Theory Training Manual

Licence to operate a Forklift Truck - TLILIC2001

Version 10 September 2016

Welcome to the start of your forklift licensing course

This training manual contains all of the theory / knowledge that you need to
learn before your practical training begins. The information in this manual
should be studied after you have viewed all of our training videos and
completed the on-line quiz

Training course pre-requisites

To begin this course you must:

Be at least 18 years of age

Be able to speak and understand the English language fluently
Be able to write the working out process of simple calculations
Be the holder of 100 points of suitable identification or be willing to
source this identification before your licence assessment
Be willing to spend the time required to learn the information in this
training manual prior to your face to face practical training
Be aware of our training and assessment plan outlined in this booklet
Training and assessment plan TLILIC2001
This is a mandatory training course that must be completed before you can
attempt the forklift licence assessment with a WorkCover NSW accredited
licence assessor

Course overview:

1. Complete the mandatory training course

2. Pass the licence assessment
3. Apply at Australia Post for a forklift truck (LF) licence

Step 1: Mandatory training course

Australian Forklift Training (AFT) offers x3 training course durations for you
to select from. The names of these courses are:

Advanced course
Standard course
Premium course

Your trainer will highlight the course you have been booked into and
explain the initial duration. This is the original planned duration only. The
training course is only completed when you have achieved all x3 training
milestones

Milestone 1: Score 100% in the on-line theory quiz & learn all
theory information

Important: You must be aware that all of the theory information of this
course is taught to you via a series of training videos and this training
manual. You must learn this information in your own time prior to the face
to face practical training

Milestone 2: Score 100% in a x25 question short answer theory

quiz
This is completed in the practical face to face session/s

Milestone 3: Score 100% in a practical exercise

This is completed in the practical face to face session/s
Additional training sessions are required if you do not achieve all x3 training
milestones within your scheduled course duration. Refer to our T&Cs for
fee structure

Step 2: Licence assessment

The actual licence assessment will be conducted by an accredited licence

assessor. This person cannot be your trainer

You must supply to the assessor:

100 points of approved identification

A training record (logbook) that shows you have completed the
mandatory training course and are ready for assessment

Insufficient I.D or no logbook = No licence assessment for you. Extra fees

to re-book apply

Licence assessment includes:

Knowledge assessment = 58 questions in total

100% pass mark for critical questions
90% pass mark for non-critical questions
Calculation assessment = 8 questions. Pass mark is 100%
Performance assessment = 5 tasks. Pass mark is 100%

Licence assessment results:

Competent / Pass

You will receive an interim licence and given the paperwork to apply for
your full licence at Australia Post. This must be lodged within 60 days

Not Yet Competent / Fail

You will need to undergo additional training, study or practise before

attempting the assessment again. The re-assessment cannot be for at least
48 hours and must be within 90 days. Only the not yet competent units/
tasks need to be re-assessed. Additional fees apply for a re-assessment.
Refer to our T&Cs for fee structure

You must supply 100 points of identification and a training record (logbook)
to the accredited licence assessor before the re-assessment can start
Language, Literacy and Numeracy (LLN) assistance

The training program and the licence assessment must be completed in

English, without the assistance of interpreters or dictionaries

The Knowledge licence assessment can be conducted orally with the

accredited licence assessor but the calculation assessment must be
completed in a written format only

If you feel that this course is too difficult for you to complete please let us
know prior to your first face to face practical training begins. If you do not
cancel your training day with at least 24 hour notice no refund for the
course fees will be given

Counseling Services:

Reading Writing Hotline 1300 655 506

NSW Council for Adult Literacy (02) 9514 3973

Or contact our head office for further references in your local area

Identification for the licence assessment

100 points of identification must be presented to the assessor prior to the

start of the licence assessment. The only acceptable forms of ID are listed
on the following page

Your 100 points of identification must contain the following:

Photo ID
Current residential address
Date of birth
Signature

Additional fees apply if your licence assessment is cancelled because of

insufficient identification

It is your responsibility to ensure that your identification complies with all of

the rules on the following three pages
 If you cannot supply the licence assessor with 100 points of identification
from the approved list then the licence assessment cannot start
Document Type Document Points

Primary Documents Australian birth certificate/ card issued by the Registrar of Births Deaths and 70
Marriages
1. ONLY use ONE
Passport- Australian or international (current or expired within the last two 70
primary Document
years, but not cancelled)

Australian citizenship certificate 70

Secondary Documents Current Australian drivers licence 40

Current Australian learner drivers licence/permit 40

1. Allowed to use a combination of
secondary documents
Current Australian boat operators photo licence (Note: only the personal 40
2. If you want to use credit and Watercraft Licence (PWC) is issued with a photo and is acceptable. The
savings account cards or statement NSW non-photo boat licence is not acceptable).
(up to a maximum of two) they must
be from different financial
institutions. Current NSW Firearms photo licence 40

3. Documents must contain the Current Australian issued NCOC photo licence (post 2006) or high risk work 40
participants full name, NOT initials.
licence
4. Correctional Facility: For inmates of
a correctional centre an Current state/territory proof of age or photo card (eg a NSW RTA issued 40
arrangement exists between photo card)
WorkCover and the Department of
Corrective Services to accept two
additional forms of EOI as listed Australian defence or Police photo ID card 40
below. This additional EOI applies
to Correctional Centre inmates who
Department of Veterans Affairs card 25
are being trained in a correctional
facility under this arrangement
ONLY. Current Centrelink card 25

5. Please refer to FAQ for additional Property (council) rates notice 25

explanation of EOI requirements.
Property Lease agreement 25

Home Insurance Papers 25

Utility bills eg water, electricity, gas 25

Telephone account 25

Current Medicare card 25

Current Motor vehicle registration or insurance papers 25

Credit/savings cards/bank statement (only 2 can be used from different 25

banks and with full name, not Initials)

Correctional centre inmate Min photo card 40

Correctional centre inmate Min card 5

Letter of verification from the department of corrective services 25

Frequently Asked Questions Evidence of Identity

My Identification adds up to more than 100 points but I cannot supply

evidence if my current address as I just moved recently. Is this OK?

No. You must supply I.D that contains your photo, your current address,
your date of birth and your signature.

Can I supply identification that is not contained in the list?

No. Only I.D from the list of acceptable I.D is allowed.

My drivers license has expired, can I use that?

No. All documents must be current, in date or the most recent of their type.

Passports are the only exception to this rule they are allowed to be expired
by up to two (2) years.

Can I do the training / assessment if I am not a permanent resident of

New South Wales?

No. Only NSW residents can apply in NSW. If you are only here for a short
period of time you cannot obtain your forklift license until you return to your
home state.

Can I use a Birth Certificate Extract?

No. Only full birth certificates are accepted.

Can I use my credit card and my bank access card?

If you want to use more than one credit card, savings account card or bank
statement, they must be from different banks. You can only use two (2) in
total.

Can I present a certified copy of my evidence of identity documents?

No. Only original documents will be accepted.

Can I use a utility bill from a long time ago?

No. Only the most recent version is accepted.

Can I use identification that does not have my full name printed on the
front?

No. It must have your full name not just an initial, eg. J.Blow. The only
exception is a rates notice.

Can I use two primary documents to make up the 100 points?

No. You can only use one primary document.

If I do not have a primary document. Can I make up the 100 points

from a selection of secondary documents only?

Yes. An applicant can make up the 100 points from the secondary list.
Within the documents produces, however, the combination of documents
used MUST show an example of your date or birth, current residential
address, contain a photograph of yourself and a sample of your signature.

I havent got my Centrelink card or Medicare card yet but I have

evidence if my application. Can I use that?

No. Only a card issued by Centrelink or Medicare can be used.

What if I have changed my name?

You need to provide evidence of your identity in your new name to the
value of 100 points. You cannot use any documents that use a different
name.

What is a NSW photo card (RMS issued)?

The NSW photo card is a voluntary card for people who do not hold a
current NSW drivers license, or other form of photo identification, to help
them identify themselves. Other RMS-issued cards, such as traffic
controllers or shooter licenses, are not acceptable.

To find out the RMS requirements, costs and how to apply for a NSW photo
card please contact the RMS.
NOTE: We are not allowed to show you the licence assessment questions before
you sit the exam. The 84 questions on the following pages cover the same
information as the assessment questions only re-worded slightly different. If you
can answer all 84 questions you should be able to answer the licence assessment
questions.

1. You have a high risk work licence (forklift truck licence). What are your legal
responsibilities whilst operating a forklift truck in the workplace?

You must work in a way that is safe. You must not risk the health and
safety of yourself or others

2. You can be penalised for not doing high risk work safely. What might the
punishment from the work health and safety regulator be? Name two (2)

- Suspend your licence

- Cancel your licence
- Refuse to renew your licence
- Order you to sit a licence re-assessment

3. You have passed your high risk work licence test. You must now apply for a
photo high risk work licence at an Australia Post Office. How many days do
you have to put this application in?

- 60 days

4. Your high risk work licence is valid for 5 years. If you let it expire by longer
than 12 months what will happen?

- You will not be able to renew it again

- You will need to re-do the licensing course

5. If you do not have a high risk work licence when can you operate a forklift
truck?

- When you begin a high risk work course you can operate under the
supervision of a licensed person
6. What evidence could you provide to your employer to show them that you can
carry out work that requires a high risk work licence?

- A licence card
- A training record (logbook)

7. Who might you talk to about site hazards before you start the job? Name
three (3)

- Supervisor
- Workmate
- Safety officer
- Site engineer
- Manager

8. Why is it important to talk to these people about site hazards?

- So that you are aware of the workplace rules & procedures

9. It can be dangerous to use a forklift truck with an internal combustion engine

in an area with restricted air flow. Why?

- Exhaust fumes are dangerous and can poison you

10. What type of forklift truck would be the best to use in an area with restricted
air flow?

- Electric forklift truck

11. Why should you charge a battery in an area with good air flow?

Batteries give off gasses which can explode. Good air flow helps to
remove the gasses
12. You need to refuel the forklift truck. The forklift truck uses diesel or petrol.
What is the risk if you leave the engine running while your refuel?

The fuel could catch on fire

13. You need to plan for possible hazards before you use a forklift truck. The
hazards could be inside or outside. Name seven (7) hazards you might have to
plan for?

- Overhead services such as electricity or phone lines

- Surrounding buildings
- Doorways
- Obstructions
- Other equipment in the area (cars, trucks, forklifts etc.)
- Pedestrians
- Dangerous materials such as chemicals
- Ground conditions
- Overhead obstacle such as roof beams etc.

14. The hierarchy of hazard control is a list of controls that you can use to
eliminate or lower the danger from a hazard in the workplace. What are the six
(6) levels in the hierarchy from the first choice to the last?

- Elimination: If possible, remove (take away) the hazard

- Substitution: Use a safer method if you cant remove the hazard
- Isolation: Stop access to the hazardous (dangerous) area
- Engineering Control Measures: Change the tools, equipment or
environment to make it safer
- Administrative Practices: reduce the time the worker is exposed to the
hazards by using training, job rotation, the timing of jobs etc.
- Personal Protective Equipment (PPE): use PPE if the above controls are
not enough to remove the hazard

Note: In the assessment you will only need to write the underlined part of the answer.
However, you should have a good understanding of what each steps means

Learning tip: Remember the acronym. Every Sunday I Eat A Pie

15. On a busy worksite, why is it important to look at your work area and plan the
path you will travel?

You need to check the path for hazards. And plan how you will control
these hazards

16. When is the best time to choose and check your PPE and other safety
equipment?

Before you start the job

17. When you about to lift a load that you have not previously lifted. What are five
(5) things that you must plan for (other than site hazards) before you begin?

- Is the load stable?

- How heavy is the load?
- What is the rated lifting capacity of the forklift?
- What equipment do you need? Is the equipment there?
- Attachments required for the load?
- Where will you do the lift? What do you need to do?
- How will you get in and out?
- Who do you need to talk to and communicate with?
- Do you need any permits?
- Are there any blind spots caused by the size of the load?

18. You are using a forklift truck near electric lines. Working near electric lines is
very dangerous and can kill you. What are the minimum safe distance rules
you must follow?

- 3m up to 132,000 volts
- 6m up to 330,000 volts
- 8m above 330,000 volts

In the assessment you will only be required to write the metres from each of the
voltages. The voltages will be given to you

19. Who could you talk to if you needed to find out the voltage of overhead
electric lines?

Your local power supply company

20. What are two (2) ways you can work closer to electric lines than the minimum
distances allowed?

- You might be able to get permission from the electricity supply authority
- The electric lines will need to be covered by insulation
- A safety observer should be used if working inside these distances, if the
safety observers have been adequately trained

21. Tiger tails are black and yellow pipes that hang off electric lines. What are they
for?

Tiger tails are a visual system to warn that electric lines are there

22. Name three (3) ways you can communicate and give information to other
workmates on a site?

- Signs
- Written Instructions
- Speaking to people

23. Why should you look over your forklift truck and do a pre-start check before
using it?

You must make sure the forklift truck is safe to use

24. You have a new load to pick up. You cant read the data plate. Can you lift the
load?

No

25. What should you do if the data plate is missing or you cannot read it?

- Take out the key

- Put a danger tag on the forklift truck
- Tell your supervisor
- Fill in the maintenance logbook
26. What are six (6) pre-start checks you should do before using a forklift truck?

- Data plate
- Seat, seatbelt if fitted
- Overhead guard
- Mirrors
- Tyre condition
- Mast assembly
- Lift and tilt system (hydraulic lines & hose pulleys)
- Load backrest
- Fork arms & locking pins
- Warning decals
- All fluids
- Battery, connections, security & cables

27. You have found a problem with your forklift truck. What should you do?

- Take out the key

- Put a danger tag on the forklift truck
- Tell your supervisor
- Fill in the maintenance logbook

28. When checking the tyre condition on a forklift truck. What are four (4) things
you need to check for?

- The tyre wear is even

- The tread is not worn
- No big pieces of rubber are missing
- Wheels are secure
- Tyres are secure

29. You need to do a start-up check on the forklift truck to see if it is safe and
working properly. What are three (3) things you should check after you have
started the forklift truck?

- Check gauges
- Check lights, including reverse light
- Check operation of all warning devices/horn
- Check braking system whilst moving, including hand break
- Check steering system whilst moving
- Check mast and tilt controls (to full extent of their movements)
30. You are using the forklift truck and hear strange noises. What do you do?

- Take out the key

- Put a danger tag in the forklift truck
- Tell your supervisor
- Fill in the maintenance logbook

31. What does the load backrest do?

- Stops the load touching the mast

- Stops the load falling on you

32. A forklift truck has safety guards to keep the operator safe. What safety
guards do they have? Name two (2).

- Overhead guard
- Load backrest
- Foot guard

33. Why do all tyres need to have the right air pressure?

A flat tyre can make the forklift truck unstable and it could tip over

34. Are you allowed to fix a mechanical problem on the forklift truck?

Only if your employer allows you to and if you know how to fix the problem

35. You have to move a load of 44 bags of flour on a pallet. Each bag weighs
25kgs. The pallet weighs 35kgs. What is the total weight of the load? Show
how you worked it out?

44 x 25kg = 1100kg
Weight of pallet = 35kg
Total weight of load = 1100 + 35 = 1135kg

Note: A calculator can be used to answer this question

36. What are the three (3) ways you can find out the weight of a load?

- Checking the weighbridge certificate, consignment note, or other

paperwork
- Weighing the load
- Calculating the weight of the load
- Reading the weight markings on the load

37. There is a load to be moved. The load is stacked cartons on a pallet.

Four (4) cartons per layer.
Six (6) layers high
One (1) carton = 25kg
Pallet = 15kg

What is the total weight of the load?

Total weight = 4 x 6 x 25 + 15
Total weight = 615kg

Note: A calculator can be used to answer this question but you must show how
you worked it out

38. There is a load to be moved. It is 200 litre drums full of water.

Each drum weighs 13kgs when empty
Water = 1kg per litre

What is the weight of 6 drums full of water?

Total weight = 213kg x 6

Total weight = 1278kg
39. The load centre distance is measured from the vertical face of the fork arms to
the loads centre of gravity. The x3 forklift trucks in Attachment A below are all
rated at 2000kg at a 600mm load centre distance. Which one is unsafely
carrying a load outside of the rated lifting capacity?

Answer = A

40. What does the rated lifting capacity of a forklift truck mean?

It is the maximum weight a forklift truck can lift at a maximum load

centre distance and maximum load height
41. Can a load weighing 1575kg and a load centre distance of 700mm be safely
raised by the forklift truck above?

No. The load centre distance is longer than the maximum allowed

42. Can a load weighing more than 1575kg be safely raised by the forklift truck
above?

No. 1575kg is the maximum allowed

43. You have to lift a load. You must tilt the mast forward. What is the rated lifting
capacity with the mast tilted forwards?

900kg

44. You have to lift a load. You can use the mast vertically. What is the rated
lifting capacity if the mast can remain vertical?

1575kg
45. When should you set up your hazard control measures to reduce the risk from
site hazards?

Before you start working

46. How can you warn and direct pedestrians or workmates on a worksite? Name
two (2) ways.

- Barricades (safety fences)

- A guide to direct people
- Warning signs
- Scaffolding, hoarding or gantry

47. How can you warn and direct vehicles (cars, bikes, truck and mobile plant) on
a worksite? Name two (2) ways.

- Barricades (safety fences)

- A guide to direct people
- Flashing yellow hazard lights to warn people
- Warning signs
- Scaffolding, hoarding or gantry
- Vehicle exclusion zone

48. You are using a forklift truck in a dark place. What do you need to have?

You need good lighting in the area

49. A forklift truck steers with the rear wheels. This causes rear end swing. Why
must you be careful of rear end swing?

Rear end swing is dangerous and could result in damage or harm

50. Rear end swing is dangerous. Who is it most dangerous to?

It can be dangerous to people nearby

51. You are about to reverse a forklift truck. Name three (3) things you must do
before you begin?

- Check the pathway is clear

- Check the mirrors
- Look over both shoulders
- Use the horn or flashing lights
- Use a guide

52. You are operating a forklift truck in a wet and slippery area. What two (2)
actions can you take to be safe?

- Go slow
- Be careful
- Try not to operate up or down ramps

53. You need to move a load up or down a ramp. Which direction should the
forklift truck be moving?

- When you move up the ramp the forklift truck must be going forward
- When you move down the ramp the forklift truck must be going in
reverse

54. It is unsafe to turn a loaded forklift truck when it is on a ramp or slope. Name
two (2) reasons why?

- The load can be lost

- The forklift truck might tip over

55. Are you allowed to put more counterweights on a forklift truck without
checking with the manufacturer?

No

56. Are you allowed to raise or lower a load above people? Explain your answer.

No, because it is very dangerous. The load might fall on someone and kill
them
57. Some of your workmates want to ride on the forklift truck. Is this ok?

No. It is unsafe. To carry a passenger the forklift truck must be fitted with a
passenger seat and seat belt

58. How does the seat belt keep you safe?

The seat belt will keep you in the seat. If the forklift truck tips over it will
hold you in

59. Why is it not safe to drive a forklift truck with the load raised in the air?

Because it makes the forklift truck unstable and it could tip over

60. Why does the side-shift attachment need to be in the middle when carrying a
load?

To keep the forklift truck from tipping over sideways

61. You have to move a load on the forklift truck. You cant see where to go. How
can you move the load safely?

Ask someone to help guide you

62. When you are moving the forklift truck, what is a safe height for the load?

Axle height or as low as possible

63. Carrying a load on only one fork arm can be dangerous. Name two (2) reasons
why?

- The forklift truck may tip over

- You may damage the fork arm
64. You are stacking loads on top of each other. What are three (3) things that you
need to think about when you stack loads on top of each other?

- Stack the goods on a solid, level surface

- The stack of goods should be stable and balanced
- Heavy goods need to be on the bottom

65. You are about to move a pallet. The pallet doesnt look like it is loaded safely.
What should you do before moving the pallet?

Re-stack the load

66. There is a gap between the loading dock and the truck. What do you need to
do?

You need to use bridge plates or secured dock plates to cover the gap

67. Where is the load centre distance measured between?

It is the distance measured from the vertical face of the fork arms to the
loads centre of gravity

68. If the load centre distance gets longer, what will happen to the forklift trucks
rated lifting capacity?

The weight that the forklift truck can lift is reduced

69. If the load is not pushed up right against the vertical face of the forks, what
might happen?

The weight that the forklift truck can lift is reduced and it may make the
forklift unstable
70. Most of the time a forklift truck is safe and steady. What are five (5) things that
can make a forklift truck tip over sideways?

- Turning too fast

- Turning with the load raised
- Uneven surface
- Uneven load
- Driving with a flat tyre
- Driving too fast
- Side shift attachment not in the middle
- Turning on a ramp or slope
- Driving with the load in the air

71. Most of the time a forklift truck is safe and steady. What are five (5) things that
can make a forklift truck tip over forwards or backwards?

- Too much weight (overloading)

- Load centre distance too long
- Braking severely (hard)
- Using the forward tilt with a raised load
- Load is not pushed right up against the vertical face of the fork arms
- Operating down a sloping surface load first
- Driving with the load in the air
- Driving too fast
- Uneven surface
- Uneven load

72. A forklift truck has a point of balance (fulcrum). Where is it?

It is where the front tyre touches the ground

73. Does all if the weight behind the point of balance work as a counterweight?

Yes

74. Why should you keep checking your load while you are moving?

To make sure people are safe and to make sure the load is still stable
75. There is an evacuation emergency. Who do you need to tell? Name three (3)
people.

- Other people in the area

- Safety officer
- Supervisor
- Emergency services

76. There is an evacuation emergency. What information do you need to give to

people? Name three (3) things.

- That there is an emergency

- What the emergency is
- Where the emergency is located

77. What do you do if the forklift truck starts to tip sideways and you think it might
roll over?

- Stay on the forklift truck

- Do not jump off. Brace yourself and wait until you stop moving, then get
off

78. What should you do if your forklift truck hits electric lines? List the five (5)
steps.

1. Warn other people to stay back

2. Try and break the contact with electric lines
3. Stay on the forklift truck if it is safe to do so. If you must get off, do not
touch the forklift truck and the ground at the same time. Jump off with both
feet together and continue to jump like this until you are 8 metres away.
4. Report the incident to your supervisor
5. The forklift truck must be checked over by a competent person before
using it again

79. There has been an accident on your work site. Which vehicles have the right
way in an emergency?

You must give way to all emergency vehicles, such as ambulances, police
and fire fighting trucks
80. You are looking for a place to park the forklift truck. Where are three (3)
places you should not block when you park?

- Fire-fighting equipment (fire extinguishers, water hoses)

- Emergency exits
- Doorways
- Ramps or sloping surfaces
- Pedestrian walkways (walking places)
- Where the forklift can block other traffic
- Less than 2m from train tracks
- First aid stations
- Within the safe distances to electric lines

81. Where are normal procedures (things you have to do) when you park a forklift
truck?

- Fork arms should be touching the ground

- Put the forklift truck in neutral (N) gear
- Put on the park brake
- Follow the site specific safety procedures (your worksites rules)

82. What must you do when you park on a slope or a ramp (inclined surface)?

- Do the normal parking procedures

- Chock the wheels of the forklift truck

83. Why do you need to take out the ignition key when leaving the forklift truck
unattended? (by itself)

To stop the forklift truck being moved by someone who is unauthorised

84. Name two (2) types of forklift trucks that can be operated when you hold an
(LF class) forklift licence?

- Counter balanced forklift truck

- Reach forklift truck
- Double deep reach forklift truck
- All-terrain forklift truck
- Truck mounted forklift truck
- Side loading forklift truck
Learning Tips

We recommend viewing all of our training videos and then completing the on-line
multiple choice quiz.

We then recommend that you read through all of the questions and answers in
this booklet a number of times. When you believe that you know the answers an
effective way of assessing your learning progress is to have another person
verbally quiz you on the questions, If this is not possible you could simply cover
the answers with a piece of paper and test yourself on each question.

You should record which questions you cannot answer for further study. We have
found that people who do this learn the information more quickly.
 Performance exercise
1. Site hazards and control measures
Q. You will be required to name at least x8 potential site hazards?

- Overhead service lines (inside and or outside)

- Surroundings buildings
- Doorways
- Obstructions
- Other equipment in area
- Pedestrians in area
- Dangerous materials
- Other hazards unique to the workplace (you will need to state a hazard)
- Candidate applies hazard control measures suitable to the workplace

Q. You will be asked to name specific hazard control measures that you could
use for the site hazards.

A. May include:

PPE. Hi Vis clothing & enclosed foot wear etc.

Pedestrian exclusion zone. Safety bollards / witches hats etc.
Warning signs
Marked walkways

2. Demonstrate a pre-start check on the forklift truck

You will be required to inspect all of the following where appropriate for your
specific forklift truck.

- Data plate
- Seat: condition of seat and seat attachments secured
- Safety devices (seat belts)
- Overheard guard: condition and security
- Mirrors adjusted and clean
- Tyre condition, wheel nuts and pressure
- Mast assembly
- Lift and tilt systems
- Hydraulic lines
- Hoes pulleys
- Load backrest: condition and security
- Condition of fork arms or attachments
- Pins or other locking devices checked for security
 - Underneath machine for any fluid leaks
- Controls
- Warning decals
- Compliance plate for gas installation (where fitted)
- Security of LPG gas cylinder, cylinder date and condition of system (
where applicable)
- Air filter indicator if Diesel
- Brake fluid
- Hydraulic oil
- Battery: water, connections and security
- Engine oil
- Coolant
- Transmission oil
- Power steering fluid
- Battery retaining plates, connector and cable

Q. You must be able to determine the maximum rated lifting capacity with the
mast at the vertical position?

Refer to the data plate for answer

Q. You must be able to determine the maximum rated lifting capacity with the
mast in the forward tilt position?

Refer to the data plate for answer

3. Demonstrate a start-up check on the forklift truck

You will be required to demonstrate the following inspections where appropriate
for your specific forklift truck

- Mounts correctly (three points of contract)

- Adjust seat
- Fastens seat belt
- Correctly demonstrates start up procedure
- Checks gauges
- Checks lights
- Checks operation of reversing light (where fitted)
- Checks pathway clear for travel before moving
- Checks operation of all warning devices/horn
- Checks braking system whilst moving, including hand brake
- Checks steering system whilst moving
 - Checks mast and tilt controls
- All forklift movements are tested to the full extent of their movement
(mast operation and hydraulic rams, etc.)

4. Operating exercise
You will be required to complete an operating exercise consisting of picking up
and placing loads of at least 250kg at three heights up to at least 75% of the total
lifting height? You will be required to negotiate an obstacle course in a forward
and a reverse direction whilst complying with all of the below safe operating
procedures?

- Assess the weight of the load before lifting

- Ensures travel direction is clear
- Keeps to the left in aisles or roadways for two-way traffic
- Maintains a safe distance from other vehicles
- Travels at safe speed and maintains control of forklift truck
- Takes appreciate action if the forklift truck goes undetected by others
- Looks in direction of travel when reversing
- Does not travel with load until load is lowered to safe height
- Does not hit or knock any object in the path of forklift truck
- Keeps all parts of his/her body within the forklift truck when travelling
- Selects correct hydraulic controls
- Drives or re-positions forklift truck to access the load correctly
- Correctly positions the tines relative to the rack or stack before raising
the load
- Ensure the mast is vertical, or on a slight back tilt, to stabilise the load
when raising from a rack or stack
- Moves the forklift truck clear of the rack or stack, and lower the load to a
safe travel height before reversing
- Check over both shoulders before reversing
- Ensure the load is at a safe height to clear any bumps or rises on the
floor while travelling
- Ensure the mast is tilted back slightly to ensure the load is laying
towards the load backrest or carriage while travelling
- Correctly position the load relative to the rack/stack/truck
tray/trailer/loading dock before placing the load
- Place the load evenly on the rack/stack/truck tray/trailer of loading dock
prior to withdrawing the tines
- Withdraw tines cleanly without disturbing load
- Explain correct use of the brake when raising or lowering a load on an
incline
5. You will be required to shut down and secure the forklift truck correctly?

- Park forklift truck away from dangerous areas (doorways etc)

- Lower fork arms / attachments to the ground
- Selects appropriate gear, relevant to the forklift truck transmission type
- Apply the park brake
- Remove the key to prevent unauthorised use of the forklift truck