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🦺 Forklift Safety Training Guide
For All Certified Operators – OSHA Compliant (29 CFR 1910.178)
📌 Introduction
Operating a forklift comes with serious responsibilities. According to OSHA, improper forklift use is a leading cause of workplace injuries and fatalities. This training material is designed to help you operate forklifts safely, efficiently, and in full compliance with federal regulations.
✅ OSHA Forklift Safety Basics
Standard Reference: 29 CFR 1910.178 – Powered Industrial Trucks
Key OSHA Requirements:
- Only trained and certified operators may operate a forklift.
Expert Tips : Use a forklift access control system to control who can operate a forklift.
- Daily pre-operation inspections must be completed and documented.
- Seat belts must be worn at all times.
Expert Tips: Use a seat belt warning to remind the operator.
- No passengers unless the forklift is designed for more than one person.
- No lifting people unless using an approved work platform with safety measures.
Expert Tips: Use a forklift safety cage to lift for work.
🔍 Pre-Operation Inspection Checklist (Daily)
Before each shift, inspect the forklift for:
- 🔧 Fluid levels (oil, water, hydraulic)
- 🔋 Battery charge or fuel levels
- 🚨 Brake, horn, lights, steering
- 💨 Tires (condition and inflation)
- 🛑 Fork condition and mast movement
- 🔒 Safety devices (seat belt, backup alarm, fire extinguisher)
Record all inspections. Remove forklift from service if any issue is found.
🧑🏭 Safe Operating Procedures
- Mounting and Starting
- Use handholds and step plates.
- Adjust seat and mirrors before starting.
- Buckle up. No exceptions.
- Safe Driving Rules
- 🚶 Yield to pedestrians at all times.
- 🚦 Obey all traffic signs and floor markings.
- 🐢 Drive at walking speed. Never exceed safe limits.
- 🔁 Sound horn at intersections, blind spots, or doorways.
- 🚫 Never use a cellphone or get distracted while driving.
Expert Tips: Use forklift driver mornitoring system to remind the mange the bad behaviors.
- Load Handling
- Make sure the load is stable and secure.
- Never exceed the rated capacity.
- Keep forks low to the ground when moving.
- Tilt the mast back slightly when traveling with a load.
- Stack and unstack loads carefully.
- Turning and Visibility
- Slow down before turning.
- Watch for tip-over risk during sharp turns or high speeds.
- Use spotters when visibility is limited.
Expert Tips: Use an AI camera with human detection function will help to avoid collision with pedestrians and equipment.
- Never drive with obstructed view—drive in reverse if needed.
⚠️ Forklift Hazards to Avoid
Hazard | How to Prevent It |
Tip-over | Drive slowly, especially when turning. Don’t overload. |
Falling Loads | Secure loads properly, keep them centered on forks. |
Pedestrian Accidents | Use horn, mirrors, and watch for people at all times. It will be perfect if the forklift install an anti collision system with pedestrians detection function. |
Poor Visibility | Keep clear view ahead. Use a spotter when needed. |
Carbon Monoxide (gas forklifts) | Use in well-ventilated areas only. |
🚫 What You Must NEVER Do
- ❌ No horseplay or stunt driving.
- ❌ No riding on forks or lifting people unsafely.
- ❌ Don’t leave the forklift unattended while running.
- ❌ Don’t drive over loose objects or spillages.
🧯 In Case of Emergency
- Shut down the forklift.
- Notify your supervisor immediately.
- Follow your workplace’s emergency procedures.
- Report any accident, near miss, or unsafe condition.
📜 Certification Reminder
OSHA requires re-evaluation and re-certification when:
- Operator is involved in an accident or near-miss.
- There is a change in workplace conditions (new layout, ramps, load types, etc.).
- The operator is observed operating unsafely.
📝 Final Notes
- Safety is a shared responsibility.
- Always stay alert, follow procedures, and speak up about any hazards.
- When in doubt, stop the truck and ask.
🧠 Quick Quiz for Review (Optional)
- When should you wear a seatbelt on a forklift?
- What should you do if your view is blocked by a load?
- Can you use a phone while driving a forklift?
- Name two things to inspect before using a forklift.
- What’s the maximum speed you should drive in a crowded warehouse?
If you have any questions or need a refresher, don’t hesitate to contact your supervisor or safety officer.
Stay safe. Drive smart. Respect the machine.
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