When a forklift is unsafe to operate, employees can be seriously or fatally injured if the machinery they service/maintain unexpectedly energizes, starts up or releases stored energy. Employers must ensure that employees isolate machines from their energy sources and render them inoperative before any employee services or maintains them.

Energy sources in machines and equipment can be hazardous to workers. During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy could cause injury to employees.

Warehouse operations, to uphold safety, need a lockout/tagout program to prevent equipment from being accidentally energized and injuring employees.

Lockout devices hold energy-isolation devices in a safe or “off” position. This provides protection by preventing machines or equipment from becoming energized because they are positive restraints that no one can remove without a key or other unlocking mechanism.

Tagout devices are prominent warning devices that an authorized employee fastens to energy-isolating devices to warn employees not to reenergize the machine while he/she services or maintains it.

How To Lockout/Tagout A Forklift

Locking out a forklift involves a few important steps to ensure safety. Begin by attaching a secure lockout device to the forklift. This will prevent it from being operated while maintenance or repairs are being conducted. Additionally, place a red and white warning tag on the steering wheel to provide clear visibility and information about why the forklift is locked out.

When applying the lockout device, make sure to identify and isolate all energy sources connected to the forklift. Disconnect or isolate the machine from these energy sources to eliminate any potential hazards. Once the energy-isolating devices have been identified, carefully attach the lockout or tagout device(s) to them, ensuring that energy is effectively isolated.

It’s also crucial to release, restrain, or render safe all potential hazardous stored or residual energy. This step helps further minimize any risks associated with the forklift. By following these proper lockout procedures, you can ensure a safe working environment and protect against accidental operation of the forklift.

OSHA Requirements For Lockout/Tagout Devices

OSHA has a few requirements for lockout/tagout devices. OSHA’s requirements are:

  • Durable enough to withstand workplace conditions
  • Standardized according to color, shape or size
  • Substantial enough to minimize the likelihood of premature or accidental removal
  • Labeled to identify the specific employees authorized to apply and remove them

Employees required to perform these operations should be trained and all of the employees should have a working knowledge of the procedures. Barclay offers safety programs that can help you learn how to properly carry out lockout/tagout procedures to keep your forklift work environment safe.

To request FREE out of service safety tags or more information, click here.


Barclay Brand Ferdon
2401 S Clinton Avenue
South Plainfield, NJ 07080
(908) 561-2100