERY WEIGHT MIN/MAX The minimum and maximum weight of the battery that can be installed in this truck to meet the design stability requirements. In both metric
and pounds.
RATED CAPACITY WITH VERTICAL MAST EQUIPPED AT MAX. LIFT HEIGHT -Not Applicable

Stability
Many pallet trucks are like a tricycle,
with only three wheels. If the pallet
truck is turned too quickly or stopped
abruptly, the truck can become
unstable. If this happens you can lose
control or drop the load.
Center of Gravity: Simply put, it is the
place at which an object will balance
on a single point. Common sense
dictates that the Center of Gravity is
usually at the center of an object.

Maneuvering
Driving the pallet truck at excessive speed can result in loss of control, causing the vehicle to
skid, tip over, or fall off a loading dock or other elevated surfaces. It is important to follow these
basic rules in maneuvering the pallet truck:
 When making a turn, reduce speed to a safe level, turn steering wheel in a smooth, sweeping
motion.
 Only handle stable and safely arranged loads. Never move a load outside the truck's rated
capacity.
 Pallet trucks shall not be driven up to anyone standing in front of a bench or fixed object.
 Observe all traffic regulations including the facility speed limits.
 Keep at least three truck lengths away from other trucks going in the same direction.
Visibility
When operating a pallet truck, you must understand the potential hazards of obstructed
visibility. There are many things that could impede visibility, such as: load on forks, lighting,
racks, building columns, blind intersections, tractor trailers and pedestrians to name a few.
When traveling with a load that blocks your forward view, you must travel in reverse or use a
person to guide you.

Attachments
Attachments allow the pallet truck to lift and carry specialized loads. When operating a pallet truck adapted for a specialized task, you
are responsible for understanding how to use the attachment safely. Modifications and additions to a pallet truck which could effect its
capacity and safe operation shall not be performed by the customer or user without manufacturer's prior written approval. Review the
attachment operator's manual for the correct use of the equipment. Hands-on training of any and all special pallet truck attachments
must be completed before certification.
Operating Limitations
Pallet trucks are used in almost all material handling applications. They can carry, push, pull, and lift material. Safe operation of a pallet
truck can be limited by factors such as: weight capacity, surface grades, work environment, aisle width and presence of hazardous
materials. All can limit the operation of a pallet truck. Many accidents have occurred because' of operating a pallet truck beyond its
limits. Always review the nameplate to ensure that you are aware of the weight limitations.
Workplace Related Topics
These topics are required to be discussed as per 29 CFR1910.178(1)(3)(ii). These topics should be discussed with your supervisor or the
person responsible for safety or lift truck training. These topics should include but not be limited to the following:
 Surface conditions where the vehicle will be operated;
 Composition of loads to be carried and load stability;
 Load manipulation, stacking, and unstacking;
 Pedestrian traffic in areas where the vehicle will be operated;
 Narrow aisles and other restricted places where the vehicle will be operated;
 Hazardous (classified) locations where the vehicle will be operated;
 Ramps and sloped surfaces that could affect the vehicle's stability;
 Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

OPERATOR CHECKLIST
1. SAFE OPERATING CONDITION
Any powered hand pallet truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.
2. LOCATION
No repairs shall be made in Class I, II, or III Locations (hazardous materials areas).
3. FIRE HAZARDS
Repairs to the electrical systems of pallet trucks which involve fire hazards shall be conducted only in locations designated for such repairs.
4. ELECTRICAL
Trucks in need of repairs to the electrical system shall have the battery disconnected prior to such repairs.
5. PARTS
All parts of any such pallet truck requiring replacement shall be replaced only by parts equivalent to those used in the original design.
6. ALTERATIONS
Pallet trucks shall not be altered so that the relative positions of the various parts are different from what they were when originally received from
the manufacturer, nor shall they be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts.
7. DAILY INSPECTION
Pallet trucks shall be examined before being placed in service and shall not be placed in service if the examination shows condition adversely
affecting the safety of the vehicle. Such examination shall be made at least daily. Where pallet trucks are used on a round-the-clock basis, they shall
be examined before each shift. Defects when found shall be immediately reported and corrected.
8. TEMPERATURE When the temperature of any part of any truck is found to be in excess of its normal operating temperature, thus creating a
hazardous condition, the vehicle shall be removed from service and not returned to service until cause for such overheating has been eliminated.
9. CLEANING Pallet trucks shall be kept in a clean condition, free from lint, excess oil, and grease. Non-combustible agents should be used for
cleaning trucks. Low flash point (below 100°F solvents shall not be used, High flash point (at or above 100°F solvents may be used. Precautions
regarding toxicity, ventilation, and fire hazards shall be consistent with the agent or solvent used.

Safety Checks
 To begin your inspection, be sure that the key is in the off position.
 Disconnect the battery cables. Inspect the battery connectors and cables to see that they are clean and in good
condition. Make sure that the battery gates are in place.
 Check the wheels for any signs of gouges or foreign objects
 Test all controls to ensure that they operate correctly and lift/lower motions are free and smooth.
 Check to be sure that the control handle returns freely to full upright and sets the brake automatically.
 Make sure that all safety and warning decals on the truck are clearly visible and legible.
 Inspect the truck for any fluid leaks.
 Reconnect the battery cables.
 Turn the key to the "on" position.
 Check the steering mechanism for any problems with movement.
 Test the brakes by moving the control handle to both the raised and lowered positions.
 Check the direction control and plugging functions.
 Inspect the lift and lower controls.
 Ensure that the safety reversing switch is in proper working order.
 Make sure that the horn works.

Operator Responsibility
 Safe operation is the responsibility of the operator.
 The operator shall develop safe work habits and also be aware of hazardous conditions in order to protect themselves, other personnel, the truck and other
materials.
 The operator shall be familiar with the operation and function of all controls and instruments before undertaking to operate the truck.
 Before operating any truck, operators shall have read and be familiar with the operator's and owner's manual for the particular truck being operated and they
shall also abide by all safety rules and practices.
General Safe Operation
 Unauthorized personnel shall not be permitted to operate material handling equipment.
 Never ride on a pallet truck that was not designed for a rider.
 If you are on a rider truck, never dismount until it has come to a complete stop.
Safe loading/unloading
 Approach the load squarely with forks level. While not part of the pallet truck: attention should be given to the condition of pallets.
 Loads should not be shifted by butting with the truck.
 Ensure the forks are under the pallet all the way and the load wheels are not contacting the pallet frame.
 Raise the load for traveling.
 It is the responsibility of the operator to ensure that a load is properly and neatly stacked, and where applicable, secured.
 Place the heaviest objects nearest the bottom of the load.
 Round objects should be blocked.
 It is the responsibility of the operator to know the capacity and gross weight of their loaded truck. Operate and travel only in areas approved for your load.
 The operator will always carry loads in the lowered position.
 If the stack area is not level, the approach must be from the uphill side and the truck must be LEVEL laterally before the load is raised.

OPERATING A LIFT TRUCK SAFELY
Traveling
 Pallet trucks shall not be driven up to anyone standing in front of a bench or other fixed object.
 Operators shall ensure that no passengers ride on the pallet truck.
 Keep legs and feet inside the confines or guards of the lift truck.
 Operators must look around before starting to move. A safe distance will be maintained from the edge of ramps or
platforms while on any elevated dock.
 Always travel with the pallet truck forks as low as possible.
 Avoid driving over loose objects or holes in the floor.
 Always look in the direction of travel before moving, particularly when traveling in reverse. This includes the short
reverse movement which is required when turning the truck around in confined spaces.
 Watch the swing of the pallet truck when turning corners. While negotiating turns, reduce speed to a safe level. Turn
a smooth motion. Except when maneuvering at a very low speed, the steering shall be completed at a moderate even
rate.
 It is the responsibility of the operator to maintain a safe speed at ALL times. It is the responsibility of the operator to
reduce vehicle speed when traveling on uneven road surfaces.
 The operator will reduce speed when: on wet and slippery floors, in congested areas, descending ramps or inclines,
crossing bridge plates, vision is restricted, carrying a load or traveling over uneven surfaces.

All starts, stops and turns
should be easy and gradual,
particularly when the truck
is loaded.
Keep to the right when
passing. Operators must be
sure the operator of another
vehicle is aware of his
presence and intended action.
Maintain a distance of 3
truck lengths behind another
truck going in the same
direction.
Slow down and sound horn
(short blasts) at cross aisles,
doorways, or when
approaching other trucks.
Always be aware of
Pedestrians.
The operator will stop and
sound the horn at blind
corners, railway crossings,
elevators or whenever vision
is obscured. Operators must
always be alert and look for
pedestrians.
The operator will travel in
reverse if the load being
carried obstructs forward
view.
Other trucks traveling in the
same direction at
intersections, blind spots, or
other dangerous locations,
shall not be passed
All traffic regulations shall be
observed.

 Under all travel conditions, the truck will
be operated with complete control at all
times, inside or outside of the university.
 Stunt driving and horse play will not be
permitted.
 Operation on ramps or inclines requires
special attention. Brakes should be tested
and speed reduced before descending. No
person shall be permitted to walk down
ramps ahead of the truck. Extreme caution
is required when operating near the edge of
ramps & docks.
 The operator will always travel straight up
and straight down ramps. Never attempt to
turn the vehicle while on a ramp.

Lift Code 1: Counterbalanced Rider Type, Stand Up. Lift Code 4: Three Wheel Electric Trucks, Sit Down Code 5: Counterbalanced Rider, Cushion Tires, Sit Down. Lift Code 6: Counterbalanced Rider, Pneumatic or
Either Type Tire, Sit
down.
Lift Code 1: High Lift Straddle. Lift Code 2: Order Picker. Lift Code 3: Reach Type
Outrigger.
Lift Code 4: Side Loaders:
Platforms.
Lift Code 4: Side Loaders:
High Lift Pallet.
Lift Code 4: Turret Trucks. Lift Code 6: Low Lift Platform. Lift Code 6: Low Lift Pallet.

Class IV: Internal Combustion Class V: Internal Combustion Class VI:
Electric and
Engine Trucks. Engine Trucks Internal Combustion
(Solid/Cushion Tires) (Pneumatic Tires) Engine Tractors
Lift Code 3 Lift Code 4 Lift Code 1

Class VII – Rough terrain forklift is a generic term used to describe forklifts typically intended for use on unimproved natural
terrain and disturbed terrain construction sites. However, the term “rough terrain” does not imply that the forklift can be safely
operated on every conceivable type of terrain.
There are three basic types of rough terrain forklift:
This is an example of a ruggedly constructed forklift and is designed to
be used primarily outdoors.
Vertical Mast Type
This is an example of a vehicle equipped with a telescoping boom, which
enables it to pick and place loads at various distances and lift heights in
front of the machine. The ability to reach out in front of the forklift
allows the operator flexibility in the placement of a load.
Variable Reach Type
This is an example of a portable self-propelled rough terrain forklift
that is typically transported to the job site. It is mounted on a carrier to
the back of a truck/trailer and is used to unload heavy items from the
truck/trailer at the job site. Note that not all truck/trailer mounted
forklifts are rough terrain forklifts.
Truck/Trailer Mounted Type

The two main power sources for powered industrial trucks are internal combustion, which uses a
traditional engine that runs on liquid petroleum gas (LPG), compressed natural gas (CNG), gasoline,
diesel, or other fuel, and electric, which uses an on-board battery. This section provides information on
these power sources, including some of the potential hazards and possible solutions associated with their
use and with refueling and battery charging/changing operations.
Other power sources that may become more widespread in the future include fuel cells and hybrid
systems. Hydrogen fuel cells will have zero emissions and quiet operation plus the ability to be refueled
as quickly as gasoline engines. Hybrid systems will use a combination of fuel cells and batteries.
Internal Combustion (IC) Electric

Forklifts powered by internal combustion engines run on a variety of fuels, including gasoline, diesel fuel, liquid petroleum gas (LPG), and
compressed natural gas. Forklifts with internal combustion engines can be quickly refueled but require regular maintenance checks for
leaks of fuel or oil and worn parts to keep systems working properly. Forklifts powered by internal combustion engines are also used
indoors, although this may increase exposure to exhaust and noise.
The most widely used forklifts have an internal combustion engine powered by fuels that include gas, liquid petroleum, diesel fuel, and
compressed natural gas. Forklifts with internal combustion engines can be quickly refueled but require regular maintenance checks for
leaks of fuel or oil, worn parts requiring replacement, and to keep systems working properly. Newer forklifts with internal combustion
engines have on-board sensors that monitor and adjust emissions and have catalytic converters that help
reduce emissions.
Potential Hazards
•Exposure to engine exhaust containing carbon monoxide. If the engine is not properly combusting fuel,
the exhaust may contain high levels of carbon monoxide.
•Exposure to spills and leaks of fuel and oil.
•Requirements and Recommended Practices: Do not operate in a poorly ventilated area where vapors can concentrate.
•Carefully wash away or completely evaporate spillage of oil or fuel.
•As part of the pre-operation inspection, check all fluid levels, including oil, water, and hydraulic.
•Check for leaks from the hydraulic cylinder, the battery, and the fuel system.
•Check the exhaust color for incomplete combustion. For example, black smoke may be an indication of incomplete combustion.
•Check and report unusual noises or excessive vibration.

Forklifts that use gasoline are easy to refuel. However, gasoline is very flammable.
Potential Hazards
Exposure to explosive vapors.
Requirements and Recommended Practices
Refuel only at designated safe locations.
• A designated safe location outdoors is preferable to a refueling area indoors. Do not refuel trucks in hazardous areas or around heat
sources.
• Stop the engine during refueling.
• Do not smoke while refueling.
• Do not allow the forklift to become low on fuel or run out of fuel. Sediment or other impurities in the tank could be drawn into the fuel
system causing difficulties in starting and actual damage to the internal components.
• Fill the fuel tank at the end of each day.
• Do not fill the tank to the top: it may overflow because fuel expands as it is heated.
• Follow correct refueling procedures:
1. Park the forklift in a designated refueling area.
2. Place the transmission in Neutral.
3. Lower the forks to the ground.
4. Engage the parking brake.
5. Shut off the engine.
6. Open the filler cap.
7. Fill the tank slowly (if spillage occurs, wipe off fuel and wash down the area with water).
8. Close the filler cap.

Liquid petroleum gas (LPG) is a commonly used fuel for forklifts. It is a safe fuel when handled properly. When handled improperly, it can
cause serious injury or death.
Potential Hazards
• LPG vapor is heavier than air and will seek the lowest lying area. If not adequately dissipated, it will collect in pockets and possibly
ignite when exposed to a heat source.
• LPG is extremely flammable.
• LPG is extremely cold when exposed to the atmosphere. If your skin is exposed to LPG, you can get frostbite.
• Do not refuel LPG-powered trucks in confined areas where LPG vapors could collect if a leak occurs.
• Do not leave LPG-powered trucks near heat sources, stairways, exits, or other egress areas.
• When parking LPG-powered trucks for a long period of time, turn the service valve off.
• Only trained and authorized personnel should replace LPG containers.
• Follow proper procedures for storing and handling liquid petroleum gas. 29 CFR 1910.110

Electric-powered forklifts are most commonly used indoors in warehouses. Unlike internal combustion forklifts, electric forklifts are quiet and generally
nonpolluting but present other serious hazards that must be addressed.
Electric forklifts produce zero emissions, virtually eliminate the hazard of carbon monoxide poisoning, and run more quietly than internal combustion forklifts.
However, electric forklifts present other serious hazards that must be addressed.
Potential Hazards
 Electric forklifts are powered by large lead-acid batteries, which must be routinely charged. The hazards and recommended practices for charging and
changing batteries are reviewed below.
 Designate an area for the purpose of battery charging.
 Make sure that the forklift is charged before using.
 Recognize that heavy loads drain the battery more quickly.
Battery Charging Area
A properly equipped battery charging area will have:
 No smoking.
 Warning signs posted.
 Adequate fire protection. Large installations should have a plumbed drench shower and an eyewash.
 Ample and readily available water supply for flushing and neutralizing spilled electrolyte.
 An eyewash able to provide a 15 minute flow. For large installations, there should be a plumbed drench shower and an eyewash.
 A phone or other means of communication in the event of an emergency.
 Adequate ventilation to avoid the build up of hydrogen gas during battery charging.
 Soda ash or other neutralization materials in the immediate area.
 A dry chemical, CO2 or foam fire extinguisher.
 Means to protect charging apparatus from damage from trucks.

Safely operating a forklift requires preparation, anticipation and careful attention in order to maintain control of the vehicle at all times. This section will identify
recommended practices associated with each of the following operations:
Pre-Operation
A vehicle that is in need of repair, defective or in any way unsafe should be removed from service. The problem should be recorded on a log and reported to a
supervisor immediately. This section discusses pre-operation and operational inspections that operators should perform to ensure that forklifts will operate safely.
Only operators who have been trained and evaluated in accordance with 29 CFR 1910.178 can operate forklifts.
Pre Operation Inspection
OSHA requires that all forklifts be examined at least daily before being placed in service. The operator should conduct a pre-start visual check with the key off and
then perform an operational check with the engine running. The forklift should not be placed in service if the examinations show that the vehicle may not be safe
to operate.
A vehicle in need of repair, defective or in any way unsafe, should not be driven and should be taken out of service immediately. Any problems should be recorded
on the appropriate documents and reported to a supervisor.
Before starting your vehicle conduct a pre-operation (or pre-start) inspection that checks a variety of items, including but not limited to:
 Fluid levels – oil, water, and hydraulic fluid.
 Leaks, cracks or any other visible defect including hydraulic hoses and mast chains. NOTE: Operators should not place their hands inside the mast. Use a stick
or other device to check chain tension.
 Tire condition and pressure including cuts and gouges.
 Condition of the forks, including the top clip retaining pin and heel.
 Load backrest extension.
 Finger guards.
 Safety decals and nameplates. Ensure all waring decals and plates are in place and legible.
 Operator manual on truck and legible.
 Operator compartment. Check for grease and debris.
 All safety devices are working properly including the seat belt.

Electric Forklifts
 Cables and connectors for frayed or exposed wires.
 Battery restraints.
 Electrolyte levels.
 Hood latch.
Always use personal protective equipment such as a face shield, rubber apron and rubber gloves when checking electrolyte.
Internal Combustion Forklifts
 Engine oil and coolant.
 Brake reservoir.
 Air filter, belts, hoses, and hood latch.
 Radiator.
Liquid Propane Forklifts
 Properly mounted tank.
 Pressure relief valve pointing up.
 Hose connectors.
 Tank restraint brackets.
 Tank for dents and cracks.
 Tank fits within profile of truck.
 Leaks.
Always use personal protective equipment such as a face shield, long sleeves, and gauntlet gloves when checking liquid propane tanks and fittings.

After completing the pre-operation inspection, operators should conduct an operational inspection with the
engine running. The inspection includes:
 Accelerator linkage.
 Inch control (if equipped).
 Brakes and Steering.
 Drive control: forward and reverse.
 Hoist and lowering control.
 Attachment control.
 Horn and Lights.
 Back-up alarm
Unusual noises or vibrations should be reported immediately.
Removal from Service
While driving, be aware of these potential hazards:
 Mechanical breakdown.
 Overheating and Fire.
 Leakage.

Mounting and Dismounting
Potential Hazards:
 Hitting head on overhead cage.
 Slips, trips, and falls.
Requirements and Recommended Practices:
 Be sure that your hands are clean and dry to prevent slipping when grabbing handhold.
 Check your shoes for grease before entering the vehicle.
 Grasp handhold and get a good grip. Never grab the steering wheel because it could cause you
to lose balance if it moves.
 Always be careful with your footing when mounting and dismounting vehicle.
 Pull or lower your body carefully into or out of cab. Dismounting is the opposite of mounting –
do not jump.
 Wear appropriate footwear to prevent skids.

Starting / Stopping
Starting
Before starting a forklift, be sure to conduct a pre-operation inspection. In addition, conduct an
operational check after starting the engine.
 Ensure that your way is clear. Sound your horn in warning or use a spotter if your view is
obstructed.
 Proceed cautiously down the travel path watching for dangerous blind spots.
Stopping
 Select an area to park. Do not park in an unauthorized area. Do not block an aisle or exits.
Follow the university’s parking procedures.
 Apply brake slowly and stop.
 Neutralize the controls.
 Set the parking brake.
 Turn off the ignition.
 If the truck is parked on an incline, block the wheels.

Potential Hazards
While traveling avoid these potential hazards:
 Tipover caused by driving too fast.
 Collision with pedestrians and obstacles caused by inattention and not being able to stop in time.
 Be aware of the travel conditions along your planned route.
 Under all travel conditions the truck must operate at a speed that will permit it to be brought to a stop in a
safe manner.
 The driver must slow down for wet and slippery floors.
 The driver must look in the direction of, and keep a clear view of, the path of travel.
 The driver must slow down and sound the horn at cross aisles and other locations where vision is obstructed.
 While negotiating turns, speed shall be reduced to a safe level by turning the steering wheel in a smooth and
sweeping motion.
 Grades shall be ascended or descended slowly.
 When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load
upgrade.
 Running over loose objects on the roadway surface shall be avoided.

Changing Direction
Potential Hazards:
While changing directions, be aware of these potential hazards:
 Tipover.
 Collision with a pedestrian, another vehicle or an object.
 Come to a complete stop before changing directions.
 Use a horn or warning light to warn pedestrians when reversing.
Reversing
Reversing can increase the chances of injury and accident. Use extreme caution when backing
up.
Potential Hazards:
 Pedestrians being struck by or crushed by the forklift.
 Collision with another forklift or racking.

Reversing Requirements and Recommended Practices:
 Keep a clear view.
 Look in the direction of travel. When reversing, look behind.
 Be aware of limited visibility, and use extreme caution when driving in reverse.
 Consider the use of ground guides, rear-view mirrors, spotters, or other aids to increase
visibility.
 Consider the noise level in your workplace. Do not assume pedestrians or bystanders are able
to hear a back-up alarm.
 Allow plenty of room for pedestrians. You cannot anticipate what people will do. Many have
no idea how quickly forklifts accelerate and how sharply they turn.
 Never assume pedestrians or bystanders are aware of the presence of heavy equipment and
the intended direction of travel.
 Do not grab the overhead guard when traveling in reverse. This could expose the operator’s
finger to serious injury.

Turning and Steering
Potential Hazards:
While steering, be aware of these potential hazards:
 Collision with pedestrians or objects due to the forklift’s tail swinging to the side opposite the
direction of the turn.
 Falling load following collision.
 Tipover caused by turning too sharply.
 When turning, reduce speed to a safe level.
 Proceed with caution when making turns, especially when working in confined areas or narrow
aisles. When the lift truck turns a corner, the rear of the lift truck swings in the opposite
direction of the turn.
 Anticipate the rear-end swing and start the turn as close to the inside corner as possible. Plan
your route and anticipate turns.
 Never turn with the forks elevated.
 Never turn on a grade. The forklift may Tipover laterally on even a very small grade.

Traveling on Inclines
Potential Hazards:
While traveling on a grade or incline, be aware of these potential hazards:
 Tipover
 Falling Load
 Drive loaded trucks forward going up a ramp with the load upgrade and drive in reverse
going down a ramp with the load upgrade.
 Always drive unloaded trucks with the forks downgrade.
 Never drive with the load downgrade.
 Never turn a forklift on a grade.

Pedestrian Traffic
Many pedestrians or bystanders are injured in forklift related accidents. These injuries can
occur when forklifts strike pedestrians or when pedestrians are struck by falling loads.
Forklift operators should always be aware of the conditions in their workplace, including
pedestrian traffic. Forklift traffic should be separated from other workers and pedestrians
where possible.
Potential Hazards:
 Danger of striking pedestrians and objects.
 Yield right of way to pedestrians.
 When a person or group of people walks across your planned route stop, wait until the
pedestrians pass by, and proceed cautiously through any congested area.
 If an area is cluttered, walk the route first to spot problems. Check for situation that require
a spotter, sound the horn at blind corners, doorways and aisles. Sound the horn or other
alarm when you back up.

Reminders for the Driver:
 Slow down, stop and sound horn at intersections, corners, and wherever your vision is
obstructed.
 When provided, use flashing warning light or backup alarms when traveling in reverse.
 Do not move the truck if you do not have a clear view of travel.
 Use a spotter for blind spots.
 Keep a clear view.
 Start, stop, travel, steer and brake smoothly.
 Signal to pedestrians to stand clear.
 Do not allow anyone to stand or pass under the load or lifting mechanism.
 When possible, make eye contact with pedestrians or other forklift operators.

Moving Personnel
Passengers should not be allowed on forklifts unless the forklift is specifically designed to
accommodate passengers.
Potential Hazards:
 Danger of falling.
 The OSHA standard states that unauthorized personnel are prohibited from riding on a
forklift. If riders are authorized, a safe place must be provided.
 Unless authorized, never carry passengers. NO RIDERS
 Use only specialized equipment designed to raise personnel.
 Never transport employees on a platform.
 Never transport employees on the forks.

Only trained and competent operators shall be permitted to operate a powered industrial
truck. All powered industrial truck operators must be trained and certified.
Employers need to develop and implement a training program based on the general
principles of safe truck operation, the types of vehicle(s) being used in the workplace, the
hazards of the workplace created by the use of the vehicle(s), and the general safety
requirements of the OSHA standard.
Employers must also certify that each operator has received the training and evaluate each
operator’s performance at least once every three years.
Training shall consist of a combination of formal instruction, practical training, and
evaluation of the operator’s performance in the workplace.
Trainees must operate a powered industrial truck only:
 Under the direct supervision of persons who have the knowledge, training, and experience
to train operators and evaluate their competence.
 Where such operation does not endanger the trainee or other employee.

 Apprentice, 17, who was target of warehouse forklift
prank died after being accidentally crushed into
wall.
 Female warehouse worker, 49, crushed to death by a
forklift truck loading pallets of Pringles.
 Employee killed In Forklift Accident at Des
Plaines warehouse.

Powered industrial truck accidents cause approximately
100 fatalities, 36,340 serious injuries and non-serious injuries
reach approximately 61,800 each year in general industry
and construction annually.
If companies implemented more stringent training policies, ‘
OSHA estimates that about 70% of forklift accidents in the US
could be prevented.

Question: Who can train, evaluate and certify forklift operators?
Answer: In terms of who can conduct operator training and evaluation, OSHA requires in
1910.178(2)(iii) that the trainers have the “knowledge, training, and experience” to train
operators and evaluate their competence. The OSHA standard does not further define this
requirement or set any specific certifications. OSHA has said in a letter of interpretation that
the trainer must have some experience operating the specific type of equipment being trained
on (including attachments), but does not have to operate forklifts on a regular basis.
Question: Is annual forklift training required?
Answer: No. Refresher training only needs to be conducted when operators are found to be
operating unsafely, have been in an accident or near miss, receive a poor evaluation, or when
there are changes in the workplace or type of truck. OSHA does, however, require an
evaluation of each powered industrial truck operator’s performance at least once every three
years.
Question: Do we need to train our operators on each make and model of forklift?
Answer: No, that is not necessary. But employers have to train on each “type” of truck. By
“type,” OSHA is talking about basic differences (i.e., a sit-down rider truck vs. a stand-up truck,
or an order picker vs. a pallet jack). OSHA doesn’t intend that employers have to give refresher
training because someone starts using the same type of truck made by a different
manufacturer. But keep in mind that the operator will need instruction on any topics, such as
the truck’s controls, that are different.

Question: How long is an employer required to keep forklift daily inspection sheets?
Answer: Federal OSHA requires that forklift vehicles have to be inspected at least daily, or after
each shift when used around the clock. You will find this requirement in the Powered Industrial
Truck standard at 1910.178(q)7). OSHA does not require that forklift inspection be documented
but it is prudent to do so.
Question: Does OSHA require powered industrial truck operators to have a valid driver’s license?
Answer: Federal OSHA has no requirement that a forklift operator have a valid driver’s license.
OSHA does require that every forklift operator be training and certified to operate the powered
industrial truck in the workplace, and that the operator’s performance be evaluated on the
provisions of 1910.178(l)(3) every three years. The employer must have a record documenting that
the driver has successfully completed the training. That is the only operating “license” required by
OSHA.
If you have any questions about Powered Industrial Truck Safety Compliance
please contact the OSHA Manager at 710-2492 for help and clarification.

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