Electric Forklift Safety Checklist for Beginners

The following checklist shows the order of tasks an electric forklift operator must do from the moment they consider using it until after they finish.

1. Pre-Operation Inspection

When using an electric forklift, the most important thing to do prior to anything is to examine the equipment, guaranteeing that it is in proper working order. Thus, this speeds up the discovery of potential risks and the malfunctioning of the equipment during their early stages. Verify the items listed below:

A. Visual Inspection

• Check the condition of the battery: The truck battery should be checked for a full charge, no leaks, and no corrosion on the terminals. The battery must be tightly secured.
• Examine the tires: If you’re using pneumatic tires, check them for tread wear, tears, or underinflation. Moreover, ensure that the solid tires are free of any cracks and chunks.
• Look at the forks and mast: For further information
• Check if the forks are broken, bent, or damaged in any form. Furthermore, make sure a broom is present for proper alignment and lubrication.
• Check if the forks are broken, bent, or damaged in any form.
• Do check if the mast is in proper alignment and lubricated.
• Hydraulic Circuit: Investigate possible leakage on hydraulic heads, cylinders, or nuts.
• Safety Arrangements: Make sure that the seat belts and harnesses are in excellent working condition. Check that headlights, warning buzzers, and backing-up devices are all working properly. Ensure that you can still read the warning labels and stickers.
• Make sure that the safety belts and protection devices work well.
• Observe if the headlights, horn, and reverse control are in excellent condition.
• See whether the warning stickers and tags are still in excellent condition and readable.

B. Functional Inspection

After you finish the visual inspection, proceed with the forklift functionality test. Do the following:

• Brakes: Verify the service brake, parking brake, and emergency brake to be in proper condition by testing them.
• Steering: Ensure that the car’s steering wheel turns smoothly and without extra friction or noise.
• Controls: Examine if all control levers for lifting, lowering, and tilting the forks are in a good working condition. Please ensure they are functioning smoothly without any issues.
• Battery Indicator: Make sure that the battery indicator is working and that it gives the right amount of charge.

Beginners should have the forklift’s operator manual handy for quick and convenient reference during the inspection process.

2. Workplace Safety Check

Prior to starting the forklift, go through the working environment and look for potential hazards there. Inexperienced operators should be more attentive to their surroundings and their likelihood of becoming involved in an accident.

• Clear Pathways: Make sure all aisles and paths are obstruction-free, clean, and dry.
• Load Stability: Be sure that loads are safely tied down before you move them.
• Pedestrian Safety: At all times, be mindful of the people who may be in the direction of your movement, and keep safety signs or barriers in the designated places.
• Lighting: It is important to check if the work area is properly lighted, particularly in the case of dark or confined areas.
• Floor Conditions: Watch out for floors that are slick or have ups and downs, which could lead to the truck being unable to maintain traction or stability.

3. Safe Operation Practices

After you have finished examining both the forklift and the workplace, strictly follow the safety tips below:

Mounting and Starting the Forklift

• Use the handrails (two hands and one foot) when getting on or off the forklift in order to avoid slipping or falling down.
• Make sure the seatbelt is properly fastened before the machine is started.
• Lower the safety armrest (if available) to activate the hydraulic controls.
• Switch on the forklift, allow it to warm up, verify the proper operation of all systems, and proceed with the start.
• Always drive the forklift at a moderate and steady speed; never go too fast so as to avoid accidents. Doing this will also result in no sharp turns that can cause the truck to tip over.
• Observe the forklift’s maximum weight limit: never go beyond that so as not to cause the forklift to tip over or destroy the load.
• Load Casting: Carrying a smaller amount of goods closer to the floor level (4-6 inches above the ground) is better. slightly tilt the forks back to maintain equilibrium of the load.
• Carry loads as low to the ground as possible (4-6 inches above the floor).
• Tilt the forks slightly back to stabilize the load.
• Identify Blind Spots: Always keep your eyes on the mirrors, and make sure that nothing obstructs your view. If your view is obstructed, operate the forklift in reverse or use a spotter.
• Appropriate Signaling: Pressing the horn is necessary to make other people aware of your coming presence in case you are going through intersections, blind spots, or pedestrian zones. Furthermore, consider using an alarm or turning on the lights to inform the nearby workers about your intentions.
• Press the horn when driving the forklift facing intersections, blind corners, or pedestrian areas.
• Turn on your lights and use the horn to let your nearby workers know that you are there.
• Firstly, make sure the forklift is in line with the load before picking it up.
• Make sure the forks are completely placed under the load and verify that the weight is equally distributed.
• Do not raise or lower the forks while the forklift is moving.
• Be extra careful when stacking not to tip the lift truck over or to have objects fall on you.
• Keep the forklift in a designated location, away from pedestrian traffic or exits.
• Position the forks on the floor to prevent fall hazards.
• Make sure to engage the parking brake to secure the forklift.
• Please turn off the engine and remove the key.
• Check the battery’s charge level and connect it to the charger if the charge is low.
• Examine the battery unit for any leaks, corrosion, or loose connections.
• Adhere to the battery charging guidelines provided by the manufacturer to avoid overcharging or overheating.
• Please notify the supervisor or the maintenance team of any mechanical issues or breakages you have observed.
• Wash the forklift (i.e., clear away dirt from the mast or wheels) to prevent the buildup that can influence its performance.
• Understand the fundamentals of forklift controls and operation.
• It’s crucial to familiarize oneself with the specific hazards present in the workplace.
• Practice in real-life situations under supervision.
• Pushover: If the load is too heavy or not handled properly, the forklift may tip over.
• Battery Hazards: Leaking battery acid is a source of burns or equipment damage. The wrong battery charging can cause fires or explosions.

Battery acid leaks can cause significant burns or damage equipment, and charging batteries the wrong way can lead to fires or explosions. Poor visibility or not following site traffic laws can cause car accidents, which can hurt people or damage property.

Electrocution is a very dangerous thing that can happen when you work near open electrical parts or power lines. Always use the right personal protection equipment (PPE), such as a tough hat, a high-visibility vest, and steel-toe boots, to stay safe.

When driving a forklift, be focused and don’t let things like phone calls or chats get in the way. In loud places, it’s important to be able to talk to each other.

Use radios or hand gestures to talk to your coworkers. Finally, recognize what you can and can’t do. If you’re not sure about a work or load, ask for help instead of putting yourself in danger.