When a storm is so fierce that the rain looks like it’s coming in sideways, it’s known as a powerful “driving rain.” When a truck is so fierce that you need a special certification to operate it, it’s known as a forklift. That’s why this handbook for operating these industrial machines isn’t a forklift driving guide; it’s a “Driving Forklift” Guide.
Becoming a certified forklift operator is more than just a job. It’s an acceptance into a culture of people who are proud of their skillset and less-than-humble about the joy they derive from their career (simply peruse some forklift memes or the “certified fork cliff driver” videos on TikTok and you’ll begin to understand). Knowing how to operate a forklift can set someone up for success in many different industries. However, forklift driving requires skills that go far beyond what it takes to hop into a typical sedan.
In what way are forklifts different from most automobiles?
There’s not a one-to-one comparison of forklift for cars. The typical counterbalance forklift has four wheels, a driver’s seat, a steering wheel and gas and brake pedals. In many cases, that’s where the similarities with an automobile end. In fact, some forklifts have fewer than four wheels and may not even have a steering wheel, foot pedals or a seat for an operator. That’s just the start of how forklift driving is not the same as driving a car.
Most cars have front-wheel steering. This means when someone turns the steering wheel, the front wheels are the first to respond, and they turn in the same direction as the wheel. Since the driver is basically sitting over the front wheels of an automobile, it feels intuitive to steer with front-wheel drive. The front of the vehicle also holds most of a car’s weight because the heavy engine is located under the hood. So, front-wheel steering also helps maintain the stability of the car.
A counterbalance forklift utilizes rear-wheel steering. This is primarily because the rear of the vehicle houses the heavy battery and counterweights that help keep the vehicle balanced as it lifts and carries a load. In rear-wheel steering turning the steering wheel left moves the rear of the forklift to the right and vice versa, which can be counterintuitive for someone familiar with front-wheel steering. Vehicles with rear-wheel steering also have a tighter turning radius than those with front-wheel steering. This helps a forklift better navigate narrow aisles and confined spaces. However, the tighter radius means the vehicle reacts quicker to turns, which means if the operator isn’t careful they can take a turn too quickly and cause an accident.
The car forklift differences are some of the primary reasons that everyone who operates a forklift must be certified on their specific machine.
Forklift how to drive
There are many different types of forklifts or industrial trucks. In fact, OSHA has seven official forklift classifications, and there are many varieties of trucks within those seven classifications.
Forklift controls
Even within those classifications, mastering one type of forklift may not translate to others since controls can vary across styles and manufacturers. In general, however, here is what you can expect to find on most forklifts:
- Steering wheel or control lever: Steering a forklift is like steering a car except that turning left moves the rear of the forklift to the right and vice versa. A control lever is typically found in stand-up forklifts because there is no room for a steering wheel.
- Pedals: Most forklifts have three pedals, accelerator, brake, and clutch. However, some may also have an inching pedal that’s used to disengage the transmission and slow or stop the machine.
- Directional controls: Forklifts have three gears: forward, reverse and neutral (or park). These controls are often located on the dashboard or the steering column. In some forklifts, changing gears is controlled by shifting the accelerator pedal side to side with your foot.
- Mast controls: The mast, also known as an upright, is the vertical component at the front of a forklift. It houses the forks and controls the raising, lowering and tilting of a load. The tilt control adjusts the angle of the forks, while the lift control (or fork control) raises or lowers the forks and adjusts the width between them (to accommodate different pallet sizes).
- Parking brake: A lever or pedal that should be used whenever the forklift is not in motion.
- Emergency stop button: This easily accessible button quickly shuts down all operations in case of an emergency.
Pre-op inspection
The next step is to thoroughly inspect the vehicle. According to OSHA regulations all, “Industrial trucks shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.”
One of the most effective ways to ensure that an industrial truck is ready for service is to create a daily inspection checklist. These checklists vary by model, but generally include:
- Examining brake, engine oil, transmission and radiator fluid levels.
- Checking the batteries to ensure they:
- Are free from corrosion.
- Have the correct water level.
- Have no leaks or visible cracks.
- Are fully charged.
- Checking the condition of the tires and tire pressure.
- Making sure the seat belt is working.
- Checking the controls, steering and gear shifts.
- Visually inspecting the lift system (chains, cables and forks shouldn’t be checked by hand).
Driving forklift
To get into the cab of a forklift, always use the grip handle. It can be tempting to grab the steering wheel for assistance, but it can move and cause you to lose your balance. Once you are inside and have your seatbelt on, perform a final check of the control panel. Make sure that the parking brake is set and the directional control is in neutral (or park). Finally, make sure your path is clear of obstacles and pedestrians. If your view is obstructed, be sure to use a spotter to safely guide the vehicle.
Now, you’re ready to roll. Raise the forks about four inches and tilt the mast backward (you don’t want the forks scrapping the ground when you move). Then release the parking brake, take your foot off the brake pedal and press the gas pedal to move forward. Remember that, when you steer, you are moving the rear wheels. This means that the back of the vehicle is the first to turn, which can cause the rear to swing wide if the operator is not careful. When you are ready to stop, lower the forks to the ground, put the control in neutral (or park), apply the parking brake and turn off the engine. When leaving, remember to use that grip handle (and not the steering wheel).
Picking up a load
When picking up a load the forks should be aligned with the center of the pallet. Begin by adjusting the distance between the forks, if needed, and lowering the forks. Then approach the cargo straight and slowly until the forks slide under the pallet as far as possible. Once the forks are properly positioned, lift the load about four inches off the ground and tilt the mast backward.
Carrying a load
Before moving, ensure that the load is stable and that your path is clear of obstacles and pedestrians. It’s generally recommended to travel with the load close to the ground. This provides better stability and visibility, which reduces the risk of tipping. Keep the forklift’s speed steady and avoid sudden stops and sharp turns.
Safety tips
According to the most recent OSHA statistics, every year there are approximately 62,000 non-serious forklift accidents, 35,000 forklift accidents with serious injuries and 85 fatal forklift accidents. The leading cause of fatalities in a forklift accident is rollovers.
Avoid rollovers
The weights that counterbalance a forklift help keep it from tipping over, even when carrying a heavy load. However, most forklift turnovers are caused by an operator disrupting this delicate stability by:
- Driving with the load raised too high.
- Carrying an uneven or unbalanced load.
- Driving too fast.
- Turning too quickly.
- Turning on an incline.
- Driving on uneven surfaces.
To avoid turnovers, the operator must follow all safety recommendations and ensure that a load is stable, properly balanced and does not exceed the capacity of the forklift.
Maintain visibility
A counterbalance forklift operator’s visibility is already a little hampered by the mast in front of the vehicle. Now, imagine those forks are carrying a large, heavy pallet through a busy warehouse or distribution center. Of course, you don’t have to imagine this since that’s exactly what the tines will do throughout a work shift.
Carrying a heavy load can dramatically impact an operator’s ability to see. That’s why it’s imperative to carry a load as close to the ground as possible, always look in the direction of travel and use the forklift’s mirrors. For large or awkward loads, it may be necessary to use one or many spotters as guides and maybe even to travel in reverse.
Never exceed the recommended speed limit
To maintain balance, a counterbalance forklift needs its center of gravity to lie roughly in the center of the machine (this is due to the stability triangle, a somewhat complex topic you can read about here, and here, and here, and there’s a little bit about it in here … and also here). Traveling at high speeds or taking a turn too fast can dramatically throw off that balance. Driving too fast also makes it harder for the operator to control the machine, which can lead to dangerous situations or collisions.q
Avoid pedestrians
According to OSHA, 20 percent of forklift accidents involve pedestrians either being struck by forklifts or struck by objects that are dropped or knocked over by forklifts. Blind spots are a significant risk because an operator may not see a pedestrian and if a pedestrian is distracted, they may have no idea a forklift is around the corner. Both forklift operators and pedestrians have a responsibility to maintain safety in the workplace. Operators can help avoid accidents with pedestrians by honking the forklift’s horn at intersections and blind spots.
Is forklift driving hard?
The answer to that question depends on whether the forklift driver is certified. For someone unfamiliar with the machine, it would be very difficult—and unadvisable, dangerous and a finable offense—for them to drive a forklift. However, anyone who passes a forklift certification course—and follows the safety recommendations—should have no problem operating the machine they mastered.
The drive forklift operators feel when they climb into the cab is a palpable urge to get the job done. Fortunately, Texas Motive Solutions can help your operators keep their forklifts running by ensuring that you have the best possible forklift batteries and accessories for your needs. Please call us at (888) 316-2459 or fill out this form to learn about our services and everything that we can do for you.
