FORKLIFT TRUCK

LEARNER WORKBOOK
TLILIC0003
Licence to operate a forklift truck

National Licence
www.easyguides.com.au RTO-VET Learning Materials
 Contents
Language – Literacy – Numeracy (LLN) .................................................................. 4
How to get the most out of this book...................................................................... 5
Things to consider when learning............................................................................ 6
Learning support materials.................................................................................... 7
Learning and practical tasks................................................................................... 8
What is a forklift truck?......................................................................................... 9
Basic forklift concepts......................................................................................... 10

Introduction to high risk licensing................................................................... 13

New National Vocational Education and Training (VET) licensing pathway................... 14
Training and assessment requirements.................................................................. 15
Record of training logbook................................................................................... 16
Who has a duty of care?...................................................................................... 17
Where to find licensing information....................................................................... 18
Introductory training exercise.............................................................................. 19

Chapter 1—Plan Work...................................................................................... 23

Practical Task 1........................................................................................... 47
Practical Task 2........................................................................................... 49

Chapter 2—Conduct Routine Checks................................................................ 53

Practical Task 3........................................................................................... 71

Chapter 3—Shift Load...................................................................................... 73

Practical Task 4........................................................................................... 99

Chapter 4—Shut Down and Secure Forklift Truck............................................101

Practical Task 5..........................................................................................109

Thank you........................................................................................................111
Continuous improvement form ...........................................................................112
How to get the most out of this book
As a trainer you know there are many ways a learner can find information to complete
the training tasks in these learning materials. Below are some examples.

Licensed trainer: Information book:

• Can check your workbook answers • Find
 information to help do
training tasks
• Share knowledge and experience
• D
 emonstrate and check practical
training activities.

Other learners: Other resources:

• Share knowledge • The internet
• Demonstrate skills • User manuals
• Group training exercises. • WorkSafe.

Learner’s own experience:

• On-the-job experience
• Other training.

May not be reproduced 5

Learning and Practical Tasks
If you can, have your students train with other learners. Learning is more powerful when
you and your learners share ideas and experiences. Below is a brief explanation of how
you can use the training tasks in this workbook. Please advise your students if they are to
fill in tasks on their own at home or wait until they are in the training room with you.

Theory training tasks

These tasks help the learner understand the underpinning knowledge to
safely operate a forklift. To help them complete these tasks the learner
can use the Information Book and speak to other learners and you, the
licensed operator/trainer.

Thinking questions
Thinking questions train your learner to think for themselves. For example,
the Information Book does not directly state the answer.

Practical training tasks

These tasks help the learner acquire the practical skills to safely operate a
forklift. The tasks use high-risk equipment or machinery. Only a licensed
operator/trainer can supervise the learner’s practical training tasks.

Review
At the end of each element in the workbook, the learner gets to review their
training. The review gives the learner a chance to talk with classmates and
you about what they learned. Sharing their learning experiences with others
helps them learn.

Review questions
You’ll find the review questions on the Trainer’s Resource CD. Give the
questions to the learner toward the end of training to determine if they
understand the information they have covered. You can ask your learner
to fill in these questions alone or as a group.

Review—practical tasks
The practical tasks handout is on the Trainer’s Resource CD. There is one task
for each element and the learner should do all tasks under your supervision.

8 © Easy Guides Australia Pty Ltd

What is a forklift truck?
A forklift is a powered industrial truck used to lift and move loads. It has a mast and an
elevating load carriage with a pair of fork arms or other load-holding parts.
As you can see below, there are different types of forklifts. The most common forklift is
the counterbalance truck.

Reach truck
Counterbalance forklift truck (non-counterbalance) forklift

Double-deep reach truck Truck mounted forklift truck

Rough terrain forklift truck Articulated narrow aisle forklift truck

May not be reproduced 9

Basic forklift concepts

Point of balance (fulcrum)

The most common forklift is the

counterbalance type.
This means they carry the load on
the front mounted tynes and use all
the weight behind the front wheels Fulcrum
to counterbalance the load.
The point of balance on a forklift is
called the fulcrum. Think of it as a
vertical line through the axle of the
front wheel, where the line meets
the ground.

Think of a counterbalance forklift truck

as being like a see-saw. If you put too
much weight on one end it tips over.

Load

All the weight behind the point of

balance acts as a counterweight.
Counterweight

Fulcrum

10 © Easy Guides Australia Pty Ltd

The stability triangle
A forklift has a three-point suspension that is called the stability triangle.
The stability triangle is formed by the front axle (drive wheels touching the ground)
and the centre point mount in the middle of the rear (steering axle).

The forklift centre of gravity must stay within the stability triangle

ALWAYS KEEP THE CENTRE OF GRAVITY INSIDE THE STABILITY TRIANGLE

The centre of gravity in the stability triangle is like a ball floating in water and
can easily move. The centre of gravity moves by the driver lifting, lowering, tilting,
turning, accelerating, braking, and driving over uneven ground. Any of these movements
done too quickly can send the centre of gravity outside the stability triangle.

If the centre of gravity goes outside If the centre of gravity goes outside
the fulcrum (forward point of balance) either side of the triangle the forklift
then the forklift will tip lengthways will tip over sideways (lateral tipping).
(longitudinal tipping).

Some causes include: Some causes include:

• Overloading the forklift • Driving too fast

(especially without a load)
• Braking too hard
• Turning too fast
• Sudden tilting forward of a high load
• Turning on an incline
• Shifting load centre.
• Travelling with a raised load.

May not be reproduced 11

Where to find licensing information
You can check these websites for more information about workplace health and safety.

WA WorkSafe
www.commerce.wa.gov.au/WorkSafe

NT WorkSafe
www.worksafe.nt.gov.au

QLD Workplace Health and Safety

www.justice.qld.gov.au

NSW WorkCover
www.workcover.nsw.gov.au

SA SafeWork
ACT WorkCover
www.safework.sa.gov.au
www.worksafe.act.gov.au

VIC WorkSafe
www.worksafe.vic.gov.au

TAS WorkSafe
www.worksafe.tas.gov.au/home

You can read more about the new WHS Act at www.safeworkaustralia.gov.au

May not be reproduced 19

 Chapter 1

Plan Work

May not be reproduced 23

 Theory Training Task 1
Performance Criterion: 1.5

a) Give examples of hazards you should look for before you begin work.
Above head height

Ground level to eye level

Ground level (and below)

b) Tick any of these hazards you may have come across in past or
present workplaces.

May not be reproduced 25

 Theory Training Task 2
Performance Criterion: 1.5

a) Circle all the hazards (dangers) you can find in the picture below.

b) How could the people in this picture be a hazard if you were using a
forklift near them?

c) Can you think of ways to ensure these people do not get in the way
of the forklift?

26 © Easy Guides Australia Pty Ltd

 Theory Training Task 3
Performance Criterion: 2.3

a) Circle all the hazards (dangers) you can find in the picture below.

b) Can you explain why the ground conditions would be a hazard?

c) Why might other vehicles be a hazard if you are driving a forklift?

May not be reproduced 27

 Theory Training Task 4
Performance Criterion: 1.4, 1.5

Circle the eight (8) hazardous work practices you can see in the
a) 
worksite picture below.

b) If you notice these hazards (or others) taking place what should you do?

28 © Easy Guides Australia Pty Ltd

 Theory Training Task 5
Performance Criterion: 1.5

a) What is rear-end swing?

b) Who do you think is most at risk from forklift

rear-end swing?

Theory Training Task 6

Performance Criterion: 1.5

a) Circle which would be considered an enclosed or poorly-ventilated area.

freezer carpark

shed cold storage room

b) Why do you think you shouldn’t use a petrol forklift truck

in a small freezer room?

Theory Training Task 7

Performance Criterion: 1.5, 2.3

Check the safe working distances for powerlines in your state or territory.
How many metres is the NO GO zone for distribution lines on poles in your
state or territory?

The NO GO zone for

(state/territory)
is metres.

May not be reproduced 29

 Theory Training Task 8
Performance Criterion: 1.2, 1.5, 2.3

a) What kind of forklift truck do you use on rough ground?

b) Where can you find out more information about the right forklift to use?

Theory Training Task 9

Performance Criterion: 1.5, 2.3

What is the recommended Lux (light level)

for safe forklift work in a warehouse?

30 © Easy Guides Australia Pty Ltd

 Theory Training Task 10
Performance Criterion: 2.3

What kinds of things should you plan for

before using a forklift? List three.

Theory Training Task 11

Performance Criterion: 2.3

What are some examples of information that a Safety data sheet (SDS)
previously called a Materials safety data sheet (MSDA) tells you?

May not be reproduced 31

Element 1 — Plan Work TLILIC2001 – Licence to operate a forklift truck

Performance Criterion: 1.5

Hazard control measures

What are hazard control measures?
They are actions you take to control or
prevent a danger that can injure (hurt) you.
Use controls to reduce the risk to workmates
and property. Set up the hazard controls
before you start the task. The hierarchy of
hazard control tells you the steps to take so
you can reduce the danger from hazards.
A risk is the chance of a hazard injuring a
person. In other words, what is the chance
of the hazard hurting you?

Theory Training Task 12

Performance Criterion: 2.3, 2.9

a) What is a Safe Work Method Statement (SWMS) used for?

b) What other forms could you use to show how you will control a hazard?

Safe work method statement

This SWMS is site-specific statement that must be prepared before any high-risk construction work is commenced.

Person responsible for Date:

ensuring compliance with
this SWMS:

High-risk job: Location:

What are the tasks involved? What are the hazards and risks? How will hazards and risks be controlled?
(describe the control measures and how they
will be used)

Think about the worksite and each stage of the project, including preparation and clean-up.

32 © Easy Guides Australia Pty Ltd

TLILIC2001 – Licence to operate a forklift truck Element 1 — Plan Work

Theory Training Task 13

Performance Criterion: 2.3

a) List the six levels of the Hierarchy of Hazard Control.

1.
2.
3.
4.
5.
6.

b) What is the first thing you should try if you find a hazard?

May not be reproduced 33

 Theory Training Task 14
Performance Criterion: 2.3

Label the personal protective equipment in the picture below.

b) Circle the two (2) items that must be worn on every work site when using a forklift.

34 © Easy Guides Australia Pty Ltd

 Theory Training Task 15
Performance Criterion: 2.3

Give an example of why you might have to wear each of the following.

Safety shoes Hard hat Ear protection

Face mask Safety glasses Gloves

May not be reproduced 35

 Theory Training Task 16
Performance Criterion: 2.5, 2.7

a) Where can you find out the rules, regulations and information about using
a forklift safely? List three.

b) What kinds of information might you find in the operator’s manual? List three.

36 © Easy Guides Australia Pty Ltd

 Theory Training Task 20
Performance Criterion: 1.2, 1.3

a) Draw a line to match the forklift truck with the work area you think it is
best suited for.

A four wheel drive (4WD) forklift Enclosed space

A battery (electric) powered forklift Elevated load destination

LPG powered forklift Indoor work area

Telehandler or reach truck Rough terrain

May not be reproduced 39

b) What do you think would happen if you used an electric forklift truck on uneven,
muddy ground?

c) Why is it dangerous to use a combustion engine forklift in a confined space?

Theory Training Task 21

Performance Criterion: 1.3

a) What could happen if you use a forklift on rough terrain and it’s not
suited for it?

40 © Easy Guides Australia Pty Ltd

 Performance Criterion: 1.4

Plan your path of movement

Before you start the job, look at the work area and plan the
path you will take. This helps lower the chance of injuring
workmates or damaging equipment and property.

Theory Training Task 22

Performance Criterion: 1.4

a) W
 hy is it important to decide on an agreed travel plan/path before
moving a load?

b) Give an example of something you need to think

about when planning your travel path.
Explain your answer.

Theory Training Task 23

Performance Criterion: 1.5

List some steps you can take to reduce risk

to other people, machinery and equipment.

May not be reproduced 41

 Theory Training Task 24
Performance Criterion: 1.1, 1.4

Inspect the picture below. Key

a. Draw a line to show a safe path for you Other equipment
to drive the forklift truck to the load.
b. Draw another line to show how you would Racking/Shelving
move the load to the truck.
People
c. Place a small circle where you might use
your horn to warn people of your approach. Pedestrian walkway

Load

Forklift Entrance/
Truck Exit

Truck

42 © Easy Guides Australia Pty Ltd

 Performance Criterion: 1.5, 2.1

Communication
It’s important to communicate with your workmates
when you are on a work site. There are many ways
you can communicate. You may need to read things
like work permits and written instructions.

Theory Training Task 25

Performance Criterion: 1.7, 1.8

a) List at least three (3) ways you might have instructions communicated to
you in the workplace.

b) Do you have to obey signs in the workplace?

Tick the correct answer.

Only if you think they are important.

Only if there is anyone watching.

Yes, always. They are there to

keep everyone safe.

May not be reproduced 43

 Theory Training Task 26
Performance Criterion: 1.7

When would you use hand signals to communicate?

Theory Training Task 27

Performance Criterion: 1.7

a) Who is the first person you should speak to when an

unsafe incident occurs?

b) Where can you find information about what you should do when
an incident occurs?

Theory Training Task 28

Performance Criterion: 1.7, 3.4

a) Where can you find your worksite’s emergency procedures?

b) In an emergency, such as a fire, what are the general steps you might take?

44 © Easy Guides Australia Pty Ltd