Loading and unloading. By its nature, a forklift is unstable, with a heavy load perched at just one end. And the higher the load is lifted, the more the center of gravity shifts upward, increasing instability. To counter this, operators need to learn to get the forks under the pallet as far as possible and to be sure they are centered under it. Then, once on the truck, the load should be carried as low as possible, with the mast tilted back to further shift the weight toward the truck's center.

Ramps and turns. The key to safety here is to adjust for speed and circumstances. Many ramps will need to be taken in reverse, with the load oriented uphill. This transfers the weight toward the truck and, of course, helps prevent the load from sliding off. Turns should always be taken slowly-a challenge for some inexperienced operators, entranced by the forklift's quick acceleration, who may be tempted to "hot rod" their trucks around the workplace.

Uneven surfaces. Pounded by heavy truck use, many industrial roads are pitted and strewn with potholes. Factory and warehouse floors are also often uneven. Additional hazards are posed by railroad tracks, bridge plates, or even open gaps to be crossed in entering and leaving truck trailers or rail cars at loading docks. Operators must actively look for these hazards, and adjust their speed and steering to compensate.

Refueling hazards. Forklifts are powered in three ways: gas, propane, and battery-electric. Each has its own special hazards when refueling or recharging, and most new operators will need to be trained in how it's done right. If the batteries on an electric-powered forklift are low in fluid, for example, you don't just add water, as in a car battery.

Parking hazards. Forklifts are to be operated only by qualified personnel who have received the OSHA-required training. And they need to be parked in secure areas, and never with the keys left on board. Violation of this rule recently cost a 13-year-old his life when he took off in an unsecured truck at his father's workplace and it overturned.