725 Forklift Safety Program Management

Glossary

A

• Articulating Boom. A hydraulic lifting arm that bends or "articulates" to reach over obstacles, allowing forklifts and similar vehicles to extend reach at various angles.
• Automated Guided Vehicle (AGV). A self-guided vehicle used to transport materials through designated paths in a facility without human intervention, often part of automated material handling systems.
• Automatic Fork Leveling System. A feature in forklifts that automatically adjusts the tilt of the forks to level, helping operators achieve balanced and stable lifting.

B

• Backup Alarm. An audible warning device that sounds when the forklift is moving in reverse, alerting pedestrians and other workers in the area.
• Battery Capacity. The amount of electrical energy a forklift battery can store, typically measured in ampere-hours (Ah). Higher capacity allows for longer operation between charges, important for productivity and efficiency in powered industrial truck use.
• Battery Compartment. The area on an electric forklift where the battery is housed, often including access panels and secure latches for safe installation and maintenance.
• Battery Exchange. The process of swapping a discharged battery with a fully charged one in electric forklifts to minimize downtime. Battery exchange stations are often used in high-demand operations.
• Battery Watering System. A system designed to automatically maintain the correct water level in a forklift battery, extending battery life and improving performance.
• Brake Fluid. A hydraulic fluid used in forklift braking systems to transmit force and create the pressure required for braking.

C

• Cab Enclosure. A protective enclosure for the operator, often used on outdoor or rough-terrain forklifts to provide shelter and improve operator safety.
• Capacity. The maximum load weight that a forklift or powered industrial truck can safely handle, as specified by the manufacturer. Exceeding this weight may lead to tipping or loss of control, posing safety hazards.
• Carousel System. A type of automated storage and retrieval system in which materials are transported in a rotating sequence, allowing for efficient picking and storage.
• Charging Station. A designated area where electric forklifts and battery-operated equipment are recharged, often equipped with power supplies and safety equipment.
• Clamp Attachment. An attachment that provides gripping capabilities, enabling forklifts to handle loads such as barrels, rolls, or boxes without pallets.
• Conveyor System. A mechanical handling device that transports materials across a facility using rollers, belts, or chains, commonly used in warehouses and production lines.
• Counterweight. A weight at the rear of the forklift that offsets the load being carried, maintaining balance and stability during lifting.
• Cross Docking. The process of unloading materials from incoming trucks and directly loading them onto outbound trucks with minimal or no storage time.

D

• Deadman Switch. A safety feature that automatically cuts power or stops the machine when the operator releases control, preventing unintended movement or operation.
• Diesel Fuel. A type of fuel commonly used in heavy-duty forklifts, especially those intended for outdoor or rough-terrain use.
• Dock Leveler. A platform that bridges the gap between a loading dock and a truck bed, allowing forklifts to move safely between the dock and truck.
• Dock Operations. The procedures and activities involved in loading and unloading materials at a dock, often including safety protocols and equipment usage.
• Drive Axle. The axle that connects the forklift’s engine or motor to its wheels, providing propulsion.
• Duplex Mast. A two-stage mast on a forklift, allowing for lifting to a greater height without extending the mast fully.

E

• Electric Forklift. A forklift powered by rechargeable batteries rather than an internal combustion engine, offering lower emissions and reduced noise levels.

F

• Fleet Management System. A system that monitors and manages a fleet of forklifts or other vehicles, tracking metrics like usage, maintenance needs, and fuel levels to improve efficiency.
• Fork Positioner. An attachment that enables operators to adjust the spacing of the forks without leaving the operator’s seat, improving efficiency and versatility.
• Fork Spread. The adjustable distance between the forks on a forklift, allowing for accommodation of different load sizes and stability requirements.
• Forklift Inspection. The pre-operational and routine inspection of a forklift to check for mechanical or safety issues, mandated by OSHA to ensure safe operation.
• Four-Wheel Forklift. A forklift with four wheels, providing stability and maneuverability for both indoor and outdoor use, often for handling heavier loads.

G

• Gravity Flow Rack. A type of storage system that uses gravity to move pallets or containers from the loading to the unloading end, maximizing storage space.
• Gross Capacity. The maximum combined weight that a forklift can safely lift and transport, including the load and any attachments.

H

• High Capacity Forklift. A forklift designed to handle heavier loads than standard models, often used in industries like construction or shipping for moving large equipment and materials.
• Hour Meter. A device that records the total hours of operation of a forklift, used to track maintenance intervals and monitor equipment usage.

I

J

L

• Layer Picker. An attachment that allows forklifts to pick up a single layer of goods from a pallet, often used in distribution centers to handle mixed pallets.
• Lift Truck. Another term for a forklift, emphasizing its primary function of lifting and transporting loads.
• Load Center. The horizontal distance from the front of the forks or other attachment to the center of gravity of the load; proper load center is essential for safe forklift operation and stability.
• Load Moment Indicator. A device that monitors the load's weight and distance from the fulcrum to ensure it does not exceed safe limits, preventing tipping accidents.
• Load Sensing System. A system that detects changes in load weight and center of gravity, adjusting the forklift’s performance for improved safety and stability.
• Load Stabilizer. An attachment that helps to secure loads during transport, minimizing movement and shifting.
• LP Gas. Liquefied petroleum gas, commonly used as a fuel source for forklifts, providing a clean-burning alternative to gasoline or diesel.

M

• Man Basket. A platform attachment that allows forklifts to safely lift personnel for tasks such as inventory or maintenance.
• Mast Rollers. Rollers located on the mast that facilitate the smooth movement of the carriage up and down.
• Material Handling. The movement, protection, storage, and control of materials throughout manufacturing, warehousing, and distribution.

N

• Narrow Aisle Operations. Forklift operations in tight spaces, requiring specialized equipment like reach trucks or order pickers to navigate safely.
• Net Capacity. The load-carrying capacity of a forklift when accounting for additional equipment or attachments.
• Non-Marking Tires. Tires made from a special rubber compound that leaves no marks on floors, commonly used in indoor environments.

O

• Order Picker. A forklift designed to lift operators to elevated racks to manually select inventory for order fulfillment.

P

• Pallet. A flat transport structure used to support goods in a stable manner while being lifted by forklifts or pallet jacks.
• Pallet Jack. A type of hand truck with wheels and a hydraulic lifting mechanism, designed for lifting and moving palletized loads.
• Pallet Racking. A storage system with multiple levels designed to hold palletized goods, maximizing space in warehouses.
• Pantograph. A reach mechanism in some forklifts that allows the forks to extend and retract horizontally, useful in narrow aisle storage.
• Pedestrian Alert System. A safety system that warns pedestrians of an approaching forklift, often using visual or audible alarms.
• Personnel Platform. A platform that attaches to forklifts to lift workers for high-level tasks such as maintenance or stock counting.
• Polyurethane Tires. Durable tires made from polyurethane material, commonly used in indoor forklifts for smooth and non-marking operation.
• Pre-Operation Inspection. A checklist-based inspection performed by the operator before using a forklift to ensure it is safe and operationally sound.
• Proximity Sensor. A sensor used on forklifts to detect objects or people nearby, enhancing safety by alerting the operator of potential obstacles or hazards in close proximity.

Q

R

• Ramp Operations. The use of forklifts and other material handling equipment on inclined surfaces or ramps, requiring special techniques and safety precautions to prevent tipping or sliding.
• Rated Capacity. The maximum weight that a forklift can safely lift under specific conditions as defined by the manufacturer. This rating must be strictly followed to avoid accidents.
• Reach Mechanism. A component on reach trucks that allows the forks to extend outward to access loads located deep within racking, commonly used in narrow aisle operations.
• Reach Truck. A type of narrow aisle forklift designed with an extendable carriage, enabling operators to reach loads located deep within storage racks.
• Retractable Mast. A mast design that allows the mast to retract for compact storage or extend to reach higher lifting heights. Commonly used in narrow aisles or confined spaces.
• RFID System. A technology using radio frequency identification to track pallets, forklifts, and inventory within a warehouse for improved inventory management and operational efficiency.
• Roll Prong. A forklift attachment with a single, long, cylindrical arm, ideal for handling rolled materials such as carpets, fabric rolls, or wire coils.
• Rotator. A forklift attachment that enables the operator to rotate the forks, allowing for dumping or rotating loads for precise positioning.
• Rough Terrain Forklift. A forklift designed with large, rugged tires and powerful engines, suitable for operation on uneven surfaces and outdoor environments.

S

• Side Loader Forklift. A type of forklift with forks mounted on the side, designed to carry long or bulky loads down narrow aisles.
• Simplex Mast. A single-stage mast with no free lift, commonly used when height requirements are low and overhead clearance is not a concern.
• Solid Tires. Non-pneumatic tires often made from rubber or polyurethane, designed for indoor use and smooth surfaces. They are durable and do not deflate like pneumatic tires.
• Stability Triangle. A concept that explains the stability of a forklift, based on the three points that form a triangle between the front wheels and the pivot point of the rear axle. Understanding the stability triangle is crucial for safe load handling.
• Stand-Up Forklift. A type of forklift where the operator stands rather than sits, typically used in narrow aisle and high-density storage areas.

T

• Telehandler. A type of forklift with an extendable boom, capable of lifting loads to great heights and across obstacles, commonly used in construction.
• Telescopic Boom. An extendable arm on certain forklifts and telehandlers that provides additional reach for loading and unloading.
• Tilt Control. A lever or control on the forklift that adjusts the tilt of the mast and forks, allowing the operator to safely balance loads and prevent slippage.
• Tilt Cylinder. A hydraulic cylinder that adjusts the tilt angle of the forklift mast, providing the ability to angle the load for stability and handling.
• Tilt Tray Sorter. A conveyor system that uses trays that tilt to divert packages onto different lanes, typically used in distribution centers for automated sorting.
• Triplex Mast. A three-stage mast design that allows for greater lifting height while maintaining a compact lowered height, providing versatility in confined spaces.
• Turntable. A rotating platform used in material handling to reposition loads without moving the entire forklift, often used in conveyor systems or loading docks.

U

V

W

• Walkie Stacker. A type of electric pallet jack with an extendable mast, allowing operators to lift pallets to higher shelves; typically operated by walking behind the unit.

X

Y

• Yard Truck. A vehicle specifically designed to move trailers and containers within a shipping yard or distribution facility, often used for organizing trailers in staging areas.

Z