Any District – Any School

Standard Operational Procedure (SOP)

FORK LIFTS AND POWERED INDUSTRIAL TRUCKS

Implementation Date: ********* Revision Date: *************

SOP Approved by: Name/Title/ Department

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1. Purpose: This SOP complies with requirements of California Code of Regulations

Title 8, Sections 3363, 3364, 3368. This SOP is provided to each operator/trainee and
reviewed with them as part of the training program and prior to actual operation of
equipment covered by this SOP.

2. Authorized Trained Operators: Only authorized operators that have current

certificates of training on file with the DISTRICT INFORMATION shall operate the
Department’s industrial trucks/forklifts. Training shall consist of a combination of
formal instruction, i.e. lecture, discussion, interactive computer learning, videotape,
written material practical training by demonstration of a certified operator, practical
exercises and evaluation of the operator’s performance that is to be certified. Training
program content shall include the following topics: operating instructions, warnings
and precautions for the type of industrial trucks/forklifts the operator shall be
authorized to operate; forklift controls and instrumentation - where they are located,
what they do, and how they work; motor operation; steering and maneuvering in the
work place; visibility; fork and mast operations and limitations; forklift capacity; forklift
stability; daily operator inspections and maintenance requirements; recharging of
batteries; hazardous or restricted places of operation, i.e. ramps and slopes; refresher
training when operator has been observed to operate the forklift in an unsafe manner
or involved in an accident or near miss incident. All industrial trucks/forklifts operators
shall attend training prior to being assigned to forklift operator duties and become
certified at least once every three years. The certification documentation shall include
the name of the operator, date of the training, date of the evaluation and the identity of
the person(s) performing the training or evaluation.

3. Rated Capacity Requirement: Each operator shall be required to perform a daily pre-
operation check of the industrial trucks/forklifts prior to operating the equipment. The
rated capacity of the industrial trucks/forklifts must be clearly marked on the
equipment. OPERATORS SHALL NOT PICK UP A LOAD THAT IS IN EXCESS OF
THE RATED CAPACITY OF THE FORKLIFT.

Standard Operational Procedure (SOP)

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4. Pre-Operational Requirements: The following pre – operational checklist shall be
used to assure safe operation in accordance with 8CCR 3664:

 Each operator shall be required to wear a hardhat at all times during operation of the
industrial trucks/forklifts.
 The daily pre-operations check shall include the proper functioning of the tires, horn
lights, batteries, instrumentation, brakes steering mechanism, lift system of the mast
and ignition switch.
 Industrial trucks/forklifts repair operations involving open flames or which may
produce sparks or other sources of ignition shall not be performed.
 Forklifts shall be kept in a clean condition free of debris, oil and grease.
 Batteries on the forklifts shall be disconnected during repairs to the primary electrical
system unless power is necessary for testing and repair.
 Forklifts equipped with systems capable of storing residual energy, shall be safely
discharged of the energy before work on the primary electrical system begins.
 Replacement parts for the forklifts shall be equivalent in safety to the original
equipment parts.
 Extreme caution shall be exercised when servicing the batteries of the forklifts to
reduce the risk of personal injury or fire hazards and shall be conducted only in
locations designated as safe for repairs. Only persons trained in specific safety
procedures shall be allowed to perform battery charging and/or battery maintenance.
Mechanical repairs shall be done only by or under the supervision of a qualified lift
truck mechanic/technician. All unattended industrial trucks/forklifts shall be parked with
the mast at the vertical position, forks in the down position, motor off and brake set
and wheels blocked.

5. Safety Conditions: Each operator shall be required to ensure that the following
safety conditions are complied with prior to moving the industrial truck/forklift:
a) The load to be transported is safe and secure to move;
b) The path of travel and surrounding area is clear of dangerous obstacles;
c) The operator is able to look in the direction of travel. If the forward view is
obstructed, the operator shall travel with the load trailing except on steep inclines;
d) All other employees are completely clear of the path of intended travel.

6. No Riders: Each operator shall ensure that no riders are allowed on the industrial
trucks/forklifts at any time. Employees are prohibited from riding on the forks, stunt
driving and/or horseplay at all times.

7. Operator Posture: Each operator shall not place any part of their body outside the
running lines of the industrial trucks/forklifts or between the uprights of the mast or any
part of the equipment where shear or crushing hazards exist.

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 8. Fork Travel: Each operator shall ensure that the forks are always in the lowest
possible safe position when the industrial trucks/forklifts are in a traveling motion.

9. Safety of Others: Each operator shall ensure that other employees do not stand, pass
by or perform any work under the elevated portion of the load during the operation of
the industrial trucks/forklifts at any time. Operators shall ensure that other employees
are never between the industrial trucks/forklift and any fixed or solid object where they
could become trapped or crushed during operation of the equipment.

10. Tilting the Mast: Each operator shall exercise extreme caution when picking up or
depositing loads on racks or equivalent surfaces where tilting of the mast may be
required.

11. Travel Speed and Visibility: Each operator shall be required to slow down and sound
the horn where visibility is obscured or obstructed such as cross aisles, corners, and
narrow or restricted passage ways.

12. Special Conditions: Each operator shall be required to exercise extreme caution
while operating the industrial trucks/forklifts under the following conditions.
a) Operating equipment on ascending/descending inclines shall be accomplished at
the slowest and safest speed possible
b) When ascending/descending grades the industrial trucks/forklifts shall be
operated with the load on the upgrade side of the equipment
c) When carrying loads on a grade, the load shall be raised only high enough to
safely clear the road surface
d) Industrial trucks/forklifts shall never be operated on floors, platforms or other
surfaces that shall not safely support the equipment and the load
e) When industrial trucks/forklifts are operated in and around elevated docks,
platforms, or other raised surfaces, a minimum width of one of the equipment tires
shall be maintained from the edge as a safety margin to prevent a tip over hazard
from occurring during operation of the equipment.

13. Safety Intervention: Any certified industrial trucks/forklifts operator may stop another
operator for unsafe operation of the equipment under the provisions of these
procedures. District management reserves the right to amend these procedures or
provide verbal or written instructions to assure safe operation of industrial
trucks/forklifts.

14. These procedures shall be reviewed annually by the ********. A copy of these
procedures shall be conspicuously posted at the location(s) where forklift operations
are performed and where operators shall see it. These procedures shall be reviewed
and provided as a part of any operator training.

Note 1: A mandatory poster “Operating Rules for Industrial Trucks” is available at:
http://www.dir.ca.gov/dosh/dosh_publications/IndTrucks_Eng.pdf

Note 2: Appendix A: Cal-OSHA Title 8 Regulations §3668. Powered Industrial Truck Operator Training

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 Appendix A: FORK LIFTS AND POWERED INDUSTRIAL TRUCKS (SOP)

Cal-OSHA Title 8 Regulations

§3668. Powered Industrial Truck Operator Training. (http://www.dir.ca.gov/Title8/3668.html)

(a) Safe Operation.

(1) The employer shall ensure that each powered industrial truck operator is competent to operate a powered
industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in
this subsection.
(2) Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the
employer shall ensure that each operator has successfully completed the training required by this subsection,
except as permitted in subsection (e).
(b) Training program implementation. Trainees may operate a powered industrial truck only:
(1) Under the direct supervision of persons who have the knowledge, training and experience to train operators
and evaluate their competence; and
(2) Where such operation does not endanger the trainee or other employees.
(3) Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer
learning, video tape, and written material), practical training (demonstrations performed by the trainer and
practical exercises performed by the trainee) and evaluation of the operator's performance in the workplace.
(4) All operator training and evaluation shall be conducted by persons who have the knowledge, training and
experience to train powered industrial truck operators and evaluate their competence.
(c) Training program content. Powered industrial truck operators shall receive initial training in the following
topics, except in topics which the employer can demonstrate are not applicable to the safe operation of the truck
in the employer's workplace.
(1) Truck-related topics:
(A) Operating instructions, warnings, and precautions for the types of truck the operator shall be authorized to
operate;
(B) Differences between the truck and the automobile;
(C) Truck controls and instrumentation: where they are located, what they do, and how they work;
(D) Engine or motor operation;
(E) Steering and maneuvering;
(F) Visibility (including restrictions due to loading);
(G) Fork and attachment adaptation, operation, and use limitations;
(H) Vehicle capacity;
(I) Vehicle stability;
(J) Any vehicle inspection and maintenance that the operator shall be required to perform;
(K) Refueling and/or charging and recharging of batteries;
(L) Operating limitations;
(M) Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of
vehicle that the employee is being trained to operate.
(2) Workplace-related topics:
(A) Surface conditions where the vehicle shall be operated;
(B) Composition of loads to be carried and load stability;
(C) Load manipulation, stacking, and unstacking;
(D) Pedestrian traffic in areas where the vehicle shall be operated;
(E) Narrow aisles and other restricted places where the vehicle shall be operated;
(F) Hazardous (classified) locations where the vehicle shall be operated;
(G) Ramps and other sloped surfaces that could affect the vehicle's stability;
(H) Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause
a build-up of carbon monoxide or diesel exhaust;
(I) Other unique or potentially hazardous conditions in the workplace that could affect safe operation.

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§3668. (continued)

(d) Refresher training and evaluation. Refresher training, including an evaluation of the effectiveness of that
training, shall be conducted as required by subsection (d) (1) to ensure that the operator has the knowledge and
skills needed to operate the powered industrial truck safely.
(1) Refresher training in relevant topics shall be provided to the operator when:
(A) The operator has been observed to operate the vehicle in an unsafe manner;
(B) The operator has been involved in an accident or near-miss incident;
(C) The operator has received an evaluation that reveals that the operator is not operating the truck safely;
(D) The operator is assigned to drive a different type of truck; or
(E) A condition in the workplace changes in a manner that could affect safe operation of the truck.
(2) An evaluation of each powered industrial truck operator's performance shall be conducted at least once
every three years.
(e) Avoidance of duplicative training. If an operator has previously received training in a topic specified in
subsection (c) of this section, and such training is appropriate to the truck and working conditions encountered,
additional training in that topic is not required if the operator has been evaluated and found competent to
operate the truck safely.
(f) Certification. The employer shall certify that each operator has been trained and evaluated as required by this
section. The certification shall include the name of the operator, the date of the training, the date of the
evaluation, and the identity of the person(s) performing the training or evaluation.
(g) Dates. The employer shall ensure that operators of powered industrial trucks are trained, as appropriate, in
accordance with the following dates:
(1) If the employee was hired before July 15, 2000, the initial training and evaluation of that employee must be
completed by July 15, 2000;
(2) If the employee was hired after July 15, 2000, the initial training and evaluation of that employee must be
completed before the employee is assigned to operate a powered industrial truck.
EXCEPTION: Agricultural operations as defined in Section 3437 of the General Industry Safety Orders are
exempt from the requirements of Section 3668.

NOTE: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
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