DOSH Forklift Operator key terms

A forklift whose heavy rear chassis and counterweight offset the load lifted at the front, keeping the machine stable. Most common type used in warehouses and yards.

The three-point area formed by the two front wheels and the centre of the steer axle. The combined centre of gravity must stay inside it or the forklift tips over.

The single point where the forklift's weight is considered to act. Adding a load raises and shifts this point, reducing the margin before tipping.

The horizontal distance from the vertical face of the forks to the centre of gravity of the load, usually measured at 500 mm or 600 mm. Increasing it reduces rated capacity.

The maximum load a forklift may lift, stated on the data plate for a specified load centre and lift height. It falls as load centre or lift height increases.

A plate or diagram on the forklift showing safe load limits for different load centres, lift heights and attachments. Operators must read it before lifting unfamiliar loads.

Reducing the forklift's rated capacity to account for conditions such as a longer load centre, a heavy attachment or high lift. The data plate value no longer applies.

The manufacturer's identification plate on the forklift showing model, serial number, weight, rated capacity and battery or fuel details. It is the reference for safe operation.

The vertical assembly of rails, chains and hydraulic cylinders that raises and lowers the carriage and forks. Types include simplex, duplex and triplex.

The frame that slides on the mast and carries the forks or attachment. It moves up and down and can often be shifted sideways.

The height the forks can rise before the mast sections start to extend upward. Important when working inside containers or under low doorways.

Any device fitted to the carriage instead of standard forks, such as a clamp, rotator or push-pull. Attachments change capacity and usually require derating.

The protective cage over the operator compartment that shields against falling objects. It must be fitted and undamaged whenever the forklift is in use.

The restraint that keeps the operator inside the protective compartment during a tip-over. Wearing it is a legal and manufacturer requirement on most forklifts.

Loss of stability causing the forklift to fall sideways or forward. The operator should stay in the seat, hold the wheel and brace rather than jump.

The documented check of tyres, forks, mast, chains, hydraulics, brakes, horn, lights and fluids carried out before each shift. Faults must be reported and the machine tagged out if unsafe.

Attaching a clear warning tag and removing the key from a defective forklift so it cannot be used until repaired and released by an authorised person.

The formal process of recording and passing on any fault found during inspection or use, so the equipment is repaired and the fault is tracked to closure.

Someone who has the training, knowledge, experience and qualifications to perform a task safely, such as inspecting or repairing lifting equipment.

Structured instruction and assessment covering knowledge, practical skills and site-specific hazards, required before a person may operate a forklift unsupervised.

A person who has completed required training and been formally permitted by the employer to operate a specific forklift on a specific site.

A detailed periodic inspection of lifting equipment by a competent person, required by law at set intervals, with results recorded and defects reported.

The legal obligation on employers, operators and others to take reasonable steps to protect the health and safety of themselves and others at work.

A systematic process of identifying hazards, evaluating the likelihood and severity of harm, and putting controls in place to reduce risk.

The order of preference for managing risk: eliminate, substitute, engineer, administrate, then use personal protective equipment as the last barrier.

A documented layout of routes, crossings, speed limits, one-way aisles and exclusion zones that separates forklifts, pedestrians and other vehicles on site.

A marked area where only forklifts may operate, keeping people out of the path of moving machines and swinging loads.

The minimum gap a pedestrian or machine keeps from a moving forklift, accounting for stopping distance, load swing and operator blind spots.

An area the operator cannot see directly or in mirrors, especially behind and beside a loaded forklift. Operators should reverse or use spotters when vision is blocked.

A trained person who guides the operator through blind or congested areas using agreed hand signals, staying visible and clear of the machine's path.

Moving a loaded forklift with the load low, the mast tilted back and forks clear of the ground, at walking pace and looking in the direction of travel.

Angling the mast backward or forward. Backward tilt stabilises a load during travel; forward tilt is used only for picking up and setting down.

The maximum load a racking bay, beam or shelf can safely hold, stated on a load sign. Overloading can cause rack collapse.

A regular check of racking uprights, beams and safety clips for damage, corrosion or displacement, carried out by trained staff and recorded.

A designated, well-ventilated zone for refuelling LPG or diesel forklifts, free of ignition sources and equipped with spill kits and fire extinguishers.

A ventilated zone for charging electric forklifts where hydrogen gas, acid spills and electrical hazards are controlled and no smoking or open flame is allowed.

The supply of fresh air and removal of exhaust fumes, hydrogen or fuel vapour from enclosed spaces where forklifts operate, refuel or charge.

A colourless, odourless gas in forklift exhaust that causes poisoning in poorly ventilated areas. Symptoms include headache, dizziness and nausea.

Reporting an accident, near miss or dangerous occurrence to the supervisor and, where required by law, to the regulator within the set timeframe.

A structured review of what happened, why it happened and what controls will prevent recurrence, recorded and shared with the workforce.

A control that immediately cuts power or halts movement in an emergency. Operators must know its location and function before starting work.