How to Safely Operate a Forklift

Safety is paramount when operating heavy machinery. Forklifts, commonly used in industries like warehousing, construction, and shipping, can be hazardous if not handled correctly. Below is a guide on how to operate a forklift safely.

Note: Always cross-reference the information provided here with your compliance or training personnel to ensure no important steps are omitted.

Requirements to Operate a Forklift Safely

Operating a forklift involves more than just getting on and driving. It is governed by legal and safety standards.

1. Age Restrictions: In the U.S., the minimum legal age to operate a forklift is 18, ensuring the operator possesses the necessary maturity and judgment for safe handling.
2. Training and Certification: Federal law requires formal training and evaluation before operating a forklift. This includes classroom instruction, hands-on practice, and an evaluation.
3. Refresher Training: Certification isn’t a one-time requirement. Operators must renew their certification every three years or undergo immediate retraining if involved in an accident, operating unsafely, or when a different type of forklift is introduced.

The Basics of Forklift Operation

Before starting the forklift, there are important pre-operation steps to take.

1. Pre-Operation Inspection: At the start of each shift, inspect the forklift for leaks, damages, or malfunctioning parts. Ensure that tires are properly inflated and all safety features, like horns and lights, are working.
2. Boarding the Forklift: Always approach the forklift from the side, using the handholds and steps to avoid slips or falls.
3. Adjust Before Starting: After boarding, adjust the seat, mirrors, and controls for optimal visibility and control.
4. Starting the Forklift: Start the forklift in neutral, with the parking brake engaged, to ensure safe operation.

Mastering Lift Techniques

Lifting safely is at the heart of forklift operation.

1. Load Assessment: Evaluate the load before lifting, checking its stability and weight distribution. Secure it if necessary.
2. Approach: Always approach the load head-on, as approaching from an angle may cause instability.
3. Fork Positioning: Ensure the forks are set at the appropriate height and width for the load.
4. Lifting and Moving: Lift the load carefully and keep it low while moving to maintain a low center of gravity.
5. Tilting: Slightly tilt the mast backward once the load is lifted to stabilize it during transportation.

Basic Forklift Controls

Understanding and mastering the forklift’s controls is crucial for safe operation.

1. Pedals: Forklifts have accelerator and brake pedals similar to cars. Some models include an inching pedal for precise movements.
2. Steering: Forklift steering differs from cars, especially in models with rear-wheel steering. Practice in a controlled environment before taking on real tasks.
3. Mast Controls: Familiarize yourself with mast controls for lifting, lowering, and tilting loads.
4. Gearshift: If the forklift isn’t automatic, know how to properly shift gears.
5. Safety Features: Use safety features like horns, lights, and backup alarms to communicate your movements to others.

Tips for Safe Forklift Operation

1. Wear Safety Gear: Always wear a hard hat, safety shoes, and high-visibility clothing when operating a forklift.
2. Follow Weight Limits: Never exceed the forklift’s rated capacity, as overloading can lead to tip-overs.
3. Operate Smoothly: Avoid sudden stops, starts, or turns to prevent accidents.
4. Maintain Clear Vision: If your load obstructs your view, drive in reverse or use a spotter for guidance.
5. Use Your Horn: Make it a habit to honk at intersections, blind spots, or when reversing.
6. No Passengers: Forklifts aren’t meant for passengers unless a seat is designated for them.
7. Drive on Inclines Properly: Always ascend or descend slopes slowly and straight, never diagonally.

Understanding Forklift Stability

1. Center of Gravity: When lifting a load, the forklift’s center of gravity shifts, which can affect its stability.
2. The Stability Triangle: Forklifts have a three-point suspension system, creating a “stability triangle.” As long as the center of gravity remains within this triangle, the forklift stays stable.

Maintenance and Regular Checks

1. Daily Checks: At the start of each shift, inspect the brakes, steering, controls, and safety devices.
2. Scheduled Maintenance: Follow the manufacturer’s maintenance schedule to ensure safe and reliable forklift operation.
3. Prompt Repairs: Never operate a forklift in need of repairs. Addressing issues promptly ensures safety and avoids higher repair costs.