​OSHA Forklift and Powered Industrial Truck Compliance FAQ (General Industry & Construction)

Employers often have many questions about complying with OSHA’s forklift and powered industrial truck (PIT) safety requirements. This comprehensive FAQ addresses federal OSHA standards (primarily 29 CFR 1910.178 for general industry) and highlights state-specific rules from Alabama to Wyoming. We’ve organized the information so that federal OSHA questions are first, followed by state-by-state details in alphabetical order. The answers are written in an informal tone but include specific OSHA code references and links for verification.

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Federal OSHA Forklift Compliance (General Industry & Construction)

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Under federal OSHA rules, a “powered industrial truck” (PIT) includes forklifts (of all classes), lift trucks, powered pallet jacks, industrial tow tractors (“tuggers”), and other specialized industrial trucks powered by electric motors or internal combustion engines. (It generally does not include vehicles primarily designed for earth-moving or over-the-road hauling.) Employers in general industry must follow OSHA’s 29 CFR 1910.178 standard for PITs, which covers the design, maintenance, and use of these vehicles, as well as operator training and certification requirements. For construction worksites, OSHA has similar requirements – in fact, the construction regulation (29 CFR 1926.602(d)) explicitly states that operator training must meet the same requirements as 1910.178(l). This means that forklift operators on construction sites need the same training and evaluation as those in factories or warehouses. Below, we answer frequent questions about OSHA-compliant forklift operations.

Operator Training and Certification

Q: Who is allowed to operate a forklift under OSHA rules?

A: Only trained, competent, and authorized operators can operate forklifts and other PITs. OSHA requires that “all powered industrial truck operators must be trained and certified by their organizations”. In practice, this means the employer must develop a training program and evaluate each operator’s ability to drive safely. Also, federal child labor laws prohibit anyone under 18 years of age from operating a forklift in non-agricultural employment. In short, an employee must be at least 18 years old and properly trained and certified to drive a forklift.

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Q: What does OSHA’s forklift training standard require?

A: Employers must implement a comprehensive training program for forklift operators. The training must cover: (1) the general principles of safe truck operation, (2) the specific types of vehicles used, (3) the hazards of the workplace related to forklift use, and (4) the OSHA PIT standard’s safety requirements. OSHA specifies that training include both formal instruction (e.g. lectures, videos, written materials) and practical training (demonstrations by the trainer and hands-on exercises by the trainee), followed by an evaluation of the operator’s performance. Operators must be able to do the job properly and safely as demonstrated in an evaluation. Prior to permitting an employee to operate a forklift independently, the employer must evaluate their performance and determine they are competent to operate safely.

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Q: What topics must forklift operators be trained on?

A: OSHA’s standard lists a variety of required training topics in two categories:

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• Truck-related topics – e.g. operating instructions for the specific forklift, differences from driving a car, controls and instrumentation, steering and maneuvering, visibility (especially with loads), fork and attachment use, vehicle capacity and stability, inspection and maintenance the operator will perform, refueling/charging, and any other warnings from the operator’s manual.

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• Workplace-related topics – e.g. surface conditions where the forklift will operate, load composition and stability, stacking/unstacking techniques, pedestrian traffic in areas of operation, narrow aisles or restricted areas, hazardous locations (if any) where the truck will be used, ramps and slopes, enclosed areas with poor ventilation (addressing carbon monoxide/diesel exhaust buildup), and other unique hazards in the workplace.

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The training program can omit topics that are not applicable to the employer’s situation (for example, if there are no ramps or no hazardous atmospheres, those specific topics need not be taught). But generally, most operators receive thorough instruction on all relevant items. Appendix A of 1910.178 provides non-mandatory guidance to help employers implement these training topics.

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Q: Who can conduct the forklift training and evaluations?

A: OSHA does not require a third-party or “OSHA-certified” trainer. The training (both instruction and evaluation) must be conducted by a person with the knowledge, training, and experience to train operators and evaluate their competence. This could be an employee or outside trainer, as long as they are qualified. OSHA does not issue any official “train the trainer” certification; it’s the employer’s duty to ensure the trainer is competent in forklift operations and training techniques. Many companies choose experienced operators, supervisors, or safety professionals to serve as in-house trainers. External training programs are also used, but ultimately the employer must ensure each operator is evaluated on the actual equipment and hazards of their workplace.

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Q: Does OSHA require forklift operators to have a state driver’s license or an OSHA license?

A: No. OSHA does not require a state-issued driver’s license or any sort of official OSHA operator license. The only requirement is that the employer certifies the operator’s training and competence. This OSHA certification is basically a written record by the employer (or trainer) that the employee has completed the required training and evaluation. The certification must include the operator’s name, the training date, the evaluation date, and the name of the person(s) who conducted the training/evaluation.

Many employers issue a wallet card or certificate to the operator as proof, but that is an internal practice – OSHA does not provide operator cards. The key is that if an OSHA inspector asks, the employer can produce documentation that each forklift operator has been trained and evaluated according to 1910.178(l).

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(Note: While OSHA doesn’t mandate a license card, using cards is a common best practice. Some local jurisdictions or employers may require operators to carry proof of training. But from OSHA’s standpoint, the signed certification record is sufficient.)

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Q: Our new hire says they were certified at a previous job. Do we have to train them again?

A: OSHA allows some flexibility to avoid duplicate training, but you still have responsibilities before the employee operates a forklift at your workplace. If an operator has previously received training that covers the truck and conditions at your workplace, and you verify their competency, you do not need to retrain them on those same topics. However, you must evaluate the operator’s performance in your workplace and determine they are competent to operate your equipment safely. Also, if your workplace has any unique hazards or different types of trucks than the operator used before, you need to provide training on those.

In summary, a prior certification can be accepted for portions of training, but each employer must ensure the operator is properly trained for their specific trucks and hazards and is evaluated on-site. Many employers will do an abbreviated orientation and skills check for experienced operators rather than full training from scratch, but it should be documented as an evaluation. If you’re unsure of the adequacy of past training, it’s safest to retrain the employee.

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Q: How often is refresher training or recertification required?

A: OSHA does not prescribe a set expiration (like yearly) for forklift licenses, but it does require periodic evaluation at least once every three years. Additionally, refresher training (with a new evaluation) must be done sooner than three years whenever any of these occurs:

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• The operator is observed operating unsafely or has been found to be unsafe in an evaluation.

• The operator is involved in an accident or near-miss incident.

• The operator is assigned to a different type of truck (e.g. moving from a sit-down forklift to a stand-up reach truck).

• A workplace condition changes that could affect safe operation (for example, new racking creating narrow aisles, a change from indoor to outdoor yard driving, introduction of combustible dust requiring EX-rated forklifts, etc.).

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Refresher training needs to cover the specific areas of deficiency. After refresher training, the employer should reevaluate the operator to confirm competence. Even if none of these triggers occur, remember the triennial evaluation requirement – at least every three years, each operator’s performance must be observed and documented, and any issues corrected. In practice, many employers choose to do refresher training every three years as well (since the evaluation is required, it’s a convenient interval to retrain on key topics). But OSHA’s rule is performance-based: if the operator has been safe and there are no changes or incidents, a documented evaluation suffices for the 3-year check.

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Q: What does an OSHA forklift certification look like, and what records do I need to keep?

A: The OSHA regulation requires the written certification record described above (name of operator, date of training, date of evaluation, and trainer/evaluator’s identity). There is no specific form or official card. Employers often use an in-house certificate or form for this. It’s important to keep these records on file as proof of compliance. OSHA does not require you to submit them to OSHA unless asked during an inspection or investigation. Other records that are good to keep (though not explicitly required by 1910.178) include training rosters, test results, and practical evaluation checklists for each operator. These can help demonstrate the content and quality of training if needed.

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OSHA also does not require annual refresher paperwork aside from the 3-year evaluation record. However, if refresher training is conducted due to an incident or unsafe behavior, it’s wise to document what retraining was given and when. In summary, keep the initial certification records and update evaluation records at least every 3 years or when refreshers occur. This will satisfy OSHA’s documentation requirements.

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Forklift Operation and Safety Rules

Q: What general safety rules does OSHA require when operating forklifts?

A: OSHA’s standard contains many specific operating rules that employers must enforce. Some key do’s and don’ts include:

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• No riders – Only the authorized operator can be on the forklift (unless it’s designed to carry passengers). Workers are not allowed to ride on forks or any part of the forklift not meant for passengers, and no one should be lifted on forklift forks unless using an approved man-lift platform (see further Q&A on lifting people).

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• No standing under elevated forks – No person is allowed under the elevated portion of a forklift (whether loaded or empty) unless it’s properly blocked to prevent it from falling. This is to prevent deadly crushing injuries.

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• Clear view and safe speed – Operators must look in the direction of travel and keep the forklift under control at all times. If carrying a tall load that blocks forward view, they must drive in reverse (load trailing) so they can see. OSHA requires observing all traffic regulations and plant speed limits, maintaining a safe distance (about three truck lengths) from other trucks, slowing down at intersections, on grades, and on slippery floors. While OSHA doesn’t set a specific numeric speed limit, it’s implied that speeds must be safe for the conditions – the truck should be able to stop safely when needed.

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• Use horns at crosswalks/obstructions – The operator should slow down and sound the horn at cross-aisles, blind corners, or anywhere vision is obstructed. This warning helps alert pedestrians and other operators.

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• Grades and ramps – Forklifts must ascend/descend slopes slowly and with caution. On grades over 10%, move with the load upgrade (uphill) if loaded, to prevent tipping. Always tilt the load back and raise it only as far as needed to clear the ground when on ramps. For powered pallet jacks or walkies on ramps, OSHA (and consensus standards) advise keeping the load downhill (so the device doesn’t run away).

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• Parking and leaving the truck – If a forklift is unattended (defined by OSHA as the operator being 25 feet or more away, or out of view of the truck), it must be fully parked: forks lowered to the floor, controls neutralized, power shut off, brakes set. If parked on an incline, wheels must be chocked or blocked as well. Even if the operator dismounts for a short time but stays within 25 ft and the forklift remains in view, they should at least lower the forks, neutralize controls, and set brakes. This prevents unintended movement.

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• Fork position – When traveling without a load, forks should be carried as low as possible (just high enough to clear bumps/obstacles) to improve stability. When loaded, tilt the mast back enough to stabilize the load and keep forks low during travel. Never raise or lower loads while moving – come to a stop first. Also, never travel with a load elevated higher than necessary, as it raises the center of gravity and risk of tip-over.

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• No stunt driving or horseplay – Obviously, unsafe maneuvers, racing, or horseplay with forklifts are prohibited (OSHA can cite under the general duty to operate safely). California’s rules, for example, explicitly ban stunt driving, and this is good practice everywhere.

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• Clear aisles and access – Keep aisles, passageways, and exits clear. OSHA notes that “fire aisles, access to stairways, and fire equipment must be kept clear” – meaning don’t park or place loads in a way that blocks emergency egress or firefighting equipment.

These are just highlights. OSHA’s 1910.178(m), (n), (o) sections contain many specific operating rules (which largely parallel industry consensus standards like ANSI B56.1). Employers should train operators on all these rules and post and enforce them. (In fact, Cal/OSHA explicitly requires employers to post a set of operating rules for industrial trucks at the workplacedir.ca.gov – even if not required federally, it’s a great idea to post the key rules as a constant reminder.)

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Q: Does OSHA have a speed limit for forklifts (e.g. 5 mph)?

A: No, OSHA does not set specific speed limits like an exact mph. Instead, OSHA expects that forklifts be operated at a safe speed for conditions. As noted above, the rules say you must observe “authorized plant speed limits” if your facility sets them. The truck must be kept under control at all times and be able to stop safely given the load and environment. OSHA has stated it would evaluate “the totality of circumstances” to judge if speed was unsafe – factors like the manufacturer’s design, the load stability, pedestrian traffic, surface conditions, and stopping distance all matter. Employers should set reasonable internal speed limits (some use 5 mph indoors as a guideline) and adjust based on congestion or visibility. A useful reference is the ANSI B56.1 standard, which even provides a formula to calculate stopping distances based on speed and load. In summary, drive at a safe speed – slow down where vision is obstructed or floors are slippery, and always slow down before turns to prevent tipping.

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Q: Are forklifts required to have seat belts, and must operators wear them?

A: Most rider forklifts (especially sit-down types made since the 1990s) are equipped with seat belts or other operator restraint systems. OSHA’s standard 1910.178 does not explicitly mandate retrofitting seat belts on older forklifts, but OSHA has a well-established enforcement policy: if a forklift has a seat belt, the employer must ensure operators use it. Failing to use available seat belts is commonly cited under OSHA’s General Duty Clause (Sec. 5(a)(1)), because seat belts protect operators in tip-over incidents. In fact, OSHA issued letters clarifying that employers should retrofit older forklifts with seatbelts or restraints if feasible, in order to abate the recognized hazard of tip-over ejections. Many states’ regulations echo this.

For example, Washington’s forklift safety rules explicitly require that “operators use restraint devices, such as seatbelts or lap bars, when they are provided on the PIT.”lni.wa.gov. The bottom line: if the forklift has a seat belt or restraint, it needs to be worn. If you have very old forklifts without any operator restraint, consider contacting the manufacturer about a retrofit kit – it’s a strongly recommended safety upgrade.

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Q: Do forklifts need backup alarms or flashing lights under OSHA rules?

A: Surprisingly, no, federal OSHA does not specifically require forklifts to have backup alarms, beepers, or flashing warning lights. OSHA’s Powered Industrial Truck standard only mandates that the forklift be equipped with a working horn (or other sound-producing device) that the operator can use as needed. Many new forklifts do come with backup alarms and blue or strobe lights as standard safety features or options, and employers are free to require them.

OSHA has said that employers should assess their workplace – if a backup alarm or flashing light would materially improve pedestrian safety in a particular environment, then under the General Duty Clause an employer should consider installing them. But there is no federal OSHA rule outright requiring an alarm or light on every truck. Always, at minimum, the forklift must have a horn, and operators should use it at intersections or when vision is obstructed. (Do note: some worksites or local regulations might specifically require audible or visual alarms on industrial trucks. Also, OSHA’s construction vehicle rules often require backup alarms on earthmoving equipment, but those don’t apply to most forklifts.)

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Q: Are we required to put a fire extinguisher on our forklifts?

A: Federal OSHA does not specifically require a portable fire extinguisher on every forklift. There’s nothing in 1910.178 that mandates it. However, there are a couple of considerations:

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• If a forklift operates in an area where fire hazards are present (for example, handling flammable materials or in a location where fires are possible), OSHA’s general fire protection standards might require accessible extinguishers in the area. But that doesn’t necessarily mean on the truck; it could be on a wall or column nearby.

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• If a manufacturer provides an extinguisher on the forklift as standard, you should not remove it without good reason. If it’s there, OSHA would expect it to be maintained (per the fire extinguisher maintenance rules in 1910.157). You also can’t remove or modify safety equipment on a PIT without manufacturer approval (1910.178(a)(4) prohibits unsafe modifications).

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So, while you don’t have to add extinguishers to trucks that don’t have them, if you choose to (or the manufacturer installed one), ensure operators are trained to use them and that they’re kept in working order. (As a side note, the NFPA 505 standard for PITs only says that if an extinguisher is required by the authority having jurisdiction or the user, it should be installed per manufacturer’s recommendations. So it’s optional unless a local code or site condition makes it necessary.)

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Q: What about driving forklifts into trucks or railroad cars – any special precautions?

A: Yes, OSHA has rules for situations like loading/unloading trucks, trailers, and railcars:

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• Secure the truck/trailer: The trailer or railcar being loaded must be prevented from moving. OSHA requires setting the brakes and wheel chocks on trucks/trailers while forklifts are loading themo. This prevents the trailer from rolling or sliding away from the dock. If a trailer isn’t attached to a tractor, fixed jacks may be needed to support the front end to prevent up-ending when a forklift drives inside. In railcars, wheel stops or other locking devices on the track can prevent movement.

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• Bridge plates / dockboards: Use a proper dockboard or bridge plate when driving between a loading dock and a trailer or railcar. OSHA says portable or powered dockboards must be secured in position (e.g. with locking pins or being anchored) to prevent slippage. Ensure the dockboard can handle the weight of the forklift plus load.

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• Check floor conditions: Inspect the flooring of trucks, trailers, or railcars for weaknesses or breaks before driving a forklift onto them. You don’t want the floor to collapse.

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• Ventilation: If using a gas/propane forklift inside an enclosed truck trailer or boxcar, be mindful of carbon monoxide buildup. OSHA mentions that enclosed or poorly ventilated areas could cause hazardous CO exposure, so consider portable ventilation or using electric forklifts in such scenarios.

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• Railcar specifics: OSHA’s longshoring/marine terminal rules cover some details for railcars and vessels, but generally, similar principles: secure movement, use proper ramps, watch clearances.

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Following these practices prevents the dangerous scenario of a forklift falling off a loading dock or trailer (a major source of fatalities). Always verify the trailer is locked in place and the dock plate is secure before entry.

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Q: Can we modify a forklift or add attachments?

A: Yes, but with caution and approval. OSHA 1910.178(a)(4) says that “modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without the manufacturer’s prior written approval.” If you do get an attachment (like a sideshifter, drum clamp, boom, etc.), or you modify a forklift (e.g. change engine, counterweight, or add a cab), you must:

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• Obtain written approval from the manufacturer for the specific modification or attachment. The manufacturer (or a qualified professional engineer if the original company is out of business) needs to confirm that the modification is safe and won’t destabilize the vehicle. If the original manufacturer no longer exists and wasn’t bought by another, OSHA advises getting a Qualified Registered Professional Engineer to review and approve the modification in lieu of manufacturer approval.

• Update capacity markings: Per 1910.178(a)(5), if you add any attachment that was not factory-installed, the forklift’s nameplate (data plate) must be updated to show the attachment and the truck/attachment combination’s approximate weight and new rated capacities. Essentially, the data plate should reflect how the attachment affects lifting capacity (often attachments reduce capacity). The employer/user is responsible for ensuring the forklift is properly labeled after modification.

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• No reduction in safety: Any modification must not reduce the original safety factors of the forklift. For instance, you cannot remove the overhead guard or drill holes in forks (that would weaken them) without proper engineering review.

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In summary, get approval and instruction for mods, and update the labels accordingly. If those steps aren’t done, OSHA can cite you for non-compliance. A common example: using a forklift to lift people with a personnel platform – this isn’t a factory configuration, so it should be done only with an approved safety platform and manufacturer guidance (see next Q&A).

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Q: Is it okay to use a forklift to lift personnel on a platform (manbasket)?

A: Lifting workers with a forklift is generally discouraged unless no safer equipment (like an aerial lift) is available, but OSHA does recognize it can be done with strict precautions. For construction sites, OSHA has specific provisions: a forklift can lift a work platform with people if you follow 1926.602(c)(1)(viii), which among other things requires a secure safety platform attached to the forks, a way for the person on the platform to shut off power, and proper fall protection if needed. Also, the forklift should not move horizontally while people are elevated (except minor adjustments), per the scaffold rules for forklifts. So in construction, it is permitted with precautions.

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In general industry, OSHA’s 1910.178 standard doesn’t explicitly address lifting people. However, OSHA has interpreted that if you do lift someone with a forklift, you assume the same safety measures as in construction. OSHA letters of interpretation have stated that the platform must be secure and strong, with guardrails; the forklift must be designed for it (or approved by the manufacturer for that use); and you must ensure no movement while occupied, etc. Also, if the manufacturer prohibits lifting people (many forklift manuals say “not for lifting personnel”), OSHA would likely consider it a violation of the standard (because using equipment contrary to manufacturer’s instructions can be deemed unsafe)

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So, bottom line: It’s not outright forbidden to use a forklift with a manbasket in general industry, but you need to do it in a very controlled manner. Use a properly designed work platform that is securely attached to the forks (or mast), have a way for the occupant to cut power, provide fall protection if necessary, and never drive the forklift around while the person is raised. Always check the manufacturer’s guidance – if the forklift manual or the manufacturer says “do not lift people,” then doing so would violate OSHA’s requirement to follow manufacturer’s limitations. Many companies opt to use scissor lifts or other aerial lifts instead, as those are purpose-built for lifting people and have their own OSHA standards.

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(For reference, OSHA’s scaffold standard (1910.28 and 1926.451) basically says forklifts should not be used to support scaffold platforms unless the entire platform is attached to the forks and the forklift doesn’t move while occupied. This aligns with the above requirements. Always treat lifting personnel as a special operation requiring planning and safety checks.)

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Q: What are the OSHA rules about forklift load limits and stability?

A: Employers must ensure operators do not exceed the rated capacity of the forklift and handle loads safely. Key points:

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• Capacity: Every forklift has a rated load capacity (usually given for a certain load center, like 24 inches) marked on its nameplate. OSHA says “Only loads within the rated capacity of the truck shall be handled.”. Lifting a load heavier than the forklift’s capacity is a serious violation and a huge safety risk (can cause tipping or equipment failure). Also, if using attachments, remember the effective capacity is reduced – check the updated capacity with that specific attachment (hence the importance of correct nameplates after modifications).

• Stable loads: OSHA requires that “only stable or safely arranged loads shall be handled.”. This means operators shouldn’t lift pallets that are falling apart or loads that could easily tip off the forks. If a load is unbalanced or off-center, use extra caution or reposition it. Long or high loads that could affect stability may need to be adjusted (perhaps carried low, or with a spotter).

• Tilt and handling: OSHA mentions using care when tilting loads, especially when they’re elevated. When picking up a load, the forks should be placed under it as far as possible, then lift and tilt back slightly to secure it. Avoid excessive forward tilt at height, as that can tip the load off or the forklift forward.

• No “bulldozing” with forks: A question often comes up: can you push piles of materials with the fork tips (like a bulldozer)? This is generally not a safe practice. OSHA can cite it under the rule requiring stable loads and proper handling if it creates a hazard. Pushing with the tips could cause objects to slip or the forklift to be put in an unsafe orientation. Forklifts are made for lifting and carrying, not plowing materials across the floor. Use proper equipment (like a dozer or sweeper) or attachments if you need to push materials.

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Q: Do we have to inspect forklifts daily? What does OSHA say about pre-operation inspections?

A: Yes, OSHA requires that forklifts be examined at least daily (pre-shift) and unsafe trucks be taken out of service. Specifically, 1910.178(q)(7) says “Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily.” If a forklift is used around the clock on shifts, OSHA says inspect after each shift. These inspections typically include a checklist of items like: tires, brakes, horn, lights, steering, controls, mast chains, fluid levels, etc. If any defect is found that affects safety (for example, brakes not working, hydraulic leak, cracked fork, non-functioning horn), the truck must be removed from service until fixed.

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OSHA does not explicitly require you to keep a written log of daily inspections, but it’s strongly recommended. In practice, most companies have operators fill out a daily or pre-shift inspection checklist and keep those on file. That way, you have proof that you are complying with the requirement and you can track maintenance issues. Some state OSHA plans (and other standards like ANSI) essentially mandate written pre-use checklists, but federal OSHA stops short of requiring the paperwork – they just require that the inspection happens.

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One more note: things like leaking fuel systems are specifically mentioned – “No truck shall be operated with a leak in the fuel system until the leak has been corrected.”. Also, if repairs are needed, they should be done in a designated safe area and only by authorized personnel. OSHA expects that any safety defects are reported and fixed promptly.

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Q: Are there OSHA requirements for forklift maintenance?

A: Yes – the PIT standard says forklifts must be kept in a safe operating condition. Key maintenance-related rules:

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• If a forklift is found unsafe, you have to pull it from service until repaired. (As noted above, that’s part of the daily exam rule.)

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• Maintenance or repair that involves fire hazards (like work on the fuel system or ignition of a propane truck) should be done in areas with no open flames or ignition sources, etc., as a precaution.

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• Only qualified persons should repair or service forklifts. OSHA doesn’t detail this, but it’s implied that you shouldn’t have untrained employees making major repairs.

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• Keep all safety equipment and guards in place: For instance, overhead guards (the cage on top that protects the operator from falling objects) must not be removed except for authorized reasons. OSHA says an overhead guard is required on high-lift trucks to protect against falling objects (though it acknowledges it’s not designed for a full capacity load drop). Likewise, load backrest extensions (the vertical extension on the forks carriage) should be used when needed to prevent part of the load from falling back on the operator. If those are broken or missing, fix/replace them.

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• Forks, chains, and other load-engaging parts should be checked – if forks are cracked or worn beyond wear limits, they should be taken out of service. (ANSI B56.1 suggests fork inspection and a limit of 10% wear on blade thickness, etc., though OSHA doesn’t quote those specifics, it’s good practice.)

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• Fuel and battery maintenance: Don’t let fuel or oil spills accumulate – OSHA requires that spillage be cleaned or allowed to evaporate and the fuel cap replaced before restarting the engine. For battery-powered trucks, batteries must be properly secured in the truck, electrolyte levels maintained, etc. Water for flushing eyes or skin should be available where battery charging occurs (as battery acid is corrosive) – this comes from ANSI and OSHA’s battery handling rules (1910.178(g) and the general sanitation standard).

In short, preventive maintenance is crucial. While OSHA doesn’t specify an interval (like “do preventive maintenance every 6 months”), you are expected to follow manufacturer’s maintenance schedules and keep the truck safe. Documented maintenance and repair logs are good to have to show you’ve been diligent in upkeep.

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Special Equipment: Pallet Jacks, Order Pickers, Aerial Lifts, etc.

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Q: Does the OSHA forklift standard apply to pallet jacks, tuggers, and other small PITs?

A: Yes. The OSHA standard covers all types of powered industrial trucks, not just traditional forklifts. This includes electric motor hand trucks and hand/rider trucks (which is OSHA’s term for pallet jacks, whether walk-behind or ride-on). It also includes stand-up reach trucks, order pickers (high-lift stock pickers), turret trucks, tow tractors (tuggers) that pull carts, and even industrial sweepers or scrubbers if they are ride-on and used in an industrial environment. Essentially, if it’s a powered vehicle used in a workplace to carry, push, pull, lift, stack or tier material, it falls under the PIT umbrella.

So, operators of all these variants must be trained and certified just like forklift drivers. The training should be tailored to the specific equipment – for example, if you’re training someone on a walkie pallet jack, you’d cover its controls, stability (which is different from a forklift), and any unique risks (like getting caught between the jack and a wall). Likewise, an order picker (which elevates the operator on a platform) has unique topics like use of fall protection harness, etc., which should be addressed (OSHA would consider those “workplace-specific hazards” to train on).

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Important: The only exceptions OSHA notes are for vehicles not powered by electric or internal combustion engine (e.g., manual pallet jacks or compressed-air-powered trucks) and for vehicles used for earth moving or over-the-road haulage. So, a skid-steer loader or a backhoe is not covered by 1910.178 (those have other standards), and a tractor-trailer truck is not a PIT. But a ride-on floor scrubber or airport baggage tug is considered a PIT and requires training.

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For quotes or questions, call 1-800-277-2267 or email us at Sales@Employeeforklifttraining.com or go to Schedule Training

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Q: Are boom lifts, scissor lifts, and aerial work platforms covered under the forklift/PIT rules?

A: No, equipment like scissor lifts, telescopic boom lifts, bucket trucks, etc. are not covered by 1910.178. They fall under other OSHA standards. In general industry, aerial lifts (like bucket trucks or boom lifts) were covered by the old 1910.67 standard (Vehicle-Mounted Elevating and Rotating Work Platforms) and updated rules in 1910 Subpart F for aerial work platforms (incorporating ANSI A92 standards). Scissor lifts are treated by OSHA as a type of scaffold or aerial lift (OSHA has issued guidance classifying scissor lifts under the scaffold standard 1910.27 and requiring guardrails, etc.). The key point: Aerial work platforms require their own operator training, but not necessarily the same as forklift training – though there is overlap in concepts (stability, fall protection, etc.).

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So if your question is, for example, does a boom lift operator need forklift certification? The answer is no – they need aerial lift training per the aerial lift standards. Similarly, a scissor lift operator doesn’t need “forklift certification” but must be trained on the scissor lift in accordance with OSHA’s scaffold/use regulations. Some employers cross-train employees on both if they use both, but it’s a separate category of equipment. Always refer to the specific OSHA standard for the equipment: forklifts/PITs (29 CFR 1910.178) versus aerial lifts (1910.67 or 1926.453, etc., and new ANSI A92 guidelines).

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However, note that something like a telehandler (telescopic boom forklift) is both a forklift and often used like an aerial device with baskets. A telehandler is covered by 1910.178 as a PIT when used to lift loads, and if you attach a personnel platform to it to lift people, you have to follow the guidelines (which as discussed align with construction forklift rules and aerial lift rules). In construction, a telehandler is often treated under forklift rules for material handling and must meet scaffold rules when lifting people.

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In summary, forklift/PIT training covers material handling vehicles. Aerial lifts have separate rules. Don’t assume someone with a forklift license is qualified to run a boom lift or vice versa – unless they’ve been trained on both devices.

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For quotes or questions, call 1-800-277-2267 or email us at Sales@Employeeforklifttraining.com or go to Schedule Training