License to operate a forklift truck 2

TLILIC2001A Licence to operate a forklift truck Information Booklet
LICENCE TO OPERATE A FORKLIFT TRUCK
TLILIC2001A Licence to operate a forklift truck Information Booklet
Module one
Module two - Carry our routine checks, shift load and shut down
TLILIC2001A
LEARNER GUIDE
Module one - Plan work
Carry our routine checks, shift load and shut down
TLILIC2001A
LEARNER GUIDE

Doc - TLILIC2001A Licence to operate a forklift truck Version - 4.0 Page 2 of 54
Release - Feb 2015 Review - Feb 2016 Document uncontrolled when released
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TABLE OF CONTENTS
Review Log...................................................................................................................................................5
Module 1 Basis.............................................................................................................................................5
1.1 Introduction............................................................................................................................................6
1.1.1 Course Overview...........................................................................................................................................6
1.1.2 What Is A Forklift?.........................................................................................................................................6
1.1.3 Parts Of A Forklift..........................................................................................................................................7
1.1.4 High Risk Work And WHS Legislation ..........................................................................................................7
1.1.5 Making The Application.................................................................................................................................8
1.1.6 High Risk Work LicenCes .............................................................................................................................8
1.2 Plan Work ...............................................................................................................................................9
1.2.1 Occupational Health & Safety/Work Health & Safety Requirements.............................................................9
1.2.1.1 Harmonisation Of Work Health & Safety Legislation.............................................................................9
Key Elements Of The Work Health & Safety Legislation ...........................................................................10
1.2.2 Duty of Care................................................................................................................................................11
1.2.3 Safe Work Practices....................................................................................................................................11
1.2.4 Safe Work Method Statements...................................................................................................................12
1.3 Risk Management ................................................................................................................................13
1.3.1 Consultation and Communicating With Others ...........................................................................................14
1.3.2 Risk/Hazard Identification ...........................................................................................................................14
1.3.2.1 Working Near Electric/Power Lines.....................................................................................................16
1.3.2.2 Task-Related Hazards ........................................................................................................................19
1.3.3 Risk Assessment.........................................................................................................................................19
1.3.3.1 Risk Analysis.......................................................................................................................................19
1.3.3.2 Risk Evaluation ...................................................................................................................................20
1.3.4 Risk Treatment............................................................................................................................................21
1.3.4.1 Consider Hazard/Risk Control Strategy Options.................................................................................21
1.3.4.2 Specific Control Strategies For Traffic & PEDESTRIANS...................................................................22
1.3.4.3 Specific Control Strategies For Operating At Night Or In Darkened Areas & FOR WET /SLIPPERY
AREAS............................................................................................................................................................22
1.3.4.4 Implement The Control Strategy.........................................................................................................22
1.3.5 Monitoring and Reviewing the Risk Management Process.........................................................................23
1.3.6 Reporting And Record Keeping ..................................................................................................................23
1.4 Forklift Trucks......................................................................................................................................24
1.4.1 Counterbalanced Forklifts...........................................................................................................................25
1.4.2 Rear End Swing..........................................................................................................................................26
1.4.3 Forklift Stability & Centre Of Gravity ...........................................................................................................26
1.4.3.1 Centre Of Gravity................................................................................................................................26
1.4.3.2 Stability Triangle..................................................................................................................................27
1.4.3.3 Load Centre Distance .........................................................................................................................28
1.4.3.4 Forklift Rated Capacity........................................................................................................................30
1.4.4 Forklift Attachments ....................................................................................................................................31
1.5 Getting From A To B............................................................................................................................32
1.6 Communications..................................................................................................................................32
Module 2 Basis...........................................................................................................................................33
2.1 Pre-Start Checks..................................................................................................................................34
2.1.1 Visual Checks .............................................................................................................................................34
2.1.2 Decals And Signage....................................................................................................................................34
2.1.3 Fluid Checks ...............................................................................................................................................35
2.1.4 Forklift Controls...........................................................................................................................................35

2.1.5 Safety Devices............................................................................................................................................36
2.1.6 Tyres...........................................................................................................................................................36
2.1.7 Check Attachments.....................................................................................................................................36
2.1.8 Logbook ......................................................................................................................................................37
2.2 Start The Forklift ..................................................................................................................................37
2.3 Operational Checks.............................................................................................................................38
2.4 Report A Fault ......................................................................................................................................38
2.5 Shift A Load..........................................................................................................................................38
2.5.1 Check The Load..........................................................................................................................................39
2.5.1.1 Calculating Load Weight.....................................................................................................................39
2.5.2 Apply Hazard Control Measures.................................................................................................................40
2.5.2.1 Forklifts & Pedestrians........................................................................................................................41
2.5.3 Picking Up A Load.......................................................................................................................................42
2.5.3.1 Using Two Forklifts To Pick Up A Load...............................................................................................42
2.5.4 Travelling With A Load................................................................................................................................43
2.5.4.1 Safe Forklift Operating Procedures.....................................................................................................44
2.5.5 Travelling On Ramps ..................................................................................................................................44
2.5.6 Placing A Load............................................................................................................................................45
2.5.7 Using Forklift Attachments..........................................................................................................................45
2.5.7.1 Forklift Work Platforms........................................................................................................................46
2.5.7.2 Jib Attachments...................................................................................................................................47
2.5.7.3 Lifting Gear..........................................................................................................................................47
2.5.7.4 Carpet Spike Attachments ..................................................................................................................49
2.5.7.5 Rotating And Side Shift Attachments..................................................................................................49
2.5.7.6 Drum Clamps......................................................................................................................................49
2.6 Emergency Procedures.......................................................................................................................50
2.6.1 Lateral Instability.........................................................................................................................................50
2.6.2 Longitudinal Instability.................................................................................................................................50
2.6.3 Forklift Rollover Procedure..........................................................................................................................51
2.6.4 Contact With Electric/Power Lines..............................................................................................................51
2.6.5 Forklift Malfunction......................................................................................................................................52
2.7 Shut Down And Secure Forklift Truck ...............................................................................................52
2.7.1 Parking The Forklift.....................................................................................................................................52
2.8 Post-Operational Checks ....................................................................................................................53
Forklift Inspection Checklist.....................................................................................................................54

REVIEW LOG
Version Number Date Updated Details of Updates
Version 4H
Released
June 2012
Version 4HR1
Supersedes
previous version.
Released
December, 2012
Content updated.
V2.0 Released -
March 2013
Less pictures to make doc smaller - some small amendments to
wording according to feedback received from trainers
V3.0 Released Feb
2015
Data plate example replaced for clarity and consistency
V4.0 Released March
2015
Changes to wording in 1.4.1and 1.4.2
MODULE 1 BASIS
This module is based on the unit of competency TLILIC2001A Licence to Operate a Forklift Truck:
Element 1 – Plan Work.
1.1 Potential workplace hazards are identified.
1.2 Hazard control measures are identified consistent with appropriate standards to
ensure the safety of personnel and equipment.
1.3 Appropriate forklift truck is selected according to the load and workplace conditions.
1.4 Working area is inspected to determine appropriate path of movement for loads and
forklift truck.
1.5 Communication methods are identified according to procedures.

1.1 INTRODUCTION
This training course is based on the National High Risk Licence Unit of Competence TLILIC2001A:
licence to operate a forklift truck.
The National Standard for Licensing Persons Performing High Risk Work aims to facilitate the operation of
a nationally uniform, competency-based licensing system for persons performing certain types of high risk
work.
The National Standard recognises the importance of quality training as an underpinning principle in
providing skilled workers, and that the most effective form of training is a combination of informal and
formal training methods. It requires training and assessment to be undertaken by a Registered Training
Organisation (RTO).
1.1.1 COURSE OVERVIEW
Throughout this unit you will learn about:
Planning out your work.
Conducting routine checks on the forklift.
Shifting loads safely.
Shutting down and securing the forklift after use.
1.1.2 WHAT IS A FORKLIFT?
A forklift is a powered industrial truck equipped with a mast
and an elevating load carriage to which is attached a pair of
fork arms or another attachment.
This can also include trucks on which the operator is raised
with the attachment for order picking.

Doc - TLILIC2001A Licence to operate a forklift truck
Release - Feb 2015
1.1.3 PARTS OF A FOR
It is important that you understand the different parts and controls of a forklift. Below is a diagram outlining
some important parts of a forklift:
1.1.4 HIGH RISK WORK
When are you under training?
Any person who is undertaking training for a High Risk Work (HRW) licence according to the
& Safety (WHS) regulations must be
being supervised at the workplace by a person with a c
As a person under training you are learning everything you need to know to ensure that you are going to
be working safely and efficiently.
Once you have completed your training and have been assessed you will be able to m
for a HRW licence.
KEY
A Forks/Tines.
B Load Backrest.
C Carriage.
D Mast.
E Hydraulic Lift Ram.
F Overhead Guard.
G Lights & Horn.
H Steering and Lever
Controls.
I Hydraulic Tilt Ram.
J Drive Wheels.
K Rear/Steering Wheels.
L Counter Balance.
M Operator’s Seat.
ANSD
Version - 4.0
Review - Feb 2016 Document uncontrolled when released
1.1.3 PARTS OF A FORKLIFT
is important that you understand the different parts and controls of a forklift. Below is a diagram outlining
1.1.4 HIGH RISK WORK AND WHS LEGISLATION
Any person who is undertaking training for a High Risk Work (HRW) licence according to the
regulations must be currently enrolled in a course of HRW training with a RTO
being supervised at the workplace by a person with a current HRW licence for the work.
Once you have completed your training and have been assessed you will be able to make your application
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Document uncontrolled when released
is important that you understand the different parts and controls of a forklift. Below is a diagram outlining
Any person who is undertaking training for a High Risk Work (HRW) licence according to the Work Health
with a RTO and
urrent HRW licence for the work.
ake your application

Release - Feb 2015
1.1.5 MAKING THE APPLICATI
Under the requirements of Work Health & Safety (WHS) l
(HRW) licenses must provide the following information:
Their name.
Evidence of identity (e.g. driver
you on enrolment
A passport-sized photograph of themselves (to be used on the HRW photo licence).
A copy of the statement of attainment/certification that they have succes
been assessed for the relevant unit of competency for the HRW licence they are applying for.
Under no circumstances can any applicant provide false or misleading information. Applicants are
expected to make the following declarations:
That they do not currently hold an equivalent HRW licence granted under corresponding WHS law
by another WHS regulator.
Any details of convictions or of being found guilty of any offence under the WHS Act or the WHS
regulations in any jurisdiction in Aus
Whether or not they have ever entered into an enforceable undertaking under the WHS Act or
WHS regulations in any jurisdiction in Australia, and providing the details if they have.
Whether or not they have ever previously had an equivalent HRW lice
cancelled under the WHS Act or the WHS regulations in any jurisdiction in Australia.
1.1.6HIGH RISK WORK LICEN
The holder of a HRW licence is responsible for taking reasonable care and not adversely affecting the
health and safety of other people while performing the HRW.
High risk work licences will need to be renewed every 5 years
Failing to work safely when performing high risk work can lead to the licence holder being
penalised under WHS regulations:
1. Their licence may be suspended
OR
2. The regulator may refuse to rene
renewal). High risk work licences will need to be
Version - 4.0
MAKING THE APPLICATION
of Work Health & Safety (WHS) legislation all applicants for High Risk Work
(HRW) licenses must provide the following information:
ty (e.g. driver’s licence, passport). - 100 Points ID as per information provided to
sized photograph of themselves (to be used on the HRW photo licence).
A copy of the statement of attainment/certification that they have successfully completed and
expected to make the following declarations:
hat they do not currently hold an equivalent HRW licence granted under corresponding WHS law
by another WHS regulator.
ny details of convictions or of being found guilty of any offence under the WHS Act or the WHS
regulations in any jurisdiction in Australia.
hether or not they have ever entered into an enforceable undertaking under the WHS Act or
hether or not they have ever previously had an equivalent HRW licence refused, suspended or
The application for a HWR licence must be made within 60
days of receiving a statement of attainment (issued by a RTO)
or a notice of satisfactory assessment issued by an assessor
HIGH RISK WORK LICENCES
health and safety of other people while performing the HRW.
licences will need to be renewed every 5 years.
penalised under WHS regulations:
suspended or cancelled.
The regulator may refuse to renew the licence (if the matter is raised at the time of
renewal). High risk work licences will need to be renewed every 5 years.
Page 8 of 54
egislation all applicants for High Risk Work
100 Points ID as per information provided to
sized photograph of themselves (to be used on the HRW photo licence).
sfully completed and
hat they do not currently hold an equivalent HRW licence granted under corresponding WHS law
ny details of convictions or of being found guilty of any offence under the WHS Act or the WHS
hether or not they have ever entered into an enforceable undertaking under the WHS Act or
nce refused, suspended or
The application for a HWR licence must be made within 60
of receiving a statement of attainment (issued by a RTO)
actory assessment issued by an assessor.
w the licence (if the matter is raised at the time of

Release - Feb 2015
Under no circumstances may an employer/PCBU allow a person to conduct high risk work if they
are not competent to do so, unless t
supervised at the workplace by a person with a cur
If a holder of a high risk work licence is no longer competent to carry out the work they hold a
licence for they must stop doing the work and retrain to become fully competent, or return the HRW
licence to the WHS regulator.
1.2 PLAN WORK
It is important that you are aware of the requirements relating to your work. Before you begin your tasks
ensure that you access the relevant documentation and plan your work.
Requirements relating to your work may include:
OHS/WHS requirements.
Duty of care.
Safe work practices.
Safe Work Method Statements
1.2.1 OCCUPATIONAL HEALTH
SAFETY REQUIREMENTS
Occupational Health & Safety/Work Health & Safety (OHS/WHS)
keep your workplace safe.
These can be broken down into four main types:
Acts Laws to protect the health, safety and welfare of people at work
Regulations Gives more details or information on particular parts of the Act.
Codes of Practice Are practical instructions on how to meet the terms of the Law.
Australian Standards
Give you the minimum levels of performance or quality for a hazard, work
process or product.
1.2.1.1 HARMONISATION OF WOR
In response to industry calls for greater national consistency, the
Commonwealth, states and territories have agreed to implement
nationally harmonised Work Health & Safety (
commence on 1 January 2012.
While not all states and territories have actually implemented the model
WHS legislation as of the start of 2012, it is important to be aware of
these changes, as all states and territories will eventually
them.
Version - 4.0
may an employer/PCBU allow a person to conduct high risk work if they
are not competent to do so, unless the person is enrolled in a course of HRW training and is
supervised at the workplace by a person with a current HRW licence for the work.
f a holder of a high risk work licence is no longer competent to carry out the work they hold a
st stop doing the work and retrain to become fully competent, or return the HRW
PLAN WORK
the relevant documentation and plan your work.
Requirements relating to your work may include:
Safe Work Method Statements (SWMS).
OCCUPATIONAL HEALTH & SAFETY/WORK HEALTH
NTS
Occupational Health & Safety/Work Health & Safety (OHS/WHS) is defined as laws and guidelines to help
These can be broken down into four main types:
Laws to protect the health, safety and welfare of people at work.
Gives more details or information on particular parts of the Act.
Are practical instructions on how to meet the terms of the Law.
ocess or product.
HARMONISATION OF WORK HEALTH & SAFETY LEGISLATION
In response to industry calls for greater national consistency, the
Commonwealth, states and territories have agreed to implement
nationally harmonised Work Health & Safety (WHS) legislation to
While not all states and territories have actually implemented the model
WHS legislation as of the start of 2012, it is important to be aware of
these changes, as all states and territories will eventually implement
Page 9 of 54
may an employer/PCBU allow a person to conduct high risk work if they
he person is enrolled in a course of HRW training and is
f a holder of a high risk work licence is no longer competent to carry out the work they hold a
st stop doing the work and retrain to become fully competent, or return the HRW
&
is defined as laws and guidelines to help

Release - Feb 2015
Harmonisation aims to develop consistent, reasonable and effective safety standards and protections for
all Australian workers through uniform WHS laws, regulations and codes of practice.
Key Elements Of The Work Health & Safety Legisla
The following key elements of the WHS legislation will impact the way you do your job, and the
responsibilities of your workplace:
The legislation also outlines requirements for:
The reporting requirements for notifiable incidents.
Licences, permits and registrations (e.g. for persons engaged in high risk work or users of certain
plant or substances).
Provision for worker consultation, participation and representation at the workplace.
Provision for the resolution of health and safety issues.
Protection against discrimination.
Many specific details relating to WHS will be negotiated within the workplace in accordance with the
legislation.
It is important that you speak with your Health and Safety Representative or supervisor for more
information on how these elements will effect your day
relating to health and safety.
It is important that you are familiar with the
The following OHS/WHS legislative r
Duty of Care.
Australian Standards.
Industry OHS/WHS Standards and Guidelines.
Health and Safety Representatives, Committees and Supervisors.
Job Safety Analysis (JSA) and Safe Work Method Statements (SWM
Licences, Tickets or Certificates of Competency.
National safety standards.
OHS/WHS and Welfare Acts and regulations.
Safety Codes of Practice.
Talk to your OHS/WHS officer or representative if you have any
questions about OHS/WHS legislation.
Version - 4.0
all Australian workers through uniform WHS laws, regulations and codes of practice.
Key Elements Of The Work Health & Safety Legislation
The legislation also outlines requirements for:
The reporting requirements for notifiable incidents.
rmits and registrations (e.g. for persons engaged in high risk work or users of certain
Provision for the resolution of health and safety issues.
otection against discrimination.
on on how these elements will effect your day-to-day operations, or if you have any concerns
It is important that you are familiar with the OHS/WHS laws that exist in your state or territory.
ve requirements will affect the way that you work:
Standards and Guidelines.
Health and Safety Representatives, Committees and Supervisors.
Job Safety Analysis (JSA) and Safe Work Method Statements (SWMS).
Licences, Tickets or Certificates of Competency.
National safety standards.
and Welfare Acts and regulations.
alk to your OHS/WHS officer or representative if you have any
questions about OHS/WHS legislation.
Page 10 of 54
rmits and registrations (e.g. for persons engaged in high risk work or users of certain
day operations, or if you have any concerns
ist in your state or territory.
alk to your OHS/WHS officer or representative if you have any

1.2.2 DUTY OF CARE
All personnel/workers have a legal responsibility under duty of care to do everything reasonably practicable
to protect others from harm by complying with safe work practices, including activities that require licences,
tickets or certificates of competency or any other relevant state and territory OHS/WHS requirements.
This includes:
Employers/PCBUs and self-employed persons.
Persons in control of the workplace.
Supervisors.
Designers.
Manufacturers.
Suppliers.
Workers.
Inspectors.
1.2.3 SAFE WORK PRACTICES
Safe work practices are methods that must be implemented to
make sure a job is carried out as safely as possible.
Safe work practices include:
Day to day observation of OHS/WHS policies and
procedures.
Emergency procedures.
Risk assessment.
Use of basic fire-fighting equipment.
Safe work practices are governed by legislative
requirements and workplace procedures. Safe work
practices relate to:
Drugs and alcohol at work.
Access to site amenities, such as drinking
water and toilets.
General requirements for safe use of plant and equipment.
General requirements for use of personal protective equipment
and clothing.
Smoking in designated areas.
Housekeeping to ensure a clean, tidy and safe work area.
Preventing bullying and harassment.
Storage and removal of debris.
Safe work practices should be referred to, and documented, when completing Safe Work Method
Statements as a guideline for how to carry out a task safely.
NO
SMOKING

1.2.4 SAFE WORK METHOD STATEMENTS
A Safe Work Method Statement (SWMS) details how specific hazards and risks, related to the task being
completed, will be managed and is developed by the employer/PCBU for their employees/workers.
SWMS fulfill a number of objectives:
They outline a safe method of work for a specific job.
They provide an induction document that workers must read
and understand before starting the job.
They assist in meeting legal responsibilities for the risk
management process, hazard identification, risk assessment
and risk control.
They assist in effectively coordinating the work, the materials
required, the time required and the people involved to achieve
a safe and efficient outcome.
They are a quality assurance tool.
Completing a SWMS:
1. Break the job down into logical steps taking into consideration what is required to be achieved by
the task.
2. Against each step, identify the workplace hazards in this activity i.e. the ways that a person [or
plant] could be injured or harmed [or damaged] during each step.
3. Decide on measures required to mitigate hazards, i.e. what could be done to make the job safer
and prevent the injuries or harm that may occur.
4. Identify roles and responsibilities for actions and outcomes to make ensure risk controls are
carried out and supervision of the process occurs.
5. Ensure the SWMS is fully understood by all workers prior to commencing the task.
The Safe Work Method Statement must be available for inspection at any given time. It must also be
reviewed each year and amended if necessary.
Safe Work Method Statements may also be referred to as Safe Work Procedures (SWP) or Job Safety
Analysis (JSA).
A SWMS must be prepared in
consultation with those people who
will be doing the job.

Release - Feb 2015
1.3 RISK MANAGEMENT
Risk management is the process of reducing or managing the risks when working with a hazard or in a
hazardous situation and should take into consideration the context of the organisation and
Risk management must be conducted in accordance with:
Risk management is made up of the following stages:
Consultation and communicating with others
carried out at every stage of the risk management process.
Version - 4.0
RISK MANAGEMENT
anagement is the process of reducing or managing the risks when working with a hazard or in a
and should take into consideration the context of the organisation and worksite
anagement must be conducted in accordance with:
Legislative, organisational and site
requirements/procedures.
Australian Standards (AS/NZS ISO
31000:2009).
Codes of Practice.
Employment and workplace relations
legislation.
Equal employment opportunity and disability
legislation.
anagement is made up of the following stages:
Consultation and communicating with others, as well as monitoring and review, should be planned for and
carried out at every stage of the risk management process.
Page 13 of 54
anagement is the process of reducing or managing the risks when working with a hazard or in a
worksite.
and site
Australian Standards (AS/NZS ISO
Employment and workplace relations
Equal employment opportunity and disability
hould be planned for and

1.3.1 CONSULTATION AND COMMUNICATING WITH OTHERS
Communication and consulting with others is an important part of the risk management process and should
take place at all stages.
Identifying risks and hazards and coming up with ways of controlling them includes talking to the people
with knowledge of the situation, or who are directly affected by any action you may take.
Controlling a hazard can be a team effort and it’s important that everybody knows what they need to do
and how/if they need to change their work process to suit.
Make sure you talk to the right people. This can include:
Safety officers.
Site engineers (where applicable).
Supervisors.
Colleagues.
Managers who are authorised to take responsibility for the workplace or operations.
It is important to communicate with workplace personnel/workers and safety officers before starting on a
worksite to ensure that any workplace policies and/or site-specific procedures are adhered to.
1.3.2 RISK/HAZARD IDENTIFICATION
HAZARDS CREATE RISK. CHECK FOR HAZARDS.
A RISK is the chance of a hazard hurting you or
somebody else or causing some damage.
A HAZARD is the thing or situation that causes injury,
harm or damage.
If you can remove or at least control a HAZARD you can
reduce the RISK involved.
Hazards may be classified into Site Hazards and Other
than Site Hazards
Before conducting a risk assessment at a worksite, check
to see what systems and procedures are in place as they may affect the outcomes of the risk assessment.
It is important that suitably knowledgeable personnel/workers are involved in the risk identification process.
Common workplace (Site) hazards include:
Ground conditions:
Condition of pavement.
Slopes, ramps and inclines.
Underground services.
Non-weight bearing surfaces.

Release - Feb 2015
Overhead hazards:
Electric/Power lines.
Overhead service lines.
Bridges.
Poor lighting.
Surrounding structures:
Buildings.
Obstructions.
Traffic:
Pedestrians.
Vehicles.
Other plant.
Weather:
Wind.
Lightning.
Rain.
Other hazards (e.g. dangerous materials).
Other things to consider (i.e. other than site hazards):
Clear Path for travel
Weight of the load - can the forklift lift the load safely
Can the forklift handle the task
Poor load placement.
Irregular loads.
Part of your job is to look around to see if you can find any hazards
forklift.
A good tip is to check:
Above head height – remembe
can reach much higher than you can!
At eye level – look around to see if there is
anything in the way of where you want to
drive the forklift.
On the ground (and below)
bumps, slippery surfaces and rubbish can
all be dangerous. Also make sure that any
ramps or flooring can take the weight of the
forklift.
Version - 4.0
Overhead service lines.
Surrounding structures:
Other hazards (e.g. dangerous materials).
(i.e. other than site hazards):
can the forklift lift the load safely
t handle the task - is it the correct type of forklift
Poor load placement.
Part of your job is to look around to see if you can find any hazards before you start using the
remember the forklift
can reach much higher than you can!
look around to see if there is
anything in the way of where you want to
On the ground (and below) – humps and
bumps, slippery surfaces and rubbish can
Also make sure that any
ramps or flooring can take the weight of the
Page 15 of 54
before you start using the

Make a note of any hazard you identify in the area. Remember, a hazard can also be a situation so keep
an eye on how the people around you are working too.
Each task/procedure/function needs to be evaluated for risks, as well as the work area where the work is
being carried out.
You should also check records of injuries and incidents, safety tags and talk to other workers.
Material Safety Data Sheets (MSDS) can be useful tools in identifying potential hazards so make sure
you check the MSDS documents for your site.
In Summary
Before Commencing Work, talk/consult with:
• Other workers,
• Your manager,
• Supervisor,
• Team leader or
• Workplace Health & Safety representative
To find out:
• About the hazards identified
• If the risk has already been addressed,
If you find that there is no documentation or guideline in place to resolve an identified risk, you need to
assess the risk and identify a feasible course of action to deal with it.
It is important that all records, policies and procedures are kept up to date so that the most relevant
information is available and used.
Hazard Control must be applied in the pre planning stage
1.3.2.1 WORKING NEAR ELECTRIC/POWER LINES
Operating the forklift near electric/power lines can be extremely dangerous.
It is very important that you are aware of the safe operating distances for different types of electric/power
lines and the steps you must take if the task requires you to work closer than these prescribed distances.
Generally, if you are required to work closer than the prescribed safe
work distance you must:
Contact the relevant local electrical authority for exemption.
Have the electric/power lines shut off (or insulated if this is
not possible).
Use a trainer observer (NSW, other states differ)
Distances vary depending on the voltage of the electric/power lines.
You should refer to the local electrical authority for information and advice to determine the voltage
of electric/power lines in your work area.

NSW
In New South Wales, equipment operation may not be any closer than the following distances to
electric/power lines:
Electric/Power Line Type Distance
Up to 132kV 3.0m
132kV up to 330kV 6.0m
more than 330kV 8.0m
Again, to work closer than these distances requires:
• Authority from the relevant electrical authority and adherence to cl.64(2)(e) of the regulations.
• Having the Power lines shut off if possible
• Use a trained observer
If you have to work closer than these minimum distances then you must contact the relevant authorities to
seek an exemption.
The term "Spotter" is not used in NSW; however you must use an "Observer". Both the operator and the
observer must be trained.
SA / TAS / ACT (AS2550.1)
In South Australia, Tasmania and the ACT, equipment must not be closer than the following distances to
electric/power lines:
Distribution lines up to and including 133kV (usually
poles)
6.4m or 3.0m with a qualified ‘spotter’
Transmission lines greater than 133kV (towers) 10m or 8m with a qualified ‘spotter’
A ‘spotter’ is a competent person who watches and guides plant and equipment around electric/power
lines. Check with each state authority for their spotter requirements.
VIC
In Victoria the Framework for Undertaking Work Near Overhead and Underground Assets states that
equipment must not be closer than the following distances to electric/power lines:
Distribution lines up to and including 66kV (power
poles)
6.4m or 3.0m with a qualified ‘spotter’
Transmission lines greater than 66kV (towers) 10m or 8m with a qualified ‘spotter’
QLD
The Queensland Electrical Safety Regulation breaks down the distances in detail. Exclusion zones are
broken down not only by size of electric/power line but also by the competency level of the operator. This
means that the requirements should be clarified with the electrical authority before work commences even
if the distance appears to be outside the zones.
The Code of Practice gives the following minimum distances as guidance:

Up to 132kV 3.0m
132kV up to 330kV 6.0m
330kV to 500kV 8.0m
WA
In Western Australia this falls under Regulation 3.64 from the OSH Regulations and states the following as
the minimum distances:
Less than 33kV 3.0m
Over 33kV 6.0m
Over 133kV 8.0m
NT
In the Northern Territory safe electric/power line working distances falls under the Electricity Reform
(Safety and Technical) Regulations. Table 2, Schedule 3 gives the following minimum distances:
Up to 33kV 1.5m
Above 33kV to 132kV 3.0m
TIGER TAILS
Tiger tails are used as a visual aid (they highlight the power lines) to identify the location of overhead
electric/power lines. It is important to note that tiger tails DO NOT insulate the electric/power lines so
exclusion zones and safe operating distances must still be maintained, even when tiger tails are present.
The requirements for the other states have been included as you licence is a national licence. You do not
however have to memorise all the requirements, only the states you work in.

Release - Feb 2015
1.3.2.2 TASK-RELATED HAZARDS
There may be other factors that you need to consider when pl
site hazards, but hazards relating to the way the task is carried out.
When planning out the task, some things you
1.3.3 RISK ASSESSMENT
A Risk Assessment involves completing a Risk Analysis and a Risk Evaluation.
By assessing the likelihood and consequence of the risk you are able to understand the situation better
and respond in an appropriate way.
1.3.3.1 RISK ANALYSIS
Risk analysis involves considering what are the ca
Consequence What would be the outcome of the event occurring?
How severe would the outcome be?
Likelihood What is the chance of the event/consequence occurring?
Has the event happened before?
Is it likely to happen again?
Risk Level The combined result of likelihood and consequence.
Version - 4.0
RELATED HAZARDS
There may be other factors that you need to consider when planning out the task that are not
site hazards, but hazards relating to the way the task is carried out.
When planning out the task, some things you may consider (other than site hazards) are:
.3 RISK ASSESSMENT
A Risk Assessment involves completing a Risk Analysis and a Risk Evaluation.
respond in an appropriate way.
Risk analysis involves considering what are the causes and sources of risks and comprises 3 factors:
What would be the outcome of the event occurring?
How severe would the outcome be?
What is the chance of the event/consequence occurring?
Has the event happened before?
Is it likely to happen again?
The combined result of likelihood and consequence.
Page 19 of 54
anning out the task that are not necessarily
are:
comprises 3 factors:

Using a table similar to the one shown here you can analyse how high the risk level is:
LIKELIHOOD
CONSEQUENCE
Insignificant
Minor
First Aid
Required
Moderate
Medical
Attention and
Time Off Work
Major
Long Term
Illness or
Serious Injury
Severe
Kill or Cause
Permanent
Disability or
Illness
Almost Certain M H H VH VH
Likely M M H H VH
Possible L M H H VH
Unlikely L L M M H
Rare L L M M M
1.3.3.2 RISK EVALUATION
Risk evaluation is based upon the outcomes and results of the risk analysis.
Risk evaluation involves making decisions about which risks need to be treated and the order in which they
should be treated. It should take into consideration the context of the risks in relation to:
The organisation.
The worksite.
The relevant laws.
Regulations.
Other policies, procedures and requirements.
Using a table similar to the one shown you can evaluate how soon you should act to remove or control the
hazard to achieve an acceptable level of risk:
RISK LEVEL ACTION
VERY HIGH
Act immediately:
The proposed task or process activity must not proceed. Steps must be taken to lower
the risk level to as low as reasonably practicable using the hierarchy of risk controls.
HIGH
Act today:
The proposed activity can only proceed, provided that:
1. The risk level has been reduced to as low as reasonably practicable using the
hierarchy of risk controls.
2. The risk controls must include those identified in legislation, Australian
Standards, Codes of Practice etc.
3. The risk assessment has been reviewed and approved by the Supervisor.
4. A Safe Working Procedure or Safe Work Method has been prepared.
5. The supervisor must review and document the effectiveness of the
implemented risk controls.
MEDIUM
Act this week:
The proposed task or process can proceed, provided that:
1. The risk level has been reduced to as low as reasonably practicable using the
hierarchy of risk controls.
2. The risk assessment has been reviewed and approved by the Supervisor.
3. A Safe Working Procedure or Safe Work Method has been prepared.
LOW
Act this month:
Managed by local documented routine procedures, which must include application of
the hierarchy of controls.
Any task with a risk level that is Very High is absolutely unacceptable to carry out. Steps must be taken to
reduce the risk level

Release - Feb 2015
1.3.4 RISK TREATMENT
Once risks have been identified, analysed and evaluated
treatment options need to be considered and applied.
Risk treatment involves selecting one or more options to modify a
risk and then implementing the selected option/s
Risk treatments should be recorded in a risk treatment plan.
Once an option has been implemented it
risk control.
1.3.4.1 CONSIDER HAZARD/RISK CONTROL STRATE
The Hierarchy of Hazard Control is the name given to a range of control methods used to eliminate or
control hazards and risks in the workpla
1. Elimination Completely remove the hazard.
2. Substitution
S
dangerous.
3. Isolation Isolate
4. Engineering Measures Use equipment to lower the risk level.
5. Administrative/ Safe
Work Practices
S
6. Personal Protective
Equipment
The least effective control. Use PPE while you carry out
should be selected at the planning stage of your work, and checked
/(inspected)
It is important to consider all of the options available when deciding on the best course of action. N
options are feasible or possible under some circumstances.
Version - 4.0
.4 RISK TREATMENT
Once risks have been identified, analysed and evaluated, risk
considered and applied.
Risk treatment involves selecting one or more options to modify a
risk and then implementing the selected option/s.
should be recorded in a risk treatment plan.
plemented it may be referred to as a
/RISK CONTROL STRATEGY OPTIONS
control hazards and risks in the workplace. The Hierarchy has 6 levels:
Completely remove the hazard. This is the best kind of hazard control.
Swap a dangerous work method or situation for one that is less
dangerous.
solate or restrict access to the hazard.
Use equipment to lower the risk level.
Site rules and policies attempt to control a hazard.
The least effective control. Use PPE while you carry out your work.
/(inspected) before starting the job - select and check these first.
It is important to consider all of the options available when deciding on the best course of action. N
options are feasible or possible under some circumstances.
Page 21 of 54
This is the best kind of hazard control.
for one that is less
your work. This
select and check these first.
It is important to consider all of the options available when deciding on the best course of action. Not all

Release - Feb 2015
You may need to use a number of control
level. The risk treatment plan should clearly identify the order in which to impl
treatments.
1.3.4.2 SPECIFIC CONTROL
PEDESTRIANS
If the work area is going to be shared with pedestrians, site
personnel/workers, vehicles or mobile plant, you will need to make
sure you have selected appropriate control measures
include:
Using a flag person to control traffic.
mobile plant
Setting up warning signs and barriers.
Setting up pedestrian exclusion zones.
Setting up vehicle exclusion zones.
1.3.4.3 SPECIFIC CONTROL
NIGHT OR IN DARKENED AREAS
AREAS
LIGHTING - If forklift operations are being carried out at night or in
darkened areas, adequate lighting needs to be provid
This is to ensure that the forklift operator and associated
their work safely.
WET/SLIPPERY - Operators should drive slowly and with great care, don't brake suddenly, and turn
corners slowly
1.3.4.4 IMPLEMENT THE CON
Control strategies need to be implemented before starting the task, or as soon as a hazard is identified
during operation.
Consult with other workers and management to ensure the implementation is done correctly and does not
have a negative bearing on other trades, procedures or workers.
Once the risk control measure is in place you will need to review the level of risk to determine if more
needs to be done to lower the risk level.
The acceptable level of risk is determined by an organisati
Talk to your supervisor or health and safety representative if you are not sure about whether or not the risk
has been reduced enough to carry out the work.
If you determine the risk to be at an unaccept
can be reviewed by an authorised person.
Version - 4.0
You may need to use a number of control strategies in conjunction to reduce the risk level to an acceptable
level. The risk treatment plan should clearly identify the order in which to implement the individual risk
L STRATEGIES FOR TRAFFIC &
If the work area is going to be shared with pedestrians, site
personnel/workers, vehicles or mobile plant, you will need to make
appropriate control measures. These may
Using a flag person to control traffic. - for vehicles of
Setting up warning signs and barriers.
Setting up pedestrian exclusion zones.
Setting up vehicle exclusion zones.
TROL STRATEGIES FOR OPERATING AT
AREAS & FOR WET /SLIPPERY
If forklift operations are being carried out at night or in
darkened areas, adequate lighting needs to be provided across the entire work area.
nsure that the forklift operator and associated personnel/workers can see properly and carry out
Operators should drive slowly and with great care, don't brake suddenly, and turn
ONTROL STRATEGY
bearing on other trades, procedures or workers.
needs to be done to lower the risk level.
The acceptable level of risk is determined by an organisation’s policy, goals and objectives towards safety.
has been reduced enough to carry out the work.
If you determine the risk to be at an unacceptable level, the work must not be carried out until the situation
can be reviewed by an authorised person.
Page 22 of 54
in conjunction to reduce the risk level to an acceptable
ement the individual risk
can see properly and carry out
Operators should drive slowly and with great care, don't brake suddenly, and turn
on’s policy, goals and objectives towards safety.
able level, the work must not be carried out until the situation

1.3.5 MONITORING AND REVIEWING THE RISK MANAGEMENT
PROCESS
Monitoring and review are an important part of the risk management process and should be planned for at
every stage.
Monitoring and review involves regular surveillance and checking and responsibilities concerning it should
be clearly defined.
The risk treatment plan should be complete and adhere to workplace policies and procedures. The risk
treatment plans should be discussed with appropriate personnel/workers and included within the
management process of the organisation.
Monitoring and review should:
Be used to detect any changes, including changes to risks, which may require revision of
treatments, or the emergence of new risks.
Ensure that treatments and controls are effective and efficient.
Aim to improve risk assessment through obtaining further information.
Be used to analyse events and changes that have occurred through the implementation of the
process and any lessons that may be learned from this.
It is important that monitoring and review results are recorded and reported according to organisational
policies and procedures.
1.3.6 REPORTING AND RECORD KEEPING
Make sure you record any action you’ve taken and talk
to your supervisor and OHS/WHS officer about the
control strategies in place.
Reports and records could include:
Risk Assessment Reports.
Incident Reports.
Job Safety Analysis (JSA).
Safe Work Method Statements (SWMS).
Keeping records is important as they can help ensure that any risk management activities are traceable.
Records also provide a basis for improving methods and tools in the risk management process, as well as
improving the overall process.

Release - Feb 2015
1.4 FORKLIFT TRUCKS
Selecting the correct equipment for the job is very important. Before starting the job you will need to think
about:
The ground conditions.
The work areas ventilation.
How much room you have to work in.
The type of load.
These factors will influence your choice of forklift truck and attachments.
There are a few kinds of forklift trucks that you might use. These include:
Each type of forklift has its strengths and limitations. The type of work you are do
kind of forklift to use.
DO NOT
combustion forklift in a
confined space (e.g. container,
Version - 4.0
FORKLIFT TRUCKS
The work areas ventilation.
How much room you have to work in.
ll influence your choice of forklift truck and attachments.
There are a few kinds of forklift trucks that you might use. These include:
Each type of forklift has its strengths and limitations. The type of work you are doing will determine the best
DO NOT use an internal
combustion forklift in a
confined space (e.g. container,
cool room).
Page 24 of 54
ing will determine the best

Release - Feb 2015
1.4.1 COUNTERBALANCE
Never add additional counterweights to the forklift truck without referring to
the forklift manufact
To locate the point of balance (fulcrum
Draw an imaginary line through the
of the front axle. The point that th
touches the ground is the point of
(fulcrum)
Version - 4.0
1.4.1 COUNTERBALANCED FORKLIFTS
Counterbalanced forklifts are among the most
types of forklift truck. These forklifts use the entire weight
of the forklift (behind the point of balance) as a
counterweight to the weight of the load.
By using the entire weight of the forklift, a load can be
lifted safely without tipping the forklift forwards
weight of the load is less than the entire we
forklift).
the forklift manufacturer instructions first.
fulcrum)
e middle
the line
f balance
Page 25 of 54
the most common
These forklifts use the entire weight
of the forklift (behind the point of balance) as a
By using the entire weight of the forklift, a load can be
t tipping the forklift forwards (if the
eight of the

Release - Feb 2015
1.4.2 REAR END SWING
What is it?
Rear end swing is the rapid sideways movement at the
rear of the forklift truck.
Since forklifts steer with the back wheels, the rear of
the forklift turns up to three and a half times faster than
the speed of travel.
Why is Rear End Swing dangerous?
The swinging back end of the forkli
It can collide with people and other
buildings, posts, goods, etc
Pedestrians are most at risk from Rear End Swing
How can we control this hazard?
In order to eliminate the hazard of the rear end
operators need to keep to the inside of every turn to
allow enough room for the rear of the forklift to s
As soon as forklift operators become
damage to stock, racking and machinery is caused by the rear of the forklift hitting it.
A solution to this is to reinforce the dangers of
forklift operating areas.
1.4.3 FORKLIFT STABI
Stability is an important part in the safe operation of forklifts. Some factors that affect the stability or the
forklift are:
Centre of gravity.
Stability triangle.
Load centre distance.
Forklift rated capacity.
1.4.3.1 CENTRE OF GRAVITY
The centre of gravity (CG) of any object is the single
point about which the object is balanced in all
directions. Every object has a CG.
The forklift truck has moving parts and therefore has a
CG that moves. The CG moves forward and back as
the mast is tilted forward and back. The CG moves up
and down as the upright moves up and down.
When the lift truck picks up a load, the truck and load
have a new combined CG. The stability of the lift truck is determined by the location of its CG, or if the
truck is loaded, the combined CG.
Version - 4.0
1.4.2 REAR END SWING
wing is the rapid sideways movement at the
s steer with the back wheels, the rear of
the forklift turns up to three and a half times faster than
dangerous?
ift is a hazard.
r things such as
Pedestrians are most at risk from Rear End Swing
?
the rear end swing,
operators need to keep to the inside of every turn to
allow enough room for the rear of the forklift to swing around.
become careless about watching the swing, damage starts to occur. Most
damage to stock, racking and machinery is caused by the rear of the forklift hitting it.
A solution to this is to reinforce the dangers of rear end swing and to exclude pedestrian access from
1.4.3 FORKLIFT STABILITY & CENTRE OF GRAVITY
TY
ravity (CG) of any object is the single
point about which the object is balanced in all
e forklift truck has moving parts and therefore has a
CG that moves. The CG moves forward and back as
the mast is tilted forward and back. The CG moves up
and down as the upright moves up and down.
When the lift truck picks up a load, the truck and load
ave a new combined CG. The stability of the lift truck is determined by the location of its CG, or if the
Page 26 of 54
careless about watching the swing, damage starts to occur. Most
pedestrian access from
ave a new combined CG. The stability of the lift truck is determined by the location of its CG, or if the

1.4.3.2 STABILITY TRIANGLE
In order for the forklift truck to be stable, the CG must stay within the area represented by a triangle drawn
between the drive wheels and the pivot of the steering axle. This area is called the stability triangle.
If the CG moves forward of the drive axle, the truck tends to tip forward (longitudinal). If the CG moves
outside of the stability triangle, the truck tends to turn on its side (lateral).
The centre of gravity, and therefore the stability, of the loaded truck is affected by a number of factors
including size, weight, shape, and position of the load. Other factors are the height to which the load is
elevated, the amount of forward or backward tilt, tyre pressure, and the dynamic forces created when the
truck is moving.
These dynamic forces are caused by things like acceleration, braking, operating on uneven surfaces or on
an incline, and turning.
These factors must be considered when travelling with an unloaded truck as well, because an unloaded
truck will tip over to the side more easily than a loaded truck with its load in the lowered position.

Release - Feb 2015
The centre of gravity of the forklift can move outside the stability triangle if:
The load is picked up on the tip of the forks.
The load is tilted forward.
The load is tilted too far back when raised.
The load is wide.
Forklift movement causes the centre of gravity to shift
1.4.3.3 LOAD CENTRE DISTANCE
The Load Centre Distance is: The
attachment) to the centre gravity of the load
As load centre distance
increases, the forklift’s capacity
decreases. The use of special
attachments instead of forks will
also decrease the regular capacity
of the forklift truck.
If the load is not hard up against
the heel of the fork arms, the forklift
truck’s capacity is reduced and
stability may also be affected.
Forklift stability is also be affected
by the height of the load - the comb
14.3.4)
Version - 4.0
y of the forklift can move outside the stability triangle if:
cked up on the tip of the forks.
tilted too far back when raised.
Forklift movement causes the centre of gravity to shift.
TANCE
he distance from the front face of the forks (or the load face of an
attachment) to the centre gravity of the load.
increases, the forklift’s capacity
also decrease the regular capacity
the forklift
bined rating is known as the "Rated Capacity" (more on th
Page 28 of 54
of the forks (or the load face of an
his below -

Release - Feb 2015
The forklift trucks shown here are rated
Version - 4.0
The forklift trucks shown here are rated at 4200kg at 600mm load centre:
Of these forklifts, only forklift B has a load that
is within the rated capacity of the forklift:
The load centre distance for forklift B is
500mm (within the 600mm limit for 4200kg).
Forklifts A and C have a load centre distance
of 700mm and 650mm (beyond the 600mm
limit).
Page 29 of 54
Of these forklifts, only forklift B has a load that
is within the rated capacity of the forklift:
tance for forklift B is
500mm (within the 600mm limit for 4200kg).
Forklifts A and C have a load centre distance
of 700mm and 650mm (beyond the 600mm

Release - Feb 2015
1.4.3.4 FORKLIFT RATED CAPACITY
The rated capacity is the maximum load the forklift truck can
distance and height.
Shown here is an example of a forklift load chart:
Reading this data plate
• It's a Yale Forklift (make),model YL2.5A
• The maximum height that the forklift can lift is 3600mm
• It has Solid Tyres
• The maximum working load limit (WLL
is 2500kg.
• When the Load Centre increased by 100mm
• When the Load Centre increased by 300mm (to 900mm), the SWL reduced by 600
• When we put on a pair of slippers, this increased the fork length to 3000mm. If the load centre is
at 1500mm with these slippers on then the SWL is only 1500kg.
• When we tilt the forks forward 5°, then with a Load Centre of 600mm the SWL is reduced to
2050kg.
Challenge Questions to think about...
? What does it mean when we say increase the Load Centre? Can you give an example?
? Why does the SWL reduce when we tilt the mast forward?
? Why would we need to know the maximum height lift?
? Does the SWL change as we lift the load higher
question, clue - this is on the data plate!
? What is meant by the term "Rated Capacity"?
? Does this data plate show the ca
Version - 4.0
CAPACITY
The rated capacity is the maximum load the forklift truck can handle at a certain load centre
Shown here is an example of a forklift load chart:
It's a Yale Forklift (make),model YL2.5A
The maximum height that the forklift can lift is 3600mm
aximum working load limit (WLL/SWL) of the forklift when using forks with the mast
When the Load Centre increased by 100mm (to 700mm), the SWL reduced by 200kg!
When the Load Centre increased by 300mm (to 900mm), the SWL reduced by 600kg!
When we put on a pair of slippers, this increased the fork length to 3000mm. If the load centre is
at 1500mm with these slippers on then the SWL is only 1500kg.
When we tilt the forks forward 5°, then with a Load Centre of 600mm the SWL is reduced to
Questions to think about...
What does it mean when we say increase the Load Centre? Can you give an example?
Why does the SWL reduce when we tilt the mast forward?
Why would we need to know the maximum height lift?
change as we lift the load higher and higher of the ground? (This is a more advanced
this is on the data plate!)
What is meant by the term "Rated Capacity"?
apacity of the forklift for different heights?
Page 30 of 54
at a certain load centre
with the mast Vertical
the SWL reduced by 200kg!
kg!
When we put on a pair of slippers, this increased the fork length to 3000mm. If the load centre is
When we tilt the forks forward 5°, then with a Load Centre of 600mm the SWL is reduced to
? (This is a more advanced

1.4.4 FORKLIFT ATTACHMENTS
There are a number of attachments available for forklifts. These include:
Rotating Attachment Drum Clamp Carpet Spike Jib Attachment
Blade Attachment Work Platform/Basket Fork Extensions Bale Clamp
Before using any attachment on the forklift, make sure you check the manufacturer’s specifications and
load chart to see that the attachment can be used safely. Also make sure the attachment is secured
properly before trying to lift a load with it.
If you are not familiar with the attachment, read the manufacturer’s instructions and ask somebody to show
you how to use it.

1.5 GETTING FROM A TO B
When determining the path of movement for the forklift (and the load you are carrying) you should
check the path that you’re intending to take to make sure that you have identified all hazards in the
path of movement and implemented effective control measures.
Check that the forklift will fit and that there are no obstacles in the way. Also check for any other
equipment or people working in the area.
1.6 COMMUNICATIONS
As a forklift driver you need to be able to communicate
with those around you while you work, and you need to be
able to understand the instructions to use the forklift safely.
These can include:
Manufacturer’s guidelines (instructions,
specifications, checklists).
Industry operating procedures.
Workplace procedures (work instructions,
operating procedures, checklists).
Workplace communications (that is methods of
communication) may take the form of:
Verbal and non-verbal language.
Written instructions.
Signage.
Hand signals.
Listening.
Questioning to confirm understanding, and appropriate
worksite protocol.
WWW.SAFEWORKSIGNS.COM
FORKLIFT
ACCESS

MODULE 2 BASIS
This module is based on the unit of competency TLILIC2001A Licence To Operate A Forklift Truck:
Element 2 – Carry out routine
checks.
Element 3 – Shift load.
Element 4 – Shut down.
2.1. Forklift is visually checked for any damage or defects.
2.2. All signage and labels are visible and legible according to the appropriate standard.
2.3. All controls are located and identified.
2.4. Pre-start operational checks are carried out according to procedures.
2.5. Forklift is started according to procedures and checked for any abnormal noise.
2.6. Post start operational checks are carried out according to procedures.
2.7. All forklift functions and safety devices are tested to their maximum according to
procedures.
2.8. Defects and damage are reported and recorded according to procedures, and
appropriate action is taken.
3.1. The weight of load is assessed to ensure compliance with forklift truck data plate
specifications.
3.2. Appropriate hazard prevention/control measures are implemented and
communicated with personnel in the work area.
3.3. Forklift is operated at a safe speed and according to procedures.
3.4 Loads are moved and placed to ensure stability of material and avoidance of
hazards.
3.5 Load movement is monitored constantly ensuring safety to personnel and load, and
structural stability.
3.6 Unplanned and/or unsafe situations are responded to in line with procedures.
4.1 Forklift truck is parked to avoid hazards.
4.2 Forklift is shut down according to procedures.
4.3 Routine post-operational forklift checks are carried out according to procedures.
4.4 Forklift is secured to prevent unauthorised access/use.
4.5 All defects and damage are reported and recorded according to procedures, and
appropriate action is taken.

Release - Feb 2015
2.1 PRE-START CHECKS
Before you use the forklift you MUST
Always use a forklift inspection checklist when doing routi
check everything properly and so that you can report any problems that you find.
There are a number of areas that may need to be filled out
Company/machine/operator details.
Forklift parts/operational check
Fault report.
Maintenance report.
Return to service signoff.
An example of a daily inspection checklist can be found in Appendix 2A.
2.1.1 VISUAL CHECKS
Walk around the forklift and check to see
Ensure that you check:
The condition of the forks/tynes or attachment.
Under the forklift for oil leaks.
The condition of the mast and of the hydra
The condition and security of the load backrest (load guard). This
is important as the load guard stops th
mast and also stops the load from falling on the operator.
For visual evidence of structural weaknesses (including paint
separation or stressed welds).
VISUAL CHECKS OF THE FORKLIFT FOR DAMAGES AND OR DEFECTS MUST TAKE PLACE
BEFORE USE
2.1.2 DECALS AND SIG
Check that the forklift has the appropriate signage and labels. This
includes the data plate. Make sure you can read it clearly and that it is
firmly attached to the forklift.
DO NOT USE A FORKLIFT WITHOUT A DATA/LOAD PL
If the forklift does not have a data/load plate, or you cannot read it,
you must tag out the forklift and report the defect to an authorised
person.
Version - 4.0
START CHECKS
MUST check that it is safe to use.
Always use a forklift inspection checklist when doing routine checks on the forklift truck to make sure you
check everything properly and so that you can report any problems that you find.
There are a number of areas that may need to be filled out, including:
Company/machine/operator details.
Forklift parts/operational checklist.
An example of a daily inspection checklist can be found in Appendix 2A.
2.1.1 VISUAL CHECKS
Walk around the forklift and check to see if there is any visible damage.
The condition of the forks/tynes or attachment.
der the forklift for oil leaks.
he condition of the mast and of the hydraulic rams and hoses.
The condition and security of the load backrest (load guard). This
is important as the load guard stops the load from fouling the
mast and also stops the load from falling on the operator.
or visual evidence of structural weaknesses (including paint
separation or stressed welds).
2.1.2 DECALS AND SIGNAGE
Check that the forklift has the appropriate signage and labels. This
includes the data plate. Make sure you can read it clearly and that it is
DO NOT USE A FORKLIFT WITHOUT A DATA/LOAD PLATE!
If the forklift does not have a data/load plate, or you cannot read it,
you must tag out the forklift and report the defect to an authorised
Page 34 of 54
to make sure you

2.1.3 FLUID CHECKS
Check the following fluid levels:
Hydraulic oil.
Engine oil.
Transmission oil.
Brake fluid.
Cooling water.
Fuel.
Battery electrolyte level in each cell.
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 ignite.
2.1.4 FORKLIFT CONTROLS
Check that you can find and identify the forklift controls. Check the operator’s manual if you are unsure.

2.1.5 SAFETY DEVICES
Check that the forklift has the appropriate safety devices fitted.
These can include:
Lights:
Flashing amber light.
Head lights.
Brake lights.
Reverse lights.
Guards:
Roll-Over Protection (ROP).
Falling Object Protection (FOP).
Load backrest.
Foot guard.
2.1.6 TYRES
Air Filled Tyres - Check that the pressure of
air-filled tyres is correct. This will help to
maintain stability for the forklift.
Solid Rubber Tyres - If the forklift is fitted with
solid rubber tyres, check that there are no
large pieces of rubber missing, make sure
that any wear is even between the tyres and
make sure that the wear has not reached the
wear limit line.
2.1.7 CHECK ATTACHMENTS
Make sure any attachments (including the forks) are
securely fixed.
Check that modifications are approved and that
attachments are fitted to the manufacturer's
specifications (e.g. as per forklift or attachment data
plate).
Do not use any forklift that has been modified beyond
the manufacturer’s recommendations.

Release - Feb 2015
2.1.8 LOGBOOK
Check for any previous faults with the forklift. Make sure these faults have been fixed before using the
forklift.
2.2 START THE FO
Once you have visually checked the forklift, start it as per the manufacturer’s guidelines.
ALWAYS WEAR YOUR SEATBELT WHENEVER YOU OPERATE THE FORKLIFT.
STOP YOU FALLING OUT IF THE FORKLIFT TIPS OVER AND PREVENTS YOU FROM
BEING PROPELLED INTO THE FORKLIFT STRUCTURE OR OUT OF THE FORKLIFT IN THE
Version - 4.0
HE FORKLIFT
Once you have visually checked the forklift, start it as per the manufacturer’s guidelines.
ALWAYS WEAR YOUR SEATBELT WHENEVER YOU OPERATE THE FORKLIFT.
IF THE FORKLIFT TIPS OVER AND PREVENTS YOU FROM
ED INTO THE FORKLIFT STRUCTURE OR OUT OF THE FORKLIFT IN THE
EVENT OF A COLLISION.
Page 37 of 54
ALWAYS WEAR YOUR SEATBELT WHENEVER YOU OPERATE THE FORKLIFT. IT WILL
IF THE FORKLIFT TIPS OVER AND PREVENTS YOU FROM
ED INTO THE FORKLIFT STRUCTURE OR OUT OF THE FORKLIFT IN THE

2.3 OPERATIONAL CHECKS
Operational checks are done once the forklift has been started. Always start the forklift according to the
manufacturer’s specifications. Listen for any abnormal noises during start-up as these may indicate a fault.
Operational checks include:
Hazard warning systems (for example lights and horns) and gauges are functional.
Attachment movements and control functions are smooth and comply with operating
requirements.
Steering, transmission and brake functions comply with operating requirements.
CHECK ALL MOVEMENTS AND FUNCTIONS TO THEIR FULL EXTENT!
2.4 REPORT A FAULT
If you find anything wrong with the forklift during your checks you
must:
1. Immediately stop the forklift and remove the keys.
2. Tag the forklift as out of service to stop anybody using it.
3. Record the problem in the logbook or on the inspection
checklist. Give as much detail as possible.
4. Report the fault to your supervisor or other authorised person.
5. DO NOT use the forklift until repairs are carried out.
2.5 SHIFT A LOAD
The main function of driving a forklift is to move items from one place to another. Ensure you are always
careful when using forklifts.

2.5.1 CHECK THE LOAD
Before you try to lift something, check that the forklift
will be able to shift it safely.
Is the load within the safe working load of the forklift?
Check the load plate to make sure.
You can check (determine) the weight of a load a number of ways:
Weigh the load.
Check for markings on the load.
Calculate the weight of the load.
Check the weighbridge certificate.
When using an attachment, always make sure you have factored in the weight of the attachment with your
calculations.
Check the shape of the load. Make sure the heaviest part of the load is against the mast.
If the load is unstable or poorly stacked, restack it before you try to move it.
You may need to secure the load using shrink wrap or
strapping/banding. Check the pallet that the load is sitting on. If it is too
damaged to lift, re-stack the load onto a new pallet.
2.5.1.1 CALCULATING LOAD WEIGHT
If you find you need to calculate the weight of a load, make
sure you consider:
How many items there are.
What each item weighs.
The weight of the pallet the items are placed on.

Release - Feb 2015
For example:
You need to move a load of cartons that have been stacked on a
pallet.
There are 6 cartons per layer and 4 layers on the pallet.
Each carton weighs 33kg.
The pallet is standard size and we
To work out how much this load weighs you need to add the total
weight of all of the cartons to the weight of the pallet:
33kg x 6 x 4 = 792kg
792kg + 15kg = 807kg
2.5.2 APPLY HAZARD CONTROL
Once you are ready to use the forklift m
measures.
Talk to the other workers in the area to
have put in place.
Setting up barricades and traffic control to keep the area clear.
Placing pedestrian control
Moving any obstructions out of the way.
Wearing personal protective equipment such as hi
Setting up adequate lighting in the work area.
Version - 4.0
You need to move a load of cartons that have been stacked on a
There are 6 cartons per layer and 4 layers on the pallet.
Each carton weighs 33kg.
The pallet is standard size and weighs 15kg.
To work out how much this load weighs you need to add the total
weight of all of the cartons to the weight of the pallet:
APPLY HAZARD CONTROL MEASURES
Once you are ready to use the forklift make sure you have implemented the required hazard control
Talk to the other workers in the area to ensure they are aware of the work and the control measures you
Control measures could include:
Disconnecting power when working near
electric/power lines or overhead services.
Putting safety tags on electrical switches/isolators to
stop somebody from turning the power back on while you are
working on or near electric/power lines.
Insulating electric/power lines.
Using a safety observer (also known as a spotter)
inside the exclusion zone to make sure you don’t get too close
to electric/power lines.
Setting up barricades and traffic control to keep the area clear.
edestrian controls (barricades, signs, etc.) to limit the number of people in the area.
Moving any obstructions out of the way.
Wearing personal protective equipment such as high-visibility clothing and non-slip work boots.
Setting up adequate lighting in the work area.
Page 40 of 54
quired hazard control
control measures you
orking near
Putting safety tags on electrical switches/isolators to
stop somebody from turning the power back on while you are
ty observer (also known as a spotter)
exclusion zone to make sure you don’t get too close
the number of people in the area.
slip work boots.

Release - Feb 2015
2.5.2.1 FORKLIFTS & PEDESTRIANS
• NEVER lift loads over people’s heads as there is a risk of injury or death if the load
or part of the load falls from the forklift truck.
• NEVER let people ride or be lifted on the forks or a pallet!
• Passengers may only be carried on the fo
equipped to carry more than one person
Version - 4.0
PEDESTRIANS
At any time forklifts are being used in an area
pedestrian access, there should always be signs,
barriers and designated pedestrian walkways.
areas a flagman must be used to direct traffic and warn
people nearby that there is a forklift being
forklifts should be fitted with safety flashing amber
lights and horns.
Barriers with appropriate safety signs, or a traffic
controller, should always be provided when the forklift
is being operated over a roadway, footpath or public
access area.
NEVER lift loads over people’s heads as there is a risk of injury or death if the load
or part of the load falls from the forklift truck.
NEVER let people ride or be lifted on the forks or a pallet!
Passengers may only be carried on the forklift if it has been designed and
equipped to carry more than one person (has a second seat)
Page 41 of 54
ny time forklifts are being used in an area with
there should always be signs,
barriers and designated pedestrian walkways. In public
areas a flagman must be used to direct traffic and warn
people nearby that there is a forklift being used. All
forklifts should be fitted with safety flashing amber
Barriers with appropriate safety signs, or a traffic
should always be provided when the forklift
footpath or public
NEVER lift loads over people’s heads as there is a risk of injury or death if the load
NEVER let people ride or be lifted on the forks or a pallet!
rklift if it has been designed and
(has a second seat).

Release - Feb 2015
2.5.3 PICKING UP A L
When picking up a load with the forklift ensure that you:
1. Approach the load from front on.
2. Insert the forks all the way into the pa
3. Raise the forks and tilt the load back slightly for
stability.
4. Position the load at axle height
operating surface as practicable
• If the pallet appears to be unsafely loaded then you
must repack or reload or re strap
attempting to lift.
• DO NOT carry the load on only one fork arm. If you
do the stability of the forklift may be affected, and you may cause damage to the forklift.
2.5.3.1 USING TWO FORKLIFTS
Some situations may call for two forklifts to be used to lift a load. It may be because of the siz
length of the load.
When using two forklifts for the same load:
Use only experienced operators.
Have a third person who is responsible and experienced control the ope
Ensure that the load applied to each forklift truck is no more than 75% of its rated capacity, taking
account of stability, load-centre distance and any other factors which may affect the forklift truck’s
safe working load.
The distance travelled is limited to clearing the load carrier.
Version - 4.0
2.5.3 PICKING UP A LOAD
When picking up a load with the forklift ensure that you:
Approach the load from front on.
Insert the forks all the way into the pallet.
Raise the forks and tilt the load back slightly for
Position the load at axle height or as low to the
operating surface as practicable for safe travel.
If the pallet appears to be unsafely loaded then you
repack or reload or re strap the load before
DO NOT carry the load on only one fork arm. If you
USING TWO FORKLIFTS TO PICK UP A LOAD
or two forklifts to be used to lift a load. It may be because of the siz
When using two forklifts for the same load:
Use only experienced operators.
Have a third person who is responsible and experienced control the operation.
centre distance and any other factors which may affect the forklift truck’s
s limited to clearing the load carrier.
Page 42 of 54
or two forklifts to be used to lift a load. It may be because of the size, shape or
centre distance and any other factors which may affect the forklift truck’s

Release - Feb 2015
2.5.4 TRAVELLING WIT
Keep the load at about axle height
mast backwards for stability.
Do not travel or turn the forklift with the load ra
the forklift while travelling, braking or turning. This creates a hazard that could result in the forklift tipping
over, rolling over or losing the load.
It is unsafe to carry a load with only one fork arm because:
• The load is unstable and will affect the stability of the forklift truck
• May cause damage to the fork
Maintain a safe operating speed based on:
The size and type of the load.
Worksite policies, procedures and signage.
Weather conditions.
Ground/floor conditions.
Personnel/workers and other equipment in the area.
Forklift technical limitations and capabilities.
You need to constantly monitor the load movement to ensure that personnel/workers in the area are safe,
and that the load and forklift are stable.
Version - 4.0
2.5.4 TRAVELLING WITH A LOAD
Keep the load at about axle height or as close to the ground as possible while travelling
Do not travel or turn the forklift with the load raised up in the air. The load height can affect the stability of
over, rolling over or losing the load.
only one fork arm because:
The load is unstable and will affect the stability of the forklift truck
May cause damage to the fork
If the load blocks your view, travel in reverse. Get somebody to direct
you and keep an eye out for other people or equipment in the area.
Make sure the warning devices are working correctly and a
check your mirrors and look over both shoulders before reversing in
the forklift.
Be aware of rear end swing. This can be very dangerous for people
nearby.
operating speed based on:
The size and type of the load.
Worksite policies, procedures and signage.
Personnel/workers and other equipment in the area.
Forklift technical limitations and capabilities.
d to constantly monitor the load movement to ensure that personnel/workers in the area are safe,
and that the load and forklift are stable.
Page 43 of 54
while travelling and tilt the
The load height can affect the stability of
Get somebody to direct
nt in the area.
Make sure the warning devices are working correctly and always
look over both shoulders before reversing in
Be aware of rear end swing. This can be very dangerous for people
d to constantly monitor the load movement to ensure that personnel/workers in the area are safe,
FORKLIFT
SPEED LIMIT
WWW.SAFEWORKSIGNS.COM

License to operate a forklift truck 2

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