PROC-002 | Forklift Operating Procedure | Version 1.0 | February 2026

Purpose

To ensure the safe operation of counterbalance forklifts at [YOUR BUSINESS NAME].

Scope

All licensed forklift operators at [YOUR BUSINESS NAME].

Licence Requirement

You must hold a current High Risk Work Licence — LF class (Forklift) to operate any forklift at [YOUR BUSINESS NAME]. Operating a forklift without a current licence is illegal and may result in immediate termination.

Licence details must be recorded in the Training Register (REG-005).

Required PPE

Steel-capped safety boots

Hi-vis vest

Hard hat (in container unloading area and racking areas)

Seatbelt (must be worn at all times when operating)

Pre-Start Checks

Complete the Forklift Daily Pre-Start Checklist (CHECK-001) before operating. Check:

Tyres (pressure, condition, no damage)

Forks (no cracks, bends, or damage; heel and tip condition)

Mast (no damage, chains lubricated, free movement)

Hydraulics (no leaks, correct fluid level)

Brakes (service and park brake function)

Steering (smooth operation)

Lights and horn (functioning)

Seatbelt (intact and functioning)

LPG/fuel (adequate supply, no leaks)

Battery (if electric — charge level, no damage)

Overhead guard (intact, no damage)

Load backrest (intact, no damage)

Do not operate a forklift with any defect. Report defects immediately using FORM-012.

Safe Operating Rules

1. Speed limit: Maximum 10 km/h in the warehouse; 5 km/h at intersections and pedestrian crossings.
2. Pedestrians always have right of way. Stop and give way to all pedestrians.
3. Sound the horn at all blind corners, intersections, and before entering/exiting the building.
4. Travel with forks lowered (150–300mm above ground) and mast tilted back.
5. Never carry passengers on the forklift.
6. Never allow anyone under raised forks.
7. Do not exceed the rated capacity shown on the data plate.
8. Secure loads before moving. Ensure loads are stable and within the load centre.
9. Travel in reverse when load obstructs forward vision.
10. Maintain safe following distance — minimum 3 forklift lengths from other forklifts.
11. Do not use a mobile phone while operating.
12. Wear seatbelt at all times.

Refuelling (LPG)

1. Shut down the forklift engine before changing LPG cylinders.
2. Refuel/change cylinders in the designated refuelling area only.
3. No smoking or ignition sources within 3 metres.
4. Wear gloves when handling LPG cylinders.
5. Check connections for leaks after cylinder change.

Shutdown Procedure

1. Lower forks fully to the ground.
2. Apply the park brake.
3. Tilt mast forward until forks are flat on the ground.
4. Turn off the engine/isolate power.
5. Remove the key.
6. Park in the designated forklift parking area.

If Something Goes Wrong

Forklift tip-over: Stay in the cab, grip the steering wheel, brace your feet, lean away from the direction of fall. Do NOT jump out.

Collision: Stop immediately, check for injuries, call for help, do not move the forklift until instructed.

Pedestrian struck: Call 000 immediately. Do not move the forklift. Preserve the scene.

Related Documents: CHECK-001, SWMS-002, SOP-001, REG-003 | Legislation: WHS Regulation 2011 (Qld) Part 5.1; AS 2359; Code of Practice: Managing Risks of Plant in the Workplace