How to Drive a Forklift: Safety and Operation Guide

Table of contents

1. TL;DR
2. Forklift Operators Requirements
3. How to Operate a Forklift Safely?
4. Good Practices for Safe Forklift Driving
5. Frequently Asked Questions

TL;DR

• Operating a powered industrial truck requires the operator to be over 18 years of age and hold an OSHA-approved forklift certification.
• Prior to driving, forklift operators must execute daily visual and operational safety inspections, including checks on hydraulic lift cylinders and mechanical controls.
• Correct load handling mandates stabilizing weights by tilting the mast backward, maintaining low fork clearance of 2-4 inches during transit, and strictly observing clearance boundaries.
• Operational safety is optimized by utilizing certified high-quality attachments made of structural steel and keeping clear zones free of bystanders.

On one hand, driving a forklift may seem like a straightforward task with no need to undergo any previous forklift operator training. On the other hand, the Internet is swamped with videos of failed attempts to perform even the easiest forklift tasks.

Most of them cause severe financial implications and pose a significant threat to the health and safety of forklift operators and their surroundings. So, is a successful forklift operation really a walk in the park? Today's article will provide you with an answer to that nagging question.

Forklift Operators Requirements

Even if it seems like a small vehicle anyone could operate, forklifts should be treated with adequate care and certain rules must be followed. A forklift is a short name for the official name of the machines, which are officially called powered industrial trucks.

To drive one of them, the operator must be over 18 and obtain a forklift certification resulting from undergoing a forklift training program approved by OSHA (The Occupational Safety and Health Administration). It consists of formal instruction, practical training, and a performance evaluation which results in obtaining a forklift license.

How to Operate a Forklift Safely?

Obtaining appropriate certification consistent with OSHA regulations is not the factor allowing one to just get in the forklift and start the operation. Certain steps must be taken to ensure safe forklift operation. The below quick steps will give any forklift driver an ultimate guide on how to appropriately operate their powered industrial truck.

Get Familiar with the Machine

The best way to start an operation with a new machine is to study the operator’s manual. It is also essential because there are plenty of forklift types and models on the market that differ in the way they operate. However, most of them will be built similarly. Let us look at the most important forklift parts and components:

1. Mast - allows the forklifts to raise and lower the load (through hydraulic pistons and tilt loads).
2. Carriage - a support platform located on the front of a forklift; it moves along the mast and connects it with the forks.
3. Hydraulic lift cylinder - powers the machine to raise and lower the load on the carriage.
4. Forks - carry the loads.
5. Backrest - supports the the load; thanks to the backrest the load does not fall toward the operator.
6. Overheard guard - prevents the fall of any objects on the forklift operator.
7. Controls - levers and pedals allowing the operation of the machine (moving, stopping, lifting, tilting).
8. Nameplate - lists the most important forklift information (weight, lift capacity, mast height).
9. Seat - a part of a sit-down forklift but not a stand-up forklift.

Perform Safety Checks

Thanks to the knowledge of the crucial forklift components, the forklift drivers can conduct their safety checks before they start the operation. Such procedure is part of OSHA's requirements on appropriate forklift operation and prevents the occurrence of accidents and injuries. The process consists of the performance of visual inspection (engine off) and operational inspection (engine on).

Inspect the Forklift Controls

The main responsibility of the operator is to be able to control the forklift. However, this obvious duty is not possible without knowing the ins and outs of forklift controls operation. Therefore, we list the elements of control system below:

1. Directional controls - help the driver to move the forklift forward and backward. Pay attention to whether this control is operated by foot or mounted on the column.
2. Hydraulic lift controls - there are usually three types:
   - Raising/lowering — upward/downward movement of the forks.
   - Tilt — forward/backward movement of the mast.
   - Auxiliary — side-to-side movement of the attachment (and the load).
3. Pedals - an accelerator pedal (moving), a brake pedal (stopping), and a clutch (inching) pedal (for extra control of movement in tight spaces).
4. Parking brake - used when starting or exiting the vehicle
5. Steering wheel - indicates the direction of the forklift operation.

Correctly Maneuver the Machine

Before you start lifting, you must know how to safely operate the machine itself. Have a look at the below steps for a quick and correct procedure:

1. The safe way to enter the forklift is by using the grip handle, as the steering wheel can move and ultimately cause the driver to lose balance.
2. Fastening the seat belt is a must whenever you are in the driver's seat.
3. Before starting the machine, ensure that the parking brake is on and the directional control is in neutral.
4. Place the forks 2-4 inches from the ground (use the lift controls).
5. Stabilize the load by tilting the mast.
6. While keeping your foot on the brake, inspect whether it is safe to start the operation.
7. Move the direction lever forward, release the brake (parking and the pedal), and slowly press the gas pedal to start moving forward.
8. The steering wheel is the way to control the turns. However, be aware that it is the back wheels of the machine that make that move, so the forklift's back may swing out if the front is not kept close to the inside of the turn.
9. If you want to stop operating, remember to lower the forks all the way down. Then put the control in neutral, turn the engine off, and use the parking brake to secure the forklift in place.

Moving, Lifting and Lowering the Load

As the name indicates, one of the main functions of forklifts is to lift objects. Therefore, we will now guide you through an appropriate lifting procedure.

Approaching the Load:

- Approach the load (stop at the proximity of 8-12 inches from the load).
- Position the forks are at the correct height for the lift.
- Move the direction control to a neutral position.
- Set the starting brake.

Positioning:

- Move the forks under the load at at least two-thirds the length of the load.
- Ensure the forks do not extend beyond the load to avoid tipping another pallet.
- Distribute the load’s weight evenly between the forks (the center).
- Slowly tilt the mast back to ensure the stabilization of the load.

Lifting:

- Check the overhead space for any obstruction before lifting the load (otherwise your vision might be blocked by it).
- Slowly lift the load by about 4 inches.
- Tilt the mast back a little so the load can rest against the backrest extension.
- Ensure the load is clear of obstructions.
- Slowly place the life control lever in a neutral position.

Lowering:

- Once the load is positioned right above its unloading place stop the forklift.
- Shift into neutral and apply the parking brake.
- Lower the forks until the load is safely resting in the desired position.
- Reverse the forklift at the proximity of 8 to 12 inches from the load.

Good Practices for Safe Forklift Driving

Lastly, we would like to give you some standard rules to keep at the back of your head anytime you use the forklift. They are the easiest way to avoid any dangerous situations that may cause hazards to your (and your surroundings's) health and safety.

Stabilize the Machine

One of the most common reasons for forklift accidents is overturned vehicles. To mitigate the risks of tip-overs, ensure that the loads are appropriately balanced and adhere to the load capacity of the machine.

Ensure Appropriate Visibility

To make sure your visibility is not impaired always move with forks lowered to 2-4 inches off the ground. When raising and lowering loads, always ensure enough clearance.

Keep a Safe Distance

Operate the forklift at a safe distance from the edges of ramps or platforms to avoid a tip-over. Whilst lifting the load, it is advisable to stay 8 to 12 inches from the surrounding objects, loads, or pallets before lowering the mast.

Be Mindful Of the Surroundings and Other People

One of the most crucial safety rules while using the forklift is to always ensure no one is in the area of forklift operation. In case of emergency always use the horn to alert others of forklift operation. A forklift is a vehicle but should not be treated as a car, so do not lift people or give rides. Under no circumstances should you speed, especially when carrying loads.

Choose High-quality Equipment

Smooth and safe operation is not only assured by a knowledgeable operator. Having good-quality equipment is equally important. Therefore, purchase your forklift equipment from a trusted supplier. Skidsteers.com not only guarantees a wide variety of telehandler & forklift attachments made of American steel. We also offer support and guidance in all equipment-related matters. Want to know more? Give us a call and one of our advisors will answer all queries you might have!

Frequently Asked Questions

What are the basic requirements to become a forklift operator?

According to OSHA regulations, an individual must be at least 18 years of age and successfully complete an approved forklift training program, which consists of formal instruction, practical training, and a performance evaluation to obtain a forklift license.

How should an operator configure the forks and mast when driving a forklift?

When moving a forklift, the forks should be raised 2 to 4 inches off the ground. The mast should be slowly tilted backward toward the cabin to stabilize the load and prevent it from shifting.

What daily checks are required before operating a forklift?

OSHA requires operators to conduct daily pre-operation safety checks. This process is divided into a visual inspection (performed with the engine turned off) and an operational inspection (performed with the engine turned on) to detect any mechanical faults or leaks.