
Experience Everything Compliance Network Has to Offer
OSHA’s standard for the operation and maintenance of Powered Industrial Trucks (PITs) in the workplace applies to vehicles including forklifts, order pickers, powered pallet jacks, yard jockeys, and stand-up and narrow aisle lift trucks. Excessive speed, obscured vision, load instability, workplace conditions, and improper use are all common causes of PIT accidents. To protect PIT operators, OSHA’s design, training, operation, and capacity stability requirements must be fulfilled, and PITs must be inspected daily.
The Occupational Safety and Health Administration (OSHA) has standards for the operation and maintenance of Powered Industrial Trucks (PITs) in the workplace. Design, training, operation, and capacity stability requirements ensure that operators of PITs of all classes are safe in the workplace. Additionally, OSHA requires daily inspections of PITs to ensure that every component is in working order.
The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard applies to most types of material handling equipment that are powered for horizontal movement. This includes:
What equipment is not covered?
OSHA’s PIT standard does not cover the following:
There are many classes and types of Powered Industrial Trucks (PITs), from the common sit-down type to the narrow aisle stand-up type, and from order pickers to powered pallet jacks. They may be powered by electricity, liquefied petroleum gas (LPG), diesel fuel, or gasoline. Some classes are approved for use in certain hazardous conditions.
PITs can be grouped into the following classifications:
No matter the class, the Occupational Safety and Health Administration (OSHA) requires operators be trained and evaluated prior to being allowed to operate the equipment in the workplace.
As a historical note, OSHA issued a Request for Information in the March 11, 2019, Federal Register, acknowledging that the PITs standard at 1910.178 lists 11 different designations of trucks— D, DS, DY, E, ES, EE, EX, G, GS, LP, and LPS. However, the notice stated that eight other type-designated units — CGH, CN, CNS, DX, G/CN, G/LP, GS/CNS, and GS/LPS — are not reflected in OSHA’s current standard. The agency explains that these eight type-designated units have different requirements for safe operation, maintenance, and handling due to their fuel source, but they are generally the same in design and function as the 11 truck types currently listed in the standard. OSHA is considering adding the eight truck types to modernize its standard, but a proposal is a long-term to-do item
The most basic provision in the Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard is that equipment must be designed to meet certain safety standards. In doing this, OSHA requires that all new or acquired PIT equipment comply with the American National Standards Institute (ANSI) B56.1-1969.
The ANSI standard has undergone several revisions since 1969 — the most current being the 2020 edition — so most equipment purchased will likely be made to a newer version of ANSI B56.1 than what the OSHA standard references. As a historical note, on February 16, 2022, OSHA proposed to modernize the design and construction requirements for its PITs standard to add reference to the latest ANSI/ITSDF design and construction standards. These include ANSI/ITSDF B56.1-2020, B56.5-2019, and B56.6-2021. PIT manufacturers and users will want to watch for the issuance of a final rule.
Employers must pay particular attention with the rapid changes in technology for safety devices and attachments for forklifts and other PITs:
As long as equipment comes with these devices already installed by the manufacturer, there is usually no issue in regard to OSHA accepting the design, even though these devices may not have been available when the original OSHA standard was written.
Powered Industrial Trucks (PITs) are used in almost all industries. They can be used to move, raise, lower, or remove large objects or a number of smaller objects on pallets or in boxes, crates, or other containers. Because PIT movement is controlled by the operator and is not restricted by the frame of the machine or other impediments, virtually unrestricted movement of the vehicle about the workplace is possible.
The hazards commonly associated with PITs vary for different vehicle types, makes, and models. Each type of truck presents different operating hazards. For example, a sit-down, counterbalanced high lift rider truck is more likely than a motorized hand truck to be involved in a falling load accident, because the sit-down rider trucks can lift a load much higher than a hand truck can.
Accident prevention
The methods or means to prevent an accident and to protect employees from injury vary for different types of trucks. For example, operators of sit-down rider trucks are often injured in tip-over accidents because of the natural tendency to jump downward and land on the floor or ground, where they can then be crushed by the vehicle’s overhead guard as the vehicle tips over. Therefore, operators of sit-down trucks need to be trained to remain in the operator’s position in a tip-over accident and to lean away from the direction of fall to minimize the potential for injury.
On the other hand, when a stand-up rider truck tips over, the truck operator can exit the vehicle by simply stepping backward, perpendicular to the direction of the vehicle’s fall, to avoid being crushed. In this situation, the operator usually should attempt to jump clear of the vehicle and should be trained accordingly.
Safe operation and workplaces
Driving a PIT 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 walking-working surface. This accident can be made more dangerous if the load being carried partially obscures the operator’s vision. A vehicle that is out of control or being operated by a driver whose vision is obscured can strike an employee, run into a column or other part of the building, or strike material, causing it to topple and injure employees in the area. Effective driver training teaches operators to minimize these hazards.
Other characteristics of a PIT that affect safe truck operation are the truck’s tendency to become unstable, its ability to carry loads high off the ground, and its characteristic mode of steering with the rear wheels while being powered by the front wheels. Moving loads upward, downward, forward, and backward causes a shift of the center of gravity of the vehicle and can adversely affect its stability. When a load is raised or moved away from the vehicle, the vehicle’s longitudinal stability is decreased. When the load is lowered or moved closer to the vehicle, its longitudinal stability is increased.
The workplaces where PITs are being used can also present a variety of different hazards. The safety of industrial truck operations can be decreased by workplace conditions such as rough, uneven, or sloped surfaces; unusual loads; hazardous areas; narrow aisles, blind spots, or intersections; and pedestrian traffic or employees working close to the path of travel. Finally, there are hazardous work practices that relate to all trucks, including operating at excessive speed, operating too close behind another PIT, poor loading practices, and carrying unauthorized passengers. In addition, poor truck maintenance can contribute to accidents.
Many accidents have occurred because of unsafe truck operation. For example, employees have fallen from trucks while using them to change light bulbs on overhead fixtures or riding on the forks to manually retrieve items from high racks. Many accidents have occurred when an operator has attempted to drive with an obstructed view in the direction of travel and has run into another employee. Improper truck maintenance has caused death from over exposure to carbon monoxide, loss of brakes, or rupture of hydraulic lines. Also, PITs that damage the legs of a storage rack may expose employees to struck-by hazards from falling materials stored on the rack.
Caution about under-ride hazards
A stand-up forklift operator was crushed and killed when the bottom half of the forklift passed beneath a beam of a storage rack. The Occupational Safety and Health Administration (OSHA) cited the employer under section 5(a)(1) of the Occupational Safety and Health Act for not furnishing a workplace free of recognized serious hazards, such as the under-ride hazard. The Occupational Safety and Health Review Commission later confirmed that employer training and extra-wide aisles were “inadequate” precautions in the case. Instead, the commission said OSHA’s suggested abatement measures were physically and economically feasible and would materially reduce the hazard. Those measures included adjusting shelf heights, installing rack barriers, or installing rear post guards on the forklifts.
Center of gravity — The point on an object at which all of the object’s weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.
Counterweight — The weight that is built into the truck’s basic structure and used to offset the load’s weight and maximize the vehicle’s resistance to tipping over.
Grade — The slope of a surface, which is usually measured as the number of feet of rise or fall over a 100-foot horizontal distance (the slope is expressed as a percent).
Load center — The horizontal distance from the load’s edge (or the fork or other attachment’s vertical face) to the line of action through the load’s center of gravity.
Powered Industrial Truck (PIT) — Fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines, excluding compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, and vehicles intended primarily for earth moving or over-the-road hauling.
Stability triangle — The three-point suspension system that runs along an imaginary line between a forklift’s two front tires and the center of the rear axle. Even though the vehicle has four wheels, it is only supported at these three points.
Motorized hand truck — The Occupational Safety and Health Administration’s (OSHA) term for a powered pallet jack.
Pallet jack — A type of PIT used to move materials from one place to another. They do not typically raise the material very high.
Walkie — A common industry term for powered pallet jack that can only be operated by a walking operator.
Walkie-rider — A type of pallet jack that can be operated by a walking operator on the ground, or by a riding operator who stands on a built-in platform.
Failure to train and evaluate a Powered Industrial Truck (PIT) operator is a top serious OSHA violation for the PITs standard, so that means Occupational Safety and Health Administration (OSHA) officers will likely be checking to see that proper training has been completed in any facility with PIT operations, and failure to train PIT operators can lead to hefty OSHA penalties.
OSHA has specific requirements for PIT operator training. These requirements include who can train operators, the frequency at which they should be trained, the content of the trainings, and more specific requirements based on the type of truck and workplace.
Who can train?
OSHA requires that 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.
However, for PIT operators that are temporary employees, OSHA’s Temporary Worker Initiative (TWI) Bulletin No. 7 explains that the staffing agency is responsible for generic PIT training, and the host employer provides the necessary site-specific PIT training and evaluation. That’s because the host employer is most familiar with the equipment being used and controls the conditions of the worksite.
Frequency
While forklift training is not required annually, OSHA does require an evaluation of each PIT operator’s performance at least once every three years.
In addition, refresher training must be provided when:
Content
PIT operators must receive a combination of the following types of training:
The Occupational Safety and Health Administration (OSHA) regulation outlines several Powered Industrial Truck (PIT)-related topics:
The regulation also requires training in several workplace-related topics:
Evaluation
Evaluation of each PIT operator’s performance is required at least once every three years.
Certification
OSHA has no requirement that a forklift operator have a valid driver’s license but does require that every forklift operator be trained and certified to operate the PIT in the workplace. The employer must have a record documenting that the driver has successfully completed the training.
Where chemicals or other hazardous substances are or can be present, special precautions must be taken to select the correct type of PIT.
To make the correct selection, the employer must know the:
Classified locations
The table below, used with permission of the Washington Department of Labor and Industries, shows the criteria to pick the safest forklift for certain workplaces.
In an area where this hazard classification is present: | Operators should use this type of forklift. | |
Class I Flammable gases or vapors are or may be present in quantities sufficient for explosion or ignition. | Division I Condition exists continuously, intermittently, or periodically under normal operating conditions. | Division II Condition may occur accidentally e.g., puncture of a storage drum. |
Acetylene, acetaldehyde, butadiene, cyclopropane, diethyl ether, ethylene, ethylene oxide, isoprene, propylene oxide, hydrogen (or gases or vapors equivalent in hazard to hydrogen, such as manufactured gas), unsymmetrical dimenthylhydrazine (UDMH) | Forklift use prohibited. | DY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers. |
Acetone, acrylonitrile, alcohol, ammonia, benzine, bensol, butane, ethylene dichloride, gasoline, hexane, lacquer solvent, natural gas, naphtha, propane, propylene, styrene, xylenes, vinyl acetate, vinyl chloride. | EX | DY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers. |
Class II Combustible dust is present. | Division I Explosive or conductive mixture may be present under normal conditions or where equipment failure can lead to both this condition and arching or sparking. | Division II Explosive mixture not normally present but where deposits of dust may cause heat rise in electrical equipment |
Aluminum, magnesium, and their commercial alloys; other metals of similarly hazardous characteristics. | Forklift use prohibited. | Forklift with electrical enclosures manufacturer approved where magnesium, aluminum, or aluminum bronze may be present. |
Carbon black, coal or coke dust. | EX | Forklift manufacturer approved for this location. |
Other combustible dusts. | EX | DY, EE, EX |
Class III Easily ignitable fibers or flyings are present but not likely to be in suspension in quantities sufficient to ignite. | Division I Locations in which these materials are handled, manufactured, or used. | Division II Locations in which these materials are stored or handled (other than manufacturer). |
Baled waste, cocoa fiber, cotton, excelsior, hemp, istle, jute, kapok, oakum, sisal, Spanish moss, synthetic fibers, tow. | DY, EE, EX | DS, DY, ES, EE, GS, LPS (Type E may continue to be used if used previously at this location.) |
Unclassified Locations Piers and wharves inside and outside general storage, general industrial, or commercial properties. | D, E, G, LP (more protective designations may also be used) |
All forklifts have a hazard designation assigned to them that tells whether they are suitable for use in certain kinds of hazardous atmospheres. The designation can be found on the forklift’s load capacity plate. The table below explains the designations.
Type | Built-in Safeguards Against Fire Hazards |
D (Diesel forklift) | Minimal safeguards for fire hazards |
DS | D additional for fuel, exhaust and electrical systems |
DY | DS all electrical equipment enclosed |
E | Minimal safeguards for fire hazards |
ES | E prevents sparks and limits surface temperatures |
EE | ES all electric motors and equipment completely enclosed |
EX | Can be used in flammable vapor or dust atmospheres |
G (Gasoline forklift) | Minimal safeguards for fire hazards |
GS | G additional for fuel, exhaust and electrical systems |
LP | Minimal safeguards for fire hazards |
LPS | LP additional for fuel, exhaust and electrical systems |
Perhaps the most critical operational element for Powered Industrial Trucks (PITs) is capacity and stability. In fact, it’s the basic reason most PITs exist. But it can be a hard concept to grasp and explain to workers.
Most PITs work on essentially the same principle as a teeter-totter — the weight of the load on the forks must be counterbalanced by the weight of the truck body. The load weight that each lift can handle can be found on the nameplate, also known as a data plate, capacity plate, or ID plate. The nameplate will state the capacity of the lift — in other words, the manufacturer’s guideline for how much weight can be safely lifted.
The capacity data on the nameplate is critical information, but it was calculated using a load with a specific load center, commonly 24 inches. So, unless every load an operator lifts has a load center of 24 inches — or whatever load center the truck was rated at — and is placed perfectly on the forks, employers have to remember that the actual capacity will be reduced. The same thing goes for attachments — which also typically reduce capacity.
Stability training
Trainers need to have a thorough understanding of load composition and impart it to operators. Trainers must be thoroughly familiar with concepts such as:
Stability triangle
Almost all counterbalanced PITs have a three-point suspension system, meaning the vehicle is supported at three points. This is true even if the vehicle has four wheels. The truck’s steer axle is attached to the truck by a pivot pin in the axle’s center. When the points are connected by imaginary lines, this three-point support forms a triangle called the stability triangle.
Longitudinal stability
The axis of rotation when a truck tips forward is the front wheels’ points of contact with the pavement. When PITs tip forward, the truck will rotate about this line. When a truck is stable, the vehicle moment must exceed the load-moment. As long as the vehicle-moment is equal to or exceeds the load-moment, the vehicle will not tip over. On the other hand, if the load-moment slightly exceeds the vehicle-moment, the truck will begin to tip forward, thereby causing the rear to lose contact with the floor or ground and result in loss of steering control. If the load-moment greatly exceeds the vehicle-moment, the truck will tip forward.
To determine the maximum safe load-moment, the truck manufacturer normally rates the truck at a maximum load at a given distance from the front face of the forks. The specified distance from the front face of the forks to the line of action of the load is the load center.
Because larger trucks normally handle loads that are physically larger, these vehicles have greater load centers. Trucks with a capacity of 30,000 pounds or less are normally rated at a given load weight at a 24-inch load center. Trucks with a capacity greater than 30,000 pounds are normally rated at a given load weight at a 36- or 48-inch load center. To safely operate the vehicle, the operator should always check the data plate to determine the maximum allowable weight at the rated load center.
Although the true load-moment distance is measured from the front wheels, this distance is greater than the distance from the front face of the forks. Calculating the maximum allowable load-moment using the load-center distance always provides a lower load moment than the truck was designed to handle.
When handling unusual loads, such as those that are larger than 48 inches long (the center of gravity is greater than 24 inches) or that have an offset center of gravity, etc., a maximum allowable load moment should be calculated and used to determine whether a load can be safely handled. For example, if an operator is operating a 3,000-pound capacity truck (with a 24-inch load center), the maximum allowable load-moment is 72,000 inch-pounds (3,000 times 24). If a load is 60 inches long (30-inch load center), then the maximum that this load can weigh is 2,400 pounds (72,000 divided by 30).
Lateral stability
The vehicle’s lateral stability is determined by the line of action’s position relative to the stability triangle. When the vehicle is not loaded, the truck’s center of gravity location is the only factor to be considered in determining the truck’s stability. As long as the line of action of the combined vehicle and load’s center of gravity falls within the stability triangle, the truck is stable and will not tip over. However, if the line of action falls outside the stability triangle, the truck is not stable and may tip over.
Factors that affect the vehicle’s lateral stability include the load’s placement on the truck, the height of the load above the surface on which the vehicle is operating, and the vehicle’s degree of lean.
Dynamic stability
The stability of a PIT is further complicated by dynamic forces that result when the vehicle and load are put into motion. The weight’s transfer and the resulting shift in the center of gravity due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations.
When determining whether a load can be safely handled, the operator should exercise extra caution with loads that cause the vehicle to approach its maximum design characteristics. For example, if an operator must handle a maximum load, the load should be carried at the lowest position possible, the truck should be accelerated slowly and evenly, and the forks should be tilted forward cautiously. However, no precise rules can be formulated to cover all of these eventualities.
Frequency
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
The daily inspection requirements below broadly apply to several kinds of Powered Industrial Trucks (PITs): electric forklifts, gas and diesel forklifts, liquefied petroleum gas (LPG) forklifts, order pickers, powered pallet jacks, reach trucks, and stand-up tow tractors. They must be inspected for these requirements daily, with additional specific requirements for every type of PIT.
Tires
On electric forklifts, gas and diesel forklifts, LPG forklifts, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, the tires must be in good repair (e.g., no cuts, separation from the rim, or excessive wear) and properly inflated. There must be lug nuts present on each tire, and the lug nuts must each be tightly secure.
Forks
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, powered pallet jacks, reach trucks, and pallet jacks, the forks must be properly aligned and in good repair (e.g., no cracks, bends, or excessive wear). Where present, the top clip retaining pin for each fork must be tightly secure and in good repair (e.g., no cracks). Load back rests must be securely attached and in good repair (e.g., no cracks or bends).
On reach trucks, the telescoping forks must be in good repair (e.g., no cracks, bends, or excessive wear).
Mast and carriage
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, and reach trucks, the mast assembly must be in good repair (e.g., no cracks or dents, missing stops, or broken welds). The hydraulic cylinders must be in good repair (e.g., no cracks or leaks). The lift chains and rollers must be in good repair (e.g., no cracks, kinks, or rust) and properly lubricated. Additionally, the tension of the lift chains must be correct.
On an order picker, the hoist lines, cables, lift chains, and rollers must be in good repair (e.g., no cracks, kinks, or rust).
Body
The body of the PIT must be in good repair (e.g., no cracks or dents) and clean (e.g., no grease or lint). The covers over the battery and other hazardous parts must be in place and secure. The overhead guard must be securely attached and in good repair (e.g., no cracks, bends, broken welds, or missing bolts). The nameplate must be present and legible. The safety decals or warning labels must also be legible. Any wiring, belts, lights, headlights, taillights, reflectors, warning lights, hoses, chains, and cables must be in good repair (e.g., no cracks, bends, frays, breaks, leaks, or kinks). Any lights or headlights must be aimed correctly. The control levers must be properly labeled.
On a powered pallet jack, the operator must ensure the hand guard is in place.
Cab
The cab should be clean, with the seatbelt working properly and in good repair (e.g., no frays or excessive wear). The seat itself must also be in good repair and adjusted properly. Control levers must be properly labeled. The mirrors must be in good repair (e.g., no cracks or breaks), clean, and adjusted properly.
Platform
Operators of order pickers, powered pallet jacks, and stand-up tow tractors must also inspect the PIT’s platform. The order picker’s work platform must be clean and in good repair (e.g., no cracks or holes). The guardrails or other limiting devices on the order picker must be in good repair (e.g., no cracks or bends) and must close properly and lock securely. The powered pallet jack and stand-up tow tractor riding platforms must be clean and in good repair (e.g., no cracks or holes).
Fluids
Where applicable, such as sit-down forklifts, hydraulic and brake fluid levels must be adequate.
Gas or diesel forklifts should have sufficient fuel for operation and adequate engine oil and radiator coolant levels.
Where applicable, operators should ensure the engine oil level, radiator coolant level, and transmission fluid level are adequate.
Battery
A PIT’s battery must be charged and in good repair (e.g., no corrosion or missing cable insulation), with its connections tight and in good repair (e.g., no cracks or excessive wear) as well. The cell caps in the battery cover must be in place and the electrolyte level must be adequate.
Battery gates (pallet jacks) and compartments should be secured.
Attachments
The nameplate on the PIT should account for any attachment being used, with the attachment in good repair (e.g., no cracks or bends).
Systems and controls
PIT inspectors (which can be the operator) must check that several components of the system and controls are working. They must check if the motor is running smoothly. They must also check that the accelerator is working and functioning smoothly, and that the steering is smooth and responsive (e.g., free of excessive play).
The employee must ensure the horn, whistle, gong, or other warning device sounds. The brake must be working and functioning smoothly (e.g., no grabbing), along with the parking brake (e.g., holds the forklift on the incline). The drive control and tilt control must work in forward and reverse and function smoothly (e.g., no excess drift for the tilt control). The lift controls must raise and lower the forks properly and function smoothly (e.g., no excess drift), and the attachment control must work and function smoothly (e.g., no hesitation). Additionally, the turn signal, backup alarm, lights, battery discharge indicator, and hour meter should also be working.
On electric forklifts, order pickers, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, employees should ensure the battery discharge indicator is working.
Gas or diesel forklift and LPG forklift operators must ensure the engine runs smoothly, and that the fuel gauge, ammeter indicator lamp, oil pressure indicator lamp, and water temperature gauge work.
Propane tank
On an LPG forklift, the operator must ensure the propane tank restraint brackets are in good repair (e.g., no cracks, bends, or rust) and that the tank is properly mounted on the locator pin. The tank must fit within the profile of the truck and be in good repair (e.g., no cracks, dents, or rust). The hoses and connectors must be in good repair (e.g., no cracks or kinks) and securely attached. Additionally, the pressure relief valve must be pointing up.
Pallet jacks have their own set of inspection requirements. Pallet jack operators must inspect the:
Operation
All Powered Industrial Trucks (PITs) must be designed and constructed in compliance with the American National Standards Institute (ANSI) standard B56.1-1969. (1910.178(a)(2)) Employers must ensure that only approved trucks are used in areas where flammable gases or vapors, combustible dust, or ignitable fibers are present in the atmosphere. Trucks with internal combustion engines that operate in buildings or enclosed areas must be checked to ensure they do not cause harmful concentrations of dangerous gases or fumes.
Any trucks not in safe operating condition are to be promptly removed from service. (1910.178(q)(1)) Repairs to fuel and ignition systems must be conducted only in areas specifically designated for them. (1910.178(q)(3)) Trucks are to be inspected daily, or after each shift if used around the clock, and before being placed in service. (1910.178(q)(7)) Directional lighting must be provided on each truck that operates in an area with less than two foot-candles per square foot of general lighting. (1910.178(h)(2)) Any trucks used by a company must be correctly designated for that type of operation (based on atmosphere, hazards of materials handled, etc.). (1910.178(c)(2))
Material handling
When assessing how a PIT will handle material, employers and operators must ensure there is sufficient clearance for equipment through aisles and doorways. (1910.176(a)) There must also be clearance signs to warn of clearance limits, and permanent aisles and passageways must be appropriately marked. (1910.176(e), 1910.176(a)) Bags, containers, bundles, etc. need to be stacked, blocked, interlocked, and limited in height so they are stable and secure. (1910.176(b))
Operators must use dock boards (bridge plates) when loading or unloading operations are taking place between vehicles and docks, and trucks and trailers should be secured from movement. (1910.178(m)(7))
Battery charging
Battery charging installations (located in areas designated for that purpose) and the batteries themselves must be charged in a properly vented room. (1910.178(g)(1), 1910.178(g)(2)) The local ventilation must be sufficient to disperse fumes. (1910.178(g)(2)). Facilities must be provided for flushing and neutralizing spilled electrolyte, fire protection, and protecting charging apparatus from damage by trucks. (1910.178(g)(2))
A conveyor, overhead hoist, or equivalent material handling equipment must be provided for handling batteries. (1910.178(g)(4)) Any reinstalled batteries must be properly positioned and secured in the truck. (1910.178(g)(5)) A carboy tilter or siphon must be provided for handling electrolyte. (1910.178(g)(6))
When charging batteries, employees must make certain not to pour water into acid, and that trucks are properly positioned with brakes applied first. (1910.178(g)(7), 1910.178(g)(8)) They must also ensure that the vent caps are functioning. (1910.178(g)(9)) Smoking must be prohibited in battery charging areas, and precautions taken to prevent open flames, sparks, or electric arcs in the charging area, such as keeping tools and other metallic objects away from the top of any uncovered batteries. (1910.178(g)(10)-(12))
Fueling
Fueling an internal combustion engine with a flammable liquid while the engine is running must be prohibited. (1910.178(p)(2)) Employees should ensure fueling operations are done in such a manner that the likelihood of spillage will be minimal. (1910.178(p)(2)) If spillage does occur, employees should take measures to control any vapors before restarting the engine. (1910.178(p)(3))
Aisles and walkways
Aisles must be marked and in good condition, with their widths maintained. (1910.22(b)(1)-(2)) They must also be clean and free of obstructions. (1910.22(b)(1)) Additionally, employees must ensure that fire aisles, access to stairways, and fire equipment are all clear. (1910.178(m)(14)) The aisles and passageways must be properly illuminated.
There should be safe clearance for equipment through all aisles and doorways. (1910.176(a)) Any pits and floor openings should be covered or otherwise guarded. (1910.22(c); .23(a)) Additionally, there must be standard guardrails present where aisle or walkway surfaces are elevated four feet or more above any adjacent floor or the ground. (1910.23(c)) Adequate barriers and warnings should be provided to prevent employees from stepping into the path of traffic where vehicles may be operated.
Housekeeping
Work areas, floors, walkways, and other surfaces should be clean and orderly. (1910.22(a), 1910.141(a)(3)(i)) Employees should check if there are any spilled materials or liquids present and if work surfaces are dry, and mats or grating should be used where drainage is needed. (1910.141(a)(3)(ii)1910.22(a)(2)) Employees should use compressed air for cleaning under 30 pounds per square inch (psi). (1910.242(b)) Employees should also check for any accumulation of dust and/or other potential contaminants. (1910.141(a)(3))
Personal protective equipment (PPE)
Employees must wear foot protection anywhere there is risk of foot injuries in the workplace. (1910.132(a); .136(a)) They must also wear hard hats anywhere danger of falling objects exists. (1910.135(a)(1)) Companies should also ensure the use of protective goggles or face shields where there is danger of flying particles or corrosive materials. (1910.133(a)(1))
Approved safety glasses must be worn where there is a risk of eye injuries such as punctures, abrasions, contusions, or burns. 1910.133(a)(2) Employees should wear appropriate safety glasses, face shields, etc. while using hand tools or equipment which might produce flying materials or be subject to breakage. (1910.133(a)(1))
Companies must ensure that employees use required protective clothing or equipment as needed, and that it fits properly, is functional and in good repair, and marked with ANSI or ASTM International specifications. (1910.132(a), 1910.132(e), .135(b))
Postings
Required truck operating rules should be posted.
Recordkeeping
Any inspection and maintenance records should be kept on file.
Training
Only trained personnel should be allowed to operate industrial trucks, and the training methods used to train operators must be documented and meet the requirements specified in 1910.178(l).
Documentation
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
Once an inspection has been conducted, the Occupational Safety and Health Administration (OSHA) expects employers to fix safety issues before allowing operation. But what constitutes something severe enough to require the equipment be taken out of service?
In OSHA’s standards, there are a few very specific conditions that warrant immediate removal of equipment from service. These include:
In addition, there is also a general provision to remove “unsafe” equipment. OSHA has said they will take a variety of factors into consideration when making the determination as to whether a truck is unsafe. But, at the least, any item that could present harm or risk would need to be taken out of service.
Items that could constitute unsafe conditions include:
Safe procedures
The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard does provide a few “rules of the road” that operators should adhere to. The key to a successful safety program is setting proper rules, training operators on those rules, and then following up consistently when there are deviations.
The basic rule for traveling is that operators maintain control of the PIT at all times. Other rules include:
Load handling
Many incidents can happen during load placement or retrieval. To avoid this, employers should ensure that operators are doing the following:
The Occupational Safety and Health Administration (OSHA) requires that permanent aisles and passageways be free from obstructions and appropriately marked where mechanical handling equipment is used. OSHA recommends that employers consider separating pedestrians from lift trucks by providing:
Operators and pedestrians should be trained on the plant’s procedures and hazards associated with Powered Industrial Truck (PIT) operation in pedestrian areas.
It is noteworthy that OSHA proposed a nearly $13,000 penalty for a serious violation of Section 5(a)(1) of the Occupational Safety and Health Act when a distribution center allegedly exposed employees to struck-by hazards from PITs and over-the-road trucks in the yard area at night. The agency explains that the company could abate the hazards by providing and requiring the use of high visibility reflective vests for workers who walk or work in the yard area.
A Powered Industrial Truck (PIT) is considered “unattended” when the operator is 25 feet or more away from the vehicle (even if it remains in their view), or whenever the operator leaves the vehicle, and it is not in their view.
When a PIT is left unattended, the:
Note: Wheels must be blocked if the truck is parked on an incline.
When the operator of an industrial truck is dismounted and within 25 feet of the truck still in their view, the:
Put another way, when the operator is dismounted and within 25 feet of the PIT still in his or her view, as long as the operator takes the three actions, the power may be left on.
OSHA was asked to define “in his [or her] view,” wondering if this includes when the operator is not looking at the vehicle for short periods of time. The agency replied in a September 11, 2018, letter of interpretation, “The standard does not define the term ‘in his [or her] view.’ ... [A] vehicle would normally remain in view of an operator during momentary or brief periods of time that an operator may glance away from the vehicle, provided that there are no other obstructions to the view.”
Many injuries occur when forklift operators lose control while driving on ramps. For example, an operator was backing a forklift out of a warehouse and came too close to the side of a ramp. The forklift went over the edge of the ramp, tipped over, and crushed the operator.
Operators should be aware of procedures to follow when traveling on ramps and other inclines with a load. These include:
When walking with a pallet jack with or without a load, generally the forks should be pointed downgrade, regardless of direction of travel.
One of the most dangerous operations involving powered industrial trucks (PITs) is the loading or unloading of trucks, trailers, and railroad cars. Not only may the vehicle being entered be unstable, but the means of going from the warehouse to the vehicle by way of a dockplate can also be dangerous. While entering and leaving truck trailers or railroad cars, operators must be aware of the following:
One of the common uses of forklifts and pallet jacks is to load/unload trucks, trailers, or railroad cars. This requires the Powered Industrial Truck (PIT) to enter the transport vehicle over a dockboard (also known as a bridge plate) at loading docks. If the truck, trailer, or car is not secured to the dock or otherwise chocked, blocked, or secured, it can move over time or with the right amount of force. The dockboard can also fall between the trailer and the dock as the forklift crosses it.
The Occupational Safety and Health Administration (OSHA) PIT standard lists a number of situations in which special procedures must be followed before starting entry into a railcar or truck trailer:
The OSHA Walking-Working Surfaces standard contains requirements for dockboards (bridge plates):
Capacity/design
All dockboards put into service after January 17, 2017, must comply with the requirements of the Occupational Safety and Health Administration (OSHA)’s Walking-Working Surfaces rule.
Dockboards are considered walking-working surfaces and employers are required to evaluate them for fall hazards. If it is determined that a fall hazard exists, the employer must utilize some form of fall protection.
The evaluation also helps employers determine if their dockboards can support the maximum intended load. The maximum intended load (weight and force) includes:
Employers must decide, based on the maximum intended load, what structural material must be used to construct a dockboard. For example, portable dockboards that only need to support lightweight loads moved by a hand truck could be made from aluminum. On the other hand, steel may be needed to construct a portable dockboard that will have to support the weight of a motorized pallet jack, load, and employee.
Fixed jacks
OSHA’s PIT standard states that “[f]ixed jacks may be necessary to support a semi-trailer and prevent upending during loading or unloading when the trailer is not coupled to a tractor.” OSHA’s standard does not specify a particular type of jack, nor the number and placement of such jacks.
OSHA strongly recommends following both the trailer and the jack manufacturer’s instructions on the appropriate number and placement of these jacks
Battery charging
The Occupational Safety and Health Administration (OSHA) requires employers to charge batteries only in a properly equipped location. A properly equipped battery charging area will have:
Only trained personnel should charge and change batteries in electric forklifts. In addition to training in battery changing and charging procedures, these employees should be trained on emergency procedures in the event of an acid splash, including how to use eyewash and shower facilities.
OSHA directive STD 01-11-004 offers further clarification. It says that “battery charging” areas where power industrial truck batteries are charged only — meaning no maintenance is performed, batteries are not removed from the trucks, and no electrolyte is present in the area — are not subject to the requirement of paragraph (g)(2) of 1910.178. However, the charging areas shall be in compliance with paragraphs (g)(1) and (g)(8) to (g)(12) of the regulation, and personal protective equipment (PPE) shall be used when and where required.
Best practices and requirements
In addition to having a properly equipped charging area, it is important employees follow safety procedures when charging batteries. OSHA has requirements covering some portions of the charging operation. Trained personnel should:
Liquefied petroleum gas (LPG) is a commonly used fuel for powered industrial trucks (PITs). It is a safe fuel when handled properly. However, when handled improperly, it can cause serious injury or death. In fact, 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.
What’s more, LPG is extremely flammable, and it is extremely cold when exposed to the atmosphere. If skin is exposed to LPG, it can get frostbite. To combat these hazards, employers should adhere to the following:
While the Occupational Safety and Health Administration (OSHA) Powered Industrial Truck (PIT) standard does not specifically address changing cylinders on liquid petroleum gas (LPG)-powered forklifts, industry best practices include:
When it comes to making modifications to forklifts or other Powered Industrial Trucks (PITs), the Occupational Safety and Health Administration (OSHA) is stringent. OSHA requires that employers obtain the manufacturer’s prior written approval for modifications or additions that “affect capacity and safe operation.” OSHA has interpreted this provision broadly to include most lifting attachments, as well as manbaskets.
When these changes are allowed, capacity, operation, and maintenance instruction plates, tags, or decals must be changed accordingly.
Front-end attachments
If the truck is equipped with front-end attachments other than factory installed attachments, employers must request the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.
Other provisions
OSHA also has a couple of other “hidden” provisions that pertain to altering PITs. (“Hidden” in that they are in a separate section of the regulation than the modification/attachment section.)
OSHA requires that all parts be replaced only by parts equivalent as to safety with those used in the original design.
OSHA also requires that PITs are not altered so that the “relative positions” of the parts are different from what they were when originally received from the manufacturer. They must not be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts.
When in doubt, ask
When an employer or employee has questions about adding or replacing parts, it’s best to check with the equipment manufacturer or OSHA local area office, to be on the safe side. There are many variables that can come into play, and that may not be obvious at first glance. For example, the addition of an after-market hours meter may seem (and may well be) perfectly harmless, but if the truck has been rated to operate in certain explosive/hazardous locations, the installation could potentially negate that rating if the meter isn’t up to the same standards.
Powered Industrial Trucks (PITs) can incorporate many warning and safety devices to help protect operators, pedestrians, and other PIT operators. Some are required, some recommended, and some required only in certain instances.
The Occupational Safety and Health Administration (OSHA) specifically requires an operator-controlled horn for PITs.
OSHA also requires directional lighting when general lighting is less than two lumens per square foot. For example, the general lighting in an inspected warehouse where PITs were used was less than 1 lumen per square foot, and the trucks did not have directional lighting. OSHA cited the company for a willful violation, which brought a $62,537 penalty.
As far as other beepers/lights (such as backup warnings and strobe lights), there is no specific requirement, but OSHA has said that if these warnings are needed based on the specific operating conditions, then the Agency could cite employers under the General Duty Clause of the Occupational Safety and Health Act.
What about seatbelts?
OSHA’s current enforcement policy is that employers must require operators of equipment that are equipped with operator restraint devices, including seat belts, to use the devices.
In addition, OSHA may also cite employers who do not take advantage of a manufacturer operator restraint system or seat belt retrofit program. Two enforcement cases illustrate this approach:
Powered pallet jacks
Powered pallet jacks are a type of Powered Industrial Truck (PIT) used to move pallets. Pallet jacks are battery powered and are one of two designs: either walk-behind or ride-on.
There are different types of pallet jacks as well, such as low lift or high lift. The controls for different designs may vary.
OSHA requires employers to:
Unlike forklifts, order pickers are designed to lift the operator to retrieve items. However, there are potential hazards from falling. The Occupational Safety and Health Administration (OSHA) requires that operators wear appropriate fall protection equipment that is properly fitted and adjusted unless guardrails are in place. OSHA strongly encourages the use of body harnesses, rather than belts, on elevated platforms of Powered Industrial Trucks (PITs).
A body belt is allowed to be used as part of a travel restraint system; however, it must eliminate the possibility of an employee going over the edge of a walking-working surface. A travel restraint system rigged to allow free fall even a small distance would not be an acceptable system under OSHA’s Subpart D Walking-Working Surfaces requirements. This is typically problematic with order pickers because of the size of a platform and the type of lanyard used.
A self-retracting lanyard does not eliminate the possibility of an employee going over the edge; therefore, it cannot be used as part of a travel restraint system. Self-retracting lanyards can only be used as part of a personal fall arrest system.
If a “static” lanyard and a body belt are used, the “static” lanyard must be short enough to prevent the employee from stepping off the edge. This means an employer would have to have multiple lanyard lengths to match the heights of all employees using them. Employers would also need to ensure the correct length is used by the correct employee.
Rough terrain forklifts are designed to operate on uneven and sometimes dirty surfaces. To do this, they are designed with larger tires. They also typically carry heavier loads, such as on construction sites, so their capacities are often higher.
Operators of these forklifts should be trained and evaluated with the environment to be operated in mind. They must understand the unique circumstances, including general hazards that may be on a construction site (e.g., falling objects, unexpected debris).
There are many occasions when employees need to work at heights. Ideally, equipment designed for that specific purpose would be used (e.g., ladder or aerial lift), but there are times when it may be necessary to utilize a forklift to elevate personnel. There are only a few ways this can be done safely.
First, operators must never be allowed to lift workers who are standing on the forks, pallet, or load. Serious injury or fatality can occur, and the Occupational Safety and Health Administration (OSHA) prohibits this practice.
Instead, workers must turn to either manbaskets, order pickers, or similar solutions.
Manbaskets
When it comes to elevating personnel on a platform attached to a forklift, OSHA regulations do not specifically address the issue. However, OSHA does address forklift modifications/additions in general (which includes personnel platforms) by requiring that employers obtain the manufacturer’s prior written approval before making any modifications or additions that affect capacity and safe operation.
OSHA bulletin SHIB 06-03-2021, “Hazards of Using Job-Made Boxes/Baskets/Platforms,” alerts employers and employees about the sometimes-fatal fall, crush, and struck-by hazards associated with job-made boxes. Job-made boxes, baskets, and platforms are makeshift attachments for powered industrial trucks, such as forklifts. Since these makeshift aids for assisting with working at heights are not manufacturer-approved or stability/load tested, they are not permitted under 29 CFR 1910.178.
When either the manufacturer or a professional engineer has determined it is safe to lift personnel using a specifically designed platform, OSHA requires proper fall protection be provided, either built into the platform itself in the form of railing, or using personal fall arrest systems (e.g., lanyards, harnesses). For example, an employee was operating a platform when he fell approximately 16 feet to the floor, suffering a concussion. The employee was not tied off to the lift at the time of the incident.
In addition, the platform should be secured to the forks, and personnel protected from moving parts of the forklift.
The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard applies to most types of material handling equipment that are powered for horizontal movement. This includes:
What equipment is not covered?
OSHA’s PIT standard does not cover the following:
There are many classes and types of Powered Industrial Trucks (PITs), from the common sit-down type to the narrow aisle stand-up type, and from order pickers to powered pallet jacks. They may be powered by electricity, liquefied petroleum gas (LPG), diesel fuel, or gasoline. Some classes are approved for use in certain hazardous conditions.
PITs can be grouped into the following classifications:
No matter the class, the Occupational Safety and Health Administration (OSHA) requires operators be trained and evaluated prior to being allowed to operate the equipment in the workplace.
As a historical note, OSHA issued a Request for Information in the March 11, 2019, Federal Register, acknowledging that the PITs standard at 1910.178 lists 11 different designations of trucks— D, DS, DY, E, ES, EE, EX, G, GS, LP, and LPS. However, the notice stated that eight other type-designated units — CGH, CN, CNS, DX, G/CN, G/LP, GS/CNS, and GS/LPS — are not reflected in OSHA’s current standard. The agency explains that these eight type-designated units have different requirements for safe operation, maintenance, and handling due to their fuel source, but they are generally the same in design and function as the 11 truck types currently listed in the standard. OSHA is considering adding the eight truck types to modernize its standard, but a proposal is a long-term to-do item
Powered Industrial Trucks (PITs) are used in almost all industries. They can be used to move, raise, lower, or remove large objects or a number of smaller objects on pallets or in boxes, crates, or other containers. Because PIT movement is controlled by the operator and is not restricted by the frame of the machine or other impediments, virtually unrestricted movement of the vehicle about the workplace is possible.
The hazards commonly associated with PITs vary for different vehicle types, makes, and models. Each type of truck presents different operating hazards. For example, a sit-down, counterbalanced high lift rider truck is more likely than a motorized hand truck to be involved in a falling load accident, because the sit-down rider trucks can lift a load much higher than a hand truck can.
Accident prevention
The methods or means to prevent an accident and to protect employees from injury vary for different types of trucks. For example, operators of sit-down rider trucks are often injured in tip-over accidents because of the natural tendency to jump downward and land on the floor or ground, where they can then be crushed by the vehicle’s overhead guard as the vehicle tips over. Therefore, operators of sit-down trucks need to be trained to remain in the operator’s position in a tip-over accident and to lean away from the direction of fall to minimize the potential for injury.
On the other hand, when a stand-up rider truck tips over, the truck operator can exit the vehicle by simply stepping backward, perpendicular to the direction of the vehicle’s fall, to avoid being crushed. In this situation, the operator usually should attempt to jump clear of the vehicle and should be trained accordingly.
Safe operation and workplaces
Driving a PIT 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 walking-working surface. This accident can be made more dangerous if the load being carried partially obscures the operator’s vision. A vehicle that is out of control or being operated by a driver whose vision is obscured can strike an employee, run into a column or other part of the building, or strike material, causing it to topple and injure employees in the area. Effective driver training teaches operators to minimize these hazards.
Other characteristics of a PIT that affect safe truck operation are the truck’s tendency to become unstable, its ability to carry loads high off the ground, and its characteristic mode of steering with the rear wheels while being powered by the front wheels. Moving loads upward, downward, forward, and backward causes a shift of the center of gravity of the vehicle and can adversely affect its stability. When a load is raised or moved away from the vehicle, the vehicle’s longitudinal stability is decreased. When the load is lowered or moved closer to the vehicle, its longitudinal stability is increased.
The workplaces where PITs are being used can also present a variety of different hazards. The safety of industrial truck operations can be decreased by workplace conditions such as rough, uneven, or sloped surfaces; unusual loads; hazardous areas; narrow aisles, blind spots, or intersections; and pedestrian traffic or employees working close to the path of travel. Finally, there are hazardous work practices that relate to all trucks, including operating at excessive speed, operating too close behind another PIT, poor loading practices, and carrying unauthorized passengers. In addition, poor truck maintenance can contribute to accidents.
Many accidents have occurred because of unsafe truck operation. For example, employees have fallen from trucks while using them to change light bulbs on overhead fixtures or riding on the forks to manually retrieve items from high racks. Many accidents have occurred when an operator has attempted to drive with an obstructed view in the direction of travel and has run into another employee. Improper truck maintenance has caused death from over exposure to carbon monoxide, loss of brakes, or rupture of hydraulic lines. Also, PITs that damage the legs of a storage rack may expose employees to struck-by hazards from falling materials stored on the rack.
Caution about under-ride hazards
A stand-up forklift operator was crushed and killed when the bottom half of the forklift passed beneath a beam of a storage rack. The Occupational Safety and Health Administration (OSHA) cited the employer under section 5(a)(1) of the Occupational Safety and Health Act for not furnishing a workplace free of recognized serious hazards, such as the under-ride hazard. The Occupational Safety and Health Review Commission later confirmed that employer training and extra-wide aisles were “inadequate” precautions in the case. Instead, the commission said OSHA’s suggested abatement measures were physically and economically feasible and would materially reduce the hazard. Those measures included adjusting shelf heights, installing rack barriers, or installing rear post guards on the forklifts.
Failure to train and evaluate a Powered Industrial Truck (PIT) operator is a top serious OSHA violation for the PITs standard, so that means Occupational Safety and Health Administration (OSHA) officers will likely be checking to see that proper training has been completed in any facility with PIT operations, and failure to train PIT operators can lead to hefty OSHA penalties.
OSHA has specific requirements for PIT operator training. These requirements include who can train operators, the frequency at which they should be trained, the content of the trainings, and more specific requirements based on the type of truck and workplace.
Who can train?
OSHA requires that 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.
However, for PIT operators that are temporary employees, OSHA’s Temporary Worker Initiative (TWI) Bulletin No. 7 explains that the staffing agency is responsible for generic PIT training, and the host employer provides the necessary site-specific PIT training and evaluation. That’s because the host employer is most familiar with the equipment being used and controls the conditions of the worksite.
Frequency
While forklift training is not required annually, OSHA does require an evaluation of each PIT operator’s performance at least once every three years.
In addition, refresher training must be provided when:
Content
PIT operators must receive a combination of the following types of training:
The Occupational Safety and Health Administration (OSHA) regulation outlines several Powered Industrial Truck (PIT)-related topics:
The regulation also requires training in several workplace-related topics:
Evaluation
Evaluation of each PIT operator’s performance is required at least once every three years.
Certification
OSHA has no requirement that a forklift operator have a valid driver’s license but does require that every forklift operator be trained and certified to operate the PIT in the workplace. The employer must have a record documenting that the driver has successfully completed the training.
The Occupational Safety and Health Administration (OSHA) regulation outlines several Powered Industrial Truck (PIT)-related topics:
The regulation also requires training in several workplace-related topics:
Evaluation
Evaluation of each PIT operator’s performance is required at least once every three years.
Certification
OSHA has no requirement that a forklift operator have a valid driver’s license but does require that every forklift operator be trained and certified to operate the PIT in the workplace. The employer must have a record documenting that the driver has successfully completed the training.
Where chemicals or other hazardous substances are or can be present, special precautions must be taken to select the correct type of PIT.
To make the correct selection, the employer must know the:
Classified locations
The table below, used with permission of the Washington Department of Labor and Industries, shows the criteria to pick the safest forklift for certain workplaces.
In an area where this hazard classification is present: | Operators should use this type of forklift. | |
Class I Flammable gases or vapors are or may be present in quantities sufficient for explosion or ignition. | Division I Condition exists continuously, intermittently, or periodically under normal operating conditions. | Division II Condition may occur accidentally e.g., puncture of a storage drum. |
Acetylene, acetaldehyde, butadiene, cyclopropane, diethyl ether, ethylene, ethylene oxide, isoprene, propylene oxide, hydrogen (or gases or vapors equivalent in hazard to hydrogen, such as manufactured gas), unsymmetrical dimenthylhydrazine (UDMH) | Forklift use prohibited. | DY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers. |
Acetone, acrylonitrile, alcohol, ammonia, benzine, bensol, butane, ethylene dichloride, gasoline, hexane, lacquer solvent, natural gas, naphtha, propane, propylene, styrene, xylenes, vinyl acetate, vinyl chloride. | EX | DY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers. |
Class II Combustible dust is present. | Division I Explosive or conductive mixture may be present under normal conditions or where equipment failure can lead to both this condition and arching or sparking. | Division II Explosive mixture not normally present but where deposits of dust may cause heat rise in electrical equipment |
Aluminum, magnesium, and their commercial alloys; other metals of similarly hazardous characteristics. | Forklift use prohibited. | Forklift with electrical enclosures manufacturer approved where magnesium, aluminum, or aluminum bronze may be present. |
Carbon black, coal or coke dust. | EX | Forklift manufacturer approved for this location. |
Other combustible dusts. | EX | DY, EE, EX |
Class III Easily ignitable fibers or flyings are present but not likely to be in suspension in quantities sufficient to ignite. | Division I Locations in which these materials are handled, manufactured, or used. | Division II Locations in which these materials are stored or handled (other than manufacturer). |
Baled waste, cocoa fiber, cotton, excelsior, hemp, istle, jute, kapok, oakum, sisal, Spanish moss, synthetic fibers, tow. | DY, EE, EX | DS, DY, ES, EE, GS, LPS (Type E may continue to be used if used previously at this location.) |
Unclassified Locations Piers and wharves inside and outside general storage, general industrial, or commercial properties. | D, E, G, LP (more protective designations may also be used) |
All forklifts have a hazard designation assigned to them that tells whether they are suitable for use in certain kinds of hazardous atmospheres. The designation can be found on the forklift’s load capacity plate. The table below explains the designations.
Type | Built-in Safeguards Against Fire Hazards |
D (Diesel forklift) | Minimal safeguards for fire hazards |
DS | D additional for fuel, exhaust and electrical systems |
DY | DS all electrical equipment enclosed |
E | Minimal safeguards for fire hazards |
ES | E prevents sparks and limits surface temperatures |
EE | ES all electric motors and equipment completely enclosed |
EX | Can be used in flammable vapor or dust atmospheres |
G (Gasoline forklift) | Minimal safeguards for fire hazards |
GS | G additional for fuel, exhaust and electrical systems |
LP | Minimal safeguards for fire hazards |
LPS | LP additional for fuel, exhaust and electrical systems |
Perhaps the most critical operational element for Powered Industrial Trucks (PITs) is capacity and stability. In fact, it’s the basic reason most PITs exist. But it can be a hard concept to grasp and explain to workers.
Most PITs work on essentially the same principle as a teeter-totter — the weight of the load on the forks must be counterbalanced by the weight of the truck body. The load weight that each lift can handle can be found on the nameplate, also known as a data plate, capacity plate, or ID plate. The nameplate will state the capacity of the lift — in other words, the manufacturer’s guideline for how much weight can be safely lifted.
The capacity data on the nameplate is critical information, but it was calculated using a load with a specific load center, commonly 24 inches. So, unless every load an operator lifts has a load center of 24 inches — or whatever load center the truck was rated at — and is placed perfectly on the forks, employers have to remember that the actual capacity will be reduced. The same thing goes for attachments — which also typically reduce capacity.
Stability training
Trainers need to have a thorough understanding of load composition and impart it to operators. Trainers must be thoroughly familiar with concepts such as:
Stability triangle
Almost all counterbalanced PITs have a three-point suspension system, meaning the vehicle is supported at three points. This is true even if the vehicle has four wheels. The truck’s steer axle is attached to the truck by a pivot pin in the axle’s center. When the points are connected by imaginary lines, this three-point support forms a triangle called the stability triangle.
Longitudinal stability
The axis of rotation when a truck tips forward is the front wheels’ points of contact with the pavement. When PITs tip forward, the truck will rotate about this line. When a truck is stable, the vehicle moment must exceed the load-moment. As long as the vehicle-moment is equal to or exceeds the load-moment, the vehicle will not tip over. On the other hand, if the load-moment slightly exceeds the vehicle-moment, the truck will begin to tip forward, thereby causing the rear to lose contact with the floor or ground and result in loss of steering control. If the load-moment greatly exceeds the vehicle-moment, the truck will tip forward.
To determine the maximum safe load-moment, the truck manufacturer normally rates the truck at a maximum load at a given distance from the front face of the forks. The specified distance from the front face of the forks to the line of action of the load is the load center.
Because larger trucks normally handle loads that are physically larger, these vehicles have greater load centers. Trucks with a capacity of 30,000 pounds or less are normally rated at a given load weight at a 24-inch load center. Trucks with a capacity greater than 30,000 pounds are normally rated at a given load weight at a 36- or 48-inch load center. To safely operate the vehicle, the operator should always check the data plate to determine the maximum allowable weight at the rated load center.
Although the true load-moment distance is measured from the front wheels, this distance is greater than the distance from the front face of the forks. Calculating the maximum allowable load-moment using the load-center distance always provides a lower load moment than the truck was designed to handle.
When handling unusual loads, such as those that are larger than 48 inches long (the center of gravity is greater than 24 inches) or that have an offset center of gravity, etc., a maximum allowable load moment should be calculated and used to determine whether a load can be safely handled. For example, if an operator is operating a 3,000-pound capacity truck (with a 24-inch load center), the maximum allowable load-moment is 72,000 inch-pounds (3,000 times 24). If a load is 60 inches long (30-inch load center), then the maximum that this load can weigh is 2,400 pounds (72,000 divided by 30).
Lateral stability
The vehicle’s lateral stability is determined by the line of action’s position relative to the stability triangle. When the vehicle is not loaded, the truck’s center of gravity location is the only factor to be considered in determining the truck’s stability. As long as the line of action of the combined vehicle and load’s center of gravity falls within the stability triangle, the truck is stable and will not tip over. However, if the line of action falls outside the stability triangle, the truck is not stable and may tip over.
Factors that affect the vehicle’s lateral stability include the load’s placement on the truck, the height of the load above the surface on which the vehicle is operating, and the vehicle’s degree of lean.
Dynamic stability
The stability of a PIT is further complicated by dynamic forces that result when the vehicle and load are put into motion. The weight’s transfer and the resulting shift in the center of gravity due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations.
When determining whether a load can be safely handled, the operator should exercise extra caution with loads that cause the vehicle to approach its maximum design characteristics. For example, if an operator must handle a maximum load, the load should be carried at the lowest position possible, the truck should be accelerated slowly and evenly, and the forks should be tilted forward cautiously. However, no precise rules can be formulated to cover all of these eventualities.
Stability triangle
Almost all counterbalanced PITs have a three-point suspension system, meaning the vehicle is supported at three points. This is true even if the vehicle has four wheels. The truck’s steer axle is attached to the truck by a pivot pin in the axle’s center. When the points are connected by imaginary lines, this three-point support forms a triangle called the stability triangle.
Longitudinal stability
The axis of rotation when a truck tips forward is the front wheels’ points of contact with the pavement. When PITs tip forward, the truck will rotate about this line. When a truck is stable, the vehicle moment must exceed the load-moment. As long as the vehicle-moment is equal to or exceeds the load-moment, the vehicle will not tip over. On the other hand, if the load-moment slightly exceeds the vehicle-moment, the truck will begin to tip forward, thereby causing the rear to lose contact with the floor or ground and result in loss of steering control. If the load-moment greatly exceeds the vehicle-moment, the truck will tip forward.
To determine the maximum safe load-moment, the truck manufacturer normally rates the truck at a maximum load at a given distance from the front face of the forks. The specified distance from the front face of the forks to the line of action of the load is the load center.
Because larger trucks normally handle loads that are physically larger, these vehicles have greater load centers. Trucks with a capacity of 30,000 pounds or less are normally rated at a given load weight at a 24-inch load center. Trucks with a capacity greater than 30,000 pounds are normally rated at a given load weight at a 36- or 48-inch load center. To safely operate the vehicle, the operator should always check the data plate to determine the maximum allowable weight at the rated load center.
Although the true load-moment distance is measured from the front wheels, this distance is greater than the distance from the front face of the forks. Calculating the maximum allowable load-moment using the load-center distance always provides a lower load moment than the truck was designed to handle.
When handling unusual loads, such as those that are larger than 48 inches long (the center of gravity is greater than 24 inches) or that have an offset center of gravity, etc., a maximum allowable load moment should be calculated and used to determine whether a load can be safely handled. For example, if an operator is operating a 3,000-pound capacity truck (with a 24-inch load center), the maximum allowable load-moment is 72,000 inch-pounds (3,000 times 24). If a load is 60 inches long (30-inch load center), then the maximum that this load can weigh is 2,400 pounds (72,000 divided by 30).
Lateral stability
The vehicle’s lateral stability is determined by the line of action’s position relative to the stability triangle. When the vehicle is not loaded, the truck’s center of gravity location is the only factor to be considered in determining the truck’s stability. As long as the line of action of the combined vehicle and load’s center of gravity falls within the stability triangle, the truck is stable and will not tip over. However, if the line of action falls outside the stability triangle, the truck is not stable and may tip over.
Factors that affect the vehicle’s lateral stability include the load’s placement on the truck, the height of the load above the surface on which the vehicle is operating, and the vehicle’s degree of lean.
Dynamic stability
The stability of a PIT is further complicated by dynamic forces that result when the vehicle and load are put into motion. The weight’s transfer and the resulting shift in the center of gravity due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations.
When determining whether a load can be safely handled, the operator should exercise extra caution with loads that cause the vehicle to approach its maximum design characteristics. For example, if an operator must handle a maximum load, the load should be carried at the lowest position possible, the truck should be accelerated slowly and evenly, and the forks should be tilted forward cautiously. However, no precise rules can be formulated to cover all of these eventualities.
Frequency
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
The daily inspection requirements below broadly apply to several kinds of Powered Industrial Trucks (PITs): electric forklifts, gas and diesel forklifts, liquefied petroleum gas (LPG) forklifts, order pickers, powered pallet jacks, reach trucks, and stand-up tow tractors. They must be inspected for these requirements daily, with additional specific requirements for every type of PIT.
Tires
On electric forklifts, gas and diesel forklifts, LPG forklifts, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, the tires must be in good repair (e.g., no cuts, separation from the rim, or excessive wear) and properly inflated. There must be lug nuts present on each tire, and the lug nuts must each be tightly secure.
Forks
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, powered pallet jacks, reach trucks, and pallet jacks, the forks must be properly aligned and in good repair (e.g., no cracks, bends, or excessive wear). Where present, the top clip retaining pin for each fork must be tightly secure and in good repair (e.g., no cracks). Load back rests must be securely attached and in good repair (e.g., no cracks or bends).
On reach trucks, the telescoping forks must be in good repair (e.g., no cracks, bends, or excessive wear).
Mast and carriage
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, and reach trucks, the mast assembly must be in good repair (e.g., no cracks or dents, missing stops, or broken welds). The hydraulic cylinders must be in good repair (e.g., no cracks or leaks). The lift chains and rollers must be in good repair (e.g., no cracks, kinks, or rust) and properly lubricated. Additionally, the tension of the lift chains must be correct.
On an order picker, the hoist lines, cables, lift chains, and rollers must be in good repair (e.g., no cracks, kinks, or rust).
Body
The body of the PIT must be in good repair (e.g., no cracks or dents) and clean (e.g., no grease or lint). The covers over the battery and other hazardous parts must be in place and secure. The overhead guard must be securely attached and in good repair (e.g., no cracks, bends, broken welds, or missing bolts). The nameplate must be present and legible. The safety decals or warning labels must also be legible. Any wiring, belts, lights, headlights, taillights, reflectors, warning lights, hoses, chains, and cables must be in good repair (e.g., no cracks, bends, frays, breaks, leaks, or kinks). Any lights or headlights must be aimed correctly. The control levers must be properly labeled.
On a powered pallet jack, the operator must ensure the hand guard is in place.
Cab
The cab should be clean, with the seatbelt working properly and in good repair (e.g., no frays or excessive wear). The seat itself must also be in good repair and adjusted properly. Control levers must be properly labeled. The mirrors must be in good repair (e.g., no cracks or breaks), clean, and adjusted properly.
Platform
Operators of order pickers, powered pallet jacks, and stand-up tow tractors must also inspect the PIT’s platform. The order picker’s work platform must be clean and in good repair (e.g., no cracks or holes). The guardrails or other limiting devices on the order picker must be in good repair (e.g., no cracks or bends) and must close properly and lock securely. The powered pallet jack and stand-up tow tractor riding platforms must be clean and in good repair (e.g., no cracks or holes).
Fluids
Where applicable, such as sit-down forklifts, hydraulic and brake fluid levels must be adequate.
Gas or diesel forklifts should have sufficient fuel for operation and adequate engine oil and radiator coolant levels.
Where applicable, operators should ensure the engine oil level, radiator coolant level, and transmission fluid level are adequate.
Battery
A PIT’s battery must be charged and in good repair (e.g., no corrosion or missing cable insulation), with its connections tight and in good repair (e.g., no cracks or excessive wear) as well. The cell caps in the battery cover must be in place and the electrolyte level must be adequate.
Battery gates (pallet jacks) and compartments should be secured.
Attachments
The nameplate on the PIT should account for any attachment being used, with the attachment in good repair (e.g., no cracks or bends).
Systems and controls
PIT inspectors (which can be the operator) must check that several components of the system and controls are working. They must check if the motor is running smoothly. They must also check that the accelerator is working and functioning smoothly, and that the steering is smooth and responsive (e.g., free of excessive play).
The employee must ensure the horn, whistle, gong, or other warning device sounds. The brake must be working and functioning smoothly (e.g., no grabbing), along with the parking brake (e.g., holds the forklift on the incline). The drive control and tilt control must work in forward and reverse and function smoothly (e.g., no excess drift for the tilt control). The lift controls must raise and lower the forks properly and function smoothly (e.g., no excess drift), and the attachment control must work and function smoothly (e.g., no hesitation). Additionally, the turn signal, backup alarm, lights, battery discharge indicator, and hour meter should also be working.
On electric forklifts, order pickers, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, employees should ensure the battery discharge indicator is working.
Gas or diesel forklift and LPG forklift operators must ensure the engine runs smoothly, and that the fuel gauge, ammeter indicator lamp, oil pressure indicator lamp, and water temperature gauge work.
Propane tank
On an LPG forklift, the operator must ensure the propane tank restraint brackets are in good repair (e.g., no cracks, bends, or rust) and that the tank is properly mounted on the locator pin. The tank must fit within the profile of the truck and be in good repair (e.g., no cracks, dents, or rust). The hoses and connectors must be in good repair (e.g., no cracks or kinks) and securely attached. Additionally, the pressure relief valve must be pointing up.
Pallet jacks have their own set of inspection requirements. Pallet jack operators must inspect the:
Operation
All Powered Industrial Trucks (PITs) must be designed and constructed in compliance with the American National Standards Institute (ANSI) standard B56.1-1969. (1910.178(a)(2)) Employers must ensure that only approved trucks are used in areas where flammable gases or vapors, combustible dust, or ignitable fibers are present in the atmosphere. Trucks with internal combustion engines that operate in buildings or enclosed areas must be checked to ensure they do not cause harmful concentrations of dangerous gases or fumes.
Any trucks not in safe operating condition are to be promptly removed from service. (1910.178(q)(1)) Repairs to fuel and ignition systems must be conducted only in areas specifically designated for them. (1910.178(q)(3)) Trucks are to be inspected daily, or after each shift if used around the clock, and before being placed in service. (1910.178(q)(7)) Directional lighting must be provided on each truck that operates in an area with less than two foot-candles per square foot of general lighting. (1910.178(h)(2)) Any trucks used by a company must be correctly designated for that type of operation (based on atmosphere, hazards of materials handled, etc.). (1910.178(c)(2))
Material handling
When assessing how a PIT will handle material, employers and operators must ensure there is sufficient clearance for equipment through aisles and doorways. (1910.176(a)) There must also be clearance signs to warn of clearance limits, and permanent aisles and passageways must be appropriately marked. (1910.176(e), 1910.176(a)) Bags, containers, bundles, etc. need to be stacked, blocked, interlocked, and limited in height so they are stable and secure. (1910.176(b))
Operators must use dock boards (bridge plates) when loading or unloading operations are taking place between vehicles and docks, and trucks and trailers should be secured from movement. (1910.178(m)(7))
Battery charging
Battery charging installations (located in areas designated for that purpose) and the batteries themselves must be charged in a properly vented room. (1910.178(g)(1), 1910.178(g)(2)) The local ventilation must be sufficient to disperse fumes. (1910.178(g)(2)). Facilities must be provided for flushing and neutralizing spilled electrolyte, fire protection, and protecting charging apparatus from damage by trucks. (1910.178(g)(2))
A conveyor, overhead hoist, or equivalent material handling equipment must be provided for handling batteries. (1910.178(g)(4)) Any reinstalled batteries must be properly positioned and secured in the truck. (1910.178(g)(5)) A carboy tilter or siphon must be provided for handling electrolyte. (1910.178(g)(6))
When charging batteries, employees must make certain not to pour water into acid, and that trucks are properly positioned with brakes applied first. (1910.178(g)(7), 1910.178(g)(8)) They must also ensure that the vent caps are functioning. (1910.178(g)(9)) Smoking must be prohibited in battery charging areas, and precautions taken to prevent open flames, sparks, or electric arcs in the charging area, such as keeping tools and other metallic objects away from the top of any uncovered batteries. (1910.178(g)(10)-(12))
Fueling
Fueling an internal combustion engine with a flammable liquid while the engine is running must be prohibited. (1910.178(p)(2)) Employees should ensure fueling operations are done in such a manner that the likelihood of spillage will be minimal. (1910.178(p)(2)) If spillage does occur, employees should take measures to control any vapors before restarting the engine. (1910.178(p)(3))
Aisles and walkways
Aisles must be marked and in good condition, with their widths maintained. (1910.22(b)(1)-(2)) They must also be clean and free of obstructions. (1910.22(b)(1)) Additionally, employees must ensure that fire aisles, access to stairways, and fire equipment are all clear. (1910.178(m)(14)) The aisles and passageways must be properly illuminated.
There should be safe clearance for equipment through all aisles and doorways. (1910.176(a)) Any pits and floor openings should be covered or otherwise guarded. (1910.22(c); .23(a)) Additionally, there must be standard guardrails present where aisle or walkway surfaces are elevated four feet or more above any adjacent floor or the ground. (1910.23(c)) Adequate barriers and warnings should be provided to prevent employees from stepping into the path of traffic where vehicles may be operated.
Housekeeping
Work areas, floors, walkways, and other surfaces should be clean and orderly. (1910.22(a), 1910.141(a)(3)(i)) Employees should check if there are any spilled materials or liquids present and if work surfaces are dry, and mats or grating should be used where drainage is needed. (1910.141(a)(3)(ii)1910.22(a)(2)) Employees should use compressed air for cleaning under 30 pounds per square inch (psi). (1910.242(b)) Employees should also check for any accumulation of dust and/or other potential contaminants. (1910.141(a)(3))
Personal protective equipment (PPE)
Employees must wear foot protection anywhere there is risk of foot injuries in the workplace. (1910.132(a); .136(a)) They must also wear hard hats anywhere danger of falling objects exists. (1910.135(a)(1)) Companies should also ensure the use of protective goggles or face shields where there is danger of flying particles or corrosive materials. (1910.133(a)(1))
Approved safety glasses must be worn where there is a risk of eye injuries such as punctures, abrasions, contusions, or burns. 1910.133(a)(2) Employees should wear appropriate safety glasses, face shields, etc. while using hand tools or equipment which might produce flying materials or be subject to breakage. (1910.133(a)(1))
Companies must ensure that employees use required protective clothing or equipment as needed, and that it fits properly, is functional and in good repair, and marked with ANSI or ASTM International specifications. (1910.132(a), 1910.132(e), .135(b))
Postings
Required truck operating rules should be posted.
Recordkeeping
Any inspection and maintenance records should be kept on file.
Training
Only trained personnel should be allowed to operate industrial trucks, and the training methods used to train operators must be documented and meet the requirements specified in 1910.178(l).
Documentation
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
Once an inspection has been conducted, the Occupational Safety and Health Administration (OSHA) expects employers to fix safety issues before allowing operation. But what constitutes something severe enough to require the equipment be taken out of service?
In OSHA’s standards, there are a few very specific conditions that warrant immediate removal of equipment from service. These include:
In addition, there is also a general provision to remove “unsafe” equipment. OSHA has said they will take a variety of factors into consideration when making the determination as to whether a truck is unsafe. But, at the least, any item that could present harm or risk would need to be taken out of service.
Items that could constitute unsafe conditions include:
The daily inspection requirements below broadly apply to several kinds of Powered Industrial Trucks (PITs): electric forklifts, gas and diesel forklifts, liquefied petroleum gas (LPG) forklifts, order pickers, powered pallet jacks, reach trucks, and stand-up tow tractors. They must be inspected for these requirements daily, with additional specific requirements for every type of PIT.
Tires
On electric forklifts, gas and diesel forklifts, LPG forklifts, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, the tires must be in good repair (e.g., no cuts, separation from the rim, or excessive wear) and properly inflated. There must be lug nuts present on each tire, and the lug nuts must each be tightly secure.
Forks
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, powered pallet jacks, reach trucks, and pallet jacks, the forks must be properly aligned and in good repair (e.g., no cracks, bends, or excessive wear). Where present, the top clip retaining pin for each fork must be tightly secure and in good repair (e.g., no cracks). Load back rests must be securely attached and in good repair (e.g., no cracks or bends).
On reach trucks, the telescoping forks must be in good repair (e.g., no cracks, bends, or excessive wear).
Mast and carriage
On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, and reach trucks, the mast assembly must be in good repair (e.g., no cracks or dents, missing stops, or broken welds). The hydraulic cylinders must be in good repair (e.g., no cracks or leaks). The lift chains and rollers must be in good repair (e.g., no cracks, kinks, or rust) and properly lubricated. Additionally, the tension of the lift chains must be correct.
On an order picker, the hoist lines, cables, lift chains, and rollers must be in good repair (e.g., no cracks, kinks, or rust).
Body
The body of the PIT must be in good repair (e.g., no cracks or dents) and clean (e.g., no grease or lint). The covers over the battery and other hazardous parts must be in place and secure. The overhead guard must be securely attached and in good repair (e.g., no cracks, bends, broken welds, or missing bolts). The nameplate must be present and legible. The safety decals or warning labels must also be legible. Any wiring, belts, lights, headlights, taillights, reflectors, warning lights, hoses, chains, and cables must be in good repair (e.g., no cracks, bends, frays, breaks, leaks, or kinks). Any lights or headlights must be aimed correctly. The control levers must be properly labeled.
On a powered pallet jack, the operator must ensure the hand guard is in place.
Cab
The cab should be clean, with the seatbelt working properly and in good repair (e.g., no frays or excessive wear). The seat itself must also be in good repair and adjusted properly. Control levers must be properly labeled. The mirrors must be in good repair (e.g., no cracks or breaks), clean, and adjusted properly.
Platform
Operators of order pickers, powered pallet jacks, and stand-up tow tractors must also inspect the PIT’s platform. The order picker’s work platform must be clean and in good repair (e.g., no cracks or holes). The guardrails or other limiting devices on the order picker must be in good repair (e.g., no cracks or bends) and must close properly and lock securely. The powered pallet jack and stand-up tow tractor riding platforms must be clean and in good repair (e.g., no cracks or holes).
Fluids
Where applicable, such as sit-down forklifts, hydraulic and brake fluid levels must be adequate.
Gas or diesel forklifts should have sufficient fuel for operation and adequate engine oil and radiator coolant levels.
Where applicable, operators should ensure the engine oil level, radiator coolant level, and transmission fluid level are adequate.
Battery
A PIT’s battery must be charged and in good repair (e.g., no corrosion or missing cable insulation), with its connections tight and in good repair (e.g., no cracks or excessive wear) as well. The cell caps in the battery cover must be in place and the electrolyte level must be adequate.
Battery gates (pallet jacks) and compartments should be secured.
Attachments
The nameplate on the PIT should account for any attachment being used, with the attachment in good repair (e.g., no cracks or bends).
Systems and controls
PIT inspectors (which can be the operator) must check that several components of the system and controls are working. They must check if the motor is running smoothly. They must also check that the accelerator is working and functioning smoothly, and that the steering is smooth and responsive (e.g., free of excessive play).
The employee must ensure the horn, whistle, gong, or other warning device sounds. The brake must be working and functioning smoothly (e.g., no grabbing), along with the parking brake (e.g., holds the forklift on the incline). The drive control and tilt control must work in forward and reverse and function smoothly (e.g., no excess drift for the tilt control). The lift controls must raise and lower the forks properly and function smoothly (e.g., no excess drift), and the attachment control must work and function smoothly (e.g., no hesitation). Additionally, the turn signal, backup alarm, lights, battery discharge indicator, and hour meter should also be working.
On electric forklifts, order pickers, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, employees should ensure the battery discharge indicator is working.
Gas or diesel forklift and LPG forklift operators must ensure the engine runs smoothly, and that the fuel gauge, ammeter indicator lamp, oil pressure indicator lamp, and water temperature gauge work.
Propane tank
On an LPG forklift, the operator must ensure the propane tank restraint brackets are in good repair (e.g., no cracks, bends, or rust) and that the tank is properly mounted on the locator pin. The tank must fit within the profile of the truck and be in good repair (e.g., no cracks, dents, or rust). The hoses and connectors must be in good repair (e.g., no cracks or kinks) and securely attached. Additionally, the pressure relief valve must be pointing up.
Pallet jacks have their own set of inspection requirements. Pallet jack operators must inspect the:
Operation
All Powered Industrial Trucks (PITs) must be designed and constructed in compliance with the American National Standards Institute (ANSI) standard B56.1-1969. (1910.178(a)(2)) Employers must ensure that only approved trucks are used in areas where flammable gases or vapors, combustible dust, or ignitable fibers are present in the atmosphere. Trucks with internal combustion engines that operate in buildings or enclosed areas must be checked to ensure they do not cause harmful concentrations of dangerous gases or fumes.
Any trucks not in safe operating condition are to be promptly removed from service. (1910.178(q)(1)) Repairs to fuel and ignition systems must be conducted only in areas specifically designated for them. (1910.178(q)(3)) Trucks are to be inspected daily, or after each shift if used around the clock, and before being placed in service. (1910.178(q)(7)) Directional lighting must be provided on each truck that operates in an area with less than two foot-candles per square foot of general lighting. (1910.178(h)(2)) Any trucks used by a company must be correctly designated for that type of operation (based on atmosphere, hazards of materials handled, etc.). (1910.178(c)(2))
Material handling
When assessing how a PIT will handle material, employers and operators must ensure there is sufficient clearance for equipment through aisles and doorways. (1910.176(a)) There must also be clearance signs to warn of clearance limits, and permanent aisles and passageways must be appropriately marked. (1910.176(e), 1910.176(a)) Bags, containers, bundles, etc. need to be stacked, blocked, interlocked, and limited in height so they are stable and secure. (1910.176(b))
Operators must use dock boards (bridge plates) when loading or unloading operations are taking place between vehicles and docks, and trucks and trailers should be secured from movement. (1910.178(m)(7))
Battery charging
Battery charging installations (located in areas designated for that purpose) and the batteries themselves must be charged in a properly vented room. (1910.178(g)(1), 1910.178(g)(2)) The local ventilation must be sufficient to disperse fumes. (1910.178(g)(2)). Facilities must be provided for flushing and neutralizing spilled electrolyte, fire protection, and protecting charging apparatus from damage by trucks. (1910.178(g)(2))
A conveyor, overhead hoist, or equivalent material handling equipment must be provided for handling batteries. (1910.178(g)(4)) Any reinstalled batteries must be properly positioned and secured in the truck. (1910.178(g)(5)) A carboy tilter or siphon must be provided for handling electrolyte. (1910.178(g)(6))
When charging batteries, employees must make certain not to pour water into acid, and that trucks are properly positioned with brakes applied first. (1910.178(g)(7), 1910.178(g)(8)) They must also ensure that the vent caps are functioning. (1910.178(g)(9)) Smoking must be prohibited in battery charging areas, and precautions taken to prevent open flames, sparks, or electric arcs in the charging area, such as keeping tools and other metallic objects away from the top of any uncovered batteries. (1910.178(g)(10)-(12))
Fueling
Fueling an internal combustion engine with a flammable liquid while the engine is running must be prohibited. (1910.178(p)(2)) Employees should ensure fueling operations are done in such a manner that the likelihood of spillage will be minimal. (1910.178(p)(2)) If spillage does occur, employees should take measures to control any vapors before restarting the engine. (1910.178(p)(3))
Aisles and walkways
Aisles must be marked and in good condition, with their widths maintained. (1910.22(b)(1)-(2)) They must also be clean and free of obstructions. (1910.22(b)(1)) Additionally, employees must ensure that fire aisles, access to stairways, and fire equipment are all clear. (1910.178(m)(14)) The aisles and passageways must be properly illuminated.
There should be safe clearance for equipment through all aisles and doorways. (1910.176(a)) Any pits and floor openings should be covered or otherwise guarded. (1910.22(c); .23(a)) Additionally, there must be standard guardrails present where aisle or walkway surfaces are elevated four feet or more above any adjacent floor or the ground. (1910.23(c)) Adequate barriers and warnings should be provided to prevent employees from stepping into the path of traffic where vehicles may be operated.
Housekeeping
Work areas, floors, walkways, and other surfaces should be clean and orderly. (1910.22(a), 1910.141(a)(3)(i)) Employees should check if there are any spilled materials or liquids present and if work surfaces are dry, and mats or grating should be used where drainage is needed. (1910.141(a)(3)(ii)1910.22(a)(2)) Employees should use compressed air for cleaning under 30 pounds per square inch (psi). (1910.242(b)) Employees should also check for any accumulation of dust and/or other potential contaminants. (1910.141(a)(3))
Personal protective equipment (PPE)
Employees must wear foot protection anywhere there is risk of foot injuries in the workplace. (1910.132(a); .136(a)) They must also wear hard hats anywhere danger of falling objects exists. (1910.135(a)(1)) Companies should also ensure the use of protective goggles or face shields where there is danger of flying particles or corrosive materials. (1910.133(a)(1))
Approved safety glasses must be worn where there is a risk of eye injuries such as punctures, abrasions, contusions, or burns. 1910.133(a)(2) Employees should wear appropriate safety glasses, face shields, etc. while using hand tools or equipment which might produce flying materials or be subject to breakage. (1910.133(a)(1))
Companies must ensure that employees use required protective clothing or equipment as needed, and that it fits properly, is functional and in good repair, and marked with ANSI or ASTM International specifications. (1910.132(a), 1910.132(e), .135(b))
Postings
Required truck operating rules should be posted.
Recordkeeping
Any inspection and maintenance records should be kept on file.
Training
Only trained personnel should be allowed to operate industrial trucks, and the training methods used to train operators must be documented and meet the requirements specified in 1910.178(l).
Documentation
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
Pallet jacks have their own set of inspection requirements. Pallet jack operators must inspect the:
Operation
All Powered Industrial Trucks (PITs) must be designed and constructed in compliance with the American National Standards Institute (ANSI) standard B56.1-1969. (1910.178(a)(2)) Employers must ensure that only approved trucks are used in areas where flammable gases or vapors, combustible dust, or ignitable fibers are present in the atmosphere. Trucks with internal combustion engines that operate in buildings or enclosed areas must be checked to ensure they do not cause harmful concentrations of dangerous gases or fumes.
Any trucks not in safe operating condition are to be promptly removed from service. (1910.178(q)(1)) Repairs to fuel and ignition systems must be conducted only in areas specifically designated for them. (1910.178(q)(3)) Trucks are to be inspected daily, or after each shift if used around the clock, and before being placed in service. (1910.178(q)(7)) Directional lighting must be provided on each truck that operates in an area with less than two foot-candles per square foot of general lighting. (1910.178(h)(2)) Any trucks used by a company must be correctly designated for that type of operation (based on atmosphere, hazards of materials handled, etc.). (1910.178(c)(2))
Material handling
When assessing how a PIT will handle material, employers and operators must ensure there is sufficient clearance for equipment through aisles and doorways. (1910.176(a)) There must also be clearance signs to warn of clearance limits, and permanent aisles and passageways must be appropriately marked. (1910.176(e), 1910.176(a)) Bags, containers, bundles, etc. need to be stacked, blocked, interlocked, and limited in height so they are stable and secure. (1910.176(b))
Operators must use dock boards (bridge plates) when loading or unloading operations are taking place between vehicles and docks, and trucks and trailers should be secured from movement. (1910.178(m)(7))
Battery charging
Battery charging installations (located in areas designated for that purpose) and the batteries themselves must be charged in a properly vented room. (1910.178(g)(1), 1910.178(g)(2)) The local ventilation must be sufficient to disperse fumes. (1910.178(g)(2)). Facilities must be provided for flushing and neutralizing spilled electrolyte, fire protection, and protecting charging apparatus from damage by trucks. (1910.178(g)(2))
A conveyor, overhead hoist, or equivalent material handling equipment must be provided for handling batteries. (1910.178(g)(4)) Any reinstalled batteries must be properly positioned and secured in the truck. (1910.178(g)(5)) A carboy tilter or siphon must be provided for handling electrolyte. (1910.178(g)(6))
When charging batteries, employees must make certain not to pour water into acid, and that trucks are properly positioned with brakes applied first. (1910.178(g)(7), 1910.178(g)(8)) They must also ensure that the vent caps are functioning. (1910.178(g)(9)) Smoking must be prohibited in battery charging areas, and precautions taken to prevent open flames, sparks, or electric arcs in the charging area, such as keeping tools and other metallic objects away from the top of any uncovered batteries. (1910.178(g)(10)-(12))
Fueling
Fueling an internal combustion engine with a flammable liquid while the engine is running must be prohibited. (1910.178(p)(2)) Employees should ensure fueling operations are done in such a manner that the likelihood of spillage will be minimal. (1910.178(p)(2)) If spillage does occur, employees should take measures to control any vapors before restarting the engine. (1910.178(p)(3))
Aisles and walkways
Aisles must be marked and in good condition, with their widths maintained. (1910.22(b)(1)-(2)) They must also be clean and free of obstructions. (1910.22(b)(1)) Additionally, employees must ensure that fire aisles, access to stairways, and fire equipment are all clear. (1910.178(m)(14)) The aisles and passageways must be properly illuminated.
There should be safe clearance for equipment through all aisles and doorways. (1910.176(a)) Any pits and floor openings should be covered or otherwise guarded. (1910.22(c); .23(a)) Additionally, there must be standard guardrails present where aisle or walkway surfaces are elevated four feet or more above any adjacent floor or the ground. (1910.23(c)) Adequate barriers and warnings should be provided to prevent employees from stepping into the path of traffic where vehicles may be operated.
Housekeeping
Work areas, floors, walkways, and other surfaces should be clean and orderly. (1910.22(a), 1910.141(a)(3)(i)) Employees should check if there are any spilled materials or liquids present and if work surfaces are dry, and mats or grating should be used where drainage is needed. (1910.141(a)(3)(ii)1910.22(a)(2)) Employees should use compressed air for cleaning under 30 pounds per square inch (psi). (1910.242(b)) Employees should also check for any accumulation of dust and/or other potential contaminants. (1910.141(a)(3))
Personal protective equipment (PPE)
Employees must wear foot protection anywhere there is risk of foot injuries in the workplace. (1910.132(a); .136(a)) They must also wear hard hats anywhere danger of falling objects exists. (1910.135(a)(1)) Companies should also ensure the use of protective goggles or face shields where there is danger of flying particles or corrosive materials. (1910.133(a)(1))
Approved safety glasses must be worn where there is a risk of eye injuries such as punctures, abrasions, contusions, or burns. 1910.133(a)(2) Employees should wear appropriate safety glasses, face shields, etc. while using hand tools or equipment which might produce flying materials or be subject to breakage. (1910.133(a)(1))
Companies must ensure that employees use required protective clothing or equipment as needed, and that it fits properly, is functional and in good repair, and marked with ANSI or ASTM International specifications. (1910.132(a), 1910.132(e), .135(b))
Postings
Required truck operating rules should be posted.
Recordkeeping
Any inspection and maintenance records should be kept on file.
Training
Only trained personnel should be allowed to operate industrial trucks, and the training methods used to train operators must be documented and meet the requirements specified in 1910.178(l).
Documentation
The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.
Safe procedures
The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard does provide a few “rules of the road” that operators should adhere to. The key to a successful safety program is setting proper rules, training operators on those rules, and then following up consistently when there are deviations.
The basic rule for traveling is that operators maintain control of the PIT at all times. Other rules include:
Load handling
Many incidents can happen during load placement or retrieval. To avoid this, employers should ensure that operators are doing the following:
The Occupational Safety and Health Administration (OSHA) requires that permanent aisles and passageways be free from obstructions and appropriately marked where mechanical handling equipment is used. OSHA recommends that employers consider separating pedestrians from lift trucks by providing:
Operators and pedestrians should be trained on the plant’s procedures and hazards associated with Powered Industrial Truck (PIT) operation in pedestrian areas.
It is noteworthy that OSHA proposed a nearly $13,000 penalty for a serious violation of Section 5(a)(1) of the Occupational Safety and Health Act when a distribution center allegedly exposed employees to struck-by hazards from PITs and over-the-road trucks in the yard area at night. The agency explains that the company could abate the hazards by providing and requiring the use of high visibility reflective vests for workers who walk or work in the yard area.
Many injuries occur when forklift operators lose control while driving on ramps. For example, an operator was backing a forklift out of a warehouse and came too close to the side of a ramp. The forklift went over the edge of the ramp, tipped over, and crushed the operator.
Operators should be aware of procedures to follow when traveling on ramps and other inclines with a load. These include:
When walking with a pallet jack with or without a load, generally the forks should be pointed downgrade, regardless of direction of travel.
One of the most dangerous operations involving powered industrial trucks (PITs) is the loading or unloading of trucks, trailers, and railroad cars. Not only may the vehicle being entered be unstable, but the means of going from the warehouse to the vehicle by way of a dockplate can also be dangerous. While entering and leaving truck trailers or railroad cars, operators must be aware of the following:
One of the common uses of forklifts and pallet jacks is to load/unload trucks, trailers, or railroad cars. This requires the Powered Industrial Truck (PIT) to enter the transport vehicle over a dockboard (also known as a bridge plate) at loading docks. If the truck, trailer, or car is not secured to the dock or otherwise chocked, blocked, or secured, it can move over time or with the right amount of force. The dockboard can also fall between the trailer and the dock as the forklift crosses it.
The Occupational Safety and Health Administration (OSHA) PIT standard lists a number of situations in which special procedures must be followed before starting entry into a railcar or truck trailer:
The OSHA Walking-Working Surfaces standard contains requirements for dockboards (bridge plates):
Capacity/design
All dockboards put into service after January 17, 2017, must comply with the requirements of the Occupational Safety and Health Administration (OSHA)’s Walking-Working Surfaces rule.
Dockboards are considered walking-working surfaces and employers are required to evaluate them for fall hazards. If it is determined that a fall hazard exists, the employer must utilize some form of fall protection.
The evaluation also helps employers determine if their dockboards can support the maximum intended load. The maximum intended load (weight and force) includes:
Employers must decide, based on the maximum intended load, what structural material must be used to construct a dockboard. For example, portable dockboards that only need to support lightweight loads moved by a hand truck could be made from aluminum. On the other hand, steel may be needed to construct a portable dockboard that will have to support the weight of a motorized pallet jack, load, and employee.
Fixed jacks
OSHA’s PIT standard states that “[f]ixed jacks may be necessary to support a semi-trailer and prevent upending during loading or unloading when the trailer is not coupled to a tractor.” OSHA’s standard does not specify a particular type of jack, nor the number and placement of such jacks.
OSHA strongly recommends following both the trailer and the jack manufacturer’s instructions on the appropriate number and placement of these jacks
One of the common uses of forklifts and pallet jacks is to load/unload trucks, trailers, or railroad cars. This requires the Powered Industrial Truck (PIT) to enter the transport vehicle over a dockboard (also known as a bridge plate) at loading docks. If the truck, trailer, or car is not secured to the dock or otherwise chocked, blocked, or secured, it can move over time or with the right amount of force. The dockboard can also fall between the trailer and the dock as the forklift crosses it.
The Occupational Safety and Health Administration (OSHA) PIT standard lists a number of situations in which special procedures must be followed before starting entry into a railcar or truck trailer: