Forklifts, also known as powered industrial trucks (PITs), are essential equipment found in most industrial and construction environments. These machines come in various types and are used for different tasks, each with its own set of safety guidelines. Understanding the proper operation and maintenance of forklifts is crucial to preventing accidents and ensuring a safe workplace.

While forklifts are generally safer than large machinery like cranes or excavators, they still pose significant risks if not handled properly. According to OSHA, forklift overturns are the leading cause of fatalities involving these vehicles, accounting for about 25% of all forklift-related deaths. In the U.S., nearly 100 workers die and over 20,000 are seriously injured each year due to forklift accidents, highlighting the importance of safety training and awareness.

Diesel-powered forklifts are typically designed for outdoor use because their exhaust can be harmful in enclosed spaces. Operating them indoors without proper ventilation can lead to dangerous conditions. It's important to follow manufacturer guidelines and ensure that all forklifts are used in appropriate settings.

Many facilities use colored tape to mark forklift zones, helping workers stay aware of potential hazards. Mirrors placed near corners also assist operators in seeing around blind spots, improving overall visibility and reducing the risk of collisions.

Handling the Forklift Load Preparation

Before lifting any load, it's vital to make sure it is centered and balanced. An off-center load can easily tip the forklift, leading to serious accidents. Here are some key steps to follow:

• Secure the load so that it is stable and well-ordered.
• Inspect the load for damage and secure it with wrapping or banding if necessary.
• Center the load on the forks.
• If the load cannot be centered, move slowly and with extra caution.
• Distribute the heaviest part of the load close to the front wheels to maintain balance.
• Never exceed the forklift’s weight capacity. Always account for the weight of attachments as well.
• The forklift’s capacity rating assumes a specific load center. If the load is off-center, oversized, or unevenly distributed, it may exceed the rated capacity.
• Use the load extension backrest to improve stability.

Takeaway: The top image shows a properly balanced forklift load. The bottom image shows an imbalanced and dangerous load. Improperly balanced loads can cause the forklift to tip over.

Approaching the Forklift Load

When approaching a load, it's important to do so carefully and methodically. Follow these steps to ensure safety:

• Approach the load slowly and stop 8–12 inches away.
• Position the truck perpendicular to the load with the forks at the correct height.
• Set the direction control to neutral.
• Do not move the forks until the forklift has fully stopped and the brakes are engaged.
• Use the inching pedal to carefully move the forks into position.

Notes: Always stop 8–12 inches in front of the load to allow enough space to maneuver the forks safely.

Mast Position

The position of the mast plays a critical role in maintaining load stability. Always be cautious when adjusting the mast:

• Monitor the load while moving the mast. Loads can become unbalanced during this process.
• Avoid tilting the mast forward unless you're picking up or placing a load.
• When stacking, tilt the mast back just enough to stabilize the load.
• Keep the mast tilted back while traveling to keep the load stable.
• Tilt the mast forward carefully when placing the load on the stack.
• Never travel with the mast tilted forward. This increases the load distance and reduces stability.

Notes: The mast should be vertical when approaching a load.

Notes: Tilting the mast forward increases the load distance and the risk of imbalance.

Notes: Tilting the mast back helps reduce the load distance and improves stability.

Positioning Forklift Forks

• Ensure the forks are level before inserting them into the pallet.
• Place the forks under the load as far as possible to help center the weight.
• Slide the forks into the pallet until they are fully under the load. They should be at least two-thirds the length of the load. If not, consider using a different forklift.
• Be careful not to puncture or hit items on the other side of the pallet.
• Center the weight between the forks and adjust them to distribute the load evenly.
• Carefully tilt the mast back to stabilize the load. This helps balance the center of gravity.

Notes: Slide the forks into the pallet until they are fully under the load. Be careful not to extend beyond the pallet and hit other objects. The forks must be at least two-thirds of the way under the pallet to lift it safely.

Lifting the Load

• Check for overhead clearance before raising the load. Look for pipes, lights, or other obstructions.
• Lift the load slightly above the lower stack—about 4 inches—and ensure it is stable.
• Lift the load and then tilt the mast back slightly to rest it against the backrest extension.
• Make sure the load is not caught on anything or moving unexpectedly.
• Slowly return the lift control lever to the neutral position.

Notes: Lift the load slowly and carefully 4 inches up. Check that the load is balanced and under control.

Lowering the Load

• Be cautious of falling loads and potential impacts when lowering the load.
• Return the mast to a vertical position before lowering the load.
• Lower the load so that its lowest point is 6 to 8 inches from the floor.

Notes: Tilting the mast backward helps stabilize the load and keeps it secure during movement.

Group Discussion Topics

• Is your forklift in good working condition? (e.g., tires, hydraulic lines, signs, etc.). Conduct a daily visual inspection.
• What are the main forklift hazards in your workplace?
• Is the forklift suitable for indoor or outdoor use?
• Are bystanders and other workers aware that a forklift is operating nearby?
• What could lead to a forklift rollover?

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