In brief
The Regulation on Work Equipment requires the forklift to be visually inspected by the operator before each start of work, its functions to be tested and this to be recorded. Three things determine the tip-over risk: the load chart, the direction of the load on a ramp and speed on bends; what protects the operator at the moment of tipping over is the cab or overhead guard together with a fastened seat belt.
Forklift safety starts in the first minutes of the shift
When forklift safety is mentioned, most businesses think of the annual periodic inspection report. But the engineer who signs the report sees the forklift once a year; the operator sees it every day. We wrote this article from the point of view of the person sitting in the forklift seat: what to check at the start of the shift, how to read the load chart, how to prevent tip-overs on ramps and bends, and why the belt saves lives at the worst moment.
The basis is the Regulation on Health and Safety Requirements for the Use of Work Equipment. Annex III of the regulation requires work equipment to be checked by its operators before each start of work. During use, equipment is visually inspected for cracks, loose connections, deformation, wear and corrosion, its functions are tested and these checks are recorded. Equipment showing cracks or excessive wear is taken out of use and immediately sent for periodic inspection.
Annex II of the same regulation sets two more basic rules: self-propelled work equipment is used only by employees who have received appropriate training, and traffic rules and speed limits are set and enforced in the area where the equipment moves.
Forklift daily checklist
The list below contains the checks common to diesel, LPG and battery-powered counterbalance forklifts. If the manufacturer’s user manual contains additional items, add them to the list.
| Check point | What do you look for? | If there is a finding |
|---|---|---|
| Forks and fork carriage | Cracks, bending, thinning at the tips, locking pins in place | Do not use the forklift; report it to your supervisor |
| Mast, chains, hoses | Slack or uneven tension in the chains, hydraulic leaks | Out of use; service is called |
| Tyres and wheels | Cuts, missing chunks, excessive wear; pressure in pneumatic tyres | Out of use or tyre replacement |
| Brakes | Service brake and parking brake, tested empty and with a light load | Out of use |
| Steering and controls | Play, stiffness; lift, lower and tilt levers returning | Out of use |
| Seat belt and seat | Belt buckle, cuts in the belt webbing, seat mounting | No work until the belt is repaired |
| Overhead guard and load backrest | Weld cracks, missing bolts, holes drilled afterwards | Out of use |
| Warning systems | Horn, reversing alarm, rotating or blue light, headlights | Repair; no reversing manoeuvres |
| Energy system | LPG cylinder connection and smell of leaks; battery cables and terminals; fuel leaks | If there is a leak, do not switch on the ignition |
| Capacity plate | Is it legible, does it match the attachment? | No work until the plate is renewed |
The check form can be paper or digital; what matters is that it is filled in every shift, that it is clear who is informed when “not OK” is ticked, and that the form is kept. Annex III also requires maintenance and repair records to be kept for the service life of the equipment.
Forklift load capacity: how to read the load chart
If the capacity plate on the forklift says “2.5 tonnes”, this does not mean that 2,500 kg can be lifted in all conditions. The value on the plate applies to a specific load centre (the horizontal distance from the fork face to the load’s centre of gravity, often 500 mm) and a specific lift height. Capacity falls as the load moves forward or is raised higher.
The table below is a representative chart prepared to illustrate reading; on your own forklift, use only the values on your own plate.
| Lift height | Load centre 500 mm | Load centre 600 mm | Load centre 700 mm |
|---|---|---|---|
| Up to 3,000 mm | 2,500 kg | 2,200 kg | 1,900 kg |
| 4,500 mm | 2,200 kg | 1,900 kg | 1,650 kg |
Apply three rules when reading it:
- Estimate the load’s centre of gravity. On an evenly loaded pallet 1,200 mm deep, the centre of gravity is at about 600 mm; you cannot use the 500 mm row on the plate.
- Base it on the highest rack. If you are going to put the load at 4.5 metres, look at the capacity at the highest point, not when lifting from the floor.
- If an attachment is fitted, the old plate is invalid. A side shift, rotator or roll clamp both adds weight and moves the load centre forward. Obtain the capacity with the attachment from the manufacturer and have the plate updated.
Do not try a load of unknown weight on the basis of “if it lifts it, it lifts it”. The rear wheels getting lighter, the steering going light and the mast swaying forward are signs that capacity has been exceeded; at this point, lower the load slowly.
Forklift tip-overs: on ramps, on bends and with the load raised
A counterbalance forklift balances on a triangle formed by the two front wheels and the midpoint of the rear axle. When the combined centre of gravity of the load and the forklift moves outside this triangle, the forklift tips over. Four situations the operator can control upset this balance:
- Speed on bends. The typical scenario for a lateral tip-over is an empty or loaded forklift turning fast. Slow down before the turn; do not turn the steering sharply.
- Moving with the load raised. The higher the load, the higher the centre of gravity. Lift the load only a few fingers’ width off the floor, tilt the mast back and then move. Do not change direction with a raised load.
- Ramps and slopes. When loaded, the load must always stay on the upper side of the slope: go up the ramp forwards, come down in reverse. When empty, the forks face the lower side of the slope. Never turn on a ramp and never enter a ramp at an angle.
- Floor. Potholes, manhole covers, speed bumps, wet or oily floors and the gap between the ramp and the lorry bed cause sudden lurching. At a lorry loading ramp, do not drive in without seeing that the vehicle is chocked and the dock leveller is seated.
For forklifts working outdoors, as around the port and free zone in Gemlik, wind, rain and muddy and uneven ground also increase the risk of tipping over. Walk the outdoor routes at the start of the shift to check them; if the ground has deteriorated, change the route or postpone the work.
Forklift seat belts: surviving a tip-over
Annex I of the regulation requires forklifts with an employee on board to have a cab for the driver against the risk of tipping over, or to be constructed so as to prevent the driver from being crushed by parts of the forklift if it tips over. On sit-down forklifts, this protection has two parts: the overhead guard or cab, and the seat belt that keeps the operator in the seat. If the belt is not fastened, the overhead guard alone does not work, because an operator thrown from a tipping forklift often ends up under the guard or the mast.
Know in advance what to do when a tip-over starts:
- Do not jump.
- Hold the steering wheel firmly with both hands.
- Press your feet against the floor.
- Lean your body away from the direction of the tip-over.
Belt use is also a matter of the employee obligations listed in Article 19 of Law No. 6331: the employee uses the safety devices of equipment correctly and does not remove or alter them arbitrarily. The employer’s duty is to monitor belt use and not to accept working without a belt. Some businesses prefer interlock systems that prevent movement until the belt is fastened; if such a change is to be made, it should be planned together with the manufacturer.
Seven rules when carrying loads
- If your view is blocked, drive in reverse. If the load blocks your view ahead, travel in reverse and look in the direction of travel. The regulation requires aids to improve visibility to be used when the driver’s field of view is restricted.
- Do not carry passengers. No one rides on the forks, a pallet or any part of the forklift. Under Annex II, people cannot be carried on mobile work equipment unless the production standard or user manual explicitly permits it.
- Do not lift people. Raising an employee on a pallet with a forklift is possible only in exceptional and emergency situations, with the necessary measures and under supervision. This is not used for routine racking work.
- Give way to pedestrians. Stop at blind corners and sound the horn; do not use pedestrian walkways as forklift routes.
- Observe the speed limit. The speed limit set by the business is not a recommendation but part of the traffic arrangement required by Annex II.
- Pick up the load evenly. Insert the forks fully into the pallet and adjust the spacing between the forks to the load.
- Park correctly. Forks on the floor, handbrake on, ignition key not left in. The regulation requires devices to prevent unauthorised persons from starting the forklift; leaving the key in removes this protection.
Separating forklift and pedestrian routes inside the warehouse is a separate planning matter and is addressed in the risk assessment. You can find example scoring in our risk assessment guide.
Training, certificates and periodic inspection
The forklift is used only by operators who have received appropriate training in its safe use. The content of this training must be specific to the workplace: the ramp in the warehouse, racking heights, the attachment used and pedestrian traffic. Operators’ vocational certificate status needs to be assessed according to the nature of the work done; we explained which certificates are accepted in our vocational training certificate guide.
The operator’s daily check does not replace the periodic inspection. Forklifts and pallet trucks are inspected at least once a year, unless the standard sets a shorter period, by a competent person registered in EKİPNET (the Ministry’s register of persons authorised for periodic inspections); details are in our article on periodic inspection intervals for work equipment. By adding inspection dates to the OHS calendar, you will not miss any, including hired forklifts.
In warehouse and logistics businesses in Bursa and the surrounding provinces, assessing forklift risks on site, preparing operator instructions and setting up check forms are part of our OHS specialist service. You can plan the annual inspections with our periodic inspection service. For other sector-specific risks, see our logistics and warehousing page.
Frequently Asked Questions
Is a forklift daily check form mandatory?
Yes. Annex III of the Regulation on Work Equipment requires the equipment to be checked by the operator before each start of work and the visual inspection and function tests to be recorded. The format of the form is free; it can be paper or digital.
How often is the periodic inspection of a forklift carried out?
At least once a year unless the standard sets a shorter period. The inspection is carried out by a competent person registered in EKİPNET, and the contract is set up through ISG-KATİP (the Ministry’s online OHS registration system) at least one day before the inspection.
Is it right to jump when a forklift is tipping over?
No. An operator who jumps often ends up under the overhead guard or the mast. With your belt fastened, hold the steering wheel firmly, press your feet against the floor and lean your body away from the direction of the tip-over.
Can a person be lifted on a pallet with a forklift?
Not for routine work. Equipment manufactured for the purpose is used to lift people. Under the regulation, equipment not manufactured for lifting people can be used for this purpose only in exceptional and emergency situations, with the necessary measures and under supervision.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.