The document outlines forklift safety training, including essential topics such as safe operations, training standards, and the importance of proper maintenance. It highlights the need for competent operators to prevent accidents, as nearly 100 workers are killed annually due to forklift-related mishaps. Additionally, it emphasizes the significance of refresher training and evaluation to ensure ongoing operator competency.

1. 2008
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Forklift Safety Training Class

2. Contents
• Forklift safety
• Introduction
• Training and Standards
• CD# One –
Forklift Fundamentals
• Review Quiz# One
• CD# Two –
Forklift Operations
• Review Quiz# Two
• Types of Forklifts
• Maintenance
• Day-to-Day Considerations
• Daily Checklist
• Refuel procedures
Do’s & Don’ts
• Conclusion
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3. Forklift Safety
Learning the safe
way to operate a forklift …
…may save your life
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4. A forklift is a powerful tool that allows
one person to precisely lift and place
large heavy loads with little effort.
Using a tool such as a forklift, cart or
hand truck instead of lifting and
carrying items by hand can reduce the
risk that you will suffer a back injury.
However, there is great risk of injury or
death when a forklift operator:
· has not been trained in the principles of physics that allows it to lift heavy
loads,
· is not familiar with how a particular forklift operates,
· operates the forklift carelessly, or
· uses a forklift that is not safe due to malfunctioning or missing parts.
Introduction
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5. Introduction
Every year nearly 100 workers are killed and 20,000 are seriously injured in
forklift mishaps. According to the National Traumatic Occupational Fatalities
(NTOF) Surveillance System 1530 workers field from forklift related accidents
between 1980 and 2001. At least 22% of these deaths were caused by forklift
overturns and another 20% to workers on foot being struck by the forklift. With
well over one million forklifts in operation today, emphasis must be placed on
both worker and pedestrian safety.
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6. Forklift Fatalities, 1992-1996
86 89
120
95
114
1992 1993 1994 1995 1996
Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts
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7. Forklift Fatalities by Age Group
1992 -1996
3%
10%
22%
21%
12%
5%
27%
Under 20
20 - 24
25 - 34
35 - 44
45 - 54
56 - 64
65 & over
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8. Industries Where Powered Industrial Truck
Accidents Occurred
Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and
Mechanical Engineering Safety Standards.
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9. Nonfatal Occupational Injuries and
Illnesses by Source, 1996
Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.
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10. An effective material safety program is required
to limit accidents. An important part of this program
Is operator selection and training. There are federal and
Industry standards which cover both operator selection
and training.
OSHA Standards require that the employer ensure that a :
1. Forklift operator is competent to operate the forklift he or she is
assigned to use.
2. The employer must document operator training and an evaluation of
the operator’s performance while using the forklift.
A copy of the Osha Standards –
Subpart N-Materials Handling and Storage.
Section 1910.178, Powered industrial trucks
Will be on hand in the Shipping and Receiving department.
Training and Standards
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11. Operator Training pt1
• Safe operations
– The employer shall ensure that each powered
industrial truck operator is competent to operate a
powered industrial truck safely, as demonstrated
by successful completion of the training and
evaluation specified in the OSHA standard.
– Prior to permitting an employee to operate a
powered industrial truck (except for training
purposes), the employer shall ensure that each
operator has successfully completed the required
training (or previously received appropriate
training).
A copy of the Osha Standards – Subpart N-Materials Handling and Storage.
Section 1910.178, Powered industrial trucks will be on hand in the Shipping and Receiving department.
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12. Training Program Implementation
• Trainees may operate a powered industrial
truck only:
– Under direct supervision of a person who
has the knowledge, training, and
experience to train operators and evaluate
their competence; and,
– Where such operation does not endanger
the trainee or other employees.
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13. Training Program Implementation
(continued)
• Training shall consist of a combination of:
– Formal instruction (e.g., lecture, discussion,
interactive computer learning, written
material),
– Practical training (demonstrations and
exercises performed by the trainee), and
– Evaluation of the operator’s performance in
the workplace
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14. Training Program Implementation
(continued)
• Training and evaluation
shall be conducted by a
person with the
knowledge, training and
experience to train
powered industrial truck
operators and evaluate
their competence.
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15. Refresher Training and Evaluation
• Refresher training, including an evaluation of the
effectiveness of that training, shall be conducted
to ensure that the operator has the knowledge
and skills needed to operate the powered
industrial truck safely.
• Refresher training required when:
– Unsafe operation
– Accident or near-miss
– Evaluation indicates need
– Different type of equipment introduced
– Workplace condition changes
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16. Powered Industrial Trucks -
Operator Training
1910.178 (l)
1915.120 (a)
1917.1 (a)(2)(xiv)
1918.1 (b)(10)
1926.602 (d)
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17. Powered Industrial
Truck - Definition
• A mobile, power-propelled truck used to carry,
push, pull, lift, stack or tier materials.
[American Society of Mechanical Engineers
(ASME) definition]
• Excluded are vehicles used for earth moving
and over-the-road hauling.
• Commonly known as forklifts, pallet trucks,
rider trucks, fork trucks, or lift trucks.
• Can be powered through electric or
combustion engines.
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18. Performance-Oriented
Requirements
• The powered industrial truck operator
training requirements are performance-
oriented to permit employers to tailor a
training program to the characteristics of
their workplaces and the particular types
of powered industrial trucks operated.
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19. Refresher Training and Evaluation
(continued)
• An evaluation of each powered industrial
truck operator’s performance must be
conducted:
– After initial training,
– After refresher training, and
– At least once every three years
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20. Forklift Fundamentals
CD# 1
17 minutes
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21. 1.) each forklift is designed to perform specific tasks in set situations
and should never be used in any other way.
True or False
2.) OSHA requires that you be qualified for each type of forklift and
each kind of work Situation you encounter.
True or False
Review Quiz
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22. Forklift Operations
CD# 2
18 Minutes
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23. 1.) Using good judgment on every load and carry is the mark of a
professional forklift operator.
True or False
2.) In the traveling position, the forks are about one foot above
the floor.
True or False
Review Quiz
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24. A forklift is a type of “powered industrial truck” covered by OSHA standards. Like
other powered industrial trucks, its purpose is to move carry, push, pull, and lift a
material load then stack it or place it in a storage rack (tier). Forklifts come in
many sizes and capacities. They can be powered by batteries, propane, gasoline
or diesel fuel. Some are designed to be used in a hazardous location or
atmosphere where an ordinary forklift might cause a fire or explosion.
Powered industrial trucks are classified into seven types based on their
characteristics.
• Class 1 - Electric Motor, Rider, Counter-Balanced Trucks (Solid
Pneumatic Tires)
• Class 2 - Electric Motor Narrow Aisle Trucks (Solid Tires)
• Class 3 - Electric Motor Hand Trucks or Hand/Rider Trucks
• Class 4 - Internal Combustion Engine Trucks (Solid Tires)
• Class 5 - Internal Combustion Engine Trucks (Pneumatic Tires)
• Class 6 - Electric and Internal Combustion Engine Tractors
Pneumatic Tires). There are no forklifts in this class.
• Class 7 - Rough Terrain Forklift Trucks (Pneumatic Tires)
Types of Forklifts
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25. Good maintenance practices are essential to keep trucks
safe and productive. Maintenance procedures must also be
safe for those who perform the maintenance
Trained Mechanics
Mechanics must be trained in safe maintenance
and repair practices, such as
1. securing moveable parts,
2. proper use of tools,
3. wearing of protective clothing,
4. use of protective equipment.
5. And safe operating procedures of the forklift trucks
and their attachments.
Maintenance
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26. Day-to-Day Considerations
Onsite Considerations
• Pedestrians
• Daily Checks
• Lifting & Transporting
Loads
• Charging
• Do’s & Don’ts
• Forklifts capacities –
Diesel 3000 lbs,
Gas (old yellow) 6000 lbs-
Electric 2000 lbs
• Rough Terrain –
Extended-reach FLT –
Additional attachments include lift cage, a fabricated attachment for forks
to lift extra long pallets, a small fabricated attachment to tow trailers,
and a attachment /w chains to lift shelters and generators.
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27. Daily Checklist
• Tires
• fluid levels
• Chains
• Horn
• Lights
• Water
• Steering
• Mast
• Battery
• Hydraulic leaks
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28. REFUELLING and
BATTERY MAINTENANCE
• Diesel
• Gas
• Electric
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29. DIESEL & GAS FUEL
• Use refuelling area –Our Refuelling area is behind
shipping and receiving, across from the warehouse
#2. Fire Extinguisher, Gloves, and Dry Sweep are
available .
• Turn off engine and
use parking brake
• Avoid overfilling the fuel tank
• Refuel forklifts when gage reads ½ and below
* Always strap equipment before movement
* Always use Ground Guides
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30. BATTERY CHARGING
• Change in a well ventilated area - Motor
pool
• Use eye protection when making
connections
• Have eye wash facilities available
• Have an acid neutralizing agent
available
• Don’t over fill the batteries with water

31. “DON'T”
• DO NOT
– Consume alcohol while at work
– Pick up a load if someone is standing close
– Allow people to walk underneath the load
– Try to pick up an unsuitable load
– Leave a lift truck unattended with the engine running
– Carry passengers
– Drive over cables or piping
– Operate with the load raised except at creep speed
– Drive forward if visibility is impaired by a load
– Make sharp turns, only turn at creep speed
– Alter, remove or disconnect any mechanical or safety devices
on any forklift. ONLY AUTHORIZE PERSONNEL CAN .
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32. “DO’S”
• DO…..
– Only issue keys to authorized drivers
– On completion of work, park lift truck in designated area
– Be careful with pedestrians / obey site rules / speed limits
– Sound horn at potential danger spots
– Stop before entering building, sound horn then proceed
– Avoid violent breaking
– Travel slowly down slopes with the fork facing uphill
– Always use the hand brake when necessary
– Never travel across an incline
– Before you raise a load check over head for obstructions
– Always check for traffic when dismounting
– Avoid driving over wet, grease and oil spilled areas
– Report all accidents and safety violations to your supervisors
immediately.
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33. Certification
• The employer shall certify that each
operator has been trained and evaluated
as required by the standard.
• Certification shall include:
– Name of operator
– Date of training
– Date of evaluation
– Identity of person performing the training or
evaluation
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34. Any Questions?
We have a two part test before
Certification
A Written and a Driving test
Good Luck
Conclusion
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35. The End
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