• No uncorrectable vision problems;
• No uncorrectable hearing loss;
• No physical impairments that could impair safe operation of a lift truck;
• No neurological disorders; and
• Not taking medications that affect vision, perception, or physical ability.

Normal refresher training and evaluation should be conducted at least once every three years after the initial training.

Training Program Implementation
Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

All operator training and evaluation should be conducted by persons with the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

Training Program Content
Powered industrial truck operators shall receive initial training in the following topics, except in topics that the agency can demonstrate are not applicable to safe operation of the truck in the agency's workplace.

• Truck-Related Topics
  • 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 operation
  • 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 the operator will be required to perform
  • Refueling and/or charging and recharging of batteries
  • Operating limitations
  • Any other operating instructions, warnings, or precautions listed in the operator's manual for the type of vehicle the employee is being trained to operate
     
• Workplace-Related Topics
  • Surface conditions where the vehicle will be operated
  • Composition of loads to be carried and load stability
  • Load manipulation, stacking, and un-stacking
  • Pedestrian traffic in areas where the vehicle will be operated
  • Narrow aisles and other restricted places where the vehicle will be operated
  • Hazardous (classified) location 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 carbon monoxide or diesel exhaust
  • Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation

• The operator has been observed to operate the vehicle in an unsafe manner or the operator has been involved in an accident or near-miss incident;
• The operator has received an evaluation that reveals the operator is not operating the truck safely;
• The operator is assigned to drive a different type of truck; or
• A condition in the workplace changed in a manner that could affect the safe operation of the truck.

• Such examinations should be made at least daily before each shift.
• Industrial trucks used on a round-the-clock basis should be examined before each shift.
• Defects, when found, should be immediately reported and corrected.

• At the start of each shift, the operator should check the assigned forklift truck to ensure it is in safe working order.
• If for any reason the operator believes that the forklift truck is unsafe to drive or operate, it should be immediately reported to the supervisor.
• Among the items to check are:
  • Operator controls;
  • Brakes;
  • Fluid lines and levels;
  • Lights;
  • Filters;
  • Safety devices (horn, fire extinguishers, etc.);
  • Backup horns;
  • Movements of forks; and
  • Seat belts.

• All repairs should be made by authorized personnel.
• Remove the truck from service and tag it out of service until the defect can be repaired or the truck can be replaced.

• Forklift trucks should not be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts without the manufacturer’s written authorization.
• Additional counter-weighting of forklift trucks should not be done unless approved by the forklift truck manufacturer.

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Safe Operating Procedures

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Improper use of forklifts can cause serious injuries and property damage. Safe operation of a forklift can reduce the risk of accidents in the workplace. Always consult the manufacturer's operating procedures in the owner's manual for recommended operating procedures for a specific type of forklift. The basic, safe operating procedures are discussed in the following paragraphs.

Speed
Excessive speed can lead to accidents in the workplace. Drive at a safe speed, start and stop gradually, and follow at least three truck lengths behind the truck ahead to allow ample time and space for safe stopping. Drive slowly on wet or slippery floors, over dock plates, and around corners. Always obey posted speed limits, traffic regulations, and other road signs, including floor markings.

Turns
Forklifts require special turning techniques because of their design. Forklifts are taller, narrower, and 2-3 times heavier than most vehicles. In fact, forklifts have very quick steering compared to a car. Because a forklift is generally steered by the rear wheels, the driver must always be careful when steering because the rear end of the forklift swings in a wide arc. Use extreme caution when turning. Avoid turning too sharply. This can cause the forklift to swerve or tip over sideways. Turns should be made smoothly, gradually, and at a safe speed.

Load Capacity
Selection of the right kind of forklift is the first step in safety. Load capacity is naturally the first consideration. Every forklift has a maximum safe load capacity marked on its nameplate. This rating indicates the load capacity in pounds and the load center in inches. For example, a forklift with a 5,000 pound (2,268 kilogram) load capacity and 24-inch load center means it can lift 5,000 pounds if the load's center of gravity is 24 inches from the face of the load arms. Every operator should be familiar with the maximum load limits and should be required to never exceed that load capacity.

Example of a nameplate that is attached to every forklift. Graphic from Forklift Operation and Safety online training course, www.free-training.com/OSHA/forklift/Know/41.htm.

Forklifts are designed with weight in the rear to counterbalance the load carried in front. The front wheels are the balance point between the forklift and its load. Overloading the forklift can make it unstable, and it may tip over. The operator should never add extra weight to counterbalance an overload because this makes the forklift difficult to steer and puts extra strain on the hydraulic system, tires, axle, chains, forks, and motor.

	Vehicle center of gravity when unloaded. Vehicle center of gravity when unit is becoming unstable. Vehicle center of gravity when loaded.
Graphic from Department of Consumer and Employment Protection, Government of Western Australia, www.worksafe.wa.gov.au

The Load
Only stable or safely arranged loads should be handled. Use caution when handling off-center loads that cannot be centered.

Only loads within the rated capacity of the forklift truck should be handled.

The long or high (including multiple-tiered) loads that may affect capacity should be adjusted.

Forklift trucks equipped with attachments should be operated as partially loaded trucks when not handling a load.

Forks or other load engaging attachments should be placed as far under the load as possible; the mast should be carefully tilted backward to stabilize the load.

Use extreme when tilting the load forward or backward, particularly when high tiering.

• Tilting forward with forks (or other load engaging attachments) elevated should be prohibited except to pick up a load.
• An elevated load should not be tilted forward except when the load is in a deposit position over a rack or stack.
• When stacking or tiering, use only enough backward tilt to stabilize the load.

• Loading
  Before loading, plan the route and inspect the load to ensure it is within the rated capacity of the forklift. Also, inspect the condition of pallets and cargo, trailer-to-dock levelers, and vehicle restraints. Make sure the load is within the forklift's weight limit. Overloads make the forklift difficult to steer and may cause the forklift to turn over.
   
  Make a plan for loading. Think in advance how to make each load stable and centered. If the load consists of loose items, stack and secure the items carefully. Place irregular-shaped or long objects and heavy objects with the weight as low as possible. Block round objects, e.g., pipe, and secure if necessary so they will not roll off the forklift. This increases stability and makes steering easier. Check the maximum lift height on the forklift's nameplate, and do not stack materials higher than recommended. If the type of load presents a hazard, install a vertical load backrest extension to protect the driver.
   
  When raising a load, line up with the center of the load and approach it straight on with the forks in the traveling position. Lift the load smoothly and slowly in order to check the stability and weight of the load. Maintain a stable load while picking up materials by keeping the forks level, at an equal distance from the center stringers, and spread toward the outside of the materials. Lower the load approximately six inches off the floor. Six inches is the maximum height for carrying a load. Tilt the mast back to cradle the load before traveling with the load. Never raise or lower the forks while driving, turning, or maneuvering.
   
• Unloading
  When unloading materials onto a rack, stack, truck, or railroad, raise and position the load to the correct height. Check overhead clearance levels. Move slowly into position and tilt the elevated load forward only when directly over the unloading area. When stacking, know how high materials can be safely stacked. Always finish lowering the forks before backing, and look over the shoulder while carefully backing out.
   
  Never place a load in an aisle or fire lane or in front of a stairway or fire equipment. Be especially careful to observe "this side up" signs.

• Stop truck and raise load slowly while inching forward.
• When load reaches desired height, tilt upright forward until it is vertical.
• Position load over stack so it lines up squarely.

• The heavier the load and the higher it is raised, the higher the forklift truck’s center of gravity is forced, reducing stability.
• When lifting a load, always check for any overhead obstructions that might be damaged or cause the load to spill or topple the truck.

• Stacking right to the ceiling may block the sprinkler system 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 you stack materials.
• Do not stack material in aisles or roadways.

• Maintain a safe distance (recommended 3-5 feet) from the edge of ramps or platforms while on any elevated dock, platform, or freight car;
• Ensure sufficient headroom under overhead installations, lights, pipes, sprinkler system, etc.;
• Observe all traffic safety rules, including authorized plant speed limits;
• Maintain a safe distance, approximately three truck lengths, from the truck ahead; keep the truck under control at all times;
• Yield the right-of-way to pedestrians;
• Yield the right-of-way to ambulances, fire trucks, or other emergency vehicles;
• Slow down and sound the horn at cross aisles and other locations where vision is obstructed;
• Look in the direction of, and keep a clear view of, the path of travel;
• Travel with the load trailing if the load being carried obstructs forward view;
• Cross railroad tracks diagonally wherever possible; and
• Ascend or descend grades slowly.
  • When ascending or descending grades in excess of 10 percent, loaded trucks should be driven with the load upgrade.
  • When ascending or descending grades in excess of 10 percent, unloaded trucks should be driven with the forks pointed downgrade.
  • On all grades the load and forks (or other load engaging attachments) should be tilted back, if applicable, and raised only as far as necessary to clear the road surface.

• operate at a speed, under all travel conditions, that will permit the forklift truck to be brought to a stop in a safe manner;
• Slow down for wet and slippery floors;
• Note any oil or fuel leakage from any forklift truck and report the deficiency to supervisors immediately.
• Properly secure dockboard or bridgeplates before they are driven over; dockboard or bridgeplates should be driven over carefully and slowly and their rated capacity never exceeded; and
• Approach elevators slowly, and then enter squarely after the elevator car is properly leveled.
  • On the elevator, the controls shall be neutralized, power shut off, and the brakes set.
  • Motorized hand trucks must enter elevator or other confined areas with load end forward.

• Operate a forklift truck under the influence of prescription or over-the-counter medications that may interfere with safe operation of the forklift truck in any manner (i.e., drowsy, dizzy, loss of attention);
• Drive forklift trucks up to anyone standing in front of any fixed object;
• Run over loose objects on the roadway surface;
• Allow persons to stand or pass under the elevated portion of any truck, whether loaded or empty;
• Park closer than 8 feet from the center of railroad tracks;
• Allow any person to ride on forklift trucks except the operator, unless the forklift truck has provisions (additional seating authorized by the manufacturer) for passengers;
• Place arms or legs between the uprights of the mast or outside the running lines of the truck;
• Use a forklift truck for opening or closing freight car doors or moving freight cars;
• Block fire aisles, access to stairways, or fire equipment with the forklift truck or the load being handled;
• Pass other trucks traveling in the same direction at intersections, blind spots, or other dangerous locations;
• Participate in stunt driving or horseplay; or
• Push or tow other forklift trucks.

• Use a safety platform firmly secured to the lifting carriage and/or forks.
• Personnel on the safety platform should be provided with a means of shutting off the power to the truck as an emergency precaution.
• The driver of the truck should remain at the controls of the truck as long as personnel are occupying the elevated platform.
• Provide protection from falling objects, as indicated, necessary by the operating conditions.

• Fully lower the fork (or other load engaging attachments)
• Neutralize controls;
• Shut off power;
• Set brakes; and
• Block wheels if the truck is parked on an incline.

• The operator is 25 feet or more away from the vehicle that remains in his view; or
• The operator leaves the vehicle and it is not in his view.

• The forks (or other load engaging attachments) shall be fully lowered;
• Controls neutralized; and
• Brakes set to prevent movement.

• Avoid racing the engine, braking repetitively, idling for long periods of time, and using the hydraulic systems erratically;
• Avoid storing or parking forklifts in cold areas so exhaust from warm-ups are reduced;
• Tune the forklift regularly;
• Never leave the forklift running inside an enclosed space; and
• Install a catalytic converter to reduce carbon monoxide emissions, if possible.