Reach Truck Safety ================== 1. Start safely This guide reviews key reach truck safety points. Only trained and authorised operators should use the truck, and operators must understand the controls, the workplace and its traffic plan. 2. Check before use Before operating the truck, complete and record the pre-shift checklist. Check the mast, chains, reach mechanism, forks, load backrest, hydraulics, wheels, controls, brakes, steering and warning devices in line with the manufacturer's instructions. Isolate and report an unsafe truck. 3. Use the travel position Before travelling, retract the reach mechanism unless the manufacturer or safe system says otherwise. Use the correct driving position, normally with the fork heels approximately one hundred and fifty millimetres above the floor and the mast slightly tilted back. Keep a clear view and look in the direction of travel. 4. Know four facts before lifting Before lifting, confirm the load weight, its load centre, the required lift height, and that the capacity plate confirms this truck can safely handle the load under those conditions. 5. Check capacity at height Check the capacity plate for the actual load, lift height and attachment. A reach truck's available capacity may reduce as height or load centre increases. Never rely on guesswork or exceed the stated limit. 6. Understand the load centre The load centre is measured forward from the vertical face of the forks to the load's centre of gravity. A longer load centre increases leverage and normally reduces the truck's safe lifting capacity. 7. Position the load correctly Place the load against the fork heels wherever practicable and spread the forks so the weight is supported evenly. Check the pallet and load are stable before lifting. 8. Keep a clear view Always maintain a clear view and look in the direction of travel. If the load blocks forward vision, use the approved safe method: travel in reverse where safe, or use a trained banksman in accordance with the site's safe system of work. 9. Protect pedestrians Keep pedestrians outside the operating aisle and stacking zone. Slow down and check the route at blind corners, doorways and aisle exits. Where site procedure requires it, sound several short, sharp horn bursts. 10. Protect truck stability Keep the load low while travelling and use smooth steering, acceleration and braking. Do not turn or travel with a raised load unless an approved procedure specifically requires it. 11. Check the aisle and racking Before raising the load, check overhead and side clearances, the pallet location and the condition of the racking. Stop and report damage, obstruction or an unsuitable location. 12. Stack slowly and square Approach the location squarely and stop before raising or lowering. Secure the truck as trained, then make small, controlled reach and hydraulic movements. Confirm the pallet is supported before withdrawing the forks. 13. Use slopes only as approved Reach trucks may have restrictions on gradient use. Follow the manufacturer and site procedure. Where travel on a slope is permitted, keep the heavy end uphill and never turn across the slope. 14. Maintain safe separation Allow for rear-end swing when turning and keep a safe distance from other trucks. In normal conditions, three truck lengths is a useful minimum, increased where the route or surface requires it. Stop for obstructions rather than driving around them unsafely. 15. Park safely Park in the authorised place with the reach retracted and the forks fully lowered. Select neutral, apply the brake, switch off and secure the key or access control. 16. Stop and ask High-level handling leaves little room for error. Stop if visibility, racking, the load or the truck is unsafe. This video supports, but never replaces, practical training and assessment. Important: This video is theory-support material only. It does not replace practical training, familiarisation, supervision, manufacturer instructions, site rules or formal assessment. © 2026 FLT Academy Ltd • fltacademy.co.uk • All rights reserved