Forklifts, also known as powered industrial trucks (PITs), are a common piece of equipment found in most job sites and industrial warehouses. These machines come in various types, each with unique applications and safety considerations. Understanding the differences between forklift models is essential for safe operation and efficiency.
While forklifts are generally safer than large construction equipment 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 machines, accounting for about 25% of all forklift-related deaths. In the U.S., nearly 100 workers die and over 20,000 are seriously injured in forklift accidents each year.
Diesel-powered forklifts are designed for outdoor use due to the harmful fumes they emit. Using them indoors without proper ventilation can be extremely dangerous. It’s important to always follow safety guidelines when operating any type of forklift, whether it's electric, diesel, or propane-powered.
Many factories use colored tape to mark forklift zones, helping workers stay aware of their surroundings. Mirrors placed near corners also assist operators in seeing around obstacles, reducing the risk of collisions.
Handling the Forklift Load Preparation
Proper load preparation is crucial for forklift safety. Always ensure the load is centered and balanced. An off-center load can easily cause the forklift to tip over, especially at higher elevations.
- Secure the load to make sure it's stable and well-ordered.
- Inspect the load for damage. If damaged, secure it with wrapping or banding before moving.
- Center the load on the forks to maintain balance.
- If the load cannot be centered, move slowly and with extra caution.
- Place the heaviest part of the load closest to the front wheels to keep the center of gravity stable.
- Never exceed the forklift’s weight capacity. Factor in the weight of any attachments used.
- Be aware that the forklift’s capacity rating assumes a specific load center. Off-center or oversized loads may exceed this limit.
- Use the load extension backrest to help stabilize the load.
Takeaway: The top image shows a properly balanced forklift load, while the bottom image demonstrates an imbalanced and potentially dangerous load. Improperly balanced loads increase the risk of tipping and accidents.
Approaching the Forklift Load
- Approach the load slowly and stop 8–12 inches away from it.
- Position the truck perpendicular to the load with the forks at the correct height.
- Set the direction control to neutral before attempting to maneuver the forks.
- 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: Stopping 8–12 inches in front of the load gives you enough space to adjust the forks safely.
Mast Position
- Monitor the load while adjusting the mast. Loads can become unbalanced during movement.
- Exercise caution when tilting the mast forward—only do so when 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 maintain stability.
- Slowly tilt the mast forward only when positioning the load onto the stack.
- Never travel with the mast tilted forward, as this increases the load’s distance from the center of gravity and reduces stability.
Notes: The mast should be vertical when approaching a load to ensure proper balance.
Notes: Tilting the mast forward increases the load’s distance from the center of gravity, making it less stable.
Notes: Tilting the mast back helps reduce the load’s distance from the center of gravity, improving 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 of the way under the pallet for safe lifting.
- Be careful not to extend the forks beyond the pallet, as this could hit other objects.
- Center the load evenly between the forks and adjust as needed.
- Gently tilt the mast back to stabilize the load after positioning the forks.
Notes: Make sure the forks are fully under the load and at least two-thirds of the way in. This ensures a safe lift and prevents damage to the load or surrounding items.
Lifting the Load
- Check for overhead clearance before raising the load. Look for pipes, lights, and other obstructions.
- Lift the load about 4 inches above the lower stack and check its stability.
- Once lifted, tilt the mast back slightly to rest the load against the backrest extension.
- Make sure the load isn’t caught on anything or moving unintentionally.
- Slowly return the lift control lever to the neutral position.
Notes: Lift the load slowly and carefully, ensuring it remains balanced and stable throughout the process.
Lowering the Load
- Be cautious of falling loads and potential collisions when lowering the load.
- Return the mast to a vertical position before beginning the lowering process.
- Lower the load so that its lowest point is 6–8 inches above the floor.
Notes: Tilting the mast backward helps stabilize the load and keeps it secure during the lowering process.
Group Discussion Topics
- Is your forklift in good condition? Perform a daily visual inspection of tires, hydraulic lines, and signage.
- What are some forklift hazards specific to your workplace?
- Is the forklift designed for indoor or outdoor use?
- Are bystanders and other workers aware that a forklift is operating nearby?
- What factors could lead to a forklift rollover?
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