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

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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.

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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)

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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.

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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.

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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;6

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;

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.

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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.

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)

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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

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

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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.

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

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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.

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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 fork-

lift 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.

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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

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

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of machines adapted for temporary use as lift trucks should be adequately trained to use the attachments they need for the jobs they do.

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.

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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.

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

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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 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:

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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;

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.

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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 five-

yearly 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.

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;

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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

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.

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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

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

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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

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

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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;

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.

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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

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.

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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;

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.

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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.

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, pivot-

steer (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.

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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.

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

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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 co-

operate 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.

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.

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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.

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:

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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;

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.

99 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;

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.

be able to supervise and evaluate trainees.

101 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).

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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).

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Figure 1 Industrial counterbalance lift truck

Figure 2 Higher capacity counterbalance truck

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.

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Figure 5 Variable reach truck (telehandler)

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)*

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* Regulation 9 of PUWER still requires operators to be properly trained even though these trucks are not covered

by the L117 ACOP training requirements.

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 33

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.

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.

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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

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

35

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’.

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

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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.

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.

37

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’.

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.

38

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);

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);

39

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).

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.40

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

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:

41

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:

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:

42

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

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

43

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.

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

44

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).

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

45

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

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.

46

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.

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:

47

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.

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 barrier48

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.

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.

49

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.

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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);

51

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;

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:

52

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.

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; 53

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.

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.

54

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).

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

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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.

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.

56

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

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;

57

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.

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;

58

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

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.

59

Appendix 1 Useful contacts (to be added)

60

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.

61

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.

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.

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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.

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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

achieved

Renewal

date?

Checked? Limitations?

Specific vehicles the employee is allowed to control:

1 6

2 7

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3 8

4 9

5 10 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 to

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:

65

Duration of training:

Date of training:

Familiarisation training

Lift truck(s) used for training:

Model:

Number:

Instructed by:

Duration of training:

Date of training:

66

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.

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References (to be added)

Further information (to be added)

Glossary (to be added)

68