Safe Operating Practices
1.5 hours
Learning Objectives
- •Apply safe traveling practices for loaded and unloaded lift trucks, including on grades
- •Apply pedestrian-safety rules around lift trucks in shared work areas
- •Explain safe load handling — stacking, picking, and placing
- •Describe the hazards of refueling, charging, and operating different fuel types
Topics Covered
- •Travel with the load trailing (in reverse) when the load blocks the forward view
- •On grades over 10 percent, drive a loaded truck with the load pointed upgrade — going up or down
- •Keep forks low and mast tilted back while traveling; raise the load only to stack or pick
- •Slow down and sound the horn at intersections, blind corners, and doorways
- •Pedestrian rules: never drive up to anyone standing in front of a fixed object; no one walks or stands under elevated forks or load; no unauthorized riders
- •Keep arms, legs, and head inside the running lines of the truck; never reach through the mast
- •Maintain a safe following distance — about three truck lengths — and travel at a speed that allows a safe stop
- •Load handling: center the load on the forks, get the forks fully under the load, stack squarely, do not stack beyond rated capacity
- •Fuel-type hazards: LP refueling away from buildings and ignition sources with no engine running; battery charging in ventilated areas, acid into water, no smoking or sparks; diesel/gasoline — no open flame to check fuel, fix leaks before operating
Resources
Self-Check Questions
Question 1: You must drive a loaded forklift down a grade steeper than 10 percent. Which way should the load face?
- A. Downgrade (load pointing down the slope)
- B. Upgrade (load pointing up the slope)(correct)
- C. It does not matter on a forklift
- D. Sideways across the slope
Show Explanation
Explanation:
On grades over 10 percent, a loaded truck must be driven with the load upgrade — whether going up or down. This keeps the load from running away downhill and keeps the truck stable. Exam tip: load upgrade, always, on steep grades.
Question 2: A load on your forks is tall enough to block your view straight ahead. What should you do?
- A. Lift the load higher so you can see under it
- B. Travel with the load trailing (drive in reverse), looking in the direction of travel(correct)
- C. Have a coworker sit on the load to watch ahead
- D. Drive faster to spend less time with the blocked view
Show Explanation
Explanation:
When the load obstructs the forward view, OSHA requires the operator to travel with the load trailing — driving in reverse and looking in the direction of travel. Raising the load higher only makes the truck less stable.
Question 3: A coworker is standing between your forklift and a fixed workbench. What does OSHA require?
- A. Drive up slowly until they notice you
- B. Sound the horn once and continue
- C. Do not drive up to anyone standing in front of a bench or other fixed object(correct)
- D. It is allowed as long as the forks are lowered
Show Explanation
Explanation:
OSHA prohibits driving a truck up to anyone standing in front of a fixed object — the person could be pinned. Wait for them to move clear before approaching that area.
Question 4: A coworker asks for a ride on the forks of your forklift to reach an upper shelf. What is the correct response?
- A. Allow it if they hold on tightly
- B. Allow it if you go slowly
- C. Refuse — riding on the forks or on the truck by unauthorized personnel is prohibited, and no one may be under or on elevated forks(correct)
- D. Allow it only if a supervisor approves
Show Explanation
Explanation:
Unauthorized personnel may not ride on a powered industrial truck, and no one may stand or pass under elevated forks. Lifting a person requires a properly secured work platform and the correct procedures — never bare forks.
Question 5: Which is the correct procedure for charging a forklift battery?
- A. Charge anywhere convenient and smoke breaks are fine nearby
- B. Charge in a designated, well-ventilated area; keep flames, sparks, and smoking away; when adding electrolyte, pour acid into water(correct)
- C. Pour water into acid to dilute it faster
- D. Charge the battery while the truck is being driven
Show Explanation
Explanation:
Charging batteries release hydrogen gas, which is explosive. OSHA requires a designated, ventilated charging area free of flames, sparks, and smoking. When mixing electrolyte, always pour acid into water — never water into acid, which can cause a violent reaction.
Question 6: What is the safe practice when refueling an LP (propane) forklift?
- A. Leave the engine running so the tank fills faster
- B. Refuel inside a closed room to keep the cylinder warm
- C. Shut the engine off, refuel away from buildings and ignition sources, and wear appropriate gloves and eye protection(correct)
- D. Use an open flame to check the connection for leaks
Show Explanation
Explanation:
LP refueling is done with the engine off, away from buildings and ignition sources, and only by trained personnel using proper PPE — liquid propane can cause instant freeze burns. Never use a flame to check for leaks; LP vapor is heavier than air and can collect and ignite.