CSCS Counterbalance Forklift key terms

A lift truck with a heavy counterweight at the rear that balances a load carried on forks at the front. It can lift, lower and transport loads and is the most common truck on UK sites.

The maximum load a truck is designed to lift at a specified load centre and lift height, as shown on its data plate. Lifting more than this can cause tip-over.

The horizontal distance from the vertical face of the forks to the centre of gravity of the load. A load centre greater than the one stated on the data plate reduces the truck's safe capacity.

A fixed plate on the truck showing the model, serial number, truck weight, battery or ballast details, and the rated capacity at stated load centres and lift heights. It is the operator's reference for safe loading.

Heavy cast iron or steel mass built into the rear of a counterbalance truck. It offsets the turning moment created by the load on the forks and helps keep the truck stable.

An imaginary triangle drawn between the centre of the rear steer axle and the two front wheels. The combined centre of gravity of truck and load must stay inside it or the truck will tip.

The point through which the whole weight of an object acts. In a forklift, the combined centre of gravity of truck and load shifts with load weight, height and tilt.

An overturn of the forklift, usually forwards when overloaded, when the load is raised while travelling, or when the load centre is too large. Staying in the seat and wearing the belt reduces injury.

The vertical assembly of channels, chains and hydraulic cylinders that raises and lowers the fork carriage. Mast type and free lift affect headroom and lifting height.

The height the forks can rise before the mast sections begin to extend upwards. It allows lifting in low headroom such as inside containers or under rack beams.

The moving frame that runs up and down the mast and carries the forks or an attachment. It is connected to the lift chains and hydraulic cylinders.

The load-engaging tines fitted to the carriage. They must be the correct length for the load, fully under it, and free from cracks or excessive heel wear.

Thinning of the curved part of a fork where the horizontal blade meets the vertical shank. Excessive wear weakens the fork and reduces its rated capacity; it must be measured and reported.

Checks carried out by the operator before each shift, including tyres, forks, mast, chains, hoses, brakes, horn, lights, seat belt and fluid levels. Defects must be reported and the truck taken out of service if unsafe.

A belt that keeps the operator inside the protective frame if the truck tips over. It must be worn whenever the truck is moving or lifting, and must be checked before use.

A strong frame above the operator's seat that protects against falling objects and helps form a survival space if the truck rolls over. It must never be removed or modified.

An audible warning device used to alert pedestrians and other drivers, especially at blind corners, doorways and crossings. It must be tested during the pre-use check.

A seat or pedal switch that stops the truck's drive and hydraulic functions when the operator leaves the seat. It prevents runaway movement and accidental operation.

The brake that holds a stationary truck on a slope or when parked. It must be applied whenever the operator leaves the seat and tested during pre-use checks.

The forward or backward lean of the mast, controlled by a hydraulic lever. Back tilt keeps the load stable during travel; forward tilt is used only for picking up or placing loads.

A hydraulic attachment that moves the fork carriage sideways for fine alignment. It lets the operator position loads without moving the truck, but adds weight and reduces capacity.

Any equipment fitted to the carriage instead of standard forks, such as a clamp or rotating head. It changes the load centre and capacity, so the truck's rating must be adjusted.

The safe way to move with a load: forks about 150 to 200 mm above the ground, mast tilted back, load stable and low, and speed suited to conditions.

Keeping forklifts and people apart using marked walkways, barriers, crossing points and site rules. Where segregation is impossible, use warning signs, low speed and eye contact.

An area the operator cannot see, often caused by the load on the forks or by truck pillars. If the load blocks the view, travel in reverse or use a trained banksman.

Driving backwards when a load obstructs the forward view. It keeps the load low and the operator looking in the direction of travel; a banksman may be needed in busy areas.

Moving on a slope: travel with the load uphill and the forks pointing up the slope. On gradients, keep the load low, use low gear and avoid turning across the slope.

The edge of a loading dock or ramp. Keep a safe distance, approach square, use wheel chocks or restraints on vehicles, and never drive over an unprotected edge.

Loading or unloading a lorry or trailer. Check the trailer's brakes are applied, wheels chocked, floor sound, and that it cannot move away from the dock during loading.

Replenishing diesel or LPG fuel. The engine must be off, smoking prohibited, area ventilated, PPE worn and spills cleaned up with the correct kit; report leaks.

Replacing a gas cylinder: close the valve, run the engine until the line is empty, wear gloves and eye protection, fit the new cylinder and leak-test with soap solution, never a flame.

Recharging a traction battery. Park in a designated ventilated area, switch off, connect the charger correctly, wear eye and face protection, and keep flames and sparks away because hydrogen is produced.

Adding distilled or deionised water to lead-acid cells. Check the level after charging, never overfill, use PPE, and follow the manufacturer's instructions to avoid acid burns.

The procedure for parking the truck: park in the designated area, lower forks flat to the floor, tilt the mast forward slightly, apply the parking brake, neutralise controls, switch off and isolate.

Telling the supervisor or maintenance team about a fault found on the truck. The truck should be tagged out and not used until repaired; the report should be recorded in the log.

The maximum load a racking bay or beam level is designed to hold. Always check the rack load sign and never exceed it when stacking; damaged racking must be reported.

The condition of a load that will not shift, fall or collapse during lifting and travel. Use banding, wrapping, correct pallet type and check the load before moving.

Using a forklift to raise people. This is allowed only with a purpose-built, secured work platform with guard rails and a restrained operator; never lift people on bare forks.

The employer's written confirmation that a person has been trained, tested and is competent to operate a specific type of forklift on site. Unauthorised use is a serious safety breach.

A control or action that immediately stops the truck's movement and lifting functions. The operator must know its location and use it if control is lost or a person is in danger.