Consultation on combined L117 Rider-operated lift trucks: Operator
training and HSG6 Safety in working with lift trucks
Guidance for employers
15 June 2011
© Crown copyright XXXX
First published XXXX
ISBN 978 0 7176 XXXX X
You may reuse this information (excluding logos) free of charge in any format or medium,
under the terms of the Open Government Licence. To view the licence
visit www.nationalarchives.gov.uk/doc/open-government-licence/, write to the Information
Policy Team, The National Archives, Kew, London TW9 4DU, or email
psi@nationalarchives.gsi.gov.uk.
Some images and illustrations may not be owned by the Crown so cannot be reproduced
without permission of the copyright owner. Enquiries should be sent to
copyright@hse.gsi.gov.uk.
This Code has been approved by the Health and Safety Executive, with the consent of the
Secretary of State. It gives practical advice on how to comply with the law. If you follow the
advice you will be doing enough to comply with the law in respect of those specific matters
on which the Code gives advice. You may use alternative methods to those set out in the
Code in order to comply with the law.
However, the Code has a special legal status. If you are prosecuted for breach of health and
safety law, and it is proved that you did not follow the relevant provisions of the Code, you
will need to show that you have complied with the law in some other way or a Court will find
you at fault.
2
Contents
Preface
Notice of Approval
Part 1: Introduction and legal requirements
Part 2: Rider-operated lift trucks: Operator training – Approved Code of Practice and
guidance
Part 3: The lift truck
Part 4: Safe movement of lift trucks and pedestrians
Part 5: Principles of safe use and maintenance
Appendix 1: Useful contacts
Appendix 2: Objectives to consider for inclusion in a basic training course
Appendix 3: Basic training: Tests of operator skills
Appendix 4: Example of employer’s training record
Appendix 5: Supervisor attributes
References (to be added)
Further reading (to be added)
Glossary (to be added)
3
Notice of Approval
By virtue of section 16(4) of the Health and Safety at Work etc Act 1974, and with the
consent of the Secretary of State for the Environment, Transport and the Regions, the
Health and Safety Commission* has on 3 June 1999 approved the revision of the Code of
Practice entitled Rider-operated lift trucks: Operator training.
The Code of Practice gives practical guidance with respect to the requirements of regulation
9 of the Provision and Use of Work Equipment Regulations 1998 as they relate to the basic
training of operators of rider-operated lift trucks.
The Code of Practice comes into effect on 1 October 1999.
Signed
ROSEMARY BANNER
Secretary to the Health and Safety Commission
3 June 1999
* The Health and Safety Commission (HSC) and the Health and Safety Executive (HSE)
merged on 1 April 2008 to form a single national regulatory body. From that date, the Health
and Safety Executive became responsible for approving Codes of Practice, with the consent
of the Secretary of State.
4
Preface
This publication combines the previous versions of L117 Rider-operated lift trucks: Operator
training (published 1999) and HSG6 Safety in working with lift trucks (published 2000).
The Approved Code of Practice (ACOP) text on operator training (paragraphs 28 to 42
shown in bold) has not been altered, but the guidance has been updated. Although the
ACOP does not explicitly cover all types of lift truck, the general principles can be used as a
guide when training operators of other truck types.
An ‘operator’ in this publication is anyone who operates a lift truck, even as a secondary or
occasional part of their job and so the ACOP and guidance is not limited to people
specifically designated as lift-truck operators.
The publication is aimed particularly at employers and those responsible for the safe
operation of lift trucks, as well as those in control of worksites, the self-employed, managers
and supervisors. It is divided into five parts:

Part 1 outlines the legal requirements for the safe use and operation of lift trucks.

Part 2 includes the ACOP and guidance on operator training to help employers meet
their legal obligations to ensure all operators receive adequate training. The ACOP
has a special legal status, explained on the Copyright page.

Part 3 includes information on types of lift truck and what you need to look for to
make sure they are safe to operate.

Part 4 deals with how to move loads safely and how to protect pedestrians.

Part 5 includes guidance on the safe use and maintenance of lift trucks.
The ACOP text is in Part 2 is highlighted in bold type and the guidance in the publication is
in plain text.
5
PART 1: INTRODUCTION AND LEGAL REQUIREMENTS
Introduction
1
Lift trucks are widely used throughout industry for moving materials and goods, but
they are involved in about a quarter of all workplace transport accidents. Every year, about
1500 lift truck accidents result in injury, on average eight of them fatal. These injuries can
ruin lives and businesses. Even an incident not causing injury may result in costly damage to
lift trucks, buildings, fittings and the goods being handled.
Who should read this publication?
2
This publication includes an Approved Code of Practice on operator training, as well
as accompanying guidance on training and safe operation of lift trucks. It is aimed
particularly at employers and those responsible for the safe operation of lift trucks, as well as
people in control of worksites, the self-employed, managers and supervisors. HSE has also
produced a simple leaflet for employers, Lift truck training and safe operation: Advice for
employers and a pocket card for operators, Use lift trucks safely: Advice for operators.
Others involved with lift trucks, such as trade union health and safety representatives and lift
truck trainers, may also find it useful. The guidance does not replace formal training.
Managing lift truck operations
3
A few simple measures can help prevent lift truck accidents, for example:
Safe driver

provide adequate training for operators, supervisors and managers.
Safe vehicle

use suitable equipment for the job to be done;

ensure lift trucks are properly maintained;
Safe site

manage lift truck operations using safe systems of work;

lay out premises to ensure lift trucks can move safely;
6

ensure premises and driving surfaces are properly maintained;
The law
4
Employers have a duty under health and safety law to ensure, as far as is reasonably
practicable, the health, safety and welfare of their employees. The main legislation applying
to the use of lift trucks is:

Health and Safety at Work etc Act 1974 (HSW Act);

Management of Health and Safety at Work Regulations 1999;

Provision and Use of Work Equipment Regulations 1998 (PUWER);

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER);

Workplace (Health, Safety and Welfare) Regulations 1992;

Construction (Design and Management) Regulations 2007 (CDM);

Control of Substances Hazardous to Health (COSHH) Regulations 2002 (as
amended).
Health and Safety at Work etc Act 1974 (HSW Act)
5
Under the HSW Act, you, as an employer, have to ensure the health and safety of
yourself and others who may be affected by what you do or do not do. It applies to all work
activities and premises.
6
Employees also have responsibilities under the Act. They must take reasonable care
for their own health and safety and that of other people and must co-operate with you and
others to help them comply with their legal duties.
Management of Health and Safety at Work Regulations 1999
7
The Management of Health and Safety at Work Regulations 1999 require you to
carry out a risk assessment to protect your workers and your business. A risk assessment is
simply a careful examination of what in your work could cause harm to people, so that you
can weigh up whether you have taken enough precautions or should do more to prevent
harm. It helps you focus on the risks that really matter – the ones with the potential to cause
real harm.
7
8
Risk assessment also provides the basis for safe systems of work to eliminate or
reduce risks as far as possible. Safe systems of work are formal procedures to ensure work
is carried out safely where risks cannot be controlled adequately by other means. You must
ensure that any systems of work are properly implemented and monitored, and that those at
risk have details of them. Make sure your workers are actively involved in the risk
assessment process.
9
When thinking about your risk assessment, remember:

a hazard is anything that may cause harm, such as chemicals, electricity, working
from ladders, an open drawer etc;

the risk is the chance, high or low, that somebody could be harmed by these and
other hazards, together with an indication of how serious the harm could be.
10
Risk assessment can be broken down into five steps:
Step 1 Identify the hazards.
Step 2 Decide who might be harmed and how.
Step 3 Evaluate the risks and decide on precautions.
Step 4 Record your findings and implement them.
Step 5 Review your risk assessment and update if necessary.
11
If you employ five or more people you must keep a record of the significant findings
of your assessment.
Provision and Use of Work Equipment Regulations 1998 (PUWER)
12
PUWER applies to all work equipment. The regulations require that:

work equipment should be suitable for the purpose for which it is used or provided,
and should be properly maintained and inspected at suitable intervals (see
paragraphs 201 to 212);

where the use of work equipment is likely to involve specific risks, the use,
maintenance etc of that equipment is restricted to people given the task of using
and/or maintaining it; and
8

users, supervisors and managers have received adequate training for purposes of
health and safety, including:
-
training in the methods which may be adopted when using work equipment;
-
any risks which such use may entail; and
-
precautions to be taken.
Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
13
LOLER deals with specific hazards/risks associated with lifting equipment and lifting
operations. If you are an employer or self-employed person providing lifting equipment for
use at work, or you have control of the use of lifting equipment, you should ensure that every
lifting operation involving a lift truck is:

properly planned by a competent person. This is usually the operator for most lift
truck work, so they should have the appropriate training, knowledge and expertise;

appropriately supervised;

carried out in a safe manner using suitable equipment.
14
You need to ensure the lift truck has been thoroughly examined by a competent
person within the previous 12 months (6 months for lifting accessories or lift trucks used for
lifting people).
Workplace (Health, Safety and Welfare) Regulations 1992
15
The Workplace (Health, Safety and Welfare) Regulations require workplaces to be
organised to ensure that vehicles and pedestrians can move around safely. This includes:

sufficient lighting to enable people to work and move around safely (including not
obscuring lights by stacking goods in front of them);

construction of floors and traffic routes to ensure they are suitable for the purpose for
which they will be used and do not expose users to health and safety risks;

organisation of traffic routes to enable pedestrians and vehicles to circulate safely;
and

the need to ensure that doors or gates which can be pushed open from either side
give a clear view, when shut, of the space close to both sides.
9
Construction (Design and Management) Regulations 2007 (CDM)
16
Regulation 38 of CDM outlines the steps to be taken to ensure vehicle safety on site.
This includes ensuring that any vehicle is operated in a safe manner by a competent person.
Competence is a combination of training, capacity and experience. This publication provides
a framework for a minimum standard of initial training and does not fully cover the
requirements of CDM. For more information look at L144 Managing health and safety in
construction.
Control of Substances Hazardous to Health (COSHH) Regulations 2002 (as amended)
17
The COSHH Regulations require you to carry out an assessment of exposure to
hazardous substances and, where necessary, introduce appropriate control measures.
Examples of hazardous substances in lift truck operations are:

exhaust fumes from internal combustion engines;

fuel oils; and

battery acid.
18
Maintenance operations and certain loads may expose people to other hazardous
substances, so your COSHH assessment should identify these, and the methods to control
exposure to them. Make all employees aware of them and ensure appropriate first-aid
facilities are available.
19
There is more detailed advice on these and other legal requirements in the Approved
Codes of Practice (ACOPs) and guidance listed in the ‘References’ and ‘Further reading’
sections at the end of this publication.
10
PART 2: RIDER-OPERATED LIFT TRUCKS: OPERATOR TRAINING
APPROVED CODE OF PRACTICE AND GUIDANCE
Introduction
20
The ACOP paragraphs 28 to 42 (in bold text) advise on the basic training of lift-truck
operators. To comply with their duties under regulation 9 of the Provision and Use of Work
Equipment Regulations 1998 (PUWER) and general duties under the Health and Safety at
Work etc Act 1974, you as an employer must ensure that all operators you employ, both new
and existing, are adequately trained and, when necessary, provide additional or refresher
training.
21
For the purposes of this publication an operator is anyone who operates a lift truck,
even as a secondary or occasional part of their job, and is not limited to people specifically
designated as lift-truck operators.
22
The ACOP relates to stacking rider-operated lift trucks, including articulated steering
truck types. ‘Rider-operated’ means any truck capable of carrying an operator and includes
trucks controlled from both seated and stand-on positions, which may be fixed or fold-away.
Straddle carriers and non-lift trucks fitted with removable attachments which modify their
function, allowing them to be used temporarily as lift trucks, eg agricultural tractors with forklift attachments, are not included.
23
The employer’s duty under PUWER to provide training also extends to operators of
all other types of truck. Operators of types of lift truck not covered by this ACOP, eg
pedestrian-operated trucks and straddle carriers, will also need training. The advice
given in the ACOP and guidance on training can be used as an indication of the standard of
training to provide for all types of lift truck.
24
Organisations involved in lift-truck training should be able to advise on suitable
training, but you will need to take account of the advice on instructor selection in this
guidance when choosing a training provider, to ensure they have the relevant expertise and
experience.
25
Training undertaken in accordance with the ACOP and guidance is not the same as
achievement of competence-based qualifications such as Scottish or National Vocational
11
Qualifications (SVQs/NVQs). These qualifications are gained and awarded on the basis of
evidence of performance and understanding within the workplace. Training (eg a lift truck
certificate of basic training) may contribute to SVQs/NVQs, but neither is a substitute for the
other.
Self-employed operators
26
Self-employed lift-truck operators also have responsibilities under the Provision and
Use of Work Equipment Regulations 1998 to ensure they undergo the same type of training,
achieving the same standard, as employers are required to provide to their employees.
Safety representatives
27
Safety representatives appointed in accordance with the Safety Representatives and
Safety Committees Regulations 1977 should be consulted about the training arrangements
for lift-truck operators. If there are no appointed safety representatives, employers will need
to consult with their employees either through elected safety representatives or directly in
accordance with the Health and Safety (Consultation with Employees) Regulations 1996.
Safety representatives and employees can play an important role in encouraging the safe
operation of lift trucks.
Approved Code of Practice
What is covered?
28
The ACOP covers stacking rider-operated lift trucks, including articulated
steering truck types. ‘Rider-operated’ means any truck capable of carrying an
operator and includes trucks controlled from both seated and stand-on positions,
which may be fixed or fold-away. The purpose of this coverage is to include all types
of lift truck having similar training requirements and to which the advice can
reasonably be applied. Straddle carriers and non lift trucks fitted with removable
attachments which modify their function, allowing them to be used temporarily as lift
trucks, eg agricultural tractors with fork-lift attachments, are not included. Operators
of machines adapted for temporary use as lift trucks should be adequately trained to
use the attachments they need for the jobs they do.
12
Obligation to provide basic training
29
Employers should not allow anyone to operate, even on a very occasional
basis, lift trucks within the scope of this ACOP who have not satisfactorily completed
basic training and testing as described in this ACOP, except for those undergoing
such training under adequate supervision.
Selection of instructors
30
When arranging for training, employers should satisfy themselves that it is in
accordance with this ACOP. Operator training should only be carried out by
instructors who have themselves undergone appropriate training in instructional
techniques and skills’ assessment.* They should give instruction only on the types of
lift truck and attachments for which they have been trained and successfully tested as
operators. Instructors also need sufficient industrial experience to enable them to put
their instruction in context and an adequate knowledge of the working environment in
which the trainee will be expected to operate.
Training area and facilities
31
Basic training may be given at a suitable training centre or venue, or on an
employer’s premises. Where practicable, training areas should be sheltered from
adverse weather conditions.
32
Basic training needs to be carried out off the job. Even when conducted on an
employer’s premises this means that the instructor and trainees, together with the lift
truck and loads, should be wholly concerned with training, kept away from normal
commercial operations, and not be diverted to other activities while training is in
progress. Lift trucks used for training must be in good mechanical condition, properly
maintained (taking into account manufacturers’ recommendations), conform to all
legal requirements and be suitable for the particular uses to which they will be put.
33
A suitable manoeuvring area should be provided and appropriately marked.
While training is in progress access to this area should be restricted to the instructor
* Training may be carried out by in-house trainers or externally if the expertise is not available within the
company.
13
and trainees. The area will need to include facilities for simulating the manoeuvring
space likely to be encountered in the workplace, including slopes. For rough terrain
trucks an appropriate surface and obstacles representative of the conditions for
which training is being provided is necessary.
34
A supply of realistic loads appropriate to the training being given, such as
loaded and unloaded pallets, bags, sacks, bales, drums, bulk materials and freight
containers is necessary to make training realistic. Similarly, there should be
appropriate facilities for simulating loading and unloading from racking at various
heights as well as road vehicles.
35
A training room or other suitable accommodation, together with appropriate
training aids (eg projectors, models) should be made available to enable the
instructor to cover, under reasonable conditions, the principles of lift-truck operation.
Training structure and content
36
Training should be largely practical in nature and of sufficient length to enable
trainees to acquire the basic skills and knowledge required for safe operation,
including knowledge of the risks arising from lift-truck operations. It should not be
altered to suit immediate operational or production needs.
37
The ratio of trainees to instructors needs to allow each trainee adequate time
to practise operating the truck under close supervision and to prepare for the
practical tests.
38
Training should follow a carefully devised programme which ensures that each
stage is introduced in an appropriate sequence, building on what has gone before,
and allowing adequate time for learning and practice before the next stage is tackled.
The easier driving skills should be dealt with before progressing to more difficult
operations such as pallet or other load handling. At each stage the instructor will
need to explain and demonstrate safe operation, which should then be practised by
the trainees under direct supervision.
39
Basic training should be given on all the types of lift truck and attachments
that operators will or could be required to use in their work. If the operator is
subsequently required to operate another type of lift truck, or there is a change of
14
handling attachment, additional, practical conversion training will be required.
Employers should also consider the need for conversion training* where the truck
type does not change, but the size and weight alters significantly.
40
The course content will depend upon the lift-truck operations the trainee will
be expected to carry out. The objectives of a basic training course, some of which are
listed in Appendix 2, need to be tailored to fit all the lift-truck operations to be
undertaken by the operator.
Testing
41
The instructor should assess a trainee’s progress continuously to ensure that
the required standards are achieved at each stage of basic training. Additionally,
trainees are required to pass a test or tests, practical and theoretical, of the skills and
knowledge needed for safe operation.
Records
42
Employers need to keep a record for each employee who has satisfactorily
completed basic training and testing in accordance with this ACOP. The record
should include enough information to identify the employee and the nature and
content of the training and testing completed. Either a copy of any certificate of basic
training issued, or the relevant details, should be included in employers’ records.
*This term should be ‘familiarisation training’ as defined in the accompanying guidance.
Selecting operators and trainees
43
Take care when selecting potential lift truck operators. They should be:

reasonably fit, both physically and mentally, to safely control and operate lift trucks
and have the learning ability and potential to become competent operators;

reliable, with a responsible attitude to their work;

physically capable – you should assess this on an individual basis. Reasonable
adjustments may be required to enable some disabled people to work as lift truck
operators. The Equality Act 2010 may apply;
15

over the minimum school-leaving age (16), except in docks, where they must be at
least 18 years old. Look at: http://www.hse.gov.uk/youngpeople/index.htm; and

adequately supervised if under 18, unless they have the necessary competence and
maturity. Children under 16 should never operate lift trucks.
Medical considerations
44
People selected to operate lift trucks should be free from physical defects that might
pose a threat to their own health or safety or the safety of others who might be affected by
their operation of lift trucks. However, people with disabilities need not be excluded from
work with lift trucks, and you should obtain medical advice about their suitability for the
particular work they will be required to do.
45
Fitness for operating should always be judged individually. Some people with
disabilities have developed skills which compensate for their disability. You will need to do a
risk assessment to identify hazards associated with the job and working environment and to
identify the areas of concern to consider.
Frequency of medical examination
46
DVLA medical requirements only apply to lift trucks on the road, but HSE
recommends you follow the advice in their guidance ‘At a glance’ for all work with lift trucks
http://www.dft.gov.uk/dvla/medical/ataglance.aspx. The advice in paragraphs 47 to 53
(including the recommendations for medical examination according to age) is based on the
DVLA requirements.
47
It is advisable for you to agree the requirements for medical examination of
employees, in advance, in a contract of employment.
48
All existing and potential lift truck operators should be examined for fitness before
employment and at five-yearly intervals from age 45. Group 2 licences are renewable fiveyearly from age 45 and, where an individual is both a lift truck operator and holds a Group 2
entitlement, these examinations can be made at the same time. A lift truck operator who
continues after age 65 should have annual examinations for fitness.
49
Examination is also recommended after an absence of more than one month or after
a shorter absence if it is likely that the illness may have affected fitness to operate lift trucks.
16
This examination is recommended to provide positive confirmation of fitness to operate lift
trucks. Fitness to return to work when signed off by a GP may not indicate fitness to operate
a lift truck.
50
If you or any operator suspect or become aware of a condition which might affect
their ability to operate a lift truck, then an examination should also be carried out.
Medication
51
Fitness to operate lift trucks may be impaired temporarily by the effects of
medication, whether prescribed or purchased over the counter. Where an employee is taking
drugs prescribed by a medical practitioner it should be established that these will not affect
operating ability. Lift truck operators should ask advice from their general practitioner or the
pharmacist about the potential effects any medication may have on their ability to drive
safely, and should notify you if there is a risk of adverse effects which may compromise
safety. In some cases it may be necessary for them to stop operating lift trucks until the
nature and extent of any side effects has been established.
52
You should consider the following when assessing the normal level of fitness
requirements:

General: Lift truck operators should usually have full movement of the trunk, neck
and limbs, and normal agility. However, a very experienced worker who loses a limb
may be successfully re-employed after retraining. A stable disposition is required, but
a history of previous mental illness should not necessarily preclude selection. An
individual who is dependent on alcohol or non-prescribed drugs should not be
employed as a lift truck operator;

Vision: The ability to guide the lift truck and its load safely depends upon good
judgement of space and distance and this generally requires the effective use of both
eyes, although some people with monocular vision can carry out certain kinds of lift
truck work satisfactorily. Distance vision should be of the same standard as for
driving a car on public roads. If distance vision is corrected by glasses or contact
lenses these should always be worn while operating a lift truck;

Hearing: The ability to hear instructions and warning signals is important, but if a risk
assessment specific to the job and the individual indicates that deafness does not
17
constitute a significant risk then it should not disqualify someone from operating a lift
truck;

Epilepsy: This should not debar a worker from operating a lift truck if he/she is
eligible for an ordinary driving licence (ie has been free from epileptic attack for one
year) but any recurrence of seizures must always be reassessed medically. Flashing
beacons may trigger epileptic fits.
53
More details on the medical standards required for lift truck operators can be found
on HSE’s website: www.hse.gov.uk/workplacetransport/personnel/index.htm.
54
It may be useful to apply a selection test to avoid wasteful attempts to instruct
unsuitable trainees. Lift truck training organisations, trade associations and sector skills
councils may be able to give you more advice (see Appendix 1).
What should training include?
55
Operator training should always include three stages:

Basic training to fully cover the basic skills and knowledge required to operate a lift
truck safely and efficiently.

Specific job training: knowledge of the operating principles and controls of the lift
truck to be used and how it will be used, including conditions they will meet at work,
systems of work and specific handling attachments.

Familiarisation training: operation on the job under close supervision.
56
The first two stages, which can be combined, should take place off the job (ie away
from production and other pressures). Familiarisation training needs to be done on the job,
under close supervision. Lift truck operators, including occasional users, should be given the
opportunity to put what they have learned during training into practice in the workplace.
Basic training
57
Basic training needs to cover fully the skills and knowledge required for the safe
operation of the type of lift truck and handling attachments (if any) which the trainee will be
required to operate, including the risks arising from lift-truck operation. As well as those
directly related to the operation of trucks, include associated tasks, such as the hazards
18
associated with refuelling. Appendix 2 may be used as a starting point when drawing up a
list of objectives for a basic training course.
How long does the training need to be?
58
As a rough guide, the normal length of a course for novice operators would be five
days. It is difficult to specify how long a course should last as there are many issues which
affect the rate of learning. The course should be long enough to meet the requirements of
appendices 2 and 3.
59
Operators with some experience of lift trucks or relevant experience of similar
vehicles may need less extensive training than those with no experience. However, do not
overestimate the value of such experience. The ability to drive private cars or other
conventional road vehicles, for example, does not remove the need for proper training on lift
trucks, which have very different stability and handling characteristics as well as different
controls. An operator with basic training on one type of lift truck or handling attachment
cannot safely operate others, for which they have not been trained, without additional,
conversion training (see paragraphs 81 to 83).
Evidence of training
60
Where employees claim to be trained and experienced, you should insist upon
evidence. You need to ensure that their training, experience and ability is sufficient and
relevant to the lift trucks and handling attachments to be used. Where evidence, such as a
training certificate, is not available, you should arrange assessment of the person’s
competence and provide any training which the assessment indicates is necessary before
allowing the employee to operate a lift truck (see Appendix 3).
61
Given the wide range of lift trucks, operator experience and company requirements,
some training organisations will arrange for a basic course to be tailored to meet a client’s
requirements. The basic training described in Appendix 2 can be adapted for this purpose,
as long as the appropriate basic training objectives are achieved.
Training ratios
62
The ratio of trainee : instructor : truck should enable the instructor to demonstrate
each part of the practical training and enable the trainee to obtain adequate hands-on
19
experience. There should be enough time for each trainee to have sufficient practical
experience to become a safe operator and to do so under close supervision. A trainee :
instructor : truck ratio of 2:1:1 is probably ideal, but in any case it should not exceed 3:1:1
except for theory sessions. The opportunity to learn from the performance of other trainees
can be valuable.
63
It is essential that newly trained operators are given specific job and familiarisation
training as described in paragraphs 64 to 67. Once they are fully trained, you should give
operators the opportunity to put the skills and knowledge acquired during training into
practice at the workplace to reinforce that training. Newly acquired skills can quickly be lost if
they are not used.
Specific job training
64
Specific job training is a further essential element of training. It will normally follow the
completion of basic training but may be combined or integrated with it. The same trainee :
instructor : truck ratio for basic training applies to specific job training.
65
Specific job training will be tailored to the employer’s particular needs and include,
where appropriate:

knowledge and understanding of the operating principles and controls of the lift truck
to be used, especially where these relate to handling attachments specific to the job,
or where the controls are different from those on which the operator has been
trained. Routine inspection and servicing of that truck in accordance with the
operator’s handbook or instructions issued by the manufacturer need to be covered,
in so far as they may reasonably be carried out by the operator. This should be
repeated whenever the design of truck is changed;

use of the truck in conditions that the operator will meet at work, eg gangways;
loading bays; racking; lifts; automatic doors; confined areas; cold stores; slopes;
rough terrain; loading platforms; vehicles; and bad weather conditions;

instruction on site rules, eg site layout; one-way systems; speed limits; general
emergency procedures; use of protective clothing and devices including operator
restraints and eye and hearing protection; work near excavations, overhead lines and
other hazards;
20

training in the work to be carried out, eg loading particular kinds of vehicle; handling
loads and materials of the kind normally found at that workplace, including assessing
weight; using the lift truck to support working platforms where appropriate; and

safe systems of work, which should include custody arrangements to ensure that
keys are never left in unattended lift trucks, or in a place where they are freely
available, to prevent their use by unauthorised operators.
Familiarisation training
66
Familiarisation training is the third stage of training and may include:

applying, under normal working conditions, the skills already learned in basic and
specific training;

learning to drive and operate a new truck of the same classification;

becoming familiar with the lift truck activities of the employer;

learning a new function within the operation of the employer’s business;

familiarisation with site layout, local emergency procedures and any other particular
feature of the work which it is not practicable to teach off the job.
67
All these elements need to be carried out on the job and under close supervision, by
someone with appropriate knowledge, possibly the trainee’s usual supervisor. Include
familiarisation training in the operator’s training record.
Testing
68
The instructor should continuously assess a trainee’s progress to ensure that the
required standards are achieved throughout training. At the end of the training, the trainee
should take a test to demonstrate that they have the necessary practical and theoretical
knowledge and skills to operate lift trucks safely (see Appendix 3).
Authorisation
69
After they have completed their training satisfactorily, you should give the employee
written authorisation to operate the type or types of lift truck for which all three elements of
training have been successfully completed. You should issue authorisations on an individual
basis and record them centrally. Authorisations should state the operator’s name, the date of
21
authorisation, the types or categories of lift truck to which they relate and any special
conditions, such as operational limitations.
70
You should not allow people to operate lift trucks on any premises without
authorisation (except in the case of a trainee under close supervision). You will also need to
ensure you are satisfied that authorised operators continue to be competent.
Certificates of basic training
71
There is no legal requirement for certificates of basic training to be issued, but HSE
strongly recommends them as a useful, practical means of providing documentary evidence
that relevant training has taken place and an appropriate level of operating ability has been
achieved. The employee will need evidence of training on any change of employment. It is in
the interests of both employers and employees for employees to have the original certificate
to limit any opportunities for forgery presented by photocopies. If the employee only receives
a copy, it will need to be annotated in some way to establish its validity so that it can be
recognised by other employers.
Competence
72
Training will not in itself ensure the competence of individuals: this will develop with
experience and should be monitored and measured against occupational standards.
Competence to operate a machine does not mean competent to operate in all conditions.
Basic training only covers standard situations and HSE would not expect an operator to be
able to undertake complex lifts in difficult environmental conditions without further training
and experience. Even experienced lift truck operators may need to be supervised if they are
required to lift an abnormal load, or to lift in potentially hazardous conditions. Continued
supervision will be necessary to ensure that good standards of operation are maintained.
Refresher training and monitoring
73
An ongoing programme of training and refresher training will usually be necessary for
all operators, to make sure their skills continue to be up to date. Even trained and
experienced lift truck operators need reassessing to ensure they continue to operate lift
trucks safely. HSE recommends regular refresher training to make sure operators:

maintain good driving habits;
22

learn new skills where appropriate; and

reassess their abilities.
74
You can identify the need for further training using a formal process of monitoring
and assessment. This assessment should form part of your normal monitoring procedures
and be formally timetabled to ensure it is done at reasonable intervals. You may find it useful
to record reassessment in operators’ personnel records.
75
If you do not have a manager/supervisor who has been formally trained to assess
operators, then the periodic assessment of an operator should be carried out by a person
who is competent to assess, such as a lift truck instructor.
76
Refresher training might also be appropriate where operators:

have not used trucks for some time;

are occasional users;

appear to have developed unsafe working practices;

have had an accident or near miss; or

have had a change in their working practices or environment.
77
There is no specific requirement to provide refresher training after set intervals,
however, you should consider a gap between training and refresher training of between
three to five years, depending on the risks. Some companies provide refresher training more
often than this.
78
You may decide that automatic refresher training after a set period of time is the best
way to ensure that employees are adequately trained but, where you adopt this approach, it
will still be necessary to monitor performance in case refresher training is required before the
set period ends.
79
Refresher training should only be available to those who can prove that they have
been formally trained under the requirements of the L117 ACOP.
80
If the working practices of newly recruited lift truck operators and existing operators
change, you need to assess their requirements and provide appropriate conversion or
familiarisation training. Training providers can arrange short assessment courses to judge
the ability and training needs of experienced operators who have had limited formal training.
23
Conversion training
81
Conversion training enables trained and experienced operators to extend the range
of lift trucks they are qualified to drive. It involves learning to operate a truck of a different
category, such as a counterbalanced operator converting to operate, eg a reach truck, pivotsteer (articulated) lift truck, or very narrow aisle man-up stacking truck.
82
It may be appropriate, however, for an operator to go through conversion training
where, for example, they are already a fully trained operator on a counterbalanced truck (eg
electric, small) but wish to operate another counterbalanced truck of a significantly greater
size or motive power.
83
Conversion training should be approached with the same attention to detail as basic
training to ensure that all gaps in and variants on existing skills and knowledge are identified
and covered during training. There may be significant variations in the arrangement or
application of controls, even in the same truck types. Operators need testing on their ability
to operate the new truck in the same way as they were tested after their initial basic training.
Records
84
You should keep adequate records for each employee who has satisfactorily
completed any stage of lift-truck training, including conversion and refresher training. The
record will need to include enough information to identify the employee and the nature of
training completed. You should also keep records of how trainees perform in associated
tests. An example of an employer’s training record is given in Appendix 4. The record could
include a copy, or details, of any certificate of training which is issued.
Supervisor training
85
You have a responsibility under PUWER to provide adequate supervision and it is
therefore essential that supervisors have enough training and knowledge to recognise safe
and unsafe practices. This does not mean that they need full operator training, but they do
need to understand the risks involved, and how to avoid or prevent them. You should also
consider training in health and safety management, risk assessment and safe systems of
work.
24
86
Supervisors also need enough training so that they can evaluate the advice of fully
trained and experienced operators to ensure they do not override the operator’s advice and
reduce safety. Some organisations offer training courses for supervisors and managers of
lift-truck operations.
87
Supervisors should be able to:

carry out an effective observation and know what to look for;

communicate effectively with operators and line managers;

recognise bad practice and unsafe behaviour;

develop good working relationships;

raise health and safety standards;

raise and address issues confidently and not be afraid of conflict.
88
See Appendix 5 for a checklist of supervisor attributes.
Visiting operators and drivers
89
If you are not in control of premises where your employees may operate lift trucks,
you need to liaise with those who do control such sites to co-ordinate your efforts and cooperate to ensure that only people trained as described in this publication are allowed to
operate lift trucks. This is just as important on multi-occupied sites, such as business parks
and markets where lift trucks may be shared. The responsibility of those in control of
premises to ensure that the workplace is safe does not detract from your duty to ensure your
own employees are adequately trained.
90
You should ensure that your employees (eg lorry drivers, maintenance or inspection
personnel) who use lift trucks on other people’s premises are fully trained to do so, and that
this information is made available to those in control of those premises. You could provide
documentation for each individual operator, or written assurance that all your employees
who will visit the site and be expected to operate lift trucks are trained and competent to do
so. Those in control of premises used by visiting operators should use this information to
make sure, before allowing lift trucks to be used, that the visiting operators have been
adequately trained to safely operate those lift trucks.
25
91
It is highly unlikely that visiting lorry drivers will have undergone training which would
enable them to safely use lift trucks provided by those in control of premises. Drivers with
their own lift trucks or regular contractors’ drivers who frequently visit the same sites may be
satisfactorily trained and have sufficient site knowledge to operate safely.
Agency workers and contractors
92
When you use agency workers or contractors, consider them in your risk
assessments, taking into account their level of experience and familiarity with the work. The
same health and safety standards that apply to permanent employees should also apply to
agency workers and contractors.
93
An employer’s health and safety duties towards agency workers or contractors
cannot be passed to another party by civil contracts. Employment agencies and employers
of lift truck operators should ensure there is a clear understanding of who is responsible for
the day-to-day management of the health and safety of agency workers or contractors,
preferably recorded in writing.
94
You should establish the competence and experience of agency workers and
contractors before contracting them. Once they are on site, make sure they are working to a
safe system of work. You should also make sure their activities will not endanger other
employees.
Workers from outside the UK
95
A qualified instructor will need to assess lift truck operators with training certificates
from outside the UK, eg by operators attending refresher training in the UK.
96
When employing workers from outside the UK:

consider and manage the needs of those who may not speak English well, or at all;

make sure they have received and understood the information, instruction and
training they need to work safely and consider how to ensure it is acted upon;

make sure they are adequately supervised and can communicate with their
supervisors.
26
Instructor selection and training
97
When choosing how to carry out training, you could:

send your employees to an external training organisation for training on their
premises;

use an employee from your own company to train your own employees on your
premises (a company in-house instructor);

employ a commercial or self-employed instructor to conduct training on your
premises (a commercial in-house instructor).
Instructor competence
98
Successful training depends on the competence of instructors so you should have a
system in place to check their competence and suitability. Ask them to supply evidence of:

training and post-training experience on the type of truck to be used, both as
instructor and operator;

knowledge of and familiarity with conditions in the industry where the trainees will
work;

expertise in any requirements peculiar to the operation of the truck(s) and in the work
trainees will be expected to undertake;

99
documentation such as:
-
a certificate of training (instructor qualification);
-
an insurance certificate (public liability at least);
-
proof they can train on the vehicles in question.
Since training is mainly carried out using a demonstration followed by supervised
practice, it is essential that each demonstration by the instructor is free from technical errors
and misjudgements. Instructors must also be able to make effective use of practical and
theoretical instructional techniques.
100
Good instructors should:

be skilled in lift truck operations and instructional techniques;

have the ability to adapt their approach to suit the needs of different trainees;
27

be able to communicate effectively;

be able to lead and control the training sessions effectively;

keep their own training and experience as instructors up to date, especially if not
training regularly.

101
be able to supervise and evaluate trainees.
Instructors need to be reassessed periodically as appropriate. Reassessment is
particularly important if instructors have not done any training for some time.
102
Professional teaching/training/assessment qualifications or awards are available, eg
National Occupational Standards, National/Scottish Vocational Qualifications (NVQs/SVQs).
28
PART 3: THE LIFT TRUCK
What to look for when selecting a lift truck
103
When buying, hiring or using a lift truck, consider the following:

the type of truck, eg rough terrain, reach, stacker, variable reach (see paragraphs
104 to 117);

the capacity or size of truck in relation to how it will be used, including the effects of
any attachment and the environment (see paragraphs 118 to 133);

attachments, eg fork carriage side shift, extended forks, drum-handling equipment
(see paragraphs 120 to 133);

the motive power, eg electric, diesel, LPG (see paragraphs 134 to 146);

the need for additional operator training (see Part 2);

maintenance (see Part 5).
Types of lift truck
104
Although the lift trucks illustrated and described are the main types covered by this
publication, this is not an exhaustive list. In all cases the operating instructions of the
manufacturer or authorised supplier (the ‘authorised representative of the manufacturer’)
should be followed. The ACOP (paragraphs 28 to 42) does not cover straddle carriers,
industrial tractors or platform trucks.
Industrial counterbalance lift truck
105
These have a counterweight to balance the load on the fork arms. The fork arms and
load project out from the front of the machine (see Figure 1). Loads can be raised or lowered
vertically and the mast may be tilted forwards or backwards up to 15° (but in practice more
usually about 5°). This type of lift truck is only suitable for use on substantially firm, smooth,
level and prepared surfaces. A wide range of attachments is available. Higher capacity lift
trucks come in a range of sizes and can be as much as 50 tonnes (see Figure 2).
Figure 1 Industrial counterbalance lift truck
Figure 2 Higher capacity counterbalance truck
29
Industrial reach truck
106
These are called reach trucks because the mast is moved forwards or ‘reached out’
to pick up the load. For travelling, the load is reached back and carried within the wheelbase.
This allows greater manoeuvrability in areas where space is restricted. These lift trucks are
only suitable for use on substantially firm, smooth, level and prepared surfaces and are
particularly used in warehouses.
Figure 3 Industrial reach truck
Rough-terrain counterbalance lift truck
107
These are similar in design to the industrial counterbalanced lift truck but are
equipped with larger wheels and pneumatic tyres (and often with all-wheel drive), giving
them greater ground clearance. They are more able to operate on uneven and soft ground
and are mainly used in the construction industry and in agriculture. They may be used with a
range of attachments.
Figure 4 Rough-terrain counterbalance lift truck
Variable reach truck (telehandler)
108
These are fitted with a boom that is pivoted at the rear of the machine. The boom is
raised and lowered by hydraulic rams. In addition, the boom can be extended or retracted
(telescoped) to give extra reach or height. They may be two- or four-wheel drive, and have
two-wheel, four-wheel or crab steering. Some have a rotating upper structure or turret
allowing the telescopic boom to be rotated (or slewed) through 360 degrees. Some are
equipped with stabilisers or chassis levelling devices to enable them to be levelled on slightly
sloping ground to reduce the risk of tipping over during lifting or lowering.
109
They are used mainly in agriculture and the construction industry. A range of
attachments may be used with them.
Figure 5 Variable reach truck (telehandler)
30
Side-loading lift truck
110
The operator is positioned at the front and to one side of the lift truck. The load is
carried on the deck, the mast moving sideways to pick up or set down the load. This type of
lift truck is used for stacking and moving long loads such as bales of timber and pipes, and
may be fitted with stabilisers for use when picking up or setting down loads.
Figure 6 Side-loading lift truck
Container handling stacker truck
111
These may be either masted or telescopic, and are often fitted with a spreader for
lifting freight containers. The spreader may attach to the side or top of the container. These
are specialist lift trucks used mainly in container terminals.
Figure 7 Container handling stacker truck
Articulated (pivot steer) lift truck
112
These are similar to the conventional counterbalance truck but the front driving axle
is pivoted around an articulation point to enable the mast to be rotated up to 90° on either
side of the longitudinal axis.
Figure 8 Articulated lift truck
Pedestrian-operated lift truck (pallet stacker)*
113
These may be electrically or manually powered for lifting and for traction. The
operator walks with the machine and controls it with a tiller. They have a limited lift height,
usually up to 3 m.
Figure 9 Pedestrian-operated lift truck (pallet stacker)*
* Regulation 9 of PUWER still requires operators to be properly trained even though these trucks are not covered
by the L117 ACOP training requirements.
31
Order pickers
114
Low-level order pickers are pedestrian-controlled or ride-on pallet trucks used for
manual picking of single items. They have typical lift heights of 1200 mm, similar to a pallet
truck.
Figure 10 Low-level order picker
115
Medium- and high-level order pickers are rider-operated with the operator’s platform
rising with the fork carriage to enable order picking at height. Typical lift heights are to about
8 m.
Figure 11 Medium-level order picker
Very narrow aisle (VNA) trucks
116
VNA trucks are rider-operated with the operator’s platform rising with the fork
carriage to enable order picking and pallet placement at height, typically up to 12 m. The
trucks operate in aisles just wider than the trucks and are wire or rail guided within the aisles.
Figure 12 Very narrow aisle (VNA) truck
Straddle trucks
117
These are a form of reach truck where the load wheel legs are spaced to clear a
standard pallet to allow a pallet to be placed on or lifted from floor level. They may or may
not have a reach function. They should not be confused with straddle carriers that are
generally used to transport containers.
Figure 13 Straddle truck
Lift truck capacity
118
Do not load lift trucks beyond their actual (safe) capacity. The actual capacity (safe
working load) is a function of the rated capacity, lift height and load centre distance (ie the
distance from the centre of gravity of the load to the front face of the fork shank) and any
attachments that might be fitted. This information is shown on the lift truck capacity data
plate.
32
Figure 14 A rating plate
Counterweight
119
Unless approved by the manufacturer or authorised supplier the weight of the
counterweight should not be changed, as this will adversely affect the lift truck’s stability and
safety. On electric lift trucks, only batteries of the size and weight specified by the lift truck
manufacturer should be used, as batteries are part of the counterweight and an incorrect
weight will affect stability.
Attachments
120
Some loads can be handled more efficiently and safely by using suitable
attachments, for example fork arm extensions, booms, rotating heads, drum clamps, paper
roll clamps, bale clamps, load stabilisers etc. Attachments, including fork extensions, should
not be used without professional advice.
121
Fitting an attachment will alter the characteristics of the lift truck and so require a
reduction in the actual capacity of the lift truck, called derating. Where derating is necessary,
only a lift truck engineer or another person with equivalent qualifications should carry it out.
Alternatively it may be necessary to use a lift truck with a larger capacity. Consult the
manufacturer or authorised supplier about the suitability of an attachment for a particular lift
truck and the necessary derating. A new rating plate relating to the attachment should be
applied to the lift truck.
122
Attachments may be mounted on the fork arms or directly onto the carriage. In all
cases they should be securely fastened and you should ensure that the attachment or
securing device does not foul any part of the mast structure during raising or lowering of the
attachment. Follow the instructions for using the attachment supplied by the manufacturer or
authorised supplier at all times.
123
At the start of each shift, check the security of any attachment fitted to the lift truck
and report any defects immediately. Where defects are found which may affect the safe
operation of the lift truck, it should not be used until they are rectified.
124
A wide range of removable attachments is available for use with lift trucks. Those
described here are some of the more common ones currently in use, though some of the
33
more specialised attachments used with telescopic materials handlers such as bale grabs
and silage forks are not included.
125
The following are examples, not exhaustive, of typical lift truck attachments:
Fork arm extensions
126
These may be hydraulically operated telescopic fork arms replacing the fixed fork
arms or simple box sections which may be slipped onto the fork arms and secured in place.
They may be used to reach loads in deep racking or to handle extra depth loads.
Side shift carriage
127
This attachment may be mounted either on the existing fork carriage or in place of it.
A side shift carriage enables horizontal sideways movement of the fork arms to allow precise
positioning.
Fork positioner
128
This is a hydraulically operated attachment which allows the operator, while
remaining in the operating position, to change the position of the fork arms relative to each
other. The fork arm centres can therefore be adjusted to accommodate different load widths.
Figure 15 Side shift carriage
Figure 16 Fork positioner
Rotator
129
This attachment is mounted on the fork carriage and usually used in conjunction with
another attachment. It allows the load to be rotated vertically about an axis parallel to the
longitudinal axis of the lift truck. Some rotators have the facility to tilt the load forward from
the vertical to the horizontal and beyond and are usually known as ‘tipplers’.
34
Clamps
130
These attachments are designed for a variety of purposes such as lifting reels, bales
or cartons. They may be used in conjunction with a rotator. The clamps may be faced with
rubber or other material to improve grip.
Figure 17 Rotator and clamps
Figure 18 Paper and reel clamp
Figure 19 Automatic double-drum clamp attachment
Crane jib
131
This attachment may be mounted directly on the fork carriage or carried on the fork
arms. A crane jib may be of a fixed length or extendable or include a number of lifting points.
On some it is possible to vary the angle of the jib from the horizontal.
Hoppers
132
These attachments are usually carried on the fork arms. They are fitted with a
mechanism which, when operated, causes the hopper to tip forward and discharge its
contents. Once empty, the hopper returns to its normal position and re-engages the holding
mechanism. Manually released hoppers and skips are also available.
Figure 20 Crane jib attachment
Figure 21 Hydraulically operated hopper
Figure 22 Boom
Booms
133
These attachments usually consist of a circular section pole mounted on the fork
carriage. Designed for lifting rolls of carpet, coils of wire or similar cylindrical loads, they
come in a variety of diameters and lengths.
35
Lift truck power sources
134
Lift trucks are mostly powered by electric batteries or by internal combustion engines.
There are risks associated with each which require proper precautions.
Refuelling industrial trucks with internal combustion engines
135
Areas used for refuelling industrial trucks with diesel, LPG or petrol should be outside
and you should consider the risk of fire and explosion. Refuelling should not take place
where there is a likelihood of an accumulation of flammable vapours if there is a spillage, eg
drains, pits, gulleys etc. Prohibit smoking and clearly display notices in these areas and
make sure engines are switched off before refuelling. When handling fuel oils or fuelling a lift
truck, wear protective gloves.
136
The Petroleum Licensing Authority can advise on the standards necessary to comply
with the Petroleum (Consolidation) Act 1928 as amended by the Dangerous Substances and
Explosive Atmospheres Regulations 2002 (DSEAR).
137
Change the fuel cylinders of LPG-powered lift trucks outside buildings away from
pits, drains, lift shafts and sources of ignition and in any case in an area that is adequately
ventilated and where notices prohibiting smoking are clearly displayed.
138
If the lift truck is fitted with integral tanks or if employers refill their own cylinders, the
installation for refilling should comply with the advice given in the UKLPG Code of Practice 1
Part 1, Bulk LPG storage at fixed installations. Further information on the use of LPG can be
obtained from UKLPG.
Charging batteries – electrically powered industrial trucks
139
Charging batteries, including those that are described as maintenance free, gives off
explosive hydrogen gas. If this is allowed to collect and a source of ignition (naked flame or
spark) is present, then the gas and battery will explode. Battery charging should therefore
take place in a well-ventilated area where smoking, naked flames or other ignition sources
are prohibited. Designate a separate room or area for charging batteries. The area should be
designated ‘No smoking’ and ‘No naked lights’.
36
140
Only after full charging has taken place should the battery electrolyte levels be
checked to ensure they are within the limits specified by the manufacturer and topped up if
they are below the minimum level.
141
Keep electrical apparatus and any other potential sources of ignition a safe distance
from the battery and not in a position where any spillage of electrolyte could fall onto the
electrical apparatus. A safe distance is far enough away to enable the gas to diffuse into the
atmosphere and reduce the potential for explosion.
142
When charging vehicle batteries:

always use the correct charging unit as specified by the vehicle/battery manufacturer
and follow the manufacturer’s instructions;

ensure the battery charger has been stopped, terminated or switched off before
connecting/disconnecting batteries;

where possible, raise the battery cover to aid ventilation during charging; and

wear the correct PPE where required (eg acid-proof apron, gloves and goggles or a
visor).
Changing batteries
143
Where batteries have to be changed, eg in a double shift system, a safe system of
work should be in place. The person responsible for changing the batteries should have
suitable training and instruction on how the change is to be carried out safely. Battery acid
also presents a hazard to skin and eyes. Where there is a possibility of battery acid being
splashed, the minimum protection required is protective gloves and eye protection.
Use of industrial trucks where flammable materials may be present
144
Lift trucks should not be used in areas where flammable vapour, gases or dusts are
liable to be present, unless they have been suitably designed and equipped for such use.
There are two main hazards associated with the use of lift trucks in flammable atmospheres:

direct ignition of the surrounding flammable atmosphere (eg by hot surfaces,
unprotected electrical equipment or hot sparks from the exhaust);
37

ingestion of a flammable atmosphere into the engine air intake. If this happens, the
engine is liable to accelerate out of control causing over-speeding, and possible
flashback through the intake to ignite the surrounding flammable atmosphere.
145
Diesel-fuelled trucks may be used, as long as certain precautions are being taken.
Petrol and LPG-fuelled trucks should not be used because they cannot, as yet, be protected
for such use. If there is any doubt about the suitability of a lift truck for use in such
circumstances get competent advice from the manufacturer.
Confined spaces
146
Never use petrol-fuelled internal combustion engines in confined spaces. Portable
gas (LPG) cylinders and diesel-fuelled internal combustion engines are nearly as dangerous
as petrol-fuelled engines, and are inappropriate unless exceptional precautions are taken.
Where you cannot avoid using them, adequate ventilation needs to be provided to prevent a
build-up of harmful gas, and to allow internal combustion engines to operate properly. The
exhaust from engines should be vented to a safe place well away from the confined space,
downwind of any ventilator intakes for the confined space, and the means checked for
leakage within the confined space. Guidance on the Confined Spaces Regulations 1997 is
given in the Approved Code of Practice Safe work in confined spaces.
Other features of lift trucks
147
You will also need to consider the following features of a lift truck:

restraining systems (see paragraphs 148 and 149);

roll-over protective structures (ROPS) and falling object protective structures (FOPS)
(see paragraphs 150 to 152);

load back-rest extension (see paragraph 153);

protection from the weather (see paragraphs 154 and 155);

wheels and tyres (see paragraphs 156 to 166);

brakes (see paragraph 167);

dangerous moving parts (see paragraph 168);

lights (see paragraph 169);

noise levels (see paragraph 170);

seat design and vibration (see paragraph 171).
38
Restraining systems
148
Most lift trucks which carry a seated ride-on operator should be fitted with a
restraining system, such as a seat belt, if risk assessment indicates that there is a risk of the
vehicle rolling over and the operator falling from the operating position and being crushed
between the truck and the ground. Where restraining systems are fitted they should be used.
149
Where a restraining system cannot be fitted, and the risks are sufficiently high, it may
be necessary to use another lift truck which has such a system. Any lift truck which is fitted
with a roll-over protective structure (ROPS) to protect operators from the risk of injury
resulting from 180° or more roll-over should be fitted with seat belts.
Roll-over protective structures (ROPS) and falling object protective structures (FOPS)
150
Any lift truck capable of raising load greater than 1800 mm should be fitted with an
overhead guard or falling object protective structure (FOPS) to protect the operator from
falling objects.
151
ROPS should be fitted to lift trucks where there is a risk of the truck rolling or tipping
over. Masted lift trucks are unlikely to roll over due to the mast limiting the movement to 90°.
Variable reach trucks can roll over 180° and therefore should be fitted with ROPS. Any lift
truck fitted with ROPS should also be fitted with an operator restraint.
152
ROPS and FOPS are designed and manufactured to specific European standards to
ensure they meet the required performance criteria. They should not be modified in any way
and if they are damaged you should consult the truck manufacturer.
Load back-rest extension
153
A load back-rest extension should be fitted if the lift truck is used to move objects
liable to fall on the operator. The load back-rest extension should be high enough to prevent
the load rolling over the top of it.
Figure 23 Load back-rest extension
39
Protection from the weather
154
Where lift trucks are used outside, provide adequate protection for the operator from
the effects of adverse weather conditions. Do not allow operators to apply ad hoc or
temporary weather proofing to lift trucks. Using boards, shrink-wrap or plastic sheeting to
cover the seating position is usually inappropriate because vision will be reduced,
particularly overhead. Where possible, use lift trucks fitted with cabs.
155
Stop lift truck operations where weather conditions are bad enough to adversely
affect the performance of the lift truck or expose the operator to danger, for example
excessive wind speed, poor visibility due to mist or fog, lightning or heavy rain. Bad weather,
even after it is over, may leave unsafe conditions, for example waterlogged and unstable
ground following a period of heavy rain.
Wheels and tyres
156
Wheels and tyres come in a variety of designs and types, depending on how they will
be used.
157
Wheels may be:

One piece rims – a single piece rim, usually used with solid tyres, with a press-on
band or a snap-in tyre (SIT).

Split or divided rims – a two-piece rim, split or divided at the flange. The tyre is fitted
to one rim and the second rim is bolted to the first to retain the tyre.

Multipiece rims – two to five piece rims. The separate components make up the
second flange that retains the tyre on the rim, the first flange being part of the rim.
They are used with a pneumatic tyres, tubed or tubeless.
158
Tyres may be solid or pneumatic. Typically solid tyres are fitted to warehouse trucks
and trucks used on smooth surfaces. Pneumatic tyres are generally fitted to rough terrain
trucks and larger trucks, eg container handling trucks. The tyre construction and material
depends on how they will be used.
159
Solid tyres may be:
40

Press-on band – a solid tyre with a steel core that is pressed onto a rim. It relies on
friction between the rim and band to retain the tyre and prevent slipping.

Snap-in tyre (SIT) – a solid tyre which is pressed onto the rim. A bead moulded on
the inner bore of the tyre engages into a groove in the rim to retain the tyre. Friction
between the rim and the tyre prevents slipping.
160
Pneumatic tyres may be tubed or tubeless and are usually fitted to split or divided
rims and multi-piece rims.
Tyre fitting
161
Pneumatic tyres have considerable stored energy and there have been accidents
due to the sudden release of pressure, particularly during inflation. Tyre removal and fitting
usually requires the use of specialised tools and fittings, so it is recommended that the
process is carried out by people with suitable equipment and training. HSG216 and
INDG433 provide further information.
Tyre and wheel maintenance
162
It is important to check and maintain tyres and wheels:

Inspect all tyres for damage daily. Pay particular attention to the side walls.

Change solid tyres if they are worn down to the 60J line, a line moulded into the tyre
wall close to the bottom of the tread, or if there is significant damage to the tyre tread,
eg chunking where large pieces of tread have disappeared.

Always replace tyres with the equivalent type (the same size, type and ply).

Check pressures on pneumatic tyres weekly or more often if there is evidence of
deflation. They should be maintained at the manufacturer’s recommended pressure.
Failure to do this can result in instability and reduced tyre life.

Inspect wheel rims daily for damage. Damage to the flanges of pneumatic tyred rims
is potentially dangerous as it could cause rapid pressure loss.

Tighten hub bolts to the correct torque every time a wheel is fitted and check the
tightness after 24 hours.
Figure 24 60J line
Figure 25 Chunking on a solid tyre
41
Divided rims
163
Divided or split rims consist of two parts bolted together with the whole assembly
being bolted to the hub with hub bolts or clamps. Always deflate tyres before loosening the
hub bolts and remove the wheel before loosening the rim clamp bolts. When fitting a tyre the
rims should be bolted together and the tyre inflated to no more than 1 Bar. Check the tyre to
ensure it is properly seated. Then bolt the wheel to the hub and inflate the tyre to the working
pressure.
Multi-piece rims
164
Anyone who may be required to remove multi-piece wheels with pneumatic tyres
from vehicles should review the system of work provided. Visual examination should aim to
positively establish that the wheel is safe to remove. Where the flange ring is obscured
preventing visual examination, for example on dual wheel assemblies, the system of work
should always require tyres to be deflated except in exceptional circumstances where other
measures have been taken to control the risk. It is best practice in all situations to deflate
pneumatic tyres before removing wheels of the multi-piece type. If the tyre is deflated, the
person re-inflating the tyre should be competent and have the correct equipment to carry out
the process safely.
Pneumatic tyres
165
Remove pneumatic tyres from rims before carrying out hot work on the rim, for
example welding, as the tyre may explode due to ignition of hydrocarbon vapour in the tyre.
Replacing a tyre on one side only may introduce a tilt if the tyre on the other side is also
worn.
166
Guidance on the servicing of tyres on commercial wheels or divided wheels, which
are sometimes found on lift trucks, is in Safety during tyre inflation in motor vehicle repair.
Further guidance is in HSG261 Health and safety in motor vehicle repair and associated
industries.
42
Brakes
167
Lift trucks should have an efficient braking system capable of stopping a laden lift
truck smoothly and rapidly, and holding the lift truck when parked. The braking system
should be properly maintained.
Dangerous moving parts
168
Guards should be provided to prevent access to the dangerous moving parts of the
lift truck which are within the operator’s reach in the normal operating position, for example
traps caused by telescopic mast sections, lifting chains etc.
Lights
169
Suitable lights should be provided at the front and rear if the lift truck has to be driven
at night, or in areas with insufficient natural or artificial light, such as in drive-in racking.
Consider fitting a flashing yellow light on the top of the lift truck to warn other people.
Noise
170
When selecting lift trucks, consider the likely effects on noise levels in the workplace
by the use of particular types of lift truck and whether you could use quieter ones.
Manufacturers are required to give information on the noise emission of their lift trucks.
Further guidance on noise at work is given in Controlling noise at work: The Control of Noise
at Work Regulations 2005.
Seat design and vibration
171
Many operators have to sit on their lift truck for much of the working day so it is
important that the design and maintenance of the seat reduces fatigue and discomfort and
prevents ill health caused by vibration. Modern lift trucks do not produce much vibration and
seats are now ergonomically designed and adjustable. However, contact the manufacturer
for advice if the seat proves to be unreasonably tiring or passes on excessive vibration, as
this is probably due to damage or a fault, which should be rectified as soon as possible (see
L141 Whole-body vibration. The Control of Vibration at Work Regulations 2005. Guidance on
Regulations).
43
PART 4: SAFE MOVEMENT OF LIFT TRUCKS AND PEDESTRIANS
172
Think about the safe movement of lift trucks and loads as part of your overall safety
policy for people, plant and equipment. Select lift trucks which are suitable for use in all the
conditions and applications likely to be encountered in the workplace where they are to be
used.
173
Reduce risks at points where lift trucks might meet other traffic or pedestrians,
including areas where lift trucks load and unload other vehicles. When using lift trucks
outside the workplace is unavoidable, for example to load or unload lorries which cannot
enter the workplace and are parked on public roads, your risk assessment should include
extra hazards which are not part of the work activity, such as movement of road vehicles and
pedestrians. This risk assessment should form the basis of a safe system of work, and you
should take account of the extra risk when planning lifting operations.
Protect pedestrians
Pedestrians
174
Where possible, prohibit pedestrians from entering areas in which lift trucks are
operating. Where this is not possible, assess the risks to pedestrians and, where necessary,
provide ways to adequately control the risks:

separate pedestrian activities from areas where trucks are operating, where
reasonably practicable. Use a physical barrier where possible;

define, designate and clearly mark pedestrian routes and crossing places;

provide sufficient clear and unambiguous warning signs at strategic locations to
inform people that trucks operate in the premises or area;

display notices instructing industrial truck operators to sound horns at appropriate
locations. All warning and safety signs should conform to the Health and Safety
(Safety Signs and Signals) Regulations 1996;

clearly mark buildings, rooms, doorways, and traffic routes to avoid unnecessary
traffic movements.
Figure 26 Arrangement of doors for separating pedestrian routes from traffic routes
44
175
Where it is not possible to segregate pedestrians from lift trucks, consider other
measures such as audible warning devices, flashing warning beacons or CCTV:

Audible warning devices: These vary from simple manually operated horns to
automatic reversing bleepers. If using audible warnings, you need to assess the
effects of background noise, nuisance levels, and confusion on direction or source,
particularly if more than one vehicle is being used in the area. You will also have to
meet the requirements of the Control of Noise at Work Regulations 2005.

Flashing beacons: These may be effective, particularly where lighting is poor or lift
trucks operate intermittently, or where audible devices are likely to be ineffective or
cause a nuisance. Epileptic fits may be triggered by flashing beacons.

Closed-circuit television (CCTV) may be appropriate for some vehicles where the
driver cannot see clearly behind or around the vehicle.

High-visibility clothing: Where the risks to their safety cannot be adequately
controlled by other methods, all pedestrians should wear high-visibility clothing. Lift
truck operators should be provided with such clothing at all times and instructed to
wear it whenever they leave the operating position of the lift truck.
Members of the public
176
The public should not be allowed in industrial truck operating areas. If a lift truck
needs to enter an area when the public has access, such as during normal opening hours in
a retail warehouse, there should be a written procedure outlining the precautions to be
taken. These should include barricading off the area where the lift truck is operating and
giving loudspeaker announcements to warn people.
Employees and visiting drivers
177
Wherever possible, restrict access to lift truck operating areas to those staff who
operate truck equipment or have a supervisory role. The same general precautions as listed
in paragraph 176 for members of the public may be appropriate to protect employees who
do not normally have to enter truck operating areas.
45
Industrial truck operating areas
178
All industrial truck operating areas should be suitably designed and properly
maintained. Make sure the surfaces used by lift trucks are as level and firm as possible, and
preferably surfaced with concrete or other suitable material. Some lift trucks, however, are
designed to operate on rough or uneven surfaces.
Driving areas
179
Consider the following:

Driving areas should be as flat as possible and free from obstructions. Encourage
your employees to report any significant defects.

Avoid potholes and accumulations of loose material on the ground as they are
particularly hazardous to small-wheeled lift trucks.

Roads, gangways and aisles should have sufficient width and overhead clearance for
the largest lift truck using them to do so safely, whether loaded or unloaded, and if
necessary, to allow other vehicles and loads to pass each other in safety.

Road humps are unsuitable for lift trucks and if possible should be avoided in areas
where they operate. If they are used to reduce the speed of other traffic, provide a
bypass for use by industrial trucks.

Use one-way traffic systems to reduce the risk of collisions.

Try to eliminate gradients where possible. Never drive lift trucks up or down gradients
that exceed the maximum gradient specified by the manufacturer or authorised
supplier. Do not travel or turn across a gradient in a lift truck.
Visibility and warning signs
180
Consider the following:

Avoid sharp bends, blind spots, and overhead obstructions where possible. Where
you cannot remove such hazards, use clearly marked barriers, eg with black and
yellow diagonal stripes. Clearly mark any overhead obstructions. Where you cannot
use barriers, use signs, warning devices, mirrors etc. Consider instructions to sound
horns or restrict speed.

Identify, protect and clearly mark by black and yellow diagonal stripes features of the
building or operating area, eg support columns, racking, pipework or other plant.
46

Clearly mark the edges of loading bays, excavations and pits, for example by black
and yellow diagonal stripes (Figure 27), if lift trucks are operating nearby. Where
possible, put barriers around the edges (Figure 28).

Flexible doors of transparent or translucent material may reduce risks where vehicles
have to pass through. The lift truck operator should have a clear view through the
closed doors before proceeding.
Figure 27 Clearly marked edges of inspection pit
Figure 28 Clearly marked barrier
Figure 29 Impact barrier
Lighting
181
Make sure roadways both inside and outside buildings are adequately lit, particularly:

at road junctions and rail crossings;

near buildings and plant;

in pedestrian areas;

where there is regular movement of vehicles and other mobile plant; and

in the area immediately inside a building where vehicles may pass from bright
sunlight into the building.
182
Arrange lighting to avoid glare (for example, flexible doors of transparent or
translucent material will reflect like a mirror if it is much darker on one side of the door than
on the other) and sudden changes of lighting levels (for example, where lift trucks may pass
from bright sunlight into the building).
Parking areas
183
Provide enough parking areas for all lift trucks. As far as possible, park lift trucks in a
secure compound or in a supervised area where they will not be easily accessible to
unauthorised people. These areas should, if practicable, be separate from main
thoroughfares and operating areas. Wherever possible, provide suitable parking areas for
recharging or maintenance.
47
Controlling the use of industrial trucks
184
You should have a system in place to ensure that lift trucks are only used by
authorised operators:

Lift trucks should be fitted with a device to prevent unauthorised use, such as a
switch with a removable key, or a keypad with PIN number.

Keep keys, where used, in a secure place when the lift truck is not in use, such as
the supervisor’s or gatekeeper’s office. They should be issued by a responsible
person and retained by the operator(s) until the end of the work period.

Never leave lift trucks unattended with the keys in the ignition or the keypad
energised. At the end of the shift, lift trucks should be parked safely and the keys
returned to the responsible person or the keypad de-energised.

On LPG trucks, the gas supply should be turned off at the storage tank if the truck is
to be left for any period of time.
Use of lift trucks on the public road
185
Anyone driving a lift truck on the public road must comply with the appropriate road
traffic legislation. Any questions regarding the need for driver and vehicle licensing when lift
trucks are used on the road should be addressed to the Driver and Vehicle Licensing
Agency (DVLA), Swansea SA6 7JL, Tel: 0300 790 6801.
48
PART 5: PRINCIPLES OF SAFE USE AND MAINTENANCE
Checklist for safe operation of lift trucks
186
Although no substitute for proper training, the following simple rules are set out for
the benefit of lift truck operators and their supervisors, and should always be followed.
Operating
Never:

operate a lift truck unless you are trained and authorised to do so;

operate controls from outside the cab;

stand on or near the controls to reach the load or anything outside the cab;

travel on soft or uneven ground unless the lift truck is suitable for this purpose;

run over unprotected cables or flexible pipes;

attempt to turn on or travel across a ramp or an incline;

leave a lift truck parked on a gradient;

block firefighting equipment or exits by parking or stacking in front of them;

attempt to carry out repairs – leave this to a qualified maintenance engineer;

drink alcohol or take drugs when operating a lift truck.
Always:

carry out a pre-shift check of the lift truck;

wear operator restraints, where fitted;

travel at a speed suitable for the environment;

look in the direction of travel;

travel with the fork arms lowered while maintaining ground clearance;

watch out for pedestrians and bystanders;

watch out for obstructions;

keep to the left (or centre of a gangway or aisle between racking);

avoid sudden stops and violent braking;

slow down at corners, doorways, and at every potential danger spot and sound the
horn where appropriate;

use steps or handholds when mounting or dismounting from the lift truck;
49

apply the parking brake, select neutral and, preferably, switch off the engine when
leaving the lift truck.
People
Always:

use a safe, integrated, working platform when lifting a person.
Never:

carry passengers, unless the lift truck is designed and equipped to do so;

lift a person on the forks or on a pallet;

allow people to walk under raised forks or loads;

pick up a load if someone is standing close to it.
Loads
Always:

observe floor loading limits – find out the weight of the laden lift truck;

take note of the longitudinal load limiting indicator (LLMI) when fitted;

before raising a load, ensure there is enough overhead clearance;

ensure there is adequate clearance for the machine, eg in aisles, gangways;

ensure bridge plates are secure and strong enough to withstand the weight of the lift
truck and the load;

lower loads as soon as they are clear of the racking;

lower loads at a safe speed;

use suitable attachments for lifting unusual or wide loads.
Never:

lift loads greater than the working capacity of the truck;

move a load that appears unsuitable or unstable (including on a damaged pallet);

lift loads with unsuitable attachments;

travel with a bulky load which blocks the view in front of you;

travel with a raised load, unless the truck is designed for this purpose.
50
Slopes
Always

travel slowly when descending slopes;

when driving on slopes, ensure:
-
when carrying the load, it faces uphill;
-
when no load is carried, the fork arms face downhill;
-
where fitted, the tilt is adjusted to suit the gradient and the fork arms are
raised to provide ground clearance; and
-
you avoid turning or stacking.
Attachments
Never:

use attachments unless:
-
de-rating (ie reducing the rated capacity of the industrial truck) has been
carried out by a competent and authorised dealer or manufacturer;
-
you have been properly trained and are competent and authorised to use the
truck with the attachment;
-
the attachment is used in accordance with the manufacturer’s instructions.
When you have finished working:

leave the lift truck with the fork arms fully lowered;

apply the parking brake, select neutral, switch off and remove the key;

return keys or other activating devices to their place of safe-keeping.
Lift truck stability
187
Select lift trucks and attachments to suit how they will be used. For example, long
loads require particular attention to reduce the risk of overturning due to a swinging load or
loss of the load due to insufficient support.
51
188
People operating lift trucks or supervising their operation must understand their
characteristics. Lift trucks are designed to lift loads, move them and re-stack them in a
different place. The mass of a counterbalance lift truck acts as a counterweight so that the
load can be lifted and moved without the lift truck tipping. However, the lift truck can be
tipped forward if the load is too heavy, if the load is incorrectly placed on the fork arms, or if
the lift truck is accelerated or braked harshly while carrying a heavy load.
189
The stability of lift trucks is also affected by the forces generated when turning,
especially at speed, or if the lift truck is tilted sideways by travelling across an incline for
example, or by the wheels running into a pothole or over an obstruction. The danger of a lift
truck being turned on its side is greater with the load in the raised position than in the
lowered position, and if the lift truck is turned during travel when unladen. Never travel with
raised loads and drive with care when unladen, particularly when turning.
190
Understand the ‘triangle of stability’ on lift trucks with a single rear wheel or pivoting
rear axle and the effect on stability.
Figure 30 Triangle of stability
Working platforms on lift trucks
191
Before using a working platform on a lift truck, make sure you are familiar with the
requirements in HSE Guidance Note PM28 Working platforms (non-integrated) on fork-lift
trucks http://www.hse.gov.uk/workplacetransport/pm28.pdf.
192
Work at height is a high-risk activity, so the planning and selection of work equipment
and safe means of access and egress and working area is important. There is a variety of
equipment now available for work at height, such as mobile elevating work platforms.
193
The primary function of a lift truck, with the exception of man-up trucks (such as order
pickers) is the carriage, raising and lowering of materials, not people. The Work at Height
Regulations 2005 place a duty on employers to select the most suitable work equipment for
the task, regardless of the duration of the task. Integrated working platforms offer a higher
degree of safety than non-integrated platforms (ie those without operating controls in the
platform).
52
194
Restrictions on the circumstances in which non-integrated working platforms can be
used on lift trucks mean that such use is only permitted for ‘occasional unplanned use’ that
would otherwise be carried out using a less safe means of access.
195
Examples of occasional use are:

non-routine maintenance tasks for which it is impractical to hire in purpose-built
access equipment;

the replacement of light fittings in high-rise warehouses if the task is not carried out
as part of periodic maintenance operations;

tasks that would otherwise be carried out using less safe means of access such as
ladders, because it is impractical to hire in purpose-designed people lifting equipment
due to the short duration and occasional nature of the task, eg clearing a blocked
gutter;

checking on high-level damage to racking suspected of causing an immediate risk or
checking on the condition of damaged roof lights.
196
Routine or planned tasks, particularly those associated with production or pre-
planned activities such as periodic maintenance or stocktaking, are not exceptional
circumstances and are not examples of unplanned occasional use. Consequently, lift trucks
fitted with non-integrated working platforms are not suitable for stock checking, order picking,
routine maintenance or the transfer of goods or people from one level to another.
197
The Construction (Design and Management) Regulations (CDM) require all
construction work to be adequately planned, so non-integrated baskets must not be used in
construction.
Lift trucks on loading platforms and trailers
Loading platforms
198
Permanent loading platforms, as used in warehouses or in factories, should be
constructed and designed to carry the foreseeable maximum load safely. Temporary loading
platforms, as on building sites, should be clearly marked with the maximum load that they
are designed to carry, and lift truck operators should be advised of this load. When
manoeuvring, ensure the lift truck does not damage the platform or its supporting structure.
53
Trailers
199
Trailers of articulated lorries are less stable when they have been disconnected from
their towing units. They should always be braked when they are being loaded. Because the
lift truck may jolt the trailer which it is loading and cause the landing legs to collapse,
consider providing additional jacks for stability. Bridge plates, strong enough to support the
lift truck and its load, should be provided and fixed securely if the lift truck has to drive onto
the trailer for loading or unloading. If the deck of the trailer is not strong enough to support
the weight of a lift truck and its load, an effective means, such as steel plates, should be
used to distribute the weight of the wheel loads over an adequate area.
200
Where possible, additional means should be provided to prevent the unevenly loaded
trailer moving or tipping during the loading operation. Bear in mind that trailers are
particularly unstable and will upend.
Maintenance
201
There is a requirement under PUWER for all work equipment to be regularly
maintained in accordance with the manufacturer’s recommendations. In addition to changing
oils and filters, and any mechanical adjustments, this will normally include inspection of all
safety related components.
202
Employers should have:

a planned routine maintenance system;

a documented pre-shift check;

a system for reporting defects and for ensuring that remedial work is carried out; and

thorough examination/safety inspection.
203
The manufacturer’s or authorised supplier’s instructions on inspection, maintenance
and servicing should be followed. Operators, unless suitably qualified and authorised, should
not carry out repairs and adjustments to lift trucks.
Pre-shift checks
204
At the beginning of each shift the operator should check the lift truck and document
the results in accordance with the manufacturer’s operator’s manual. Report to the
54
supervisor any defects which might affect its safe operation to ensure they are put right. In
all cases, checks must conform to manufacturer’s requirements. Checks may typically
include:

condition of wheels, tyres and security of wheel nuts. Pneumatic tyres if fitted should
be inflated to the proper pressure; incorrectly inflated tyres can affect the stability of
the lift truck and the load. Check all tyres for damage, eg swarf, nails and other
embedded material, cuts and bubbles and check all wheel nuts for tightness. Check
wheels for damage, particularly to the flanges on rims fitted with pneumatic tyres;

functional test on the parking brake, service brakes and steering gear to ensure that
they are working efficiently;

fluid levels, eg check fuel, water, lubricating oil and hydraulic oil levels are correct in
internal combustion engine industrial trucks;

batteries of battery-operated lift trucks to check they are adequately charged and
leak free, the charger is switched off, the charge lead disconnected and properly
stored, and the battery retention device is in place;

functional test on systems for lifting, tilting and manipulation, including attachments.
These should be working properly;

inspect hydraulic systems visually to check for obvious leaks, and make sure
hydraulic fluid levels are correct when the fork arms are in the parked position;

condition and security of the overhead guard and load back-rest extension.

audible warning signal, eg a horn;

lights;

mirrors, if fitted;

signs of damage.
Defect reports
205
If there is a breakdown or a defect identified, this should be reported immediately to
the supervisor through a defect reporting system. Where the defect is a safety critical item
(eg brakes, steering) the truck should be withdrawn from service until it is rectified. You
should have a system in place to prevent future use of the truck until the fault is rectified.
Retain reports until the next thorough examination.
55
Thorough examination
206
Lifting parts of industrial trucks, such as the mast, chains, carriage, forks and tilt
mechanism, need to be thoroughly examined by a competent person at least every 12
months, or in accordance with an examination scheme. A ‘report of thorough examination’
will be issued by the competent person and must be retained by the employer for at least
two years.
207
Equipment that is used to lift people, even on an occasional basis, or attachments
not permanently fitted to a specific truck must be thoroughly examined at least every six
months, or in accordance with an examination scheme.
208
For lifting equipment less than one year old (or 6 months for machines used for lifting
people), a copy of the manufacturer’s Declaration of Conformity should be provided.
209
The competent person:

should have enough appropriate practical and theoretical knowledge and experience
of the lifting equipment so that they can detect defects or weaknesses, and assess
how important they are in relation to the safety and continued use of the equipment;

should not be the same person who performs routine maintenance as they would be
responsible for assessing their own work;

should be sufficiently independent and impartial to make objective decisions;

may be employed by a separate company, or selected by an employer from members
of their own staff.
210
If the competent person considers that there is a defect indicating an existing or
imminent risk of serious personal injury to the operator or others, they should indicate this on
the report of thorough examination and recommend to a person in authority that the
equipment should be withdrawn from service immediately. The competent person is required
to copy any report made under these circumstances to the appropriate enforcing authority.
211
Further guidance is given in the British Industrial Truck Association guidance note
GN28 Thorough examination and safety inspections of industrial lift trucks. Detailed advice
on maintenance, inspection, reports and records required under the Provision and Use of
56
Work Equipment Regulations 1998 and the Lifting Operations and Lifting Equipment
Regulations 1998 is given in Safe use of work equipment and Safe use of lifting equipment.
Hired lift trucks
212
Hirers have a duty to ensure that their lift trucks are safe for their employees to use
and are thoroughly examined at appropriate intervals. It is important for both the hire
company and the hirer to establish which party will carry out safety-related maintenance and
thorough examinations. Hirers need to ensure that necessary inspections and pre-use
checks are carried out and defects reported and remedied as necessary. Hirers are also
responsible for providing an operator who is trained to the standard of the L117 ACOP.
57
Appendix 1 Useful contacts (to be added)
58
Appendix 2 Objectives to consider for inclusion in a basic training course
On completion of training, the trainee should be able to:
1
State the reasons for operator training, the risks associated with lift-truck operations
and the causes of lift-truck accidents.
2
State the responsibilities of operators to themselves and others, including their duties
under sections 7 and 8 of the Health and Safety at Work etc Act 1974.
3
Identify the basic construction and main components of the lift truck, stating its
principles of operation and load handling capabilities and capacities.
4
Identify, as appropriate, handling attachments which may be used with the lift truck.
5
Locate and state the purpose and method of use of all controls and instruments
6
Place the forks or other handling attachment in predetermined positions employing
the appropriate controls.
7
Identify various forms of load, and state the procedures for their stacking, destacking
and separation; assess the weight, and, where relevant, the load centre of a load; and
decide if the load with its known weight and load centre is within the truck’s rated/derated
capacity.
8
State the factors which affect machine stability, including: turning, especially related
to speed and sharpness of turn; load security and integrity; rated capacity and rated load
centres; centres of gravity; and speed and smoothness of operation.
9
Follow correct procedures when loading and unloading vehicles.
10
Make visual checks to ascertain the safety, soundness and rating of structures
designed to receive loads, and place and remove loads on and from those structures at
various heights.
11
Pick up and place loads, and drive and manoeuvre the machine in forward and
reverse motions laden and unladen on inclines, in restricted spaces and on level ground
(including rough terrain as applicable) following correct procedures and precautions.
59
12
Park the machine, following correct procedures and precautions.
13
Where applicable state the purpose, and demonstrate the procedures for the use, of
safety devices including stabilisers, level indicators, and load indicators, if fitted.*
14
Carry out inspection and maintenance tasks appropriate to operators as required by
the machine manufacturers and any relevant legislation.**
15
State the actions to be taken in an emergency while in control of a lift truck, for
example, action to be taken in the event of tipover.
16
State why it is essential to have vehicle key custody arrangements.
* This should include the importance of using seat restraints.
** This would include pre-shift checks.
60
Appendix 3 Basic training: Tests of operator skills
Testing could include the following as appropriate:
1
Operation of the truck within the safety limits defined by the manufacturer.
2
Carrying out a pre-shift check when the truck is to be used.
3
Correct mounting and dismounting procedure and correct driving position.*
4
Competent use of controls.
5
Movement of the truck with forks or attachments in the correct travel position, laden
and unladen.
6
Correct insertion and withdrawal of forks or other handling attachments without
damage to pallet or load.
7
Manoeuvring a laden and unladen truck forward and in reverse in a narrowly
confined area.
8
Performing both a left and a right 90º turn with a loaded truck in a narrowly confined
area without touching the sides of the area.
9
Stacking and destacking loads:
(a)
at different levels;
(b)
in front of a fixed vertical face;
(c)
on the floor alongside similar loads.
10
Loading/unloading a vehicle (a suitable simulation may be used where a vehicle is
not available).
11
Correct parking of the truck.
* This should include the importance of using seat restraints and seat belts.
61
Appendix 4 Example of employer’s training record
Company name:
Company address:
Employee’s full name:
Department:
Date to review this summary sheet:
Road licence (attach a copy):
Driving licence?
❑ Yes ❑ No
Clean licence?
❑ Yes ❑ No
Specialist licence?
❑ Yes ❑ No
Type:
Training or qualifications (attach copies)
Course
Date
Renewal
achieved
date?
Checked?
Limitations?
Specific vehicles the employee is allowed to control:
1
6
2
7
3
8
4
9
5
10
62
All
Basic training
Lift truck type(s) used for training:
Model/capacity:
Attachments:
Organisation carrying out training:
Course description, location and reference number:
Duration and dates of course:
days from
Name of instructor:
Reference number:
Date of test:
Name of person conducting test:
Reference number:
Specific job training
Lift truck(s) used for training:
Model:
Number:
Instructed by:
Duration of training:
Date of training:
63
to
Familiarisation training
Lift truck(s) used for training:
Model:
Number:
Instructed by:
Duration of training:
Date of training:
64
Appendix 5 Supervisor attributes
1
Supervisors should know and understand:

the principles of safe lift truck operation;

what the lift truck can and cannot be used for;

the hazards associated with lift truck operation including:
-
overturning – stability;
-
electrocution – contacting overhead power lines;
-
colliding with pedestrians;
-
crushes and trapping;
-
falling loads;
-
falling from height (when lifting people);
-
loss of control;
-
insecure attachments;

the checks and inspections that are required on a daily basis;

what can happen if the lift truck is poorly maintained;

how to attach and detach an attachment correctly;

how to carry out checks to ensure the attachment has been correctly engaged;

that accidents are mainly caused by incorrect planning;

the increased risks when lift trucks are being operated in the vicinity of other people
and to maintain an exclusion zone wherever possible;

their responsibilities under the Health and Safety at Work Act, PUWER AND LOLER.
65
References (to be added)
Further information (to be added)
Glossary (to be added)
66