Study Guide on how to operate a forklift in NSW | Nov.16 Edition

1. November 2016.
Forklift theory
Study Guide
The information in this study guide is designed to help you with the practice
test you will be required to sit and pass prior to the Workcover assessment
and provide you with the knowledge required for the Workcover assessment.
Please study this information.

2. HRW stands for High Risk Work
Operating a forklift is considered High Risk Work (HRW)
a Forklift licence is a High Risk Work licence
MAKING THE APPLICATION
The application for a HRW licence must be made within 60 days of receiving a Statement
of Attainment or a Notice of Satisfactory Assessment issued by an assessor.
HIGH RISK WORK LICENCES
High Risk Work licences will need to be renewed every 5 years, if you fail to renew your
licence within 12 months of the expiry date.
 You will need to be Retrained & reassessed
You have legal responsibilities as a HRW licence holder 2 of which are to
 OPERATE WITH CARE
 ENSURE THE SAFETY OF YOURSELF AND OTHERS
If requested by your employer you must provide written evidence of a
● Current HRW licence
You are only able to perform HRW without a HRW licence if you are
Enrolled in a HRW course or Supervised by a HRW licensed operator
Failing to work safely when performing high risk work can
lead to the licence holder being penalised under WHS
Regulations:
licence may be suspended or cancelled.

3. It is important that you consult (communicate) with the appropriate personnel about site
hazards before you start work:
to ensure that workplace laws, policies and procedures are understood and followed.
People you may need to consult with are:
●Safety Officers ● Supervisors ● Workmates ● Managers
As a forklift operator it is important to always check your work area for hazards before
commencing work to ensure the work area is safe, a hazard is any situation that can cause
harm or property damage
Site Hazards:
There are also things you need to consider other than hazards these are preventive
measures to avoid hazards
Thing to consider other than hazards:
●Service Lines ● People ● Obstructions ● Poor Weather ● Poor Lighting
●Bridges ● Buildings ● Dangerous Goods ● Other Vehicles ● Door ways
● Electrical power lines ● Uneven surfaces ● Wet Surfaces
● Weight of load ● Communication ● Size of work area ● Type of forklift
● Permits required ● Path of travel ● Height restrictions ● PPE

4. WORKING NEAR ELECTRIC/POWER LINES
Minimum distances from power lines
Up to 132kV 3.0m
132kV up to 330kV 6.0m
more than 330kV 8.0m
To work closer than these distances:
 Call the electrical authority for a permit
• Have the power shut off
 Use a trained observer
To find out the voltage of over head power lines you need to contact the power company
Controls
Tiger tails are used as a visual aid to identify the
location of overhead power lines. It is important to
note that tiger tails DO NOT insulate the power lines
so exclusion zones and safe operating distances must
still be maintained, even when tiger tails are present.
What to do if you come into contact with power lines:
 Attempt to break contact with power lines if safe. If not
 Remain in the forklift
 call for help
 Don’t touch any metal parts if it is not safe to remain on the
forklift
 Warn others to stay away
 Jump off with both feet together
 Hop away at least 8m DO NOT WALK OR RUN

5. When determining your path of travel you must consider
 All Hazards and Controls
Measures to control Pedestrians & Vehicles
●Flag Person ● flashing lights ●Warning signs ●Barriers
●Walkways ● Exclusion zones
Charging batteries produce explosive gases so
always charge in well ventilated areas
to allow the explosive gases to escape
When operating in wet and slippery conditions you must
●Reduce speed ●Proceed with caution ●No sudden braking
● Corner slower ●Allow extra braking distance.
When working at night and in darkened areas
ENOUGH lighting is required for the work area in order to be
able to drive and work safely. This may mean EXTRA lighting

6. Hierarchy of Control
The hierarchy of control is an order of priority a level from highest to lowest, starting with
the best way to control a hazard to the least effective way to control a hazard.
The hierarchy of control must be in the following order:
1. Elimination Eliminate the hazard (Remove the danger or take
away the hazard)
2. Substitution Substitution with safer equipment or a safer method
or way
3. Isolation Isolate (physically separate) the hazard (barriers/
fencing)
4. Engineering controls Make / request changes to a Mechanical or
Electrical device
5. Administrative controls Training, Company policies and signage
6. PPE Personal Protective Equipment
PPE should be selected at the planning stage
Hazard controls should be applied as soon as the hazard is identified.
DO NOT use an internal combustion forklift in a confined space
The fumes could kill!
Best
control
TO
Least
effective
control
The best forklift to use in a confined space is an
Electric Forklift

7. COUNTERBALANCED FORKLIFTS
YES! All the weight behind the point of balance is acting as a counterweight
NO! You are NOT allowed to add additional counter weights without first
checking with the manufacturer.
Rear End Swing
The fast sideways movement of the rear of
the forklift can hit someone
It is very important to be aware of rear end swing
especially when travelling close to objects such as
wall, racking, vehicle and people. Always look
over your shoulder to make sure the rear of your
forklift is going to clear all objects.
The point of balance (FULCRUM) is
where the front tyres touch the ground

8. As the load centre is increased
the lifting capacity of the
forklift is reduced
The higher a load is lifted
the less stable the forklift
becomes. If you had two
forklifts the same but one
had a higher lift height
than the other, the forklift
with higher lift height
would have a low SWL
Safe Working Load
(SWL)
Using forward tilt
changes the SWL
of the forklift
because you are
moving the load
out away from the
forklift
Rated capacity
The amount of weight the forklift can safely lift at given heights and load centres

9. Increasing the load centre Reduces lifting capacity of the forklift
Vertical face of
the forks
Load centre of
gravity
From
To
Ways to communicate in the workplace
● Verbal ●Written instructions ● Signage ● Hand signals.
If the load is not hard up against the heel of the fork
arms (vertical face) the forklifts
capacity is reduced and stability is affected.
LOAD CENTRE DISTANCE
The load centre distance is measured
from the vertical face of the forks to the loads centre of gravity

10. OPERATIONAL CHECKS
It is important to carry out inspections on your forklift before and after use to detect any
damage and to ensure that the forklift is safe to use
PRE-START CHECKS
 Fluids
 Tyres
 Data plate
 All guards
 Mast
 Rams
 hoses
 Chain
 Forks
 Seat
 Seat belt
POST START CHECKS
 Lights
 Warning devices
 Gauges
 Hydraulic Controls
 Brakes
 Steering
Hydraulic Oil
Engine Oil
Transmission Oil
Brake Fluid
Coolant
Fuel
Battery Water
Over Head Guard: Protects the driver from falling objects
Foot Guard: Protects the drivers feet from falling objects
Load Guard/ Back rest: Protects the driver & the Mast
Head & Park
Brake
Reverse
Indicators
Over head
All controls must be
checked to it full extent
Height
forward & Back Tilt
Side Shift Left & Right
Horn & Reverse beeper
Hand & foot brake

11. Finding a fault
If you need to refuel the forklift make sure the engine is switched off. Re-fuelling while the
engine is running may cause the fuel to catch fire
It is important to check your forklift
wheels & tyres to ensure there are
 no large pieces of rubber missing
 No uneven wear
 No excessive wear
 Tyre pressure
 Wheel nuts are tight
 Rims for damage
Always maintain correct tyre pressure
To keep the forklift stable
With a flat tyre your
Forklift can tip over sideways
If at any stage you find a fault then you must
●Remove key ●Tag out of service
● Report to your supervisor ● Record in the log book
If the forklift does not have a DATA PLATE, or it is
unreadable you must
●Remove key ●Tag out of service
● Report to your supervisor ● Record in the log book
Listen for any abnormal noises during start-up as these may indicate a fault. If you
hear an abnormal noise then ●shut the machine off ●Remove key
●Tag out of service ● Report to your supervisor ● Record in the log book
Solid Rubber
Air filled

12. CHECK THE LOAD
You can check the weight of a load a number of ways:
Weigh the load.
Check for markings on the load.
Calculate the weight of the load.
Connotes
Delivery dockets
ALWAYS WEAR YOUR SEATBELT WHEN EVER YOU
OPERATE THE FORKLIFT. IT WILL STOP YOU FROM
FALLING OUT IF THE FORKLIFT IF IT TIPS OVER
AND PREVENTS YOU FROM BEING PROPELLED
INTO THE FORKLIFT STRUCTURE OR OUT OF THE
FORKLIFT IN THE EVENT OF A ACCIDENT
Check the shape of the load. Make sure
the heaviest end of the load is against the
heel of the forks (vertical face)
If the load is unstable or poorly stacked,
restack the load before you try to move it.

13. There are 6 cartons per layer and 4
layers on the pallet.
Each carton weighs 33kg.
The pallet weighs 15kg.
IT IS IMPORTANT TO SHOW ALL WORKING OUT
6 X 4 = 24 X33=792kg + 15 = 807kg
NEVER lift loads over people’s heads, as there is a
risk that the load may fall and kill someone
NEVER let people ride or be lifted on the forks or a
pallet it is against the law.
Passengers may only be carried on a forklift
if the forklift has an approved seat to carry a
passenger
At times you may be required to calculate the weight of a load to ensure the load is
within the lifting capacity of the forklift.

14. Never drive with your load raised as this
can tip your forklift forward
Never turn while travelling on a ramp or
sloped surface as doing this
can tip your forklift over sideways and lose
your load
Keep the load at no higher than axle height
while travelling and tilt the mast backwards for
stability.
You need to constantly monitor the load
movement to ensure that:
• The load and forklift are stable.
• Keep other workers safe
If you are driving with a large load where your
view is obstructed, you should
● Travel in reverse
●Ensure your reverse beeper is working
●Look over both shoulders
●Use a guide

15. When stacking loads on top of each other you must ensure that you have a:
firm level surface
Heavy goods are on the bottom.
Not too high
If loading onto a truck from a loading dock make
sure there is a secured dock plate in place to fill
the gap between the truck and the loading dock.
When travelling with a load on a ramp (either up or down), always face the load uphill
(load pointing up the ramp).
 Travel forward up a
ramp! (Load facing up
the ramp)
 Travel in reverse
down a ramp! (load
facing up the ramp)

16. Emergency procedures & communications
In an emergency it is important to know what communications needs to be carried out
and who you need to communicate with
What you need to communicate
 Type of emergency
 Location of emergency
 Who is involved
Who you need to communicate with
 Supervisor
 Other workers
 000
It is important that you give right of way to all emergency vehicles
during emergency situations.

17. Things that can tip your forklift sideways:
Things that can Tip your forklift forward
Uneven load.
Uneven surfaces.
Driving too fast
Turning too fast
Turning with the load raised
Turning on a ramp
Side shift not centred.
Flat tyre.
Carrying a load on one fork arm
Uneven load.
Uneven surfaces
Driving too fast
Overloading.
Severe braking.
Too much forward tilt
Driving with the load raised
Increasing the load centre forward
Driving forward down a slope loaded
Load not positioned against the heel of
the fork arms.

18. Your side shift attachment must always remain centred before travelling with a load
To keep your load and forklift stable
Never carry a load on one fork arm as this will
Make the forklift unstable and damage the fork arm
You can only make minor repairs to a forklift
If you are trained and authorised to do so.
If your forklift is tipping over either
forward or sideways
Don’t try to jump off and Brace yourself

19. Parking procedures
When parking the forklift you must follow the correct parking procedures.
 Apply the handbrake
 Neutral
 Fork arms lowered to ground
 Remove the key
 Turn off the gas
Always remove the key from the ignition after use
To prevent unauthorised use
Always park your forklift in designated areas and not in the following areas
 On sloping surfaces.
 First Aid Stations.
 Fire fighting equipment
 Near doorways.
 Walkways.
 Emergency exits.
 Blocking traffic.
If you have to park your forklift on an incline you
will need to
Chock the wheels and follow normal parking
procedures

20. The forklifts shown here are rated at 4200kg at 600mm load centre. Which load can be lifted safely?
Just halve the overall length of the load if the load centre is more than 600mm the load is not safe to lift.
Half of 1400
= 700 load centre
Half of 1300
= 650 load centre
Half of 1000
= 500 load centre