TLID1007C
Operate
a
forklift
Contents
What this Learner’s Guide is about ........................................ 2
Planning your learning ........................................................... 3
How you will be assessed ...................................................... 6
Section 1............................................................................................. 8
Before you drive the forklift .................................................... 8
Section 2........................................................................................... 16
Types of forklifts and attachments ....................................... 16
Section 3........................................................................................... 52
Forklift safety........................................................................ 52
Section 4........................................................................................... 66
Driving the forklift ................................................................. 66
This
Learner’s
Guide
is
about
the
skills
and
knowledge
required
to
operate
a
forklift,
including
checking
forklift
condition,
driving
the
forklift
to
fulfil
operational
requirements,
monitoring
site
conditions
and
monitoring
and
maintaining
forklift
performance.
Assessment
of
this
unit
will
usually
be
undertaken
within
a
licensing
examination
conducted
by,
or
under
the
authority
of,
the
relevant
state/territory
OHS
Authority.
Persons
achieving
competence
in
this
unit
will
need
to
fulfil
all
of
the
relevant
state/territory
OHS
regulatory
requirements
concerning
the
safe
operation
of
forklifts.
This
unit
of
competency
is
from
the
Transport
and
Logistics
Training
Package
(TLI07).
It
is
important
to
plan
your
learning
before
you
start
because
you
may
already
have
some
of
the
knowledge
and
skills
that
are
covered
in
this
Learner’s
Guide.
This
might
be
because:
• you
have
been
working
in
the
industry
for
some
time,
and/or
• you
have
already
completed
training
in
this
area.
Together
with
your
supervisor
or
trainer
use
the
checklists
on
the
following
pages
to
help
you
plan
your
study
program.
Your
answers
to
the
questions
in
the
checklist
will
help
you
work
out
which
sections
of
this
Learner’s
Guide
you
need
to
complete.
This
Learner’s
Guide
is
written
with
the
idea
that
learning
is
made
more
relevant
when
you,
the
learner,
are
actually
working
in
the
industry.
This
means
that
you
will
have
people
within
the
enterprise
who
can
show
you
things,
discuss
how
things
are
done
and
answer
any
questions
you
have.
Also
you
can
practise
what
you
learn
and
see
how
what
you
learn
is
applied
in
the
enterprise.
If
you
are
working
through
this
Learner’s
Guide
and
have
not
yet
found
a
job
in
the
industry,
you
will
need
to
talk
to
your
trainer
about
doing
work
experience
or
working
and
learning
in
some
sort
of
simulated
workplace.
Assessment
of
this
Unit
of
Competency
will
include
observation
of
real
or
simulated
work
processes
using
workplace
procedures
and
questioning
on
underpinning
knowledge
and
skills.
It
must
be
demonstrated
in
an
actual
or
simulated
work
situation
under
supervision.
Section 1
Section outline
Legal requirements
Your responsibilities
Legislation refers to certain rules and conditions that you need to follow.
This
may
be:
• before
you
are
legally
qualified
to
drive
a
forklift
• while
you
are
driving
a
forklift.
Although
it
is
not
quite
the
same,
think
of
it
as
similar
to
the
driver’s
licence
system.
Before
you
can
legally
drive
a
car
on
the
road
you
have
to
learn
what
to
do
and
then
be
examined
on
driving
the
car.
You
need
to
complete
a
theory
test
and
then
be
assessed
on
your
driving
skills.
Forklift
legislation
requires
you
to
do
the
same.
Therefore, it is essential to know exactly what your requirements are.
When you have completed this task take your answers to your
trainer for checking.
Forklift legislation
In your own words, write down what you need to do before you can
drive a forklift in your workplace.
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The
Occupational
Health,
Safety
and
Welfare
Act
applicable
in
your
State/Territory
not
only
requires
you
to
fulfil
certain
obligations
before
you
drive
a
forklift,
but
also
while
you
are
driving
a
forklift.
These
obligations
are
legal
obligations
and
you
are
required
to
comply
with
them
by
law.
Failure
to
do
so
would
deem
you
responsible
and
liable
in
the
event
of
an
accident.
Workers are required to show a duty of care at all times.
Personal safety
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Safety of workmates
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Your
employer
also
has
legal
responsibilities
to
comply
with.
As
these
responsibilities
directly
affect
you,
it
will
be
helpful
if
you
are
aware
of
these
responsibilities.
Facilities
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Equipment
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Information
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Systems of work
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Refer to your OHSW Act to check your answers then discuss with
your trainer.
Section 2
Section outline
The
forklift
is
a
materials
handling
vehicle
that
is
widely
used
in
the
transport
industry.
It
is
invaluable
for
its
ability
to
move
a
large
amount
of
material
in
a
very
short
time
using
a
minimum
of
labour.
There
are
four
main
types
of
forklift
that
you
are
likely
to
see
in
the
industry.
They
are:
• counterbalanced
forklift
• straddle
forklift
or
reach
truck
-‐
also
known
as
non-‐
counterbalanced
• order
pickers
• side
loading
forklift.
Each
of
these
forklifts
are
used
for
different
purposes
in
the
workplace.
They
can
however
be
used
for
a
variety
of
tasks.
What does a
counterbalanced
forklift look like?
(draw or find a
picture and place in
the space opposite)
Why is it called a
‘counter
balanced’
forklift?
Where is the
balance point or
fulcrum of a
counterbalanced
forklift found?
What does a
straddle forklift
look like? (draw
or find a picture
and place in the
space opposite)
How is the
weight of the
load distributed
on a straddle
forklift?
What is a
straddle forklift
primarily
designed for?
What is the
primary power
source for
straddle
forklifts?
Order pickers
What does an
order picking
forklift look like?
(draw or find a
picture and place
in the space
opposite)
Why is it called
an ‘order
picker’?
What is the
difference
between an
order picker
and a straddle
forklift?
What does a
side loading
forklift look like?
(draw or find a
picture and place
in the space
opposite)
Why is it called
a ‘side loading’
forklift?
What types of
loads are
handled by the
side loading
forklift?
Give two
examples of
workplaces that
might use the
side loading
forklift.
Power
sources
or
modes
of
propulsion
for
forklifts
can
be
divided
into
two
main
types.
They
are:
• internal
combustion
(fuels)
• electric
(battery).
The
internal
combustion
motor
in
forklifts
is
similar
to
that
used
in
motor
vehicles
and
is
designed
to
operate
on
a
variety
of
fuels
such
as:
• petrol
• diesel
• LPG
(Liquid
Petroleum
Gas)
• natural
gas.
Electric
forklifts
are
battery
powered
forklifts.
A
bank
of
batteries
or
one
very
large
battery
is
used
to
power
the
forklift
instead
of
fuel
substances.
Electric
powered
forklifts
are
becoming
more
and
more
popular
within
industry
but
electric
powered
forklifts
also
have
some
disadvantages.
Just as a car has many features and components that you need to
know before you drive it, so does a forklift.
Component Number
Overhead guard
Steering wheels
Load Backrest
Forks
Mast
Drive wheels
Counterbalance
Hoist chains
Parking brake
It
is
important
to
understand
how
some
of
these
components
can
effect
the
safe
operation
of
the
forklift.
For
this
reason
you
will
need
to
know
about:
• types
and
use
of
different
tyres
• types
of
forks
(tines)
available
• mast
and
lifting
mechanism
• forklift
controls.
Research into the types available and their use in your industry.
You can research into this by:
• discussing with your trainer
• discussing with a forklift trainer
• reading manuals and books.
Forks
Masts
Forklift controls
By
law,
every
forklift
is
required
to
have
a
manufacturer’s
data
plate.
This
data
plate
should
include
the
following
information:
• maximum
safe
working
load
• load
centre
distance
• maximum
lift
height
• make,
model
and
serial
number
• mast
tilt
(in
degrees)
• tyre
type
and
recommended
pressure
• gross
vehicle
weight
• attachment
details
(if
one
is
fitted).
It
is
critical
that
you
know
the
information
on
the
manufacturer’s
data
plate
so
that
the
forklift
is
driven
and
used
within
the
safe
operating
capacity.
Using the activity work sheet, complete the definition and then
select one of your workplace forklifts and give actual data plate
readings.
distance
Maximum safe
working load
Maximum lift
height
Mast tilt -
degrees
The
load
centre
distance
is
the
most
important
and
most
difficult
concept
to
understand
in
forklift
driving.
The
load
centre
distance
directly
affects
the
forklift’s
stability
and
therefore
affects
safety
as
well.
To
understand
the
load
centre
distance
you
need
to
know
what
‘centre
of
gravity’
is
and
how
to
calculate
the
centre
of
gravity
of
an
object.
Your
trainer
will
help
you
with
this
concept,
but
in
general,
the
centre
of
gravity
of
an
object
is
where
it
would
balance
in
all
directions
(if
you
could
suspend
the
object
from
this
point).
For
example,
for
a
basketball
as
it
is
perfectly
symmetrical,
it
would
be
at
the
very
centre
of
the
ball.
For
a
plate,
it
would
be
the
centre
of
its
base
and
half
way
through
the
base.
For
a
brick,
it
would
be
at
the
point
where
two
diagonal
lines
drawn
across
the
face
of
the
brick
meet
and
then
half
way
through
the
brick.
1200mm
2.2m
1800mm
1.8m
800mm diameter
1.5m
2.5m
Ask your trainer to explain this concept to you and to help you
understand the concept, indicate on the diagram below the load
centre distance.
A
standard
pallet
is
square
and
has
the
dimensions
1200mm
x
1200mm
as
per
the
diagram
below.
1200mm 1200mm
As
the
majority
of
forklift
loads
are
contained
on
pallets,
forklift
manufacturers
designed
the
forklift
with
a
600mm
load
centre.
This
matches
with
the
standard
stacked
pallet
centre
of
gravity.
For
example,
see
diagram:
1200mm
600mm
Load centre
Question 1
What happens to the capacity of the forklift if the load has a load
centre greater than 600mm?
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Question 2
There are four different loads shown on the next page (drawings
show side elevation). You are to determine and circle the loads
which your forklift can safely lift.
900kg
Question 3
If the load centre of the load is less than 600mm, will you be able to
carry more than the maximum safe working load?
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Forklift attachments
A
forklift
attachment
is
an
extra
piece
of
equipment
that
is
used
on
the
forklift
in
place
of
the
original
forks.
Sometimes
the
forks
are
removed
and
the
attachment
is
bolted
to
the
fork
carriage,
and
sometimes
the
attachment
is
fitted
to
the
forks.
There
are
many
types
of
forklift
attachments.
Some
are
standard
type
attachments
and
can
be
purchased
from
a
dealer,
e.g.
drum
clamps.
Others
are
specially
designed
and
made
to
do
a
specific
task.
Most
attachments
have
special
safety
considerations
that
you
need
to
take
into
account
when
you
drive
the
forklift.
Personnel lifts or work platforms What are personnel lifts used for?
There are also certain safety requirements and procedures that you
need to know before using jibs and slings on a forklift. For
instance, one of the main safety considerations for operators using
jibs is the moving centre of gravity, therefore, extreme care needs
to be taken when determining a safe working load for the forklift.
Section 3
Forklift safety
Section outline
The
most
important
aspect
of
forklift
driving
is
safety.
As
a
forklift
driver
you
must
be
aware
that
there
are
always
people
working
around
you
and
if
there
was
an
accident
they
may
be
injured.
It
would
be
a
terrible
burden
to
have
on
your
conscience
that
your
workmate
was
injured
by
an
accident
that
you
could
have
prevented.
Forklift
safety
has
a
very
high
profile
in
Australia
as
statistics
show
‘one
in
ten
workplace
accidents
in
Australia
involves
a
forklift’
(1993).
These
accidents
can
be
prevented
only
if
companies
and
individuals
realise
the
implications
of
these
accidents
and
take
steps
to
prevent
them
from
happening.
Before you even consider driving the forklift, you need to complete
three tasks. They are:
• plan your work - inspect the work area
• select the correct forklift
• make your presence known.
Steps Questions
Select the correct forklift What do you need to consider when selecting a
forklift to do a job?
Make your presence known When do you need to let people know that you are
about to drive a forklift in the area?
The
wearing
of
personal
protective
clothing
is
an
important
factor
for
your
protection
and
is
a
legal
OHS
requirement.
The
types
of
personal
protective
equipment
are
varied
and
their
use
is
determined
by
the
nature
of
the
tasks
you
perform.
Some
types
of
personal
protective
equipment
include:
• safety
helmets
• safety
glasses
• safety
boots
and
shoes
• gloves
• aprons
• overalls.
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There
are
many
types
of
accidents
that
can
happen
to
a
forklift
operator
or
workmate.
The
more
common
causes
of
accidents
are:
• being
hit
by
a
moving
forklift,
including
feet
being
run
over
• operator
being
hit
by
a
falling
object
• other
employees
being
hit
by
a
falling
object
• boarding
or
leaving
the
forklift
• forklift
tipping
over
• collision
with
other
vehicles
or
objects
• parts
of
the
operator’s
body
protruding
outside
of
the
cab
and
striking
an
object.
There
are
also
many
safety
rules
that
need
to
be
observed
while
driving
a
forklift.
Then look through the list of forklift safety tips provided to you on
the following pages.
Then categorise each of the tips into the given headings on the
page following these tips.
3 Report damage or faulty equipment 4 Do not operate the forklift until faults
immediately are corrected
7 Use the attachments and ancillary 8 Do not use the forklift for any
equipment only for its intended use purpose other than what it is
designed to do
9 Do not allow internal combustion 10 Know your loads and how to carry
engines to idle unnecessarily in an them properly
enclosed or semi-enclosed area
11 Carry only those loads that are rated 12 Handle only stable loads
within the capacity of the forklift
13 Centre the weight of the load between 14 Be aware of rear end swing
the forks
15 Ensure that the forks are fully inserted 16 Always travel with the forks no more
and the load is up against the fork than axle height
back rest
19 Always lift and lower the loads with the 20 Tilt the elevated load forward only
forks tilted slightly back when directly over the unloading
position
21 Watch floor strength everywhere 22 Ensure that you travel in the correct
especially on loading ramps and bridge direction when driving up and down
plates inclines
23 Avoid bumps, dirt, wet spots, rough 24 Check all bridge plates for width,
ground or anything that may cause the capacity and security before driving
forklift to become unstable on
25 Ensure that truck wheels are chocked 26 Do not obstruct emergency exits,
before attempting to load via a bridge aisles or thoroughfares when either
plate using or parking the forklift
27 Cross railway lines diagonally - railway 28 Know critical clearance areas and
lines should be recessed or chocks put locations of overhead pipes, wiring,
in place doorways, etc.
31 Keep yourself and others clear of the 32 Always travel with the fork tips
lifting mechanism pointed slightly up - even when
unloaded
33 Report all accidents immediately 34 Keep all hands, legs, head, etc.
inside the operator’s compartment
35 Use only secured, approved safety 36 Never allow anyone to go under the
platforms when lifting personnel load or forks
37 Make sure that nobody stands or walks 38 When leaving the forklift, ensure that
between the forklift and a stationary it is in a parked condition - forks
object lowered, park brake on, power shut
off, etc.
43 If forward visibility is obstructed, travel 44 Always clean up any spilled fuel, oil
in reverse or flammable liquids before starting
engine
47 Always concentrate on the job at hand 48 Avoid sudden stops and starts
- never be distracted
49 Always carry the load with the centre 50 Know what the common handling
of gravity directly in the middle of the symbols mean
forks
51 Never elevate loads while on an incline 52 Ensure that all tyre pressures are
correct and the same
53 Use only electric forklifts in enclosed 54 Make sure that you travel slowly
areas when you have a load
55 Do not wear rings, wrist watches, 56 Take extreme care when loading and
jewellery or metal objects when battery unloading containers - they are an
charging as these may contact the enclosed area
electrical parts and cause arcing
57 Take extreme care when driving over 58 Never alter the forks in any way,
wet surfaces. The braking distance shape or form
will be considerably more
Place the number of the forklift safety tip next to the appropriate
category.
e.g. 40 ________________________________________________________
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e.g. 52 ________________________________________________________
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Forklift loads
e.g. 12 ________________________________________________________
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Workplace environment
e.g. 21 ________________________________________________________
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Personal safety
e.g. 34 ________________________________________________________
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e.g. 30 ________________________________________________________
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Section 4
Section outline
Before
using
any
forklift
it
is
essential
that
you
conduct
a
pre-‐operation
safety
check
on
both
the
forklift
and
the
worksite.
This
check
is
to
ensure
that
the
equipment
is
safe
to
use
and
the
actual
worksite
is
safe
to
work
in.
Note
that
in
relation
to
the
safety
check
on
the
forklift:
• the
extent
of
the
safety
check
will
be
determined
by
company
requirements
and
any
OHS
regulations
• there
may
be
the
need
to
complete
a
checklist
to
fulfil
workplace
policies
and
regulations
before
using
the
equipment
• the
check
is
to
ensure
that
there
are
no
faults
or
damage
to
the
forklift
which
make
it
unsafe
to
operate.
Note
that
in
relation
to
the
safety
check
on
the
worksite:
• this
check
is
to
ensure
that
the
worksite
(the
path
that
you
will
actually
be
taking
when
moving
the
load)
is
free
from
obstacles
or
safety
hazards
• you
should
inform
people
who
may
be
working
in
or
near
your
path
• you
should
erect
barriers
and
signs
to
inform
other
people
of
any
possible
danger
(where
necessary).
Horn ✔
Park Brake ✔
Steering ✔
Etc.
Etc.
Forklift
Forklift
Ask you trainer to give you an imaginary forklift task. Check out the
work area where you would be using the forklift and identify any
potential hazards or risk areas that might affect the safety of the
operation.
Write down areas that have potential hazards and any hazards or
risks that you actually found. Then identify the actions that you
would take (or actually took) to eliminate the hazard.
Check out your answers with your trainer and then add any that
you may have missed for future reference.
Once
an
inspection
is
complete,
the
results
of
that
inspection
need
to
be
reported.
Many
workplaces
have
a
standard
checklist
and
procedure
for
the
reporting
of
forklift
pre-‐operational
checks.
All
employees
who
use
the
forklift
use
this
standard
procedure.
Tyres - not flat, not damaged, wheel Fan belt - correct tension
nuts not loose, tyre pressure
Steering
Name ________________________
This
part
of
the
unit
deals
with
the
operation
of
the
forklift.
It
is
essential
that
you
operate
the
forklift
under
supervision
whilst
you
are
in
training.
Failure
to
do
so
will
have
both
you
and
your
employer
liable
in
the
event
of
an
accident.
Think about the procedure you are supposed to follow when you
first get into a car and start the engine.
Now relate this to the forklift. List the first five steps you would take
when you get into a forklift.
a.
b.
c.
d.
e.
The
forklift
controls
are
different
from
those
of
a
car
or
motorbike
in
that
they
only
have
one
forward
and
one
reverse
gear.
They
have
no
clutch
but
they
do
have
a
brake
and
an
accelerator.
Steering
The
forklift
is
different
from
most
other
vehicles
in
that
it
is
steered
by
the
back
wheels
and
powered
by
the
front
wheels.
Instead
of
the
vehicle
following
the
front
wheels
around
a
corner
(as
a
car
does),
the
back
of
the
forklift
will
swing
out,
thereby
turning
the
vehicle.
This
is
commonly
called
‘Tail
Swing’.
The tail swing of the forklift occurs whenever the forklift is turned
around a corner and is one of the main skills that you, as a forklift
driver, need to master if you wish to become a competent forklift
driver.
Why do you think the forklift is designed and built with rear wheel
steering?
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When
you
first
start
driving
the
forklift
you
will
be
shown
where
the
pivot
point
is
on
the
forklift.
The
pivot
point
is
an
imaginary
point
where
the
forklift
pivots
whilst
turning
a
corner.
The
forklift
is
not
like
a
car
where
a
turning
circle
is
required
as
a
forklift
can
virtually
turn
on
a
point.
It
is
essential
to
know
where
the
pivot
point
of
the
forklift
is
so
that
you
are
able
to
manoeuvre
in
very
small
spaces.
It
differs
slightly
between
forklifts.
You
will
learn
much
more
about
driving
the
forklift
when
you
begin
your
practical
driving
part
of
the
unit.
When
driving
a
forklift
you
must
always
be
conscious
of
the
safety
factor.
There
are
many
rules
and
safety
precautions
that
you
must
follow
when
you
are
in
charge
of
the
forklift.
Many
accidents
can
occur
when
the
forklift
is
being
brought
to
a
halt.
Forklifts
should
be
brought
to
a
halt
gradually
as
wheel
sliding
and
hard
braking
is
dangerous,
unnecessary
and
harmful
to
the
forklift
truck.
If
hard
braking
occurs
there
is
a
very
high
possibility
of
the
load
tipping
over,
thereby
damaging
stock,
wasting
time
and
possibly
causing
injury
to
somebody.
After
you
have
brought
the
forklift
to
a
halt,
it
needs
to
be
parked
correctly.
The
correct
parking
procedure
is:
• ensure
that
the
forklift
parking
position
is
suitable
-‐
e.g.
not
in
front
of
exits,
level
ground,
not
in
walkways
• make
sure
that
the
tips
of
the
forks
are
touching
the
ground
by:
− tilting
the
mast
slightly
forward
− lowering
the
forks
until
the
tips
are
touching
the
ground
• put
the
forklift
in
NEUTRAL
• apply
the
parking
brake
• turn
off
the
forklift
and
remove
the
key
(according
to
your
company
policy)
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List the items that you think you would need to look at in the post-
operational check.
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As
part
of
your
driving
skills
you
will
obviously
need
to
know
how
to
refuel
the
forklift.
Rules
• Before
refuelling
shut
off
the
engine
and
the
lights
and
do
not
restart
engine
until
refuelling
has
finished.
• Smoking
is
prohibited
in
any
area
where
the
truck
is
being
refuelled.
• Refuelling
should
be
done
well
away
from
welding,
open
flames
and
sparks.
• If
you
detect
a
fuel
leak,
don’t
start
the
forklift,
pull
it
outside
and
ask
for
help
(from
your
trainer,
supervisor
or
maintenance).
With
LPG
the
refuelling
process
involves
changing
over
a
gas
bottle,
not
simply
filling
up
the
tank
as
we
do
with
motor
vehicles.
The
following
procedure
should
be
followed
when
replacing
the
LPG
gas
cylinder
on
the
forklift.
Before
changeover
• Smoking
is
prohibited
in
any
area
where
the
truck
is
being
refuelled.
• Keep
the
engine
running.
• Close
the
cylinder
shut
off
valve
and
let
the
engine
run
until
it
stops.
• While
changing
over
cylinder
always
wear
gloves
and
use
eye
protection.
Conducting
changeover
• Unscrew
the
bottle
fitting
making
sure
that
you
are
wearing
gloves
• Remove
the
cylinder
and
store
empty
cylinder
upright
in
the
designated
area
(must
be
under
cover).
• Connect
up
the
new
cylinder.
© Australian National Training Authority 2003 Page 85
Customised and Developed by Armstrong’s Driver Education July 2009 ADELG1011
TLID1007C Operate a forklift
After
changeover
• Start
forklift
and
continue
work.
• If
a
leak
is
detected
in
the
fuel
system,
stop
immediately,
turn
off
isolator
valve,
put
an
appropriate
sign
on
forklift
and
report
leak
to
supervisor.
Battery charging
If
you
have
an
electric
forklift
you
will
obviously
have
to
recharge
the
battery
rather
than
refuel
the
forklift.
When
the
forklift
needs
it's
battery
changed,
the
forklift
must
be
stationary
and
moved
so
that
it
is
in
the
proper
parked
position.
Batteries
should
be
charged
in
a
designated
area
that
is
free
from
obstacles,
welding
equipment,
sparks
and
open
flames.
It
should
also
have
proper
ventilation
as
batteries
during
charging
give
off
hydrogen
gas
that
is
extremely
flammable.
The
area
should
also
be
a
non-‐
smoking
as
a
cigarette
could
cause
an
explosion.
The
following
diagram
shows
a
forklift
driver
involved
in
many
unsafe
practises.
List
the
unsafe
practises
that
you
can
identify.
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Loading
and
stacking
is
again
a
very
practical
skill
and
will
need
to
be
learnt
at
your
practical
sessions.
However
there
is
some
theory
that
you
can
learn
before
you
drive
the
forklift.
As
a
forklift
driver,
you
will
lift,
stack,
de-‐stack
and
move
loads
every
day
and
so
these
skills
will
become
second
nature
to
you
in
time
and
with
practice.
The following exercise lists the correct procedures for lifting and
carrying a load. Fill in the missing words
square to the load and the forks are ...................... and at the
2. Move forward slowly until the forks are entirely under the
that the forks do not ..................... past the back of the load.
load.
Stacking a load
The
following
is
the
correct
procedure
to
use
when
stacking
and
unstacking
a
load
of
pallets.
You
should
follow
this
procedure
at
all
times:
• Approach
the
stack
with
the
load
down
and
tilted
backwards.
• Halt
at
the
base
of
the
stack
by
applying
brakes.
• Raise
the
load
to
the
desired
stacking
height.
• Drive
forward
until
the
load
is
over
the
stack.
• Tilt
mast
to
a
vertical
position.
• Lower
the
load
onto
the
stack.
• When
the
load
is
stacked
securely,
lower
the
fork
arms
until
free
of
the
pallets.
• Move
the
truck
backwards
making
sure
that
the
forks
are
clear
of
the
pallets.
(Note:
It
may
be
beneficial
to
tilt
the
forks
forward
as
the
truck
is
moved
backwards).
• When
the
forks
are
clear
of
the
stack,
lower
the
forks
and
tilt
slightly
backwards.
De-‐stacking
a
load
• Halt
at
the
base
of
the
stack
-‐
remember
to
ensure
that
the
load
is
within
capacity
of
the
forklift.
• Raise
the
forks
to
the
desired
height.
As
you
do
so
tilt
mast
until
it
is
vertical.
• Insert
forks
to
their
full
extent
by
driving
forward.
• Lift
load
clear
of
stack
and
carefully
apply
backwards
tilt.
• When
the
load
is
clear
of
the
stack,
move
back
slowly
until
it
is
clear
-‐
(remember
to
look).
• Lower
the
load
carefully
and
smoothly
to
travelling
height,
apply
further
backward
tilt
before
moving.
The
stacking
and
de-‐stacking
with
a
reach
truck
is
the
same
as
a
counterbalance
truck
except
that
the
reach
truck
has
the
option
to
move
the
forks
forward
to
pick
and
place
the
load.
This
ensures
that
the
reach
truck
is
more
compact
and
able
to
move
in
smaller
spaces.
Remember
to
always
bring
the
load
within
the
wheel
confines
before
moving
the
load.
When
loading
vehicles
the
first
priority
with
any
load
is
to
keep
the
load
within
the
legal
axle
load
requirements
and
within
the
permissible
load
dimensions.
To
be
able
to
do
this
you
need
to
be
able
to
understand
some
‘truckie’
terms.
The
‘truckie’
terms
that
you
will
need
to
understand
are:
• TARE
-‐
the
mass
(
weight
)
of
the
vehicle
without
its
load
• AGGREGATE
MASS
-‐
the
maximum
allowable
loaded
mass
of
a
particular
vehicle
When
loading
vehicles
it
is
essential
to
distribute
the
load
to
keep
the
centre
of
gravity
as
low
as
possible
and
the
vehicle
evenly
balanced.
If
possible,
items
should
be
placed
against
the
headboard
of
the
vehicle
so
that
they
can
be
secured
properly
and
they
are
in
no
danger
of
moving
during
braking.
Larger,
heavier
items
should
be
placed
at
the
bottom
of
the
load.
The
vehicle
should
be
loaded
to
give
an
even
weight
distribution
over
its
floor
area.
This
may
require
packing
such
as
timber
planks
or
block
wedges.
Try
to
always
distribute
the
load
so
that
light
crushable
objects
are
not
loaded
in
front
of
the
heavier
large
objects
otherwise
they
might
be
squashed
during
braking.
Heavy
solid
items
should
also
be
loaded
so
that
part
of
the
item
is
over
the
region
of
the
axles.
This
will
help
distribute
the
load
evenly.
If
high
loads
need
to
be
transported
always
try
to
use
low
platform
vehicles
as
high
loads
will
seriously
affect
the
centre
of
gravity
of
the
load
and
put
it
in
serious
danger
of
over
turning
when
cornering.
There is feedbac
Learner’s Guide
During this activity you will be required to practise using the forklift
within a variety of workplace situations.
This activity only allows you to practise using the equipment. There
will be separate assessment exercises that you need to complete.
Your trainer will give you different workplace tasks to do. They
must include:
• using the forklift unloaded
• using the forklift with a variety of loads
• using the forklift with long, wide loads
• loading and unloading a truck
• stack and de-stack a load (low and high stacks) in both narrow
and wide aisles.
Each time you use the equipment, fill in the logbook contained in
the Assessment Tasks section of this Learner’s Guide.
Once you feel that you are competent in the use of this equipment
in all of the above tasks, approach your trainer and request an
assessment.
Additional
resources
Websites:
• Workcover
Authority
of
NSW
http://www.workcover.nsw.gov.au/
• WorkSafe
Victor
http://www.workcover.vic.gov.au/wps/wcm/connect/WorkSafe
• WorkCover
Queensland
http://www.workcover.qld.gov.au/
• WorkCover
WA
http://www.workcover.wa.gov.au/
• WorkCover
SA
http://www.workcover.com/home.aspx
• ACT
WorkCover
http://www.workcover.act.gov.au/
• Workplace
Standards
Tasmania
http://www.wst.tas.gov.au/node/WST.htm
• NT
WorkSafe
http://www.worksafe.nt.gov.au/
Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.
There are four main types of forklifts that you are likely to see within
the road transport industry. These are discussed below:
Counterbalance forklift
What does a
counterbalance
forklift look like?
(draw or find a picture
and place in the space
opposite)
Where is the A point on the ground vertically below the front axle
balance point or
fulcrum of a
counterbalance
forklift found?
What does a
straddle forklift look
like? (draw or find a
picture and place in the
space opposite)
How is the weight of The weight of the load is distributed between the
the load distributed four wheels of the forklift while moving. This
dismisses the need for the forklift to counter-
on a straddle balance any load.
forklift?
Order pickers
What is the The order picker and the straddle are quite similar
difference between in their looks but with an order picker the operator
and the forklift controls are actually lifted to the
an order picker and desired height.
a straddle forklift?
With a straddle forklift it is only the load which is
lifted to the desired height.
What types of loads Usually long loads such as timber, pipes, metal
are handled by the bars, containers.
side loading forklift?
Centre of Gravity
1200mm
2.1m
600mm
700mm
900mm
1800mm
600mm
1.8m
800mm diameter
Dead centre
1.5m
1.25m 0.75m
2.5m
Load backrest
Question 1
What happens to the capacity of the forklift if the load has a load
centre greater than 600mm?
Question 2
Capacity - 1000kg
There are four different loads shown below. You are to determine
which of the loads can be safely lifted with your forklift. Circle the
loads that can be safely lifted.
900kg
Question 3
If the load centre of the load is less than 600mm, will you be able to
carry more than the maximum safe working load?
1. Approach the load slowly making sure that the forklift is square
to the load and the forks are level and at the correct height for
sliding under the load.
2. Move forward slowly until the forks are entirely under the load
and the load is resting against the fork backrest. Ensure that
the load is centred and take care to ensure that the forks do
not protrude past the back of the load.
6. Slowly back away from the load ensuring that the forks do not
catch on the load.
Note: There are numerous ways in which the truck may be loaded
using these loads. This is one example. If your answer differs
from the one shown above, consult your trainer to ensure that your
answer is correct.