Sit-Down Forklift Safety: Best Practices & OSHA Training Guidelines

Operating a sit-down forklift requires more than just experience. It requires OSHA-compliant training, regular safety checks, and knowledge of operating best practices tailored to your warehouse environment. 

This guide outlines the required training, daily checklists, and sit-down forklift safety habits to reduce accidents and improve operational efficiency.

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OSHA Forklift Training Requirements

According to OSHA Standard 1910.178, all powered industrial truck operators, including those operating sit-down rider forklifts, must earn a formal certification before they can operate any material-handling equipment.

These forklift operator certifications include 3 parts:

1. Formal instruction: available through an online OSHA-approved course or classroom instruction.
2. Practical training: a hands-on review of the equipment parts, controls, and other site-specific hazards to be aware of on your job site.
3. Performance evaluation: conducted by an employer or qualified trainer to review handling skills and safety. 

Certifications must be renewed every 3 years at minimum. In some cases, they may be required sooner if an operator is involved in an accident, safety violation, or there’s a change in the equipment they’ll be driving. 

Safe Driving Practices for Sit-Down Forklifts

The most common forklift injuries occur when operators bypass the basic safe driving practices. Use these forklift safety best practices to keep everyone in your warehouse safe:

• Always wear a seatbelt, even on low-speed forklifts.
• Keep arms and legs inside, and never lean outside the operator cage.
• Drive at safe speeds, especially when cornering or carrying loads.
• Avoid ramps unless trained, and never turn on an incline.
• Always use horns at intersections to prevent pedestrian collisions.
• Keep forks low while traveling unloaded.
• Never allow passengers – one seat means only one operator.

Safety Mistakes to Avoid

Along with those best practices, here are some common sit-down forklift safety mistakes to avoid to ensure your warehouse is following proper OSHA safety procedures:

• Operating without certification – not only is it an OSHA violation, but it creates an unsafe environment for all employees. 
• Letting loads obstruct visibility – increases the risk of collisions with pedestrians, other vehicles, and shelving.  
• Turning with the load raised – impacts the forklift’s center of gravity, boosting the likelihood of a tip-over.
• Ignoring floor hazards like spills or ramps – increases risks of slips or sliding that could lead to rollovers. 
• Overloading beyond forklift capacity – puts strain on hydraulics, masts, and tires.

Daily Pre-Shift Safety Checklist

As part of their required OSHA forklift training, operators will learn that machines must be inspected daily before being used. Forklifts are powerful machines, and operating equipment that isn’t up to safety standards can not only put your business at risk of a safety fine, but can also put your operators at risk of a hazard.

Daily pre-shift safety checklists have 2 parts: engine-off and engine-on checks. 

Engine-Off Checks

You should always begin with an engine-off, visual inspection to make sure there’s no visible signs of damage to the exterior or interior cabin of the machine. 

Any problems you find during this visual inspection should be reported to your supervisor and noted in your pre-shift checklist paperwork. Try referencing our guide to the most common forklift problems and how to fix them.

Engine-On Checks

Any issues you discover at this stage will require attention from a certified mechanic, as they are a severe risk to operator safety and the longevity of your machine functioning. 

Download our free OSHA-aligned forklift checklist.

OSHA-Compliant Forklift Specs to Look For

When buying a new or used forklift, don’t forget to keep OSHA compliance top-of-mind. Investing in a machine that’s already compliant can save you extra time and costs that may be required to get your machine up to standards.

Be sure the sit-down forklift you’re buying includes:

• Operator restraint system
• Overhead guard
• Load backrest
• Warning lights and audible backup alarms
• OSHA-rated seatbelt
• Manufacturer capacity data plate

Forklift Inventory can match you with OSHA-compliant forklift models from Toyota, Hyster, Crown, and other brands.

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FAQs About Sit-Down Forklift Safety