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Forklift Safety - PowerPoint PPT Presentation

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Forklift Safety. Motor Vehicle Accidents. To protect employees. To protect company assets. It’s the law!. Why Forklift Safety?. Fatalities Source BLS. 7 th on OSHA’s Top 10 list. Powered Industrial Trucks – 1910.178 (3,262 Total Violations) Top 5 sections cited:

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Motor Vehicle Accidents

To protect employees

To protect company assets

It’s the law!

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Fatalities Source BLS

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7th on OSHA’s Top 10 list

Powered Industrial Trucks – 1910.178 (3,262 Total Violations)

  • Top 5 sections cited:

    • 1910.178(L)(l) Failure to ensure each powered industrial truck operator is competent to operate a powered industrial truck safely

    • 1910.178(L)(4)(iii) Failure to evaluate each powered industrial truck operator’s performance at least once every three years

    • 1910.178(L)(6) Failure to certify that each operator has been trained and evaluated

    • 1910.178(p)(1) Failure to take damaged powered industrial trucks out of service

    • 1910.178(Q)(7) Failure to examine powered industrial trucks before placing in service

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Benefits to Forklift Safety Training

  • Improve Attitude

  • Increase Production

  • Increase Operator Safety

  • Lower Maintenance Costs

  • Lower # of Accidents/Severity

  • Lower Insurance Cost

  • Fulfill OSHA Requirements

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Danger Label

Caution Label

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Operator’s Manual

OSHA says you SHALL Read and Understand the Operator’s Manual

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Lift Truck vs. Automobiles

  • Automobiles

    • For personal use

    • Weighs less than 5,000 lbs.

    • Front wheel steering

    • Training required

    • Operates on smooth, paved surfaces

  • Lift Trucks

    • Not for personal use

    • Weighs greater than 5,000 lbs.

    • Rear wheel steering

    • Training required

    • Operates on various surfaces

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Mast:What do you really need to know?

  • Never reach into/through mast

  • Never stand under forks/load

    • Never allow others under

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Lift Truck Balance

  • Internal Combustion


  • Electric Powered

    • Industrial battery

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  • Moving center of gravity outside stability Pyramid:

    • Loss of steering

    • Loss of traction

    • Unstable load

    • Potential for a tip over

    • Potential for a tip up

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Daily Inspection


Industrial trucks shall be examined before being placed in service…

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Completion of Inspection

  • Report defects to appropriate personnel

  • Never operate a truck in need of repair

  • Authorized & trained personnel repair trucks

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The Operational Inspection

  • Operator restraint system

  • Horn

  • Warning devices

  • Unusual engine noise

  • Fuel level

  • Gauge readings

  • Hydraulics

  • Steering lock to lock

  • Service brake

  • Park brake

  • Plugging on electric powered trucks

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Operating a ForkliftTraveling & Maneuvering

Mounting – Dismounting

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Operating a ForkliftStarting & Stopping

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Operating a ForkliftOperational Speeds

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Safe Operating Guidelines

  • Safe distance from docks and ramps, stairway, fire aisle & equipment

  • No on-the-go directional changes (IC trucks)

  • Operating surfaces must support truck and load

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Speed vs. Reaction

Speed 8.7 mph


13 feet per second

Reaction Time

18-21 years = ¾ second

21- over = 1.5 second

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Pedestrian Traffic

  • Pedestrians have right of way

  • When approaching corners, intersections:

  • When passing pedestrians

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Operating the ForkliftUsing the Pedal

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Operating ForkliftSteering/Turning/Changing Directions


Tip over : Collision : Struck-by/Crushing Injuries : Load falls

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  • All operators must be certified by the following

  • Retraining

  • Certification includes