Our Blogs Forklifts and Safe Operation and Maintenance Tips

Date Posted:5 November 2024

By ensuring that operators are well-trained, conducting regular pre-operation inspections, and following safety guidelines, businesses can reduce the likelihood of accidents.

Forklifts are essential pieces of equipment in warehouses, construction sites, and industrial facilities. They enable the safe and efficient movement of heavy loads, ensuring smooth operations in material handling and logistics. However, forklifts also pose significant safety risks if not operated and maintained properly. To prevent accidents and ensure the longevity of the equipment, it’s crucial to understand safe forklift operation and implement regular maintenance practices.

In this blog, we’ll delve into the key safety considerations for forklift operation and provide essential maintenance tips to keep your equipment in top condition.

Importance of Safe Forklift Operation

Operating a forklift requires skill, awareness, and adherence to safety standards. Forklift-related accidents can result in serious injuries or even fatalities, as well as damage to property. By following safety protocols and encouraging safe practices, workplaces can significantly reduce the risks associated with forklift operation.

Forklift Safety Guidelines

Here are some key safety tips for operating forklifts:

1. Ensure Operator Training and Certification

One of the most critical safety steps is ensuring that all forklift operators are properly trained and certified. Untrained or inexperienced operators are at higher risk of causing accidents. Training should cover:

Proper operation techniques
Load capacity and stability
Hazard recognition
Emergency procedures

Operators should also be familiar with the specific model of forklift they are using, as features and controls can vary.

2. Conduct Pre-Operation Inspections

Before operating a forklift, operators should conduct a thorough inspection to ensure the equipment is in safe working condition. A pre-operation checklist may include:

Checking fluid levels (oil, hydraulic fluid, and coolant)
Ensuring that tires are in good condition and properly inflated
Inspecting forks for cracks or wear
Testing brakes, lights, and horn
Checking that seatbelts are functioning properly

Identifying and addressing any issues before starting the forklift can prevent accidents and mechanical failures.

3. Adhere to Load Capacity Limits

Exceeding the forklift’s load capacity is a common cause of accidents. Overloading can make the forklift unstable and lead to tipping over. Operators should always adhere to the manufacturer’s specified load capacity, which can be found on the data plate of the forklift.
It’s also important to distribute the load evenly and ensure it is secured before lifting. Uneven or unsecured loads increase the risk of losing control while operating the forklift.

4. Maintain Clear Visibility

Proper visibility is crucial when operating a forklift. Operators should ensure they have a clear view of the path ahead, particularly in tight or congested areas. When carrying large loads that obstruct forward visibility, operators should drive in reverse.

Additionally, the use of mirrors and cameras can enhance visibility, especially when manoeuvring in complex or confined spaces.

5. Operate at Safe Speeds

Speeding while operating a forklift can increase the risk of accidents, especially when navigating corners or uneven surfaces. Operators should always follow the facility’s speed limits and avoid sudden stops or sharp turns. It’s important to drive at a speed that allows full control of the forklift.

6. Be Cautious on Ramps and Inclines

Driving a forklift on ramps or inclines presents additional safety challenges. Operators should:

Travel slowly and cautiously
Keep the load uphill when going up or down slopes
Avoid turning on a slope, as this can cause the forklift to tip over

When carrying loads on inclines, the forklift should face forward when going uphill and in reverse when going downhill.

7. Avoid Horseplay and Distractions

Operating a forklift requires full attention. Distractions, such as using a mobile phone, can lead to dangerous mistakes. Similarly, horseplay or reckless behaviour should never be tolerated. Operators should remain focused on the task at hand and avoid any behaviour that could compromise safety.

Forklift Maintenance Tips

Regular maintenance is essential to ensure the longevity of your forklift and reduce the risk of mechanical failures. Here are some essential maintenance tips:

1. Develop a Routine Maintenance Schedule

Forklifts should undergo regular inspections and servicing to identify and address potential issues before they lead to breakdowns. A routine maintenance schedule should include:

Regular oil and filter changes
Battery inspections and maintenance (for electric forklifts)
Checking hydraulic systems for leaks
Lubricating moving parts
Inspecting and replacing worn tires

Following the manufacturer’s recommended maintenance schedule will keep the forklift running smoothly and reduce the likelihood of unexpected downtime.

2. Monitor Fluid Levels
Checking and maintaining fluid levels is critical to keeping the forklift’s engine, transmission, and hydraulic systems in good condition. Low fluid levels can cause overheating or damage to internal components, leading to costly repairs.

Operators should regularly check fluid levels for:

Engine oil
Transmission fluid
Hydraulic fluid
Brake fluid
Coolant

Topping up fluids as needed and addressing any leaks immediately can prevent more significant issues down the line.

3. Check Tire Condition

Tires are a critical component of forklift safety and performance. Worn or underinflated tires can compromise the forklift’s stability and handling. Inspect tires for wear, punctures, or damage, and ensure they are properly inflated according to the manufacturer’s specifications.
Solid tires should be replaced when they are severely worn, while pneumatic tires should be checked for proper inflation and any signs of damage.

4. Ensure Battery Health (For Electric Forklifts)

For electric forklifts, maintaining the health of the battery is essential for reliable operation. Operators should:

Regularly check battery water levels and top up with distilled water as needed
Clean the battery terminals to prevent corrosion
Ensure the battery is charged properly, avoiding deep discharges or overcharging

A well-maintained battery will extend the lifespan of the forklift and reduce the risk of power failures.

5. Inspect Forks for Wear

The forks of a forklift are subject to heavy use and wear over time. Regularly inspect the forks for cracks, bends, or excessive wear. Any damaged or worn forks should be repaired or replaced to prevent accidents, such as loads slipping or the forklift becoming unbalanced.

6. Test the Braking System

The braking system is one of the most critical safety features of a forklift. Regularly testing the brakes and ensuring they are in good working condition is essential for preventing accidents. If the brakes feel spongy or unresponsive, they should be inspected and repaired immediately.

Forklifts are invaluable tools in many industries, but they also come with significant safety risks if not operated and maintained properly. By ensuring that operators are well-trained, conducting regular pre-operation inspections, and following safety guidelines, businesses can reduce the likelihood of accidents. Additionally, implementing a comprehensive maintenance schedule will keep forklifts in top condition and extend their lifespan.

At Verdex, we provide high-quality forklifts and material handling equipment designed to meet the safety and operational needs of businesses across Australia. Explore our range to find reliable and durable solutions for your workplace.