How to Operate a Forklift Safely

Driving a forklift is not just about getting in and going. It needs proper training, careful attention, and strict safety rules. It is important to know how to do pre-operational checks. This applies to both experienced operators and those new to the job.

You also need to safely move and maintain the forklift. Let’s break down the key steps to operating a forklift safely.

Pre-Operation

Before starting up a forklift, a thorough pre-operational inspection is essential. This ensures that the machine is in good working order and prevents potential hazards.

*Pre-operational inspection requirements vary between models and manufacturers. The information below serves as a general guide only.

General Pre-Operational Forklift Inspection Checklist

Before operating a forklift, it’s important to carry out a visual and functional inspection. Start by checking the tyres for any damage or signs of low pressure. Inspect the forks carefully for cracks, bends, or other signs of wear. Make sure all the safety features, including horns and lights, are working properly. Look around the hydraulic system for any visible leaks. It’s also essential to test the brakes, steering, and operational controls to ensure they’re responsive. Lastly, confirm that the operator restraint system is in good condition.

Pre-Operational Inspections for Electric Forklifts

• Check battery charge levels.
• Inspect cables and connectors for signs of wear or corrosion.
• Look for any exposed wires or electrical damage.

Pre-Operational Inspections for Internal Combustion Forklifts

• Check fuel levels.
• Examine the exhaust system for leaks or excessive smoke.
• Once the forklift is turned on and the display visible, ensure the engine oil and coolant levels are sufficient.

Pre-Operational Inspections for Liquid Propane Forklifts

• Inspect the propane tank for damage or leaks.
• Check that the hose and fittings are secure and not worn.
• Make sure to mount the propane tank correctly.

How to Operate a Forklift: Travelling and Manoeuvring

Once your forklift has passed the pre-operational checks, it’s time to operate it safely.

• Always wear your seatbelt and remain within the counterbalance forklift’s cab.
• Keep your hands, feet, and body inside the operator compartment.
• Maintain a safe speed and follow posted speed limits.
• Keep a safe distance from pedestrians and other vehicles.
• Avoid sudden stops or sharp turns that could cause instability.
• Use your horn at blind corners or when approaching other workers.
• Reverse your travel if something obstructs your forward view.

How to Operate a Forklift: Handling Loads

Proper load handling is critical for maintaining balance and avoiding tip-overs.

• Ensure the load is stable and evenly distributed on the forks.
• Do not exceed the forklift’s load capacity.
• Lift the load smoothly and avoid jerky movements.
• Keep the load low while travelling to maintain a lower centre of gravity.
• Tilt the forks slightly backward to secure the load.
• Stack loads properly and avoid overloading shelves or racking systems.

How to Operate a Forklift: Maintenance and Removal from Service

Regular maintenance ensures forklifts remain in safe working condition. If inspectors find a forklift unsafe during inspection or operation, they should remove it from service immediately.

• Conduct daily and scheduled maintenance checks.
• Report any issues to a supervisor or maintenance team.
• Never attempt to repair a forklift unless qualified to do so.
• If someone deems a forklift unsafe, tag it as ‘Out of Service’ until repairs are completed.

Other Essential Safety Tips

Never Operate Unlicensed

In Australia, operating a forklift without the appropriate high-risk work licence is illegal. Ensure you have the required certification before use.

Wear Your Safety Gear

Always wear the required personal protective equipment (PPE), including high-visibility clothing, steel-toe boots, and a hard hat.

Check the Forklift Every Day

A quick daily inspection can prevent serious mechanical failures and accidents.

Follow Speed Restrictions

Speed limits exist for a reason—staying within them reduces the risk of accidents, especially in busy workplaces.

Don’t Get Complacent

Even experienced operators can make mistakes. Stay alert, follow procedures, and never take shortcuts when it comes to safety.

By following these guidelines, you’ll help create a safer workplace for yourself and those around you. Always prioritise safety and operate your forklift with care.

Looking for forklifts that suit your application? View our product range in the link below.

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