Forklift Training Manual - TLILIC2001 - Licence to operate a forklift truck OPEN 6 DAYS A WEEK - Start Training
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Forklift Training
Manual
TLILIC2001 - Licence to operate a forklift truck
OPEN 6 DAYS A WEEK PHONE (03) 9756 0244
Forklift Training Manual Feb 2018 V9.docx 2
INTRODUCTION
To drive a forklift truck in Australia you must hold a National Forklift Licence. This manual has
been produced by START Training to assist you in gaining your Forklift Licence.
All applicants must be 18 years of age or over. Current Photo Identification (Driver's Licence, Key
Pass) is required at time of testing.
If there is anything in this manual that you do not understand please feel free to contact one of
our instructors on:
Ph: (03) 9756 0244 or
E-mail: info@starttraining.com.au
Refund Policy
Please note that 3 days notice is required for any cancellations or rebooking.
• If at least 3 days notice is given then a full refund will apply.
• If less than 3 days notice is given then the deposit paid is not refundable and the full cost
of the course may apply.
Forklift Training Manual Feb 2018 V9.docx 3
Forklift Training Manual Feb 2018 V9.docx 4
Contents
Introduction ………………………………. 3
Contents ………………………………. 5
Legislative requirements for High Risk Work ................................. 7
Element 1 Plan Work ………………………….……. 11
What is a Forklift ………………………….……. 13
Duty of Care ………………………….……. 16
Identifying hazards ………………………….……. 18
Hazard prevention and control ................................... 25
Data Plates ………………………….……. 30
Load Centre Distance ………………………….……. 31
Plan Work Summary ………………………….……. 37
Element 2 Conduct Routine Checks ………………………….……. 39
Daily Inspections ………………………….……. 43
Controls ………………………….……. 46
Starting your Forklift ………………………….……. 52
Conduct Routine Checks summary ………………………………… 54
Element 3 Shift Load ………………………….……. 55
Determining Load Weight ………………………….……. 57
Hazard Control ………………………….……. 62
Forklift Dynamics ………………………….……. 64
Operating an Forklift ………………………….……. 68
Emergency Situations and Procedures ………………………………… 80
Shift Load summary ………………………….……. 83
Element 4 Shut down and Secure Forklift Truck ……………………………... 85
Parking the Forklift ………………………….……. 87
Securing the Forklift ………………………….……. 88
Reporting and recording faults ……………………….......... 89
Shut down and secure Forklift summary ……………………………….. 90
Appendix A Load calculations .................................. 91
Appendix B Fitting a LPG gas cylinder ……………………………….. 94
Forklift Training Manual Feb 2018 V9.docx 5
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Legislative requirements for
High Risk Work (HRW)
Forklift Training Manual Feb 2018 V9.docx 7
Legislative requirements for High Risk Work (HRW) licence applicants.
When can I drive a forklift?
To drive a forklift in Australia you need to have a forklift (LF) endorsed HRW (High Risk Work)
Licence issued by WorkSafe. This is a nationally recognised and will allow you to drive a
forklift in all states and territories in Australia.
If you are asked to drive a forklift (perform high risk work) then you must show your
employer evidence in the form of:
• a HRW Forklift licence or
• Written evidence that you are undertaking
a registered training organizations (RTO)
forklift licence course
If you do not have a HRW (High Risk Work Licence) licence when can you under take High risk
Work?
Under the WHS Regulations you are considered under training when:
• You are enrolled in a course for HRW training and
• You are being supervised at a workplace by a person with a current HRW
license for the work.
How do I get a HRW forklift licence (LF?)
You must enroll in a training course with a registered training organisation (RTO) that has been
approved by WorkSafe. Upon completion of the training you will need to undertake and pass the
National Forklift assessment. This National assessment has three parts to it:
• A theory assessment
• A calculations assessment
• A practical drive assessment
Forklift Training Manual Feb 2018 V9.docx 8
Successful completion of assessment
Once you have successfully completed your assessment you will
be issued ‘A Notice of Assessment (NOA)’ and a licence application
form by the registered training organisation (RTO). You must take
these to the Post Office to be processed within 60 days.
The ‘Notice of Satisfactory Assessment’ is your temporary licence
for this 60 day period and allows you to operate the forklift until
your licence arrives in the mail.
The HRW licence needs to be renewed every five years. This can
be done at any Australia Post outlet you need to provide the
following:
• Current ID (100 points)
• Your existing HRW licence
• $45 licence renewal fee
What happens if I let my licence expire?
If you allow your licence to expire and you do not renew it within 12 months of the expiry date
the licence cannot be renewed and you will have to:
• Complete a training course with an approved RTO and apply for a new licence
or
• While continuing to work, be enrolled in a training course and work under
supervision of a HRW licence holder
Forklift Training Manual Feb 2018 V9.docx 9
Responsibilities of a HRW licence holder.
As a HRW licence holder you need to take reasonable care of your own health and safety and
not adversely affect the health and safety of others.
Failure to do so could result in you being penalized under the WHS regulations. This may result
in:
• Your licence being suspended or
• cancelled or
• The regulator (WorkSafe) may refuse to renew the licence.
• You may be directed to obtain a reassessment to determine
competency.
Forklift Training Manual Feb 2018 V9.docx 10Element 1
Plan
Work
This Element covers the following Performance Criteria:
1.1 Potential workplace hazards are identified.
1.2 Risk control measures are identified consistent with regulatory requirements
and the hierarchy of control.
1.3 Appropriate forklift truck is selected in accordance with load and workplace
conditions.
1.4 Working area is inspected to determine appropriate paths for moving loads
and forklift truck in accordance with workplace conditions.
1.5 Methods for communicating are identified and confirmed in accordance with
workplace procedures.
Forklift Training Manual Feb 2018 V9.docx 11Forklift Training Manual Feb 2018 V9.docx 12
What is a forklift truck?
A forklift is a powered industrial truck used to assist the operator to pick/ lift and transport
materials/goods in a warehouse. There are many different types of forklift trucks used in the
workplace.
The most commonly used forklift truck is the gas / petrol powered counterbalance style.
This same style of forklift truck can also be electric powered.
Forklift Training Manual Feb 2018 V9.docx 13Other styles / types of forklift truck that you may
be asked to operate are:
Electric Reach Truck – can operate in aisles
much narrower than required by a
counterbalance style Forklift and therefore allow
much better use of the warehouse space.
All Terrain Forklift – These can be
four wheel drive or two wheel
drive and are designed to operate
on rough and uneven ground.
Container Forklift -
Or Heavy duty Forklift. These
can handle loads in excess of 45
tons.
Forklift Training Manual Feb 2018 V9.docx 14Double Reach Forklifts – Are similar to a
normal reach truck but are designed to
place stock into a different style of racking
that is much deeper than normal.
Side Loader Forklifts – Are
designed to handle wide loads and
not only drive forwards and
backwards but can drive sideways
as well. In this way they do not
need as much space to turn and
can still operate in narrow aisles.
Forklift Training Manual Feb 2018 V9.docx 15Identifying workplace hazards
A hazard is anything or any situation with the potential to cause injury or harm. In other
words it is ‘anything’ or any action that can hurt or injure you or anyone around you.
Under our ‘Duty of Care” we have a responsibility to act in a safe manner for ourselves and
anyone around or near us.
Duty of Care
Definition.
The duties under the Act are expressed in broad terms, for example:
• An employer must, as far as practicable, provide a work environment, in which
employees are not exposed to hazards,
• Employees must take reasonable care for their own safety and health, and that of
others, at work; and
• Self-employed persons must, as far as practicable, ensure the work does not adversely
affect the safety and health of others.
Such wide-ranging duties are called ‘general duties’ or ‘general duty of care’ – the latter
reflecting that a ‘duty of care’ is owed in law by one person to another.
Forklift Training Manual Feb 2018 V9.docx 16What this means in simple terms is that:
The Employer –
• Must provide a safe workplace that is
without risk to health.
• It means that the Employer must provide
information, instruction, training and
supervision as is necessary to enable
employees to perform their work safely.
• It also means that equipment should be
maintained in safe working order.
The Employee –
All workers need to ensure that they work in a manner that is not harmful to their own
health and safety and the health and safety of others.
• Employees must not place themselves or others at risk.
• Employees must comply with safe work practices, including making sure they hold
license’s, tickets or certificates of competency where necessary.
• Employees must carry out their tasks or use equipment according to any safety
instruction.
• Employees must co-operate with their employer and follow all systems or
procedures in the workplace to the extent necessary to allow compliance with the
Act.
Forklift Training Manual Feb 2018 V9.docx 17The most common types of hazards we will encounter in most workplaces are:
UP HIGH
- Roller door clearances - Lighting/illumination
- Electric lines - Overhead service lines
- Bridges - Wind and bad weather conditions
EYE LEVEL
- Pedestrians - Plant and Equipment
- Dangerous Materials - Obstructions
- Facilities - Surrounding structures
- Buildings - Access and Exit Points
- Vehicle traffic; - Other equipment
- Blind corners - Confined spaces
- Poorly lit areas - Stock protruding from racking
DOWN LOW
- Wet surface condition, - Uneven surfaces,
- Spills, - Debris,
- Underground Services, - Weight bearing ability.
- Slopes - Loading dock edges
OTHER
- Tidal areas - Chainsaws
- Pressure washers - Safety tags
- Records of incidents and injuries
Forklift Training Manual Feb 2018 V9.docx 18Hazardous work practices
Not all hazards are environmental. We or other workers in the area sometimes cause them.
These kinds of hazards may need to be reported or controlled.
• Working in inadequate light
• Stock badly stacked
• Driving equipment to fast
• Smoking near refueling stations
• Not using pedestrian walkways
• Not wearing protective clothing
• Hazards not barricaded off or contained
• Using petrol, gas or diesel equipment in poorly
ventilated areas.
If you feel the area is unsafe to work in DO NOT START WORK. Report the situation to your
supervisor or manager.
Forklift Training Manual Feb 2018 V9.docx 19Planning for the job
Apart from hazards we also need to consider a number of other things before commencing
work (SPACE):
• Specifics of the task
• Permits required for the task
• Availability of Equipment
• Capacity of the forklift
• Equipment required for the task
• Characteristics of the load
• Location of task
• Attachments
• Communication (safe and adequate)
• Blind spots – due to corners, the mast or the load.
Forklift Training Manual Feb 2018 V9.docx 20Some common hazards / accidents that forklift trucks are involved in include: -
Damage To: - Caused by: -
• Stock • Not planning your route.
• Equipment • Not allowing for rear end swing
• People (see next page).
• Load falling from forklift.
• Not barricading the area that is
being worked in.
• Not taking hazardous ground
conditions into consideration.
• Pedestrians in the work area.
• Driving too fast.
Forklift Truck Tip Over Caused by: -
• Operating across a ramp or sloped
surface.
• Turning too quickly.
• Braking too hard (whilst turning
and in a straight line).
• Overloading the forklift.
• Having the load centre too far
forward.
• Driving down a ramp forwards.
• Speeding.
• Driving and/or turning with the
load in the air.
Being overcome by petrol, diesel or LPG If there forklift truck has an internal
fumes combustion engine (petrol, diesel or LPG)
and is being operated in an area with
restricted airflow then the operator may
be overcome by the forklift’s exhaust
fumes. You must use an electric fork in
areas with restricted airflow.
Forklift Training Manual Feb 2018 V9.docx 21‘What is Rear End Swing’
Many accidents in the warehouse can be attributed to Forklift ‘rear end swing’ or ‘tail swing’.
It is the action of the rear wheels of the forklift truck swing outside the line of the front
wheels whilst turning.
This rapid sideways movement presents a hazard to people close by, structures, plant and
equipment that may be struck by the rear of the machine. It also is a major factor in roll
over of forklift trucks.
Most rollovers occur on unloaded machines as they are at their most unstable when
operating without a load.
If full lock is used when turning a Forklift truck, you should remember that the rear of the
machine may swing up to 3 ½ times faster than the front of the machine. If you are travelling
at 3kph then the rear of the machine will swing at 10kmh. Note that on order pickers and
reach forklifts the rear wheels are nearly in the middle of the machine so that ‘front end
swing’ is nearly as fast and dangerous as ‘rear end wing”.
Poor Ventilation
As many Forklift Trucks are petrol, gas or diesel powered you need to understand that if you
are working in an area with restricted airflow then you may be overcome by the exhaust
fumes. This can be fatal.
The following areas would be considered as a having restricted airflow areas and an electric
forklift should be used:
• A freezer
• A cold storage room
• A container
• A shed
• A store room
• Any other small area
Forklift Training Manual Feb 2018 V9.docx 22Power line clearances
As Forklift Trucks often work outside near electric lines, WorkSafe requires you to know the
legal requirements for working around electric lines.
In Victoria the regulations state that you cannot work within:
• Power Poles
3 metres with a spotter
6.4 metres without a spotter
• Towers
8 Metres with a spotter
10 metres without a spotter
Power Poles Towers
In other States these clearances may change. If working interstate you need to check these
clearances with the relevant authority.
If you need to work closer than these clearances you need to:
• Seek an exemption from the relevant authority.
• Where possible have the electrical supply shut off. If this is not possible, the electric
lines must be insulated by an authorised/competent person.
• The use of a spotter within the exclusion zone may also be appropriate, dependent on
legislation within the state/territory.
To determine the voltage of electric lines in your work vicinity you need to contact the local
power authority for advice.
Forklift Training Manual Feb 2018 V9.docx 23In Victoria ‘Tiger Tails’ are used as a visual system to warn people about power lines
If you come into contact with electric lines you need to:
• Warn others to stay away
• Try to break contact with the power lines
• If safe to do so stay on the forklift.
If you must leave the machine, jump clear ensuring you don’t have contact
with the vehicle and the ground at the same time, landing with your feet
together and then continue to jump or shuffle with your feet together until
you are at least 8 metres clear of the vehicle.
• Repot to management, power company and safety regulator.
• Do not use the forklift until it has been checked.
Forklift Training Manual Feb 2018 V9.docx 24Hazard prevention and control
Once you have identified hazards in your workplace you need to decide how to deal with
them before you start work. In some cases it might be as simple as clean up the mess or
move the hazard.
In other cases though you may need to consult
with and report the hazard to:
• Safety officer
• Workplace Engineers (where applicable)
• Supervisor
• Other workers
• Managers who are authorised to take
responsibility for the workplace
operations.
The reason for this is so that you understand any workplace policies and/or site specific
procedures that need to be adhered to so that the correct hazard controls will be used.
Depending on your workplace you may have to fill out paperwork to show how you will
control hazards. This may include:
• Job Safety Analysis (JSA)
• Safe Work Method Statement (SWMS)
• Or other paperwork.
Regardless of what paperwork needs to be done hazard control methods must be put into
place before you start work to prevent injury/harm to personnel or damage to equipment
and/or property.
Forklift Training Manual Feb 2018 V9.docx 25Hierarchy of hazard control
To help us in the formal process of dealing with hazards in the workplace there is a system
that is referred to as the hierarchy of hazard control.
There are six levels to the Hierarchy of Hazard control.
Most Effective Elimination
Substitution
Isolation
Engineering
Administration
Least Effective PPE
Forklift Training Manual Feb 2018 V9.docx 26Hierarchy of Hazard control
The hierarchy of hazard control is a list of control measures that can be used to eliminate or
minimize the exposure to a hazard in the workplace. The diagram above shows the 6 levels
in the hierarchy from most effective to least effective control.
The six steps are:
1. Elimination
If possible remove the hazard completely. e.g. Use electric forklifts or order pickers
inside instead of petrol powered machines.
2. Substitution
If you cannot completely remove the hazard then you should consider a safer method
to be used. E.g. Use a spotter to warn the forklift operator that there are people
nearby or use an Electric Forklift in confined spaces rather than a petrol forklift.
3. Isolation
Lower the risk of exposure or injury by restricting or preventing access to the hazard.
For example separate pedestrians and forklifts by the use of exclusion zones and the
use of barriers and walkways.
4. Engineering
This is where equipment and work processes are improved through engineering
solutions to reduce risk. E.g. Use lights, reverse beeper, speed limiters, barriers or
horns to warn people nearby.
5. Administration
Administrative measures and safe work practices such as the use of signs, line
marking, induction programs and training can all help reduce hazards and exposure to
risks.
6. Personal Protective Equipment. (PPE)
The use of PPE to control a hazard is always the last choice and least effective
measure of control. It should always be used in conjunction with the other above
listed methods of control. PPE is such things as safety boots, Hi-visibility clothing, eye
protection etc. When using PPE make sure it is appropriate for the conditions, that fits
correctly and you have been given adequate instruction in its use.
Forklift Training Manual Feb 2018 V9.docx 27Personal Protective Equipment
PPE (Personal Protective Equipment) is common in nearly all workplaces these days.
PPE is an item of clothing or piece of equipment that is worn on the body to protect you from
certain hazards.
It cannot totally eliminate the hazard or potential injury but it will help in reducing the risk of
injury and assist in keeping you safer.
The most common form of PPE in most warehouses are safety boots and hi-visibility clothing
but as a Forklift truck operator you may also be required to wear other PPE as deemed
appropriate by your employer.
What PPE is required needs to be decided at the planning stage of the work and the PPE
should be inspected prior to commencing work.
Other forms of PPE that you may have to wear may include the following:
Forklift Training Manual Feb 2018 V9.docx 28Hazard control measures are in place
Some examples of hazard control measures that may need to be implemented in the
workplace for pedestrian, other workers, vehicles or mobile plant safety are:
• Flag person
• Flashing hazard lights
• Hoardings, gantries or scaffolding
• Pedestrian barricades and warning signs
• Pedestrian exclusion zone
If you find a hazard in your work area that you cannot control you need to report it
immediately to a supervisor.
All risk control measures need to be in place before commencing work or as soon as a
hazard is identified whilst working.
Selection of equipment
As mentioned earlier there are a number of types of forklift commonly used. So before
commencing work you need to decide which type is appropriate for the work to be done and
does it require any special attachments for the intended task. You also need to know if the
forklift is capable of handling the loads you are required to lift and to the height you need to
operate. To determine this there are a number of things we need to understand regards the
machines capabilities.
Forklift Training Manual Feb 2018 V9.docx 29Data Plate (Load Plate)
All forklift trucks in Australia are required by law to have a legible data plate attached to the
machine. This is so that the operator can easily and quickly determine the load capacity of
the machine they are about to operate. If the forklift does not have a data plate, or is
unreadable, do not use it.
The Data Plate gives us numerous important facts about the machine. It tells us the
machines rated capacity. This is dependent on:
• The maximum load that can be carried
• To what height can that load be carried and/or lifted and,
• At what load center as shown on the data plate (load chart).
It may also tell us other information such as:
• What attachments can be used
• Tyre Pressure
• Weight of the machine
• Weight of the battery
• The model and year of manufacture of the machine.
Note: It is illegal and very dangerous to exceed the rated capacity on the data plate.
Forklift Training Manual Feb 2018 V9.docx 30Load Centre Distance To properly understand what the data plate is saying in regards to the machines lifting capacity we must understand the concept of ‘Load Centre Distance’. Load Centre is defined as “The distance measured from the vertical face of the forks to the loads center of gravity All forklift trucks in Australia are re-rated at a 600mm Load Centre when they are imported into Australia because the standard size pallet used throughout Australia is based on a ‘chep’ pallet. They are approximately 1200mm x 1200mm in size thus having a load center distance of 600mm. Forklift Training Manual Feb 2018 V9.docx 31
Load Centre Distance (continued)
Most palletized loads are square and evenly stacked in which case the load center will be in
the center of the load.
Therefore if the load is picked up hard against the vertical face of the forks, the Load Centre
distance will be half the length of the load. (This is 600mm in the case of a ‘chep’ pallet).
But, if the load is unusually shaped, has been stacked heavier at the front than the back or
the pallet is not hard up against the vertical face of the forks then the loads center of
gravity will be moved forward thus increasing the load center distance which may
• reduce the forklifts capacity.
• or affect the stability of the forklift
Forklift Training Manual Feb 2018 V9.docx 32Travel Route / Path of Movement
It is important to inspect your work area for potential hazards and decide on the safest path
to take when moving your load and operating the forklift truck. This will help prevent
accidents, injury to other personnel or damage to machinery, equipment and stock.
Things to consider will include:
• What hazards are present? (People, stock on the
floor etc).
• Where will you have to stop/ relocate the load
to?
• Where should you slow down?
• Where should you sound the horn?
• Will you need to reverse?
• Is ventilation adequate?
• Is there adequate lighting?
• What is a safe speed
• Is the ground surface suitable
Do you have room to move / can you see?
In planning your path you need to consider if you need to move things out of the way and do
you have adequate clearance overhead and sufficient lighting in the areas you are about to
move through.
Effective traffic management
Whilst operating the forklift truck it is important to reduce the risks to people working around
you. So you will need to let people know you are working in the area. This can be done by:
• Posting signs
• Erecting barriers / barricades
• Using a flag person to control the flow of traffic.
Forklift Training Manual Feb 2018 V9.docx 33Communication
In every workplace communication is very important in reducing hazards and risk of injury.
There are a number of ways in which people may communicate with you or other site
personnel. They may include:
• Verbal (listening and asking questions)
• Written instructions (such as JSA’s or operating procedures)
• Signage
• Appropriate worksite protocol
Verbal communication
This the most used form of communication in the workplace. Your manger, supervisor or
workmates may give you verbal instructions; listen carefully on how to do your job safely and
properly.
It is very important that if you don’t understand the instructions that you ask questions and
clarify what you were asked to do. Don’t guess at what you have been asked to do. It is not
foolish to ask a question. It may prevent you from having an accident.
If you are asked to do something or use a machine that you have not been trained to use then
you are entitled to ask for help and your employer has a ‘duty of care’ to provide you with the
necessary training.
If you are unsure ask for help from an experienced operator
or competent person.
Forklift Training Manual Feb 2018 V9.docx 34Written Instructions
Written instructions come in many forms. They may be:
Company policies or work instructions – These will include site and
emergency procedures. These are rules and guidelines, which are put
into place to ensure work is carried out properly and safely. It is
important that you are familiar with how your company expects you to
work and what you need to do in an emergency. If you don’t know
contact your manger or OH&S representative.
An operating manual – Each forklift truck comes with an operating
manual. You need to take the time to read it and become familiar with
that particular type of forklift.
Material Safety Data Sheets – or MSDS’s contain information on how to
handle and transport chemicals and what to do if there is an accidental
spill.
Work Permits – set out the safety control measures that are required
prior to commencing work and are used to ensure workers understand
the site conditions and offer guidelines of what they shouldn’t do.
They are sometimes referred to as an induction onto the machine or
the area.
Signage
Every workplace will have safety signs posted around the work area. These signs are
important because they remind you of any restrictions, hazards or special requirements (such
as PPE) for the work site. You must follow the instructions on these signs as they are posted
to keep you and your co-workers safe.
Forklift Training Manual Feb 2018 V9.docx 35Appropriate worksite protocols
In some cases the company you work for may have their own specific forms of
communication. An example of this is the use of hand signals. You have to use hand signals to
communicate. It may be because the work area is very noisy or you may have someone
guiding you because your vision is limited because of a large load.
Always make sure you understand what the
hand signals you and your assistant are using
mean before you start work.
HAND & WHISTLE SIGNALS
Based on AS2550.1.2002
Motion Hand signal Whistle Motion Hand signal Whistle
1 long 1 long
1 short 2 short
Turning left Turning right
3 short 4 short
Luffing boom up
1 short N/A
Stop Travel and traverse
Creep speed: appropriate hand signal for motion is clenching and unclenching hand
Forklift Training Manual Feb 2018 V9.docx 36SUMMARY
Plan work
Make a thorough check of your workplace before you start work to identify any
hazards or risks.
Put in place any hazard control measures that you can. Report any hazards that
cannot be controlled to your supervisor, manager etc.
Use PPE when necessary
Make sure you use the correct type of Forklift Truck for the job/work conditions
Check the forklift trucks data plate before lifting anything.
Set a travel plan or path to prevent accidents
Understand the different ways in which your job instructions and requirements may
be communicated to you i.e. verbal, written, signs or hand signals.
Forklift Training Manual Feb 2018 V9.docx 37Forklift Training Manual Feb 2018 V9.docx 38
Element 2
CONDUCT
ROUTINE
CHECKS
This element covers the following Performance Criteria:
2.1 Prior to operation, forklift is visually checked for any damage or defects.
2.2 All signage and labels are checked to ensure they are visible and legible,
according to the appropriate standard.
2.3 All controls are located, identified and confirmed.
2.4 Pre-start operational checks are carried out accordance with manufacture
specification and workplace procedures.
2.5 Forklift truck is started accordance with manufacturer specification and
workplace procedures, and is checked for any abnormal noise.
2.6 Post- start operational checks are carried out in accordance with manufacture
specifications and workplace procedures.
2.7 All forklift truck functions and safety devices are tested to their maximum in
accordance with manufacture specifications and workplace procedures.
2.8 Issues, defects and damage identified during routine checks are reported and
recorded accordance with workplace procedures, and appropriate action is
taken.
Forklift Training Manual Feb 2018 V9.docx 39Forklift Training Manual Feb 2018 V9.docx 40
Forklift Training Manual Feb 2018 V9.docx 41
Forklift truck safety guards
There are three safety guards on the forklift truck to protect you.
Overhead guard
Protects the
operator from
falling objects
Load guard / Backrest
Stops the load from
hitting the mast and
protects the driver
Foot guard
Protects the
operators feet
Forklift Training Manual Feb 2018 V9.docx 42Daily inspection checklist
As an operator you will be required to check the forklift on a daily basis before use and
complete a daily check sheet to record any faults that you may find.
Daily check sheets allow you to:
• Record defects
• Record routine maintenance
• Record any other work that needs to be done.
Forklift Training Manual Feb 2018 V9.docx 43Daily inspections
For your safety it is important to make sure the forklift is in proper working condition and
safe to use before attempting to use it. There are two forms of checks that must be done.
They are:
1. Pre-Start checks (Visual walk around and fluids check)
2. Start-up checks (Once on the forklift)
Details of what operational checks can be found in the:
• Operators Manual
• Manufacturers Handbook
Pre-start check
Before starting your Forklift it is important to walk around the machine and do a visual check.
Things you should check are:
• No Danger/ out of order tag is attached
• Tyres/wheels are ok
• Any attachments
• All guards (load guard/backrest, foot guard and overhead guard)
• Battery
• There are no leaks
• Forks are not damaged or cracked
• Mast and Hydraulics are not damaged or leaking
• There is no structural damage
• The data plate is attached and readable
• The operators manual and logbook are available
• Fuels
• Fluids (oils and water)
Forklift Training Manual Feb 2018 V9.docx 44If during your visual check you notice any major faults such as hydraulic leaks, structural
damage or missing data plates you must (STIRR):
• Stop do not operate
• Tag out of service
• Isolate it so it cannot be used (Remove key)
• Record the fault in the log book.
• Report the fault to an authorized person.
As part of your visual check you had to make sure the data plate was attached and readable.
This is very important, as this is what tells you how much load the forklift can carry, at what
load centre and to what height you can operate the machine.
If there is no data plate attached or it is unreadable it is illegal to drive the machine. You
must (STIRR):
• Stop do not operate
• Tag out of service
• Isolate it so it cannot be used (Remove key)
• Record the fault in the log book.
• Report the fault to an authorized person.
Forklift Training Manual Feb 2018 V9.docx 45Controls
Although most forklifts have a similar layout for their controls there are a number of
machines on the market that have very different layouts and control functions. It is important
to consult the operator’s manual for your particular forklift before operating it.
Below is an example of the control layout for a typical Counter balance Forklift Truck.
Steering Wheel
Up / down lever
Handbrake
Tilt Lever
Gear lever
Side shift lever
Brake pedal Accelerator Pedal
Forklift Training Manual Feb 2018 V9.docx 46Fluids (Pre-Start checks)
On a forklift there are a number of fluids that need to be checked:
1. Brake Fluid
2. Hydraulic Fluid/ Power steering fluid
3. Battery Electrolyte level in each cell
4. Gas / petrol / diesel
5. Transmission fluid
6. Engine Oil
7. Coolant
Battery
A large number of forklifts are battery operated. It is important to maintain the battery in a
good condition, as they are expensive to replace. When doing your visual checks you need to
make sure that the battery is:
• Not damaged or leaking.
• Is fully charged.
• The terminals are clean and undamaged.
• The electrolyte is at the correct level.
• The battery is secured properly.
Note: Some employers will not want you to do anything with the battery unless you have
received the appropriate training. Always wear the appropriate PPE when checking batteries.
When connecting and disconnecting the battery from the charger always make sure that
everything is turned off – especially the charger as batteries give off explosive gases when
they are being charged and these can build up in an enclosed space over time.
DO NOT SMOKE NEAR A CHARGING BATTERY
Forklift Training Manual Feb 2018 V9.docx 47Gas bottle checks
A lot of forklifts operate on LPG gas which is contained within a gas bottle mounted to the
rear of the Forklift. It is important to check for:
• Any gas leaks.
• The general condition of the system.
• The security of the system.
• The tank is in date.
• The forklift has a gas compliance plate.
• The pressure relief valve is positioned at the top.
Refueling / Changing gas bottles
Only properly trained and authorised personnel are
permitted to change gas cylinders and/or batteries, and
to charge batteries.
Fuel system checks
If the forklift has a petrol or diesel engine you need to
ensure that there are no fuel leaks.
If a fuel leak is suspected or detected do not start the forklift. You must immediately:
• Stop do not operate
• Tag out of service
• Isolate effectively isolate it so it cannot be used (Remove key)
• Record the fault in the log book.
• Report the fault to an authorized person.
If the machine is diesel operated you may need to consult the manual for information on
further checking the fuel and exhaust systems e.g., air filter and fuel filter elements may need
to be checked.
NEVER REFUEL A RUNNING FORKLIFT it could ignite the fuel and result in a fire.
Forklift Training Manual Feb 2018 V9.docx 48Tyre and wheel checks
It is important to the stability of the forklift that all tyres are inflated to their correct
pressure, in good condition and free of punctures.
What do we check?
• No large pieces of rubber missing.
• Tyre not worn down.
• Wear is even.
• Ensure security of wheels
• To make sure tyres are securely fitted
Wheel nuts must all be secured and rims must be in good condition free of dents and
damage.
Attachment checks
Forklifts can be fitted with a variety of attachments to assist in moving various types of loads.
Attachments must be:
• The right type for the forklift and loads and should be stated on the Data Plate.
• That it is correctly fitted and secured to the forklift by a suitable locking device or pins.
Forklift Training Manual Feb 2018 V9.docx 49Some common attachments used on forklifts are: Fork tines Carpet spike/ Roll prong Safety cage / Work platform Drum clamp / Rotator Jib Fork extensions Bin tipper Load spreader Forklift Training Manual Feb 2018 V9.docx 50
Safety cage / Work platform
If you are going to lift someone in a safety cage / work
platform you must:
• Ensure that the safety cage is approved and has
a data plate attached to it.
• That you remain at the controls of the forklift
whilst someone is in the safety cage.
• That the forklift be in neutral with the
handbrake applied whilst the safety cage is
raised.
• That you do not drive with the safety cage in the
air. It must be lowered each time you need to
move to another position.
• You are not allowed to use a stepladder or other
device inside the safety cage to gain extra
Height checks
height.
It is important to know the “Overall extended height and collapsed height” of your forklift
before commencing work.
• Overall extended height – is the height of
the mast from the ground to the top of the
backrest when the mast is fully extended. It
is important for the operator to know this so
that they are aware if the mast can hit the
roof or other overhead hazards. It also tells
the operator at what height they can place
their loads.
• Collapsed height - is the height of the mast
when fully lowered to the ground. This
measurement allows the operator to know
if the machine will be able to ‘fit’ through
the doorways, under any mezzanine floors
or can be driven into a shipping container
to unload it.
Forklift Training Manual Feb 2018 V9.docx 51Starting your forklift
Getting on and off the forklift
Most forklifts are mounted from the
left side so as to avoid bumping the
mast controls by accident.
We also should use three bodily points
of contact (foot, hand, hand) to avoid
slipping or falling off.
Starting the forklift
Before starting your forklift:
• Make sure you have read the operators manual.
• Check it doesn’t have an out of order tag on it.
• Check the battery has sufficient charge or there is
enough fuel.
• Check the brake is applied.
• Visually check the forklift for damage, leaks and
wear.
• Check the area is clear.
Once you have started the forklift conduct you’re start-up checks.
Forklift Training Manual Feb 2018 V9.docx 52Start-up checks
When you have started your forklift there are a number of further checks that must be done.
The following tests/ checks need to be performed:
• Warning devices (Flashing light, Horn and beepers)
• Lights if fitted
• Brakes are working.
• Hydraulics
• Steering is in working order.
• Gauges are working.
• Forward and reverse functions operate.
• If electric, the emergency cut out switch is working.
Once you have started the forklift listen to see that there are no unusual noises or vibrations
as this may indicate that there is a problem or fault.
If you detect any fault or hear any
abnormal noise you should:
• Stop do not operate
• Tag out of service
• Isolate effectively isolate it so it
cannot be used (Remove key)
• Record the fault in the log book.
• Report the fault to an authorized
person.
If you are competent and authorised by your employer you may carry out minor repairs.
Forklift Training Manual Feb 2018 V9.docx 53Element 2
Summary
Conduct Routine Checks
Use daily inspection checklist to record maintenance and defects.
Complete a visual check of the forklift for damage or defects.
Check that all signage and labels are attached and readable.
Make sure you know where all the forklift controls are and what they do.
Pre-start operational checks are made including:
• Attachments
• Fluids
• Tyres
• Battery
• Warning devices
• Brakes
• Steering
Faults and defects are recorded using the proper paperwork and reported to the
appropriate person.
Forklifts with faults have their keys removed and are tagged with an out of order tag
so that others will not use the machine.
Forklift Training Manual Feb 2018 V9.docx 54Element 3
Shift
Load
This element covers the following Performance Criteria:
3.1 Weight of load is assessed to ensure compliance with forklift truck data plate
specifications.
3.2 Appropriate hazard prevention/control measures are implemented and
communicated to personnel in the work area.
3.3 Forklift is operated at a safe speed in accordance with manufacturer specifications
and workplace procedures.
3.4 Loads are moved and placed to ensure stability of material and avoidance of hazards.
3.5 Load movement is monitored constantly ensuring safety of personnel and load, and
structural stability.
3.6 Unplanned and/ or unsafe situations are responded to in accordance with workplace
procedures and emergency plans.
Forklift Training Manual Feb 2018 V9.docx 55Forklift Training Manual Feb 2018 V9.docx 56
Determining load weight
In our pre-operational checks we read the data plate on the forklift to determine how
much weight the machine could carry. Before picking up or moving a load we need to
also determine how much the load may weigh.
This can be done in a number of ways:
1. By reading the consignment note or weighbridge docket that came
with the load.
2. Weighing the load.
3. By calculating the weight of the load.
4. The load weight may appear on the load itself or on the packaging
in which it is delivered and transported.
Consignment Notes
A consignment is usually sent with most deliveries and is issued by the carrier
as a record of what ahs actually been sent. It will usually contain information
on:
• Pallet control.
• Number of items.
• Description of items.
• Who is to receive the items?
• A place for the receiver to sign to say
they have received the goods.
• The weight of the pallet load or the
individual items.
Weighbridge dockets
A weighbridge docket can be used if the delivery truck has been over a weighbridge
and had the load weighed. Weighbridge dockets are only useful if there is only one
item (i.e. one large crate) on the truck as the docket only gives the total weight of the
load, not individual pallet weights.
Forklift Training Manual Feb 2018 V9.docx 57Calculation
Calculation is probably the most common method used by operators. It can be as
simple as identifying the weight of one item on the pallet and multiplying that weight
by the number of items on the pallet (if all are the same).
Example 1.
If one box on the pallet weighs 10kg and there are 20 boxes on the pallet then it is:
10kg x 20 = 200kg (plus the weight of the pallet)
Example 2.
If there are 4 drums of water on the pallet at 200litres in each drum and the drums
weigh 10kg each then it is:
Water weighs 1 litre = 1kg
4 x 200 = 800 for the weight of the water
plus 4 x 10 for the weight of the drums = 40kg
800 + 40 = 840kg (plus the weight of the pallet)
Example 3.
There are six cartons on each layer of the pallet and there are three layers and each
carton is 15kg then the total weight is:
Cartons 6 X 3 = 18 cartons
Weight of the cartons is 18 X 15kg = 270kg
Total pallet weight = 270kg plus the weight of the pallet
Forklift Training Manual Feb 2018 V9.docx 58Load Centre Distance
Once we have determined how much the load weighs we then have to check our ‘load centre
distance’ to confirm that the load is within our rated capacity.
As mentioned earlier Load Centre distance is defined as “The distance measured from the
vertical face of the forks to the loads center of gravity
Remember: If you increase the Load Centre distance you will reduce the lifting
capacity of the Forklift.
Forklift Training Manual Feb 2018 V9.docx 59Load Centre distance calculations
The machines below are rated at 2000kg at a 600mm Load Centre
a) If the load to be moved weighs 2400kg which forklift could move the load?
None of the machines are capable of lifting the load as they are all rated at a
2000kg maximum.
b) If the load to be moved was 2000kg which forklift can lift the load?
‘B’ can lift the load as it has a load centre of 600mm and
‘C’ can lift the load as it has a load centre of 500mm and they are rated to
2000kg at a 600mm Load Centre as.
‘A’ cannot lift the load as the load centre is 700mm which is greater than the
600mm rating.
c) If the load was 2000 kg can Forklift ‘C’ lift the load?
Yes, the load is within the 2000kg that the machine is rated for; the load has a
load centre of only 500mm which is less than the rated load centre of 600mm
so the machine can safely lift it.
d) If the forklift is rated at 2200kg at a 600mm load centre and we try to lift up a
2200kg load with a load centre greater than 600mm what will happen to the forklift.
The Forklift will be overloaded and possibly tip forward.
It is important for your safety to understand load centre distance and
how it affects the capacity of your machine.
Forklift Training Manual Feb 2018 V9.docx 60The longer the load the more the forklifts capacity is reduced Forklift Training Manual Feb 2018 V9.docx 61
Hazard control
Before commencing work it is necessary to ensure that all hazard control measures
are in place. If you are unsure what these are for your particular employer then you
need to check with your supervisor or manager.
Hazard controls will include:
• Putting barricades in place.
• Putting signage in place (if not already there).
• Letting other people know you are working in the area.
• Moving obstructions.
• Turning on additional lighting.
• Putting on your PPE.
• Getting someone to assist as a flagman (if required).
• Anything else necessary to do the job safely.
What sorts of goods are you moving?
Sometimes the load or goods you
are moving may be comprised of
dangerous goods such as
chemicals, explosives (aerosols/
air bags for cars) and other
dangerous goods.
If you are handling times like
these then you need to check the
companies Material Data Safety
Sheets (MSDS) to see what action
you need to take when handling
and packing them and what to do
if there is a chemical spill.
Forklift Training Manual Feb 2018 V9.docx 62Safety devices
When using the forklift you must always check that the warning devices are working
correctly. E.g.:
• Horn
• Reverse beeper
• Flashing light
This is particularly important when working around other people or equipment.
Insufficient lighting
If you are working at night in a
darkened area such as:
• A store room
• A container
• Or other dimly lit areas
You are required to obtain
adequate lighting across the
entire area, sufficient for the
forklift to safely conduct its
operations.
Forklift Training Manual Feb 2018 V9.docx 63Forklift dynamics
Before we start moving our load and driving the forklift around there are some basic
concepts that we need to understand.
The Stability Triangle
Forklifts have a 3-point suspension. The rear axle is supported by a pivot pin in the
centre of the axle enabling some up and down movement of the rear wheels when
working.
The area between points A, B, and C in the diagram below is known as the stability
triangle. If the centre of gravity moves outside the stability triangle, the forklift will
start to tip over.
Many accidents occur as a result of the forklift tipping over, either forward
(longitudinally) or sideways (laterally). The centre of gravity moves about like a ball in
a bowl of water and is affected by how the operator drives, brakes, accelerates turns
and even moves across uneven ground. Understanding this will help you avoid tipping
the forklift over.
Forklift Training Manual Feb 2018 V9.docx 64The Point of Balance (Fulcrum)
The point of balance (fulcrum) is where the front tyre meets the ground.
All the weight behind the point of balance acts as a counterweight.
It is very important to understand these principals of balance, because if the load is
not properly balanced, then the forklift can tip over.
The forklift is like a seesaw. The weight behind the point of balance acts as a
counter-weight and provided that the balance between the counter-weight and the
load remain in favour of the forklift then everything will remain balanced and be OK.
However, if the weight of the load exceeds that of the counter weight then the forklift
will tip over.
You are not allowed to add additional counter weights to the forklift without
referring to the forklift manufacturer.
Forklift Training Manual Feb 2018 V9.docx 65Forward / backward (longitudinal) stability
The forklift is an unbalanced machine with one end heavier than the other and should
never be allowed to have more weight forward of the fulcrum than behind it. If the
centre of gravity of the load and the machine combined, moves forward of the
fulcrum, the machine is in danger of tipping forward.
Some causes of tipping forward or backward while travelling are:
• Overloading.
• Load not positioned against the heel of the fork
arms.
• Sever braking.
• Incorrect use of forward tilt (if fitted).
• Driving over uneven surfaces.
• Unevenly distributed load.
• Operating on a sloping surface.
• Driving too fast (loaded or unloaded), including
reversing.
• Shifting of the load centre forward
Sideways (lateral) stability
As with forward stability, we have to consider the centre of gravity of the machine. If
the centre of gravity of the machine shifts to far to one side, the forklift is in danger of
tipping to that side.
Some causes of tipping over sideways while travelling are:
• Unevenly distributed load.
• Operating across a slope.
• Turning at an unsafe speed.
• Driving over uneven surfaces.
• Driving too fast (loaded or unloaded).
• Side shift not centered.
• Driving with flat or under-inflated tyre.
• Turning with the load raised.
Forklift Training Manual Feb 2018 V9.docx 66If your forklift tips over
If the forklift was to roll over sideways you
need to:
• Remain in/on the forklift.
• Brace yourself until the forklift is
stationary and safe to exit.
All counterbalance forklifts are fitted with seatbelts with the important function of:-
• Stops the operator from falling out in the event of a rollover.
• Stops the operator being propelled into the forklift structure or out of the
forklift in a collision
Forklift Training Manual Feb 2018 V9.docx 67Operating a forklift
• You must always wear a seat belt when
operating a counter balance forklift.
• When operating the controls on the
machine it is important that you:
o Use the correct controls.
o Use them in a safe and smooth
way.
• You must raise the fork arms from the ground (high
enough to avoid bumps in the ground but still below
axle height) before driving off to avoid the load or
fork tynes from scraping on the ground.
• You may need to tilt the mast back slightly whilst travelling to maintain load stability.
• Keep the ‘side-shift’ centralised to maintain forklift
and load stability.
Forklift Training Manual Feb 2018 V9.docx 68• If you need to carry a passenger on the machine it
needs to be specifically designed and equipped to
carry more than one person.
• Keep all parts of your body within the forklift whilst
travelling.
• Do not operate the machine if you:
o Have been drinking alcohol.
o Are taking illegal drugs.
o Are over tired or stressed.
o Are on medication that may make you drowsy.
• Obey all traffic signals, traffic management plans and
workplace procedures.
• Give way to all emergency vehicles.
Forklift Training Manual Feb 2018 V9.docx 69People and forklifts
Accidents between pedestrians and mobile plant within workplaces are very common
so as a forklift operator it is very important to watch out for and be aware of people
around you.
• Never raise your loads near or over people, if the load
falls you could injure or kill someone. It is also against
OH&S safe working procedures.
• Never lift someone or the bare fork arms or load as
they may slip and fall, injuring them. This is also
against OH&S safe working procedures.
• Use your horn and lights so that people are aware you
are coming.
• Use your horn when turning corners to warn others of
your approach.
• Use your horn when approaching doorways to warn
others that you are coming through.
Forklift Training Manual Feb 2018 V9.docx 70Operate at a safe speed
WorkSafe does not specify a safe speed for the operation of forklifts. It is up to you
the operator to decide what a safe speed is for the forklift at the time. This will
depend upon what is happening around you and what the environment is like. If the
company has a set speed limit for that particular area it does not mean you can
exceed the speed limit but it means that it may be sensible to drive much slower than
the posted speed limit.
Some things that will affect how fast you can drive are:
• Speed Limit signs
• People in the area
• Size load
• Surface condition
• Obstructions
• The physical space you have to
operate in
• Other equipment in the area.
Obstructed vision
If your view is obstructed, before moving you need to:
1. Check the pathway is clear
2. Check the mirrors
3. Looking over each shoulder if reversing
4. Use warning devices such as horn and
flashing lights.
5. Use a guide if required.
Forklift Training Manual Feb 2018 V9.docx 71You can also read
