CSCS Counterbalance Forklift cheat sheet

HSWA 1974 section 7: employees must take reasonable care of themselves and others, and cooperate with the employer on health and safety.

PUWER 1998 requires work equipment to be suitable, maintained, inspected and used only by trained, competent people.

LOLER 1998: lifting operations must be planned by a competent person; thorough examination at least every 12 months (6 months if lifting people).

RIDDOR requires reporting of deaths, specified injuries, dangerous occurrences and over-7-day incapacitation.

MHSWR 1999 requires a suitable and sufficient risk assessment of forklift operations, including pedestrians and loads.

Operator authorisation: only trained and authorised operators may use a truck; refresher training is typically recommended every 3–5 years or after incidents.

PPE is determined by risk assessment: typically safety footwear, hi-vis, and hard hat in areas with overhead hazards.

A defect that affects safety must be reported and the truck taken out of service; using a defective truck is a breach of duty.

Complete a documented pre-shift inspection before use; record defects and tag out any truck that is unsafe.

Check forks for cracks, bent tips and heel wear; fork thickness wear beyond about 10% of original (or the manufacturer's limit) requires replacement.

Inspect mast chains for equal tension, kinks, corrosion and lubrication; check hoses and hydraulic cylinders for leaks.

Check engine oil, coolant, hydraulic fluid and fuel levels; for electric trucks check battery charge and electrolyte where applicable.

Test horn, lights, brakes, steering and parking brake in a clear area before starting work.

Check tyres for damage, pressure and wear; type must suit the floor surface (pneumatic, cushion, solid).

Confirm the data plate is legible and matches the truck and any attachment fitted.

Check seat belt/operator restraint, overhead guard and load backrest are present and undamaged.

Record the hour-meter reading and any defects in the log; do not operate until repairs are completed and checked.

Read the operator manual for the specific truck; control layout, capacities and warning devices vary between models.

The data plate gives rated capacity at a stated load centre and lift height, plus truck weight and battery weight.

Counterbalance trucks use a rear counterweight; rear-wheel steering makes the rear end swing outward in turns.

Mast type affects free lift and collapsed height: simplex, duplex and triplex masts have different overhead clearance needs.

Attachments (side-shift, clamp, rotator) change capacity and load centre; use the attachment data plate.

Identify tyre type and suitability: cushion tyres for smooth indoor floors, pneumatic for rough outdoor surfaces.

Locate the parking brake, emergency isolation, horn, lights and any travel-speed controls before moving.

Check the load backrest and overhead guard are fitted; they protect the operator and keep loads from shifting backward.

Stability triangle: the combined centre of gravity must stay inside the triangle formed by the two front wheels and the rear steer axle centre.

Rated capacity decreases as load centre distance increases and as lift height increases; always use the data plate for the actual condition.

Tilting the mast forward moves the combined centre of gravity forward; tilting back moves it rearward but raises the load slightly.

Dynamic forces from braking, acceleration, turning and uneven ground shift the centre of gravity and can tip a truck within its static capacity.

Travel with forks about 100–150 mm above the floor and the mast tilted back; never travel with a raised load.

Reduce speed before turns; centrifugal force acts sideways and lateral stability is lower than longitudinal stability.

Rear-wheel steering means the rear swings outward; allow clearance for the counterweight when turning.

Use smooth, progressive control movements; abrupt steering, braking or lifting increases load swing and tip risk.

Load centre is the horizontal distance from the fork face to the load's centre of gravity; standard ratings use 500 mm or 600 mm.

Approximate capacity at a new load centre = rated capacity × rated load centre ÷ actual load centre (same lift height).

Example: 2,000 kg rated at 500 mm gives about 1,667 kg at 600 mm; lift height and attachments may reduce this further.

Never exceed the data plate capacity; check load weight, dimensions and stability before lifting.

Stacking: approach square, forks level, lift clear, tilt back slightly, reverse before lowering; check overhead clearance.

De-stacking: confirm stack stability, approach square, lift clear, tilt back and reverse before lowering.

Keep the load within the fork length and against the backrest; do not lift loads with damaged pallets or unsecured items.

Do not lift people with forks; use an approved work platform and a documented procedure.

Start-up: seat belt on, parking brake applied, controls neutral, start, test horn, steering and brakes before moving.

Travel with the load low and tilted back; look in the direction of travel and keep a clear view ahead.

On ramps keep the load uphill: loaded trucks travel forward up the slope, unloaded trucks reverse up.

Never carry passengers; no riders on forks, pallets, chassis or counterweight.

Obey site speed limits, use the horn at blind corners and slow down in pedestrian areas.

Park with forks flat on the floor, mast tilted forward, parking brake on, controls neutral and key removed.

Do not leave a running truck unattended; lower the load and shut down if leaving the seat.

Report any incident, near miss or damage immediately and complete the required records.

Keep pedestrians outside the truck's working zone; stop if a pedestrian enters or cannot be seen.

Use segregated walkways and marked routes; never allow pedestrians to walk under raised forks or near a suspended load.

Slow down and sound the horn at blind corners, doorways and aisle intersections; use mirrors.

Rear-wheel steering swings the rear outward; check rear clearance before turning near racking or people.

Maintain a safe following distance from other trucks; no overtaking in narrow aisles.

Before entering a trailer or dock, check the dock leveller, wheel chocks/restraint, trailer floor and lighting.

Use a spotter for oversized loads or restricted visibility; agree signals before moving.

Check overhead clearance, doorway heights and floor conditions before proceeding.

Refuel or recharge only in designated, well-ventilated areas with no smoking or ignition sources.

LPG: close the cylinder valve before disconnecting, check hoses and connections for leaks, and change cylinders with the engine off.

Diesel: stop the engine, avoid spills, use a spill kit and clean up before restarting.

Lead-acid batteries release hydrogen during charging; keep vents clear and avoid sparks, flames or smoking.

Use acid-resistant PPE and eyewash when checking electrolyte; add distilled water only as specified.

The battery is part of the counterweight; do not remove or swap it unless trained and authorised.

End of shift: park in the designated area, forks down, key off, recharge/refuel, report defects and complete the log.

Record hour-meter readings and defects for the next operator; defective trucks must be tagged out.