This document discusses forklift and driver safety. It covers topics like powered industrial truck competency training, certification of training, safe operating conditions, and examining trucks for defects. It then discusses common forklift hazards and fatalities that have occurred, like rollovers and workers being crushed. The document outlines OSHA inspection criteria for forklifts and training requirements to prevent injuries and lawsuits.

1. Forklift and Driver Safety
johnanewquist@gmail.comDraft 1 6 2018

2. Materials Handling & Storage
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178(q)(7)
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POWERED INDUSTRIAL TRUCKS – COMPETENCY TRAINING
POWERED INDUSTRIAL TRUCKS – REFRESHER TRAINING IN RELEVANT TO
POWERED INDUSTRIAL TRUCKS – CERTIFICATION OF TRAINING
POWERED INDUSTRIAL TRUCKS – SAFE OPERATING CONDITION
POWERED INDUSTRIAL TRUCKS – EXAMINATION FOR DEFECTS

3. Objectives
• Explain common
forklift and
motorized
equipment hazards
• Describe methods to
prevent prior
fatalities and
lawsuits.
• Photo by Joe Keenan

4. Nov 2017
• Columbus Division of Fire
paramedics were called at
3:41 p.m. about a person
injured in a forklift rollover
accident at the warehouse
Typical Forklift Rollover

5. Sep 2017
• The Associated Press reported
that the victim, Phillip Terry of
Indianapolis, “was fatally crushed
when a forklift’s lift fell on him
while he was doing maintenance
work on it.”
• Terry was killed on Sept. 24 at an
Amazon facility in the
Indianapolis suburb of Plainfield.

6. May 2017
• Burnsville MN
• Saunders, of Burnsville, was killed
May 5 when a forklift he was
operating in the yard area of the
store tipped over and crushed
him.
• His heart stopped beating on the
way to the hospital, and he was
pronounced dead around 9 a.m.
at Hennepin County Medical
Center in Minneapolis.
Typical Forklift Rollover

7. Aug 2017
• Bath PA
• Miguel A. Amonte, 32, died of
blunt force injuries suffered
12:21 p.m. when the forklift he
was operating hit a steel post in
the warehouse at 6835 Silver
Creek Road, East Allen Township,
the Lehigh County coroner’s
office said.
Damaged forklift after hitting fixed
object

8. May 2017
• A Menards worker was
killed Friday in what the
Hennepin County Medical
Examiner is calling a "forklift
mishap" while working at
the Burnsville MN store.
• 27-year-old Alec Saunders
on Tuesday.
• Witnesses say the worker
was trying to move two-by-
fours when the forklift
started to flip over. They say
he tried to jump off the
equipment and that's when
it landed on top of him.

9. August 2016
• Des Plaines IL
• Urbano A. Merlos, 37, was pinned between a
truck and a forklift about 5:30 p.m. at the
facility at 333 Howard Ave. in Des Plaines,
according to the Cook County medical
examiner’s office.

10. Aug 2015
• Army vet hurt in
McCormick Place
forklift accident
awarded $15.2 million
• Ankle degloved when
hit by untrained forklift
operator.

11. Training
• The Standard also requires that
operators receive training in the
topics which are applicable to the
safe operation of the truck in the
employer’s workplace.
• Employees must be trained
separately for each different type
of forklift they will be using, but
they do not need to complete
separate training for the same
type of forklift made by a
different manufacturer. For classroom training element, the
employer may demonstrate the
employee's successful completion by
a written or oral test or other
appropriate means, such as an
evaluation by the instructor

12. Training

13. Evaluation
Date of Certification
Operator’s name
Trainer’s Name
Employers must conduct
classroom-type training and
actually observe the employee
operating the equipment under
the physical conditions at the
workplace, such as aisles,
ramps, and loading docks.

14. Certification
OSHA also requires initial
certification and recertification
of forklift drivers every three
years.
• The employer must provide a
certificate stating the
employee has completed the
training.
• The employee must be
retrained and recertified
every three years, at a
minimum, or after an
accident or “near miss” which
resulted from an unsafe act.

15. Operator Manual

16. Trainer Qualification

17. Refresher Training
• Observe the powered
industrial truck operator
during normal operations to
determine if the operator is
performing safely, and
• Ask pertinent questions to
ensure that the operator
has the knowledge or
experience needed to
operate a truck safely.

18. Retraining

19. Seat Belts
• Reduces the incidence and
severity of injuries to the
operator in the event of a tipover
accident.
• Forklift trucks are particularly
susceptible to tipovers.
• Section 5(a)(1) of the OSH Act.

20. Seat Belts

21. Seat Belt Disrepair

22. Unattended Load
• Some forklifts require
inspections once shut
off
• Drivers are leaving
them on

23. Unattended Load

24. Unattended Load

25. Pass Under Loads

26. Pass Under

27. Unsafe Operation

28. Operator Unsafe

29. Eye level 7 ft - 3 in above
ground level
39’ 0”
21’ 2”
Operator sight distances
from eye level to ground
Vehicle:
High Reach RT
Fork Lift
10’ 9”
7’ 9”
3’ 0”
85’ 0”
14’ 10”
18’ 2”

30. OSHA Inspections
• Lift Chains and rollers
• Is there wear or damage or kinks,
signs of rust, or any sign that
lubrication is required?
• Is there squeaking?
• Forks
• Are they cracked or bent , worn,
or mismatched?
• Is there excessive oil or water on
the forks?

31. OSHA Inspections
• Steering
• Is there excessive free play?
• If power steering, is the pump
working?
• Brakes
• If pedal goes all the way to the
floor when you apply the service
brake, that is the first indicator
that the brakes are bad.
• Brakes should work in reverse,
also.
• Does the parking brake work?

32. OSHA Inspections
• Lights - If equipped with lights,
are they working properly?
• Horn - Does the horn work?
• Back Up Alarm - If equipped with
backup alarm, is its functioning?

33. OSHA Inspections
• Load Handling Attachments
• Is there hesitation when hoisting
or lowering the forks, when using
the forward or backward tilt, or
the lateral travel on the side
shift?
• Is there excessive oil on the
cylinders?

34. OSHA Inspections
• Propane Tank - Is the tank guard
bracket properly positioned and
locked down?
• Propane Hose
• Is it damaged?
• Is the connector threaded on
squarely and tightly?
• Propane Odor - If you detect the
presence of propane gas odor,
turn off the tank valve and report
the problem.

35. OSHA Inspections
• Engine Oil - Check levels.
• Engine Coolant - Visually check
the level. Note: Never remove
the radiator cap to check the
coolant level when the engine is
running or while the engine is
hot.
• Stand to the side and turn your
face away.
• Always use a glove or rag to
protect your hand.
Leak in
radiator

36. OSHA Inspections
• Transmission Fluid - Check levels.
• Windshield Wipers - Do they
work properly?
• Seat Belts - Do they work?
• Tow Hook
• Does it engage and release
smoothly?
• Does the safety catch work
properly?
• Control Lever - Does the lever
operate properly?

37. OSHA Inspections
• Overhead Guard - Are there
broken welds, missing bolts, or
damaged areas?
• Hydraulic Cylinders - Is there
leakage or damage on the lift, tilt,
and attachment functions of the
cylinders?
• Mast Assembly - Are there
broken welds, cracked or bent
areas, and worn or missing stops?

38. OSHA Inspections
• Battery Check
• Are the cell caps and terminal
covers in place?
• Are the cables missing insulation?
• Hydraulic Fluid - Check level.
• Gauges - Are they all properly
working?

39. Nameplates

40. Forklift Decals

41. OSHA Inspections
• Tires
• What do the tires look like?
• Are there large cuts that go
around the circumference of the
tire?
• Are there large pieces of rubber
missing or separated from the
rim?
• Are there missing lugs?
• Is there bond separation that
may cause slippage?

42. Bad Tires

43. Forklift Repair

44. Storage

45. Racks

46. Slabs
• Several death
happening when lifting
large flat objects

47. Modifications

48. Power Lines
10 foot safe clearance up to 50,000 volts.
Avoid storing material under the lines.
Scaffold hits power lines video link.

49. 2000
• Ybor City, FL
• RT Forklift moving
trusses hit powerlines.
• Debris caught on fire.
• $40-50 million loss

50. Problems
• Issue?

51. 2015
• De-energize first
• Insulated electrical
sleeve for incidental
contact

52. Electrical
• 1/12/1999
• An employee was operating a
side loader, loading and
unloading rail car containers in a
terminal yard.
• A 7200-volt overhead power line
ran nearby, about 8.8 meters
above the ground.
• The mast on the loader reached
up to about 9.1 meters.
• The employee brought the mast
of the loader into contact with
the power line.
• Three employees at the site were
electrocuted

53. 2000
• In Atlantic States, the employer was
indicted for defrauding OSHA by
altering existing conditions at the
employer’s foundry to conceal safety
hazards to which employees were
exposed.
• In March 2000, an employee died after
he was run over by the employer’s
forklift.
• The defendants faced a host of
allegations, including conspiring to
cover up the circumstances of Coxe's
death.
• The jury eventually found the group
guilty on 70 counts, including 52
felonies
Former Atlantic States
Cast Iron Pipe
Co. maintenance
supervisor Jeffrey
Maury was sentenced
today to 30 months in
prison for convictions
handed down three years
ago against the Phillipsburg
foundry and four of its

54. Questions?