Navigating a forklift isn't just about moving cargo from point A to point B. It's a complex process that begins with a simple yet crucial step: starting the forklift itself. This may seem like a simple task, but it's the gateway to mastering a skill that's essential in countless industries across the globe.
Whether you're new to the world of warehouse management, venturing into the construction business, or looking to expand your skill set in an industry where forklift operation is a must, understanding the right way to start and operate a forklift is critical.
In this guide, we'll take you through the step-by-step process of how to start a forklift, highlighting the vital elements of operator training, safety checks, control understanding, and more.
We'll not only provide you with practical advice but also help you understand the underlying importance of each step, ensuring you're well-equipped and ready to handle this heavy-duty machine with ease and safety.
Let's take the first step on your journey to becoming a confident, skilled, and certified forklift operator.
Learn the Forklift Controls
Learning how to start a forklift and knowing the basic forklift controls are important. It is simple. Starting a forklift is basically the same as starting a car. But please do take reasonable care when doing so, accidents do happen when performing a simple activity like this. Here’s a video showing this:
Now that you’ve watched this short clip. Please keep in mind that you cannot operate a forklift without proper training. Every operator has to be trained and certified first before working with this truck in compliance with the OSHA regulation. If you’ve failed and an accident happened, you and your company could be cited with a violation.
Before you even turn the key in the ignition, it's essential to understand the various controls at your fingertips in the cab of a forklift. Knowing how to maneuver the forklift with precision and safety can only be accomplished by understanding the functionality of each control.
A. Overview of Common Forklift Controls
Common forklift controls are generally divided into two groups: driving controls and mast controls. The driving controls consist of a steering wheel, an accelerator pedal, a brake pedal, and in some models, a clutch. The mast controls to regulate the vertical and lateral movements of the forks, including lift, lower, tilt, and side shift controls.
B. Specifics about Steering, Acceleration, and Braking Controls
The steering wheel controls the direction of the forklift and works similarly to a regular car's steering. The accelerator pedal, typically controlled by the right foot, allows the forklift to move forward or backward, while the brake pedal, managed by the left foot, is used to stop the machine or reduce speed. Some models may have a clutch to aid in changing the gears or directions.
C. Explanation of Lifting and Lowering Controls
The lifting and lowering controls are typically levers located to the right of the operator's seat. Pulling the lever towards the operator raises the forks while pushing it away lowers them. These controls allow the operator to pick up, carry, and drop off loads at varying heights.
D. Special Controls: Tilt, Side Shift, etc.
In addition to basic lifting and lowering, many forklifts have special controls to enhance maneuverability and flexibility. These may include a tilt function, which tilts the mast backward or forward to stabilize loads during movement, and a side shift function, which moves the forks and carriage from side to side, allowing precise load placement without moving the entire forklift.
E. Importance of Getting to Know Your Specific Forklift Model
It's important to note that while these controls are common in many forklifts, there can be significant differences between various models and manufacturers. Always review the operator's manual for your specific forklift model and get familiar with its unique features and controls. Remember, knowledge is the first step to a safe and efficient operation.
Starting the Forklift
Before you hit the ignition, it's essential to understand that starting a forklift isn't like starting an ordinary vehicle. Forklifts are powerful industrial machines, and their operation requires a certain level of safety knowledge and responsibility. Let's walk you through the process.
A. Initial Safety Checks
The very first step in starting a forklift is to perform a safety check. This includes ensuring the parking brake is engaged, checking that all controls are in the neutral position, and verifying there are no personnel or obstructions in your immediate vicinity. It's also important to check the fuel level and ensure there are no leaks or mechanical issues that could pose safety risks.
B. Step-by-Step Guide to Starting a Forklift
- Ensure you're wearing the necessary personal protective equipment (PPE), including a hard hat, safety shoes, and high-visibility clothing.
- Mount the forklift using the three-point contact system: one hand on the steering wheel, one hand on the grab handle, and one foot on the step.
- Once seated, fasten the seat belt. This is a crucial step, as it will prevent you from being thrown out of the seat if the forklift tips over.
- Check the forklift controls to make sure they are all in the neutral position and the parking brake is engaged.
- Now you're ready to start the engine. Insert the key into the ignition and turn it to start the forklift. Some newer models may have a push-button start; in this case, push and hold the start button until the engine runs.
C. Explanation of What to Do if the Forklift Doesn't Start
If the forklift doesn't start, don't panic. Make sure the forklift is in neutral and the parking brake is engaged. Check the fuel level. If it's still not starting, there might be a mechanical issue. Do not attempt to fix this yourself unless you're trained to do so. Instead, notify your supervisor or a maintenance technician.
D. Safety Measures to Take Once the Forklift is Operational
Once the forklift is running, don't rush into action. Take a moment to check the functionality of the lights, horn, and other warning devices. Test the brakes, the lifting and lowering controls, the steering, and the tilt function. Only when you're satisfied that everything is working correctly should you disengage the parking brake and start to move.
Remember, operating a forklift is a significant responsibility, and safety should always be your top priority. Now that you know how to start a forklift, you're ready to learn how to operate it, which we'll cover in the next section.
Basic Operating Procedures
Once the forklift is up and running, the real work begins. Operating a forklift isn't just about lifting and moving loads. It requires precision, focus, and a deep understanding of safety principles. In this section, we'll walk you through the basic operating procedures of a forklift.
A. Driving the Forklift
- How to Move Forward and Backward: To move the forklift forward, release the parking brake and gently press the accelerator. Always remember to keep your speed moderate and never exceed the speed limit. To move backward, check your surroundings first, especially for pedestrians. Then, shift the gear to reverse and press the accelerator. Always look in the direction you're moving.
- Turning and Maneuvering in Tight Spaces: Always approach turns slowly and at a right angle. Make sure to tilt the mast backward slightly and keep the load low for stability. For maneuvering in tight spaces, operate at a reduced speed, and use your horn as necessary to alert others to your presence.
B. Lifting and Moving Loads
- How to Safely Lift and Lower Loads: To lift a load, approach it straight on with the forks at ground level. Once the forks are fully under the load, lift it by pulling the lifting control towards you. Make sure to lift the load just high enough to clear the ground. To lower the load, push the lifting control away from you.
- Guidelines for Carrying Loads: Always keep the load as low as possible for better stability. Make sure the heavier side of the load is closer to the front of the forklift. Never carry a load that exceeds the forklift's maximum capacity, and never move a load that is not secure.
C. Parking the Forklift
- How to Safely Park a Forklift: When you are done using the forklift, park it in a designated area. Lower the forks to the ground, shift the forklift into neutral, and apply the parking brake. Always turn off the forklift and remove the keys before exiting.
- When and Where to Park: Forklifts should be parked in designated areas away from traffic and pedestrians. Never park on a ramp or incline unless it's an emergency, and never block exits, stairways, or fire equipment.
Remember, the operation of a forklift is a serious job that requires constant attention to safety and proper procedures. By adhering to these guidelines, you can ensure a safe and productive work environment.
Common Reasons Why the Forklift Doesn’t Start
There could be some situations when the forklift doesn’t start. This problem is common to old and improperly maintained truck. To troubleshoot a forklift that doesn’t start, try to eliminate your suspicions, here are some common reasons:
- Is the truck getting power? If your forklift is electric, were the batteries fully charged? Try turning on the auxiliary functions of the truck (brake, horn, lights, and other non-engine parts), are they functioning? If not, the truck’s batteries are discharged.
- If you have an internal combustion truck, check the oil fluid level. Some models of forklifts won’t let gas valve open if the engine oil level is insufficient. Also, check for a possible gas leak that causing the forklift not to start, it is very obvious to verify if there’s a gas leak because of the smell of the gasoline or diesel fumes in the air.
- If the forklift is LPG-powered and it won’t start, if there is no cranking startup noise if you turn the key, the battery may be dead. The operator of the previous shift forgot to turn the lights off and left the ignition on, the battery has drained.
- Is the weather cold causing the engine not to start? If it is cold outside and the forklift is exposed to the weather for a long time. The fuel regulator can freeze. Try to move the truck to a warmer place for a while before starting it on the second try.
- A forklift won’t start unless it is in neutral gear just like your car. Check the lever it might be in a forward or reverse position, if it is, just put it to neutral and try starting again. Make sure the forklift is not in gear.
- In some models of forklifts, there is a feature called an emergency power-off switch or power supply shut-off button, if it is in one position, it prevents the truck from starting.
- In some types of trucks, it won’t start unless you have the right start code. It is an electronic key or access code preventing any unauthorized person from using the forklift.
- If there is an alert code appearing. If it does, a mechanic is required to find out the error code so that it will be fixed.
You arrive at the site and are ready to work. You enter the compartment and turn the ignition. The forklift won’t start. It is every operator’s nightmare. So what will you do then? There is a myriad of reasons causing the forklift not to start, just as we mentioned above. Learning how to start a forklift is simple, but there could be some circumstances it won’t fire up. You can do some basic troubleshooting and diagnosis yourself. If it still doesn’t after several attempts, it is time to call a professional. Some issues letting the forklift not fire up requires a professional mechanic.
Before Starting the Forklift, Do Pre-Shift Inspection
It is imperative to conduct an equipment pre-shift inspection before starting the truck. This ensures that the equipment is in good operating procedures. It is just a visual walkaround of the forklift. Here are what you need to inspect:
- Check all tires for damage and excessive wear. When there’s less than one inch from the lettering on the tire to the top of the tire, it is an obvious sign that the tire should be replaced. Likewise, if there are chunking, tearing and flat spots, it is time to have them replaced.
- Check for any damage, cracks, or oil leaks on the mast assembly. Are there any signs of a hydraulic fluid leak on the hose or chain? If there is, report it superior for immediate repair.
- Check if the tilt cylinder carriage shows any sign of leaks. See if the load backrest and carriage are firmly attached.
- See if the forks are straight and evenly spaced. The forks should also be free from any cracks or damage. If there is any sign of wear, use a caliper to measure the thickness of the forks. As a general rule, if the forks are worn more than 10 percent at their heel, the forks should be replaced.
- Check the overhead guard if it the properly secure.
- Check the truck’s engine coolant if it is at the right level and see if the battery terminals and cables are free from rust and dirt and that it is tightly secure.
- Check the hydraulic fluid level; when checking the forks should be fully lowered. The engine oil should be checked and be filled in accordance with the manufacturer’s recommendation. Also, inspect the brake fluid level.
- Inspect the wirings, hoses and other connections if they are clean and free from damage.
- The operator should refer to the inspection checklist provided for maintenance specific to each brand and model.
- Other small things to inspect are the fork pins and other locking devices, they should be secured and in place to prevent the forks from sliding.
- Are the safety decals and data plate still in place and readable? The decals indicate and safety precautions the operator must take while the data plate shows the truck's specification (load capacity, lifting height, brand, model, etc.).
- Now enter the compartment, and check if the driver’s seat and seat belt are tight and secure. Also, inspect the rearview mirrors if adjusted to suit the operator’s view.
- Before you start driving, check the gauges if they are working and make sure the warning lights (backup alarm, blue or strobe light, etc) are working properly.
- See if the horn and the travel alarm are working condition.
- Drive forward for several feet and reverse and hit the brake to see if it is in working order. See the steering wheel for unwanted noises and see if it creates vibration.
- Lastly, operate the truck, put the lift to full lifting height and lower it again. Operate the tilt cylinder forward and back to the original position, and test if the side shift works properly by moving it right and left to the full extent.
- It is crucial to make the operation safe by doing an inspection. Forklift pre-inspection is every operator’s important responsibility. According to OSHA, one in fifteen accidents involving forklifts is caused by poor maintenance. By doing a pre-shift inspection, you’re able to identify issues with the truck and by that, you’re doing a good job to prevent accidents from happening.
Before Starting A Forklift and Commencing Work, Identify Workplace Hazards
Prior to operating the forklift, it is important to do a site inspection to identify hazards that may be an issue. Some workplace hazards include the following:
- Overhead service line or power line in the vicinity. If there are power lines, the supervisor must complete a risk assessment to mitigate such hazards.
Doorways – make sure that there’s enough opening that the forklift can fit in. - Passing pedestrians – is the most common hazard, passing pedestrians being struck by trucks is a common issue that should be avoided. Be vigilant when there are pedestrians around.
- Uneven surfaces are common when the operation is outdoors. Some variants of forklift tires don’t work on the uneven road surface so make sure the forklift has the right type of tires for outdoor use.
- Ramps and inclines are also a hazard. It is a day-to-day activity in many facilities. When descending on an incline with a loaded truck, travel in reverse with the forks and load pointed up the grade and when traveling on an incline with an unloaded truck, always drive with the forks pointed downgrade, irrespective of whether you are going up or down the ramp.
It is very critical to do a site assessment and identify hazards prior to starting a forklift and commencing work. Take reasonable care to control them because if you fail it could result in a serious accident. Once you do these site inspection measures, you should be right to do.
Advanced Tips and Troubleshooting
While understanding the basics of operating a forklift is essential, to truly master this skill, one must also become familiar with advanced tips and troubleshooting techniques. Let's delve into some ways to improve your forklift handling, tackle common issues, and identify when it's time to seek professional help.
A. Tips for Improving Forklift Handling and Safety
- Practice Regularly: The best way to improve your handling skills is to practice consistently. This not only familiarizes you with the controls but also allows you to better understand the forklift's limitations and capabilities.
- Stay Alert: Always maintain awareness of your surroundings. Be mindful of the people and objects around you, as well as any potential hazards in your operating environment.
- Follow Load Capacity Guidelines: Overloading can lead to instability and potential tipping. Always adhere to the forklift's maximum load capacity and ensure loads are evenly distributed.
- Regular Maintenance: Regularly check and maintain the forklift to ensure it's in optimal condition. This includes monitoring fluid levels, checking for leaks, and ensuring that the tires are in good condition.
B. Common Problems and Solutions
- Forklift Won't Start: Check if the forklift is in neutral and the parking brake is engaged. If it still won't start, inspect the fuel level. If none of these issues is the culprit, there might be a mechanical issue that requires professional assistance.
- Unresponsive Controls: If the controls become unresponsive, stop the forklift immediately and switch off the engine. Consult the operator's manual or contact a maintenance technician.
- Overheating Engine: If the engine overheats, stop the forklift, switch off the engine, and allow it to cool down. Regular maintenance and checks can help prevent overheating.
C. When to Seek Professional Maintenance Help
While minor issues can often be addressed by the operator, certain situations call for professional help. These include persistent mechanical issues, any form of fluid leakage, brake failure, or any damage to the mast or forks. It's essential to report these issues immediately to prevent accidents and maintain the forklift's longevity.
Remember, while troubleshooting can be a useful skill, safety should always be the top priority. If you're unsure about a problem or its solution, it's always better to seek professional help than to risk causing further damage or endangering yourself and others.
How to Turn a Forklift Off
Turning off a forklift is not just a matter of switching off the ignition; it requires a series of safety-focused steps to ensure the forklift is left in a secure and safe state. Here is a step-by-step guide on how to turn off a forklift correctly:
- Find a Safe Parking Spot: Look for a designated parking area away from pedestrian paths and operational zones. Ensure the location is flat and level to avoid any uncontrolled movement of the forklift.
- Lower the Forks: Fully lower the forks to the ground. This reduces the risk of someone tripping over them or getting hurt if they accidentally walk into them.
- Neutralize Controls: Place all the control levers in the neutral position. This helps prevent any unexpected movements when the forklift is next started.
- Engage the Parking Brake: Apply the parking brake to ensure that the forklift stays in place.
- Turn Off the Ignition: Turn the key to the 'off' position or press the stop button, depending on your model.
- Remove the Key: Always remove the key from the ignition. This prevents unauthorized or untrained individuals from operating the forklift.
- Exit Safely: When dismounting, use the three-point contact system for safety: one hand on the steering wheel, one hand on the grab handle, and one foot on the step. Never jump off a forklift as it could lead to accidents.
Remember, safety should be your primary concern when operating a forklift. Always follow these steps and any additional guidelines provided by your forklift manufacturer or workplace safety rules.
To Conclude This
Mastering the art of how to start a forklift involves much more than just turning a key. It's about understanding the safety checks, controls, and basic operation procedures, and even knowing when it's time to seek professional help. A task that may seem simple at first glance holds the key to a world of operational efficiency and safety in countless industries globally. By arming yourself with this knowledge, you're taking a significant step toward becoming a confident, skilled, and certified forklift operator.
Whether you're new to the world of warehouse management, expanding your skill set, or breaking ground in construction, we trust that this comprehensive guide has provided you with the essential steps and safety procedures needed to start a forklift. Remember, each forklift model can have its unique features and controls. Therefore, always consult your operator's manual and receive proper training before operating a forklift.
Operating a forklift is a significant responsibility, but with the right knowledge and focus on safety, it's a task anyone can master. Keep these tips in mind, and you'll be well on your way to successfully starting and operating a forklift. Stay safe, and happy lifting!
Don't forget to bookmark this guide for future reference, share it with your colleagues, and check back for more tips and tricks on how to operate heavy machinery safely and efficiently. If you have any questions or need more detailed information on starting a forklift or any other operational aspects, please don't hesitate to get in touch.