FORKLIFT TRUCK

SAFETY AND LICENCE

GUIDE WORKBOOK
Training support material for:

TLILIC0003
Licence to
operate
a forklift truck

Learner name: ________________________________________

Student number: ________________ Date: _________________
 Introduction to
forklift trucks

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 INTRODUCTION TO FORKLIFT TRUCKS

Parts of a forklift truck Overhead guard Flashing hazard light

Head lamp Operator’s seat

Mirror Gas bottle

Hydraulic controls Seat belt

Instrument panel Data plate/

load chart/rating plate
Mast
Counterweight
Lift chain
Fuel cap
Lift cylinder
Assist grip
Backrest
Engine hood
Locking pins
T
I GH Rear wheel
Vertical face of fork WE Foot step
T ER
UN
Fork carriage CO Foot guard

Fork (tyne) Heel Tilt cylinder Note:

Operator’s manual
Front wheel (usually located behind
operators seat)

Notes

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 PC 3.1 INTRODUCTION TO FORKLIFT TRUCKS

QUESTION 1 The fulcrum (point of balance) is at the bottom of the

front tyre.
A forklift has a point of
It is the point where the front tyre touches the ground.
balance (fulcrum).
Where is it? Load/weight

Counterweight

Point of balance (fulcrum) Point of balance (fulcrum)

Yes. All the weight behind the point of balance

QUESTION 2 acts as a counterweight. Counterweight
Does all of the weight
behind the point of
balance work as a Load/weight
counterweight?

Counterweight

Point of balance (fulcrum) Point of balance

(fulcrum)

Notes

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 ELEMENT 1
Plan work/task

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 PC 2.1 CHAPTER 1 – PLAN WORK/TASK

Hazard versus risk

What is the difference?
Different hazards and risks emerge constantly—sometimes instantly.

Hazard Risk
A hazard is any thing or any situation which could A risk is the chance of a hazard causing harm such as
injure or harm you. injury, illness or even death.
In other words, it is anything that can hurt you. In other words, how likely it is that somebody
or something may be harmed by the hazard.

Notes

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PC 1.1 CHAPTER 1 – PLAN WORK/TASK

Site inspection
There are a lot of hazards and risks on work sites that you need to be aware of.
Hazards can cause accidents, injuries and even death.
Hazards and hazard controls need to be considered when planning work.
The work site should be inspected by looking for hazards and risks that exist:
• Above eye level (in the air)
• At eye level
• Below eye level (on the ground).
You should always follow workplace procedures for conducting site inspections.

Above eye level

(in the air)

At eye level

Below eye level

(on the ground)

Notes

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 PC 1.5 CHAPTER 1 – PLAN WORK/TASK
Hazard control (continued)

Personal Protective Equipment (PPE)

The best way to make the workplace safe is to take away hazards altogether. But often you can’t do this.
This is where Personal Protective Equipment (or PPE) can help.
PPE is clothing or equipment worn on the body to protect you from hazards. PPE will not take away
the risk of harm altogether, but it will help keep you safe. These are some examples of PPE.

High visibility clothing

Hard hat Dust mask

Safety glasses Long sleeved

top

Long pants

Safety gloves

Sunscreen
Ear muffs Safety shoes

Note: Before starting any work all PPE should be chosen and checked to make sure it is in good working order

Notes

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 PC 1.6 CHAPTER 1 – PLAN WORK/TASK

Traffic management
Pedestrians and other vehicles are a major hazard where forklifts are in operation. Whenever there is a chance of forklifts
colliding with pedestrians or other vehicles in the workplace a traffic management plan should be in place.
Always look at your workplace traffic management plan before operating the forklift.

Rear-end swing
Because forklifts steer with the rear wheels, when a forklift turns it creates a hazard called rear-end swing.

Rear-end swing is the fast sideways movement at Rear-end swing is hazardous to any pedestrians,
the rear (counterweight section) of the forklift. other vehicles and structures in the area.

Remember:
Counterweight section Pedestrians and forklifts do not mix!

Notes

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 CHAPTER 2

Prepare for work/

task

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 PC 2.4 CHAPTER 2 – PREPARE FOR WORK/TASK

Getting on and off the forklift

You should get on and off the forklift from the left side.
Always use 3 points of contact — Three parts of your body should touch the forklift at the same time:
• Both hands and one foot
or
• Both feet and one hand is best.

Note:
• Never jump off the forklift
• Always face the forklift when getting on or off
• Always check hand and foot holds for slip hazards
such as water, grease and oil.
• Do not grab the steering wheel.

Notes

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 PC 2.8 CHAPTER 2 – PREPARE FOR WORK/TASK
Operational checks (continued)

Make sure warning devices such as the flashing Test that the horn and reverse buzzer is working properly
light and audible alarms are working

Check the gauges Look around and make sure the path is clear before you move.
This makes sure no new hazards have entered the work area.

Notes

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 PC 2.6 CHAPTER 2 – PREPARE FOR WORK/TASK

QUESTION 47 1. Do not operate. Isolate the forklift by 2. Put a danger tag on the forklift so no one
taking out the keys. else can use it.
What should you do if the
data plate is missing or
you cannot read it?

3. Tell your supervisor. 4. Write the problem in the logbook.

Notes

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 CHAPTER 3
Perform work/task

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 PC 3.4 CHAPTER 3 – PERFORM WORK/TASK
Tipping over – What do you do?

1.  Stay in / on the forklift. Lean away from 2.  Hold on to the steering wheel.
the direction the forklift is tipping.

3.  Brace yourself. Wait until the forklift is 4.  DO NOT jump from a forklift.
still and it is safe to get off.

Notes

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 PC 3.5 CHAPTER 3 – PERFORM WORK/TASK
Forklift truck movements (continued)

Vertical mast Forward tilt Backward tilt

When travelling with a load the mast should always be slightly tilted back.
This helps to support the load and prevent it sliding off the forks when braking.

Notes

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 PC 3.1 CHAPTER 3 – PERFORM WORK/TASK

QUESTION 53 Checking the weighbridge note, Weighing the load

consignment note, or other information.
What are some ways you
can find out the weight
of a load?

Calculating the weight of the load and pallet. Reading the weight on the load
For example: 50 kg × 6 + 20 = 320 kg

50 kg 50 kg 50 kg

50 kg 50 kg 50 kg

20 kg

Notes

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 PC 3.1 CHAPTER 3 – PERFORM WORK/TASK

QUESTION 54 Total weight = cartons × layers × carton weight + pallet

Total weight = 4 × 6 × 25 + 35
There is a load to be
moved. The load is cartons Total weight = 635 kg
stacked on a pallet.
• Four (4) cartons
per layer
• Six (6) layers 1 box = 25 kg
• One (1) carton = 25 kg
25 kg × 4 cartons × 6 layers
• Pallet = 35 kg
What is the total weight? = 600 kg

Show your working out.

Pallet
35 kg

635 kg

Notes

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 PC 3.1 CHAPTER 3 – PERFORM WORK/TASK

READING PLATE Read this data plate (load chart):

(LOAD CHART)
Use this data plate to
answer the next five FORK TRUCK LOAD AND WARNING NOTICE
(5) questions. Operators must be trained and authorised. Do not operate the lift truck
if it is in need of repair. This capacity plate is not transferable and is
Questions 56 to invalidated by any change to specifications.
Questions 65
MODEL: A12345A
S/NO: 123456
MAST: 2W370
MAST/CARRIAGE TILT DEGREES: TYRE PRESSURES KPA:
FORWARD/DOWN: 6 FRONT: 686
BACK/UP: 12 REAR: 686
DRIVE WHEELS: SINGLE TYRE TYPE: PNEUMATIC
TRACTION BATTERY WEIGHT (KG) MIN: N.A. MAX: N.A. VOLT: N.A.
TARE WEIGHT WITHOUT TRACTION BATTERY (KG): 2745 HIRE 921

RATED CAPACITIES - SIDESHIFT & LOAD IN CENTRE POSITION

LOAD CENTRE LIFT/LOAD HEIGHT MAST VERTICAL MAST FORWARD
(MM) (MM) CAPACITY (KG) CAPACITY (KG)
SIDESHIFT 600 3700 1575 900

PLATE I.D.: 12345 DEALER: EASY GUIDES PTY LTD

Notes

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 CHAPTER 4

Pack up

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 PC 4.1 CHAPTER 4 – PACK UP

Shutting down
Always check the manual for your forklift to make sure you are shutting it down properly. Always follow any rules for your worksite.
There are some things you must do when shutting down the forklift.

Lower the forks and to the ground Put the forklift in neutral

Put the park brake on Remove the key. Get off

the forklift making sure you
maintain three (3) points of
contact.

Notes

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PC 4.1, 4.2 CHAPTER 4 – PACK UP

QUESTION 92 To stop the forklift truck being moved by someone who is unauthorised
(does not have permission).
Why do you need to
take out the ignition key
when leaving the forklift
unattended (by itself)?

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