Operating forklifts safely
Following these tips will help prevent rough-terrain forklift accidents,
80% of which are due to operator error
By Elizabeth Keating
t’s never been more important to ensure that fork-
I lift operators have adequate training. The Occupa-
tional Safety and Health Administration (OSHA) is
about to crack down on untrained operators and
their employers with OSHA 29 CFR part 1910.178. This
updated regulation, when published as a final rule
later this year, will cover lift-truck operator training.
The existing regulation is amb i g u o u sa n ds a y st h a t
“onlytrained and authorized operators shall be per-
mitted to operate a powered industrial truck” but
does not define “trained and authorized.” The new
When placing a load overhead, make sure there are no
people below.
regulation will require operators to be retrained and
recertified on the specific trucks they operate and
for their usual work environment in practical and
theoretical ways. OSHA will outline required ele-
ments of this retraining and recertification process
to make it easier for employers to establish a “quali-
ty training program.”
I fn e w so ft h e s ei m p e n d i n g ,m o re stringent OSHA
regulations is not enough to prompt more thorough
training, the danger to a contractor’s employees (of
death and inj u ry ) and to its business (with claims,
litigation, and OSHA fines) should. Most forklift acci-
dents are attributed to operator error. In fact, one
study conducted in Cook County, Ill., found that 25%
of operators involved in accidents had imbibed alco-
hol (Ref. 1). In addition, this study found people were
killed most commonly when a forklift struck them
(pedestrians) o rc ru s h e dt h e m( o p e r a t o r s )w h e n it
tipped over, fell off a dock, or fell off a truck.
While rough-terrain trucks are designed to meet
standard ANSI B56.6 - 1983 and to be “capable of be-
ing operated safely and e ff iciently despite uneven,
rutted, or sloping surfaces, and when rain, sleet, or
snow is present,” the risk of accidents can be mini-
mized by heeding the following tips (Ref. 2):
Before starting the engine
■ Before starting the engine, you must have ade-
quate training and the permission of your supervi-
sor and know the rated loadcapacity, speedrange,
braking and steering characteristics, turning ra-
dius, and operating clearances of the forklift you
plan to operate. Read the manufacturer’s manual.
Remember that conditions such as rain, snow, ice,
and loose gravel change the forklift’s operating ca-
pabilities.
■ M a k es u re y o uu n d e r s t a n dh a n d , flag, whistle, siren,
and bell sign a l sa n dw h e n t ou s el i g h t s , turn signals,
flashers, h o rn s , and sirens (see Figure 1).
■ Check for anything that might need to be repaired
(broken, missing, or damaged p a rt s ) ; check the
service and parking brakes; and check the forks
for welds, cracks, and misalignment. Repair and
replace as necessary.
■ When checking the hydraulic system, take great
 care because pressurized diesel
fuel and hydraulic fluid can dam-
age the skin. Instead of your hand,
Forklift signals
use a piece of cardboard or wood
to detect leaks, and wear safety
goggles.
■ To ensure maximum vision, clean
thewindows,windshields, and
lights, and make sure the wipers
operate properly.
■ To p re v e n ts l i p s ,c l e a nt h es t e p s ,
pedals, and floor, and b ru s h
away dust, mud, snow, and ice.
■ Just before starting the forklift,
walk completely around it to
check that no one is present, and
let people nearby know what you
are about to do.
■ When climbing into the operator’s
cab, keep either two hands and
one foot or two feet and one hand
in contact with the machine at all
times ( t h re e -point contact). Al-
ways use the appropriate handles
and steps, and never use levers
Figure 1. Do not operate a forklift until you have learned what the forklift
or the steering wheel to pull your- signals mean.
self up into the cab.
■ Learn where fire extinguishers and first-aid and sites where there is a lot of noise, a flashing warn-
emergency equipment are kept, how to operate ing light is necessary if the noise level makes it dif-
them, and where to get help in a hurry. ficult to hear the warning alarm. If the noise on the
jobsite is more than 90 decibels, hearing protec-
Starting the engine tion must be worn. Wear a respirator or a filter
■ Exhaust fumes can cause injury or death. If you mask on very dusty jobsites.
must start the forklift in an enclosed space, make ■ Make sure the automatic alarm system works
sure there is enough ventilation to replace haz- when the forklift moves in reverse.
ardous exhaust fumes with fresh air. ■ Inspect the surface over which you will move the
■ Allow the engine to warm up for one minute before load, and look for anything that might make you
moving, and investigate any unusual noises. lose control or cause the forklift to tip over (such
■ Wear a hard hat if there is no overhead guard on as soft soil, deep mud, standing water, or oil
the cab and safety glasses, goggles, or a face spills). Know where you will make your pickups,
shield if there is any risk of particles falling from lifts, and turns, and make sure the forklift can clear
overhead loads directly into your eyes. On job- all overhead obstacles.

Glossary
Boom: the pivoting section of the forklift that allows horizontal and/or vertical movement of the load.
Cab: where the truck operator sits while operating the forklift.
C a rr i a g e : the structure that supports the forks.
Crane boom: an attachment that goes on the end of the boom that allows the forklift to act as a crane.
Fork load-rating capacity: the maximum load capacity an individual fork can carry safely at any given load center
(see Figure 2).
Landing point: where the load is deposited.
Load backrest: the part of the carriage and forks that restrains the load when it is tilted up or toward the rear.
Load chart (also called identification plate): the chart that indicates the safe height and distance for a given load
weight (see Figure 3).
Load-leveling system: this levels the forklift lifting mechanism with the ground.
Outrigger: a temporary support that extends from and is connected to the truck to give it more stability.
Pinch and wrap points: places on the forklift where the mechanism would c ru s h an object at that point.
Signalperson: someone who guides the truck operator when he or she has restricted vision.
Truss boom: a hooklike attachment that goes on the end of the boom, allowing the forklift to lift objects.
Before loading
■ Always refer to the machine’s load chart before Location of
picking up the load. Remember, the greater the stamped fork
rating
reach, the smaller the lift capacity. Each fork has a
Maximum
maximum load-capacity rating (listed in the manu- load
facturer’s manual), and any combination of forks center
is the sum of their rated capacities. When the load
rating of the vehicle differs from the load-capacity
rating of the forks, take the lower value as the
overall load capacity.
■ Inspect the landing point to ensure that it can
support the load (hollow floors and scaffolds can
give way).
■ Inspect the load to be lifted (it must be stable), ap-
proach it slowly and squarely with the fork tips
straight and level, and p o s i t i o ni te q u a l l y on both
forks. Continue forward until the load touches the Figure 2. Never exceed the sum of the forks’ load-rating
capacities.
backrest.

Picking up the load

■ If the load seems unstable in any way, separate it
stability and load position on the forks. Never try
into two or more loads.
to lift the load with only one fork.
■ I ft h e f o r k l i f th a sc o u n t e rw e i g h t s (one on either
■ Travel in as low a gear as possible and avoid sud-
side), make sure they are in place before raising
den stops, starts, or turns. They can shift or top-
the load. Never add extra counterweights to com-
ple the load.
pensate for an overload.
■ Keep all parts of your body inside the cab, avoid
■ Raise the load only when the brakes are set. If the
forklift has a frame-leveling system, level the frame the pinch and wrap points, and keep all shields
before raising a load when on a slope, and before and guards in place.
depositing a load when the machine is near its ■ Never lift a load over anyone or give rides on the
height- or distance-extension limits. forklift.
■ Watch the machine’s rear clearance when you
Moving with the load turn.
■ Before you start to move the machine, check for ■ W h e ny o um o v ew i t h a load,keep the forks tilted
back, the load as close to the
ground as possible, and the
General dos and don’ts boom retracted.
DON’Ts
■ If you cannot see where you are
Do not lift another truck.
Do not smoke while refueling. going, get a signalperson to
Do not speed shift or pop the clutch. guide you.
Do not start, stop, or downshift suddenly—you could topple the load. ■ If you are carrying a suspended
Do not drive near the edge of an excavation. load, use a tether to restrict its
Do not modify or remove any part of the equipment. movement.
Do not use attachments (such as a truss boom or a crane boom) unless ■ When carrying round objects
authorized by the manufacturer. However, when using attachments, oper- (such as drums, reels, or cylin-
ate the forklift as a partially loaded unit. (The additional weight of the at-
tachments should be considered part of the load capacity.)
ders), keep the forks tilted back
Do not operate the forklift in an area where there is flammable dust or va- and use a tie-down if necessary.
por unless there is good ventilation. Sparks from the electrical system and ■ Be especially alert and careful
engine exhaust can cause an explosion. when operating near the edge of
Do not lift double-tiered loads—they are difficult to control. a loading dock, embankment,
DOs ditch, or ramp.
Have the brakes adjusted if the t ru c kp u l l st oo n es i d ew h e ns t o p p i n g . ■ When traveling with a load on in-
Always request that overhead power lines, overhead or u n d e rg ro u n d clines, slopes, or ramps, point
cables, and other power s o u rc e s be de-energized or take other suitable the (loaded) forks uphill.
precautions.
■ When traveling without a load
Use low gears whenever possible.
Operate the truck from the seat with the seatbelt buckled. on inclines, slopes, or ramps,
If a forklift starts to tip, stay in the cab, hold on firmly, and lean away from point the forks downhill.
the point of impact. ■ Never allow the forklift to coast
in neutral.
 6000 LBS
2700 KG

5000 LBS
2270 KG

4000 LBS
1800 KG

3000 LBS
1350 KG

2500 LBS
1150 KG

2000 LBS
900 KG

Small loads can be lifted higher and extended further Figure 3. There should be a load chart similar to this on
than large ones. the body of the forklift. Always check it before moving
a load to make sure you are not going to exceed the
forklift’s capabilities.

■ When there is other jobsite traffic, drive on the

right-hand side of the “road” and stay four lengths
f ro mt h ev e h i c l ei nf ro n t .
Depositing the load
■ When placing a load on the ground, make sure
the area under it is clear, lower the load to the
ground, tilt the forks to the horizontal position,
and back away carefully to disengage the forks.
■ When placing a load overhead, make sure there
are no people near the area where the load could
tip or fall.
■ Do not raise the load for placement if the forks are
tilted to one side. If your forklift has a leveling
mechanism, level the forklift before the load is
raised. If the forklift has outriggers, they should
be lowered into position before the boom is raised.
■ Set the parking brake and slowly raise the load at a
slight back tilt.
■ At the slightest indication of instability, stop, low-
er the load and restack it, or break it into two or
more loads. (Remember a forklift becomes less
stable as loads are raised higher.)
■ As you raise the load close to the required height,
slow down to the minimum speed, raise it slightly
higher than the landing point, and gently lower it
until the forks are free. At the slightest indication
of overloading—such as cracking, squeaking tim-
ber, or excessive scaffold bowing—lift the load, re-
tract the boom, and lower it to the ground.
■ Once the load is where you want it, retract the
forks, lower them to the traveling height, and re-
turn for the next load.
Shutdown
■ Park the truck on level ground and out of traffic,
deep mud, or water if possible.
■ Idle the engine for gradual cooling.
■ Leave the transmission in neutral, set the parking
brake, and lower the boom completely. Tilt the
boom all the way forward.
■ Shut off the engine, cycle the hydraulic controls
(to eliminate residual pressure), and remove the
ignition key.
■ Face the forklift when you dismount, using three-
point contact.
■ Put blocks under the wheels if you must park on a
slope or incline.
Training
When OSHA’s final rule is published later this year,
 Safety basics
Tether a suspended load. Avoid ruts and ditches.
the Industrial Truck Association (ITA)
will publish a comprehensive list of
trainers and training programs for em-
ployers that want to establish a total
quality training program. Requests for
this free list should be faxed to Magan
Crane at ITA (202.296.9884).
Videos, training manuals, and cours-
es on the safe operation of rough-ter-
rain forklifts are available f ro m indus-
try associations. For instance, the Oak
Brook, Ill.-based Mason Contractors As-
sociation of America (630-782-6767)
publishes a training manual and accom-
panying video that can be completed
under the guidance of an instructor to
educate employees on the safe opera-
tion and maintenance of forklifts.
When the loaded boom is
at its maximum extension
or height, the forklift’s
center of gravity is at its Do not drive across a
most critical stability limits slope with the boom up.
and extreme caution
should be used.
References
1. Barry D. Lifschultz and Edmund R. Donoghue,
“Deaths Due to Forklift Truck Accidents,” Forensic
Science International 65 (1994), pages 121-134.
The authors of this study reviewed deaths resulting Carry the load as low as
from forklift accidents between 1884 and 1992 in possible and fully retracted.
Cook County, Ill. (which contains Chicago). The
percentage mentioned was based on cases where
toxicologic results were available.
2. “Forklift Trucks that Conquer Rough Terrain,”
Modern Materials Handling, December 10, 1994.
3. Rough Terrain Forklift Safety and Maintenance
Training Manual, Mason Contractors Association
of America 1550 Spring Rd., Suite 320, Oak Brook,
IL 60521.
When placing loads at
PUBLICATION #M970061 high elevations and on
Copyright © 1996, The Aberdeen Group downhill grades, use ex-
All rights reserved treme caution.