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Write a toolbox talk on FORKLIFT OPERATION

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Published by SALUS

Safe Forklift Operation =======================

Date: 2026-08-07

Duration: \[DURATION] minutes

Presenter: \[PRESENTER NAME]

Location: \[LOCATION]

Objective

Provide workers with practical guidance for safe forklift operation, including operator qualification, pre-use inspection, load handling, pedestrian protection, traffic management, hazard recognition, PPE, incident prevention, and emergency response expectations.

Introduction

Forklifts, also called powered industrial trucks (PITs), are essential material-handling tools, but they can cause severe injuries or fatalities when operated unsafely. Source materials note that forklift-related incidents have resulted in hundreds of deaths and thousands of lost-time injuries, which shows why disciplined operating practices, training, and daily inspections are critical. Safe operation depends on matching the right truck to the task, understanding site-specific hazards, and following the manufacturer’s instructions and workplace rules every time the truck is used.

Presenter Note: Open by emphasizing that forklift safety is not just an operator issue; it affects pedestrians, loaders, supervisors, and everyone working in the travel path.

Key Points

1\. Only trained and authorized operators may use a forklift: Forklift operators must be trained, evaluated, and authorized for the specific type of powered industrial truck they will operate. Training must cover both general forklift principles and site-specific hazards such as traffic patterns, ramps, narrow aisles, ventilation concerns, and load characteristics. Operators must also be re-evaluated at least every three years, and sooner if unsafe operation, an accident, a near miss, or workplace changes indicate the need for refresher training. [5]

[5] [7]

Know the controls, capacity, stability limits, and operating restrictions of the truck you are assigned.
Do not assume experience on one forklift transfers automatically to another model or attachment.
Report any condition that affects safe operation immediately.
2\. Complete a pre-use inspection before every shift: Each powered industrial truck must be inspected at the beginning of each shift. The inspection should verify that the truck is safe to operate, that the data plate is readable, and that critical systems such as brakes, steering, horn, tires, forks, mast, lights, seat belt, and hydraulic components are in good condition. Any defect that could affect safety must be reported and the truck removed from service until repaired. A faulty truck must not be operated. [1]

[8] [12]

Check for leaks, damaged forks, bent mast components, worn tires, loose controls, and missing guards.
Verify that the seat belt or restraint is present, accessible, and functional.
Confirm that warning decals, the operator’s manual, and the load-rating plate are present and readable.
3\. Respect load capacity and maintain stability: Never exceed the forklift’s rated capacity. The nameplate identifies the truck type and capacity, and the operator must understand that attachments, fork extensions, elevated loads, and off-center loads reduce stability and may reduce usable capacity. Keep the load low during travel, tilt it back when appropriate, and avoid sudden braking, sharp turns, or traveling with the load elevated. Stability is controlled by keeping the combined center of gravity within the stability triangle. [2]

[9] [13]

Check the nameplate before lifting any load.
Keep loads centered and secure; do not pick up loads on the tips of the forks.
Use extra caution on ramps, slopes, rough surfaces, and when turning.
4\. Protect pedestrians and control traffic: Pedestrian safety is one of the most important forklift hazards. Establish clear, separate pathways for pedestrians and forklifts, and use marked crossings, mirrors, warning devices, and right-of-way rules to reduce collision risk. Operators should slow down at intersections, sound the horn where visibility is blocked, and make eye contact with pedestrians before moving when there is any doubt about who has the right of way. If a pedestrian enters the travel path, stop and wait until the area is clear. [3]

[5] [11]

Use designated walkways and keep pedestrians out of forklift operating zones.
Slow down at blind corners, cross aisles, and restricted areas.
Never assume a pedestrian sees the forklift or understands your intended path.
5\. Use safe travel, ramp, and dock practices: Forklifts must be driven smoothly and at a speed that allows the operator to stop safely. Travel in reverse if the load blocks forward visibility. When operating on ramps or inclines, keep the load pointed uphill and avoid turning sideways on ramps. Loading docks and trailers must be secured before entry, with brakes set and wheels chocked or otherwise restrained. These controls prevent rollaway, tip-over, and trailer separation incidents. [4]

[4] [15]

Keep the load tilted back and only as high as necessary to clear the floor.
Use reverse travel when the load blocks the forward view.
Verify that trailers are secured before driving into them.

Hazard Identification

Forklift work involves multiple interacting hazards. The most serious incidents usually occur when several risk factors combine, such as poor visibility, excessive speed, unstable loads, pedestrian exposure, or unsafe surfaces. Identifying these hazards before work begins is the best way to prevent collisions, tip-overs, struck-by incidents, and dropped loads.

Untrained or unauthorized operation of the forklift: Loss of control, collisions, tip-overs, dropped loads, serious injury, or fatality due to improper operation or misuse of controls and attachments. [5]

(Risk: High)

Overloading or handling an unstable load: Forward or sideways tip-over, load drop, equipment damage, and crushing injuries to the operator or nearby workers. [13]

[3]

(Risk: High)

Pedestrian exposure in shared work areas: Struck-by incidents, crushing injuries, or fatalities if pedestrians enter the forklift travel path or blind spots. [3]

(Risk: High)

Poor surface conditions, ramps, and uneven terrain: Skidding, loss of steering control, load shift, tip-over, or collision with fixed objects. [1]

[6] [6]

(Risk: Medium)

Fueling, charging, or ventilation-related hazards: Fire, explosion, electrical shock, battery-related injury, or carbon monoxide exposure in enclosed or poorly ventilated areas. [1]

[4]

(Risk: Medium)

Presenter Note: Ask the group to identify which hazards are most likely in their own work area, then connect each hazard to a specific control.

Control Measures

Use the hierarchy of controls to reduce forklift risk. Eliminate unnecessary forklift-pedestrian interaction where possible, substitute safer equipment or methods when practical, engineer traffic separation and dock restraints, apply administrative controls such as training and traffic rules, and use PPE as the last line of defense. The strongest programs combine physical separation, clear procedures, and consistent supervision rather than relying on operator skill alone.

Separate forklift and pedestrian traffic: Mark walkways, use barriers or designated crossings where possible, and keep pedestrians out of forklift operating lanes. Reinforce right-of-way rules and require eye contact before movement when pedestrians are nearby. [3]

[14]

Control speed and turning behavior: Operate at a speed that allows safe stopping, slow down at intersections and blind spots, and make smooth, sweeping turns. Avoid abrupt braking and sharp turns, especially with elevated or off-center loads. [4]

[6]

Keep loads low, centered, and stable: Travel with the load tilted back and only high enough to clear the floor. Verify capacity on the data plate, center the load, and do not exceed rated limits or use damaged attachments. [4]

[2]

Secure trucks, trailers, and loading docks before entry: Set brakes, chock wheels, and use mechanical dock restraints or jack stands when needed. Inspect trailer floors and ramps for weakness, slippery spots, and secure attachment before driving on or into them. [4]

[15]

Remove defective equipment from service immediately: If the inspection reveals a defect that affects safety, tag the truck out of service, report it to supervision or maintenance, and do not return it to operation until repairs are completed and the truck is verified safe. [1]

[10]

Use manufacturer-approved attachments and follow capacity limits: Confirm that the truck is marked for the attachment and that the rated capacity with the attachment is known. Do not improvise lifts or use free rigging unless the manufacturer and applicable rules allow it. [6]

[1]

Safe Work Procedures

Verify operator authorization, review the task, and confirm the correct forklift type and attachment for the job before starting work. [5]
Perform the pre-use inspection at the start of the shift and document any defects or concerns before operating the truck. [1]
Check the load rating plate and confirm the load weight, center of gravity, and attachment effects before lifting. [2]
Travel with the load low, tilted back as needed, and use reverse travel when the load blocks the forward view. [4]
Slow down at intersections, sound the horn where visibility is limited, and stop for pedestrians or other traffic until the path is clear. [4]
Before leaving the forklift, lower the carriage, neutralize the controls, set the brakes, and use three points of contact when mounting or dismounting. [4]

Presenter Note: Walk the group through the sequence: inspect, plan the route, verify the load, travel safely, and park correctly.

Personal Protective Equipment (PPE) Requirements

Seat Belt or Operator Restraint: Use the seat belt or restraint system every time the forklift is operated if the truck is equipped with one. The restraint helps keep the operator in the cab during a tip-over and reduces the chance of being thrown from the seat. The belt must be accessible, functional, and kept clean and free of damage so it can be used immediately. [3]

[5]

Do not bypass or defeat the restraint system.
Replace damaged or contaminated belts before use.
Adjust the belt properly before moving the truck.
High-Visibility Apparel: Wear high-visibility apparel when walking in areas where forklifts operate, especially outside designated walkways or in mixed-traffic zones. High-visibility clothing helps operators detect pedestrians sooner and is an important control in busy warehouses, yards, and loading areas. [3]
Use apparel that is clean and visible from multiple directions.
Do not rely on clothing alone; stay in designated pedestrian routes.
Combine visibility apparel with eye contact and communication.
Safety Boots: Wear fully laced safety boots with appropriate impact protection and ankle support when working around forklifts, loading skids, or handling materials. Boots help protect feet from dropped loads, rolling pallets, and contact with rough surfaces during mounting and dismounting. [11]
Keep laces secured to prevent trips and snags.
Choose footwear suitable for the floor conditions and work environment.
Inspect soles for wear that could reduce traction.
Work Gloves: Use leather gloves or task-appropriate gloves when handling skids, shifting loads, or checking material that may have sharp edges or splinters. Gloves should improve grip and protect hands without creating a snag hazard around moving parts. [11]
Select gloves that fit properly and do not interfere with control operation.
Remove damaged gloves from service.
Do not wear gloves that are oily or contaminated.

PPE is the last line of defense and does not replace training, inspection, traffic control, or safe operating practices. PPE must be worn correctly, kept in good condition, and replaced when damaged or contaminated.

Real-World Example or Case Study

A warehouse operator entered a trailer without confirming that the trailer was secured to the dock. As the forklift moved forward to place a pallet, the trailer shifted slightly away from the dock, creating a gap and causing the forklift to drop a wheel edge near the dock plate. The operator stopped before a full tip-over occurred, but the near miss exposed a serious hazard. The corrective actions were to require wheel chocks or dock restraints before entry, verify brakes and trailer condition, and reinforce the rule that no forklift enters a trailer until the trailer is secured and the path is clear. The lesson is simple: a few seconds spent on dock security can prevent a catastrophic fall or crush incident. [15] [4]

Presenter Note: Use this example to show how one missed step at the dock can create a high-consequence event.

Group Discussion

Discuss the following questions:

What are the three most likely forklift hazards in our work area today, and what controls are in place for each one?
How do we verify that a load is within capacity before lifting, especially when attachments or fork extensions are used?
What should you do if you see a pedestrian, a damaged pallet, or a defective forklift during operations?

Presenter Note: Encourage workers to answer using examples from their own routes, docks, aisles, and storage areas.

Emergency Procedures

If the forklift becomes unsafe, stop work immediately, lower the load if it can be done safely, set the brakes, and shut the truck down. [4]
If a tip-over, collision, dropped load, or near miss occurs, keep clear of the hazard area, notify supervision, and secure the scene so no one else is exposed. [11]
If there is a fuel, battery, or ventilation emergency, move to a safe area, eliminate ignition sources if it can be done safely, and get medical or emergency assistance as needed. [1]

[4]

Questions and Answers

Questions are encouraged. If something is unclear, stop and ask before operating the forklift. A short question now is far better than an incident later.

Q: Do forklift operators need certification?

A: Yes. Operators must be trained, evaluated, and authorized to operate the specific type of powered industrial truck assigned to them. Employers must document training and evaluation, and operators must be re-evaluated at least every three years or sooner when conditions change or unsafe operation is observed. [5] [5]

Q: What should I do if I find a defect during the pre-use inspection?

A: Do not operate the forklift. Report the defect to supervision or maintenance, remove the truck from service, and ensure it is repaired and verified safe before returning it to use. [1] [10]

Q: How should loads be carried during travel?

A: Carry the load low, tilted back as needed, and only high enough to clear the floor. If the load blocks forward visibility, travel in reverse and keep the route clear of pedestrians and obstacles. [4] [4]

Summary

Recap of main points:

Only trained, evaluated, and authorized operators may run a forklift, and refresher training is required when conditions or performance indicate it. [5]
Inspect the truck at the start of each shift and remove any defective equipment from service immediately. [1]
Keep loads within rated capacity, travel low and stable, and use extra caution on ramps, turns, and uneven surfaces. [13]
Protect pedestrians through separation, communication, and traffic control, and stop whenever the travel path is not clear. [3]

Action Items

Specific actions participants should take:

Complete your pre-use inspection before every shift and report defects immediately. [1]
Verify load weight, attachment effects, and truck capacity before lifting or moving any load. [2]
Use designated routes, slow down at blind spots, and yield to pedestrians. [3]
Wear required PPE correctly, especially the seat belt, and replace damaged PPE before use. [5]
Stop work and notify supervision immediately if you see a near miss, collision, unstable load, or unsafe condition. [11]

Remember: Inspect it. Secure it. Drive it safely. Protect people first.

Report all hazards, near-misses, and incidents to your supervisor immediately.

Safety powered by SALUS

15 source record(s)

Sources used for this answer

[1] FACT SHEET: Operating powered industrial trucks (forklifts)

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## Qualifications for trainers (cont.) OPERATING POWERED INDUSTRIAL TRUCKS (FORKLIFTS) ## Pedestrian safety Most forklift-related incidents in Oregon involve pedestrians. Establish clear, separate pathways for pedestrians and forklifts. High visibility apparel should be worn when walking outside of designated walkways. Minimize blind spots and highlight intersections and restricted areas. If there is a right- of-way, ensure that everyone is aware of it. Otherwise, require the operator to make eye contact with the pedestrian (and get acknowledgment) before moving the forklift. ## Using seatbelts Seatbelts and other restraint systems should be used when provided. Seatbelts keep the operator in the cab during a tip over and prevent the operator from being thrown from the seat. Manufacturers' operating manuals also require operators to use seatbelts. Likewise, operators must be trained in the manual's instructions, warnings, and precautions. ## Lifting workers with a forklift Unless prohibited by the forklift manufacturer, workers can be lifted on a platform. The platform must be firmly secured to the lifting carriage or the forks, equipped with guardrails, and have a barrier that prevents bodily contact with the mast. The operator must stay with the forklift when workers are on the platform. The combined weight of the platform and workers should be less than one-half of the forklift's rated capacity. ## Attachments and fork extensions The forklift must be marked to identify the attachment and the capacity of the forklift with the attachment (at maximum elevation and load centered). Each fork extension should be stamped on the side with the individual load rating. Fork extensions should not be longer than 150 percent of the supporting fork's length. ## Factors affecting a forklift's stability The Stability Triangle shown in red below illustrates where the center of gravity (CG) should be for the forklift to remain stable. It's important to make sure operators…

[2] SC OSHA FACT SHEET: Powered Industrial Trucks (Forklifts)

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# Training and Evaluation (cont.) ## Using Seatbelts (cont.) South Carolina OSHA Occupational Safety and Health Administration South Carolina Department of Labor, Licensing and Regulation ## Lifting workers with a forklift Unless prohibited by the forklift manufacturer, workers can be lifted on a platform. The platform must be firmly secured to the lifting carriage or the forks, equipped with guardrails, and have a barrier that prevents bodily contact with the mast. The operator must stay with the forklift when workers are on the platform. The combined weight of the platform and workers should be less than one-half of the forklift's rated capacity. ## Attachments and fork extensions The forklift must be marked to identify the attachment and the capacity of the forklift with the attachment (at maximum elevation and load centered). Each fork extension should be stamped on the side with the individual load rating. Fork extensions should not be longer than 150 percent of the supporting fork's length. ## What can cause a forklift to tip sideways? • Excessive speed (especially while turning) • Moving with an elevated mast • Sloping surfaces • Slick surfaces • Tight turns • Shifting or off-center loads - Turning sideways on ramps For more information, visit: https://osha.llr.sc.gov # What can cause a forklift to tip forward? • Sloping surfaces - Excessive speed - Forks striking an obstruction - Traveling down ramps with load forward • Heavy braking • Overloading • Forward-tilting elevated mast - Shifting or off-center loads ## Guidelines for operating a forklift safely • Look in the direction of travel and look to the rear when backing up. Drive in reverse if the load obstructs the forward view. • Slow down and honk at cross aisles and other areas where vision is obstructed. • Operate the forklift at a speed that will allow it to stop safely. • When making turns, slow down and turn in a smooth, sweeping motion. Ensure that pedestrians…

[3] Forklift Safety Guide

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# How a Forklift Works Stability Triangle and Center of Gravity Unloaded Forklift Maximum Load with mast vertical Forklifts have a "stability triangle." The sides of the triangle as shown in the illustration are formed by the center of each front wheel and the center of the rear wheel, or at the center of the axle if there are two rear wheels. A vertical line extending from the center of gravity of the vehicle-load combination must be inside of the stability triangle to prevent the forklift from tipping forward, falling sideways or dropping its load. The center of gravity of the forklift-load combination can move outside the stability triangle if: ■The load is picked up on the tip of the forks ■The load is tilted forward ■ The load is tilted too far back when raised ■The load is wide ■ Forklift movement causes the center of gravity to shift. 5,000 5000 +24 Forklift + load center of gravity Unstable Stable Unloaded forklift's center of gravity ## These actions will have the following effects: <table><tr><th>Action</th><th>Center of gravity moves</th></tr><tr><td>Tilting the load forward</td><td rowspan="4">Toward the front axle</td></tr><tr><td>Raising the load while tilted forward</td></tr><tr><td>Driving on an incline with the load downhill</td></tr><tr><td>Stopping forward travel or accelerating backward</td></tr><tr><td>Tilting the load back</td><td rowspan="4">Toward the rear axle</td></tr><tr><td>Raising the load while tilted back</td></tr><tr><td>Driving on an incline with the load uphill</td></tr><tr><td>Accelerating forward or stopping backward travel</td></tr><tr><td>Driving across an inclined surface</td><td>Toward the downhill side of the triangle</td></tr><tr><td>Driving across a rough or uneven surface</td><td>Toward the rut or low side of the triangle</td></tr><tr><td>Turning</td><td>Toward the side now facing the original direction of travel</td></tr></table> 12

[4] Forklift Operator’s Daily Checklist

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# Forklift Operator's Daily Check List Check each item Before Start of Each Shift Date_____________ Check one: [ ] Gas/LGP/Diesel Truck [ ] Electric Sit-down [ ] Electric Stand-up [ ] Electric Pallet Truck Serial Number: <empty> Hour meter reading: <empty> Operator: <empty> Supervisor's OK: <empty> Let you supervisor and/or maintenance know of any problem. DO NOT OPERATE A FAULTY TRUCK. Your safety is at risk. Check boxes: ok [x] NG = needs attention, or repair – circle problem and comment * * (if equipped) <table><tr><th>OK</th><th>NG</th><th>Visual Check</th><th>Comment</th></tr><tr><td></td><td></td><td>Tires/wheels: wear, damage, nuts tight</td><td></td></tr><tr><td></td><td></td><td>Head/Tail/Working Lights: damage, mounting, operation</td><td></td></tr><tr><td></td><td></td><td>Gauges/Instruments: damage, operation</td><td></td></tr><tr><td></td><td></td><td>Operator Restraint: damage, mounting, operation, oily, dirty</td><td></td></tr><tr><td></td><td></td><td>Warning Decals/Operator's Manual: missing, not readable</td><td></td></tr><tr><td></td><td></td><td>Data Plate: not readable, missing</td><td></td></tr><tr><td></td><td></td><td>Overhead Guard: bent, cracked, loose, missing</td><td></td></tr><tr><td></td><td></td><td>Load Back Rest: bent cracked, loose, missing</td><td></td></tr><tr><td></td><td></td><td>Forks: bent, worn, stops OK</td><td></td></tr><tr><td></td><td></td><td>Engine Oil: level, dirty, leaks</td><td></td></tr><tr><td></td><td></td><td>Hydraulic Oil: level, dirty, leaks</td><td></td></tr><tr><td></td><td></td><td>Radiator: level, dirty, leaks</td><td></td></tr><tr><td></td><td></td><td>Fuel: levels, leaks</td><td></td></tr><tr><td></td><td></td><td>Battery: connections loose, charge, electrolyte low</td><td></td></tr><tr><td></td><td></td><td>Covers/Sheet metal: damaged, missing</td><td></td></tr><tr><td></td><td></td><td>Brakes: linkage, reservoir fluid level, leaks debris on floor</td><td></td></tr><tr><td></td><td></td><td>En…

[5] SC OSHA FACT SHEET: Powered Industrial Trucks (Forklifts)

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# Powered Industrial Trucks (Forklifts) Fact Sheet (cont.) ## What vehicles are considered powered industrial trucks? (cont.) South Carolina OSHA Occupational Safety and Health Administration South Carolina Department of Labor, Licensing and Regulation # Training and Evaluation Forklift operators must have classroom instruction, hands-on training, and an evaluation to determine their competency. The evaluation must take place in the workplace so the trainer can observe the operator perform typical tasks in the operator's environment. Someone other than the employer can do the training and the evaluation; however, training out of the workplace must be supplemented with on-site training that covers site-specific hazards and tasks the operator will be performing. The employer must certify that each operator has been trained and evaluated. The certification must include the operator's name, the trainer's name, and the training and evaluation dates. Operators must be re-evaluated at least once every three years and receive refresher training ## WHEN: • An operator is observed operating the forklift unsafely • After a forklift accident or near-miss incident • An operator is assigned to operate another type of forklift - There is a change in the workplace that could affect the safe operation of forklift For more information, visit: https://osha.llr.sc.gov Agricultural employers must provide refresher training at least annually. ## Qualifications for trainers Trainers must have the knowledge, training, and experience necessary to train and evaluate forklift operators. Their experience should include the practical skills and the judgment they have shown to operate the equipment safely. Outside certification as a trainer is not required. pen Sans Light 11.9 font size/white ## Pedestrian Safety Establish clear, separate pathways for pedestrians and forklifts. High visibility apparel should be worn when walking outside of designated walkways. Minimize blind sp…

[6] Forklift Safety: Training requirements and helpful tips

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# These topics must be covered when training or evaluating a forklift operator. Employers must document that employees have been trained and/or evaluated in all the topics listed below. Use of this checklist for that purpose is optional. ## General Forklift Topics - Operating instructions, warnings and precautions for types of industrial truck the operator will be authorized to operate. ㅁㅁ - Differences between the forklift and an automobile. - Vehicle controls and instrumentation: where they are located, what they do and how they work. - Engine or motor operation. - Steering and maneuvering. - Visibility (including restrictions due to loading). - Fork and attachment adaptation, operation and use limitations. - Vehicle capacity. - Vehicle stability. - Vehicle inspection and maintenance that the operator will be required to perform. ООП - Refueling and/or charging and recharging of batteries. - Operating limitations. - Other operating instructions, warnings or precautions listed in the operator's manual for the types of vehicles that the employee is being trained on. ## Workplace-Specific Topics - Surface conditions where the vehicle will be operated. - Composition of loads to be carried and load stability. - Load manipulation, stacking and unshackling. - Pedestrian traffic where the vehicle will be operated. - Narrow aisles and other restricted places where the vehicle will be operated. - Hazardous (classified) locations where the vehicle will be operated. - Ramps and other sloped surfaces that could affect the vehicle's stability. - ப Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust. - ப Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation. - Retraining required if changes in workplace conditions could affect safe operation (such as: new trenches, new worker ac…

[7] Safe Operation of Forklifts and other powered industrial trucks (PITs)

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# Forklift Stability Triangle Vehicle Center of B Gravity (Unloaded)) A Center of Gravity C of Vehicle and Stability Triangle and Maximum Load Center of Gravity (Theoretical) Unloaded Forkin Maximum Load with mast vertical Almost all counterbalanced powered industrial trucks supported at three points. This is true even if the vehicle has four wheels. The truck's steer axle is attached to the truck by a pivot pin in the axle's center. When this point is connected to the front wheels with imaginary lines, this three-point support forms a triangle called the stability triangle. So long as the center of gravity remains within this stability triangle, the truck is stable and will not tip over. Washington State Department of Labor & Industries 21

[8] FACT SHEET: Operating powered industrial trucks (forklifts)

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## What can cause a forklift to tip sideways? (cont.) OPERATING POWERED INDUSTRIAL TRUCKS (FORKLIFTS) ## What can cause a forklift to tip forward? • Sloping surfaces • Excessive speed • Forks striking an obstruction • Traveling down ramps with load forward • Heavy braking • Overloading • Forward-tilting elevated mast • Shifting or off-center loads ## Guidelines for operating a forklift safely • Look in the direction of travel and look to the rear when backing up. Drive in reverse if the load obstructs the forward view. • Slow down and honk at cross aisles and other areas where vision is obstructed. • Operate the forklift at a speed that will allow it to stop safely. • When making turns, slow down and turn in a smooth, sweeping motion. Ensure that pedestrians or other obstacles are clear of the backswing. • Keep arms and legs within the periphery of the forklift. • When traveling with a load, make sure the load is tilted back and raised only as high as necessary to clear the ground. Loads must face upgrade on slopes greater than 10 percent. • When loading trucks and trailers, make sure they are secured at the loading dock, the brakes are set, and the wheels are chocked. Use jack stands when necessary to prevent trailers from upending. Look for weakness or slippery spots on trailer floors. When used, portable yard ramps must be secured to the truck or trailer. • Be aware of carbon monoxide poisoning when operating propane-powered forklifts indoors. Provide good ventilation. Early symptoms of poisoning include headaches, dizziness, and nausea. • Before getting off a forklift, lower the carriage, neutralize the controls, and set the brakes. Use three points of contact when getting on or off a forklift. ● Inspect forklifts daily or after each shift if they are used round the clock. Forklifts not in safe operating condition must be removed from service. The data plate must be in place and readable. ● Follow the manufacturer's recommendations when…

[9] Forklift Safety Guide

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# How a Forklift Works ## Pre-use Inspection Checklist The forklift must be checked for defects daily-usually by the operator or a designated person prior to beginning and after a shift. Even if you operate a forklift safely, a defect can cause or contribute to a serious accident. Some things to look for are: - Is the horn working? Sound the horn at intersections and wherever vision is obstructed. - Are there hydraulic leaks in the mast or elsewhere? These could cause slipping hazards or lead to hydraulic failure. - Are fuel connections tight and battery terminals covered? Dropping a piece of metal across battery terminals can cause an explosion. - Is there a lot of lint, grease, oil or other material on the forklift that could catch on fire? - Do sparks or flames come out from the exhaust system? - Does the engine show signs of overheating? - Are tires at proper pressure and free of damage? A tire with low pressure or a tire failure can cause a forklift to tip or fall when a load is high. - Do all controls such as lift, lower and tilt work smoothly? Are they labeled? - Is there any deformation or cracks in the forks, mast, overhead guard or backrest? - Are lights operating if used at night or in dark locations? - Is steering responsive? A lot of play or hard steering will reduce your control. - Do brakes stop smoothly and reliably? Sudden stops can cause tipping. - Are seat belts (if equipped) working and accessible? - Is the load capacity plate readable? Any defects that would affect safety must be corrected before the forklift is returned to service. Appendix A is a sample operator pre-use inspection checklist. 14

[10] Forklift Trucks - Traffic Management

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CCOHS CCHST Canadian Centre for Occupational Health and Safety Centre canadien d'hygiène et de sécurité au travail Forklift Trucks # Forklift Trucks - Traffic Management ## On this page Why is important to manage forklift trucks and pedestrian traffic? What should be considered when planning for forklift truck traffic management in a workplace? What are some controls that can be considered in a traffic management plan? ## Why is important to manage forklift trucks and pedestrian traffic? Traffic management is one way to minimize the risk of an incident by creating controls to ensure everyone's safety. When planning for traffic management, be sure to consult with the health and safety committee or representative, forklift operators, and workers (including pedestrians) who have tasks in the area. After controls are in place, they must be regularly reviewed to ensure their effectiveness. A forklift truck safety program should consider many factors. Please see the various other OSH Answers documents on forklift trucks for more information. ## What should be considered when planning for forklift truck traffic management in a workplace? Create a written traffic management plan. Conduct a hazard assessment to determine what hazards are present and what controls are required. Factors specific to traffic control include: - The flow of all traffic, including both forklift truck and pedestrian needs - The tasks or jobs being done, including areas where there is a higher potential for collisions - The braking distance of forklift trucks when carrying a load, the distance loads could fall (including rolling or splashing), and factors that affect forklift stability - The equipment or items used or stored in the area Forklift Trucks - Traffic Management CCOHS

[11] DOSH Directive: Powered Industrial Trucks Used to Load and Unload

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DOSH Directive Department of Labor and Industries Division of Occupational Safety and Health Keeping Washington safe and working 7.07 # Powered Industrial Trucks Used to Load and Unload Updated: February 15, 2019 I. Purpose - This DOSH Directive provides guidance to DOSH enforcement and consultation staff in applying the requirements of the Forklifts and Other Powered Industrial Trucks standard, chapter 296-863 WAC, when loading or unloading highway trucks with Powered Industrial Trucks (PITs). - II. Scope and Application - This Directive applies to DOSH operations statewide, and replaces all previous direction, whether formal or informal. This Directive has been reviewed for applicability, and remains effective with a new issue date of February 15, 2019. - For the purpose of this Directive, “CSHO" refers to enforcement and consultation staff. - III. Reference • Chapter 296-863 WAC, Forklifts and Other Powered Industrial Trucks - IV. Definition - Powered Industrial Truck (PIT) means a mobile, power-driven vehicle used to carry, push, pull, lift, stack, or tier material. - The definition of PIT is very broad and includes: fork trucks, forklifts, tractors, motorized hand trucks, powered pallet jacks and other specialized industrial trucks. Each one of these PITs has different characteristics, and regional staff and employers have asked when is it appropriate to cite an employer for not chocking or blocking the wheels of a truck or trailer being loaded by a PIT. V. Background - WAC 296-863-[redacted postal code] requires that when trucks and trailers are being loaded or unloaded with a Powered Industrial Truck (PIT), the truck or trailer must be secured to prevent movement by the chocking or blocking of the wheels, or with a mechanical device that secures the truck or trailer to the loading dock. - The primary purpose of chocking or blocking the wheels is to prevent the truck or trailer from moving away from the loading dock from the inertia cre…

[12] Forklift Safety Guide

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# Operator's Daily Checklist: Gas or LPG Forklift 1 | # Operator's Daily Checklist: Electric Forklift Check each item before the shift starts. Put a check in the box if the item is OK. Explain any unchecked items at the bottom and report them to a supervisor. Do not use an unsafe forklift! Your safety is at risk. Forklift Serial Number: Operator: ## Hour Meter Reading: Date: <table><tr><th></th><th>Visual Check</th></tr><tr><td></td><td>Tires are inflated and free of excessive wear or damage. Nuts are tight.</td></tr><tr><td></td><td>Forks and mast are not bent, worn or cracked.</td></tr><tr><td></td><td>Load back rest extension is in place and not bent, cracked or loose.</td></tr><tr><td></td><td>Overhead guard is in place and not bent, cracked or loose.</td></tr><tr><td></td><td>Attachments (if equipped) operate OK and are not damaged.</td></tr><tr><td></td><td>Forklift body is free of excessive lint, grease or oil.</td></tr><tr><td></td><td>Engine oil is full and free of leaks.</td></tr><tr><td></td><td>Hydraulic oil is full and free of leaks.</td></tr><tr><td></td><td>Radiator is full and free of leaks.</td></tr><tr><td></td><td>Fuel level is OK and free of leaks.</td></tr><tr><td></td><td>Battery connections are tight.</td></tr><tr><td></td><td>Covers over battery and other hazardous parts are in place and secure.</td></tr><tr><td></td><td>Load-rating plate is present and readable.</td></tr><tr><td></td><td>Warning decals and operators' manual are present and readable.</td></tr><tr><td></td><td>Seat belt or restraint is accessible and not damaged, oily or dirty.</td></tr><tr><td></td><td>Engine runs smooth and quiet without leaks or sparks from the exhaust.</td></tr><tr><td></td><td>Horn works.</td></tr><tr><td></td><td>Turn signal (if equipped) operates smoothly.</td></tr><tr><td></td><td>Lights (head, tail, and warning) work and are aimed correctly.</td></tr><tr><td></td><td>Gauges and instruments are working.</td></tr><tr><td></td><td>Lift and lower…

[13] Safe Operation of Forklifts and other powered industrial trucks (PITs)

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# Forklift Nameplate The nameplate will list the type of forklift and the capacity IMPROPER OPERATION OR MAINTENANCE AWARNING COULD RESULT IN INJURY OR DEATH MODEL SERIAL No. 3FM 000000 TYPE LPS TRUCK WT. 8680 ibs Weight CAPACY OF STANDARD TRUCK WITH SIMPLEX MAST A FORKS 000 AT 24 IN. LOAD CENTER WITH MAXIMUM HEIGHT OF 130 IN. RATED CAPACITY WITH Type OPTIONAL OPTIONAL MAST AND/OR ATTACHMENT LISTED BELOW MAST: VERTICAL FORKS ONLY ATTACH 24 156 24 4500X Load capacity ATCH/MODEL Sideshifter MEETS DESIGN SPECS ANSI 856.1 OSHA This forklift is a propane (LP) powered forklift, weighing 8680 lbs. with a lifting capacity of up to 4500 lbs. Washington State Department of Labor & Industries 19

[14] Toolbox Talk: Powered Industrial Trucks (PIT)

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# POWERED INDUSTRIAL TRUCKS (PIT) Date Posted: 05/30/2024 Powered industrial trucks (PIT) are essential material handling tools, better known in the work environment as forklifts. PITS help save time and reduce material handling efforts when maintained and used safely. However, according to the Bureau of Labor Statistics (BLS), from 2011 to 2017, 614 workers lost their lives in forklift-related incidents, and more than 7,000 nonfatal injuries with days away from work occurred every year. ## DOES AN OPERATOR NEED TO BE CERTIFIED TO OPERATE A PIT? PITs are divided into seven classifications. Two factors determine how a truck is classified - the fuel used and the intended use of the truck. Businesses must choose the appropriate class of truck for their purposes. All forklift operators must be trained and qualified for the type of PIT they will operate. ## BEFORE OPERATING, INSPECT THE PIT • Each powered industrial truck must be inspected at the beginning of each shift. • A PIT that needs repair is defective or unsafe should be removed from service. The problem should be recorded on a log and reported to a supervisor immediately. The truck should also be taken out of service and locked out/tagged until the repairs have been made and the truck is safe to operate. • PIT must not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer, nor will they be changed by eliminating any parts. • Adding additional counterweights to fork trucks may not be done unless the PIT manufacturer approves. ## HAZARDS FOR PIT OPERATION Untrained PIT Operators: In accordance with WAC 296-863-[redacted postal code], PIT operators must be trained in the safe operation of the equipment and be competent. Only trained and authorized operators are permitted to operate PIT. An evaluation of PIT operator performance must be conducted, at minimum, every three years. Unsafe Operation: Speeding or danger…

[15] Forklift Trucks - Professional Operator

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# Forklift Trucks - Professional Operator (cont.) ## What should an operator do when operating the forklift truck? (cont.) - Check for adequate overhead clearance before raising the load. - Operate a forklift smoothly when stopping, starting, lifting and tilting. - Know the blind spots of the lift truck with and without a load. - Use corner mirrors, back-up alarms, buzzers and warning lights to help prevent collisions. - Communicate with workers who are nearby so they understand where you plan to travel. - Keep pedestrians away from a forklift in operation. Operate with extreme caution when near pedestrians and yield the right of way to pedestrians. - Stop when anyone crosses the route being travelled. Lower the load to the floor, and wait until it is clear. - Operate at a safe speed, taking into consideration all conditions. - If loading another vehicle (e.g., transport truck), verify that the load wheels on the other vehicle are chocked before driving into the space. - Use proper procedures when travelling on inclines or ramps. See Forklift Trucks - Maintaining Truck Control. - Ensure that the fire exits, stairways and fire equipment are not blocked by the truck or the load. - Wear leather gloves when moving or shifting loads or when checking skids. - Wear fully laced safety boots to provide impact protection when moving loads or skids and to provide ankle support when mounting and dismounting the lift truck. - Remain alert and prepare for the unexpected. - Note anything that affects the normal operation of the forklift and tell the supervisor immediately. - Keep hands, arms, head, feet and legs inside the confines of a moving forklift. - Stay in the truck in case of overturn. - Maintain posture in the direction of travel. - Go over railroad tracks at an angle, where possible. - Make sure no one is standing or passing under the elevated portion of the forklift truck. - Report any collisions, damage or near-miss incidents to a s…

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Publisher: SALUS
Final reviewer: Francis Langlois
Original answer: Aug 7, 2026

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