In this article, we set out to explain how to operate a forklift. If you've been wanting to learn how to drive a forklift, then this is a great starting point for you.
You'll learn valuable and helpful information in this article, but please know that you won't know how to drive a forklift safely just as a result of reading this article. That takes more extensive forklift operator training, including demonstrations from a skilled instructor, practice forklift operation by you, and a forklift operator skill demonstration evaluated by your instructor.
But, as we said, if you're looking for a great and helpful 101-level introduction of how to operate a forklift, then you're in the right place.
How to Operate a Forklift: Pre-Operation, Traveling and Maneuvering, and Load Handling
We'll break down instruction on how to drive and operate a forklift into three sections:
Pre-operation, including pre-operation inspections
Traveling and maneuvering the forklift
Handling loads with the forklift
As you'll see, each of the three sections will be broken down into instructions for smaller tasks involved in learning how to drive a forklift.
Remember that before anyone operates a forklift, they must receive proper forklift safety training. OSHA details the specifics for that in 1910.178(l) and we have a separate article on forklift operator training requirements as well.
Forklift Pre-Operation Duties
Before you can operate a forklift, you're going to need to:
Perform operational inspections with the engine running
Instructions for performing each of these steps of operating a forklift are provided below.
This should go without saying, but we'll say it anyway: if a forklift has been taken to service because it's defective, needs repair, or is in any other way unsafe, never return it to service until the problem has been resolved.
Pre-Operational Forklift Inspection
In 29 CFR 1910.178(g)(7), OSHA requires all forklifts be examined at least once a day before they are placed into service. If a forklift is used around the clock, then inspections must occur after every shift.
The forklift operator should preform two inspections:
Pre-operational visual inspection with key off
Operational inspection with engine running
We'll cover both inspections in this section, starting with the pre-operational inspection.
If the forklift operator determines that the forklift needs repair or servicing as a result of the inspection(s), the forklift must be immediately removed from service.
General Pre-Operational Inspection Items
Before the forklift is turned on, visually inspect the following:
Oil level
Water level
Hydraulic fluid level
Hydraulic hoses (look for leaks, cracks, or any other defects)
Mast chains (look for cracks, breaks, or any other defects). Use a stick or similar device to check the chain tension. The forklift operator should never place a hand into the mast.
Tires, including condition and pressure (be sure to inspect for cuts and gouges)
Forks (check the condition, including the top clip retaining pin and heel
Loaded backrest extension
Finger guards
Safety decals and nameplates (make sure they are all in place and legible; check that the information on the nameplate matches the model and service numbers and attachments)
Operator manual (make sure it's there on the truck and that it's legible and complete--no missing or torn pages, etc.)
Operator compartment (check for debris, grease, etc.)
Safety belt and all other safety devices (make sure they're all working properly)
Pre-Operational Inspections for Electric Forklifts
If you have an electric-powered forklift, check these items during the pre-operation inspection in addition to the items on the "general" list:
Cables and connectors (look for frayed, exposed, or otherwise damaged wires)
Battery restraints
Electrolyte levels (always use proper personal protective equipment, such as a face shield, rubber apron, and rubber gloves, when checking the electrolyte level)
Hood latch
Pre-Operational Inspections for Internal Combustion Forklifts
If you have a forklift powered by an internal-combustion engine, check these items during the pre-operation inspection in addition to the items on the "general" list:
The liquid propane tank (ensure it's properly mounted; check for dents and cracks; check to make sure it fits within the profile of the tank)
Remember to always use proper personal protective equipment, such as a face shield, long sleeves, and gauntlet gloves, when making these inspections
Per-Operational Inspections for Liquid Propane Forklifts
If you have a forklift powered with liquid propane, check these items during the pre-operation inspection in addition to the items on the "general" list:
People frequently get hurt while attempting to mount the forklift they'll operate. In particular, hazards include:
Hitting your head on the overhead cage
Slipping, tripping, and falling, especially when feet slip off the step
Here are some ways to avoid these hazards:
Make sure your hands are clean, dry, and empty when mounting the forklift
Wear appropriate shoes or boots that avoid skids
Check your shoes for grease or anything else slippery
Grab the handhold and get a good trip. Don't grab the steering wheel as a way to mount the forklift--the steering wheel may move, causing you to lose your balance
Be careful with your footing at all times; be aware of what you're doing, do it slowly, and be intentional
Pull your body up into the forklift-don't jump
Starting the Forklift
Don't try to start the forklift before you've completed the pre-operational inspection. Once that's done, start the forklift and then prepare to complete the operational forklift inspection before driving off.
Operational Forklift Inspection
After the pre-operational inspection (with key off) is complete and you've mounted the forklift, it's time for a operational forklift inspection.
You'll conduct this second inspection with the engine running. During the operational inspection, check:
Accelerator linkage
Inch control (if present)
Brakes
Steering
Drive control, including both forward and reverse
Tilt control, including forward and back
Hoist and lowering control
Attachment control
Horn
Lights
Back-up alarm (if present)
Hour meter
In addition to all of the above, observe for unusual noises or vibrations. If you detect any, report them immediately.
Traveling and Maneuvering the Forklift
In this next section of our instructions on how to drive a forklift, we're going to cover instructions for traveling on and maneuvering the forklift.
Many people think that operating a forklift is simple and basically like driving a car. But in fact, driving a forklift is very much different than operating a car, and that's one of many things you should know before you operate the truck.
Visibility Concerns While Operating the Forklift
Operating a forklift with blocked or partially blocked visibility increases the chances of an accident.
Impaired visibility can lead to hazards such as:
Collisions
Falling load
Having the forklift fall off a loading dock
Striking or crushing pedestrians
Because none of that is good and we want to avoid all of it, do everything possible to make sure visibility is entirely unblocked or blocked as little as possible before operating. Here are some requirements and recommendations:
Keep a clear view
Look in all directions around you before you begin
When traveling, always look in the direction of travel. This includes looking behind you when operating in reverse
Use spotters, rear view mirrors, and/or other aids to increase visibility whenever possible
When possible, use concave mirrors when entering buildings or aisles and/or when approaching corners or other blind spots
If lighting is dim (less than two lumens per square feet), use headlights
Use headlights when operating at night, outdoors, and/or in any area where additional lighting would improve quality
Drive slowly into and out of warehouses or other buildings. Moving from a bright to a dark area, or from dark to bright, can temporarily disrupt visbility.
Be cautious on loading docks and stay away from edges, which can be hard to see
Slow down and sound the horn at cross aisles and other locations where vision can be obstructed
In addition, consider adding the following at the work area to decrease hazards related to limited visibility:
Add physical barriers such as ramps, raised concrete staging areas and heavy-gauge safety chain in front of loading dock openings.
Use protective guard rails
Add a "warning track" of yellow floor paint near dock openings
Beginning to Drive the Forklift
Before you begin to move the forklift, make sure your way is clear by looking in your direction of traffic. Sound your horn and/or use a spotter if your vision is obstructed.
Once you're sure your path is clear, proceed with caution down the path of travel and watch for dangerous curves, blind spots, intersections with pedestrian traffic, and/or any other hazards.
Driving the Forklift at Speed
When you're driving the forklift at speed, always anticipate and do everything possible to avoid the following potential hazards:
Tipovers caused by driving too fast
Collision with pedestrians and obstacles caused by not paying attention and not having time to stop
In short, drive slowly and pay attention.
In addition, follow these requirements and recommended practices:
Look in the direction of, and keep a clear view of, the path of travel
Always operate the forklift at a speed that will allow you to stop it in a safe manner
Slow down when driving on wet or slippery floors
If the load you're carrying obstructs your forward view, travel with the load trailing instead
Slow down and sound the horn at cross aisles and other locations where your view is obstructed
When turning, always slow down to a safe level and turn the steering wheel in a smooth, sweeping motion
When driving up or down a grade (or incline), always do so slowly
When driving up or down a grade in excess of 10 percent, drive a loaded truck with the load upgrade
Don't run over loose objects on the path of travel
Obey and/or observe all posted speed limits and warning signs
Changing the Forklift's Direction of Travel
Changing directions on a forklift raises hazards. These include:
Tipover
Collision with a pedestrian
Collision with another vehicle
Collision with an object
To avoid those hazards, follow these requirements and recommendations:
Always stop completely before changing directions
Use a horn and/or a warning light to warn pedestrians before and while you operate in reverse
Steering and Turning the Forklift
When you're steering a forklift, potential hazards include:
Collisions with pedestrians or objects; this hazard is increased because of the way the rear end (or tail) of a forklift swings out widely to the side opposite the turn
Colliding with something and then having the load fall
Tipovers caused by turning too sharply
To avoid these hazards, follow these requirements and recommendations:
Plan your route in advance and anticipate all turns
Never turn with the forks elevated
Never turn on a grade (or incline/decline). Turning on a grade makes the forklift more likely to tipover--even a small grade.
Reduce speed to safe level when turning
Use extreme care when making a turn, especially when turning in confined areas or narrow aisles. This is because when a forklift turns a corner, the rear end of the forklift swings out widely in the direction opposite of the turn
Because the forklift's tail end swings out widely in the direction opposite of the turn, always start the turn as close as possible to the inside corner
Reversing the Forklift
Reversing a forklift increases the risks of injury and accidents. Hazards involved in reversing the forklift include:
Striking or crushing pedestrians
Colliding with another forklift or object
Always use extreme caution when backing up. In addition, follow these requirements and recommendations:
Keep a clear view in the direction of travel
Look in the direction of travel. That means looking behind you when driving in reverse.
Always be aware of limited visibility, and use extra caution when driving in reverse
Consider using ground guides, rear-view mirrors, spotters, or other aids to increase visibility while operating in reverse
Consider the noise level in your workplace and the possibility that other workers are wearing hearing protection. Don't assume that pedestrians or bystanders are able to hear your back-up alarm.
Always leave lots of room for pedestrians. Remember that you can't correctly anticipate all of their actions and many pedestrians are not familiar with the operational limits of a forklift.
Don't grab the overhead guard when traveling in reverse. This could result in harm to your finger.
Operating the Forklift on Grades (Inclines and/or Declines)
When a forklift is operated on a grade, hazards include:
Tipover
Falling load
To reduce these hazards, follow these requirements and recommendations:
Always drive unloaded forklifts with the forks downgrade
Never drive a loaded forklift with the load downgrade
When driving up a ramp, drive loaded forklifts forward with the load upgrade
When driving down a ramp, drive loaded forklifts in reverse with the load upgrade
Never turn a forklift while driving on a grade (incline or decline)
Safe Forklift Travel Practices
Forklifts always pose some level of hazards while they're being operated, including:
Overturning
A load that falls
Striking a person or crushing a person
Collisions
As a result, always follow these requirements and recommendations while operating a forklift:
Always look in all directions before beginning to travel
Always look in the direction of travel while traveling
If a load on the forks blocks your view of the intended path of travel, travel in reverse.
Always maintain a safe distance from the forklift ahead of you (about three truck lengths)
Observe all traffic regulations and posted signs, including plant speed limits
Keep the forklift under control at all times
Yield the right of way to ambulances, fire trucks, or other emergency vehicles in emergency situations
Don't pass other forklifts (or powered industrial trucks) that are traveling in the same direction while at intersections, blind spots, or at other dangerous locations
Whenever possible, avoid crossing railroad tracks in a perpendicular direction. Instead, cross them diagonally when possible
Never park closer than 8 feet from the center of railroad tracks
Always operate the forklift at a speed that will allow you to stop the forklift safely under all travel conditions
Never take part in horseplay while driving a forklift and never take part in stunt driving with a forklift
Slow down while operating on wet or slipper floors
Properly secure dockboards or bridgeplates before driving a forklift over them. While driving over them, be careful and drive slowly. Never exceed the listed capacity of a dockboard or bridgeplate.
While driving a forklift, always approach elevators slowly, wait for the elevator car to be properly leveled, and only then and enter the elevator squarely. Once on an elevator, neutralize all controls, shut off the power to the forklift, and set the brakes.
Do as much as possible to keep forklift traffic patterns separate from pedestrian traffic. When possible, use established pedestrian walkways and strictly enforce their use. Use guard rails and floor markings on pedestrian walkways.
Never carry a passenger on a forklift
Keep your arms and legs inside the forklift at all times during operation
Watch for any surface obstruction; even small ones can knock the load off your truck
Never drive a forklift up to a person who is in front of a bench or any other fixed object
Never drive into a position that would lead to a coworker being pinned between the forklift and something else if the forklift jumped forward, the brakes failed, or the wrong lever was pushed
Stopping the Forklift
When stopping a forklift, always follow these requirements and recommendations:
When preparing to stop, apply the brake slowly
If you're stopping the forklift to park, follow the recommendations below as well
Parking the Forklift
A parked forklift can present hazards to the forklift operator and to others as well.
These hazards include:
The possibility of a forklift being parked in the wrong place and, as a result, being struck by people or objects
The possibility that the forklift might somehow move
To avoid these hazards, the parked forklift should be properly secured.
A forklift is considered to be unattended if the operator is 25 feet away or further from the forklift. This is true even if the forklift is in the operator's view. In addition, the forklift is considered unattended anytime the operator leaves the forklift and the forklift is not in his view (even if the forklift is closer than 25 feet away).
When stopping a forklift, always follow these requirements and recommendations:
Avoid parking on a grade if possible
Never park in an unauthorized area
Never park in a way that blocks an aisle or an exit
Select an appropriate area to park; follow your company's recommendations for parking forklifts to do so
When preparing to stop, apply the brake slowly
Once stopped, tilt the mast forward slightly and fully lower the load
Neutralize the forklift controls
Once the forklift has stopped, engage the parking brake
Turn off the ignition
Get off the forklift without jumping (see "Dismounting the Forklift" below for more details on this)
If you've parked the forklift on a grade, block the wheels
If the forklift is disabled, and you can't lower the forks to the floor, follow proper lockout/tagout procedures (as described in 29 CFR 1910.147) and make sure nobody stands or passes under the forks and/or load.
Dismounting the Forklift
Just as its important to be careful while mounting a forklift, it's also important to be careful while dismounting a forklift.
Here are some ways to avoid these hazards:
Make sure your hands are clean, dry, and empty when mounting the forklift
Wear appropriate shoes or boots that avoid skids
Check your shoes for grease or anything else slippery
Grab the handhold and get a good trip. Don't grab the steering wheel as a way to mount the forklift--the steering wheel may move, causing you to lose your balance
Be careful with your footing at all times; be aware of what you're doing, do it slowly, and be intentional
Pull your body up into the forklift-don't jump
Forklift Tipover Risks
Forklifts tip over in two basic ways:
Tipping over forward, also known as a longitudinal tipover
Tipping over to the side, also known as a lateral tipover
What you can do to avoid a tipover depends on the type of tipover and the class of forklift you're using.
What To Do In the Event of a Tipover
If you're operating a sit-down counterbalanced forklift and it's tipping over:
Stay in the forklift; don't try to jump out
Hold tightly to the steering wheel
Brace your feet
Lean your body away from the anticipated point of impact
Lean your body forward
As mentioned earlier, tipover hazards vary depending on the type of forklift. That's also true of what an operator should do if a forklift is tipping over--procedures differ depending on the type of forklift. For example, a person operating a stand-up forklift with rear-entry access, the best thing to do during a tipover is to step backwards off of the forklift.
Handling Loads with a Forklift
The point of operating a forklift is to lift and move loads. And so part of learning how to drive a forklift is learning how to handle loads with the forklift.
As a result, we'll look at some tips and considerations for safely handling loads with a forklift in this section.
We'll consider:
Preparation for safely handling a load
Approaching the load with the forklift
Mast position on the forklift
Lifting the load
Lowering the load
High tiering
Truck trailers and railroad cars
Safe Handling Preparation
There are some general rules to follow to ensure safe handling of loads with a forklift.
Before you handle a load, watch out for:
Loads which are off-center and may cause the forklift to tipover or the load to fall off the truck
Overloading the forklift, which can cause the forklift to tipover or the load to fall
Damaged loads
Loose loads
In addition, follow these requirements and recommended practices:
Always secure the load to ensure it's stable and safely arranged.
Never carry damaged merchandise without first wrapping or banding it to secure it
Center the load when possible
When handling an off-cetner load that can't be centered, use caution.
Distribute the heaviest part of an uncentered load nearest the front wheels of the forklift
Know the load capacity of the forklift and do not overload the truck.
Remember that the forklift's load capacity is calculated assuming that the load is centered. If the load is off-center in any way, this may affect the forklift's capacity and create hazards
Use the load extension backrest
Approaching the Load
Accidents sometimes occur when a forklift operator approaches a load too fast or turns too rapidly while approaching the load.
To avoid incidents while approaching the load, follow these requirements and recommendations:
Always approach the load slowly and carefully
Stop 8-12 inches in front of the load
Make sure the truck is placed squarely in front of the load
Make sure the forks are at the correct height for lifting the load
Set the direction control to neutral
Never raise or lower the forks unless the forklift is stopped and the brake is set
Before raising the load, make sure there's enough overhead clearance. Your vision can be blocked after the load is elevated.
Use the inching pedal to creep the load to the stack.
Mast Position
The mast is the part of the forklift in the front that the actual forklifts ride up and down on.
While you're moving the mast, take care to avoid tipovers and dropped loads.
To do so, follow these requirements and recommendations:
Always use caution when using the mast to tilt loads
Never tilt the mast forward with forks elevated unless you are picking up a load or putting down a load
When stacking or tiering materials, tilt the mast backward only enough to stabilize the load and no more
When handling loads that are close to the trucks' maximum load capacity, be cautious, tilt the mast back and position the heaviest part of the load against the carriage, and travel with the mast tilted back to keep the load stable
Use caution when tilting the mast forward while positioning the load onto the stack
Never travel on a forklift with the load tilted forward. This increases the load distance and destabilizes the load.
Positioning the Forks In Preparation to Lift the Load
As with much else when it comes to learning how to drive a forklift, it’s important to be aware of the following hazards when moving the forks into position while preparing to lift a load:
Tipover
Dropping the load
Collisions
To reduce the risk of these hazards, follow these requirements and recommendations:
Before you insert the forks into a pallet, make sure the forks are level
Place the forks under the load as far as possible. The forks should be at least two-thirds the length of the load.
If pallets are closely stacked, make sure your forks don’t go through to to the other side of the pallet (where they might possible catch another pallet)
Position the load on the pallet in such a way that the load’s weight is centered between the forks
Adjust the forks to distribute the weight evenly. You can do this manually or with a fork positioner.
Once the load is on the forks, carefully tilt the mast back to stabilize the load more
When you are picking up a load that’s off-center, do so very carefully, because these loads increase the risk of a tipover
Lifting the Load with the Forklift
Once you’re properly placed the forks under the lift, it’s time to lift the load.
Be particularly careful of these hazards while lifting the load with the forklift:
Not enough clearance (above)
Falling loads
Stuck loads
To reduce the risk of these hazards, follow the requirements and recommendations below:
Before raising the load, check to make sure there’s enough clearance overhead before lifting.
Carefully lift the load up above the lower stack by about 4 inches
Once the load is clear, tilt the mast back a small amount so that the load rests against the load backrest extension
Make sure the load isn’t caught on anything
Return the life control level back to neutral slowly
Lowering the Load
After you’ve lifted the load, in most cases you’ll travel somewhere before lowering and unloading the load. Remember we’ve already covered tips for safely traveling with a loaded forklift above.
Once you’ve completed your travels and are unloading the load, significant potential hazards include:
Falling loads
Striking objects with the load
High Tiering
It is common for forklifts to be used to stack materials in multiple tiers high off of the ground. This practice is known as “high tiering.”
High tiering brings with it its own set of hazards, including:
Overloading the stack
Tipover
Follow these requirements and recommendations to reduce those hazards:
Put the heaviest loads on the bottom, with the lightest loads on the top
Reduce the load below the capacity of the reach truck as the mast is fully extended
While you deposit the load on the top tier, extend the reach mechanism forward slowly and carefully
Be cautious when tilting a load forward or backward while high tiering
Truck Trailers and Railroad Cars
Forklifts often have to enter and/or leave truck trailers and railroad cars while moving materials.
These tasks involve a new set of hazards, including:
Falling off a loading dock
Movement of the trucks or railroad cars during loading and unloading, which can cause problems for the forklift operator
Dockboards that slip or are otherwise inadequate/deficient
In order to reduce hazards associated with this type of work, OSHA’s 29 CFR 1910.178 presents a list of situations in which special precautions must take place before a forklift can enter a railroad car and/or a truck trailer. These include the following.
For trucks and railroad cars:
Make sure the floor can support the weight of the forklift and load. To determine the capacity of the trailer floor, consider multiple factors, including floor thickness, cross-member spacing, unsupported floor area, and more. As a general rule, the larger the unsupported area, the lower the forklift capacity the trailer will have for floors with the same thickness.
Make sure the entry door provides enough vertical clearance
Always drive the forklift straight across the bridge plates when entering or exiting
When working in a dark trailer, use dock lights and/or headlights
When entering or exiting, sound the forklift’s horn
Avoid using the forklift to open railroad car doors. Do so only if:
The forklift has a device specifically designed to do so
The forklift operator has been trained to use that device properly and safely
All other employees stand clear
For trucks:
Always set the brakes on highway trucks and placed wheel chocks under the rear wheels before a forklift enters.
Follow these Chocking requirements for trailers docked to buildings with downward approaches (and be aware that the braking regulations by the Federal Motor Carrier Safety Administration preempt OSHA from enforcing OSHA regulations in 29 CFR 1910.178(k)(1) and 29 CFR 1910.178(m)(7) for commercial motor vehicles (CMVs).
It may be necessary to use fixed jacks to support a semitrailer that is not coupled to a tractor while forklifts are entering and exiting to load/unload. This can help prevent upending.
For railroad cars:
Use wheel stops or other positive protection to prevent railroad cars from moving when forklifts will enter or exit for loading and unloading purposes.
Use positive protection to prevent railroad cars from being moved while dockboards or bridge plates are in position and while forklifts are entering/exiting.
Requirements for dockboards and/or bridge plates:
29 CFR 1910.30(a), OSHA’s Walking-Working Surfaces standard includes the following requirements when dockboards/bridge plates are used. These all apply when forklifts are traveling on dockboards/bridge plates as well:
All dockboards must be strong enough to carry the load on them
Portable dockboards must be secured in position. Use anchors or other devices that prevent them from slipping.
Powered dockboards must be designed and constructed to meet the specifics set forth in Commercial Standard CS202-56 (1961) “Industrial Lifts and Hinged Loading Ramps” published by the U.S. Department of Commerce
To ensure safe handling, handholds or other similar devices must be provided on portable dockboards
Additional Forklift Operation Considerations: Removal from Service and Maintenance
In addition to everything else you’ve now learned about how to drive a forklift, keep the following in mind regarding removing forklifts from service and maintaining forklifts.
Removing Forklifts from Service
Forklifts must be removed from service if there’s a problem, including:
Mechanical breakdown
Leak
Overheating
Fire
Follow these requirements and recommendations for removing forklifts from service. If a forklift operator notices any of the following, the operator should stop the forklift, park the forklift, and get assistance:
The forklift is not in safe operating condition (for any reason)
Any defects are found
The forklift emits hazardous sparks or flames from the exhaust system
The temperature of any part of the forklift is greater than normal operating temperature
A leak in the fuel system is discovered
Forklift Maintenance
One of the best ways to prevent a hazardous operating condition on a forklift is to make sure the forklift receives regularly scheduled maintenance, including preventive maintenance.
Be certain that the forklift receives regularly scheduled maintenance, and don’t operate a forklift that requires maintenance.
In addition to regularly scheduled preventive maintenance, always report repair problems to a supervisor for unscheduled maintenance as well.
Conclusion: How to Operate a Forklift
We hope you gained some benefit from this article on how to operate and drive a forklift. Please let us know if you have any additional questions.
LOTO stands for lockout/tagout. When done properly before equipment service or maintenance, lockout/tagout procedures control hazardous energy and protect workers from harm. In this article,…
