20.6 Conventional (Sit-Down Counterbalanced) Forklifts

Conventional (Sit-Down Counterbalanced) Forklifts

Where Conventional Forklifts Fit

A conventional forklift is a sit-down, counterbalanced lift truck with a vertical mast. The counterweight at the rear balances the load on the forks. These trucks work on smooth, firm surfaces such as warehouse floors, loading docks, and paved material yards. Rough-terrain forklifts and telehandlers (Section 20.2) are built for unimproved jobsite ground.

The Industrial Truck Association (ITA), used by OSHA, sorts powered industrial trucks into seven classes:

Capacity and the Data Plate

The data plate shows the truck's rated capacity at a stated load center, usually 24 inches from the fork face. It also shows maximum lift height and any capacity reductions for attachments. In construction, 1926.602(c)(1) requires the rated capacity to be posted where the operator can see it and prohibits exceeding it. Modifications that affect capacity or safe operation require the manufacturer's written approval. Moving the load farther out, raising it higher, or tilting the mast forward reduces the safe capacity. The stability triangle described in Section 20.2 applies to conventional forklifts too.

Training and Evaluation

OSHA 1910.178(l) sets the training rules, and 1926.602(d) applies the same requirements to construction work.

• Before operating: training must combine formal instruction, practical training, and an evaluation of the operator's performance in the workplace.
• Refresher training is required when the operator:
  • Has been observed operating unsafely.
  • Has been involved in an accident or near-miss incident.
  • Received an evaluation showing unsafe operation.
  • Is assigned to a different type of truck.
  • Faces a change in workplace conditions that could affect safe operation.
• Evaluation at least once every three years.
• Certification: the employer certifies that each operator has been trained and evaluated, recording the operator's name, the training and evaluation dates, and who performed the training or evaluation.

OSHA does not issue forklift licenses. Training is site- and truck-specific and is certified by the employer.

Daily Examination

Under 1910.178(q)(7), trucks must be examined before being placed in service and must not be used if a condition affects safety. The examination is required at least daily, or after each shift for round-the-clock use. Typical checks:

• Forks, mast, chains, and the carriage.
• Hydraulic leaks, tires, brakes, steering, and the horn.
• Lights, seat belt, overhead guard, and data plate.
• Fuel or battery condition.

Travel Rules from 1910.178(n)

• Obey plant speed limits and keep about three truck lengths behind the truck ahead.
• Do not pass other trucks traveling the same direction at intersections or blind spots.
• Slow down and sound the horn at cross aisles and wherever vision is blocked.
• If the load blocks the forward view, travel with the load trailing, which means driving in reverse.
• Cross railroad tracks diagonally where possible, and never park within 8 feet of the center of the tracks.
• On grades over 10 percent, drive loaded trucks with the load upgrade. On all grades, tilt the load back and raise it only enough to clear the surface.
• No riders unless a safe place to ride is provided, and no one may stand or pass under raised forks.

Parking and Leaving the Truck

Loading Trucks, Trailers, and Railcars

• Under 1910.178(k)(1), the brakes of a highway truck must be set and wheel chocks placed under the rear wheels before a forklift drives onto it.
• Railcars need wheel stops or other positive protection, and an uncoupled semitrailer may need fixed jacks to prevent upending.
• Check the trailer floor and the dock board's rated capacity before driving across.

Battery Charging and Propane Cylinders

Battery charging (1910.178(g)):

• Charge only in designated areas.
• The area needs facilities for flushing and neutralizing spilled electrolyte, fire protection, and protection for chargers from truck damage.
• Provide ventilation to disperse gas from charging batteries.
• No smoking, open flames, sparks, or arcs in the charging area.
• Keep tools and metal objects off uncovered batteries.
• When mixing electrolyte, pour acid into water, never water into acid.

Changing a propane cylinder (a typical manufacturer procedure):

1. Close the cylinder service valve and run the engine until it stops.
2. Wear gloves and eye protection, because liquid propane can cause frostbite.
3. Check the coupling seal and set the new cylinder on its locating pin.
4. Tighten the coupling and open the valve slowly.
5. Check for leaks before restarting.