Forklifts are powerful industrial machines, but their design makes them susceptible to instability and tip-overs. These accidents cause serious injuries and fatalities in the material handling industry every year. Knowing the correct, immediate response to a tipping event is crucial, as the actions taken in the first few seconds determine the operator’s survival. The goal is to stay securely within the protective frame of the machine, which drastically increases the chance of escaping serious harm.
The Immediate Life-Saving Action
If a sit-down counterbalance forklift begins to tip, the operator must immediately execute three coordinated actions: grip, brace, and lean. Firmly grip the steering wheel with both hands to anchor the upper body to the seat. This hold helps prevent the operator from being thrown from the compartment as the machine rotates.
Next, brace the feet firmly against the floorboard or pedals to secure the body in the seat and prevent sliding. The final action is to lean hard in the direction opposite to the tip. If the forklift is tipping left, the operator must lean their torso to the right, attempting to maximize the distance between their head and the ground as the machine rolls.
For a lateral tip-over, leaning away ensures the body stays within the protective confines of the overhead guard. For a longitudinal tip-over (tipping forward or backward), the operator should lean slightly forward or down while maintaining the grip and brace, protecting the head by tucking the chin towards the chest.
Why Jumping Is the Greatest Danger
The natural instinct to jump clear of a rapidly tipping machine is the most common cause of fatality in these incidents. The tip-over happens too quickly for the operator to predict the machine’s trajectory or clear the massive weight of the forklift. Attempting to jump results in the operator being thrown into the path of the falling machine or landing outside the protective zone.
The primary safety device is the Operator Restraint System (ORS), which includes the seatbelt. This system keeps the operator secured within the frame, specifically beneath the Overhead Guard (OHG). When an operator jumps, they bypass the protection of the seatbelt and the OHG, which is engineered to absorb the impact of the machine striking the ground.
In a rollover, the operator who jumps is often crushed by the overhead guard or the frame of the forklift. The resulting crush injury, particularly to the head, neck, or torso, is often fatal. Remaining seated and secured ensures the operator is contained within the protected zone of survival, allowing the machine’s safety features to function as intended.
Steps to Take After the Forklift Stops Moving
Once the forklift has come to a complete stop, the operator must remain calm and prioritize securing the scene. Turn off the engine and ignition immediately to prevent further hazards such as fuel leaks, electrical shorts, or fire. This action also ensures the machine cannot unexpectedly restart or shift position.
The operator should assess their physical condition for any injuries before attempting to move. They should also check for environmental hazards, such as a spilled load, leaking fluids, or proximity to other equipment.
Do not attempt to exit the cab until trained rescue personnel have arrived. Exiting unaided risks shifting the forklift’s weight, which could cause it to roll further or worsen internal injuries. The only exception is an immediate, life-threatening danger, such as fire.
Essential Operational Safety Rules for Tip Prevention
Preventing a tip-over is achieved by maintaining the forklift’s center of gravity within the stability triangle, a concept fundamental to safe operation. This requires rigorous adherence to rules concerning load handling, driving practices, and environmental awareness.
Load Handling
Never exceed the load capacity listed on the forklift’s data plate, as overloading is a primary cause of forward tip-overs.
Position the load as low to the ground as possible (typically six to eight inches) during transit to maintain a low center of gravity.
Tilt the mast back completely before traveling to cradle the load and shift the center of gravity toward the counterweight.
Ensure loads are balanced and secured properly, as unbalanced loads or shifting during movement leads to sudden instability.
Driving Practices
Maintain slow, controlled movements at all times.
Make turns gradually; excessive speed generates centrifugal force that can quickly cause a lateral tip.
Avoid sudden stops or starts, as these actions cause the load’s momentum to shift the center of gravity, compromising stability.
Environmental Awareness
Operators must be aware of the environment, avoiding sudden turns or changes in direction on uneven surfaces, slopes, or slick floors.
When navigating ramps or inclines, always drive with the load facing uphill.
A loaded forklift drives forward up a ramp and backs down a ramp to keep the load on the uphill side.
An unloaded forklift should travel with the forks pointing down the slope.
Required Safety Features and Pre-Operation Checks
The forklift is equipped with several features designed to protect the operator, all of which rely on pre-shift inspection. The Operator Restraint System (ORS), which includes the seatbelt, is the most important safety feature in a tip-over event and must be checked for condition and function before every use. The Overhead Guard (OHG) provides a protective canopy, and the Load Backrest Extension helps prevent the load from shifting backward onto the operator.
A comprehensive pre-operation check is required at the start of every shift to identify potential mechanical failures that could compromise stability. This inspection includes:
Visual checks for structural damage to the forks, mast, and OHG.
Checking tire condition, fluid levels, and battery status.
Verifying the smooth and responsive function of the steering, service brakes, and parking brake, as mechanical issues in these components can cause a loss of control.