Equipment

teNeed to know OSHA’s forklift refresher training requirements?

Then you’re in the right place.

Because in the article, we’ll lay out everything you need to know about them, including:

• OSHA’s 7 key forklift refresher training requirements
• The benefits of forklift refresher training
• What topics are usually covered during forklift refresher training
• How to choose a quality forklift refresher training program
• Where to find forklift refresher training courses

Let’s dive in!

What Are OSHA’s Forklift Refresher Training Requirements?

OSHA dictates that refresher training must include “an evaluation of the effectiveness of that training” and an evaluation of the operator’s performance. Per standard 1910.178(l)(4), it must also be conducted at least every 3 years. And it must be provided if any one of the following 5 situations arise:

1. The operator has been observed to operate the vehicle in an unsafe manner.
2. The operator is assigned a different type of lift truck.
3. The operator has been involved in an incident or near-miss.
4. The operator’s evaluation reveals they aren’t using proper forklift safety procedures.
5. Changes in the workplace could affect the safe operation of the forklift.

What Can “Trigger” Forklift Refresher Training?

Let’s discuss the specific scenarios that can trigger the forklift refresher training requirement.

Three Years Go By

Per the forklift refresher training OSHA standard 1910.178(l)(4)(iii), all powered industrial truck operators must be evaluated every 3 years.

That’s regardless of safety record.

In other words, even if a forklift operator has a perfect record with no accidents, near-misses, observed unsafe behavior, etc., they still must undergo refresher training every 3 years.

It should be noted that this regulation applies to all forklift operators and workers who use any forklift machine as part of their duties.

Operating in an Unsafe Manner

OSHA 1910.178(l)(4)(ii)(A) requires refresher training when the operator is not safely operating the machine.

For example, if an operator is driving a counterbalance lift truck forward with a load blocking their line of sight. Because doing so violates a key rule of safe forklift operation, the operator should undergo refresher training on effective forklift use and operation.

An Accident or Near-Miss

OSHA standard 1910.178(l)(4)(ii)(B) dictates that refresher training must happen when the operator is involved in a forklift accident or a near-miss incident.

For instance, a collision with an oncoming vehicle or pedestrian. Or a near tip-over. Technically, something as seemingly “little” as a tire coming off the ground constitutes a tip-over. This may show that the operator does not understand how to effectively operate a forklift, which requires retraining.

A Deficient Evaluation

Part of forklift operator certification requires an evaluation of the operator actually using the forklift in the workplace. If during this evaluation the evaluator observes something that indicates the operator does not understand some aspect of safe forklift operation, then the operator needs to undergo refresher training.

OSHA regulation 1910.178(l)(4)(ii)(C) states that refresher training is needed when “the operator has received an evaluation that reveals that the operator is not operating the truck safely.”

Assigned a Different Type of Fork Truck

When the operator has been assigned to drive/operate a different type of forklift truck, they need training specific to that particular truck.

For example, an operator trained and evaluated to use a sit-down counterbalanced rider will need refresher training when assigned to an operator-up counter-balanced front/side loader or a rough terrain forklift truck.

These machines have different characteristics and don’t operate the same. Conversely, the operator may not require refresher training when assigned to operate the same type of truck but from a different forklift manufacturer, unless it has sufficiently different characteristics.

Working Conditions Change

An operator needs refresher training when a condition in the workplace changes in a manner that could affect the safe operation of the truck.

For example, if the operation has been happening indoors and now the operators have to move outdoors, they may need refresher training on outdoor operations. This includes relevant topics like site inspection, machine inspection, and others.

What Can Happen If You Neglect Forklift Refresher Training

Here are some potential outcomes of neglecting forklift refresher training:

Imperiled Employees

Forklifts are powerful and complex machines that require skillful operation. Without regular refresher training, operators may forget important safety protocols and become complacent, leading to an increased risk of accidents.

Operators needed updated knowledge about safety regulations and procedures to avoid collisions, tip-overs, and other hazardous incidents. In fact, forklift accidents happen frequently. There are approximately 85 fatalities and 34,900 serious injuries every year. And many are caused by a lack of forklift safety training.

More Destruction

Besides the human costs, forklift accidents can also cause significant damage to property, infrastructure, and other equipment in the workplace. Also, inexperienced or untrained forklift operators may unknowingly misuse equipment, leading to accelerated wear and tear of forklift machines. This increases maintenance and repair costs and downtime for repairs, impacting overall productivity.

OSHA Fines

Refresher training violations remain one of the top 5 forklift-related OSHA violations. It’s considered a “serious” violation and comes with a minimum fine of $1,036 and a maximum fine of $15,625 (in 2023).

To be sure, OSHA is serious about punishing offenders.

For example, in 2018, an Ohio company received multiple citations and fines of over $69,000 after a worker died in a forklift accident. Investigation revealed that the operator had not received refresher training.

Some companies don’t realize the triggers mentioned above require immediate refresher training – even if it’s only been less than 3 years since the operator’s initial certification.

Sometimes you may perceive a near miss as “normal” at a workplace, but it’s not. It’s important to flag every unsafe incident and never allow such “gray” areas to exist in your compliance with OSHA requirements.

8 Benefits of Forklift Refresher Training

Why is forklift refresher training required?

OSHA says that the goal is “to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.”

But let’s dig a little deeper into some of the important benefits of forklift refresher training.

1. Enhanced Workplace Safety

The primary benefit of forklift refresher training is workspace safety improvements.

Training ensures that operators are up-to-date with the latest safety protocols, best practices, regulations, hazard identification, risk mitigation, and safe operating techniques.

This knowledge and awareness empower operators to take proactive steps to reduce the risk of accidents, injuries, and property damage.

2. Updated Forklift Operation Knowledge and Skills

Like any other skill, operating a lift truck requires practice and continuous learning.

Forklift refresher training is how operators can get up to speed on the latest industry standards and best practices for operating lift trucks.

This helps operators to keep up-to-date with any changes in:

• Forklift types.
• Forklift innovations.
• Parts of a forklift and their functions.
• OSHA regulations for forklifts.

3. Increased Productivity and Efficiency

Properly trained forklift operators are more proficient and efficient in their tasks, which improves productivity in the workplace.

Forklift refresher training helps operators refine their skills, learn new techniques, and become more comfortable with equipment updates or advancements.

This helps them to improve productivity and operational efficiency. This leads to smoother material handling processes, optimized workflows, reduced downtime, and increased output.

Additionally, operators who understand the latest techniques and innovations can perform tasks more effectively, minimize errors, and expedite operations.

4. Less Downtime

Forklift accidents and near-miss incidents can lead to equipment damage and unplanned downtime.

Refresher training equips operators with the knowledge to prevent common mistakes, such as collisions or improper handling, reducing the risk of equipment breakdowns. Avoiding accidents and minimizing equipment downtime, increases productivity and reduces downtime.

5. Prevents Operator Complacency

If refresher training wasn’t required, and all operators had to do was get their forklift license the one time, it would be easy to slide into a mindset of safety complacency.

Forklift refresher training serves as a safety reminder and call-to-action to renew focus on responsible lift truck usage.

6. Lower Insurance Premiums

Insurance companies may offer reduced worker’s compensation premiums when they prioritize safety and provide ongoing training to forklift operators.

By maintaining a comprehensive training program, organizations can demonstrate lower risk. This may make you eligible for lower insurance premiums and result in cost savings.

7. Lower Maintenance Costs

Operators who undergo forklift refresher training are less likely to damage forklift equipment. Considering that even a single component can cost thousands of dollars, this can help reduce maintenance and repair costs.

8. Higher Morale and Engagement

Investing demonstrates an organization’s commitment to employee safety and well-being. When workers feel valued and supported, it positively impacts morale and job satisfaction.

Trained operators are more likely to feel confident in their abilities, leading to higher engagement, motivation, and a positive work environment. This also helps improve productivity and work output.

What Topics Are Covered in Forklift Refresher Training?

Subjects that Reinforce Understanding

In an explanation letter, OSHA clarifies that refresher training should complement the initial training the operator received (under regulation 1910.178(l)(3)). In other words, refresher training should reinforce what the operator already knows. But it doesn’t necessarily mean completely retraining them.

Must Include Hands-On Evaluation

Also, keep in mind: Providing a written exam isn’t enough to constitute refresher training. OSHA makes clear that refresher training must include an evaluation of the operator actually operating the lift truck.

Ultimately at the Employer’s Discretion

The amount of refresher training needed ultimately depends on the employer’s discretion. When determining what forklift refresher topics to cover, employers should take into account specifics like:

• The operator’s skills.
• Operation requirements.
• The working environment.
• The specific attributes of the new truck.
• Any other relevant OSHA guidelines.

10 OSHA Forklift Refresher Training Examples

Here are examples of common subjects addressed during forklift operator refresher training:

Safety and Compliance

1. Safety regulations and standards. Update operators on the latest safety regulations and standards related to forklift operation. This may include understanding relevant local laws, and industry guidelines, reading forklift data plates, and compliance requirements.
2. Forklift inspection and maintenance. Review pre-operation inspection procedures to ensure the forklift is in safe working condition. How to identify and report any mechanical issues or defects promptly.
3. Review of company policies and procedures. A review of protocols related to forklift operation may also be covered in a refresher training. This ensures operators are aware of any specific rules or guidelines established by the organization.
4. Emergency situations and incident response. Include instruction on responding to emergencies or unusual situations, such as handling accidents, equipment malfunctions, power failures, evacuation procedures, fire safety, and first aid awareness.

Operational Skills and Awareness

1. Load handling and stability. Refresh operator knowledge and skills on how to assess load weight, size, and stability to determine safe lifting procedures. Topics covered include forklift load centers, proper stacking techniques, preventing load shifting, understanding load capacity limits, and handling hazardous materials or fragile loads.
2. Pedestrian safety and communication. Emphasize the importance of pedestrian safety around forklift operations. Operators learn techniques for effective communication, including horn usage, hand signals, maintaining clear lines of sight, and strategies to prevent collisions.
3. Environmental factors and special conditions. Address operating forklifts in specific environments or conditions, such as working on ramps, inclines, outdoor settings, or confined spaces.
4. Ergonomics and operator well-being. Cover ergonomic principles to minimize operator fatigue, discomfort, and injuries. Topics can include proper seating posture, seat adjustment, and techniques to reduce body strain during prolonged operation.
5.  Safe operating techniques. Topics in this area can include starting, stopping, and maneuvering the forklift, maintaining stability, positioning the forks correctly, safe forklift speed, controls, braking techniques, and turning procedures.
6. Hazard awareness and risk assessment. Emphasize identifying and mitigating hazards in the workplace. Operators learn to recognize potential risks such as uneven surfaces, pedestrian traffic, narrow aisles, or overhead obstacles.

How to Choose a Quality Forklift Refresher Training Program

When evaluating training options, it’s essential to choose a reputable and recognized training provider that can meet your specific needs.

Here are some key considerations to help you choose the right training program:

Training Program Quality

1.  Accreditation and certification. Look for a training program that is accredited by recognized organizations or regulatory bodies. Accreditation means that the training provider meets certain standards of quality and compliance and can offer certification upon completion.
2. Experienced and qualified instructors. The training program should be offered by certified, experienced, and knowledgeable instructors with expertise in forklift operations, safety regulations, and instructional techniques.
3.  Comprehensive curriculum. Review the training program’s curriculum to ensure it covers all essential and relevant topics of forklift refresher training. A well-rounded forklift refresher training curriculum will help reinforce critical skills and knowledge. The program should also be able to train and certify operators on all types and classes of forklifts.
4. Compliance with regulations. Ensure that the training program aligns with relevant safety regulations and industry standards. Verify that the program covers the necessary legal requirements and can help maintain compliance with applicable laws and regulations. Ensure the program can educate the management on regulations and standards to ensure compliance.
5. Practical training. OSHA mandates that every forklift operator receive training that includes a hands-on, practical component to demonstrate their skills. The program should include sufficient practical training sessions before evaluation.
6. Customization to workplace needs. Every workplace has unique challenges, layouts, and operational processes. Consider tailoring refresher training program to your specific workplace requirements. A quality training program should be flexible to address specific needs.

External Factors and Reputation

1. Reviews and recommendations. Research the reputation and reviews of the training program or provider. Look for feedback from other individuals or organizations who have undergone the training. Positive reviews and recommendations indicate a track record of quality and effectiveness.
2. Curriculum language. Language is an essential consideration. Verify that the program is available in a language trainees will understand.
3. Cost and value. It’s important to evaluate the training program’s cost and value proposition. Compare the fees with the quality of the program, instructor expertise, and available resources.

For questions about forklift safety, OSHA forklift training requirements, or to schedule an on-site evaluation, please contact your nearest Conger location.

Where to Find Forklift Refresher Training Courses

Here are your options for forklift refresher training courses:

Authorized Forklift Dealerships

Many material handling dealers – including Conger Industries – provide training courses, including refresher training, as part of their services. You can check with local dealers to see if they offer training programs. Try a google search for “forklift refresher training near me” and browse through the results and pick out the dealerships.

Occupational Safety Organizations

Organizations dedicated to occupational safety often offer training courses, including forklift refresher training. For example, the National Safety Council offers several safety training courses.

Community Colleges and Technical Schools

Community or technical colleges often provide industrial training programs, including forklift training or forklift refresher training. A google search of educational institutions in your area can reveal if they offer such courses.

Online Training Providers

Many online outfits have popped up in recent years offering forklift If considering this path, it’s important to ensure the course includes the topics needed to satisfy OSHA’s requirements. Also, keep in mind the hands-on evaluation. If the training is 100% online, you must ensure all operators also complete the practical portion on a real lift truck before they can be recertified.

Forklift Refresher Training Formats: Online, In-Person, and Hybrid

You can get the refresher training in 3 formats:

1. Online
2. In-person
3. Hybrid (combination of online and in-person)

Let’s discuss each in more detail.

Format 1: Online Forklift Operator Training

Many online forklift certification programs have become available in the last few years. The advantages of training courses are that they’re inexpensive, widely available, and can be conveniently completed at your own pace.

The disadvantages are that they may be varying quality, and may have little support if you have questions on the material. But their biggest downside is that many do not offer the hands-on portion of training, which is required for full OSHA compliance.

Format 2: In-Person Forklift Operator Training

It’s like a classroom lecture with an instructor, PowerPoint or projector presentation, videos, and opportunities to ask questions. Group activities are also popular. And, when you complete the in-class portion, you’ll move on to the hands-on evaluations.

This type of training is excellent for the personal attention it offers. Trainees get direct access to instructors, who can tailor the teaching to individual learning styles. Moreover, this type of training typically includes the hands-on training portion with actual forklifts. The main downsides of this training are that it’s more expensive and less widely available.

Format 3: Hybrid Forklift Operator Training

A hybrid forklift operator training model is a combination of online training and in-person training. Commonly, the online training portion covers the theory. Then the in-person portion includes the hands-on forklift evaluation.

For example, Conger offers a hybrid forklift operator training and refresher program. Training includes a 2-part blended approach. Part 1 is the classroom training portion (done online). Part 2 is the hands-on evaluation (done in person, at your facility).

Hybrid forklift operator training offers the best of both virtual and in-person training. It gives the flexibility and convenience of online training with the practical training necessary to satisfy OSHA requirements.

Common OSHA Forklift Refresher Training Requirements Questions

What Is a Forklift Refresher Course?

A forklift refresher course is a training program designed for existing forklift operators who need to update their operating skills and knowledge.

It’s a retraining program that covers relevant topics for each operator, such as load lifting, safe driving practices, pedestrian safety, and so on. The goal of the refresher training is to ensure forklift operators keep safety top-of-mind to reduce incidents in the workplace.

What Is the OSHA Standard for Forklift Training?

The OSHA standard for forklift training is outlined in 29 CFR 1910.178(I). This standard defines the key criteria required for training aspects like formal classroom instruction, practical training, evaluations, and certifications.

Who Can Train, Evaluate, and Certify Forklift Operators?

According to OSHA regulation 1910.178(l)(2)(iii), forklift operators can only be trained, evaluated, and certified by individuals who possess the “knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.”

In practice, it’s at the employer’s discretion to ensure they only select trainers that meet or exceed OSHA’s requirements. Employers should consider a combination of education, experience, certifications, and other relevant attributes when choosing their forklift operator trainers.

How Often Does OSHA Require Forklift Training?

There are no OSHA forklift refresher training annual requirements. Instead, OSHA standard 1910.178(l)(4)(iii) mandates that every forklift operator undergo refresher training and evaluation at least every 3 years. OSHA also notes 5 other behavioral and workplace circumstances that invoke the need for refresher training, even if it’s been less than 3 years.

How Long Do Forklift Certifications Last?

Per OSHA, forklift operator certification is valid for 3 years. After those 3 years, OSHA standards require that forklift operators be provided forklift refresher training.

The refresher training is also required under several other conditions, including if the operator is observed to be operating the forklift in an unsafe manner, has to drive a different forklift, or if workplace conditions change.

Do We Need to Provide Forklift Operator Training for Each Make and Model?

You don’t necessarily have to offer forklift operator training for each make or model of forklift you have. Forklift operator training is required when the type of forklift the operator will be assigned is sufficiently different from what they’ve been trained on. For example, a sit-down vs. stand-up lift truck. Or an order picker vs. pallet jack.

How Long Is a Forklift Refresher Training Course?

OSHA doesn’t give a set forklift refresher course “length.” Instead, they require that employers provide as much instruction as needed to ensure that operators possess the skills and knowledge needed to safely operate their forklifts.

Practically speaking, that may mean the refresher training can be done in a few minutes or a few hours – depending on how deficient the operator’s knowledge and skills are. However, a fully comprehensive forklift training course, including evaluation, can be completed in about 6 to 8 hours.

Conclusion

That’s it: The complete guide to OSHA’s forklift refresher training requirements.

euNeed to know about pneumatic tires for forklifts and other industrial equipment?

Then you’re in the right place because we have put together the ultimate guide!

Keep scrolling to explore everything you need to know about pneumatic tires, such as:

• What pneumatic tires are
• Their pros and cons
• The different types of pneumatic tires
• What applications pneumatic tires are good fits for
• How much do pneumatic tires cost
• And lots more! That includes checking the tires.

Let’s dive in!

What Are Pneumatic Tires?

Let’s start with a pneumatic tire definition.

Pneumatic rubber tires are the standard type of tire that people are familiar with, commonly found on your average car or truck.

But pneumatic tires are also commonly found on different types of industrial equipment, like forklifts and aerial lifts.

This article will focus on pneumatic tires for forklifts specifically.

Pneumatic tires on forklifts are suitable for operation in both indoor and outdoor environments. However, they are most effective in areas devoid of sharp objects that could puncture or deflate the tires.

Some key characteristics of pneumatic forklift truck tires are:

• Thick rubber to support the weight of the vehicle.
• Thick treads for better traction for driving and braking.
• Better traction on irregular terrain.

These characteristics determine the performance and durability of pneumatic tires.

Pneumatic Forklift Tires and Other Tire Types

There are four main forklift tire types:

1. Pneumatic tires (also called “air pneumatic”)
2. Solid pneumatic tires (sometimes referred to as “foam-filled”)
3. Cushion tires (also called “press-on”)
4. Polyurethane tires (or “poly” for short)

Let’s discuss them in detail below.

Pneumatic Forklift Tires

A pneumatic tire is just like a regular inflatable car tire. As such, they’re primarily outdoor forklift tires.

The outer tread and sidewalls of pneumatic tires contain a combination of synthetic or natural rubber, along with layers of fabric and wire. The interior of a pneumatic tire is usually empty and allows for an inner tube filled with compressed air to sit inside, keep its form, and support truck movement. The tire is attached to a metal hub linked to the axle to ensure stability and support.

The tire is filled with air to a specified pressure level based on the manufacturer’s instructions or use. The air allows the tire to handle an appropriate load and perform its function on different types of terrain.

Pneumatic forklift tires are available in various sizes tailored to different industrial machines and applications. They are the preferred tire for their rubber treads and excellent shock absorption capabilities, which aid in stabilizing the machine and minimizing bumps and jolts during use.

Cushion Forklift Tires

Cushion tires, known alternatively as press-on-tires, are solid rubber tires molded onto a thin metal (usually steel) band. The tread of cushion tires is solid rubber, offering the choice of grooved or smooth patterns.

Cushion tires are used on indoor tire forklifts, specifically designed for smooth, flat surfaces like concrete floors, making them well-suited for indoor settings like warehouses and factories. Additionally, they enable a smaller turning radius, making them ideal for maneuvering in tighter spaces.

Though designed primarily for indoor use, cushion tires are durable and allow for some light use outdoors on smooth surfaces.

Solid Pneumatic Forklift Tires

Solid pneumatic tires (also called “foam-filled” tires) are a type of pneumatic tire. But instead of the air-filled inner tube, the hollow inner side is filled with foam. Because of the foam, this tire type falls between air-filled pneumatic tires and cushion tires. The foam in solid pneumatic tires makes them solid and hardened, hence the name “solid tires.”

Many operations use foam-filled tires for heavy equipment because they cannot be deflated from punctures like air-filled tires can be. Being puncture-proof makes them excellent choices for operations with lots of sharp debris, like scrap yards, construction sites, and lumber operations.

Polyurethane Forklift Tires

Polyurethane tires are a type of press-on tire that’s lightweight and resistant to splitting, tearing, and chunking out under a load.

They combine good traction with low-rolling resistance in any operation and are durable.

Overall, polyurethane tires experience about twice the lifespan of pneumatic rubber tires and should be used indoors only for light applications like warehousing. That said, polyurethane tires are generally found on lift trucks like order pickers, pallet jacks, and reach trucks (as opposed to sit-down rider forklifts).

Non-Marking Forklift Tires

Non-marking tires are a tire type made with hydrated silicas and special additives that prevent marking the floors.

Depending on the forklift model, you can choose non-marking treads for pneumatic, solid pneumatic, or cushion tires.

Non-marking tires wear out faster than carbon-black tires and can build up static electricity, requiring an anti-static strap on the forklift to prevent discharges.

Pneumatic Forklift Tire Applications

Air-filled pneumatic tires are better suited for outdoor use where there’s less debris and fewer sharp objects to puncture or deflate. Locations like scrap yards may want to avoid using them. Extended indoor use of air-filled pneumatic tires can lead to operator discomfort due to bouncing and a generally less comfortable driving experience.

Pneumatic tires excel on rough terrains, making them ideal off-road tires for forklifts. The larger frames and flexible nature of air-filled pneumatic tires enable them to conform to irregular terrains, providing superior grip. This feature makes them well-suited for construction sites, logging areas, and lumber yards.

Solid pneumatic tires work well in applications with lots of sharp debris, scrap yards, recycling plants, and select construction sites. Their solid foam filling prevents deflation, distinguishing them from tires with air-filled inner tubes.

Air-filled pneumatic tires find common usage on sit-down style internal combustion forklifts, especially heavy-duty models.

Pros of Pneumatic Forklift Tires

Here are some advantages of pneumatic tires to consider:

• Smooth ride on uneven terrains: In outdoor environments, especially on terrains that are less than perfectly even, like gravel, pneumatic tires can make for a much smoother ride.
• Shock absorption: Pneumatic tires’ shock absorption makes them ideal for job sites with bumpy terrains or when the loads need protection from sudden shocks.
• Comfortable operation. Better shock absorption also helps provide smoother rides, less operator fatigue, and better comfort.
• Better traction for versatility: Pneumatic tires offer superior traction, making them versatile for various applications. They perform well on uneven terrain, indoors, on pavement, and off-road. Their enhanced grip provides better stability and reduces slippage on gravel, dirt, and grass surfaces.
• Less prone to damaging flooring: The nature of the softer pneumatic wheel also protects warehouse floors from scratches and other possible damage.
• Better maneuverability: The higher profile of pneumatic tires affords higher ground clearance, making them superior for operating on rough terrains like gravel.
• Less expensive: Pneumatic tires are usually cheaper than solid pneumatic or cushion tires.

Cons of Pneumatic Forklift Tires

Here are some disadvantages of pneumatic tires to consider:

• Not ideal for indoor use: Pneumatic tires may not be optimal for indoor use due to their tendency to bounce, leading to operator discomfort.
• Susceptible to deflation/puncture: Pneumatic tires can be popped by pricks from debris and sharp objects (metal, screws, nails, etc.), causing their deflation. So, if you’re in an environment liable to have those items on the ground, you may need to reconsider your selection of pneumatic tires.
• Requires air pressure maintenance:
• Pneumatic tires are susceptible to air loss through deflation or tube malfunction, necessitating regular air pressure maintenance. In contrast to solid pneumatic tires (foam-filled) or solid cushion tires, which do not lose air, pneumatic tires require monitoring of air levels and attention to valve stems.

How to Convert Pneumatic Forklift Tires to Solid

The general procedure for converting pneumatic forklift tires to solid, foam-filled tires involves:

1. Wheel Removal: Take off the wheel from the forklift.
2. Tire Cleaning: Ensure the tire’s interior is clean and free of any liquids like tire sealant or water that could interfere with foam filling.
3. Foam Filling: Inject a 2-component liquid urethane into the tire through the valve stem.
4. Sealing: Seal off the valve stem after the foam fill injection.
5. Curing: Let the tire lay flat for the liquid to solidify for the required period (24 hours to a couple of days), replacing any remaining air.

Be aware of the downsides of converting pneumatic forklift tires to solid.

For example, the curing process can take a couple of days. That means your forklift will be down and out of commission for that long. If downtime is a problem, you might want to replace your existing pneumatic tires with new solid pneumatics.

Need Help Converting Your Air Pneumatic Forklift Tires to Solid Pneumatic?

Converting forklift pneumatic tires can be challenging, so we recommend having it done by an experienced tire specialist. They possess the necessary knowledge, experience, and equipment to perform the conversion safely and effectively.

When considering converting your forklift tires, we are ready to assist you.

Where to Buy Pneumatic Tires for Forklifts and Other Industrial Equipment

Where you buy your forklift tires is as important as the tires you buy. Why?

You want to get quality and genuine tires from top forklift tire companies. You can also benefit from after-sales support, such as expert support in installation and maintenance.

So, always be careful where you get your tires. That means keeping in mind to look for vendors that:

• Have a positive reputation.
• Offer high-quality tires.
• Have tires that are compatible with your equipment.
• Offer competitive pricing.
• Have robust after-sales support.

This process ensures you get quality tires at affordable prices and benefit from any needed support for use or installation.

With that said, here are the two main ways to acquire pneumatic tires for your forklift or other industrial equipment:

1. Buy from an authorized forklift dealer
2. Buy from an E-commerce retailer

Let’s go through each option so you can make an informed decision.

1. Authorized Equipment Dealerships

You can get pneumatic tires from authorized industrial equipment dealerships (like Conger Industries).

Dealerships provide comprehensive solutions for industrial equipment needs. Purchasing from a dealership grants access to material handling experts who can assist in determining your requirements and troubleshooting any issues. By collaborating with these experts, they can facilitate the selection, ordering, installation, and ongoing maintenance of tires for your application.

Dealerships are a one-stop, turnkey solution for all your industrial equipment needs.

2. E-Commerce Retailers

You can also buy pneumatic forklift tires from online retailers. To do this, google “buy forklift tires online” and choose from the results. Once you spot a suitable retailer, you can go to the retailer’s website and buy from there.

While this avenue offers convenience, it may not always be straightforward. Especially if you’re not sure exactly what you’re looking for.

For example, minimizing overhead is the key for many online retailers to remain in business. And that may mean customer service ends up on the “chopping block.” The result? You may be on your own to figure out your forklift tire needs, make sure they’re compatible, order, install, and so on.

Contact Conger Industries for Your Pneumatic Forklift Tire Needs

Do you need pneumatic forklift tires or any other type of tire?

Grab your equipment make, model, and serial number, get a hold of us, and we’ll be happy to walk you through the process and ensure you get the right tires.

We’ll arrange a visit to your site, assemble all components, install the tires, and set up ongoing maintenance. Our tire professionals excel at delivering excellent service with minimal downtime, ensuring you’re swiftly back up and running.

Pneumatic Forklift Tire Maintenance: Everything You Need to Know

Note: Specific pneumatic tire maintenance requirements can differ from tire to tire. Always check with the tire manufacturer to determine their specific requirements. You can also get advice from tire specialists like those with Conger Industries. They can provide valuable insights and recommendations tailored to your tires.

Heavy or industrial equipment tires are expensive. To make your tires last longer, they will need regular tire maintenance.

Proper tire maintenance for industrial equipment should involve the following activities:

• Understand your tire type.
• Operator training on tire maintenance.
• Visual tire inspection.
• Check tire pressure.
• Check tread wear/depth.
• Tire rotation.
• Perform scheduled maintenance.
• Encourage good driving habits.
• Implement tire tracking practices.

Let’s look at each in more detail.

1. Understand Your Tire Type

The starting point of pneumatic tire maintenance is ensuring the correct tire type is on the right equipment. That will promote machine stability and worksite safety.

A warehouse or construction worksite is already dangerous, so ensure your forklifts have the appropriate tire type to prevent additional hazards.

Check the manufacturer’s recommendation on tire type and confirm that it should use pneumatic tires. If it should use a different tire type or has a different tire installed, contact the manufacturer or dealer and have them clarify or rectify it.

Also, avoid using different types of tires simultaneously on your industrial vehicle. It can help prolong your equipment’s life cycle and tires. And you won’t have to spend more on forklift repairs or tire maintenance.

2. Train Employees on Tire Maintenance

First, never allow workers to operate a forklift or industrial truck without OSHA-compliant training. 

Providing comprehensive training gives operators theoretical and practical knowledge of tire maintenance for operating their equipment. They will also understand how to use forklift safety tools and equipment during tire maintenance.

While operators may be familiar with car tires, industrial equipment tires are more demanding and require training and techniques.

So, before you assign your employees to carry out tire maintenance, you must ensure they understand:

• Theoretical and practical tire maintenance knowledge: You could write a manual or have a qualified mechanic demonstrate the procedure to them. Employees should know what to look for when inspecting forklift tires.
• Maintenance tools and equipment: Cover all tools used in tire maintenance.
• Tire pressure adjustment procedures: Ensure employees understand these procedures thoroughly, as they are a fundamental aspect of pneumatic tire maintenance.
• Tire maintenance safety: A tire can explode if overinflated. Employees should know safe positions for inflation that place them outside the danger zone to lower the chance of injury.

3. Conduct Regular Visual Tire Inspections

An inspection can help prevent forklift accidents and prolong the equipment’s useful life.

That includes checking the tires. OSHA notes that operators must conduct pre-operation forklift inspections “at least daily” to check “[t]ire condition and pressure including cuts and gouges.” Any deficiencies must be addressed” before operating the fork truck.

In general, the visual inspection should include:

• Tire pressure at the start of each workday. Underinflation or overinflation can lead to tire blowouts. Check for low tire pressure, which can feel like a spongy drive.
• Physical tire damage (such as cracks or punctures.)
• Sidewall integrity.
• Tire chunking.
• Worn treads (cuts and bulges.)
• Dirt or substance buildups.
• Ensure the tire nozzle is fitted and functioning. 
• Ensure that tire valve caps are securely in place.

Additionally, operators should remove from the floor any hazards (debris, potholes, liquids, etc.) that could affect the tire’s integrity before operating their lift truck.

4. Check Tire Pressure Regularly

Make sure operators check and correct pneumatic tire pressure during the inspection. Why?

There are two reasons to make sure the forklift tire pressure is correct:

1. Underinflation builds up heat, which expands the tire and can cause the tire to fail.
2. Overinflation makes tires vulnerable to impact and accelerates wear.

Proper pneumatic tire pressure can ensure optimal traction and braking capability.

Check the manufacturer’s recommendations to determine the correct pressure.

Kicking the tire to check the inflation doesn’t work. Instead, use a reliable tire pressure gauge and adjust the tire pressure as needed.

5. Check Tire Tread Wear and Depth

During pneumatic tire inspection, you should also check and measure tire tread depth depending on the pneumatic tire tread styles.

If the treads are too thin, the tire won’t provide traction.

Refer to the manufacturer’s guidelines to determine the maximum allowable wear. Once the tread reaches that point, replace the tire.

6. Ensure Consistent Tire Rotations

Regularly Rotating your forklift tires can help even out tire wear and prevent premature wear like:

• Side wear (shoulder wear on both sides).
• Center wear.
• One-sided wear.
• Diagonal wear.
• Flat spots.

7. Perform Scheduled Maintenance

Staying on top of recommended manufacturer maintenance checks to keep the tire in optimal operating condition, prevent premature failure, and reduce safety risks. Regular maintenance also helps reduce tire repair costs and ensures proper maneuverability.

Ensure your forklift maintenance schedule includes regular tire inspections and maintenance as well. If your current plan doesn’t, you may want to reach out for help maintaining your lift truck tire integrity.

8. Encourage Good Driving Habits

To keep your forklift tires functional for as long as possible, advise your operators to avoid the following driving habits:

• Ignoring maintenance.
• Neglecting tire pressure.
• Driving at top forklift speed.
• Carrying excessive loads.
• Cornering and braking instantly and harshly.
• Driving haphazardly.

Good driving and operating habits will protect your pneumatic tires longer. You can also spend less fuel and enhance vehicle and warehouse safety.

9. Implement Tire Tracking Best Practices

Lastly, since you put a lot of effort into selecting, purchasing, and maintaining tires, tracking is the best way to ensure longevity.

With tire tracking, you’ll get data to base your future tire-related decisions.,

Record each purchase, repair, maintenance, or replace a tire. Alternatively, use a tire tracker solution like GoCodes to keep these records.

If you record your tire’s purchase date, you can calculate its replacement dates based on repairs and maintenance needs.

Analyzing this tracking information can help you determine if your operators have bad driving habits or if their habits align with the manufacturer and your needs.

Tire tracking can also help you understand tire maintenance schedules based on use.

Common Pneumatic Forklift Tire Questions

What Is the Difference Between Pneumatic Tires and Regular Tires?

A “regular” tire is a pneumatic tire. Regular tires are typically air-filled, which is what “pneumatic” means.

What Is the Difference Between Pneumatic Wheels and Rubber Wheels?

When comparing solid rubber vs pneumatic wheels, “rubber wheels” generally mean the same as “cushion tires.” These are solid rubber treads that are adhered to an inner metal band.
On the other hand, pneumatic wheels are composed of an outer, relatively thin layer of rubber tread and an inner hollow core containing an air-filled inner tube. This piece of the tire is fitted around an inner metal hub and bolted to the axle.

Why Are Pneumatic Tires Used on Outside Forklifts?

Pneumatic tires have thick rubber treads to boost traction, absorb shocks, and stabilize vehicles. They grip well on uneven surfaces and rough terrain, reducing bumps and shaking. They are commonly on outdoor forklifts at construction sites, lumber yards, and outdoor warehouses.

What Are the Benefits of Pneumatic Tires?

Pneumatic tires have high shock absorption capabilities, better traction, less reduction, and more durability. Their ability to absorb the unevenness of terrain allows for a smoother ride and less bumping and shaking.

How Long Do Pneumatic Forklift Tires Last?

With regular, full-time use, forklift tires should last about a year. How long any particular tire will last depends on usage, work environment, maintenance, and driving styles.

In general, pneumatic tires tend to wear out sooner than solid pneumatic tires. Plus, they can be punctured, causing a flat tire, which will need patching and may cause quicker wear.

Do Pneumatic Tires Go Flat?

Pneumatic tires, filled with air, are prone to punctures and deflation, requiring regular air pressure checks and refills to maintain proper inflation.

Are Pneumatic Tires Puncture-Proof?

Air pneumatic tires are filled with air, making them puncture-prone. They can puncture easily from a stray nail, a pointy stone, or other objects. The solid pneumatics (foam-filled pneumatics) contain rubber-filled foam, making them more puncture-proof.

Can You Make Pneumatic Forklift Tires Solid?

It may be possible to convert air-filled tires to solid tires by filling them with a liquid that hardens inside the tire. For example, foam-filled tires are pneumatic tires filled with a liquid that hardens and replaces the air in the tire.

Do Pneumatic Tires Have Inner Tubes?

Air-filled Pneumatic tires have a separate inner tube made of rubber situated between the wheel hub and the outer tread. This inner tube is designed to hold air, much like a balloon.

Solid Pneumatic forklift tires, on the other hand, are filled with solid foam. These tires can be called “tubeless pneumatic tires.”

Do Pneumatic Tires Need Air?

Pneumatic tires, also known as “air-filled tires,” maintain their round rubber shape and structure because they air. The inside of a pneumatic tire is hollow, allowing air to sit inside and maintain its form.
But there are also foam-filled pneumatic tires (called “solid pneumatics”) that are full of foam. These tires don’t need air.

Conclusion

That’s it: Your ultimate guide to pneumatic tires!

Want to know more about forklift classes?

You’re in the right place.

Because we’ve put together the complete guide to forklift classes. You’ll learn:

• What the 7 forklift classes are
• The key characteristics of each
• The features, advantages, and benefits of each
• What applications each class is best for
• Answers to common forklift class questions

Let’s dive in!

Forklift Classes: A Complete Overview

Class I: Electric Motor Rider Trucks

Overview

Class I forklifts are electric-powered motor riders and can be either stand-on or sit-down trucks and they can have either 3 or 4 wheels.

Electric motor rider forklifts have a heavy battery that both powers the truck and also acts as a counterweight to help maintain lifting capacity. That’s why they’re called “counterbalance” forklifts.

They’re versatile and can have either cushion (solid) or pneumatic tires.  Pneumatic-tire forklifts are well-suited for outdoor settings. Whereas, cushion-tire lift trucks work best on even indoor surfaces.

Features & Benefits

• Reduced fuel costs compared to internal combustion models
• Excellent for indoor applications
• Quieter and fewer vibrations for better ergonomics
• Low maintenance costs due to fewer moving parts
• Applicable in places with strict air quality standards
• A wide variety of sizes for different applications

Applications

Class I forklift types are ideal for indoor use, especially where air quality is a concern. The following applications can be a good fit for Class I forklifts:

• General warehousing
• Cold storage warehouses
• Food, beverage, and grocery
• Medical/pharmaceuticals

Types

• 3-wheel
• 4-wheel
• Stand-up rider

Learn More

• Toyota Core Electric Forklift
• Toyota Stand-Up Electric Forklift
• CLARK 3-Wheel Electric Forklift
• CLARK 80-Volt Electric Pneumatic Forklift

Class II: Electric Motor Narrow Aisle Trucks

Overview

Class II forklifts are electric-powered motor narrow aisle forklift trucks designed to operate in tight and narrow spaces.

Class II forklifts are used indoors as side loaders or pickers to pick up, move, and deliver materials.

Some Class II forklifts may even have double-deep reach capabilities, allowing them to pick pallets from the second position in pallet racking.

Features & Benefits

• Electric motor/battery-powered
• Have solid tires (often cushion or polyurethane)
• Are designed primarily for indoor-use
• Have lower lift capacities (mostly 3,500 lbs. to 5,500 lbs.) due to their extreme lift heights
• Highly maneuverable, allowing them to operate in tight spaces and narrow aisles
• Can reach high shelves to load and unload pallets – some models can reach 40 feet
• Provide the chance to increase vertical racking space without expanding the warehouse

Applications

• General and specialty warehousing (e.g., high-volume/high-density warehouses)
• Manufacturing
• Retail

Types

There are many Class II forklift models, each with unique features. Additionally, Class II forklifts often have specialized masts or attachments to enhance their productivity and support their operations. Some models include:

• Order pickers
• Turret trucks
• Reach trucks
• Low-lift pallet jacks
• Low-lift platform trucks
• Pivoting-mast forklifts
• Side loaders
• Articulated narrow aisle forklifts

Learn More

• Combilift STE Sideloader
• Toyota Core Electric Turret Forklift
• Toyota Reach Truck
• CLARK OSX Order Picker

Class III: Electric Motor Hand Trucks or Hand/Rider Trucks

Overview

All Class III forklifts use a hand-controlled lever for steering and acceleration. In addition, Class III forklifts can be strictly walk-behind (“walkie”) models or they can be combination walk-ride models.

They’re the perfect solution for loading and unloading trailers and moving loads to staging areas. And they’re great for moving loads over short distances in narrow aisles.

Features & Benefits

• Electric/battery-powered
• Predominantly operate indoors
• Wide variety of models (walk-behind, ride-on) for greater ergonomic accommodations
• Ideal for transporting palletized loads over long distances and for stacking light loads

Applications

Class III forklifts are ideal for the following applications:

• Retail
• General warehousing
• Food and beverage

Types

There are 3 main categories of Class III forklifts:

1. Stackers
2. Pallet trucks
3. Tow tractors

These examples can be different in shape, capacity, size, or functionality based on the manufacturer.

Learn More

• Toyota Core Tow Tractor
• CLARK Electric Walkie Pallet Jack
• Toyota Center-Controlled Rider Pallet Jack
• Toyota Walkie Reach Truck
• CLARK Walkie Stacker
• CLARK End-Controlled Rider Pallet Jack
• Toyota Industrial Walkie Stacker
• Combilift CS Stacker

Class IV: Internal Combustion Engine Trucks (Cushion Tires)

Overview

The name sums up what they are: Class IV forklifts are internal combustion counterbalance lift trucks with solid (called “cushion”) tires that run on diesel, gasoline, LP gas, or compressed natural gas engines (CNG).

These are all sit-down forklifts designed for primarily indoor use on smooth, flat surfaces.

Features & Benefits

• Have solid, cushion tires designed for use on smooth, flat floors
• Cushion tires are puncture-proof since they are not air-filled and they can operate in areas with sharp debris
• Are entirely sit-down forklifts
• Are high-capacity forklifts, ranging from 3,000 lbs. to 100,000 lbs. lifting capacity
• Have internal combustion engines that run on various forklift fuel types; diesel fuel, gasoline, LPG, or CNG

Applications

Class IV forklifts are ideally suited for operation in the following areas:

• Factories
• Distribution and logistics
• Retailers
• Warehousing (large warehouse types)

Types

• Toyota paper roll special
• Toyota box car special

Learn More

• Toyota Core Internal Combustion (IC) Cushion Tire Forklift
• Toyota Large Internal Combustion (IC) Cushion Tire Forklift
• CLARK Core Internal Combustion (IC) Cushion Tire Forklift
• CLARK Large Internal Combustion (IC) Cushion Tire Forklift

Class V: Internal Combustion Engine Trucks (Pneumatic Tires)

Overview

Class V forklifts are just like Class IV forklifts, except that they have pneumatic tires instead of cushion tires.

Pneumatic tires are filled with air, like regular car tires. In other cases, they can be filled with foam, in which case they still are referred to as ‘pneumatic’ tires.

The key advantage of pneumatic tires over cushion tires is that they can work in both indoor and outdoor environments.

That said, they are generally used in mostly outdoor operations, like construction sites and lumber yards, and places that require lifting very heavy loads.

Features & Benefits

• Designed primarily for outdoor use but can be applied both indoors and outdoors
• Are entirely sit-down forklifts
• Use internal combustion (IC) engines fueled by LPG, diesel, CNG, or gasoline
• High-capacity forklifts with lifting capacities ranging from 3,000 to 125,000 pounds (or more based on model and manufacturer)

Applications

These forklifts are highly durable and can be used in a variety of settings, such as:

• Lumber yards
• Construction
• Shipyards and marinas
• Farming and agriculture

Types

• High-capacity pneumatic
• Container handlers
• Marina forklifts

Learn More

• CLARK Large Internal Combustion (IC) Pneumatic Tire Forklift
• CLARK Core Internal Combustion (IC) Pneumatic Tire Forklift
• Toyota Large Internal Combustion (IC) Pneumatic Tire Forklift
• Toyota Core Internal Combustion (IC) Pneumatic Tire Forklift

Class VI: Electric and Internal Combustion Engine Tractors

Overview

Class VI trucks are a special type of industrial truck. They are not forklifts but instead are tractors designed for pulling loads.

Ordinarily, Class VI tow tractors are sit-down style. They featured either a battery/motor or internal combustion engine powered by gasoline, LPG, or diesel.

Features & Benefits

• Pulling/tugging capacity of up to 50,000 lbs.
• Quick acceleration and relatively high top speeds
• Typically have an extremely tight turning radius

Applications

Since Class VI industrial trucks are predominantly used for towing loads rather than lifting, they’re well-suited for operations like:

• Airports
• Manufacturing assembly lines
• Large warehouses

Learn More

• Toyota Tow Tractor
• CLARK Tow Tractor
• Columbia Tow Tractor

Class VII: Rough Terrain Forklift Trucks

Overview

Rough terrain forklifts are a generic term to describe heavy-duty forklifts intended for use on unimproved terrains natural or disturbed, such as construction sites.

Most Class VII forklifts are diesel. Additionally, 4-wheel drive is common, though 2-wheel drive models also exist.

Features & Benefits

• Mostly commonly use diesel engines, for greater power and torque
• Come in various drive options (2-wheel or 4-wheel)
• Have large tractor-like tires for better maneuverability on uneven terrain
• Choice of different masts, including vertical and telescoping

Applications

• Construction
• Lumber yards
• Agriculture and farming

Types

There are 3 basic types of rough-terrain forklifts:

1. Vertical mast type: uses a straight mast for lifting loads up and down
2. Variable reach type: uses a telescoping boom for picking and placing loads at distances and heights in front of the machine (as opposed to strictly up and down as in vertical mast types)
3. Truck/trailer mounted: A portable self-propelled rough terrain forklift often transported to the job site. It is used to unload heavy items from the truck/trailer at the job site. Typically have 3 wheels and pneumatic tires

Learn More

• JLG Telehandlers
• Genie Telehandlers
• Combilift Rough Terrain (RT) Forklift

Forklift Classifications Chart

This chart breaks down all 7 forklift classes, with descriptions, examples, and applications.

Common Forklift Classes Questions

Who Came Up With “Forklift Classes”?

The Industrial Truck Association (ITA) developed the forklift class system in the 1960s and it is still in use today.  The system has been widely adopted across the industrial lift truck industry since. It helps to provide a simple identification and labeling system for the hundreds of different types of forklifts across manufacturers, regulators, dealerships, and end-users.

How Does OSHA Classify Forklifts?

OSHA uses the 7-member forklift classification system developed by the ITA to classify forklifts. It’s important to note that forklift classes aren’t an OSHA requirement. They’re simply a classification system for forklifts that OSHA adopted after its development by the ITA.

How Many Classes of Forklifts Are There?

There are 7 lift truck classes. Classes vary in terms of their design, fuel sources, intended applications, and other aspects.

What Are the 7 Classes of Forklifts?

The 7 lift truck types are:

1. Class I: Electric Motor Rider Trucks
2. Class II: Electric Motor Narrow Aisle Trucks
3. Class III: Electric Motor Hand Trucks or Hand/Rider Trucks
4. Class IV: Internal Combustion Engine Trucks (Cushion Tires)
5. Class V: Internal Combustion Engine Trucks (Pneumatic Tires)
6. Class VI: Electric and Internal Combustion Engine Tractors
7. Class VII: Rough Terrain Forklift Trucks

What Is a Class 1 Forklift?

Class I forklifts are electric/battery-powered trucks operated either from the sitting or standing position. These types of trucks are emission-free and typically used in lighter-duty, indoor environments like warehouses and distribution centers.

What Is a Class 2 Forklift?

Class II forklifts are electric/battery-powered trucks designed for use in narrow aisles. They vary widely in design, from 3-wheel to 4-wheel chassis, and sit-down and stand-up operations. They have solid tires and are used in warehouses with high-density storage.

What Is a Class 3 Forklift?

Class III forklifts are electric/battery-powered industrial trucks that are operated by a hand-manipulated control arm, either from the ground or a rider platform. They’re commonly used indoors in light-duty applications, for tasks like loading/unloading trucks, transporting materials on skids, and stacking pallets. One key advantage of Class III lift trucks is their maneuverability, making them excellent for narrow aisles and tight spaces.

What Is a Class 4 Forklift?

Class IV forklifts are internal combustion engine trucks with cushion tires designed for use on smooth, indoor surfaces. They come in a wide range of weight capacities and are typically used in warehouses, manufacturing, and retail operations.

What Is a Class 5 Forklift?

Class V forklifts are internal combustion engine trucks with pneumatic tires and designed primarily for use outdoors. They are commonly used in lumber yards, construction sites, and agricultural settings.

What Is a Class 6 Forklift?

Class VI trucks are not actually forklifts – instead, they are electric and internal combustion-powered towing tractors. These trucks are designed for moving loads horizontally, and do not feature a lifting mechanism like forklifts do. They are often used in airports, warehouses, and manufacturing facilities.

What Is a Class 7 Forklift?

Class VII forklifts are internal combustion lift trucks designed for use on rough, off-road terrains. They have large air-filled tires, powerful diesel engines, and a variety of lifting mechanisms. You can find them at work in places like construction sites, lumber yards, and agricultural settings.

How Do I Know What Class My Forklift Is?

Begin by identifying the defining characteristics that set each class of forklifts apart, to determine the appropriate class for your own forklift. For example, is it electric or internal combustion? Does it have a hand-controlled tiller arm? Does it have an upright and forks? Then compare what you have against the descriptions for each class in this article.

If you’re having trouble classifying your lift truck, contact your nearest authorized dealership for help.

What Are the Different Classes of Forklift Forks?

While forklift “class” can refer to the ITA classification, it can also refer to the fork carriage class. The carriage is the component that the forks hang on, and the distance between the top and bottom of the carriage specifies the fork class.

There are 5 total forklift fork classes. The smallest is Class 1, which provides up to 2,200 lbs. lifting capacity. The largest is Class 5, which provides up to 24,198 lbs. of lifting capacity. You can read more about forklift fork classes in our Forklift Forks article.

What’s a Tugger?

Tuggers – sometimes called “tow tractors” are industrial trucks designed for pulling instead of lifting (like forklifts). These trucks are typically used in manufacturing and distribution facilities to move carts, dollies, or other equipment around the facility. For example, some companies use them for transporting raw materials or finished products from one end of a facility to the other.

What Is Required for Class 7 Forklift Certification?

Class 7 forklifts are also known as rough terrain forklift trucks and are typically used in outdoor or off-road environments such as construction sites, lumber yards, or agricultural settings.

To obtain certification to operate a Class 7 forklift, the operator must complete specific training and meet general OSHA forklift certification requirements. These standards require that operators be trained on the specific type of forklift they’ll be using, including training specific to Class 7 forklifts.

That means employers must ensure operators are aware of the specific characteristics of class 7 forklifts and possess any/all knowledge needed to safely operate them.

Conclusion

That’s it: Forklift classes explained.

Wondering what all the forklift pros and cons are?

Whether you’re in the market for material handling equipment or just have always wondered, you’re in the right place.

Because in this post, you’ll discover:

• The advantages and disadvantages of forklifts in general
• All the great things about electric, LPG, and diesel forklifts – and the not-so-great things
• Answers to common forklift questions
• And lots more!

Let’s dive in.

General Forklift Pros

Let’s start by considering the pros and cons of all forklifts in general (compared to using manual labor or other types of material handling equipment).

Many Types to Fit Many Needs

One of the other major pros of forklift trucks is the various types available. The main types of forklifts are diesel, electric, and LPG forklifts. These forklifts have made transporting goods in warehouses, no matter how heavy or shapeless, efficient and easy. You just have to select the forklift types that fit your needs. 

Efficient

Forklifts are vastly more efficient than manual labor. They can be used in different environments, from indoor to outdoor settings making them efficient for different operations. Their efficiency can also be seen in their ability to accommodate different environments, and weights, and to work for longer hours.

Lift Heavy Weights

Forklifts can lift much greater weights than humans/manual labor. They are designed to lift, move and transport heavy loads with ease, saving time and effort. This heavy load would otherwise require several people to move. In fact, the highest capacity forklifts can lift well over 125,000 lbs.!

More Hours of Work

Forklifts can work more hours than humans, sometimes 24/7, with proper maintenance, and accommodations like battery change-overs. Working more hours means more efficiency and productivity required in a warehouse or other setting. This allows improved production or output.

Highly Customizable

Forklifts are highly versatile material handling equipment. They can be used for many purposes, in many industries, and they have lots of models and designs, attachment types, tires, and other options available. This versatility allows them to be operated in different environments and for different needs.

For instance, one option is the “cold storage” package which allows forklifts to operate in cold environments like refrigerated warehouses. This package protects sensitive components from moisture which can easily happen when switching from cold-to-ambient temperatures.

Improved Safety

Before forklifts, many factories and warehouses used pulleys and cables to move heavy materials and weighted objects. These methods had an increased risk of danger as the loads could easily cause too much tension in the cabling (causing it to snap) and could also land on employees below if not correctly fastened. Forklifts have helped improve the safety of workers in various operations.

Maneuverability

Forklifts are smaller material handling equipment, which makes them great machines for warehousing and other factory operations. They are compact enough to fit in relatively small areas such as racking isles and their size makes them easily maneuverable to turn in various directions. For instance, walkie stackers are a popular type of narrow aisle forklift.

General Forklift Cons

While forklifts are great machines, they do have some disadvantages:

High Upfront Cost

Forklifts have a relatively high upfront cost. They’re expensive, and their purchase price is only a fraction of the overall cost. Maintenance, repairs, and fuel costs add up over time.

If purchasing, there are options available to reduce this, such as leasing/renting so you can still get the job done without lots of debt. Learn more about the different forklift finance options.

Maintenance Required

When you have a forklift, ongoing maintenance and repairs are required. Maintenance costs can be high sometimes in terms of money and time. Maintenance costs money and you can incur downtime. In addition, you will need to dispose of the forklift once it has reached the end of its economic life.

Training Required

Forklifts require training and certification to operate, which is an added expense and inconvenience. Training, certification, and licensing are OSHA requirements for operating any kind of forklift.

OSHA also requires that any operator gets training for each particular forklift they operate and refresher training at least annually. Here’s a guide on how to get your forklift licensing.

Increased Danger

Forklifts can be dangerous if used incorrectly. Overall, forklifts are huge, heavy chunks of steel that can cause catastrophic damage to humans, infrastructure, and products. They must be operated under utmost care and vigilance. Examples of common forklift accidents like rollovers, pedestrian impacts, falling loads, emission poisoning, and more. 

Can’t Serve All Applications

Despite their wide versatility, forklifts are not suitable for every application. For example, extremely small spaces, steep inclines, and obstacles may prevent a forklift from being used. You need to identify the exact location fit for its operation without any risk of damage or injury. 

Emissions

Internal combustion forklifts emit fumes and noise, which can be harmful to the environment and people in the vicinity. Forklifts risk environmental impact, especially internal combustion lifts trucks emitting fumes including carbon monoxide (CO), carbon dioxide (CO2), and particulate matter (PM). 

Electric forklifts use either lead-acid or lithium-ion batteries. These power sources do not produce emissions like their internal combustion counterparts. However, the batteries themselves can be hazardous. Care must be taken when using and disposing of these items because they can become a risk to health and safety.

Electric Forklift Pros

Here are some advantages of electric forklifts over other forklifts:

No Emissions

Not producing emissions has many benefits. 

First, there’s less environmental impact, as no fumes are emitted. Second, there’s no risk to workers in the immediate vicinity, who don’t have to breathe harmful fumes. Third, it can help industries that deal with sensitive products and materials, like food processors, pharmaceuticals, and sanitary/hygiene/health care products reduce contamination.

Less Noise and Vibration

Electric forklifts produce little noise compared to LPG and diesel models. Together with no emissions, this makes them ideal for indoor operations and more friendly to employees and the environment.

Fewer Maintenance Requirements

Overall, electric forklifts have lower maintenance thanks to their lack of engine and transmission. This means they don’t require engine oil or coolant fluids, so replacing and disposing of these fluids is not necessary.

So, their only maintenance requirements extend to their battery, drive motors, and other moving components like the mast. This means fewer parts to service and replace and potentially less downtime. They also have longer maintenance intervals compared to IC forklifts giving them more uptime.

Tighter Turning Radius

Electric forklifts are better for small space/narrow aisle applications (vs. internal combustion) thanks to their tighter turning radius and greater maneuverability. They are more responsive to operator control and can help reduce damage to the workspace and products. This also allows for a more optimized warehouse and better business performance.

Better Visibility

Electric forklifts have improved rear visibility because they have no tank on the back, like in an LPG, to obstruct the operator’s view. The battery sits beneath the operator’s seat and acts as the forklift counterweight. This limits interference in the operator’s visibility and improves safety.

Electric Forklift Cons

Here are some disadvantages of electric forklifts:

Higher Upfront Costs

Electric forklifts have higher upfront costs than IC forklifts. This higher investment includes the forklift’s chassis, battery, and charger. However, their operational costs decrease over time compared to those of internal combustion forklifts (because less maintenance is required).

Electric forklifts also require battery charging stations to be installed, which increases initial costs. 

Batteries Wear Out

Electric forklift batteries eventually wear out, especially lead-acid batteries. They are typically designed to last 1,500 charge cycles or about 3 to 5 years. On the other hand, lithium-ion batteries may be able to last as much as 5X as long as lead-acid batteries.

Limited Run Time

Electric forklifts have a limited run time and require a battery recharge, which can take several hours. But this depends on the type of battery and needed charging infrastructure.

Traditional lead-acid batteries require longer charging and cooling cycles (8 hrs. to charge, 8 hrs. to cool), and are only ideal for single-shift operations. Lithium-ion batteries, however, can charge in as little as 1 hour, allowing their use in multi-shift operations. 

Only Select Models Are Suited for Outdoor Use

Unless specially protected, electronic components are susceptible to damage from condensation that occurs during temperature changes. Especially with electric forklifts, since they have even more electrical components than their internal combustion counterparts.

In wet environments, damage to electric lift trucks may also occur. Using a sealed battery along special chassis options can mitigate this risk. Generally electric forklifts aren’t designed for outdoor usage, but some like Toyota’s 80-volt electric pneumatic forklift are.

Propane Forklift Pros

Here are some of the key advantages of propane forklifts: 

Higher Lifting Capacity

Propane forklifts have a higher lifting capacity and can handle heavy loads compared to electric forklifts. This makes them ideal for heavier lifting operations where electric forklifts might not reach them.

Cost-Effective

Propane forklifts have a lower initial investment compared to electric. Also, they’re cost-effective in operations and don’t need much maintenance because of the few moving parts. However, compared to electric forklifts, propane forklifts can have higher overall operating cost because of more maintenance requirements as well as needing to buy propane fuel continuously.

Better Operational Flexibility

Propane forklifts offer the advantage of usability in a greater variety of environments and operations than electrics do. For one, propane forklifts are versatile and can operate in both indoor and outdoor settings. Overall, propane forklifts are suitable for indoor applications except if there are food, beverage, or other anti-product contamination requirements.

More Consistent Power

Compared to lead-acid electric forklifts, propane forklifts offer consistent power. There’s no need to swap batteries for continuous use making them better than most electric forklifts in high/constant-duty applications. Also, there’s little risk associated with running out of fuel other than the inconvenience of having to change propane cylinders. 

More Familiar

Experienced forklift operators may be more familiar/less resistant to propane compared to electric forklifts, which carry some negative connotations among operators. They offer familiarity with use and operations.

Propane Forklift Cons

Here are some disadvantages of propane forklifts.

Emissions

Propane forklifts produce emissions and require ventilation in indoor settings. While their emissions are not as bad as diesel or gasoline, they’re not emission-free like electric forklifts.

Shorter Lifespans

Propane forklifts have a shorter lifespan compared to electric forklifts. Their lifespan gives them a disadvantage in terms of the longer economic life that most electric forklifts enjoy. For example, LPG forklifts can last 10,000 hours or more, while electrics can last far beyond that – in some cases up to 50,000 hours!

More Maintenance Required

Propane forklifts may require more frequent maintenance compared to electric forklifts. This includes changing the engine oil, transmission fluid, radiator coolant, and air filters – components not present on electric fork trucks. Maintenance and repairs can be expensive and may result in higher costs and possible downtime.

Hazardous Fuel

Propane forklifts present more hazards to employees. Changing the propane tanks exposes workers to “cold burns” due to the low temperature of liquid propane. Also, heavy tanks can injure workers attempting to lift them. There’s also a liability exposure in the form of possible leakage of the fuel system.  It is essential to train operators in the safe handling of propane fuel.

Less Maneuverable

One key disadvantage of propane forklifts is their little maneuverability. They have a larger turning radius than electric forklifts, making them less maneuverable in tight spaces. In addition, the rearward visibility of propane forklifts is restricted due to the location of the propane tank. This decreases the overall visibility during operations. 

Diesel Forklift Pros

Here are some diesel forklift advantages to consider:

Highly-Durable

Diesel forklifts are made with robust parts to withstand the extreme forces generated by diesel engines. This can allow them to have more staying power when put against tough operating conditions and heavy weights.

High Lifting Capacity

Diesel forklifts have more power and a higher lifting capacity than other fuel types, making them suitable for heavy-duty applications. Their engines provide higher torque, which translates to better lifting and travel speed and power.

This makes diesel forklifts suitable for off-road and outdoor conditions, such as in construction, agriculture, utilities, and oil/gas industries. They’re versatile and withstand extreme operating situations.

Easier Refueling

Diesel forklifts operate efficiently and require less time for refueling compared to electric forklifts. All you have to do is open the fuel tank and fill in diesel into the tank and you’re good to go. Also, there’s no need to deal with heavy, cumbersome LPG tanks.

Diesel Forklift Cons

The following are key diesel forklift disadvantages:

Costly

Diesel forklifts are more expensive upfront than LPG trucks, although they’re often less costly than electric ones. This makes their initial cost something to consider.

Pollution

Diesel forklifts have a negative environmental impact due to diesel emissions. Their environmental impact is worse than LPG and can contain high levels of particulate matter (PM). This makes them unusable indoors.

Noisy

One key diesel forklift disadvantage is their noisier/more vibrations, especially compared to electric forklifts and LPG forklifts. This makes them less ideal for use indoors where noise/vibration is a concern.

Common Forklift Comparison Questions

What Are the Different Types of Forklifts and What Are They Used For?

There are different types of forklifts out there, under different classifications that determine their use. Here are the many forklift types based on OSHA classification:

• Class I: Electric motor rider trucks. Examples are riders (3-wheel & 4-wheel), counterbalance riders, etc. They’re mostly used for indoor applications and warehouse operations.
• Class II: Electric motor narrow aisle trucks. Examples are order pickers, reach trucks, articulated forklifts, and pivoting-mast forklifts. They help put and retrieve pallets from higher places.
• Class III: Electric motor hand trucks or hand/rider trucks. Examples are material lifts, electric walkie pallet jacks, walkie/rider pallet jacks, and more. They’re used for light-duty warehouse operations such as carrying and transporting smaller and simpler loads/pallets.
• Class IV: Internal combustion engine trucks (solid/cushion tires). These are larger internal combustion (propane/LPG) forklifts for all activities in the warehouse and production lines. They can work indoors or outdoors and are popular for their versatility. Their capacity begins from 3,500 lbs. to 110,000 lbs. (high capacity). 
• Class V: Internal combustion engine trucks (pneumatic tires). IC pneumatic forklifts are suitable for rough terrain and outdoor work environments with heavy lifting capabilities. Their capacities range from 3,500 lbs. to high capacity, one of up to 125, 000 lbs. Examples are yard trucks, marina forklifts, container handlers, etc.
• Class VII: Rough terrain forklift trucks. These forklifts are designed for use on unimproved natural terrain or disturbed environments, such as construction sites. Examples are telehandlers and off-road forklifts.

How Much Does a Forklift Cost?

On average, a new forklift can cost anywhere between $15,000 to $50,000. Used forklifts can be a more cost-effective option, with prices ranging from $5,000 to $25,000. Electric forklift prices tend to be higher compared to propane and LPG forklifts.

Just be aware that forklift prices can vary widely by condition, model/capacity, fuel type, options/accessories, geographic location, and many other factors.

What Are the Advantages of a Forklift?

Forklift machines have many advantages. They’re efficient, versatile, and can lift heavy loads with ease. They save time and effort, making them valuable assets in many industries. Forklifts can also be customized with various attachments, such as clamps, forks, and booms, making them even more versatile.

What Are the Disadvantages of a Forklift?

There are various forklift disadvantages. Forklifts are expensive to purchase and maintain and require regular servicing and repairs. They can also be hazardous if not operated correctly, leading to accidents and injuries. Internal combustion forklifts emit fumes and noise, which can be harmful to the environment and people in the vicinity.

How Often Should a Forklift Be Serviced and Maintained?

How often a forklift should be serviced and maintained depends on the type of forklift and use.

• If it’s an internal combustion forklift, servicing and maintenance are generally every 200 hours.
• If it’s an electric forklift, servicing, and maintenance are generally every 500 hours.

Forklift servicing and maintenance depend on the attributes of the forklift such as the fuel type, the usage environment, existing condition, previous maintenance practices, and other factors listed in our forklift maintenance issues guide. This may mean you need to service the lift truck sooner than the general guidelines. During forklift servicing, always follow the manufacturer’s guidelines.

What Is the Lifespan of a Forklift?

The lifespan of a forklift (i.e., the “useful life”) depends on several factors, including the type, usage, maintenance, and other factors. On average, a forklift can last anywhere between 8 to 12 years (or 10,000 hours), with proper maintenance and care. This forklift useful life guide will help you understand how long your forklift can last. 

What Is the Risk of Working with a Forklift?

Working with forklifts can be hazardous if not operated correctly. Common risks include collisions, tipping over, and falling loads. There’s also the risk of acid spill from forklift batteries and ingesting the fumes from the acid exhaust which is an environmental risk.

Our guide on forklift accidents can help you understand more risks. Following proper safety procedures and receiving adequate training before operating a forklift is important. Also, learn here about the health risks of forklift operators.

What Safety Precautions Should Be Taken When Operating a Forklift?

OSHA provides the safety precautions that should be undertaken when operating a forklift. Here are some important ones: 

• Only trained and certified operators may operate a forklift.
• Always operate a forklift machine according to the manufacturer’s instructions.
• Forklifts should be serviced and maintained regularly to ensure they operate efficiently and safely. More frequent servicing may be required for heavy usage or harsh environments.
• Always wear a seatbelt when operating a forklift.
• Never exceed the rated load and ensure the machine is stable and balanced. 
• Keep a safe distance from the platform and ramp edges.
• Have clear visibility of the work area and ensure enough clearance when raising, loading, and operating a forklift. 
• Watch for pedestrians and observe the speed limit. 
• Ensure operators are trained on the types of trucks in use.
• Repair and maintain the forklift according to the manufacturer’s recommendations.

What Kind of Training Is Required to Operate a Forklift?

Operators of forklifts are required to receive proper training and certification before operating a forklift. This includes classroom instruction and practical (hands-on) training on operating a forklift safely, followed by certification (from the employer) of the operator’s suitability to operate in workplace conditions. This forklift license guide can help you learn where, how, and when to get forklift training and a license.  

What Is a Better Alternative to a Forklift?

Depending on the application, there may be better alternatives to forklifts, such as conveyor systems, pallet jacks, tow tractors, or automated guided vehicles. These alternatives may be more cost-effective, efficient, and safer, depending on the specific needs of the operation. The better alternative to a forklift is one that effectively supports your operational needs.

How Do I Choose the Right Forklift for My Business Needs?

Budget

Decide if buying, leasing, or renting is best. You will also consider ongoing/deferred costs like fuel, maintenance, and eventual disposal.

Application and operating environment.

Consider where your forklift will operate – indoors, outdoors, or both; extreme hot or cold; uneven terrain; narrow aisles or tight spaces. This will dictate the type and model of forklift you choose. 

Type of forklift.

Based on the application you will select the forklift that fits your needs. Examples are electric or hand pallet jacks, stackers, pickers, counterbalance, reach trucks, turret trucks, articulated forklifts, diesel forklifts, etc.

Operator safety and comfort.

What features are available to protect operators, or which ones do you need for the operator? For example, Toyota’s System of Active Stability (SAS) automatically counteracts sudden movements to enhance stability and prevent tip-overs. Check if operators will be working long shifts and select a forklift that can support them.

Load characteristics.

Load weights and sizes of the load you’re handling determine the forklift you choose. Diesel forklifts are ideal for very heavy and/or oversized loads. If your loads have unusual shapes that require a special attachment, consider a forklift that can support them.

Lift heights are needed.

The “standard” lift height of a forklift is about 15 1/2 feet. Check if you need to reach heights higher than that and select one that fits or exceeds it. 

Training.

Every operator needs the training to operate a particular forklift. If you invest in the least amount of forklift operator training, you end up paying the most in the long run – in terms of operating costs and accidents. Ensure the forklift comes with available operator training to avoid such costs.

Special considerations.

Consider special needs such as environmental pollution or health issues. If medical, you may be limited to electricity to exclude the possibility of emissions.

If you need help choosing the right forklift for your business, contact Conger Industries today. Our expert Solutions Engineers are ready to assist you!

Conclusion

There you have it: all the pros and cons of forklifts.

If you’re looking to understand more about forklift lockout/tagout, you’re in the right place.

Because we’ve put together the ultimate guide!

Here’s what you can expect to learn:

• What exactly ‘lockout/tagout’ means
• What OSHA’s rules are for locking/tagging out forklifts
• How to lockout/tagout a forklift
• Common forklift lockout/tagout mistakes to avoid
• A simple forklift lockout/tagout checklist
• And lots more…

Let’s dive in!

What Is Forklift Lockout/Tagout?

Lockout/tagout (often abbreviated as ‘LOTO’) is a safety procedure used to ensure that forklifts and other equipment are properly rendered unusable before repairs or maintenance commence on them.

In practice, the LOTO procedure helps ensure that the lift truck is not accidentally started up while maintenance or repairs are being carried out. This could cause a major forklift accident, including loss of limb and life.

When Does Forklift Lockout/Tagout Apply?

Lockout/tagout procedures apply in the following circumstances:

• When workers face the potential danger of an unplanned machine startup or the release of stored energy when performing equipment maintenance and service.
• When operators must bypass or remove a guard or safety device.
• When operators need to place any part of their body into the danger zone or near the forklift machine’s point of operation.
• During all forklift set-up activities.

OSHA’s Lockout/Tagout Requirements

OSHA Title 29 CFR defines the lockout/tagout standards for all equipment, including forklifts.

These procedures are designed to protect workers from the startup of the machine or sudden release of energy during servicing and maintenance.

OSHA Title 29 CFR 1910.147 establishes the minimum performance requirements employers must do to control such hazardous energy. These include:

1. Energy control program. Develop, implement, and enforce an energy control program, employee training, and periodic inspections to ensure that before any servicing or maintenance on a forklift or equipment, it’s rendered inoperative.
2. Lockout/tagout. Use lockout devices for forklifts (one that can be locked out). Tagout devices should only be used in conjunction with lockout devices if the tagout program offers the same level of worker protection as a lockout program.
3. Employee protection. Ensure that new or overhauled equipment can be locked out.
4. Tagout program. Develop, implement, and enforce a clear tagout program if forklifts/ equipment cannot be locked out.
5. Energy control procedure. Create, document, implement, and enforce effective energy control procedures [with exceptions provided in 29 CFR 1910.147(c)(4)(i)]
6. Forklift-authorized lockout/tagout devices. Only use lockout/tagout devices that are approved for the equipment in question, and that meet the requirements of being durable, standardized, and robust.
7. Identify users. Ensure that lockout/tagout devices identify the individual users.
8. Lockout/tagout application and removal policy. Develop a lockout/tagout policy that authorizes the removal of devices solely by the worker who installed them, to maintain control over the equipment.
9. LOTO inspection. Inspect energy control procedures at least annually.
10. LOTO training. Provide effective LOTO training as mandated for all workers, who are involved in LOTO as covered by the standard.
11. Compliance. Comply with all other additional energy control provisions in the OSHA standards. This includes group lockout situations when the forklift equipment must be tested or repositioned, when outside contractors work at the site, and during personnel/shift changes.

What Is Part of a Proper Forklift Lockout/Tagout Program?

Note: Employers should consult the OSHA standards and other relevant resources to ensure that their program meets all applicable requirements.

A forklift lockout/tagout program has to have 3 core components at a minimum to be compliant with the Occupational Safety and Health Administration’s (OSHA) standards:

1. Lockout/tagout procedures
2. Periodic inspections
3. Training provisions

1. Forklift Lockout/Tagout Procedures

Forklift lockout/tagout procedures are the steps involved to ensure the machine is disabled and energy flow stopped for operators’ safety when the forklift is under maintenance/repair.

OSHA requires any facility with forklifts to have a forklift lockout/tagout procedure in place.

When done correctly, a lockout/tagout procedure disables powered forklifts from releasing hazardous energy or starting unexpectedly during servicing/maintenance activities.

A lockout/tagout procedure must include at least the following:

• A statement of the specific intended use of the procedure
• Steps for powering down and securing the forklift.
• Steps for placing, removing, and transferring the lockout/tagout devices
• Authorization or description of persons responsible for lockout/tagout devices and processes.
• A description of the specific requirements for testing the forklift to verify the lockout/tagout devices’ effectiveness.

2. Periodic Lockout/Tagout Inspections

Lockout/tagout inspections must be conducted at least annually. Only a safety supervisor or authorized employee can conduct a LOTO inspection. And, the authorized employee must NOT have been involved in the lockout/tagout procedure being inspected.

To conduct a successful LOTO inspection, the safety supervisor or authorized employee is required to do the following:

1. Identify the equipment or isolation point that the LOTO procedure is for.
2. Specify the date (and time) of the workers included in the LOTO inspection.
3. Check the forklift lockout/tagout log book and dates.
4. Correct any gaps or shortcomings in the LOTO program.
5. Review the responsibilities of authorized and affected workers for lockout, tagout, and training.
6. Sign and add their name to verify that they’ve conducted the LOTO inspection.

3. Lockout/Tagout Training

There is no specific OSHA requirement that employees trained in lockout/tagout procedures must be formally ‘certified’ to do so.

Instead, what is required is employees be trained so that they understand “the purpose and function of the energy control program” and that each employee has “the knowledge and skills required for the safe application, usage, and removal of the energy controls…”

Just as there are different levels of access for lockout/tagout, there are also different training levels for each type of access:

• Authorized employees. Training includes hazardous energy sources, hazardous energy types and magnitudes, forklift lockout devices, and energy isolation/control methods.
• Affected employees. Training includes the purpose and use of LOTO procedures.
• Other employees. For workers who are or could be in the LOTO area during the procedure, training includes prohibition rules on restarting the locked-out equipment. This helps ensure they maintain operator and pedestrian safety in the facility.

What a Forklift Lockout/Tagout Procedure Looks Like

There’s no one-size-fits-all forklift lockout/tagout procedure. Every operation must develop their own guidelines that suit their particular equipment, workflows, and so on. That said, this section will give you an idea of some common activities involved in forklift lockout/tagout procedures: 

• Provide training to all employees with proper LOTO procedures so they familiarize themselves with the procedure.
• Prepare for the shutdown. Identify and isolate the forklift to be locked out and tagged out.
• Install a locking device approved for the particular forklift to ensure it can’t be powered on.
• Shut down the unit.
• Isolate the lift truck from its energy source(s)
• Attach a locked box to the forklift.
• Place a red and white warning tag on the steering wheel. The tag should include detailed information about why the forklift is locked out.
• Attach the lockout or tagout device(s) where energy must be isolated. This helps prevent energy activation of the forklift trucks.
• Any potentially hazardous stored or residual energy must be released, restrained, or rendered safe, which may include removing the key.
• Cordon off the lockout/tagout area. Keep employees and staff at a safe distance away from the forklift during the procedure.
• Search the lockout/tagout area for potential hazards, including flammable materials, and remove them. This includes the LPG tank, if applicable.
• Establish and enforce a policy stating that only the employee who installed the LOTO can remove it once the equipment is no longer considered a threat.
• Have a procedure for work resumption. Once it’s safe to resume operating the forklift/equipment, remove LOTO devices and advise staff that the threat is over.

How to Lockout/Tagout a Forklift

Note: What follows is a lockout/tagout procedure example for material handling equipment. The exact procedure requirements can change depending on the specific equipment involved. Consult your owner’s manual for specifics on the recommended lockout/tagout procedure.

Step 1: Detail your procedure to staff and operators in full, including location.

Step 2: Notify all affected associates. Before starting the lockout/tagout procedure, communicate to ALL impacted associates that a lockout/tagout is about to begin.

Step 3. Prepare to shut down:

1. Identify and isolate the forklift to be locked out and tagged out.
2. Familiarize yourself with the type and strength of energy, the hazards posed by the energy to be controlled, and the methods of energy control.
3. Look for and remove any flammable materials and other potential hazards in the lockout/tagout area.
4. Check and ensure lockout/tagout kits for forklifts are in place.

Step 4: Shut down your forklift, following detailed shutdown procedures provided by the manufacturer. For example, turn off the ignition, remove the key, and ensure that the forklift is completely stationary.

Step 5: Lock out the power sources. Use a lockout box or other energy-isolating device to interrupt energy output. If the forklift is battery-powered, remove the battery and lock it out. If it is gas-powered, turn off the fuel supply and lock it out.

Step 6: Eliminate residual energy sources. Follow procedures to eliminate any residual energy sources. Any residual or stored energy that could pose a risk must be dissipated, secured, or eliminated.

Step 7: Test the forklift. You can attempt to start the forklift/equipment to make sure it will not start under any circumstance. If there is a possibility of reaccumulating of energy to a hazardous level, continue verifying isolation until servicing is finished.

Step 8: Tag out the forklift: Use a tag to indicate that the forklift is undergoing lockout/tagout procedures. The tag should include the date, time, and name of the employee who is performing the lockout/tagout.

Step 9: Perform maintenance.  Continue with the forklift repair or maintenance as required.

Step 10: Communicate to shifts. Make sure to communicate the breakdown across shifts to ensure no employee is out of knowledge.

Step 11. Clean up the lockout/tagout area:

1. Remove non-essential items such as parts, tools, etc.
2. Counter-check if all equipment components are operationally intact.
3. Counter-check if all staff are in safe positions or have cleared the area.
4. Notify all affected workers that the lockout/tagout devices will be removed.

Step 12: Remove the lockout/tagout devices. Only the person who attached the devices should remove them. If not, do not attempt removal and notify the warehouse safety supervisor.

Step 13. Resume work. Once the lockout/tagout is complete:

1. Put affected employees on notice that the lift truck will be re-energized.
2. Restore energy to the equipment.
3. Begin equipment startup.
4. Reintegrate equipment into operation.

6 Common Forklift Lockout/Tagout Mistakes

1. Only Removing the Key

Simply removing the forklift key does not constitute locking it out and neither does use an interlock device.

You must fully disconnect and discharge the energy source. The lift truck must be properly shut down to ensure that no energy sources are active.

Failure to correctly lockout and discharge the forklift can cause serious injury to operators and technicians.

2. “Setting and Forgetting”

Inspecting and assessing your lockout/tagout procedure is mandatory, and at least once a year.

Conduct an inspection, and during that time ask for input from your staff. Ensure you update your documentation/retrain as necessary.

3. Not Keeping Employees in the Loop

You must notify all relevant employees of the lockout/tagout procedure or schedule.

Also, ensure all employees are trained to recognize hazardous energy sources, lockout/tagout procedures, and know where to find them.

OSHA requires that you document this training, ensuring that team members know where/who to go to for reference.

You also need to schedule periodic retraining.

4. Not Tagging Machinery with a Lockout/Tagout Tag

The tag is necessary to indicate that the machinery is undergoing lockout/tagout procedures. Otherwise, unknowing employees may walk into the lockout/tagout area and risk exposure to hazards and unsafe situations.

5. Failing to Lock Out All Energy Sources

It is important to ensure that all energy sources are locked out to prevent any accidental start-up.

This can include the LPG tank for propane forklifts. Or the battery with electric forklifts. Test them to make sure they’re locked out and can’t release any energy.

6. Removing Lockout/Tagout Devices Before Work Is Complete

All lockout/tagout devices must remain in place until work is completed and the machinery is tested. Recall that the person who locked/tagged the forklift out is the only person who can remove the locking devices.

The Top 5 OSHA Lockout/Tagout Violations

The lockout/tagout standard (OSHA Control of Hazardous Energy 29 CFR 1910.147) is the fourth-most-commonly cited OSHA standard.

It is one of OSHA’s persistent inspection priorities and is punishable by fines. For example, a single violation can result in a fine of $15,625!

Top OSHA lockout/tagout violations include:

1. Failing to Have Equipment-Specific Lockout/Tagout Procedures

This is OSHA requirement 29 CFR 1910.147(c)(4) and a common citation.

Machines or equipment that can create a hazard during servicing or maintenance if they start up or cycle unexpectedly, or release stored energy, must have a document lockout/tagout procedure.

The procedure addresses how to control each type of hazardous energy associated with the machine. It also specifics how a worker can safely lock out those power sources.

Maintaining only a generic lockout/tagout procedure on file may be considered a violation by regulatory agencies.

2. Failing to Train Workers in Lockout/Tagout

This is OSHA requirement 1910.147(c)(7).

To ensure compliance with safety regulations, employers must train workers on the purpose and function of the lockout/tagout program. They must also equip employees with the necessary knowledge and skills to understand the program.

Employees fall into three different categories for training:

• Authorized employees. Persons who actually perform servicing and maintenance on locked-out equipment. Their training ensures they recognize the types of hazardous energy sources that exist in the workplace, and know how to isolate and control them.
• Affected employees. These are operators of the forklift that is being serviced or workers in an area where equipment is being serviced. Their training ensures they understand lockout/tagout and know not to interfere or place themselves in danger.
• All other employees. This includes all workers in a workplace where energy control procedures are used. They need a basic understanding of lockout/tagout, and the importance of not attempting to restart or re-energize the forklift under locked/tagged out.

3. Failing to Establish a Lockout/Tagout Program

OSHA requires that you establish a lockout/tagout program. [1910.147(c)(1)]

You need a written program that covers training, your energy control procedures, and periodic inspections. Sometimes employers neglect to create an entire written lockout/tagout program. Other times they just omit certain required elements. Both scenarios can result in a violation.

4. Failing to Follow the Proper Sequence of Lockout/Tagout

OSHA, under requirement 1910.147(d), requires that written procedures for lockout/tagout have certain elements, including:

• Specific shutdown procedures and preparation for shutdown
• Apply energy-isolating devices
• Apply locks or tags to energy-isolating devices
• Verification of isolation
• Procedures for release or restraint of stored energy
• Release from lockout or tagout
• Removal of lockout/tagout devices

Employers must ensure that workers follow these steps whenever performing lockout/tagout operations. Otherwise, it’s a risk of violation, especially if an incident occurs and an investigation reveals that the procedure wasn’t followed.

5. Failing to Protect Workers During Group Lockout/Tagout Operations

The rules for group lockout/tagout, in OSHA requirement 1910.147(f)(3), sometimes trip up employers.

When more than one person is involved in a lockout/tagout operation, all workers must “affix a personal lockout or tagout device” to the group lockout device.

Failing to make it possible for workers to successfully conduct group lockout/tagout is a violation.

Forklift Lockout/Tagout Checklist

Forklift lockout/tagout procedures can vary depending on the industry or type of equipment. That said, key sections of a forklift lockout/tagout checklist include:

1. Equipment Information

Machine information identifies the following:

• The forklift equipment that will be shut down for a lockout/tagout procedure and record the purpose of the procedure such as servicing, maintenance, or repair.
• The energy sources could cause harm if not isolated. Energy sources include electrical, mechanical, hydraulic, thermal, pneumatic, and chemical sources.

2. Area Inspection

A checklist must identify the area of inspection with the following information:

• Check that the area surrounding the forklift has no items that could pose a risk to the workers during the maintenance/servicing.
• Workers who won’t be working on the maintenance/servicing are clear of the area.

3. Employees

Employers have a role to employees as follows:

• Notify employees and make them aware of their responsibilities during the LOTO procedure and forklift maintenance/servicing.
• Inform workers that the forklift is about to be serviced/maintained and that there will be a lockout/tagout procedure.

4. Preparing Lockout/Tagout Devices

• Ensure that the proper, authorized, forklift-specific LOTO devices are available.
• Identify and record the responsible persons who will apply the devices.
• Ensure they’re trained and have the skills to operate the LOTO devices.

5. Applying Lockout/Tagout Devices

• Identify all sources of energy (primary and possibly secondary) and de-energize them.
• Isolate all sources of power before applying the LOTO devices properly to each energy-isolating device.
• Lock out the forklift machine, verify shut off, and ensure that workers know that it is out of service during lockout/tagout.

6. Removing Lockout/Tagout Devices

• Clear the lockout/tagout area, including the tools, and place back machine guarding equipment.
• Ensure the LOTO devices are removed by the same person who applied them.
• Restore energy to the forklift.
• Inform all the affected workers that the forklift is back in operation.

Common Forklift Lockout/Tagout Questions

What Does Lockout/Tagout Mean?

Lockout Tagout (LOTO) is a safety procedure used to ensure that machinery – including forklifts – is properly shut off and cannot be restarted while maintenance or servicing is being performed.

In the LOTO procedure a lockout device, such as a padlock, secures the energy isolating device to prevent the release of hazardous energy while a tagout device (i.e., a tag) warns employees not to use the equipment.

What is the Difference Between Lockout and Tagout?

Lockout meaning: Lockout involves physically disabling the energy source of a machine like a forklift that prevents energy release.

Tagout meaning: Tagout involves placing a tag, a switch, or another shut-off device on the forklift to indicate that it should not be operated.

Lockout is more secure because it prevents anyone from accidentally turning the machine on while maintenance or servicing is being performed.

What Are the Color Codes for Lockout/Tagout?

Lockout/tagout devices should be easily recognizable and clearly labeled. OSHA’s recommended color codes for lockout/tagout are:

• Red = Stop
• Yellow = Caution
• Orange = Warning
• Fluorescent orange or orange-red = Biological Hazard
• Green = Safety

Do Forklifts Need Lockout/Tagout?

Forklifts require lockout/tagout procedures when under maintenance or servicing. This helps prevent the release of hazardous energy that could cause injury or damage to the equipment.

Where Should Lockout Tags for Forklifts Be Placed?

Lockout tags should be placed on the energy-isolating device(s) that have been locked out so that the equipment controls cannot be activated until the lockout device is removed. That includes the forklift’s control levers, steering wheel, or other critical components that are necessary for operation. 

They should be clearly visible, easily recognizable, and contain the necessary information, such as the reason for the lockout/tagout, the name of the worker/technician who applied the lock/tag, and the date and time of the lockout/tagout.

What Is the Lockout/Tagout Forklift Battery Procedure?

To lockout/tagout a forklift battery, the following steps should be taken:

1. Turn off the forklift: Make sure that the forklift is completely shut down before attempting to disconnect the battery.
2. Remove the key: This will prevent the forklift from being started accidentally.
3. Disconnect the battery: Disconnect all electrical cables between the battery and the lift truck chassis.
4. Lock out the battery: Use a lockout device to prevent the battery from being reconnected. The lockout device key should be kept by the person performing the lockout/tagout.

Watch this YouTube video to see how a forklift battery lockout procedure is done: Brady BatteryBlock Power Connector Lockout | How To Install

Does Removing a Key ‘Lock Out’ a Forklift?

Simply removing the key from a forklift does not lock out the equipment. The forklift will still be connected to the power source, whether it’s powered by an LPG tank or a battery. And since the hazardous energy isn’t isolated, it can cause an unexpected energy release, risking both operators and technicians to an accident. Proper LOTO procedures require the energy source to be physically disabled by locking and tagging the energy-isolating device(s) to prevent the release of hazardous energy.

When Should You Lock Out a Forklift?

A forklift should be locked out whenever maintenance or servicing is being performed. LOTO procedures should also be followed if a forklift is involved in an accident or if there is a malfunction that requires maintenance.

Can Anyone Perform Lock Out/Tag Out?

Not just anyone can perform the lockout/tagout procedure. OSHA defines the people who can perform lockout/tagout as only authorized employees who have been trained in LOTO procedures and have been designated by their employer to perform lockout/tagout procedures.

Who Is Responsible for Lock Out/Tag Out?

Employers are responsible for ensuring that proper LOTO procedures are established and that employees are trained in those procedures. Employees are responsible for following those procedures and using LOTO devices properly. The key personnel involved in a lockout/tagout are: the safety supervisor, authorized staff, and affected employees

• Safety supervisor. This is the individual responsible for lockout/tagout, and other keys.
• Authorized employees. These are employees who lock or tag equipment so that they can safely perform servicing or maintenance.
• Affected employees. These are employees who operate the forklift on which servicing is performed or who work in the area where the servicing is performed.

Do Your Employees Need Forklift Lockout/Tagout Training?

Employees who operate or service forklifts must receive training in LOTO procedures to ensure that they understand the potential hazards and how to properly lock and tag equipment to prevent those hazards. They should also undergo periodic refresher training to keep up with the lockout/tagout procedures, equipment, and guidelines.

What Is a Lockout/Tagout Violation?

A lockout/tagout violation occurs when an employer fails to establish, implement, or enforce proper LOTO procedures, or when employees do not follow those procedures correctly. This can result in serious injuries, fatalities, or damage to equipment as defined by OSHA. Examples of violations include failure to do the following:

• Provide lockout/tagout training
• Establish a lockout/tagout program
• Identify and isolate all energy sources.
• Shutdown.
• De-energize.
• Drain residual energy.
• Create equipment-specific LOTO procedures.
• Develop and enforce a lockout/tagout policy.
• Conduct periodic LOTO inspections.

What Is the Fine for OSHA Lockout/Tagout Violations?

The fine for OSHA lockout/tagout violations can vary depending on the severity of the violation but can be as high as $134,937 per violation for willful or repeat violations. Employers can also face additional penalties, such as being required to implement corrective actions or being placed on OSHA’s Severe Violator Enforcement Program list.

The OSHA lockout/tagout standard garnered 1,440 citations and a total penalty of $9,369,143 between October 2020 and September 2021. This equates to an average lockout/tagout penalty of $6,506 for the period.

Conclusion

That’s it: everything you need to know about forklift lockout/tagout.