TLID1107C - Conduct Special Is Ed Forklift Operations - Learner Guide

TLID1107C
Conduct specialised forklift
operations
Armstrong’s Driver Education

Learner Guide
TLID1107C Conduct specialised forklift operations
Page 2 © Australian National Training Authority 2003

ADELG1017 Customised and Developed by Armstrong’s Driver Education P/L – April 2008
Contents
What this Learner’s Guide is about ........................................ 5
Planning your learning ........................................................... 6
How you will be assessed ...................................................... 9
Section 1........................................................................................... 11
Types of forklifts and attachments ....................................... 11
Section 2........................................................................................... 35
Forklift safety........................................................................ 35
Section 3........................................................................................... 43
Driving the forklift with attachments ..................................... 43
Additional resources ....................................................................... 65
Feedback on activities .................................................................... 67
© Australian National Training Authority 2003 Page 3

Customised and Developed by Armstrong’s Driver Education P/L – July 2009 ADELG1017

ADELG1017 Customised and Developed by Armstrong’s Driver Education P/L – July 2009
What this Learner’s Guide is about
This Learner’s Guide is about the skills and knowledge required to
operate a forklift with specialised attachments or all-‐terrain
equipment, including checking attachments and worksite for
suitability, selecting the type of forklift and accessories for required
load shifting tasks, and shifting load and completing work in
accordance with operational requirements. 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 specialised operation of forklifts.
The Elements of Competency from the unit TLID1107C Conduct

specialised forklift operations covered in this Learner’s Guide are listed
below.
Check attachments and worksite for suitability
Select type of forklift and accessories for the required
workplace task
Shift load and complete work
This unit of competency is from the Transport and Logistics
Training Package (TLI07).

Planning your learning
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.

Section 1: Types of forklifts and attachments
Are you able to: Yes No

1. explain the difference between the
counterbalance, straddle, order picker
and side-‐loading forklifts?
2. list the advantages and disadvantages of
internal combustion and electric forklifts?
3. identify the major forklift components?
4. interpret the forklift manufacturer’s data
plate?
5. define load centre distance and explain
how it affects forklift stability?
6. identify forklift attachments and their uses?
7. demonstrate safe use of attachments
including jibs and associated equipment?
Section 2: Forklift safety

1. identify personal safety equipment used
while inspecting and operating a forklift
with attachments?
2. explain the safety steps that a forklift
driver needs to complete before they drive
the forklift with attachments?
3. state forklift safety requirements with
regards to driving the forklift, and forklift
equipment, loads, workplace environment,
personal and workplace safety?

Section 3: Driving the forklift with attachments

1. conduct a pre-‐operational forklift safety
check?
2. conduct a pre-‐operational work area safety
check?
3. report the results of safety checks?
4. drive a loaded and an unloaded forklift with
attachments?
5. stack and de-‐stack a load?
6. load and unload a truck?
7. refuel or recharge a forklift?

How you will be assessed
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.
You will be required to:

• demonstrate the safe and correct operation of a counter
balance forklift with attachments in a work situation.


Section 1
Types of forklifts and attachments

Section outline
Areas covered in this section
Types of forklifts
Power sources or modes of propulsion
Components of the forklift
Attachments that can be fitted to the forklift

What are the types of forklifts?
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.

Activity 1: Identification of the types of forklifts
Investigate the difference between the four main types of forklifts.
You can gain this information from a variety of sources such as:
• sales brochures from retail outlets
• materials handling magazines
• transport and warehouse magazines
• the Internet
• libraries
• books
• previous knowledge and experience.
A worksheet is provided for your use and is located on the following

pages.

Counterbalance forklift
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?
List the two main power

source options that you
could find on a
counterbalanced forklift.

Straddle forklift or reach truck
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)
What is an order picking

forklift primarily designed
for?
Why is it called an ‘order

picker’?

What is the difference

between an order picker
and a straddle forklift?
Side loading forklift
What does a side loading

opposite)
What is a side loading

forklift primarily designed
for?

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.
There is feedback on this activity at the back of this Learner’s

Guide.

What are the power sources for forklifts?
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 are similar to that used in
motor vehicles and are 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.

Activity 2: Advantages and disadvantages of electric powered

forklifts
Discuss the advantages and disadvantages of electric forklifts with:

• your trainer
• your workmates
• someone who drives an electric powered forklift
• or forklift distributors.
Advantages of electric powered Disadvantages of electric powered

forklifts forklifts

Guide.

What information is included on the

manufacturer’s data plate?
By law, every forklift is required to have a manufacturer’s data plate
which has information about attachment details (if one can be fitted).
This data plate also includes 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 you choose the appropriate forklift and attachments
needed for safe operation, and the forklift is driven and used within
the safe operating capacity.

Activity 3: Data plate information for attachments
Using the activity work sheet, complete the definition and then
select one of your workplace forklifts and give actual data plate
readings.
Information Definition Data plate

information
Attachment details (you can indicate with a drawing)
Maximum safe
working load
Maximum lift height
Mast tilt - degrees

Guide.

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.
When deciding what attachment to use, you will need to take into
consideration:
The type of load that you want to move e.g. barrels, bulk materials
• weight of the load
• size of the load
• company policy
• safety considerations e.g. dangerous goods.

Activity 4: Forklift attachments
Most attachments have special safety considerations that you need

to take into account when you drive the forklift.
Forklifts can be fitted with attachments which make them safer to

handle certain loads. However, these forklift attachments change
the way the forklift handles, therefore it is essential to know how the
attachments are used and any safety considerations that you need
to know.
The worksheets on the following pages are designed to help you

through this process.
You can find out the answers to these questions by:

• discussing them with your trainer
• discussing them with a work mate
• discussing with a forklift sales person
• studying books, magazines, brochures or posters.

Drum clamp What are drum clamps used for?
Drum clamps are used instead of transporting drums

on pallets. Why?
Are they fixed to the forks or bolted on in place of the

forks?
What are the safety considerations?
Roll clamp What are roll clamps used for?
How do roll clamps work?

Push-pull attachment What are push-pull attachments used for?
How do push-pull attachments work?
Carpet spike What are carpet spikes used for?
How do carpet spikes work?

Carton clamps What are carton clamps used for?
How do carton clamps work?
Bale clamps What are bale clamps used for?
How do bale clamps work?

Rotator What are rotators used for?
How do rotators work?
Pantograph What are pantographs used for?
How do pantographs work?

Fork extension What are fork extensions used for?
How do fork extensions work?
Personnel lift or work platform What are personnel lifts used for?
How do personnel lifts work?

Jib What is a jib attachment used for?
List other associated equipment that is commonly

used with jib attachments.
What are safety considerations when using jibs?

Activity 5: Jib equipment safety
When using a jib, heavy items will be carried and suspended by

slings. The slings and associated equipment need to be thoroughly
checked each time they are used to ensure it is safe to do so.
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.
Complete the worksheet on the next page, stating relevant safety

requirements when using jibs on a forklift.

Equipment type Safety considerations
Slings (draw an example of a sling in this space)
Hooks (draw an example of a hook in this space)
Rings (draw an example of a ring in this space)
Shackles (draw an example of a shackle in this space)

Guide.


Section 2
Forklift safety

Section outline
What to do before you drive the forklift with attachments

What is required for forklift safety when using

attachments?
The most important aspect of forklift driving is safety. As a forklift
driver you are aware that there are always people working around you
and if there was an accident they may be injured. When using
attachments it is important to make sure that the appropriate
equipment is selected and secured to ensure safety and protection

Activity 6: Before you drive the forklift
Before you even consider using attachments with a forklift, you

need to complete the following tasks.
They are:
• plan your work - inspect the work area
• select the correct forklift
• select appropriate attachments
• store removed attachments
• fit the appropriate attachments
• make your presence known.
Complete the worksheet on the next page by explaining what is

involved in these three steps.

Steps Questions
Plan your work Why do you need to plan your work?
Why do you need to inspect the work area?
What do you look for?
What do you do when a hazard or a risk has been identified?

Select the correct What do you need to consider when selecting a forklift to do a job?
forklift
Select the What do you need to consider when selecting attachments?

appropriate
attachment
Store removed What do you need to consider when storing attachments?

attachments
Fit the appropriate What do you need to consider when fitting attachments.
attachments

Make your presence When do you need to let people know that you are about to drive a
known forklift in the area?
How can you alert people to the fact that a forklift is operating in the
area?


Section 3
Driving the forklift with

attachments

Section outline
Pre-‐operational safety check of forklift
Pre-‐operational safety check of work area
Reporting of checks
Refuelling and recharging a forklift
Fitting attachments to the forklift
Lifting, carrying and setting-‐down loads
Lifting, carrying and setting-‐down loads with attachments
Driving the forklift with attachments

Conduct advanced forklift operations
Fitting attachments to a forklift
With fitting attachments to a forklift, it is important for you to make
sure that the attachments are fitted according to manufacturer’s
guidelines.
These guidelines are usually found in the operating/manufacturer’s

manual. Manuals tell you what the attachment is designed to do and
how you are meant to attach it to the forklift.
Manuals will also include schematic drawings with their instructions.

Manuals are specifically designed for each attachment so it is
important for your to make sure that you are referring to the correct
manual.

Activity 7: Fitting attachments
Identify two types of forklift attachments.
Write a step by step list of instructions on how to fit the attachments

to the forklift.
The worksheet on the following page is designed to help you

through this process.
Sources of information include:

• your trainer
• forklift attachment manuals/brochures
• companies specialising in forklift attachments
• schematic drawings.

Type of forklift:
Type of attachments:
Steps: Description:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Lifting, carrying and setting down loads
As a forklift driver you can already lift, stack, de-‐stack and move
different loads. When using attachments the theory behind the
processes you are currently using is very similar.

Activity 8: Lifting, carrying and setting-down loads
The following exercise lists the correct procedures that you already
use for lifting and carrying a load. Fill in the missing words.
1. Approach the load ____________ making sure that the

forklift is square to the load and the forks are ____________
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 ____________ against the fork
backrest. Ensure that the load is ____________.
3. Raise the load until all ____________ are cleared.

____________ load backwards to ensure safe handling of
the load.
4. To transport the load, the mast needs to be tilted slightly

____________ to ensure that the load is stable. Do not
travel with the load raised higher than ____________ for
adequate clearance. This is generally no higher than
____________ .
5. To unload, first the load needs to be ____________ slightly

____________ then lowered to the ground. It may then be
necessary to tilt the mast further ____________ to ensure
that the forks are smoothly withdrawn from the load.
6. ____________ back away from the load ensuring that the

forks do not catch on the load.

Guide.

Why are pre-operation safety checks

completed?
Before using any attachment with a forklift it is essential that you conduct
a pre-operation safety check on both the forklift, the attachment and the
worksite.
This check is to ensure that the equipment is safe to use and the actual
worksite is safe to work in.
The safety check on the forklift is to:

• ensure that there are no faults or damage to the forklift
which make it unsafe to operate
• complete a checklist to fulfil workplace policies and
regulations before using the equipment.
The safety check on attachments is to:

• ensure attachments adhere to OHS regulations
• ensure attachment is fitted correctly, according to
manufacturer’s manual and secure
• ensure that attachment movements and control functions
are smooth and comply with operating requirements.
The safety check on the worksite 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
• inform people and appropriate staff who may be working
in or near your path
• erect barriers and signs to inform other people of any
possible danger (where necessary).

Activity 9: Pre-operational safety check equipment
Watch your trainer or an experienced person demonstrate a pre-

operational safety check on the forklift.
The pre-operational check will include a pre-start check and an

operational check.
The pre-start check is to check for safety features that can be

checked before using the equipment; for example, flat tyres, worn
slings, etc.
The operational check is to determine if all forklift parts are working

properly before using it on a job; for example: brakes, controls, etc.
Whilst the person is performing the pre-operational safety check,

ask them to tell you what they are checking so you can write it
down to form a list. An activity worksheet is provided to help you
and is located on the following pages. Decide if it is a pre-start
check or an operational check and mark accordingly.

Example: forklift with a jib attachment (this example is not

complete).
Name of equipment Forklift with jib attachment
Parts Checked Pre-start Pre-start Operational
Forklift
Tyres for damage, pressure
Wheel nut – not missing, tight
Safety cage – damage, not loose
Park brake
Horn
Attachment
Slings – good condition, not worn, broken

fibres/wires, rust, cuts, stretching/bending of
links
Hooks – good condition, not worn, approved

type
Fitted correctly – bolted
Ease of movement

Forklift
Parts checked Pre-start Operational

Activity 10: Check of work area
Ask your trainer to give you an imaginary forklift task using an

attachment. 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.
Hazard or risk Action taken
Check out your answers with your trainer and then add any that
you may have missed for future reference.

Guide.

Reporting of pre-operation check results
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. This
standard procedure is used by all employees who use the forklift.
However, some workplaces expect you, the employee, to be

responsible for this process.
Occupational Health and Safety regulations in some states/territories

require that a pre-‐operational check is done by you before you use the
forklift and equipment. The results then need to be recorded and
reported. Therefore, it may be your responsibility to do this.

Activity 11: Pre-operational checklist
First, find out if your workplace has a standard procedure for

conducting the pre-operational check and for recording and
reporting the results.
If so, obtain a copy of the relevant documentation for your

reference and use.
If not, study the pre-operational checklist on the next page.
Once completed, show the checklist to your trainer and discuss

what items need to be checked and if your organisation has any
other requirements that you need to complete.

Pre-operational checklist for counterbalanced forklift with

attachments
Pre-start check - outside Pre-start check - inside

visual engine compartment
No leaks or obstructions under forklift Liquid levels correct - engine oil,
hydraulic oil, brake fluid, cooling water,
transmission oil
Tyres - not flat, not damaged, wheel Fan belt - correct tension
nuts not loose, tyre pressure
Mast assembly - damage, Battery - water level, connections and
obstructions, lubrication, chain tension security
Forks/attachments - condition, secure, Battery (electric forklifts) - sufficient
locking pins secure charge, water levels
Load backrest -secure, not damaged Condition - any leaks, damage or
obstructions
Hydraulic hoses and couplings -
excessive leaking, not damaged
Body damage Operational Check
Safety cage secure Gauges and warning lights - working
Check steering wheels and cylinders Lights - check if working
Check for any loose wiring Warning signals - revolving light,

reverse beeper, indicators
Towing pin secure Horn
Check manufacturers data plate Mast controls
Driver compartment - free from Park brake

obstacles, adjust seat, adjust mirrors
Gas - turn on, check fittings secure, Foot brake
check for leaks, check level of gas
Steering
Name: ________________________ Signature ________________ Date _____________

Refuelling/recharging the forklift
As part of your driving skills you will obviously need to know how to
refuel the forklift.
It is important to follow specific instructions when refuelling the

forklift. Although there are different fuels for forklifts and therefore
different refuelling methods the following rules apply to all forklifts
when refuelling.
Rules
1. Before refuelling shut off the engine and the lights and do
not restart engine until refuelling has finished.
2. Smoking is prohibited in any area where the truck is being
refuelled.
3. Refuelling should be done well away from welding, open
flames and sparks.
4. If you detect a fuel leak, don’t start the forklift, pull it
outside and ask for help (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
• no smoking
• have the engine running
• close the cylinder shut off valve
• let the engine run until it stops
• wear gloves and eye protection.
Conducting changeover
• unscrew the bottle fitting -‐ use gloves
• remove the cylinder
• store empty cylinder upright in the designated area (must
be under cover)
• connect up new cylinder.

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 its battery changed, the forklift must be
stationary and in the proper parked position. Batteries should be
changed in a designated area which is free from obstacles, welding
equipment, sparks and open flames. It should also have proper
ventilation as batteries, during charging, give off hydrogen gas which
is extremely flammable. The area should also be a non-‐smoking -‐ a
cigarette could cause an explosion.
Tips on battery charging

• park forklift in the designated area -‐ ensure the handbrake
is on
• no smoking
• open battery compartment and leave open
• ensure vent caps are functioning properly
• leave vent caps in place to avoid electrolyte spray
• do not wear rings, wrist watches, jewellery, or other metal
objects. They may contact electrical parts which will cause
arcing and electrocution.
• keep all metallic objects away from the top of the battery
as these may also cause arcing
• if any leakage of the battery electrolyte occurs then flush it
away. Report any major spillage.

Activity 12: Battery charging
The following diagram shows a forklift driver involved in many unsafe
practices. List the unsafe practices that you can identify.
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________

Lifting, carrying and setting down loads with

attachments
When using attachments this lifting and carrying procedure needs to
be modified according to the attachment chosen. For example, when
using an auto-‐lift drum attachment you need to take into consideration
the operating arms which are used to pick up the barrels.
Procedures without attachment Attachment procedures – auto-‐lift drum
Approach the load slowly making sure Approach the load slowly making sure
that the forklift is square to the load. that the forklift is square to the load.
The forks are level and at the correct The arms are level and come in contact
height for sliding under the load. with the drums just below the first rib.
Move forward slowly until the forks are Lower the forks while slowly moving
entirely under the load and the load is forward. This will cause the arms to open
resting against the fork backrest. and then close around the drum.
Raise the load until all obstacles are When arms are completely engaged, raise
cleared. Tilt the load backwards to ensure forks until arms contact upper ribs and lift
safe handling of the load. To transport drums to desired height.
the load, the mast needs to be tilted
slightly backwards to ensure that the load
is stable.
Do not travel with the load raised higher
Do not travel with the load raised higher than necessary for adequate clearance.
than necessary for adequate clearance. This is generally no higher than 150mm
This is generally no higher than 150mm (axle height.)
(axle height.)
To unload, first the load needs to be tilted To release drums, lower forks until they
slightly forward then lowered to the contact lower ribs and start to open then
ground. It may then be necessary to tilt back away.
the mast further forward to ensure the
forks are smoothly withdrawn from the
load.


Activity 13: Lifting, carrying and setting-down loads with

attachments
Identify two types of forklift attachments.
Write down the procedure for lifting, carrying and setting down a
load. Use the example of the auto-lift drum attachment as a
guideline.
The worksheet on this page is designed to help you through this

process.
Type of forklift:
Type of attachments:
Steps: Description:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Sources of information include:

• your trainer
• forklift attachment manuals/brochures
• companies specialising in forklift attachments
• schematic drawings.

Activity 14: Driving the forklift with attachments
During this activity you will be required to practise using the forklift
within a variety of workplace situations, using a number of
attachments.
This activity must be done under supervision and according to any

regulations or workplace and equipment policies.
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 with attachments with a variety of loads
• lifting, carrying and setting-down loads with attachments.
Each time you use the equipment, fill in the log book 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

State/territory licensing authorities:

• 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/

Work area:____________________________________________________
Assessed by: _________________________________________________
Date: ________________________________________________________
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.

Activity 1: Identification of the different types of forklifts
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)
Why is it called a ‘counter Because the load being picked up is counter balanced by the
balance’ forklift? weight of the vehicle chassis, engine, counterweight and body
Where is the balance point A point on the ground vertically below the front axle
or fulcrum of a
counterbalance forklift
found?
List the two main power internal combustion engine

source options that you find
electric powered - battery
on counterbalance forklifts?

Straddle forklift or reach truck
What does a straddle forklift

look like? (draw or find a picture
and place in the space opposite)
How is the weight of the The weight of the load is distributed between the four wheels
load distributed on a of the forklift while moving. This dismisses the need for the
forklift to counter-balance any load
straddle forklift?
What is a straddle forklift The straddle forklift is primarily designed for use in the
primarily designed for? warehouse. They are designed to be manoeuvrable and to lift
pallet loads to great heights
What is the primary power Most straddle forklifts are electric powered
source for straddle forklifts?

Order pickers
What does an order picking

opposite)
What is an order picking An order picking forklift allows you to “pick out” specific goods
forklift primarily designed from higher storage areas.
for? These forklifts allow you to choose a portion of the goods
stored, eg. You can choose one unit from a pallet. This means
you do not have to unload a pallet and take out what you need
and then store it again.
Why is it called an ‘order It is called an order picker because that is its primary use. To
picker’? lift the operator to high levels where he/she can select stock
for picking a customers order
What is the difference The order picker and the straddle are quite similar in their
between an order picker looks but with an order picker the operator and the forklift
controls are actually lifted to the desired height.
and a straddle forklift?
With a straddle forklift. it is only the load which is lifted to the
desired height.

Side loading forklift
What does a side loading

opposite)
What is a side loading A side loading forklift allows you to lift goods which are long
forklift primarily designed and need to be manoeuvred into small short area. The types
of long loads, you can use this forklift for include, timber, metal
for? piping and prefabricated large posts.
Why is it called a ‘side Because unlike other forklifts the load is picked up from the
loading’ forklift? side of the forklift rather than the front. This allows the forklift
to be manoeuvrable with long awkward loads
What types of loads are Usually long loads such as timber, pipes, metal bars,
handled by the side loading containers
forklift?
Give two examples of Timber yards, timber merchants

workplaces that might use
Steel and pipe retailers
the side loading forklift?
Anyone who moves long loads of timber, steel, plastic
Container storage areas

Activity 2: Advantages and disadvantages of electric powered

forklifts
Advantages of electric powered forklifts Disadvantages of electric powered

forklifts
No exhaust fumes emitted Batteries are bulky, very heavy and very
expensive.
Therefore suitable for enclosed spaces, cool
rooms, warehouses, etc The actual forklift is usually more expensive
than an internal combustion forklift.
Very little engine noise
Battery takes quite a few hours to recharge
Virtually no vibration therefore there is either the need for an extra
battery or a long wait between forklift use.
Ongoing maintenance costs seem to be less
than internal combustion Extra cost of battery recharging equipment.
Cost saving on fuel Less power than internal combustion.
Relatively short operating time between

recharges.

Activity 3: Data plate information for attachments
Complete the chart by completing the definition and then selecting

one of your workplace forklifts and give actual data plate readings.
Information Definition Data plate

information
Load Centre The distance between the centre of

distance gravity of the load and the vertical face of
the forks on the forklift. This is usually
600mm but may be 500mm on some
forklifts
Maximum safe The maximum weight the forklift can

working load safely carry
Maximum lift The maximum height that the forklift can

height lift the maximum safe working load
Mast tilt - degrees The amount of forward and reverse tilt in

the mast. The figure is in degrees; for
example: 6 degrees.

Activity 5: Jib equipment safety
Equipment type Safety considerations
Slings There are many different types of slings - wire rope, chain,
webbing, natural fibre & synthetic.
Check slings prior to using them every time -you use it - check
for excessive wear, broken fibres or wires, weathering, mould,
rot or sun damage, rust or cracks, cuts or gouges and stretching
or bending of links.
Ensure that the SWL (Safe working load) of the sling is never
exceeded.
All slings must have a label indicating either the SWL or the
WLL (working load limit) - if the label is missing do not use the
sling.
Hooks Many different types.
Ensure that it is an approved type of hook - never homemade.
Ensure correct SWL - ensure that it is the same or less than the
sling.
Hooks used with jib attachments must always be the swivelling

type - never the fixed type.
Ensure hook is centred directly over the load before lifting to

ensure forklift stability is unaffected.
Discard if more than 10% wear is evident.
Rings Many different types.
Ensure that it is an approved type of shackle - never

homemade.
sling.
Shackles Many different types.
Ensure that it is an approved type of ring - never homemade.
sling.

Activity 8: Lifting and carrying
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.
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 centered.
Raise the load until all obstacles are cleared. Tilt the load
backwards to ensure safe handling of the load.
To transport the load, the mast needs to be tilted slightly

backwards to ensure that the load is stable. Do not travel with the
load raised higher than necessary for adequate clearance. This is
generally no higher than 150mm.
(axle height).
To unload, first the load needs to be tilted slightly forward then

lowered to the ground. It may then be necessary to tilt the mast
further forward to ensure that the forks are smoothly withdrawn
from the load.
Slowly back away from the load ensuring that the forks do not
catch on the load.


TLID1107C - Conduct Special Is Ed Forklift Operations - Learner Guide

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TLID1107C - Conduct Special Is Ed Forklift Operations - Learner Guide

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Armstrong’s Driver Education

Page 2 © Australian National Training Authority 2003

Additional resources ....................................................................... 65

Feedback on activities .................................................................... 67

© Australian National Training Authority 2003 Page 3

Page 4 © Australian National Training Authority 2003

What this Learner’s Guide is about

The Elements of Competency from the unit TLID1107C Conduct

© Australian National Training Authority 2003 Page 5

Planning your learning

Page 6 © Australian National Training Authority 2003

Section 1: Types of forklifts and attachments

Are you able to: Yes No

Section 2: Forklift safety

Are you able to: Yes No

© Australian National Training Authority 2003 Page 7

Section 3: Driving the forklift with attachments

Are you able to: Yes No

Page 8 © Australian National Training Authority 2003

How you will be assessed

Assessment of this Unit of Competency will include observation of

You will be required to:

© Australian National Training Authority 2003 Page 9

Page 10 © Australian National Training Authority 2003

Types of forklifts and attachments

© Australian National Training Authority 2003 Page 11

Areas covered in this section

Types of forklifts

Power sources or modes of propulsion

Components of the forklift

Attachments that can be fitted to the forklift

Page 12 © Australian National Training Authority 2003

What are the types of forklifts?

© Australian National Training Authority 2003 Page 13

Activity 1: Identification of the types of forklifts

Investigate the difference between the four main types of forklifts.

A worksheet is provided for your use and is located on the following

Page 14 © Australian National Training Authority 2003

Why is it called a ‘counter

Where is the balance point

List the two main power

© Australian National Training Authority 2003 Page 15

Straddle forklift or reach truck

What does a straddle forklift

How is the weight of the

What is a straddle forklift

What is the primary power

Page 16 © Australian National Training Authority 2003

What does an order picking

What is an order picking

Why is it called an ‘order

© Australian National Training Authority 2003 Page 17

What is the difference

Side loading forklift

What does a side loading

What is a side loading

Page 18 © Australian National Training Authority 2003

Why is it called a ‘side

What types of loads are

Give two examples of

There is feedback on this activity at the back of this Learner’s

© Australian National Training Authority 2003 Page 19

What are the power sources for forklifts?