Electric Pallet/Stacker Truck

1Copyright © 2016 RTITB. All rights reservedElectric Pallet/Stacker Truck - LTG4 - V3.1119

Electric Pallet/Stacker TruckLTG4 (ABA Code A1, A2, A3, A4, A5, A6, A7)

Instructor Guide

Contents

INTRODUCTION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Glossary of Common Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

How to Use this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

COURSE PLAN

Course Content from Session Library Arranged Here. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SESSION LIBRARY

Course Information: Novice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Course Syllabus: Novice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Course Information: Existing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Course Syllabus: Existing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Course Information: Refresher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Course Syllabus: Refresher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Course Information: Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Course Syllabus: Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

S1(A&B) Course Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

S2(A&B) Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

S3(A&B) Introduction to the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 S4A Preparing, Moving, Stopping and Parking the Truck (Pedestrian Operated) . . . . . . . . . . 51

S4B Preparing, Moving, Stopping and Parking the Truck (Rider Operated) . . . . . . . . . . . . . . . . . . 57

S5A Basic Steering (Pedestrian Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

S5B Basic Steering (Rider Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

S6(A&B) Progressive Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

S7(A&B) Operation of Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

S8(A&B) Battery Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

S9(A&B) Pre-use Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

S10(A&B) Load Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

S11(A&B) Truck and Load Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

S12(A&B) Pallet Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

S13(A&B) Handling Different Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

2Copyright © 2016 RTITB. All rights reserved

Electric Pallet/Stacker Truck - LTG4 - V3.1119

S14(A&B) Pallet Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

S15A Chicane (Pedestrian Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

S15B Chicane (Rider Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

S16A Turning in a Narrow Aisle (Pedestrian Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

S16B Turning in a Narrow Aisle (Rider Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

S17(A&B) Industrial Racking (Ground/Low-level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

S18(A&B) Industrial Racking (Medium-level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

S19(A&B) Industrial Racking (High-level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

S20(A&B) Negotiating Inclines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

S21(A&B) Vehicle Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 S22(A&B) Course Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

ES1A Turning and Depositing in Industrial Racking

(Low-level – Pedestrian Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

ES1B Turning and Depositing in Industrial Racking

(Low-level – Rider Operated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

RS1(A&B) Theory Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

RS2(A&B) Introduction to the Truck and Principles of Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

RS3(A&B) Pre-use Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

RS4(A&B) Assessment of Operator Ability and Remedial Tuition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

CS1A Preparing, Moving, Stopping and Parking the Truck (Pedestrian Operated) . . . . . . . . 189

CS1B Preparing, Moving, Stopping and Parking the Truck (Rider Operated) . . . . . . . . . . . . . . . . 199

CS2(A&B) Pallet Handling and Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

CS3(A&B) Turning and Depositing in Industrial Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

OS1 Using Pallet Trucks on a Dock Leveller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

OS2 Using Pallet Trucks on Tail Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Copyright © 2016 RTITB. All rights reservedElectric Pallet/Stacker Truck - LTG4 - V3.1119 3

TERMS & CONDITIONS OF USEAll rights in this publication are reserved to RTITB. Copyright © 2016. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including copying, recording or information storage and retrieval system, without prior permission from RTITB.

Whilst this course material endeavours to reflect all applicable law (as of November 2019), it clearly cannot make provision for all eventualities. Whilst every effort has been made to ensure the accuracy and sufficiency of the contents, RTITB cannot accept responsibility for omissions or incorrect interpretation of the legislation, the user must refer to the appropriate Parliamentary Acts and Statutory Instruments for clarification.

RTITB will maintain and update this course content. We will provide RTITB accredited organisations with replacement, updated pages, where possible. Major revisions will result in a complete re-issue, which users will be required to purchase.

BASIC OPERATING SKILLS TEST (ASSESSMENT) Introduction to the Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Test Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Pre-use Inspection of the Electric Pallet/Stacker Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Electric Pallet/Stacker Truck - Explanation of Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Practical Test of Basic Operating Skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Associated Knowledge Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Operator's Pre-use Inspection Sheet - Candidate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Operator's Pre-use Inspection Sheet - Instructor/Examiner . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Practical Test of Basic Operating Skills - Test Marking Sheet . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Associated Knowledge Test Marking Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Associated Knowledge Question Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Associated Knowledge Mock Question Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

APPENDICES 1 Confirmation Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

2 HSA & HSENI Equivalent Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

3 Course Delivery Feedback Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

4 Record of Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

5 Course Resource List - Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

6 Course Resource List - Medium/High Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

7 What to Expect on a Low level Pallet Truck Operator Course . . . . . . . . . . . . . . . . . . . . . . . On USB

8 What to Expect on a Medium/High level Pallet Truck Operator Course . . . . . . . . . On USB

9 Associated Knowledge - A Guide to Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

10 Course Selection Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

11 How to Use This Guide Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On USB

Contents




IntroductionThis course has been specifically designed to allow appropriately qualified instructors to set up and conduct RTITB operator training for:

• Pedestrian/Rider Pallet Truck

• Pedestrian/Rider Pallet Stacker Truck

• Pedestrian Straddle Truck

• Pedestrian Counterbalance Lift Truck

• Pedestrian Reach Truck.

This course can only be conducted by qualified and registered instructors who have successfully attended and passed the appropriate RTITB instructor course and hold an operator’s qualification for the truck intended to be used for training, and can prove continued competence.

For the sake of realism, this training course is based on commonly used trucks; other models and variants are available, therefore specification and operational differences will need to be covered in Specific Job training – more on this below. The training guidance in this document is not intended to be prescriptive; users are at liberty to amend details wherever the information provided is not applicable to their own circumstances. However, there should be no need for significant deviation from the programmes and the associated information as laid out. Instructors should note that the content is not exhaustive, and they may wish to expand sections according to local requirements.

A Basic Operating Skills Test is included with this guide. When conducted by suitably qualified staff (as described above), this test will confirm the level of ability of course members on completion of their Basic training. The same test will be used for all course members, regardless of course duration concessions based on experience or prior training.

Important Note – Specific Job and Familiarisation TrainingUpon successful completion of Basic operator training, candidates should be awarded a Certificate of Basic Operating Skills. This is recognition of the individual having successfully attended Basic training. It does not mean that they are competent, since they will have been trained only upon the truck specific to that course at that point in time.

As there are many varied and different types of equipment and attachments, it is essential that should an operator be required to operate other similar trucks or to conduct specific tasks of a nature not encompassed within this Basic operator training, then further full and comprehensive Specific Job training must be provided and documented, including the operator’s performance during training.



This course deals solely with pallet/stacker trucks listed at the beginning of this introduction. The term “truck” is widely used throughout industry with reference to this type of equipment and encompasses a range of truck types. In the interest of clarity, the guidance in this document does not cover training on trucks that are manually operated.

The scope of this training course material is primarily concerned with the operation of electric pallet/stacker trucks in their basic format – for example, basic manoeuvring, fundamental principles of stability, stacking, etc. The course duration is formulated around this basic use. Naturally, a pallet/stacker truck’s primary function is to pick up, transport and deposit/stack palletised loads from one place to another; however, it would be impossible for this Basic course to encompass and document all possible pallet/stacker trucks and load configurations. To that end, the complexity of the task, equipment and its load can only be established by the employer/training organisation, highlighting the very real necessity for Specific Job training, the nature of which will vary significantly from situation to situation.

Familiarisation training must follow Specific Job training. This is training that takes place “on the job” and should continue to evolve the operator’s appreciation and understanding of equipment operation, the machine itself, the environment in which they are working, and the types of load being transported.

Only following satisfactory completion of Basic, Specific Job and Familiarisation training should an employee be issued with an authorisation, in writing, to operate the type of truck upon which all three stages of training have been completed.

You can find out more about training requirements for material handling equipment in L117: Rider-operated Lift Trucks – Operator Training and Safe Use from the Health and Safety Executive, RTITB’s Training Recommendations for Workplace Transport, or INDG462: Lift Truck Training - Advice for Employers.

Should operators be required to operate significantly different types of truck, they must receive Conversion training before authorisation to operate is given.


ConclusionThe Health and Safety Executive’s Approved Code of Practice (L117) makes clear that all three stages of training are essential to ensure that machine operator training is thorough and comprehensive. RTITB believes that these standards are the correct ones to adopt and that they are consistent with those already in force throughout its accreditation system.

It is important that course instructors bring these requirements to the notice of employers of pallet/stacker truck operators.



Glossary of Common TermsThroughout this guide you will come across common industry terms with which you may be familiar. Following is a list of these terms, along with brief explanations and common alternatives where applicable.

TERM TERM DESCRIPTION ALTERNATIVE TERMS

Adjustable Pallet Racking (APR)

Describes the most commonly used racking system within warehouses. It is designed to carry palletised loads at multiple levels in order to increase storage density, even for non-stackable loads.

Typically this type of racking is accessed along aisles that run adjacent to the pallet locations.

Racking, pallet racking, storage, racks, storage racking.

Collision Safety Switch

A pressure sensitive safety switch/button fixed to the tiller arm that de-activates the truck or powers it in the opposite direction should it make contact with the operator

Belly button switchRepel pad

Data Plate Information plate attached to the truck which includes important details such as: manufacturer, identifying serial number, gross weight, battery weight, battery voltage, etc.

This information may be combined with other truck-related information contained on the rated capacity plate.

Capacity plate, rating plate, rated capacity data plate, manufacturer’s information plate.

Dock Leveller A dock leveller is a height-adjustable platform used to ensure smooth transition between a loading dock and goods vehicle. It is used to bridge the difference in height and distance between the warehouse floor and vehicle in the most efficient way.

Ramp

Forks Leading Describes the direction of travel when the forks are forward-most, in front of the operator.

May be referred to as “forwards” or “reverse” depending on the individual’s viewpoint. However, throughout the guide these terms have been excluded.



Forks Trailing Describes the direction of travel when the forks are rearmost, behind the operator.


Free-standing Stack

A load stack constructed in an open space which is not adjacent to any other loads.

Stack, pallet stack.

Ground-level A load position for truck types which are able to pick up and deposit loads but are unable to stack or de-stack onto/from receiving loads or beams.

Trucks that operate in this fashion are referred to as ground-level trucks.

Floor-level.

High-level A stacking position for truck types with lifting height capability of 3 metres (9 feet 9 inches) and above.

Trucks that operate in this fashion are referred to as high-level trucks.

For testing purposes the ABA classes 'high level' as testing at a lifting height of 3000mm and above.

Load Leading Describes the direction of travel when the load is forward-most, in front of the operator.


Load Trailing Describes the direction of travel when the load is rearmost, behind the operator.





Low-level A stacking position for truck types with limited lifting height capability below medium-level; relating to trucks with limited height capability.

Often this term is also used generically to describe load positions at, or about, ground-level; however, in the context of this course, low-level refers specifically to stacking position off the ground.

Trucks that operate in this fashion are referred to as low-level trucks.

For testing purposes the ABA classes ‘low level’ as testing up to a maximum lift height of 300mm.

Medium-level A stacking position for truck types with limited lifting height capability which can only raise their forks to a level corresponding with the operator’s eyes, when in the normal operating position.

For testing purposes the ABA classes ‘medium level’ as testing between a lifting height of 301mm and 2999mm.

Formerly know as Eye-level

Narrow Edge Refers to both parallel shorter faces of a pallet. Short side, short edge, small edge.

Rated Capacity Plate

Information plate attached to the truck which details the maximum carrying capacity, load centre and maximum lift height (where applicable).

This information may be combined with other truck-related information contained on the data plate.

Capacity plate, rating plate, rated capacity data plate, manufacturer’s information plate.



Stacker Refers to trucks with the capability to stack a load above ground-level.

SWL Safe Working Load is the weight that a piece of lifting equipment can safely lift, or in the context of racking, support.

Normal Working Load (NWL).

Tail Lift A tail lift is a hydraulically operated foldaway platform installed on the rear of a work truck, van, or lorry, and is designed to facilitate the material handling of goods from ground level to the level of the vehicle bed.

Tail Gate.

Truck A generic term used throughout this guide to refer to all the equipment covered in this guide including:

• Pedestrian/Rider Pallet Truck

• Pedestrian Pallet Stacker Truck

• Pedestrian Straddle Truck

• Pedestrian Counterbalance Lift Truck

• Pedestrian Reach Truck.

UDL Uniformly Distributed Load describes the safe weight distribution over a beam’s length or across the surface of a pallet.



How to use this GuideThroughout this instructor guide you will find everything you need to plan and deliver truck operator training, including:

• Session guidance for Novice, Existing, Refresher and Conversion courses

• Guidance on setting up and running end of course tests

• Multimedia visuals that can be used to supplement your delivery.

The content in this guide is divided into 4 tabbed sections:

• Introduction – Where you are now. This is where you’ll find general information on this guide, including the introduction to the guide itself and this ‘how to’ chapter.

• Course Plan – The course plan is empty for now, but this is where you will insert and organise any session guides you take from the Session Library.

• Session Library – This is where you will find all of the lessons that can be picked and arranged in your course plan. For more on picking course sessions, see ‘Building Your Course’ later in this section.

• Assessment – You’ll find everything you need to prepare and run your end of course tests in this section. From information on conducting each stage of the assessment and marking criteria through to diagrams and score sheets, it’s all under the Assessment tab.

Throughout this guide you’ll see references to supporting documents, forms and appendices – you’ll find all relevant supplementary documents on the interface supplied with this guide.


Building Your CourseThe first thing you need to know before heading to the Session Library is exactly what type of course you are aiming to run (Novice, Existing, Refresher or Conversion, truck configuration, truck height, etc.). This is important because the Session Library contains the complete A-Z of operator training. In order to get the most out of the guide you need to make sure you select the sessions that are relevant to your candidate group. You can find out which sessions you need for your chosen path by checking the Course Information found at the beginning of the Session Library. Once you know which sessions you need, you can pull them out of the library and arrange them in the Course Plan.

As any instructor will know, different candidates have different abilities and experience – a Novice candidate will need more in-depth training than an Existing operator, and a Refresher candidate will potentially require a degree of assessment and remedial tuition. Additionally, depending on ability and experience, session duration requirements may differ from group to group. This course guide has been written and designed to take all of these considerations into account. Use the Course Information to help you pick the sessions you need to deliver and then choose those sessions from the Library.

Course Information

Once you know what level of candidate you will be instructing and the operating height of the truck, take a look at the Course Information for that level and height. You’ll find this in the Session Library. Course Information contains all the important details about your course, including candidate specification, total course duration (more on duration later), the course objective and the block syllabus.

The block syllabus is an outline of your course that shows which sessions must be presented for that particular candidate level and operating height – as you might imagine, the list of required sessions for a Novice course will be longer than that of a Refresher course. The block syllabus is presented in a suggested running order; you may wish to amend the running order to better suit your group, but you should ensure that the sessions are delivered in a logical sequence.

You will notice that some syllabuses contain sessions that are divided into “A” and “B” variants; this is to accommodate operational differences between pedestrian and rider-operated trucks. For pedestrian courses select “A”, for rider courses select “B”. For trucks with a fold-away platform, please use "A" pedestrian courses.



A Note on DurationEach course has a minimum total duration which must be adhered to for the purposes of providing adequate Basic training. However, you will notice that individual sessions do not run to prescribed minimum times. Instead, each session carries its own "suggested" minimum duration. It is at the discretion of the instructor to decide how long a session should run, depending on the experience and abilities of the members of the training group. This means that you are free to focus training time on the areas that need more attention.It is important to note that even if a course runs to its guided minimum duration, this is not a guarantee that the candidates will be successful on their end of course test.

Session Information

The session guidance found in the Session Library is fully detachable, allowing you to remove each session from the library and arrange them in the Course Plan.

At the start of each session you will find useful information about the course objective, resources, suggested duration and a matrix that specifies which course paths the session relates to – some sessions will fit into more paths than others. Remember, session duration is advisory and delivery of the information should be in the context of the group you are addressing, taking into account their relative experience and abilities.

Accompanying MediaA slide deck of visuals to support delivery of your course can be found on the USB drive attached to the inside-front cover of the guide – these can be navigated around and used as you require.Use the menu built into the slide deck to navigate to visuals for different sections of the course. Click on the RTITB logo found on each slide, at any time, or the “RETURN TO MENU” button at the end of every session to return to the session menu. To continue to the next session simply click on the “GO TO NEXT SECTION” or alternatively, return to the session menu and click on the required session.


Weblink/MultimediaThis icon points to additional resources, either online or included with the content supplied with this guide.

WarningThese boxes contain critical information or warnings.

Further InformationThe information in these boxes expands on the topic being discussed.

Further ReadingThis icon provides details of documents, leaflets or books in which further information can be found.

Group ContributionThis icon is used when the accompanying information, PowerPoint or presentation requires further group discussion.

Group ParticipationThis icon is used when the accompanying information contains instructions for group participation exercises.

DemonstrationThis icon is used when the accompanying information contains guidance for practical demonstrations.

Session Objective

Session Location

Session Resources

Suggested Session Durations

Session Aim

Additional InformationThroughout this guide you will find some text in brightly coloured boxes. The information in these boxes might be simple additional information, areas where demonstrations, group contribution or participation can be used to accelerate the candidates' learning, a warning or further reading references. You’ll also find icons that denote different things like learning objectives or training locations. Following is a key explaining what each icon means.


Course PlanSelect your course content from the Session Library and arrange it here.


Session LibraryChoose an experience level and then pick your sessions.

(Remember sessions are divided into "A" and "B" variants.

"A" is for Pedestrian courses and "B" is for Rider courses).



Course Information: NoviceRatios 3:1:1, 2:1:1, 1:1:1

Minimum Course Duration – (See Syllabus 21-24)

Ratio Low-level Medium-level High-level

3:1:1 9 hours 12 hours 15 minutes 18 hours

2:1:1 7 hours 30 minutes 10 hours 15 hours

1:1:1 6 hours 7 hours 45 minutes 12 hours

Objective

By the end of this course, candidates will be able to discuss and demonstrate:

• Safe and efficient operation of a truck within the workplace, including their duties under the Health

and Safety at Work, etc. Act 1974 and the risks associated with truck use.

• Carrying out effective pre-use inspection, appropriate maintenance tasks and reporting processes.

• Essential authorisation to operate arrangements.

Location

Classroom and practical training area. Suitable access to an appropriate practical training area must be available. The practical training area must be clearly identified and protected, and should be segregated from normal working activities.

Equipment

A suitably maintained, appropriate truck, with sufficient palletised loads available for use during training. Session equipment is detailed at the beginning of each session.

Candidate Specification

All candidates should be reasonably fit, both physically and mentally, have the learning ability and potential to become competent operators and be over the minimum age of 16 years except in ports, where they must be at least 18 years old, unless they are undergoing a suitable course of training, properly supervised by a competent person. Children under 16 should never operate lift trucks. Candidates selected for this course should be reliable and have a responsible attitude towards the workplace.

At a glance: Guide to current medical standard of fitness to drive can be applied to all work with lift trucks.


Course Syllabus: Novice - Low LevelSession Session Title

S1 A and B Course Introduction

S2 A and B Theory

S3 A and B Introduction to the Truck

S4 A or B Preparing, Moving, Stopping and Parking the Truck

S5 A or B Basic Steering

S6 A and B Progressive Steering

S8 A and B Battery Care and Maintenance

S9 A and B Pre-use Inspection

S10 A and B Load Assessment

S11 A and B Truck and Load Stability

S12 A and B Pallet Handling

S13 A and B Handling Different Loads

S15 A or B Chicane

S16 A or B Turning in a Narrow Aisle

S17 A and B Industrial Racking – Ground/Low-Level

S20 A and B Negotiating Inclines

S21 A and B Vehicle Loading and Unloading

Basic Operating Skills Test (Assessment)

S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 9 hours 7 hours 30 mins 6 hours

Syllabus

The following syllabus contains the required teaching sessions for this course. Instructors are at liberty to conduct sessions to durations that suit the needs and abilities of the candidates (suggested durations are included with each session, but these are not mandatory); however, the total course time must meet the minimum duration referenced above and below.



Course Syllabus: Novice - Medium LevelSession Session Title


S2 A and B Theory





S7 A and B Operating the Hydraulic Controls







S14 A and B Pallet Stacking

S15 A or B Chicane



S18 A and B Industrial Racking – Medium-Level




S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 12 hours 15 mins 10 hours 7 hours 45 mins


Course Syllabus: Novice - High LevelSession Session Title


S2 A and B Theory













S15 A or B Chicane




S19 A and B Industrial Racking – High-Level




S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 18 hours 15 hours 12 hours



The following optional sessions can be included during your course delivery to supplement the coresessions listed in the syllabus. These sessions are not mandatory, but they may be relevant to your traininggroup and their working environment.

Please note that if you decide to run either of these sessions, the time spent delivering them must beadded to the required minimum training duration – these sessions cannot be run instead of corecourse content outlined in the syllabus.

Optional Sessions - Novice - Low, Medium, High levelsSession Session Title 3:1:1 2:1:1 1:1:1

OS1 Using Pallet Trucks on a Dock Leveller 30 mins 20 mins 10 mins

OS2 Using Pallet Trucks on Tail Lifts 60 mins 45 mins 30 mins


Course Information: ExistingRatios 3:1:1, 2:1:1, 1:1:1

Minimum Course Duration - (See Syllabus P26-29)



2:1:1 5 hours 30 minutes 6 hours 30 minutes 8 hours 30 minutes

1:1:1 4 hours 30 minutes 5 hours 30 minutes 7 hours

Objective






Location


Equipment



All candidates will have evidence of operating pallet/stacker trucks but will not have undergone formal training on the equipment (we recommend this evidence is retained in your training records). Additionally, candidates should be reasonably fit, both physically and mentally, have the learning ability and potential to become competent operators and be over the minimum age of 16 years except in ports, where they must be at least 18 years old, unless they are undergoing a suitable course of training, properly supervised by a competent person. Children under 16 should never operate lift trucks. Candidates selected for this course should be reliable and have a responsible attitude towards the workplace.




Syllabus


Course Syllabus: Existing - Low LevelSession Session Title


S2 A and B Theory










ES1 A or B Turning and Depositing in Industrial Racking – Low-Level




S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 6 hours 30 mins 5 hours 30 mins 4 hours 30 mins


Course Syllabus: Existing - Medium LevelSession Session Title


S2 A and B Theory

















S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 8 hours 6 hours 30 mins 5 hours 30 mins



Course Syllabus: Existing - High LevelSession Session Title


S2 A and B Theory














S19 A and B Industrial Racking – High-Level




S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1





Optional Sessions - Existing - Low, Medium, High levelsSession Session Title 3:1:1 2:1:1 1:1:1





Course Information: RefresherRatios 3:1:1, 2:1:1, 1:1:1



3:1:1 4 hours 5 hours 30 minutes 6 hours 30 minutes



Objective






Location


Equipment


Candidate SpecificationAll candidates will have evidence of successfully attending adequate formal operator training on the type of equipment intended for use during this training (we recommend this evidence is retained in your training records), and will be able to provide supporting documentation. Additionally, candidates should be reasonably fit, both physically and mentally, have the learning ability and potential to become competent operators and be over the minimum age of 16 years except in ports, where they must be at least 18 years old, unless they are undergoing a suitable course of training, properly supervised by a competent person. Children under 16 should never operate lift trucks. Candidates selected for this course should be reliable and have a responsible attitude towards the workplace.



Course Syllabus: Refresher - Low LevelSession Session Title


RS1 A and B Theory Update

RS2 A and B Introduction to the Truck and Principles of Stability

RS3 A and B Pre-use Inspection

RS4 A and B Assessment of Operator Ability and Remedial Tuition


S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 4 hours 3 hours 30 mins 2 hours 30 mins

Course Syllabus: Refresher - Medium LevelSession Session Title







S22 Course Close

Ratio 2:1:1 2:1:1 1:1:1


SyllabusThe following syllabus contains the required teaching sessions for this course. Instructors are at liberty to conduct sessions to durations that suit the needs and abilities of the candidates (suggested durations are included with each session, but these are not mandatory); however, the total course time must meet the minimum duration referenced above and below.



Course Syllabus: Refresher - High LevelSession Session Title







S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 6 hours 30 mins 5 hours 4 hours



Optional Sessions - Refresher - Low, Medium, High levelsSession Session Title 3:1:1 2:1:1 1:1:1




Course Information: ConversionRatios 3:1:1, 2:1:1, 1:1:1


Ratio Low Medium High

3:1:1 5 hours 30 minutes 7 hours 7 hours 30 minutes



Objective






Location


Equipment



All candidates will have successfully attended adequate operator training on other workplace transport material handling equipment (we recommend this evidence is retained in your training records), and will be able to provide supporting documentation. Additionally, candidates should be reasonably fit, both physically and mentally, have the learning ability and potential to become competent operators and be over the minimum age of 16 years except in ports, where they must be at least 18 years old, unless they are undergoing a suitable course of training, properly supervised by a competent person. Children under 16 should never operate lift trucks. Candidates selected for this course should be reliable and have a responsible attitude towards the workplace.




Course Syllabus: Conversion - Low LevelSession Session Title




CS1 A or B Preparing, Moving, Stopping and Parking the Truck


CS2 A and B Pallet Handling and Stacking

CS3 A and B Turning and Depositing in Industrial Racking



S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1


Syllabus



Course Syllabus: Conversion - Medium LevelSession Session Title










S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1


Course Syllabus: Conversion - High LevelSession Session Title










S22 Course Close

Ratio 3:1:1 2:1:1 1:1:1

Minimum Course Duration 7 hours 30 mins 6 hours 5 hours





Optional Sessions - Conversion - Low, Medium, High levelsSession Session Title 3:1:1 2:1:1 1:1:1




S1(A&B) – Course Introduction

Suggested DurationsLow-level, Medium-level, High-level

RATIO NOVICE EXISTING REFRESHER CONVERSION

3:1:1 15 mins 15 mins 15 mins 15 mins



To welcome candidates, outline the course and provide important site safety information.

Classroom

• Personal details for each candidate• Training record form for each candidate• Pens and spare notepaper, etc. for each candidate• Hand-out literature, notes folder, etc. • Copy of your course timetable• Whiteboard/flip chart• If the course is taking place on a live site, copies of relevant risk assessment and site

maps should be made available• Multimedia device/computer with a compatible projector/television.


• Safe and efficient operation of a truck within the workplace, including their duties under the Health and Safety at Work, etc. Act 1974 and the risks associated with truck use

• Carrying out effective pre-use inspection, appropriate maintenance tasks and reporting processes




Take a moment to welcome the candidates to the course, introduce yourself and allow them to introduce themselves.

Ensure that all candidate documentation and information is correct, and create a new training record for each candidate.

Familiarise candidates with the training facilities, health and safety policy as appropriate and ensure that they are aware of the relevant fire assembly points and evacuation procedures. Also point out the first aid location, emergency exits and any restricted areas within the facility.

If training is to be conducted on a live site it is critical that all attendees and visitors are familiar with the rules of the site, for example pedestrian areas, personal protective equipment (PPE) rules, any high risk activities being undertaken during the course, etc.

Outline personal and domestic service arrangements for the course:

• The training course hours of attendance, including break times

• Refreshment facilities (food and drink) and location

• Designated smoking areas if relevant

• Toilet facilities and locations

• Car parking arrangements.

Clearly state the training course objective and briefly outline the content of the course – explain that

there will be a three stage Basic operating skills test at the end of this course:

• Associated Knowledge Examination

• Pre-use Inspection

• Practical Test of Basic Operating Skills.

Inform course members that upon successful completion of the course and tests (as above) they will be awarded a Certificate of Basic Training (if applicable).

Outline the course timetable, notably the break, start and end timings. Issue training notes and any other relevant literature (where applicable). Explain that any notes on the theory subjects are provided in order to assist with revision and for future reference.

End of S1


S2(A&B) – Theory



3:1:1 40 mins 40 mins N/A N/A



To introduce candidates to the Health and Safety legislation that applies to the truck.

Classroom

• Health and Safety at Work, etc. Act 1974 (HASAWA) Regulations 2, 7 and 8• Management of Health and Safety at Work Regulations 1999• Provision and Use of Work Equipment Regulations 1998 (PUWER)• Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)• Workplace (Health, Safety and Welfare) Regulations 1992• Control of Substances Hazardous to Health (COSHH)• The Health and Safety (Safety Signs and Signals) Regulations 1996• L117: Rider-operated lift trucks – Operator Training and Safe Use• Safe Driving Practices – (appropriate for the workplace)• Pre-use inspection sheet• Multimedia device/computer with a compatible projector/television• Presentation slides (included with the guide)• Whiteboard/flip chart• If the course is taking place on a live site, copies of relevant risk assessment and site

maps should be made available• Relevant hand-out, guide or leaflet for each candidate including HSE’s leaflet

INDG457: Use lift trucks safely - Advice for operators.

By the end of this session candidates will be able to recall and discuss safety legislation that applies to the operation and use of the equipment and be able to answer questions relating to employer and employee duties under the Health and Safety at Work, etc. Act 1974.



During this session, and throughout the course, reference is made to specific Health and Safety Executive guidance and approved codes of practice that relate to UK legislation regarding safe working practices from the date of this publication. If you are delivering this course outside of the UK, it is important to adjust your delivery to suit legislative requirements for your particular geographic location. If you are delivering this course in the Republic of Ireland or Northern Ireland, please refer to Appendix 2, where you will find a table that provides some equivalent resources for some of the major HSE publications referenced in this session and throughout the course as a whole.

TheoryExplain that in any work environment there are dangers and each presents specific risks to the health and safety of those who work in the environment and anybody else affected by the work. From hazardous loads to the dangers presented by the movement of lift trucks, risks must be properly monitored and controlled. Compliance with relevant regulations is the first step to minimising and controlling risk.

Health and Safety at Work, etc. Act 1974 (HASAWA)• Explain the employer’s responsibilities under section 2 of the HASAWA.• Explain employee responsibilities under sections 7 & 8. • Explain the powers of the Health and Safety Executive’s inspectors.• Discuss the HSE’s Fee for Intervention policy with the operators.• Explain that under the Health and Safety (Fees) Regulations 2012, those who break Health and

Safety laws are liable for recovery of the HSE’s related costs, including inspection, investigation and taking enforcement action.

Management of Health and Safety at Work Regulations 1999Explain that employers have responsibility under these regulations to carry out suitable and sufficient risk assessments to protect employees and others.

Provision and Use of Work Equipment Regulations 1998 (PUWER)Explain the employer’s responsibilities under:

• Regulation 4 – to provide suitable equipment• Regulation 5 – to provide maintenance• Regulation 6 – to provide regular inspections by competent persons• Regulation 7 – to provide for specific risks• Regulation 8 – to provide information and instruction• Regulation 9 – to provide training for operators of work equipment.


Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)Explain that these regulations deal specifically with the risks associated with lifting equipment and its operation within the workplace. The regulations require:

• Employers to have control of the use of lift equipment

• All lifting operations to be properly planned

• An appropriate level of supervision

• Equipment to be suitable for the task being carried out

• Lifting operations to be carried out safely

• Lifting components to undergo a regular thorough examination.

Workplace (Health, Safety and Welfare) Regulations 1992Explain that these regulations cover a wide range of basic health, safety and welfare matters that apply to most workplaces and include the requirements for:

• The supply of adequate fresh air through good ventilation

• Sufficient lighting to operate safely

• The construction and maintenance of suitable floors and traffic routes that provide segregation

between pedestrian and vehicular traffic.

Ask the group to think about their own workplaces and whether there are any obvious risks that might need controlling, particularly from the point of view of the operator and the use of workplace transport.

Control of Substances Hazardous to Health (COSHH)Discuss working with hazardous substances with the group. Explain that, as equipment operators, the members of the group are likely to come into direct contact with hazardous substances from time to time, for example:

• Battery acid

• Hydrogen fumes

• Oils and lubricants.

Depending on the nature of their work, operators may not come into contact with or work with hazardous substances. Even so, it is important that they are able to recognise warning labels and are aware of precautions that should be taken when working with certain substances, for example:

• Personal Protective Equipment (PPE)

• Exposure risks to themselves and others on the site

• Steps to take in the event of exposure or spillage.



The Health and Safety (Safety Signs and Signals) Regulations 1996Explain that there are four categories of safety sign and that each has a defined purpose. Discuss the shapes and colours for each type of sign. Show the candidates examples to illustrate them.

Warning signs

Indicate a particular type of hazard. These are triangular with a yellow background, black pictogram and border.

CAUTION FORK LIFT TRUCKS

CORROSIVE

Mandatory instruction signs

These signs are circular with a blue background and a white pictogram, they denote that a particular type of behaviour is required. WEAR

SAFETY BOOTS

WEAR FACE PROTECTION

PEDESTRIAN ROUTE

Emergency escape or first aid signs

These signs indicate information about and locations of first aid equipment. These signs are rectangular with a green background and white pictogram and/or text.

SAFETY SHOWER

EYE WASH STATION

LIFT TRUCK PROHIBITED

SMOKING AND NAKED FLAMES

PROHIBITED

Prohibition signs

Aimed at preventing a particular type of behaviour, these signs are circular with a white background, black pictogram and red border.

Obstacles or dangerous locations signs

Used where the risk of injury from falls from height or from being struck by falling objects is low or impracticable to safeguard by other means, these markings highlight the edge of raised platforms or areas where objects may fall.


L117: Rider-operated Lift Trucks – Operator Training and Safe UseExplain that this document supports employers and those responsible for the safe operation of lift trucks by giving advice on how to comply with the law.

Discuss the ACoP's special legal status, explaining that, in the event of an incident, if you are proved to have not followed the relevant provisions of the ACoP you will be found at fault – unless you can show that you have complied with the law in some other way.

Safe Driving Practices Explain that many accidents occur because operators are either inexperienced or untrained. These accidents range from relatively minor to very serious, and may result in injury (or death) to the operator or other persons and/or damage to the equipment, buildings and facilities. Discuss this point with the candidates using any relevant up-to-date examples, which can be found at www.rtitb.co.uk/news.

Discuss the possible locations in which trucks might be used, emphasising the different constraints and manoeuvring limitations presented by different environments.

The candidates should also consider the risks associated with pedestrians in different types of environment where trucks might be used: for example, employees in a distribution centre who have undergone some form of health and safety induction will be more aware of the dangers of material handling equipment than customers shopping in a wholesalers', where trucks move products from storage areas or loading bays through to the shop floor. It could be argued that in one of these settings the operator will need to be better attuned to the potential actions of pedestrians, in particular children – although the actions of workers in a high pressure environment like a distribution centre shouldn’t be taken for granted. All workplace equipment operators have a duty of care to their colleagues and all necessary precautions must be taken to ensure their safety.

Emphasise that the equipment that will be used on this course is designed to be perfectly safe, providing that it is used correctly. Point out that there are specific rules covering operating practices that help minimise the risks presented by the equipment, and that this course will concentrate throughout on safe, correct approaches to using the equipment which comply with those rules.

Introduce and discuss the following points, which will be covered in detail throughout the practical sessions of this course:

• Personal protective equipment (PPE)

• Correct start-up and shut-down procedures

• Steering controls

• Safe manoeuvring

• Correct observations and blind spot safety awareness

• The basics of picking up and depositing

• The basics of stacking and de-stacking (where necessary)

• Safe use of industrial racking

• Pre-use inspections and fault reporting

• Battery charging/maintenance.



End of S2

Open a discussion by asking the group, what is the purpose of understanding safety and the role everyone plays in it?

Refer the candidates to relevant hand-outs on the issues discussed in this session, including HSE’s leaflet INDG457: Use Lift Trucks Safely - Advice for Operators.

Explain the role of the operator. Discuss how the day-to-day operation of the truck is a small part of the overall responsibilities involved, for example:

• Selection of correct equipment for the operation

• Pre-use inspection of the truck and defect reporting

• Safeguarding from unauthorised use

• Operator maintenance and charging

• Awareness and observation of others

• Load security, including the movement of loads to and from locations

• Awareness of the potential hazards found in the workplace and the effects they may have on the

truck and what action to take

• The safe and ideal state in which to both find and leave a truck

• Any other relevant overall responsibilities that might be applicable.

An incomplete understanding of the responsibilities associated with truck operation may result in unsafe practices. Therefore, it is important that operators value their training and ensure their operating skills are sufficiently refreshed at regular intervals. Explain that these points will continue to be covered throughout the course.


S3(A&B) – Introduction to the Truck

Suggested DurationsLow-level





Medium-level, High-level





To introduce the candidates to the truck that will be used during the course.

Classroom and practical training area

• Multimedia device/computer with a compatible projector/television• Presentation slides (included with the guide)• Manufacturer’s handbook• Truck

By the end of this session, candidates will be able to:

• Identify and explain the components and controls of the machine and describe their function

• Briefly discuss the type of truck that will be operated during the training course, its components, controls and warning systems

• Where applicable to the truck type, safely mount and dismount the truck, stowing the rider platform and guards.



Material Handling Equipment TypeDescribe the equipment type to be used for training, explain its purpose in the workplace and its limitations.

Explain that to meet the specific needs of the workplace, material handling equipment comes in a variety of configurations, with each variation offering differences in design, operating position, control configuration, capability, etc. The candidates are likely to encounter many of these differences in their respective workplaces.

Discuss some of the different pallet truck types the candidates might come across.

Operator PositionsPedestrian Operated

These trucks are operated “off the truck”, which means the operator is walking/standing alongside the truck – either with the truck stationary (for example, when stacking/de-stacking) or in transit. The truck is controlled by a tiller handle. The tiller control handle is fitted with a form of accelerator control, usually a twist grip or butterfly switch, and may also include a directional control. Braking is normally effected by releasing the accelerator control and/or placing the tiller control handle to the vertical or horizontal positions.

Pedestrian Operated With Fold-away Platform

A fold-away platform truck is essentially a pedestrian-operated truck that is fitted with a fold-down platform and side guards that can be used when travelling long distance – it is important to explain that the fold-away platform should be stowed when the truck is used within confined areas while stacking/de-stacking and loading/unloading vehicles.

Rider Operated Fixed Platform

This type of truck is commonly used to move palletised loads long distances. They are fitted with a fixed platform, which provides a permanent operating position, complete with rigid side guards, upon which the operator rides when operating/driving the truck.


BRAKE

BRAKE

Pedestrian Operated - Low LevelABA Category A1

Rider Operated - FixedABA Category A2

Pedestrian Operated - Fold–awayABA Category A1

Stacking - StackerABA Category A5

Stacking - StraddleABA Category A6

Stacking - ReachABA Category A7

Stacking - CounterbalanceABA Category A3

Rider Operated - StackerABA Category A4



Stacking TrucksTrucks may have the capability to stack palletised loads to varying heights, either free-standing or in industrial racking systems. These types of truck are divided into distinct variations, which can be identified by the location of their load wheels:

• Ground-level trucks have wheels located in the load handler. These trucks are limited to transporting

and collecting/depositing loads at ground-level only.

• Stacker trucks have their load wheel located under the forks, this requires clearance under stacks/

racks. These types of truck can stack and de-stack at a variety of heights.

• Straddle and Reach truck wheels are located within ridged legs, permitting them to handle pallets

with bottom deck boards. Straddle trucks require space either side of the pallet. Reach trucks have

the ability to project loads forwards. Like stacker trucks, these types of truck can work at a variety of

load heights.

• Counterbalance type trucks are fitted with wheels located behind the load position on the main

body of the truck. Counterbalance trucks are fitted with independent forks, which means they are

able to handle a variety of pallet types. These types of truck can work at a variety of heights.

It is important to stress that the candidates may come across equipment in the workplace that differs to that used for training – as evidenced by the variety of truck types just discussed. While the fundamentals of operation may be the same, specific controls and features may vary; therefore, Specific Job training tailored to the equipment used in the workplace and environmental/site considerations will be necessary, as will Familiarisation training on any workplace tasks to be completed by the operator.

Explain that the equipment used for training will be also be used for practical testing at the end of the course. Inform the candidates of the truck’s model/type and manufacturer, reiterating the importance of access to the manufacturer's operator manual.


Equipment TourIdentify and explain the functions of the major components of the equipment, including:

• Key/switch/starting system

• Emergency disconnect/isolator

• Load wheels, wheel arms or outriggers (where applicable)

• Fork arm securing pins and stops (where applicable)

• Mast, load guard, carriage plate (where applicable)

• Hydraulic cylinders and chains

• Tiller/control handle, audible warning device, hydraulic controls (as applicable)

• Collision safety switch (where applicable)

• Speed selector device and coast control devices (where applicable)

• Truck braking devices

• Parking brake (where applicable)

• Visual information/warning instruments

• Operator position/rider platform, side arms and presence/dead-man sensor (where applicable)

• Manufacturer's rated capacity plate and data plate

• Drive wheel

• Battery compartment, battery connector

• Other fitted controls and instruments as appropriate



Allow the candidates to mount and dismount the truck as demonstrated.

Explain and demonstrate the correct method of mounting and dismounting the truck as applicable. Explain that mounting and dismounting techniques may vary from machine to machine, depending on design/configuration. However, the basic principles of good, secure hand and footholds during mounting and dismounting, as well as observation of the area when dismounting should be remembered. Operators should consult the manufacturer's guide for specific advice on mounting and dismounting.

Stress the importance of ensuring the platform and side arms (where fitted) are fully deployed.

Make the point that the operator should never jump down from the truck.

Confirm the candidates’ understanding of the type of truck used for training, its components, controls and warning systems.

Mounting and Dismounting

End of S3


S4A – Preparing, Moving, Stopping and Parking the Truck (Pedestrian Operated)






To introduce candidates to starting and moving off, operating the truck forks leading and forks trailing, before bringing the truck to a safe, controlled stop and parking it safely.

Practical training area

• Manufacturer’s Operator Manual• Truck – pre-set to the appropriate travel height

On completion of this session candidates will be able to:

• Adopt a safe operating position• Operate the truck, forks trailing and forks leading, including braking and an emergency

stop.



Moving off Forks Leading and Forks Trailing, Controlled and Emergency Stopping

Stress that the truck must only be used when the operator is in the operating position and that the operator may only ride on the truck if an approved rider platform is fitted.

Operator Position

Link back to the introduction to the equipment and remind the candidates that pedestrian trucks are often fitted with a fold-away platform. Remind the candidates that the fold-away platform must be stowed during confined manoeuvring and stacking/de-stacking work.

Explain and demonstrate the operating position that should be adopted when riding on the fold-away platform. Whilst travelling forks leading, a two-handed grip is required on the tiller. When travelling forks trailing, at least one hand must remain on the tiller, and the other hand must remain within the confines of the truck. Explain the potential for personal injury if correct operator position is not maintained – for example, even when the truck comes to a controlled stop, if the operator is not adopting the correct operating position, there is a chance that they could fall from the truck.

Explain and demonstrate the operating positions to be adopted when using the truck with the fold-away platform stowed. Briefly explain that during travelling with forks leading, the operator should maintain a two-handed grip on the tiller, and when travelling with forks trailing a one-handed grip is necessary to allow the operator to maintain a position to the left or right of the truck while facing the direction of travel. Explain the potential for personal injury if correct operator position is not maintained.

If you are training candidates in the use of a ground-level truck, it is important that they are introduced to the procedure for setting the forks for travel and park during this session.

If you are training candidates in the use of trucks that stack above ground-level, operation of hydraulic systems is discussed in a later session; you will therefore be responsible for setting the forks to the correct height for travel and park during this session.



Explain and demonstrate the function of the collision safety switch (also known as a "belly button") fitted to the end of the tiller arm. This button responds to body contact, causing the truck to change direction or come to a controlled stop – the expected behaviour will vary, depending on truck manufacturer.

Moving off and Stopping (Forks Leading and Forks Trailing)

Explain and demonstrate the correct method to be followed when moving off on foot:

• Operate the truck's hydraulic switch to raise the forks to the required travel height (as applicable)

• Remind the candidates of the importance of operator position and hand position on the tiller (relative to direction being travelled)

• Select the travel direction (where applicable)• Complete an all-round observation• Release the park brake (where applicable)• Explain and demonstrate applying acceleration to move off. Apply gradual

pressure to the accelerator control for smooth progressive acceleration• Remind the candidates to look in the direction of travel• Show the candidates how to bring the truck to a controlled stop by releasing

the accelerator and then applying the brake gradually to come to a controlled stop (where applicable)

• Set the direction control to neutral and apply the park brake (where applicable).

Explain that it is important that an effective all-round observation is made before moving off – under no circumstances should the equipment be moved if any pedestrians are within the immediate vicinity of the truck.



Explain and demonstrate the correct method to be followed when moving off using the fold-away platform position (as applicable):

• Mount the truck platform and raise the side guards• Operate the truck’s hydraulic switch to raise the forks to the required travel

height (as applicable)• Remind the candidates of hand position on the tiller (relative to direction

being travelled)• Select the travel direction (where applicable)• Complete an all-round observation• Release the park brake (where applicable)• Explain and demonstrate applying acceleration to move off. Apply gradual

pressure to the accelerator control for smooth progressive acceleration • Remind the candidates to look in the direction of travel• Show the candidates how to bring the truck to a controlled stop by releasing


• Set the direction control to neutral and apply the park brake (where applicable).



Stress that the manual high speed control must only be used whilst the operator is on the fold-away platform.

Discuss with the candidates the fact that speed is difficult to judge, pointing out that the truck may not have a speedometer. Nevertheless, great care must be taken not to exceed the site’s speed limit. Explain that this is something that comes with experience. Suggest ways in which speed might be judged (e.g. using fixed positions) and where speed might need to be reduced (e.g. on approach to blind corners, areas of pedestrian activity, etc.).

Explain that excessive speed and braking increase the risk of an incident, especially in regards to stability, which will be covered in a later session. Stress the importance of awareness of the workplace environment and immediate surroundings, and the importance of operating at an appropriate speed.

Explain that great care should be taken when travelling behind another operator to ensure that safe stopping distances are consistently maintained.

Explain that when travelling over a wet, slippery surface, the operator should maintain a slow, controlled speed in order to avoid sudden braking and swerving, and to facilitate controlled stopping if necessary.

Coast Control

Explain, where applicable, the coast control function. In particular you should cover the circumstances in which it can be used, safety precautions, and limitations such as restricted steering.

Explain that coast control is used to move the truck short distances – for example, in a picking scenario – to enable the truck to travel to the next picking location without the need to draw down the tiller arm to the operating position. This facilitates the use of the accelerator over short distance for efficiency.

Stress that this function should not be used while other pedestrians are in the path of the truck as the braking and deceleration of the truck is gradual and the steering function is disabled in this setting.

This function should not be used on inclines. Inclines will be discussed in a later session.

Speed

Explain that trucks with rider platforms may include an automatic or manual speed selector with High and Low speed settings for optimum productivity, allowing the truck to move at higher speeds than when the operator is walking beside it.



Emergency StopExplain the correct procedure for conducting an emergency stop. Discuss how speed, ground conditions and the weight of any load being carried all affect stopping distances. Discuss the relative effect on any load being carried, the stability of the truck and the effectiveness of the brakes whilst braking in either direction, laden or unladen.

Demonstrate how to carry out an emergency stop forks leading and forks trailing, stressing the importance of keeping the tiller control straight with a firm grip. Explain that after any emergency stop, the parking brake should be applied and neutral selected (where applicable), the operator should then assess the situation and allow a short period of time to regain their composure.

Parking

Explain the precautions that should be taken when safely parking the truck. Emphasise the importance of parking the truck where it will not cause an obstruction. Also discuss the need to park the truck correctly, which requires the operator to:

• Straighten the steering control

• Apply the park brake (where applicable)

• Lower the forks to the park position (where applicable).

Ensure that throughout the session, each candidate is given sufficient time to practise the manoeuvres taught (both with and without the fold-away platform where applicable):

• Adopt a safe operating position• Prepare the truck for travel (including fork position where applicable)• Operate the truck forks leading and forks trailing, and bringing the equipment

to a controlled stop• Performing an emergency stop• Parking.

End of S4A


S4B - Preparing, Moving, Stopping and Parking the Truck (Rider Operated)



3:1:1 30 mins 20 mins N/A 15 mins







• Adopt a safe operating position• Operate the truck in both a forward and reverse direction, including braking and an

emergency stop.



Moving off Forks Leading and Forks Trailing, Controlled and Emergency Stopping

If you are training candidates in the use of a ground-level truck, it is important that they are introduced to the procedure for setting the forks for travel and park during this session.

If you are training candidates in the use of trucks that stack above ground-level, operation of hydraulic systems is discussed in a later session; you will therefore be responsible for setting the forks to the correct height for travel and park during this session.

Stress that the truck must only be used when the operator is in the operating position.

Operator Position

Explain and demonstrate the operating position that should be adopted. Whilst travelling forks leading, a two-handed grip is required on the tiller. When travelling forks trailing, at least one hand must remain on the tiller, and the other hand must remain within the confines of the truck or on any purpose-built handholds. Explain the potential for personal injury if correct operator position is not maintained – for example, when the truck comes to a controlled stop, if the operator is not adopting the correct operating position, there is a chance that they could fall from the truck.





Explain and demonstrate the correct method to be followed when moving off:• Mount the truck platform• Operate the truck’s hydraulic switch to raise the forks to the required travel



pressure to the accelerator control for smooth progressive acceleration • Remind the candidates to look in the direction of travel• Show the candidates how to bring the truck to a controlled stop by releasing


• Set the direction control to neutral and apply the park brake (where applicable) and set the direction control to neutral.


Speed

Explain that trucks with rider platforms may include an automatic as well as a manual speed selector. The automatic speed selector offers High and Low speed settings for optimum productivity. An example application of this technology is automatically slowing the truck whilst turning corners and allowing the truck to move at higher speeds whilst travelling in a straight line.

Discuss with the candidates the fact that speed is difficult to judge, pointing out that the truck may not have a speedometer. Nevertheless, great care must be taken not to exceed the site’s speed limit. Explain that this is something that comes with experience. Suggest ways in which speed might be judged (e.g. using fixed positions) and where speed might need to be reduced (e.g. on approach to blind corners, areas of pedestrian activity, etc.).

Explain that excessive speed and braking increase the risk of an incident, especially in regards to stability, which will be covered in a later session. Stress the importance of awareness of the workplace environment and immediate surroundings, and the importance of operating at an appropriate speed.



Explain that great care should be taken when travelling behind another operator to ensure that safe stopping distances are consistently maintained.

Explain that when travelling over a wet, slippery surface, the operator should maintain a slow, controlled speed in order to avoid sudden braking and swerving and to facilitate controlled stopping if necessary.

Coast Control




This function should not be used on inclines. Inclines will be discussed in a later session.



Parking

Explain the precautions that should be taken when safely parking the truck. Emphasise the importance of parking the truck where it will not cause an obstruction. Also discuss the need to park the truck correctly, which requires the operator to:





Ensure that throughout the session, each candidate is given sufficient time to practise the manoeuvres taught:

• Adopt a safe operating position• Prepare the truck for travel (including fork position where applicable)• Operate the truck forks leading and forks trailing, and bringing the equipment

to a controlled stop • Performing an emergency stop• Parking.

End of S4B


S5A – Basic Steering (Pedestrian Operated)











To introduce the candidates to basic steering manoeuvres (forks leading and forks trailing) with an unladen truck.


• Cones or barrels• Truck – pre-set to the appropriate travel height

On completion of this session candidates will be able to demonstrate how to pivot an unladen truck around a simple course in an open area, forks leading and forks trailing.



SteeringIf conducting training using a pedestrian truck fitted with a fold-away platform, recap on the earlier discussion about its usage and explain that during the exercises to be carried out during this session, the platform will be stowed.

Steering Forks Leading

Start in an open area and demonstrate the effects of moving the tiller control to the left and right while operating forks leading and forks trailing.

Show the candidates the pivoting point of the truck and the start of the turn. Explain and demonstrate the process of negotiating the turn.

Demonstrate manoeuvring forks leading. Explain that, as before, appropriate all-round observation and controlled speed is required. Stress the importance of looking in the direction of travel. It is important to point out that additional blind spots might be created by the mast on some truck models when travelling forks leading.

Explain the effect of front and rear end swing when making turns. Discuss the absolute necessity to conduct an all-round observation before, during and after steering the truck.

Steering Forks Trailing

Show the candidates the pivoting point of the truck and the start of the turn. Explain and demonstrate the process of negotiating the turn. Explain the importance of walking on the outside of the turn to avoid the truck striking the heels and feet.




End of S5A

Pivot TurnsProgress to more accurate steering exercises by performing 90° pivot turns to both sides (forks leading and forks trailing), stressing the importance of controlled acceleration when steering. Reiterate the importance of facing the direction of travel when manoeuvring a truck; this is particularly important when travelling forks trailing.

Blind CornersExplain that when negotiating a blind corner, the operator should slow down, sound the horn several times and drive wide to improve observation. Explain the importance of maintaining safe, steady progress

through the turn.


• Turning the truck left and right and performing pivot turns with forks trailing and forks leading, whilst maintaining a 75mm (3 inches) gap between the truck and a cone/barrel.


S5B – Basic Steering (Rider Operated)











To introduce the candidates to basic steering manoeuvres (forks leading and forks trailing) with an unladen truck.


• Cones or barrels• Truck - pre-set to the appropriate travel height

On completion of this session candidates will be able to demonstrate how to pivot an unladen truck around a simple course in an open area, forks leading and forks trailing.



Steering


Start in an open area and demonstrate the effects of moving the tiller control to the left and right while operating forks leading and forks trailing.


Demonstrate manoeuvring forks leading. Explain that, as before, appropriate all-round observation and controlled speed is required. Stress the importance of looking in the direction of travel. It is important to point out that additional blind spots might be created by the mast on some truck models when travelling forks leading.



Show the candidates the pivoting point of the truck and the start of the turn. Explain and demonstrate the process of negotiating the turn. Explain the benefit of changing operating position to improve observation through the turn.


Pivot TurnsProgress to more accurate steering exercises by performing 90° pivot turns to both sides (forks leading and forks trailing), stressing the importance of controlled acceleration when steering. Reiterate the importance of facing the direction of travel when manoeuvring a truck; this is particularly important when travelling forks trailing.


Blind CornersExplain that when negotiating a blind corner, the operator should slow down, sound the horn and drive wide to improve observation. Explain the importance of maintaining safe, steady progress through the turn.



End of S5B


S6(A&B) – Progressive Steering











To advance the candidates' steering ability by teaching them how to negotiate progressive turns and combined left and right turns within restricted and unrestricted areas using an unladen truck, forks trailing and leading.


• Cones or barrels• Materials to create a restricted operating area• Truck – pre-set to the appropriate travel height


• Safely and correctly negotiate combined left and right turns within an unrestricted area forks trailing and forks leading

• Safely and correctly negotiate combined left and right turns within a restricted area forks trailing and forks leading.



Progressive SteeringRemind candidates who are training on pedestrian operated trucks fitted with fold-away platforms that all confined manoeuvres should be carried out with the platform stowed.

Explain “progressive steering”. The aim is to practise steering accuracy by steering around obstacles – in this case barrels/cones – while maintaining a 75mm (3 inches) gap between the side of the truck and the obstacles.

Explain the technique of feathering, which is achieved by slightly adjusting the steering on the tiller control while negotiating a turn in order to maintain sufficient clearance.

Reiterate the need for continued observation and controlled speed. Also remind the candidates of the benefits of changing position to improve observation during the manoeuvre.

End of S6

Ensure that all candidates are given sufficient opportunity to practise the manoeuvres discussed and demonstrated during this session.

Demonstrate and explain the correct procedure for negotiating a series of right and left turns around the obstacles with the forks leading whilst maintaining a 75mm (3 inches) gap between the side of the truck and each obstacle. Ensure that during the demonstration you draw attention to the feathering technique.

Repeat the demonstration with the forks trailing.


S7(A&B) – Operation of Hydraulic Controls

Suggested DurationsMedium-level and High-level only





To introduce the candidates to the hydraulic system, its components, the function and operation of the hydraulic controls.


• Truck• PPE – gloves• Hydraulic system visual aid

By the end of the session, candidates will be able to:

• Identify and explain the component parts and controls of the hydraulic system• Demonstrate correct operation of the hydraulic system• Correctly place the truck in travel and park positions • Place the mast/carriage in a vertical position at various heights• Discuss safe operation of the hydraulic system.



PreparationBefore commencing this session, ensure that the truck is placed in an open area and that all candidates have a safe, unobstructed view of the hydraulic controls.

Functions and Component PartsIdentify and discuss the various components of the hydraulic system and, depending on the experience of the group, explain how hydraulics function – you should consider using a visual aid during your explanation. Explain that when the "lift" and "lower" functions are activated, the pump unit supplies hydraulic oil from the oil reservoir to the hydraulic cylinder.

Ensure that the candidates are stood in a controlled area and that they do not stand under raised forks at any time.


Use of Hydraulic Controls

End of S7

Demonstrate the operation of the truck’s hydraulic controls throughout their range (including height, tilt and reach, where applicable to the truck type). Explain that the controls should be operated sympathetically to reduce the risk of instability and potential injury to the operator or pedestrians, as well as damage to the truck.

Allow the candidates to operate the hydraulics under instruction, including the following where possible:

• Full lift height• Tilt and fork levelling at varying heights (where appropriate) • Reach capability (where applicable)• Varying speeds of lift control• Appropriate travel and park positions.

Summarise the key points from this session and answer any questions before carrying on to the next session.


S8(A&B) – Battery Care and Maintenance






To introduce the candidates to the care and maintenance of a traction battery.


• Truck • Corresponding battery charging unit• Truck battery record log book• Hydrometer• Container of de-mineralised water• De-mineralised water applicator for topping up battery cells• Supply of clean water for use as neutralising agent• First aid kit and sterile eye wash facility• Paper towels/wipes• Appropriate fire extinguishers• Acid proof aprons, protective goggles/face mask and PVC gauntlets• Suitable covered waste bins• Marked off charging area• Warning/information signs including "No Smoking", "Danger of Electrocution", "Corrosive

Liquids" and "Charging Procedures".

By the end of the session, candidates will be able to discuss the safety precautions and procedures required for maintaining the efficiency of a traction battery and answer questions with regard to its care and maintenance.



Battery CareDiscuss the battery commonly found in this type of truck and, where applicable, fitted to the truck used for this course.

Begin with some important safety information about the traction battery. Explain that the battery contains diluted sulphuric acid, which is a corrosive liquid. Describe the actions that operators should take if they come into direct contact with the acid. Also explain that hydrogen, a highly explosive gas, is emitted from the battery during the charging process, so charging should only be undertaken in a well ventilated area.

State the following safety rules prior to entering the charging area:

• No smoking or naked flames.

• Metal objects are not permitted within the vicinity of the battery cells.

• Truck should be parked correctly, with the ignition switched off and keys removed, where applicable.

Introduce the candidates to the charging area and explain the correct use of personal protective equipment (PPE). Discuss the warning signs displayed and the importance of understanding the information.

State that the effectiveness of a truck is determined by the efficiency and condition of its traction battery. Point out the high cost of traction batteries, therefore they should be cared for and maintained properly.

Detail how a battery is constructed and explain or demonstrate the method of measuring and recording the battery’s specific gravity, including what the measurement means. A full reading will be 1.280 and a flat charge reading will be 1.140.

Explain and demonstrate the correct procedure for topping up cells, how to clean the battery cells if they become contaminated and the correct procedure for disposing of any waste. Discuss issues that might arise if the batteries are overfilled.


Explain that operators must never continue to use a defective battery or charger. Discuss how operators can identify faulty batteries – they radiate excessive heat, emit a strong sulphur smell whilst on charge or in use, suffer from leaks, etc.

End of S8

Demonstrate how to place the traction battery on charge, observing and explaining all the necessary safety precautions before charging is attempted. Identify how the candidates can confirm that charging is taking place.

Explain that it is important to maintain a safe working environment by ensuring that cables are not causing a trip hazard.

Show the candidates how to identify when charging is complete and demonstrate how to take the battery off charge. Stress the importance of stowing the equipment away properly.

Charging the BatteryExplain when a battery should be placed on charge and that it should be well ventilated whilst charging. Discuss the effect of charging the battery too soon and the effects of deep discharging.

Throughout the session, confirm that candidates have grasped the main points discussed and are clear on the precautions and procedures required to effectively maintain the efficiency of a traction battery.

If, at any point during battery maintenance, clear liquid leaks are discovered, operators should assume that it is acid and follow appropriate procedures.

Faults must be reported immediately and the manufacturer's instructions followed.


S9(A&B) – Pre-use Inspection











To show the candidates how to inspect the truck prior to use, how to record the results of the pre-use inspection and steps that should be taken in the event that defects are found.


• Truck• Manufacturer’s operating manual• Pre-use inspection forms• PPE

Upon completion of this session, candidates will be able to discuss and demonstrate the process of inspecting a truck prior to use. Additionally, they will be able to correctly record the results of the inspection and discuss steps to take in the event that defects are identified.



Routine InspectionExplain that the pre-use inspection is a fundamental element of safe operating which prevents incidents occurring as a result of mechanical failure. Operators have a regulatory obligation to inspect work equipment prior to use in order to check that it is safe and suitable for its intended purpose. This means completing a visual inspection combined with a check that all necessary systems function.

Stress that under no circumstances should operators attempt any repairs or put themselves or others at any risk by operating a defective truck. Mechanical skills are not required to complete a satisfactory pre-use inspection.

System of CheckingExplain that prior to any checks being made it is imperative that the following is established:

• The parking brake is applied, neutral is selected and the equipment is switched off

• Correct and effective personal protective equipment (PPE) is used wherever required

• The manufacturer’s equipment recommendations are followed.

Instructors should make sure that candidates refrain from stepping over forks and instead walk around them when inspecting the truck.


Demonstrate how to make checks of the following components (where applicable) In accordance with the Manufacturer's Operating Manual (not all components will be relevant to all truck types):

• External condition• Rated capacity plate and data plate• Forks/load handler • Carriage plate, backrest extension (where applicable)• Mast, rollers/slides, lift chains and pulleys (where applicable)• Hydraulic components (where applicable)• Wheels and tyres• Operating position/platform (applicable to the truck type)• Battery• Starting procedure• Audible warnings• Hydraulic controls and lift• Drive and brake, and collision safety switch• Steering• Any additional fitted systems (where applicable).

Ensure you make the candidates aware of the items which will be considered mandatory in testing.

Show the candidates how to correctly complete the pre-use inspection form and the relevant information that should be noted. Explain that, depending on the type of truck used, additional components may need to be added to the pre-use inspection routine and inspection paperwork.

Fault Reporting Discuss the action to take when a defect is identified during a pre-use inspection, include:

• Do not use or operate the equipment

• Log the fault on the inspection sheet and complete any further visual inspections

• Isolate from use and mark the truck “out of service”

• Inform a manager or supervisor of the defect.



It is important not to touch pressurised hydraulic lines, oil, lubricants or any other liquids as they may course harm to the skin or personal injury.

End of S9

Allow each candidate to carry out a pre-use inspection, using the employer’s or manufacturer’s recording system (if appropriate), under the direction of the instructor. The candidates should also be asked questions relating to the defect reporting procedure to confirm their understanding.

Further discuss the action to be taken if a fault occurs whilst the truck is in use:

• Safely park the truck straight away

• Isolate from use and mark the truck “out of service”

• Inform a manager or supervisor of the defect.


Familiarise candidates with the weight of common and unfamiliar loads, as well as the potential risks associated with the transportation of loads on an electric pallet/stacker truck.


• A variety of palletised loads• Truck

By the end of this session, candidates will be able to discuss the potential risks associated with a variety of loads and steps that can be taken to ensure loads are safe for transportation.

S10(A&B) – Load Assessment








PreparationBefore starting the session, prepare the training area to ensure that ample quantities of various palletised loads are available to achieve the objective and also ensure that the truck is in a suitable position to enable candidates to see the capacity plate.

Load AssessmentDiscuss with the candidates common loads that they will frequently encounter in the workplace. Explain that operators need to have a good understanding of the loads they will be transporting because they directly affect the safety and stability of the truck. Explain that weight is an important consideration, but there are also other factors that have to be taken into account. During this session you will explore load assessment from all of these perspectives.


Load ConditionExplain that before an operator lifts/transports a load, they should consider its condition. It should be suitable for transportation. The operator should check the load and pallet for damage and potential leaks especially. They should also consider whether there are any protrusions that might cause injury to other people or damage to infrastructure.

Truck Capacity Ask the candidates to locate the rated capacity plate on the truck and identify the maximum gross weight that can be lifted.

Also ask them to locate the load centre information – explain that this value is calculated with the mast in the vertical position (where applicable) and with the truck on flat, level ground. The load centre is the measurement from the backrest or face of the forks to the centre of gravity of the load and it determines the carrying capacity of the truck. Explain that exceeding the load centre will reduce the carrying capacity of the truck.

Load Centre

Explain that it is important to identify where a load’s centre of gravity is because it has a direct effect on the truck's stability. A uniform pallet’s centre of gravity is at its centre. A non-uniform load with unevenly distributed weight will have a centre of gravity that is located closer to its heavier end. It is important the candidates are made aware of the correct way in which to transport the pallet for maximum stability and load security.

De-rating

Explain that as the load centre increases, the rated capacity of the truck "de-rates", or to put it another way, the effective weight of the load "increases". This can be easily demonstrated by asking a member of the group to hold a simple item like this course folder close to their body and then at arms-length. After a while, with the arms stretched out in front of the body, the folder seems to get heavier. Of course, it's not actually getting heavier, but the effect of gravity away from the body's centre makes it feel heavier. We therefore have to scale down or de-rate the carrying capacity of the truck as the load gets further from the truck's load centre.

Explain that the carrying capacity for loads exceeding the load centre can be calculated in the following way:

Capacity (1500kg) x Load centre (500mm) ÷ required load centre (600mm) = 1250kg

Some trucks are fitted with a separate load centre de-rating plate which shows the capacity of the truck

at various load centres.



End of S10

Load WeightExplain that loads are often labelled in order to provide information such as weight. However, this information should be used as a guide and should never be taken for granted as it may change – for example, a load might become wet, additional cases might be added, etc. Also, many loads are not labelled, emphasising the operator's responsibility to check all loads before lifting.

Ask the candidates how they would find out the weight of the load? Explain that the Net weight of the load (the items without the additional weight of the pallet, wrapping, etc.) may be obtained by multiplying a single given case weight by the number on the pallet. Add the approximate weight of the pallet and packaging to calculate the total Gross weight. Explain that weight may also be determined by a load weight indicator fitted to the truck or a free-standing pallet scale, where available.

Load StabilityExplain that some loads may be more susceptible to movement under braking, turning or acceleration. This can affect the stability of the truck because the load's centre of gravity shifts as the load moves. This type of load is normally referred to as a live load. Good examples of live loads are water containers or other containers with liquid contents. Stacking cases in recommended "patterns" will increase the stability of the load. Discuss different load pattern types that might be used for a variety of load types in the workplace.

Load SecurityExplain that there are many ways in which loads can be secured. Ask the candidates to identify ways in which loads are secured in their workplace, for example; stretch wrap, shrink wrap, glue, plastic or metal banding, etc.

Packing and Handling InstructionsThe load may be marked with a pictogram which represents a specific packing and handling safety instruction, for example: "keep upright", stacking limits by number, "do not stack" and "do not use fork lift".

ConfirmationSummarise the key points from this session and confirm the candidates' knowledge.


S11(A&B) – Truck and Load Stability











Introduce the candidates to the stability characteristics of an unladen and a laden truck, the dangers of overloading a truck and the causes of instability.

Classroom

• Manufacturer’s operating manual• Multimedia device/computer with a compatible projector/television• Presentation slides (included with the guide)• Visual aid/model to illustrate stability principles• Hand-out literature.

On completion of this session, candidates will be able to discuss factors that affect truck stability and steps that can be taken to reduce the risks of instability. Candidates will also be able to answer questions relating to engineering principles, balance and stability. Finally, candidates will be able to discuss correct actions to take in the event of truck tip over.



IntroductionExplain that it is important to understand the fundamental characteristics of a truck in order to minimise the risk of truck tip-over or the loss of a load from the forks, both of which could result in serious injury to the operator/others, damage to the truck, goods and infrastructure.

Explain that overall stability of the truck (and any load that it is transporting) is ultimately influenced by its "centre of gravity".

Centre of GravityExplain that the centre of gravity (CoG) of an object is the point at which its weight is equal in all directions. In the context of the truck type studied during this course, stability is achieved when the centre of gravity is within the “points of support” – where the truck makes contact with the ground, which is generally the drive, caster and load wheels (where applicable). Explain that the truck’s centre of gravity will shift in the following situations:

• Picking up and depositing loads

• Travelling and stopping

• Changing direction.

When the truck is stationary, the CoG remains in a fixed location.

Explain that, as separate items, the truck and the load have their own centres of gravity. However, when the two are combined and become one entity, a shared centre of gravity exists. Generally, the centre of gravity is situated approximately between the truck and the load when laden; and when the truck is unladen, it is located approximately in the centre of the battery.

StabilityDiscuss the factors that affect stability. Make a list on a flip chart or whiteboard (change of speed and direction, weight, load centre, site conditions, etc.) and divide them between longitudinal and lateral stability.

Perfect Balance (Pedestrian Reach and Counterbalance Only)

Explain that the term “perfect balance” is a misleading term. This is, in fact, a dangerous state in which the weight on both sides of the pivot are equal. This is dangerous situation because it means that the truck is being operated at its capacity and there is no margin for error; there is no allowance for the load being mislabelled, the operator undercutting the load, etc.

Highlight that the working load indicated on the rated capacity plate, or the maximum lift weight visual display, as appropriate, is calculated by the manufacturer with regard to all safety legislation and safe operating practices and must never be exceeded.



Lateral Instability

Explain that lateral instability is the result of the centre of gravity moving too far to either side of the truck. There are many potential causes of lateral instability, including:

• Turning at too high a speed for the conditions

• Turning with raised forks or a raised load (where applicable)

• Turning across an incline

• Driving one wheel over a bump or pothole

• Incorrect placement of the load on the forks so that it is not balanced.


Longitudinal Instability

Where applicable, explain that longitudinal instability on load legged trucks occurs as a result of the centre of gravity moving too far to the front or rear of the truck. As with lateral instability, there are a number of reasons for longitudinal instability, including:

• Violent braking with the forks trailing

• Harsh acceleration with the forks leading

• Operating incorrectly on ramps or inclines.

Longitudinal Instability (Reach and Counterbalance Only)

Discuss longitudinal instability on reach and counterbalance trucks, where applicable. Explain that the physics of longitudinal instability in reach and counterbalance trucks remain the same: the centre of gravity shifts too far to the front or rear.

Discuss the typical causes with reference to these types of truck, including:

• Overloading the truck

• Harsh use of the hoist (raising or lowering) hydraulics (link back to the earlier discussion about

"perfect fit")

• Failing to fully insert the forks (link back to the earlier discussion about "perfect fit")

• Violent braking or acceleration

• Operating incorrectly on ramps or inclines, etc. (ramps and inclines are discussed in another session).

Truck Tip Over

Discuss with the candidates actions that should be taken in the event that the truck loses stability and tips over.

Explain that should a truck tip over (laterally or longitudinally), serious or fatal injury can occur from the operator becoming trapped between the truck and the ground. State the manufacturers' recommended action to take should a truck begin to tip over.

Summarise the key points from this session and confirm learning by asking questions. Answer any questions that the group might have.

End of S11


S12(A&B) – Pallet Handling






To introduce the candidates to different pallet types and their design, as well as approaches to picking up, transporting and setting them down.


• Truck• Laden pallet (2 or 4-way of appropriate construction)• Pallet example or illustration (where possible)• Marked pallet location(s) with 75mm (3 inches) clearance all round.

On completion of this session, candidates will be able to identify different types of pallet and their suitability relative to truck type. Candidates will also be able to discuss and demonstrate approaching, picking up, transporting and depositing a laden pallet into a marked area.



IntroductionDiscuss pallet design and why it is important that operators are able to identify how a pallet has been constructed from the point of view of the load it might bear (link back to the discussion on load assessment), and how it can safely be picked up. Also explain that a pallet’s construction will also have a bearing on the type of truck that can be used to handle it.

Explain that manufacturers design and construct pallets to carry a maximum load. The maximum load should never be exceeded because doing so can damage both the pallet and the load. Discuss the most commonly used pallets.

Two-way Entry Reversible PalletsVarious Sizes ‘Stringer Pallet’

This type of pallet is configured in such a way that it only has fork openings on two parallel sides – either on the narrow face or the wide face. Two-way entry pallets, as their name implies, do not have openings for forks on all four faces, limiting their use in the workplace. As an additional point, explain that notches can be cut into the stringer board that runs down the “closed” side of the pallet in order to allow four-way entry.

Four-way Entry Non-reversible1000mm x 1200mm ‘Block Pallet’

The most common type of pallet used. These pallets can be picked up on all sides. If applicable to your course, explain that low-level load wheels must be clear of the bottom deck boards to avoid damaging the pallet. This type of pallet is not suitable for inserted load wheel stacker trucks.

Four-way Entry Non-reversible 800mm x 1200mm ‘Euro Pallet’

These pallets can be lifted using any truck type. Explain that when operating stacker trucks or low-level pallet trucks, the forks should be inserted on the narrow edge (the shortest edge on the

pallet) – this is because the truck’s load wheels sit on the bottom deck boards once inserted, so when the pallet is lifted, the board will be split from the bearers.


Recap on the discussion about load assessment. Remind the candidates that before attempting to move a laden pallet of any type, the operator must check that the pallet is appropriate for the truck’s rated capacity, that it is undamaged, and that it is safe and secure to lift, transport and deposit.

Adjusting Lateral Spread of Fork Arms (Straddle Trucks and Pedestrian Reach/Counterbalances)

Link back to 'Stability' and explain the reasons for making adjustments to fork spread – primarily to provide maximum support for the pallet – and demonstrate the method of adjusting the forks. Remind the candidates about the use of correct PPE, for example safety footwear and gloves.



Picking Up/Setting Down a Pallet

Picking Up/Setting a Pallet Down at a Vertical Face

Demonstrate and explain the procedure for making a straight line approach to pick up and set down a laden pallet. Ensure that your demonstration includes how to:

• Line the forks up centrally and squarely with the pallet at the earliest opportunity

• Stop approximately 150mm (6 inches) away from the load to allow for height adjustment of the forks (as appropriate) and to prevent pedestrians from crossing between the truck and the load

• Enter the pallet smoothly, inserting until the pallet is against the heel of the forks or load guard

• Lift the forks to travel height and apply tilt (as applicable) and move off (remind the group about observation and looking in the direction of travel)

• Make a 90° turn away and deposit the load into the prepared marked area• Withdraw the forks (remind the candidates about the importance of

observation and looking in the direction of travel• Stop with the fork tips a short distance from the load and raise the forks to

travel position• Carry out observations and move away.

Repeat the demonstration and explanation, this time picking up and depositing a laden pallet squarely to within 150mm (6 inches) of, but not touching, a vertical face.

Reiterate that loads which restrict or block vision must be transported load trailing.

UndercuttingWhen a pallet is close or adjacent to a wall or another pallet, or when a pallet cannot be heeled up immediately because the forks are longer than the length of the pallet, it will be necessary to ‘undercut’ the load – in other words it will be necessary to pick up the load contrary to standard practice where fully heeling the load is preferred.

This process is used to move the load a short distance from the obstruction so that it can be set down and heeled before applying tilt and travelling.


End of S12

Consideration must be given to the increased load centre in this situation and the decrease in the truck’s carrying capacity. Link back to the discussion on stability and rated capacity of the truck.


• Making a straight line approach• Picking up a laden pallet • Turn away to 90° • Transport and deposit a laden pallet into a marked area• Transport and deposit a laden pallet to within 150mm (6 inches) of a vertical

face.

Further guidance on the pallet safety can be found in the HSE’s Guidance Note PM15


S13(A&B) – Handling Different Loads



3:1 30 mins N/A N/A N/A



To introduce the candidates to different types of loads and correct methods to be applied when picking up, transporting and depositing them.


• Truck• Laden pallet (2 or 4-way of appropriate construction)• Example plastic or metal pallets (if available) • Illustrations of plastic or metal pallets

On completion of this session, candidates will be able to:

• Identify different types of load and discuss different adhesion properties • Demonstrate making a 90° approach to a load from both sides in an open area• Pick up, turn away at 90°, transport and deposit a laden pallet into a marked area.



PreparationPrior to the training session ensure there are ample examples of other loads or illustrations to clearly show the different types of load that candidates may come across as an operator.

Pallet VarietyExplain that although most pallets are wooden, other materials are used for a number of reasons – for example, sterile environment requirements, weight capacity, stacking ability, etc. Show or list some examples, including:

• Plastic pallets

• Metal pallets

• Intermediate bulk containers (IBCs)

• Corner post pallets

• Roll pallets/cages

• Pressed recycled pallets.

An illustration of the different types of pallet can be found on page 90.


Discuss the different types of materials that might be carried by the truck – for example, wooden pallets or metal stillages – and discuss different levels of adhesion (grip) between the forks and different types of load. Explain that some materials – for example, smooth hard materials like metal – are more likely to slip under braking or acceleration. Recap on the demonstration/discussion regarding fork spread during the ‘Pallet Handling’ session and explain that the same technique can help limit load movement.


Demonstrate and explain the procedure for travelling forks trailing past the load to a suitable stopping point and make a 90° approach from both sides in an open area in order to pick it up and set it down. During your demonstration, ensure that you discuss the following key points:

• Observation during turning• Position the forks centrally and squarely with the pallet, stopping approximately

100-150mm (4-6 inches) away from the load to allow for easier judgement of correct positioning/fork height, and to prevent pedestrians from crossing in between the forks and the load

• Enter the pallet straight, watching the forks all the way, to ensure no unnecessary contact is made

• Smooth, timely operation of the controls, ensuring the forks are fully inserted• Lift/tilt the pallet to correct travel position for the particular load and ground

conditions• Transport the pallet, paying close attention to observation and looking in the

direction of travel• Correct judgement of the 90° turn in order to approach the deposit area • Safe and accurate depositing of the pallet into the marked area.



Further guidance on the Pallet safety can be found in the HSE’s Guidance Note PM15

End of S13

Picking Up/Setting a Pallet Down at a Vertical FaceRepeat the previous exercise, but in this instance demonstrate how to deposit the load to within 150mm of a vertical face


S14(A&B) – Pallet Stacking






Introduce the candidates to free-standing stacking, the correct process for building a stack and the precautions that should be taken during the task.


• Truck• Unladen pallets (in stacks)• Protective gloves


• Build and dismantle a free-standing stack using unladen pallets• Discuss the risks associated with stacking, the dangers of incorrectly stacked pallets and

precautions that should be taken when stacking and de-stacking in this way.



IntroductionIntroduce the candidates to the subject of free-standing stacks, in particular, discuss the following:

• The purpose of placing unladen pallets in stacks

• The importance of stacking pallets of the same size and construction

• The dangers of stacking too high, off centre and not square to the stack.

On a pedestrian truck, the fold-away platform must be stowed during stacking and de-stacking manoeuvres.

Explain that incorrectly stacking pallets can cause instability, which could result in falling stacks or pallets, which in turn could result in serious injury. It is therefore important to check the condition and stability/security of the load and of the receiving stack before commencing.

Care should be taken when handling unladen pallets. Appropriate PPE should be worn for the task and proper manual handling techniques should be used. Further training should be provided if necessary.


Demonstrate and discuss the following:

• Deposit the unladen pallets onto the receiving stack squarely, centrally and safely

• Safely de-stack the unladen pallets from a stack of equally-sized pallets.

Depositing an Unladen Pallet on a StackBefore demonstrating the process, discuss safety considerations that should be remembered, including:

• Careful fork withdrawal

• Sympathetic use of hydraulic controls

• Adopting the travel position after depositing

• Overhead obstructions

• All-round visual checks.




• Deposit the unladen pallets onto the receiving stack squarely, centrally and safely

• Safely de-stack the unladen pallets from a stack of equally sized pallets.

Repeat the process to stack and de-stack at high-level.

Further manual handling training may be required by candidates. Guidance on manual pallet handling training can be found in RTITB's LTG32: Manual Handling in Transport, Warehousing and Logistics and in HSE's publication L23.

End of S14


S15A – Chicane (Pedestrian Operated)



3:1:1 30 mins N/A N/A N/A








This session is designed to further candidates' ability to accurately negotiate confined areas, both forks trailing and forks leading with a laden truck.


• Suitable materials to create a chicane• A laden truck

By the end of this session, candidates will be able to demonstrate safe and accurate negotiation of a chicane on a laden truck forks leading and forks trailing.



Before starting the demonstration, remind the candidates about the earlier discussion regarding operator position during turns. Stress the importance of completing all-round observation before setting off and initiating turns. It is also important to remind the candidates that during travelling, the operator should face the direction of travel.

During your demonstration, remind the candidates of the techniques covered in the earlier session on steering – for example, feathering the steering and maintaining control of truck speed.

Before delivering this session, ensure that you have delivered the sessions on basic and progressive steering.

PreparationBefore commencing the session, construct a chicane following the specification described in ‘Setting up the Practical Test Course’ (see the 'Assessment' section of this guide).

Negotiating the ChicaneRecap on the ‘Basic Steering’ session, during which the candidates learnt to steer and manoeuvre an unladen truck, both forks leading and forks trailing.

Explain that during this session they will continue to learn manoeuvring techniques, but now they will be in a confined area and the truck will be carrying a load.

It is important to emphasise that the load will affect the way in which the truck responds to steering inputs. Also explain that the load will present a degree of challenge when it comes to judging the forward-most position and the pivoting point of the truck.

The following guidance on load trailing manoeuvres discusses counterbalance and non-counterbalance machine types, please follow the demonstration that is appropriate to the machine used for your training course.

You may find it relevant and appropriate to discuss the turning characteristics of different truck types, depending on the training situation; for example, the location of pivot points etc. Reiterate the importance of Specific Job and Familiarisation training.


Explain and demonstrate the correct procedure for negotiating the chicane with the load trailing.

During your demonstration, explain the importance of maintaining a gap between the side of the truck and the outside wall of the chicane as the truck advances into the corner. Remind the candidates that rear end swing should be considered whenever working in confined areas.

Remember to stress the importance of carrying out observations at all times. At an appropriate point, stop and explain the importance of checking the crush zones as the truck turns.

Answer any questions.

Load Trailing (Excluding Counterbalance Machines)



Explain and demonstrate the correct procedure for negotiating the chicane with the load trailing and how these skills relate to the workplace.

Before starting the demonstration, remind the candidates about the earlier discussion regarding operator position during turns.

Enter the chicane and advance toward the apex of the inside corner. Explain that the objective is to line the pivot point up (the front wheels) with the apex.

Remember to stress the importance of carrying out observations at all times.

Begin the turn, explaining the importance of checking the crush zones as the truck turns.

Explain that the operator's position will need to change in order to safely negotiate the turn.


Repeat the manoeuvre, this time with the load leading.

Enter the chicane and advance toward the apex of the inside corner. Explain that the objective is to line the pivot point up with the apex.


As the truck completes the turn, line up for the apex of the second turn. Once again, negotiate the turn, stressing the importance of observation and awareness of the crush zones.

Straighten the wheels and move to the exit.

Load Trailing (Counterbalance Machines Only)

Load Leading (Counterbalance and Non-counterbalance Machine Types)


Continue to emphasise the importance of accurate steering, acceleration and the significance of continual observation, paying particular attention to the correct operating position.


• Negotiate a chicane, forks trailing and forks leading, laden.

End of S15A


S15B – Chicane (Rider Operated)











This session is designed to further candidates' ability to accurately negotiate confined areas, both forks trailing and forks leading with a laden truck.


• Suitable materials to create a chicane• A laden truck

By the end of this session, candidates will be able to demonstrate safe and accurate negotiation of a chicane on a laden truck, forks leading and forks trailing.



Before delivering this session, ensure that you have delivered the sessions on basic and progressive steering.

Preparation Before commencing the session, construct a chicane following the specification described in ‘Setting up the Practical Test Course’ (see the 'Assessment' section of this guide).

Negotiating the ChicaneRecap on the ‘Basic Steering’ session, during which the candidates learnt to steer and manoeuvre an unladen truck, both forks leading and forks trailing.

Explain that during this session they will continue to learn manoeuvring techniques, but now they will be in a confined area and the truck will be carrying a load.

It is important to emphasise that the load will affect the way in which the truck responds to steering inputs. Also explain that the load will present a degree of challenge when it comes to judging the forward-most position and the pivoting point of the truck.

Before starting the demonstration, remind the candidates about the earlier discussion regarding operator position during turns. Stress the importance of completing all-round observation before setting off and initiating turns. It is also important to remind the candidates that during travelling, the operator should face the direction of travel.

During your demonstration, remind the candidates of the techniques covered in the earlier session on steering – for example, feathering the steering and maintaining control of truck speed.

You may find it relevant and appropriate to discuss the turning characteristics of different truck types, depending the training situation; for example, the location of pivot points etc. Reiterate the importance of Specific Job and Familiarisation training.


Explain and demonstrate the correct procedure for negotiating the chicane with the load trailing and how these skills relate to the workplace.

During your demonstration, explain the importance of maintaining a gap between the side of the truck and the outside wall of the chicane as the truck advances into the corner. Remind the candidates that rear end swing should be considered when gauging the truck and the outside wall.

Remember to stress the importance of carrying out observations throughout the exercise. At an appropriate point, stop and explain the importance of checking the pivot point, rear end swing and front end swing.

Explain how, after reaching the first corner, the operator must line up their approach to the outside wall of the next corner and that their operating position will need to change in order to safely negotiate the turn. Discuss the danger of contact with the wall during the turn.

From the second corner, line up for a straight run to the chicane exit.


Load Trailing



Continue to emphasise the importance of accurate steering, acceleration and the significance of continual

observation, paying particular attention to the correct operating position.

Repeat the manoeuvre, this time with the load leading.

Enter the chicane and advance toward the apex of the inside corner. Explain that the objective is to line the pivot point up with the apex.


As the truck completes the turn, line up for the apex of the second turn. Once again, negotiate the turn, stressing the importance of observation and awareness of the various points of observation (pivot point, rear/front end swing).

Straighten the truck and move to the exit.


• Negotiate a chicane, forks trailing and forks leading, laden.

End of S15B

Load Leading


S16A – Turning in a Narrow Aisle (Pedestrian Operated)

To introduce the candidates to negotiating a 90° turn with an unladen and laden truck in a narrow aisle.


• Truck• Industrial racking system (as applicable)• An appropriate laden pallet• Appropriate materials to create a narrow aisle


• Demonstrate correct truck position in a narrow aisle prior to making a turn (forks trailing, laden and unladen)

• Demonstrate safe and accurate turning from the left and right to a pallet position• Discuss safe operating practices related to working in a narrow aisle.








PreparationBefore commencing the session, construct a main working aisle (refer to ‘Setting up the Practical Test Course – Main Working Aisle’ found in the 'Assessment' section). Check that all materials used to construct the aisle are in good order and that the location for the unladen turn has an appropriate pallet to turn onto with appropriate pallets occupying the adjacent locations. Ensure all other required session resources are available.

If racking cannot be provided on both sides of the "aisle", then appropriate materials should be used to construct the aisle.

When training is conducted using a pedestrian operated truck fitted with a fold-away operator platform, ensure that the platform is stowed before performing the operations discussed during the session.


Aisle PositionDiscuss with the group the basics of truck position in an aisle in the context of preparing to make turns in the aisle. Explain that, depending on the type of truck being operated, varying amounts of space will be required in order to make a turn to approach a pallet position. In essence, the further forward the pivoting point, the closer the truck will need to be positioned to the load – for example, a "load legged" truck, which has its pivoting point near to the end of the forks, will need to be positioned closer to the target position than a counterbalance truck, which has a pivoting point positioned much further back.

Making the Turn

Explain and demonstrate the process:

• Travel along the aisle, forks trailing. Discuss the truck's position and remind the candidates about the importance of facing the direction of travel and continued observation

• Show the candidates how to line up for both left and right-hand turns to 90°, emphasising the point at which to stop the truck in order to make an accurate turn and approach to the pallet position

• At the start of the turn, explain the benefits of correct position. Remind the group about observations and controlled acceleration

• Complete the turn with the truck wheels straight and the forks the correct distance from the pallet space – 150mm (6 inches) – to deter pedestrians walking between the truck and the load, and to allow for adjustments

• Demonstrate the correct procedure for turning away from the pallet space at 90° to the left and right, emphasising the need for effective observation and correct operator position

• Position the truck in an appropriate position for travelling back along the aisle and travel toward the exit. Remind the candidates about the importance of looking in the direction of travel.

Repeat the demonstration, this time carrying a load. Remember to discuss with the candidates how the load affects the truck's handling characteristics and the operator's view of rear end swing.



Discuss the key points of the demonstration:

• How to identify a reference point to aid in judging the pivot point when lining up for the turn.

• All round observation, before moving off and during the turn.

• Smooth use of the truck's controls during travelling and manoeuvring.

• Observations of the potential crush zones.

• Central position of the forks in front of the load/load-position, approximately 150mm (6 inches)

away to aid with accuracy and deter pedestrians walking between the forks and the load.

• Ensure that the truck's wheels are straight after the turn.

End of S16A

Demonstrate approaching from the other end of the aisle and the turn.


• Approach from both directions, forks trailing, completing 90° turns within a narrow aisle with an unladen and laden truck.


S16B – Turning in a Narrow Aisle (Rider Operated)






To introduce the candidates to negotiating a 90° turn with an unladen and laden truck in a narrow aisle.


• Truck• Industrial racking system (as appropriate)• An appropriate laden pallet• Appropriate materials to create a narrow aisle



• Demonstrate safe and accurate turning from the left and right to a pallet position• Discuss safe operating practices related to working in a narrow aisle.



PreparationBefore commencing the session, construct a main working aisle (refer to 'Setting up the Practical Test Course – Main Working Aisle' found in the 'Assessment' section). Check that all materials used to construct the aisle are in good order and that the location for the unladen turn has an appropriate pallet to turn onto with appropriate pallets occupying the adjacent locations. Ensure all other required session resources are available.


Aisle PositionDiscuss with the group the basics of truck position in an aisle in the context of preparing to make turns in the aisle. Explain that, depending on the type of truck being operated, varying amounts of space will be required in order to make a turn to approach a pallet position. In essence, the further forward the pivoting point, the closer the truck will need to be positioned to the load – for example, a truck which has its pivoting point near to the end of the forks, will need to be positioned closer to the target position than a counterbalance truck, which has a pivoting point positioned much further back.



• Travel along the aisle, forks trailing. Discuss the truck's position and remind the candidates about the importance of facing the direction of travel and continued observation

• Show the candidates how to line up for both left and right-hand turns to 90°, emphasising the point at which to stop the truck in order to make an accurate turn and approach to the pallet position





Repeat the demonstration, this time carrying a load. Remember to discuss with the candidates how the load affects the truck's handling characteristics and the operator's view of rear end swing.

Recap the key points of the demonstration:

• How to identify a reference point to aid in judging the pivot point when lining up for the turn

• All-round observation, before moving off and during the turn

• Smooth use of the truck's controls during travelling and manoeuvring

• Points of observation, including: pivot point, front end swing and rear end swing


away to aid with accuracy and deter pedestrians walking between the forks and the load

• Ensure that the truck's wheels are straight after the turn.

Making the Turn






End of S16B


S17(A&B) – Industrial Racking (Ground/Low-level)






Introduce the candidates to working with industrial racking and discuss precautions that should be taken during stacking and de-stacking operations at low-level.


• Truck• Industrial racking system, including signs and load notice• Storage Equipment Manufacturers' Association (SEMA) publication (or equivalent)• Laden pallet appropriate to the racking system• Appropriate materials to create a narrow aisle


• Demonstrate stacking and de-stacking a laden pallet at ground-level and/or low-level in a narrow aisle location

• Discuss the construction and function of racking and safe working practices in and around racking.



Adjustable Pallet Racking (APR)Explain that the most common type of racking is Adjustable Pallet Racking (APR). This type of racking is constructed from straight pieces of shaped steel joined together to make the structure suitable for carrying pallets; it is designed to carry palletised loads at multiple levels in order to increase storage density even for non-stackable loads. Typically this type of racking is accessed along aisles that run adjacent to the pallet locations.

Inform the candidates that there are other types of racking that they might come across, which may include Drive-in Racking, Cantilever Racking, etc. but before attempting to work with racking in their own workplace they must first undergo Specific Job training to ensure they understand the use and precautions relating to equipment in their work environment.

Point out the component parts of the adjustable pallet racking including:

• Frame

• Braces horizontal and diagonal

• Foot plates

• Uprights

• Beams

• Beam locks, bolts or welds

• Run spaces (where applicable)

• And any other relevant component parts (where applicable).

Explain that the racking is under the most stress at lower sections because the force of the weight loaded on the beams above is transferred downwards.

PreparationBefore commencing the session, construct a main working aisle referring to ‘Setting up the Practical Test Course – Main Working Aisle’ found in the 'Assessment' section. Check that the racking is in good order and that the location for the unladen turn has an appropriate pallet to turn onto with appropriate pallets occupying the adjacent locations. Ensure all other session resources are available.



Racking Load NoticeExplain that the racking load notice is an important piece of safety signage which is intended to inform users of correct operation; it is split into three parts:

1. General Safety Instructions

This includes a number of instructions and warnings that remind operators of the correct behaviours required to operate safely. Briefly discuss each item listed on the load notice attached to the racking used for training.

2. Specific Information

As the name suggests, this information is relevant to the particular installation and is included to provide guidance on the equipment's load limitations, specifically the:

• Weight of pallet that can be placed on the beams

• Total carrying capacity or safe working load (SWL) and uniform distributed load (UDL)

• Height between the beams

• Height of the first beam above the floor.

Explain that the height of the first (or bottom) beam is a crucial part of the calculation when determining the carrying capacity of the racking. Changing the height of, or removing this beam, can de-rate the carrying capacity of the racking structure, making it extremely unsafe.

Explain that loads need to be uniformly distributed along and between the beams. Normal pallets will provide a uniformly distributed load (UDL) but some other goods such as drums, coils or odd-shaped goods might not, causing the beams to become overloaded.

3. Administrative Information

Shows the supplier's contact details. This information provides users with access to help with queries about the storage equipment.

Racking InspectionsExplain the dangers of using racking incorrectly and using damaged racking. Highlight the importance of regular racking inspections by qualified personnel and state the reporting procedure for any damage found, as well as the steps that operators should take if they strike the racking.

Further information about industrial racking inspections and damage tolerances can be found in publications from the Storage Equipment Manufacturers' Association (SEMA) who publish recommendations for the use, manufacture, installation etc. of racking. Information and guidance may also be found in the manufacturer’s manual, available from the supplier.



Working at Ground-levelExplain the safety precautions that should be taken before attempting to stack or de-stack a laden pallet from a racking system at ground-level. Your discussion should include:

• Pedestrians and other operators

• Pallet condition, load stability and security

• Overall condition of the racking


• Adequate clearance of the beam above and the uprights to either side

• The ground conditions

• Stacking and load position.

Where a fold-away platform is fitted, it should be stowed away correctly during the following operation.

Recap on the 'Narrow Aisle' lesson and demonstrate the procedure for approaching from the left and right and safely de-stacking a laden pallet at ground-level. Remind the candidates that the truck should be properly secured (park brake and neutral) and the wheels should be straight before attempting to lift the pallet.

Stress the importance of inserting the forks centrally to aid load stability. Explain the importance of checking the fork height before entry in order to prevent rubbing, as this could affect the pallet’s position and/or damage it.

Explain that the operator must check the height of the pallet when lifting and the clearance above the pallet. Discuss safety precautions that must be considered before and during pallet withdrawal – including all round observation and awareness of pedestrians and crush zones.


Allow each candidate to practise:

• Approaching from the left and right and stacking a laden pallet at ground-level

• Approaching from the left and right and de-stacking a laden pallet at ground-level.

Demonstrate the process of approaching from the left and right and stacking the pallet at ground-level. Remind the candidates about properly securing the truck before operating the hydraulics and discuss the safety precautions that should be considered before placing the pallet into its location.

Remind the candidates of the importance of all round observation before manoeuvring the truck during withdrawal. Stress the importance of checking the fork height before withdrawal in order to prevent rubbing as this could affect the pallet’s position and/or damage it.



Provide all candidates with an opportunity to practise:

• Approaching the pallet position from the left and right and stack a laden pallet at low-level

• Approaching the pallet position from the left and right and de-stack a laden pallet from low-level.

End of S17

Build on the previous demonstrations. Discuss and demonstrate approaching and turning from the left and right to stack and de-stack a laden pallet from industrial racking at low-level. Ensure that throughout the demonstration you offer commentary and discussion of the key points.

Include in your explanation:

• Condition and safe working load of the beam• The dangers of overloading the racking system• Clearance overhead• Positioning of the laden pallet on the beam• Remember to ensure that the wheels are straight before attempting to lift the

pallet• Awareness of insertion and withdrawal height of the forks from the pallet to

avoid rubbing• Awareness of activity behind the truck when preparing to withdraw from the

pallet position.

Low-Level

This part of the session is not applicable to ground-level pallet trucks.



S18(A&B) – Industrial Racking (Medium-level)






To introduce the candidates to safe operating practices when stacking and de-stacking at Medium-level in industrial racking.


• Truck• Industrial racking system, including signs and load notice• Storage Equipment Manufacturers' Association (SEMA) publication or equivalent• Laden pallet appropriate to the racking system• Appropriate materials to create a narrow aisle


• Demonstrate stacking and de-stacking at Medium-level• Discuss safety precautions that should be considered when working at Medium-level.




Industrial Racking – Medium-level Build on the discussion and demonstration about ground/low-level racking and progress to Medium-level racking. Remind the candidates of the safety precautions that relate to working in racking and expand on the additional considerations that relate to Medium-level operations. Include in your discussion:

• All round visual checks

• Direction of the wheels before commencing hydraulic operation

• Condition and safe working load of the beam

• Clearance of the load to pass within the restriction of the beams (above, below and to the sides)

• Actions to take in the event of a collision with the racking

• Withdrawal and insertion of the forks at the correct height to avoid rubbing

• Levelling of the forks/load at the appropriate height (where applicable)

• The dangers of overloading the racking system at subsequent levels

• Instability caused by the load wheels moving over bottom deck boards of a ground-level pallet and

debris.


Where a fold-away platform is fitted, the platform should be stowed during the operations covered in this session.

Demonstrate approaching the pallet position from the left and right, turning 90° and stacking a laden pallet at Medium-level. Repeat the manoeuvre from both the left and right, turning 90° to de-stack the pallet. Ensure that throughout the demonstration you offer commentary and discussion of the key points. Remind the candidates about the importance of looking in the direction of travel and all round observation (particularly when manoeuvring away from the pallet position).


Provide each candidate with an opportunity to practise:

• Approaching the pallet position from the left and right before turning 90° to stack a laden pallet at Medium-level

• Approaching the pallet position from the left and right before turning 90° to de-stack a laden pallet from Medium-level.

End of S18


S19(A&B) – Industrial Racking (High-level)

Suggested DurationsHigh-level only





To introduce the candidates to the safety principles relating to working at high-level in an industrial racking system.


• Truck• Industrial racking system, including signs and load notice• Storage Equipment Manufacturers' Association (SEMA) publication or equivalent• Laden pallet appropriate to the racking system• Appropriate materials to create a narrow aisle


• Demonstrate stacking and de-stacking at high-level• Discuss safety precautions that should be considered when working at high-level.


End of S19

Industrial Racking – High-level Build on the discussion and demonstration about Medium-level racking and progress to high-level racking. Remind the candidates of the safety precautions that relate to working in racking and expand on the additional considerations that relate to high-level operations. Include in your discussion:

• Difficulties faced when judging pallet and fork arms at height

• Effects of mast and fork deflection

• Dangers of pedestrians passing underneath the raised forks/load

• Truck instability issues that might occur if the truck is turned with the hydraulics raised.

Where a fold-away platform is fitted, the platform should be stowed during the operations covered in this session.

Demonstrate approaching the pallet position from the left and right, turning 90° and stacking a laden pallet at high-level. Repeat the manoeuvre from both the left and right, turning 90° to de-stack the pallet. Ensure that throughout the demonstration you offer commentary and discussion of the key points. Stress the importance of taking care not to turn with the hydraulics raised. Remind the candidates about the importance of looking in the direction of travel and all round observation (particularly when manoeuvring away from the pallet position).


• Approaching the pallet position from the left and right before turning 90° to stack a laden pallet at high-level

• Approaching the pallet position from the left and right before turning 90° to de-stack a laden pallet from high-level.


S20(A&B) – Negotiating Inclines






Introduce the candidates to considerations that should be taken into account when negotiating inclines.

Practical training area, with an incline (where possible), or classroom, with appropriate visual aids.

• Truck• Laden pallet• Manufacturer’s operator manual • Incline or ramp (where available)• Illustrations of negotiating inclines (as necessary)• PC and compatible projector with screen (as necessary)


• Discuss the risks relating to negotiating inclines• Demonstrate or discuss negotiating an incline with an unladen truck, forks leading and

forks trailing• Demonstrate or discuss negotiating an incline with a laden truck, load leading and load

trailing.



PreparationBefore starting the session, ensure all session resources are available. If an incline is unavailable, the session can be covered theoretically using the presentation provided or reproductions of the illustrations in this guide.

Negotiating InclinesDiscuss the fact that in some workplaces it might be necessary to negotiate ramps and inclines on a truck. Explain that before attempting to travel up or down an incline, the operator must take a few things into account:

• Explain that inclines must be clean, have a non-slip surface to provide adhesion and be suitable for the truck to operate upon

• Trucks are limited in terms of the scale of gradient they can tackle – this information can be found in the manufacturer’s handbook

• The stability and security of the load must be considered – will it spill or fall from the forks? The operator must think about the dimensions of the load, its security, and the type of load (recap on the earlier discussion about longitudinal and lateral stability).

Recap on your earlier discussion regarding centres of gravity and explain how the centre of gravity will shift on a gradient. The taller and more top-heavy a truck or load, the more likely it is to tip over when it is tilted on a gradient. The illustration below shows a pallet truck on two different inclines; the second one is steep enough to cause the centre of gravity to fall outside the base of the laden truck, which will result in it toppling over.

Explain that when approaching the base of an incline it may be necessary to stop, assess the fork height and adjust it accordingly to prevent the forks/load from grounding.


Where a fold-away platform is fitted, it is recommended that this skill be demonstrated and carried out with the platform stowed away correctly, where possible.

If a suitable incline is available, demonstrate the safe method of negotiating an incline unladen, both travelling up and travelling down. Explain that in order to control the traction and adhesion of the drive wheel, the truck should travel with its forks facing down the incline. Highlight the importance of keeping up a consistent steady speed, limiting the need to brake harshly, which in turn reduces the likelihood of longitude instability.

Once the truck has negotiated the incline, it should be stopped and the forks returned to an appropriate travel height/position in order to maintain security and stability of the load, or the safety of unladen forks for the rest of the journey.

Discuss the dangers of turning on an incline. Explain that turning on an incline could result in lateral tip-over. For this reason, the truck should only travel straight up and straight down. Stress that slow, controlled speed should be maintained, and the operator should always be prepared to apply the brake.

Unladen

Laden

Where a rider platform is fitted, it is recommended that this skill be demonstrated and carried out with the platform stowed away correctly, where possible.



End of S20

When descending an incline with a laden pedestrian operated truck, it is important to adopt the correct operating position to avoid potential injury if the truck loses adhesion or rolls away. Demonstrate the correct operating position and the action of releasing the tiller control to allow it to return to the upright position which will engage the truck's brake.

Parking on an InclineExplain that trucks should not be parked on an incline; however, if circumstances arise where parking in such a location is unavoidable, the park brake must be applied and the wheels must be chocked to prevent the truck from moving. The key should be left in the truck to allow access in an emergency situation.

If a suitable incline is available, allow the candidates an opportunity to operate the truck laden and unladen up and down the incline.

If a suitable incline is not available, use the illustrations found in Appendix 1 to help confirm the candidates' understanding of the issues covered in this session and correct operation on inclines through discussion and questioning techniques.

If a suitable incline is available, demonstrate the safe method of negotiating an incline laden, both travelling up and travelling down. Explain that in order to control the traction of the drive wheel and increase load stability, a laden truck should travel with its forks facing up the incline whether it is travelling up or down the incline. If the load obscures the operator's view, a banksman should be employed to aid the manoeuvre.


S21(A&B) – Vehicle Loading and Unloading






Introduce the candidates to the process of loading and unloading vehicles.

Practical training area, or classroom, with appropriate visual aids.

• Truck• Loads• Suitable vehicle or trailer (where available) • Appropriate materials to cordon off the training area• High visibility clothing (if necessary)• Wheel chocks• Suitable lift, ramp or dock bridging platform (where available)• Local safety procedures.


• Demonstrate or discuss correct operating techniques for loading and unloading a vehicle • Discuss safe working practices that should be adopted when working in this capacity

with the equipment.



PreparationBefore starting the session have all the session resources available. If any of these resources are not available, the session may be covered theoretically using the presentation provided or illustrations, printed or drawn (as necessary).

Stress that loading and unloading can be dangerous. Heavy loads, moving or overturning vehicles and working at height can all lead to injuries or death.

Explain that loading and unloading can be dangerous.

Introduce the importance of safe working practices and make the candidates aware that adhering to the following guidance can help reduce the risks involved.

• Loading and unloading areas should be clear of traffic, pedestrians and people that are not involved in the process.

• Overhead areas should be clear of electric cables so there is no risk of contact with them.• The loading area should be level and, to maintain stability, trailers should be parked on firm and

level ground. • Loads should be spread evenly, as far as is reasonably practicable, because uneven loads can make

the vehicle unstable. • Loads should be secured and arranged appropriately so that they do not slide around.• Any available safety equipment must be used.• Prior to loading or unloading, the vehicle or trailer must have its brakes applied and any stabilisers

(such as 5th wheel supports) must be used. • The vehicle load deck should be assessed for debris/condition/integrity prior to loading. • When loading, consideration must be given to the unloading operation that will take place after

transportation to ensure the load will be in a safe and suitable condition. • All loads/pallets should be in good condition prior to loading. Loads should be properly secured

to pallets and once on the vehicle, pallets should be securely attached to the vehicle so that they cannot move or fall off.

• Overhanging loads should be kept to a minimum but ideally avoided wherever possible.• Ensure that where more than one company is involved in the operation you are aware of the

arrangements that have been agreed with regard to instructions, equipment and co-operation.• Checks must be made before unloading a vehicle/trailer to make sure load movement has not

occurred during transport. It is important to check that the load will not move or fall when restraints are released.

• There must be safeguards against drivers accidentally driving away too early. This does happen and it is extremely dangerous. Safeguards to reduce risk include:

• Traffic lights • Use of vehicle or trailer restraints• Key custody arrangements that can be enforced while loading/unloading is taking place.


The operator must take personal responsibility for their safety, do not rely on other parties to make all necessary checks and take appropriate safety steps.

Stress that the safety of the driver is important and that they should remain in an appropriate waiting area whilst loading or unloading is taking place.

Safeguards are especially important where there could be communication problems, e.g. where foreign drivers are involved.

Dock Safety PrecautionsExplain that before loading and unloading can take place, all necessary safety precautions must be undertaken. Policies and procedures regarding vehicle safety at loading docks will vary from site to site, so it is important that operators are fully aware and familiar with the processes used at their own place of employment. Example safety considerations for most sites would include:

• The driver of the vehicle is out of the cab

• Vehicle’s engine stopped

• Vehicle’s/trailer’s brakes applied and wheels chocked if necessary

• Trailer floor free of debris and able to withstand the combined weight of the pallet truck and load.

Further information on safe loading and unloading can be found on the HSE website in the vehicles at work section.

Ramps and Dock Bridging Platforms Explain the purpose of the equipment. Discuss safety checks that the operator should undertake before using the equipment:

• Compatible with the vehicle/trailer?

• Free from any damage or faults?

• Capable of withstanding the combined weight of the pallet truck and load?

• Secured to the vehicle correctly so that it cannot move or come loose during loading/unloading?

• Suitable for driving on and authorised for truck use by the owner/employer?



Goods Lifts Explain that prior to using any loading equipment the operator should check:

• For any damage or faults on the goods lift

• The equipment is clearly marked and has sufficient capacity for the truck and load(s)

• It is suitable for driving on and authorised for truck use by the owner/employer.

Explain that the truck must enter the lift with the load leading and that it must be parked away from the sides before operation of the lift commences.

Trailer SafetyExplain that the stability of the trailer can be adversely affected by the movement of the truck and its harsh operation. It is therefore important to take adequate care when loading trailers to minimise the risk of upending or damaging the trailer, collapsing the landing gear, and lateral instability.

Explain that the vehicle or trailer should have sufficient lighting and stress that extra care must be taken when loading and unloading curtain-sided trailers as there may be no edge protection.

Sequence of Loading and UnloadingExplain that vehicles and trailers should be loaded with pallets placed tight to one another and against the headboard to prevent the load from moving whilst in transit, especially under braking.

Pallets should be deposited from side to side, in order to distribute the load evenly and avoid exceeding the maximum Gross and axle weights of the vehicle/trailer. This will allow the vehicle’s capacity to be fully utilised.

Where a rider platform is fitted to pedestrian trucks, it is recommended that this skill be demonstrated and carried out with the platform stowed away correctly where possible in consideration of the confined working conditions and the head clearance of the trailer.

Wherever a suitable vehicle, lift, ramp or docking bridge platform is available this session should be delivered as a practical session.


Explain and demonstrate (if possible) safe vehicle loading practices, ensure that your demonstration/explanation includes:

• Carrying out the required safety procedures necessary to ready the vehicle before loading/unloading

• Entering the vehicle load leading and travelling centrally before manoeuvring to deposit the load against the headboard/load and/or next to an adjacent load

• Entering the vehicle forks leading and travelling centrally before manoeuvring to line-up with and pick up a load. Travel centrally out of the vehicle, making sure to carry out full observations and look in the direction of travel

• Remind the candidates that when operating a rider operated truck it is important to remember to face the direction of travel when manoeuvring out of the trailer

• Discuss the use of audible warnings when exiting the trailer back into the work environment

Ensure that throughout the session, each candidate is given sufficient time to practise or explain the manoeuvres taught. If this session is taught theoretically, ask questions to confirm learning and encourage active participation.

End of S21


S22(A&B)– Course Close






To close the course and gather course feedback.

Classroom

• Course Feedback forms• Training Records



Answer any final questions that the candidates may have and gather course feedback from each candidate. Ensure that you complete a record of training for each candidate.

Discuss assessment results with individual candidates. Provide guidance on areas of weakness; in particular, give advice on improvement.

Reiterate the need for continued safe operation.

Reiterate the importance of continued training. Remind the candidates that this was a basic training course and that further training will be required in order to gain a permit/authorisation to work in this capacity and safely conduct operations in their workplace. An example record of training and the course feedback form can be found in the appendices at the back of this guide.

End of S22

RTITB accredited training organisations are required to upload feedback scores from all candidates to NORS. There is no requirement for non-accredited training organisations; however, we would always recommend that feedback is gathered and reviewed for future development and delivery improvement.


ES1A – Turning and Depositing in Industrial Racking (Low-level – Pedestrian Operated)



3:1:1 N/A 30 mins N/A N/A



To introduce the candidates to performing 90° turns in a narrow aisle and stacking and de-stacking in industrial racking at ground and low-level.


• Truck• Industrial racking system, including signs and load notice• Storage Equipment Manufacturers' Association (SEMA) publication or equivalent• Appropriate laden pallet• Appropriate materials to create a narrow aisle



• Demonstrate safe and accurate turning from the left and right to a pallet position • Discuss safe operating practices related to working in a narrow aisle• Demonstrate stacking and de-stacking a laden pallet at ground-level/low-level • Discuss the construction and function of racking and safe working practices in and

around racking.



PreparationBefore commencing the session, construct a main working aisle (refer to ‘Setting up the Practical Test Course – Main Working Aisle’ found in the 'Assessment' section). Check that all materials used to construct the aisle are in good order and confirm the integrity of the racking. The location for the unladen turn should have an appropriate pallet to turn onto with suitable pallets occupying the adjacent locations. Ensure all other session resources are available.


When training is conducted using a pedestrian operated truck fitted with a fold-away operator platform, ensure that the platform is stowed before performing the operations discussed in this session in a confined space.

Aisle PositionDiscuss with the group the basics of truck position in an aisle in the context of preparing to make turns in the aisle. Explain that, depending on the type of truck being operated, varying amounts of space will be required in order to make a turn to approach a pallet position. In essence, the further forward the pivoting point, the closer the truck will need to be positioned to the load – for example, a truck, which has its pivoting point near to the end of the forks, will need to be positioned closer to the target position than a counterbalance truck, which has a pivoting point positioned much further back.


Making the Turn


• Travel along the aisle, forks trailing. Discuss the truck’s position and remind the candidates about the importance of facing the direction of travel and continued observation

• Show the candidates how to line up for both left and right hand turns to 90°, emphasising the point at which to stop the truck in order to make an accurate turn and approach to the pallet position





Repeat the demonstration, this time carrying a load. Remember to discuss with the candidates how the load affects the truck’s handling characteristics and the operator’s view of rear end swing.



Recap the key points of the demonstration:


• All round observation, before moving off and during the turn

• Smooth use of the truck’s controls during travelling and manoeuvring

• Observations of the potential crush zones



• Ensure that the truck’s wheels are straight after the turn.





Industrial Racking (Ground/Low-level)Explain that the most common type of racking is Adjustable Pallet Racking (APR). This type of racking is constructed from straight pieces of shaped steel joined together to make the structure suitable for carrying pallets; it is designed to carry palletised loads at multiple levels in order to increase storage density even for non-stackable loads. Typically this type of racking is accessed along aisles that run adjacent to the pallet locations.



• Frame


• Foot plates

• Uprights

• Beams





Racking Load NoticeExplain that the load notice is an important piece of safety signage which is intended to inform users of correct operation, it is split into three parts:




As the name suggests, this information is relevant to the particular installation and is included to provide guidance on the equipment’s load limitations, specifically the:








Explain that loads need to be uniformly distributed along and between the beams. Normal pallets will provide a uniformly distributed load (UDL) but some other goods such as drums, coils or odd shaped goods might not, causing the beams to become overloaded.

3. Administrative Information

Shows the supplier’s contact details. This information provides users with access to help with queries about the storage equipment.

Racking InspectionsExplain the dangers of using racking incorrectly and using damaged racking. Highlight the importance of regular racking inspections by qualified personnel and state the reporting procedure for any damage

found, as well as the steps that operators should take if they strike the racking.



• Pallet condition and load security

• Overall condition of the racking




• Correct stacking and load position.

Further information about industrial racking inspections and damage tolerances can be found in publications from the Storage Equipment Manufacturers’ Association (SEMA) who publish recommendations for the use, manufacture, installation etc. of racking. Information and guidance may also be found in the manufacturer’s manual, available from the supplier.

Where a fold-away platform is fitted, it should be stowed away correctly during thefollowing operation.


Recap on the 'Narrow Aisle' lesson and demonstrate the procedure for approaching from the left and right and safely de-stacking a laden pallet at ground-level. Remind the candidates that the truck should be properly secured (park brake and neutral) and the wheels should be straight before attempting to lift the pallet.

Stress the importance of inserting the forks centrally to aid load stability. Stress the importance of checking the fork height before entry in order to prevent rubbing as this could affect the pallet’s position and/or damage it.

Explain that the operator must check the height of the pallet when lifting and the clearance above the pallet. Discuss safety precautions that must be considered before and during pallet withdrawal – including all round observation and awareness of pedestrians and crush zones.

Demonstrate the process of approaching from the left and right and stacking the pallet at ground-level. Remind the candidates about properly securing the truck before operating the hydraulics and discuss safety precautions that should be considered before placing the pallet into its location.





Working at Low-level

This part of the session is not applicable to ground-level pallets trucks.




Build on the previous demonstration. Discuss and demonstrate approaching and turning from the left and right to stack and de-stack a laden pallet from industrial racking at low-level. Ensure that throughout the demonstration you offer commentary and discussion of the key points.

Include in your exposition:

• Condition and safe working load of the beam• The dangers of overloading the racking system • Clearance overhead• Positioning of the laden pallet on the beam• Remember to ensure that the wheels are straight before attempting to lift the



pallet position.




End of ES1A


ES1B – Turning and Depositing in Industrial Racking (Low-level – Rider Operated)






To introduce the candidates to performing 90° turns in a narrow aisle and stacking and de-stacking in industrial racking at ground and low-level.


• Truck• Industrial racking system, including signs and load notice(s)• Storage Equipment Manufacturers' Association (SEMA) publication or equivalent• Appropriate laden pallet• Appropriate materials to create a narrow aisle



• Demonstrate safe and accurate turning from the left and right to a pallet position • Discuss safe operating practices related to working in a narrow aisle• Demonstrate stacking and de-stacking a laden pallet at ground-level/low-level • Discuss the construction and function of racking and safe working practices in and

around racking.





Aisle PositionDiscuss with the group the basics of truck position in an aisle in the context of preparing to make turns in the aisle. Explain that, depending on the type of vehicle being operated, varying amounts of space will be required in order to make a turn to approach a pallet position. In essence, the further forward the pivoting point, the closer the truck will need to be positioned to the load – for example, a truck, which has its pivoting point near to the end of the forks, will need to be positioned closer to the target position than a counterbalance truck, which has a pivoting point positioned much further back.


Making the Turn








Repeat the demonstration, this time carrying a load. Remember to discuss with the candidates how the load affects the truck’s handling characteristics and the operator’s view of rear end swing.



Recap the key points of the demonstration.


• All round observation, before moving off and during the turn


• Points of observation, including: pivot point, front end swing and rear end swing








Industrial Racking (Ground/Low-level) Explain that the most common type of racking is Adjustable Pallet Racking (APR). This type of racking is constructed from straight pieces of shaped steel joined together to make the structure suitable for carrying pallets; it is designed to carry palletised loads at multiple levels in order to increase storage density even for non-stackable loads. Typically this type of racking is accessed along aisles that run adjacent to the pallet locations.



• Frame


• Foot plates

• Uprights

• Beams





Racking Load NoticeExplain that the load notice is an important piece of safety signage which is intended to inform users of correct operation, it is split into three parts:




As the name suggests, this information is relevant to the particular installation and is included to provide guidance on the equipment’s load limitations, specifically the:








Explain that loads need to be uniformly distributed along and between the beams. Normal pallets will provide a uniformly distributed load (UDL) but some other goods such as drums, coils or odd shaped goods might not, causing the beams to become overloaded.

3. Administrative information

Shows the supplier’s contact details. This information provides users with access to help with queries about the storage equipment.

Racking InspectionsExplain the dangers of using racking incorrectly and using damaged racking. Highlight the importance of regular racking inspections by qualified personnel and state the reporting procedure for any damage

found, as well as the steps that operators should take if they strike the racking.

Further information about industrial racking inspections and damage tolerances can be found in publications from the Storage Equipment Manufacturers’ Association (SEMA) who publish recommendations for the use, manufacture, installation etc. of racking. Information and guidance may also be found in the manufacturer’s manual, available from the supplier.



• Pedestrians and other operators• Pallet condition and load security• Overall condition of the racking • Sympathetic use of hydraulic controls • Adequate clearance of the beam above and the uprights to either side • The ground conditions • Correct stacking and load position.

Recap on the previous 'Narrow Aisle' lesson and demonstrate the procedure for approaching from the left and right and safely de-stacking a laden pallet at ground-level. Remind the candidates that the truck should be properly secured (park brake and neutral) and the wheels should be straight before attempting to lift the pallet.

Stress the importance of inserting the forks centrally to aid load stability. Stress the importance of checking the fork height before entry in order to prevent rubbing, as this could affect the pallet’s position and/or damage it.

Explain that the operator must check the height of the pallet when lifting and the clearance above the pallet. Discuss safety precautions that must be considered before and during pallet withdrawal – including all round observation and awareness of pedestrians and points of observation.








Working at Low-level


Build on the previous demonstrations. Discuss and demonstrate approaching and turning from the left and right to stack and de-stack a laden pallet from industrial racking at low-level. Ensure that throughout the demonstration you offer commentary and discussion of the key points.


• Necessary all round visual checks • Looking in the direction of travel• Condition and safe working load of the beam• The dangers of overloading the racking system • Clearance overhead• Positioning of the laden pallet on the beam• Remember to ensure that the wheels are straight before attempting to lift the



pallet position.




End of ES1B


RS1(A&B) – Theory Update



3:1 N/A N/A 20 mins 20 mins



To assess and update candidates’ knowledge and awareness of the Health and Safety legislation that applies to the truck and the workplace.

Classroom

• Health and Safety at Work, etc. Act 1974 (HASAWA) Regulations 2, 7 and 8• Management of Health and Safety at Work Regulations 1999• Provision and Use of Work Equipment Regulations 1998 (PUWER)• Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) • Workplace (Health, Safety and Welfare) Regulation 1992• Control of Substances Hazardous to Health (COSHH)• The Health and Safety (Safety Signs and Signals) Regulations 1996• L117: Rider-operated lift trucks – Operator Training and Safe Use• Safe Driving Practices – (appropriate for the workplace)• Pre-use inspection sheet• Multimedia device/computer with a compatible projector/television• Presentation slides (included with the guide)• Whiteboard/flip chart• If the course is taking place on a live site, copies of relevant risk assessment and site

maps should be made available• Relevant hand-out, guide or leaflet for each candidate including HSE’s leaflet INDG457:

Use lift trucks safely - Advice for operators.

By the end of this session candidates will be able to recall and discuss safety legislation that applies to the operation and use of the equipment and be able to answer questions relating to employer and employees duties.



During this session, and throughout the course, reference is made to specific Health and Safety Executive (HSE) guidance and approved codes of practice that relate to UK legislation regarding safe working practices. If you are delivering this course outside of the UK, it is important to adjust your delivery to suit legislative requirements for your particular geographic location. If you are delivering this course in the Republic of Ireland or Northern Ireland, please refer to Appendix 2, where you will find a table that provides some equivalent resources for some of the major HSE publications referenced in this session and throughout the course as a whole.

Health and Safety at Work, etc. Act 1974 (HASAWA)• Discuss the Health and Safety at Work Act with the candidates, assess their knowledge of the

relevant sections and update them on any updates or changes that may have occurred since their

last training course

• Discuss the employer’s responsibilities under section 2 of the HASAWA

• Remind the candidates of employee responsibilities under sections 7 & 8.

Management of Health and Safety at Work Regulations 1999 (MHSWR)

Discuss with the candidates the employer’s responsibility to carry out risk assessments on workplace tasks and periodically review them. Assess their knowledge and update them on any changes that may have occurred since their last training course.

Provision and Use of Work Equipment Regulations 1998 (PUWER)Discuss and confirm the candidates’ knowledge and understanding of the following sections of PUWER:

• Regulation 4 – to provide suitable equipment

• Regulation 5 – to provide maintenance

• Regulation 6 – to provide regular inspections by competent persons

• Regulation 7 – to provide for specific risks

• Regulation 8 – to provide information and instruction

• Regulation 9 – to provide training for operators of work equipment.


Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)Discuss the specific requirements of this regulation with the candidates, assess their knowledge and understanding which requires:

• Employers to have control of the use of lift equipment

• All lifting operations to be properly planned by a suitably trained person

• An appropriate level of supervision

• Equipment to be suitable for the task being carried out

• Lifting operations to be carried out safely

• Lifting components undergo a routine thorough examination.

Workplace (Health, Safety and Welfare) Regulations 1992Explain that these regulations cover a wide range of basic health, safety and welfare matters that apply to most workplaces and include the requirements for:

• The supply of adequate fresh air through good ventilation

• Sufficient lighting to operate safely

• The construction and maintenance of suitable floors and traffic routes that provide segregation

between pedestrian and vehicular traffic.

Ask the group to think about their own workplaces and whether there are any obvious risks that might need controlling, particularly from the point of view of the operator and the use of workplace transport.

Control of Substances Hazardous to Health (COSHH)Discuss working with hazardous substances with the group. Explain that, as equipment operators, the members of the group are likely to come into direct contact with hazardous substances from time to time, for example:

• Battery acid

• Hydrogen fumes

• Oils and lubricants.

Depending on the nature of their work, operators may not come into contact with or work with hazardous substances. Even so, it is important that they are able to recognise warning labels and are aware of precautions that should be taken when working with certain substances, for example:

• Personal protective equipment (PPE)

• Exposure risks to themselves and others on the site

• Steps to take in the event of exposure or spillage.



The Health and Safety (Safety Signs and Signals) Regulations 1996Explain that there are four categories of safety sign and that each has a defined purpose. Discuss the shapes and colours for each type of sign. Show the candidates examples to illustrate them.

CAUTION FORK LIFT TRUCKS

CORROSIVE

WEAR SAFETY BOOTS

WEAR FACE PROTECTION

PEDESTRIAN ROUTE

SAFETY SHOWER

EYE WASH STATION

LIFT TRUCK PROHIBITED

SMOKING AND NAKED FLAMES

PROHIBITED

Prohibition signs

Aimed at preventing a particular type of behaviour, these signs are circular with a white background, black pictogram and red border.

Warning signs

Indicate a particular type of hazard. These are triangular with a yellow background, black pictogram and border.

Mandatory instruction signs

These signs are circular with a blue background and a white pictogram, they denote that a particular type of behaviour is required.

Emergency escape or first-aid signs

These signs indicate information about and locations of first aid equipment. These signs are rectangular with a green background and white pictogram and/or text.

Obstacles or dangerous locations signs

Used where the risk of injury from falls from height or from being struck by falling objects is low or impracticable to safeguard by other means, these markings highlight the edge of raised platforms or areas where objects may fall.


L117: Rider-operated Lift Trucks – Operator Training and Safe UseExplain that this document supports employers and those responsible for the safe operation of lift trucks by giving advice on how to comply with the law.

Discuss the ACoP's special legal status, explaining that, in the event of an incident, if you are proved to have not followed the relevant provisions of the ACoP you will be found at fault – unless you can show that you have complied with the law in some other way.

Safe Driving Practices Remind the candidates that many accidents occur where operators are either inexperienced or untrained. These accidents range from relatively minor to very serious, and may result in injury (or death) to the operator or other persons, damage to the equipment, buildings and facilities. Discuss this point with the candidates using any relevant examples that may have occurred since they last attended training.

Emphasise that the equipment that will be used on this course is designed to be perfectly safe, providing that it is used correctly. Point out that there are specific rules covering operating practices that help minimise the risks presented by the equipment, and that this course will concentrate throughout on safe, correct approaches to using the equipment which comply with those rules. Ask the candidates to give examples of rules specific to their workplace that have been implemented to minimise risk and improve safety.

Remind the candidates that operating without full appreciation of their responsibilities may lead to unsafe practices being performed, so it is therefore important that operators value their training and ensure their operating skills are sufficiently refreshed at regular intervals.



End of RS1

Hand out relevant guidance or leaflets for each candidate, including HSE’s leaflet INDG457: Use Lift Trucks Safely - Advice for Operators (where applicable).

Address any areas of weakness in the candidates’ knowledge or understanding of safe operating practice theory.


RS2(A&B) – Introduction to the Truck and Principles of Stability



3:1:1 N/A N/A 40 mins 40 mins








To familiarise the candidates with the component parts and stability characteristics of the truck used during this course.

Classroom and practical training area

• Truck • Manufacturer’s operating manual• Multimedia device/computer with a compatible projector/television• Presentation slides (included with the guide)• Visual aid/model to illustrate stability principles• Hand-out literature


• Identify and explain each major component and control of the machine and describe its function

• Answer questions related to the specific type of truck used for training, its components, controls and warning systems

• Where applicable to the truck type, safely mount and dismount the truck, stowing the rider platform and guards

• Show awareness of the factors which affect the truck’s stability and how to avoid creating unsafe situations

• Discuss balance, stability and actions to take in the event of truck tip-over.



Material Handling Equipment TypeDiscuss the equipment type to be used during training. If the equipment to be used for training is different to the equipment used by the candidates in their day-to-day work, ask them to tell you about the differences, limitations, advantages, etc. of their equipment as a comparison and to gauge their knowledge.

Reiterate the variety of truck configurations that operators might come across in their work, for example: pedestrian-operated, rider-operated, dual-operated with a fold-away platform, stacker, straddle, counterbalance, reach, etc. It is important to stress that the candidates may come across very different equipment to the machine used for training. While the fundamentals of operation may be the same from machine to machine, specific controls and features will vary; therefore equipment training and familiarisation with the manufacturer’s manual will be required.

Equipment TourAsk the candidates to identify the main components of the equipment and explain their use; ensure that you correct any knowledge gaps and provide any additional relevant information. The discussion should include:

• Key/switch/starting system

• Emergency disconnect/isolator

• Load wheels, wheel arms or outriggers (where applicable)

• Fork arm securing pins and stops (where applicable)

• Mast, load guard, carriage plate (where applicable)

• Hydraulic cylinders and chains

• Tiller/control handle, audible warning device, hydraulic controls (as applicable)

• Collision safety switch (where applicable)

• Speed selector device and coast control devices (where applicable)

• Truck braking devices

• Parking brake (where applicable)

• Visual information/warning instruments

• Operator position/rider platform, side arms and presence/dead-man sensor (where applicable)

• Manufacturer’s rated capacity/data plate

• Drive wheel

• Battery compartment, battery connector

• Other fitted controls and instruments as appropriate

• Where applicable to the truck type, other fitted controls and instruments.


Mounting, Dismounting (Rider Operated)Ask the candidates to demonstrate correct mounting and dismounting procedures. If necessary, explain and demonstrate the correct method of mounting and dismounting the truck. Stress the importance of ensuring the platform and side arms (where fitted) are fully deployed and that an all-round check of the floor and the environment (including above) is made before mounting or dismounting, reiterating that the operator should never jump down.



Operator Position Ask each candidate to adopt the correct operating position in both directions, correcting them as necessary.

Rider Operated

Discuss the importance of maintaining a two-handed grip on the tiller when travelling forks leading. When travelling forks trailing a one handed grip on the tiller is required, whilst ensuring all other limbs are within the confines of the truck and/or using appropriate hand holds where applicable.

Pedestrian Operated

Remind the candidates that a two-handed grip is required on the tiller when travelling forks leading and that when travelling forks trailing a one handed grip should be used on the tiller. They should position themselves to the left or right-hand side of the truck. Discuss the risk of ankle trapping when travelling forks trailing.


StabilityDiscuss the importance of understanding the fundamental stability characteristics of a truck in order to avoid the truck tipping over or the loss of a load from the forks, which could cause serious injury to the operator/others, damage to the truck, load and surrounding structures.

Ask the candidates to discuss how the stability of the truck is affected by the centre of gravity, in particular the effect of its movement within the “points of support”. Correct any knowledge gaps and provide any additional relevant information. The discussion should include:

• Asking the candidates to identify the “points of support” – where the truck makes contact with the ground – which are generally the drive, caster and load wheels (where applicable).

• A reminder that the truck and the load have their own centres of gravity which combine when the load is added to the truck.

• Locating the truck’s centre of gravity and discussing how it can change as the truck picks up and deposits loads and changes direction.

Ask the candidates to identify the main factors that would affect stability. Divide the candidates’ answers between longitudinal and lateral instability where applicable to the truck type being trained upon; ensure that you correct any knowledge gaps and provide any additional relevant information. The discussion should include:

• Dramatic changes in speed• Dramatic changes in direction• Overloading• Incorrect tilt• Forks not being fully inserted or heeled correctly• Increased load centre and the load not being centrally positioned on the forks• Site condition, debris and potholes• Travelling over objects on the floor• Turning on an incline• Travelling and turning with the mast raised• Live loads, which create a pendulum effect, etc.



End of RS2

Perfect Balance (Pedestrian Reach and Counterbalance Only)

Discuss the term “perfect balance”. Ask the candidates to explain what is meant by this term. Perfect balance is, in fact, a dangerous state in which the weight on both sides of the pivot are equal. This is dangerous situation because it means that the truck is being operated at its capacity and there is no margin for error there is no allowance for the load being mislabelled, the operator undercutting the load, etc.

Remind the candidates that the working load indicated on the rated capacity plate, or the maximum lift weight visual display, as appropriate, is calculated by the manufacturer with regard to all safety legislation and safe operating practices and must never be exceeded.

Truck Tip Over

Ask the candidates to describe the actions to be taken in the event that the truck loses stability and tips over. Remind them that should a truck tip over, serious or fatal injury can occur. Emphasise that, should a truck tip over (laterally or longitudinally), the operator must follow the manufacturer's recommended

actions.

Negotiating an Incline

Using the illustrations found in Appendix 1 to confirm the candidates’ understanding of the issues and correct operation through discussion and questioning techniques.

Ask the candidates: before attempting to travel up or down an incline what should be considered? The operator must assess the incline’s surface, the truck’s maximum scale of gradient, the security and stability of the load and whether it is necessary to stop and adjust the fork/load height.

Remind the candidates of the importance of keeping up a consistent steady speed, limiting the need to brake harshly, which in turn reduces the likelihood of longitude instability. Once the truck has negotiated the incline, it should be stopped and the forks returned to an appropriate travel height in order to maintain security and stability of the load for the rest of the journey.

Recap that in order to control the traction and adhesion of the drive wheel, the truck should travel with its forks facing down the incline when unladen. In addition, to increased load stability, a laden truck should travel with its forks facing up the incline. If the load obscures the operator’s view, a banksman should be employed to aid the manoeuvre.

Remind the candidates that trucks should not be parked on an incline; however, if circumstances arise where parking in such a location is unavoidable, the park brake must be applied and the wheels must be chocked to prevent the truck from moving. The key should be left in the truck to allow access.


RS3(A&B) – Pre-use Inspection



3:1:1 N/A N/A 20 mins N/A








To assess the candidates’ ability to inspect the truck prior to use, record the results of the pre-use inspection and confirm their knowledge of steps that should be taken in the event that defects are found.


• Truck• Manufacturer’s operating manual• Pre-use inspection forms• PPE

By the end of the session, candidates will be able to discuss and demonstrate the process for carrying out a pre-use inspection of the truck, recording the inspection and steps that should be taken in the event that defects are identified.



The Importance of Routine InspectionsRemind all candidates that pre-use inspection is a visual inspection combined with an operational check that all necessary systems operate correctly prior to using the equipment for work activities.

Reiterate that under no circumstances should operators attempt any repairs or put themselves or others at any risk. Mechanical skills are not required to complete a satisfactory pre-use inspection.


Ask each candidate to demonstrate how to make checks of the following components on the truck – guidance on checking procedures can be found in the pre-use inspection assessment marking criteria later in this guide. Not all components in the following list will necessarily be relevant to all truck types:

• External condition• Rated capacity plate and data plate• Forks/load handler • Carriage plate, backrest extension (where applicable)• Mast, rollers/slides, lift chains and pulleys (where applicable)• Hydraulic components (where applicable)• Wheels and tyres• Operating position/platform (applicable to the truck type)• Battery• Starting procedure• Audible warnings• Hydraulic controls and lift• Drive and brake, and collision safety switch• Steering• Any additional fitted systems (where applicable).

System of CheckingAssess each candidate’s pre-use inspection process. Remind the candidates that prior to any checks being made it is imperative that the following is established:

• The parking brake is applied, neutral is selected and the equipment is switched off• Correct personal protective equipment (PPE) is used wherever required• The manufacturer’s equipment recommendations are followed.

Provide remedial training and guidance where necessary during the candidates’ demonstration.

Ensure you make the candidates aware of the items which will be considered mandatory in testing.



Fault Reporting Check each candidate’s process for reporting and dealing with defects.

Remind the candidates that any defects discovered during the inspection should be recorded and reported to relevant personnel. The report should be dated and the defective equipment should be clearly identified and taken out of use until the defects have been resolved.

End of RS3


RS4(A&B) – Assessment of Operator Ability and Remedial Tuition

Suggested Durations

Low-level Medium-level High-level

RATIO REFRESHER REFRESHER REFRESHER

3:1:1 45 mins 60 mins 1 hr 20 mins

2:1:1 35 mins 45 mins 60 mins


To assess the candidates’ ability to operate the truck, identify any areas for improvement and provide remedial tuition where necessary.


• Truck• Laden pallets or other suitable loads• Appropriate materials for constructing a steering course• Access to a ramp or incline (where appropriate)• Suitable vehicle or trailer as appropriate (where appropriate)• Access to a loading dock, bridge plate, wheel chocks, etc. (where appropriate)• PPE

By the end of this session candidates will be able to:

• Safely mount the truck/adopt the correct operating position (as applicable)• Start and prepare the truck for travel• Manoeuvre the truck, forks leading and forks trailing• Steer safely to the left and right, including 90° turns in both directions• Handle laden pallets • Build and dismantle free-standing stacks at varying heights• Stack and de-stack in an industrial racking system at varying heights (as applicable)• Negotiate ramps and inclines (as applicable)• Load and unload a vehicle (as applicable)• Perform an emergency stop• Safely stop and park the truck• Safely dismount the truck (as applicable)



IntroductionBefore starting the session, prepare the training area to enable each candidate to demonstrate the skills outlined in the session objective. Ensure that each confined manoeuvring area provides a restriction while maintaining a 75mm (3 inch) gap between the sizes of the truck and any obstacles.

Explain to the candidates that for the duration of this session they will be required to operate the truck, carrying out standard manoeuvres that they would expect to perform in their day-to-day role, and that you will offer guidance and support as necessary.

Assessment of Ability and Remedial TrainingBuild on the candidates’ existing and past experience and correct any misconceptions or incorrect practices that may have developed since their last course of training. Make effective use of demonstration and commentary when providing remedial tuition. Outline and discuss with the candidates the operations that they will be expected to carry out during this session and the expected standard – you may wish to walk them through the skills during the outline.

If the course is being conducted using a pedestrian truck fitted with a fold-away platform, the platform must be stowed for all manoeuvres within confined areas.


Prepare, Moving, Manoeuvring, Stopping and Parking the TruckThe candidates should demonstrate:

• Starting the truck, correctly positioning the forks, safe moving and stopping (including observations)

• Manoeuvring forks trailing and forks leading

• Emergency stops

• Safe and correct parking procedure.

Stacking and De-stackingThe candidates should demonstrate:

• Accurately turning 90° in a confined area

• Correct use of park brake and neutral (as applicable)

• Safe and correct fork positioning, including tilt (as applicable)

• Accurate alignment for pallet entry and withdrawal

• Sympathetic use of the hydraulic controls

• Safe load handling and correct positioning on the forks

• Ability to accurately deposit a laden pallet at a vertical face

• Safe stacking and de-stacking at varying heights as free-standing stacks and/or in industrial racking

systems (as applicable).



Negotiating InclinesAsk the candidates questions relating to the operation of the truck on a ramp or incline, assess their knowledge and understanding with regard to:

• Approaching inclines and the requirement to adjust the fork height to prevent the forks and/or

load grounding

• Direction of travel when the truck is unladen

• Appropriate travel speed

• Direction of travel when the truck is laden

• The effect of turning on an incline

• Returning the forks/load to an appropriate height once the incline has been negotiated

• Parking on inclines.

End of RS4

Depending on the nature of the training environment and the availability of inclines, you may wish to assess the candidates' ability to negotiate inclines as part of your overall assessment of their operating ability.

Loading and Unloading VehiclesThe candidates should be expected to discuss loading and unloading vehicles, the discussion should include:

• Necessary vehicle safety precautions, driver safety and control

• The compatibility, suitability and capacity of loading platforms

• Trailer instability

• Vehicle gross plated and axle weights

• Loading sequence and patterns

• The correct operating procedure and safety considerations whilst loading and unloading.


CS1A – Preparing, Moving, Stopping and Parking the Truck (Pedestrian Operated)

Suggested Durations


RATIO CONVERSION CONVERSION CONVERSION




To introduce candidates to manoeuvring the truck in open and confined areas, bring the truck to a controlled stop, and parking.


• Truck• Manufacturer’s Operator Manual• Materials to create a restricted operating area• Cones or barrels


• Adopt a safe operating position• Operate the truck both forks leading and fork trailing, including braking and an

emergency stop• Demonstrate how to pivot an unladen truck around a simple course in an open area,

forks leading and forks trailing• Safely and correctly negotiate combined left and right turns unladen within an

unrestricted area, forks trailing and forks leading• Safely and correctly negotiate combined left and right turns unladen within a restricted

area, forks trailing and forks leading.



The purpose of this session is to build on the candidates' existing training and experience of equipment similar in nature to the equipment discussed during this course. Throughout your delivery, emphasis must be placed on significant differences that exist between the candidates' previous equipment and this equipment, paying particular attention to configuration, controls, capacities, handling characteristics and operating environment.

Moving off Forks Leading and Forks Trailing, Controlled StoppingDiscuss differences relating to the controls and manoeuvrability of the equipment compared with the candidates' experience. Stress that this truck must only be operated when the operator is in the operating position and that the operator may only ride on the truck if an approved rider platform is fitted.

Operating Positions

Pedestrian

Briefly explain that during travelling with forks leading, the operator should maintain a two-handed grip on the tiller, and when travelling with forks trailing a one-handed grip is necessary to allow the operator to maintain a position to the left or right of the truck while facing the direction of travel. Explain the potential for personal injury if correct operator position is not maintained.

Rider (Fixed or Fold-away Platform)

Whilst travelling forks leading, a two handed grip is required on the tiller. When travelling forks trailing, at least one hand must remain on the tiller, and the other hand must remain within the confines of the truck. Explain the potential for personal injury if correct operator position is not maintained – for example, even when the truck comes to a controlled stop, if the operator is not adopting the correct operating position, there is a chance that they could fall from the truck.



Explain and demonstrate the operating positions to be adopted when using this truck.



Explain and demonstrate the correct method to be followed when moving off on foot:

• Operate the truck's hydraulic switch to raise the forks to the required travel height (as applicable)

• Remind the candidates of the importance of operator position and hand position on the tiller (relative to direction being travelled)

• Select the travel direction (where applicable)• Complete an all-round observation• Release the park brake (where applicable)• Explain and demonstrate applying acceleration to move off. Apply gradual



• Apply the park brake (where applicable) and set the direction control to neutral.

Remind the candidates that it is important that an effective all-round observation is made before moving off – under no circumstances should the equipment be moved if any pedestrians are within the immediate vicinity of the truck.



Explain and demonstrate the correct method to be followed when moving off using the fold-away platform position (as applicable):

• Mount the truck platform and raise the side guards• Operate the truck’s hydraulic switch to raise the forks to the required travel







Speed

Explain that this type of truck may include an automatic or manual speed selector that offers High and Low speed settings for optimum productivity, allowing the truck to move at higher speeds than when the operator is walking beside it.

Stress that the manual High speed control must only be used whilst the operator is standing on the fold-away platform.

Discuss with the candidates the fact that speed is difficult to judge, pointing out that the truck may not have a speedometer. Nevertheless, great care must be taken not to exceed the site’s speed limit. Discuss with the candidates methods used to judge and control speed on equipment they have previously used. Remind the candidates that excessive speed and braking increase the risk of an incident. Stress the importance of awareness of the workplace environment and immediate surroundings and the importance of operating at an appropriate speed.

Coast Control




This function should not be used on inclines.





ParkingRemind the candidates of the precautions that should be taken when safely parking the truck. Emphasise the importance of parking the truck where it will not cause an obstruction and the need to park the truck correctly, which requires the operator to:




Ensure that throughout the section, each candidate is given sufficient time to practise the manoeuvres taught:

• Adopt a safe operating position • Prepare the truck for travel including fork position where applicable• Operate the truck forks leading and forks trailing, and bringing the equipment



Basic Steering

Start in an open area and demonstrate the effect of moving the tiller control to the left and right while operating forks leading and forks trailing.


Discuss with the candidates the effect of front and rear end swing when making turns compared to their experience of other types of truck and the necessity for all-round observations.


Demonstrate manoeuvring forks leading. Explain that, as before, appropriate all-round observation and controlled speed is required. It is important to point out the blind spots that might be created by the mast on this type of truck, when travelling forks leading.




Show the candidates the pivoting point of the truck and the start of the turn. Explain and demonstrate the process of negotiating the turn. Explain the importance of walking on the outside of the turn to avoid the truck striking the heels and feet.

Recap about the effect of front and rear end swing and the necessity for all-round observations.

Pivot Turns

Progress to more accurate steering exercises by performing 90° pivot turns to both sides (forks leading and forks trailing), and develop the candidates’ acceleration control. Remind the candidates when required about the importance of facing the direction of travel when manoeuvring, particularly when travelling forks trailing.

Blind Corners

Discuss the safe negotiation of blind corners, paying attention to the candidates’ own experience on other equipment types. Remind them that the operator should slow down, sound the horn and drive wide to improve observation. Explain the importance of maintaining safe, steady progress through the turn.




Progressive SteeringRemind candidates who are training on pedestrian operated trucks fitted with fold-away platforms that all confined manoeuvres should be carried out with the platform stowed.

Explain “progressive steering”. The aim is to practise steering accuracy by steering around obstacles – in this case barrels/cones – while maintaining a 75mm (3 inches) gap between the side of the truck and the obstacles.

Explain the technique of feathering using this type of truck and compare it to the candidates’ experience with other equipment types. In the context of this machine, feathering is achieved by slightly adjusting the steering on the tiller control while negotiating a turn in order to maintain sufficient clearance.


Demonstrate and explain the correct procedure for negotiating a series of right and left turns around the obstacles with the forks leading whilst maintaining a 75mm (3 inches) gap between the side of the truck and the obstacle. Ensure that during the demonstration you draw attention to the feathering technique.



End of CS1A


CS1B – Preparing, Moving, Stopping and Parking the Truck (Rider Operated)

Suggested Durations










• Adopt a safe operating position• Operate the truck in both forks leading and fork trailing, including braking and an

emergency stop• Demonstrate how to pivot an unladen truck around a simple course in an open area,

forks leading and forks trailing• Safely and correctly negotiate combined left and right turns unladen within an

unrestricted area, forks trailing and forks leading• Safely and correctly negotiate combined left and right turns unladen within a restricted

area, forks trailing and forks leading.




Moving off Forks Leading and Forks Trailing, Controlled StoppingDiscuss differences relating to the controls and manoeuvrability of the equipment compared with the candidates' experience. Stress that this truck must only be used when the operator is in the operating position and that the operator may only ride on the truck if an approved rider platform is fitted.

Operating Position

Explain and demonstrate the operating positions to be adopted when using this truck.

Whilst travelling forks leading, a two handed grip is required on the tiller. When travelling forks trailing, at least one hand must remain on the tiller, and the other hand must remain within the confines of the truck. Explain the potential for personal injury if correct operator position is not maintained – for example, even when the truck comes to a controlled stop, if the operator is not adopting the correct operating position, there is a chance that they could fall from the truck.


Explain and demonstrate the function of the collision safety switch (also known as "belly button") fitted to the end of the tiller arm. This button responds to body contact, causing the truck to change direction or come to a controlled stop – the expected behaviour will vary, depending on truck manufacturer.


Explain and demonstrate the correct method to be followed when moving off:• Mount the truck platform• Operate the truck’s hydraulic switch to raise the forks to the required travel






Remind the candidates that it is important that an effective all-round observation is made before moving off – under no circumstances should the equipment be moved if any pedestrians are within the immediate vicinity of the truck.




Speed

Explain that this type of truck may include an automatic or manual speed selector which offers High and Low speed settings for optimum productivity.

Discuss with the candidates the fact that speed is difficult to judge, pointing out that the truck may not have a speedometer. Nevertheless, great care must be taken not to exceed the site’s speed limit. Discuss with the candidates methods used to judge and control speed on equipment they have previously used. Remind the candidates that excessive speed and braking increase the risk of an incident. Stress the importance of awareness of the workplace environment and immediate surroundings and the importance of operating at an appropriate speed.




ParkingRemind the candidates of the precautions that should be taken when safely parking the truck. Emphasise the importance of parking the truck where it will not cause an obstruction and the need to park the truck correctly, which requires the operator to:




Ensure that throughout the section, each candidate is given sufficient time to practise the manoeuvres taught:

• Adopt a safe operating position • Prepare the truck for travel including fork position where applicable• Operate the truck forks leading and forks trailing, and bringing the equipment




Pivot Turns

Progress to more accurate steering exercises by performing 90° pivot turns to both sides (forks leading and forks trailing), and develop the candidates’ acceleration control. Remind the candidates when required the importance of facing the direction of travel when manoeuvring, particularly when travelling forks trailing.

Blind Corners

Discuss the safe negotiation of blind corners, paying attention to the candidates’ own experience on other equipment types. Remind them that the operator should slow down, sound the horn and drive wide to improve observation. Explain the importance of maintaining safe, steady progress through the turn.

Basic Steering

Start in an open area and demonstrate the effect of moving the tiller control to the left and right while operating forks leading and forks trailing.



Demonstrate manoeuvring forks leading. Explain that, as before, appropriate all-round observation and controlled speed is required. It is important to point out the blind spots that might be created by the mast on this type of truck, when travelling forks leading.

Discuss with the candidates the effect of front and rear end swing when making turns compared to their experience of other types of truck and the necessity for all-round observations.


Show the candidates the pivoting point of the truck and the start of the turn. Explain and demonstrate the process of negotiating the turn. Recap about the effect of front and rear end swing and the necessity for all-round observations.




Progressive SteeringExplain “progressive steering”. The aim is to practise steering accuracy by steering around obstacles – in this case barrels/cones – while maintaining a 75mm (3 inches) gap between the side of the truck and the obstacles.

Explain the technique of feathering using this type of truck and compare it to the candidates’ experience with other equipment types. In the context of this machine, feathering is achieved by slightly adjusting the steering on the tiller control while negotiating a turn in order to maintain sufficient clearance.


Demonstrate and explain the correct procedure for negotiating a series of right and left turns around the obstacles with the forks leading whilst maintaining a 75mm (3 inches) gap between the side of the truck and the obstacle. Ensure that during the demonstration you draw attention to the feathering technique.



End of CS1B


CS2(A&B) – Pallet Handling and Stacking

Suggested Durations


HEIGHT CONVERSION CONVERSION CONVERSION




To introduce the candidates to handling, stacking and de-stacking various types of pallet with this type of equipment.


• Truck• Laden pallet (2 or 4-way of appropriate construction)• Pallet example or illustration (where possible)• Marked pallet location(s) with 75mm (3 inches) clearance all round • Unladen pallets• Protective gloves


• Identify different types of pallet and their suitability relative to truck type• Discuss and demonstrate approaching, picking up, transporting and depositing a laden

pallet into a marked area• Discuss and demonstrate how to build and dismantle a free-standing stack using

unladen pallets• Discuss the risks associated with stacking, the dangers of incorrectly stacked pallets and

precautions that should be taken when stacking and de-stacking in this way.



IntroductionBriefly discuss pallet design and why it is important that operators are able to identify how a pallet has been constructed from the point of view of the load it might bear, and how it can safely be picked up. Also explain that a pallet’s construction will also have a bearing on the type of truck that can be used to handle it. Ensure that the candidates’ previous experience working with pallets and other equipment is considered as part of this discussion; draw on any differences and similarities.

Remind the candidates that manufacturers design and construct pallets to carry a maximum load. The maximum load should never be exceeded because doing so can damage both the pallet and the load. Discuss the most commonly used pallets.

Two-way Entry Reversible PalletsVarious Sizes ‘Stringer Pallet’This type of pallet is configured in such a way that it only has fork openings on two parallel sides – either on the narrow face or the wide face. Two-way entry pallets, as their name implies, do not have openings for forks on all four faces, limiting their use in the workplace. As an additional point, explain that notches can be cut into the stringer board that runs down the “closed” side of the pallet in order to allow four-way entry.

Four-way Entry Non-reversible1000mm x 1200mm ‘Block Pallet’

The most common type of pallet used. These pallets can be picked up on all sides. If applicable to your course, explain that low-level load wheels must be clear of the bottom deck boards to avoid damaging the pallet. This type of pallet is not suitable for inserted load wheel stacker trucks.

Four-way Entry Non-reversible 800mm x 1200mm ‘Euro Pallet’

These pallets can be lifted using any truck type. Explain that when operating stacker trucks or low-level pallet trucks, the forks should be inserted on the narrow edge (the shortest edge on the pallet)

– this is because the truck’s load wheels sit on the bottom deck boards once inserted, so when the pallet is lifted, the board will be split from the bearers.

Remind the candidates that before attempting to move a laden pallet of any type, the operator must check that the pallet is appropriate for the truck’s rated capacity, that it is undamaged, and that it is safe and secure to lift, transport and deposit.


Discuss stability and explain the reasons for making adjustments to fork spread – primarily to provide maximum support for the pallet – and demonstrate the method of adjusting the forks. Remind the candidates about the use of correct PPE, for example safety footwear and gloves.

Adjusting Lateral Spread of Fork Arms (Straddle Trucks and Pedestrian Reach/Counterbalances)


Demonstrate and explain the procedure for making a straight line approach to pick up and set down a laden pallet. Ensure that your demonstration includes how to:

• Line the forks up centrally and squarely with the pallet at the earliest opportunity

• Stop approximately 150mm (6 inches) away from the load to allow for height adjustment of the forks (as appropriate) and to prevent pedestrians from crossing between the truck and the load

• Enter the pallet smoothly, inserting until the pallet is against the heel of the forks or load guard

• Lift the forks to travel height and apply tilt (as applicable) and move off (remind the group about observation and looking in the direction of travel)

• Make a 90° turn away and deposit the load into the prepared marked area• Withdraw the forks (remind the candidates about the importance of

observation and looking in the direction of travel• Stop with the fork tips a short distance from the load and raise the forks to

travel position• Carry out observations and move away.

Picking Up/Setting a Pallet Down at a Vertical Face

Repeat the demonstration and explanation, this time picking up and depositing a laden pallet squarely to within 150mm (6 inches) of, but not touching, a vertical face.



Reiterate that loads which restrict or block vision must be transported load trailing.


• Making a straight line approach• Picking up a laden pallet • Turn away to 90° • Transport and deposit a laden pallet into a marked area• Transport and deposit a laden pallet to within 150mm (6 inches) of a vertical

face.

Further guidance on the pallet safety can be found in the HSE’s Guidance Note PM15.

StackingIntroduce the candidates to the subject of free-standing stacks using this type of equipment, in particular, discuss the following:

• The purpose of placing unladen pallets in stacks

• The importance of stacking pallets of the same size and construction

• The dangers of stacking too high, off centre and not square to the stack.

On a pedestrian truck, the fold-away platform must be stowed during stacking and de-stacking manoeuvres:

• Explain that incorrectly stacking pallets can cause instability, which could result in falling stacks or pallets, which in turn could result in serious injury. It is therefore important to check the condition and stability/security of the load and of the receiving stack before commencing.

Care should be taken when handling unladen pallets. Appropriate PPE should be worn for the task and proper manual handling techniques should be used. Further training should be provided if necessary.



Depositing an Unladen Pallet on a StackBefore demonstrating the process, discuss safety considerations that should be remembered, including:

• Careful fork withdrawal


• Adopting the travel position after depositing

• Overhead obstructions

• All round observations.

Demonstrate and discuss the following:

• Deposit the unladen pallets onto the receiving stack squarely, centrally and safely.



• Deposit the unladen pallets onto the receiving stack squarely, centrally and safely.


Repeat the process to stack and de-stack at high-level.

Further manual handling training may be required by candidates. Guidance on manual pallet handling training can be found in RTITB’s LTG32: Manual Handling in Transport, Warehousing and Logistics and in HSE's publication L23.

End of CS2


CS3(A&B) – Turning and Depositing in Industrial Racking

Suggested Durations



3:1:1 30 mins 60 mins 1 hr 15 mins



To introduce the candidates to performing 90° turns in a narrow aisle and stacking and de-stacking in industrial racking at heights appropriate to the truck type.


• Truck• Industrial racking system, including signs and load notice(s)• Storage Equipment Manufacturers Association (SEMA) publication or equivalent• Laden pallet appropriate to the racking system• Appropriate materials to create a narrow aisle



• Demonstrate safe and accurate turning from the left and right to a pallet position • Discuss safe operating practices related to working in a narrow aisle• Demonstrate stacking and de-stacking a laden pallet at varying height (as applicable)• Discuss the construction and function of racking and safe working practices in and

around racking.




If any of the candidates have no prior experience of operating in industrial racking at the heights required to operate this truck, they will require Novice training in this type of work instead of this session.



When training is conducted using a pedestrian operated truck fitted with a fold-away operator platform, ensure that the platform is stowed before performing the operations discussed in this session in a confined space.

Aisle PositionUtilizing the candidates’ previous equipment experience, discuss the basics of truck position in an aisle in the context of preparing to make turns in the aisle. Explain that, depending on the type of truck being operated, varying amounts of space will be required in order to make a turn to approach a pallet position. In essence, the further forward the pivoting point, the closer the truck will need to be positioned to the load – for example, a truck, which has its pivoting point near to the end of the forks, will need to be positioned closer to the target position than a counterbalance truck, which has a pivoting point positioned much further back.


Making the Turn







• Position the truck in an appropriate position for travelling back along the aisle and travel toward the exit. Remind the candidates about the importance of looking in the direction of travel

Repeat the demonstration, this time carrying a load. Remember to discuss with the candidates how the load affects the truck’s handling characteristics and the operator’s view of rear end swing – draw on the candidates’ own experience with other equipment, discuss the differences and relative benefits/issues of each machine.

Discuss the key points of the demonstration, including:

• Techniques that the candidates currently use to judge pivot points when lining up for a turn

• How to gauge a reference point on this particular machine

• Remind the candidates of the importance of all-round observation


• Observations of the potential crush zones

• Central position of the forks in front of the load/load position, approximately 150mm (6 inches)






Industrial RackingFamiliarise the candidates with the racking system used during this session, including:

• Load notice

• Uniform Distributed Load of each beam

• Height of the first beam and subsequent beams

• Any other relevant information.

Working in Racking (Ground-level)

Remind the candidates of the safety precautions that should be taken before attempting to stack or de-stack a laden pallet from a racking system at ground-level. Your discussion should include:


• Pallet condition and load security

• Overall condition of the racking and actions to take in the event of a collision with the racking




• Correct stacking and load position.





Recap on the issues discussed in the previous 'Narrow Aisle' lesson and demonstrate the procedure for approaching from the left and right and safely de-stacking a laden pallet at ground-level. Remind the candidates that as with other equipment, the truck should be properly secured (park brake and neutral) and the wheels should be straight before attempting to lift the pallet.

Stress the importance of inserting the forks centrally to aid load stability. Stress the importance of checking the fork height before entry, in order to prevent rubbing as this could affect the pallet’s position and/or damage it. Remind the candidates that the operator must check the height of the pallet when lifting and the clearance above the pallet. Discuss safety precautions that must be considered before and during pallet withdrawal – including all-round observation and awareness of pedestrians and crush zones.


Remind the candidates of the importance of all-round observation before manoeuvring the truck during withdrawal. Stress the importance of checking the fork height before withdrawal in order to prevent rubbing, as this could affect the pallet’s position and/or damage it.






Working in Racking (Low-level)



Build on the previous demonstrations and discuss and demonstrate approaching and turning from the left and right to stack and de-stack a laden pallet from industrial racking at low-level. Ensure that throughout the demonstration you offer commentary and discussion of the key points, paying particular attention to operational differences with regard to the candidates’ previous experience with other equipment.


• All round observation • Looking in the direction of travel• Condition and safe working load of the beam• The dangers of overloading the racking system • Clearance overhead• Positioning of the laden pallet on the beam• Remember to ensure that the wheels are straight before attempting to lift the



pallet position.





Working in Racking (Medium-level)

Build on the discussion and demonstration about ground and/or low-level racking and progress to Medium-level racking. Remind the candidates of the safety precautions that relate to working in racking and expand on the additional considerations that relate to Medium-level operations. Include in your discussion:

• Condition and safe working load of the beam at Medium-level

• Clearance of the load to pass within the restriction of the beams (above, below and to the sides)

• Withdrawal and insertion of the forks at Medium-level to avoid rubbing

• Levelling of the forks/load at the appropriate height (where applicable)

• The dangers of overloading the racking system at subsequent levels

• Instability caused by the load wheels moving over bottom deck boards and stringer-bars of a

ground-level pallet.

Demonstrate approaching the pallet position from the left and right, turning 90° and stacking a laden pallet at Medium-level. Repeat the manoeuvre from both the left and right, turning 90° to de-stack the pallet. Ensure that throughout the demonstration you offer commentary and discussion of additional key points.




• Approaching the pallet position from the left and right before turning 90° to stack a laden pallet at Medium-level

• Approaching the pallet position from the left and right before turning 90° to de-stack a laden pallet from Medium-level.

Working in Racking (High-level)

Build on the discussion and demonstration about Medium-level racking and progress to high-level racking. Remind the candidates of the safety precautions that relate to working in racking and expand on additional considerations that relate to high-level operations. Include in your discussion:

• Difficulties faced when judging pallet and fork arm height

• Effects of mast and fork deflection

• Dangers of pedestrians passing underneath the raised forks/load

• Truck instability issues that might occur with this truck type, compared to the candidates’ experience

of other equipment.

Demonstrate approaching the pallet position from the left and right, turning 90° and stacking a laden pallet at high-level. Repeat the manoeuvre from both the left and right, turning 90° to de-stack the pallet. Ensure that throughout the demonstration you offer commentary and discussion of additional key points. Stress the importance of taking care not to turn with the hydraulics raised. Remind the candidates about the importance of looking in the direction of travel and all-round observation (particularly when manoeuvring away from the pallet position).


• Approaching the pallet position from the left and right before turning 90° to stack a laden pallet at high-level

• Approaching the pallet position from the left and right before turning 90° to de-stack a laden pallet from high-level.

End of CS3


OS1 – Using Pallet Trucks on a Dock Leveller






To introduce the candidates to the process of loading and unloading vehicles via a dockleveller.

Practical training area/suitable dock leveller or bridging platform. Alternatively, the session can be conducted in a classroom with appropriate visual aids.

• Truck• Suitable loads• Suitable vehicle or trailer (where available)• Appropriate materials to cordon off the training area• High visibility clothing• Wheel chocks (if necessary)• Suitable dock leveller or bridging platform (where available)• Local safety procedures• FTA - Loading Dock Safety Guide• HSG136: A Guide to Workplace Transport Safety• PC and compatible projector with screen (as necessary)


• Demonstrate and discuss correct operating techniques for loading and unloading a vehicle via a dock leveller or bridging platform

• Discuss safe working practices that should be adopted when working in this capacity with the equipment.



Before you deliver this session, ensure that your candidates are familiar with and competent in the use of basic hydraulic controls and that they are familiar with the fundamentals of handling palletised goods.

PreparationPrior to starting this session ensure that all necessary course resources are available. Additionally, to aid candidates during session delivery, instructors should consider using presentations, illustrations and training aids/models as necessary.

This session is additional to the core syllabus. Time spent delivering this session must be added to your total training time.

Stress that loading and unloading vehicles is a high risk activity. Incidents involving heavy loads, moving vehicles and working at height can lead to serious injuries or death.

Explain that before loading and unloading can take place, all necessary safety precautions must be in place. Company policies and procedures regarding vehicle safety at loading docks must be adhered to, so it is important that operators are fully aware and familiar with the processes to be used. Example safety considerations include:

• Loading and unloading areas should be clear of traffic, pedestrians and people that are not involved

in the process

• The loading area ground conditions should be level and firm

• Prior to loading or unloading, the vehicle must be correctly positioned and secured

• The vehicle keys should be removed and the driver must be made aware of the loading activities

being conducted. The driver should remain in a designated safe area while the operation is

conducted

• The trailer access point dimensions (height, width etc) should be checked to ensure they are

compatible with the size of the load and pallet truck to be used

• The trailer load deck should be assessed for debris/condition/integrity prior to loading

• All loads/pallets should be in good condition prior to loading

• Trailer stability should be maintained by evenly distributing loads on the trailer bed

• Loads should be secured and arranged to prevent movement during transport


• Great care must be taken when loading/unloading unsupported semi-trailers - excessive weight

placed over the kingpin may result in the trailer tipping forwards

• Where the lift truck has a mast all round observations are to be made to ensure that adequate

clearances above exist

• Consideration should be made for load positioning in order to aid the unloading operation

• Before releasing load restraints and during unloading, care must be taken to ensure that load

movement or damage has not occurred during transportation

• Risk assessments must be completed and followed for all vehicle loading/unloading activities

including appropriate measures to prevent falls from trailers with open sides.

There is a high risk of vehicle drivers accidentally driving away too early, before the operation is complete.This is a frequent and dangerous occurrence in industry as a whole, therefore safeguards must be in place to reduce this risk. Safeguarding techniques include:

• Traffic light systems

• Use of vehicle or trailer restraints /axle locking systems

• Steering wheel clamps

• Key custody arrangements that can be enforced while loading/unloading is taking place

• Ensuring that the driver is out of the cab and in a designated waiting area during the operation.

Safeguards are especially important where there could be communication problems, e.g. where foreign drivers are involved, or where ambient noise hinders communication.

Further information on safe loading and unloading can be found on the HSE website in the ‘Vehicles at work’ section. Further information on securing vehicles can be found on the HSE website in the ‘Site-based ways to stop vehicles from moving’ section.

Ramps and Dock Bridging PlatformsExplain the purpose of the ramp/dock bridging platform. Discuss safety checks that the operator shouldundertake before using the equipment:

• Confirm compatibility with the vehicle/trailer• Ensure the ramp/platform is free from any damage or faults• Confirm that edge/fall protection is securely fitted• Confirm that the platform can withstand the combined weight of the pallet truck and load• Ensure that the platform is secured to the vehicle correctly to prevent movement during loading/

unloading (including the use of wheel chocks or axle locks)• Confirm that the platform is level• Confirm that the platform is suitable for being driven upon• Confirm the condition and functionality of dock engagement systems, including mechanical

interlocks and traffic light systems.



Explain that trailers should be loaded with pallets placed tight to one another, starting at the headboard, to help prevent the load from moving whilst in transit, especially under braking.

Pallet orientation on the trailer should also be considered, in order to maximise load bed capacity (the wide face should be placed across the trailer - subject to machine/pallet compatibility). Pallets should also be deposited side by side as this assists with even load weight distribution.

Where a rider platform is fitted to pedestrian trucks, prior to starting stacking/de-stacking operations the platform should be placed in the correct stowed position.

Trailer SafetyExplain that the stability of the trailer can be adversely affected by the movement of the truck and its operation. It is therefore important, especially when working with unsupported semi-trailers, to minimise the risks involved including:

• Trailer tipping forwards

• Landing gear collapse

• Trailer stability

• Load bed integrity

• Working at height risks with curtain-sided or open-type trailers

• Trailer suspension movement.

Loading and Unloading SequenceWhen negotiating the dock leveller, it is important to consider the direction of travel. Where possible, operators should avoid reversing onto the trailer as this will necessitate the need to turn around on the trailer bed and therefore increase the risk of a fall from height on open sided trailers.

Explain and demonstrate safe vehicle loading practices, ensure that your explanation/demonstration includes:

• Carrying out the required safety procedures necessary to ready the vehicle before loading

• Entering the vehicle load leading and travelling centrally before manoeuvring to deposit the load against the headboard/load and/or next to an adjacent load

• Travelling centrally and exiting the vehicle forks trailing, making sure to carry out full observations and look in the direction of travel.


Ensure that throughout the session, each candidate is given sufficient time to practise or explain the manoeuvres taught. If this session is taught theoretically, ask questions to confirm learning and encourage active participation.

Explain and demonstrate safe vehicle unloading practices, ensure that your explanation/demonstration includes:

• Carrying out the required safety procedures necessary to ready the vehicle before unloading

• Entering the vehicle forks leading and travelling centrally before moving to collect the pallet/load

• Collecting the pallet/load and travelling centrally before manoeuvring load trailing onto the dock leveller, making sure to carry out full observations and look in the direction of travel.

Ensure that throughout the session, each candidate is given sufficient time to practise the manoeuvres taught. Ask questions to confirm learning and encourage active participation.


OS2 – Using Pallet Trucks on Tail Lifts






Introduce the candidates to the process of loading and unloading vehicles with a pallet truck using a tail lift.

Practical training area, or classroom with appropriate visual aids.

• Truck• Suitable loads• Suitable vehicle fitted with a tail lift• Appropriate materials to cordon off the training area• High visibility clothing (if necessary)• Wheel chocks (if applicable)• Local safety procedures• SOE: Preventing Falls and Falling Loads from Tail Lifts• HSG136: A Guide to Workplace Transport Safety• PC and compatible projector with screen (as necessary).


• Demonstrate and discuss correct operating techniques for loading and unloading a vehicle using a tail lift

• Discuss safe working practices that should be adopted when working in this capacity with the equipment.



Before you deliver this session, ensure that your candidates are familiar with and competent in the use of basic hydraulic controls and that they are familiar with the fundamentals of handling palletised goods.

This session is additional to the core syllabus. Time spent delivering this session must be added to your total training time.

PreparationPrior to starting this session ensure that all necessary course resources are available. Additionally, to aidcandidates during session delivery, instructors should consider using presentations, illustrations and training aids/models as necessary.

Stress that loading and unloading vehicles is a high risk activity. Incidents involving heavy loads, moving vehicles and working at height can lead to serious injuries or death.

Introduce the candidates to the importance of safe working practices and make the candidates aware that adhering to the following guidance can help reduce the risks involved:

• Loading and unloading areas should be clear of traffic, pedestrians and people who are not involved

in the process

• Checks should be made to ensure that the tail lift has an in date Report of Thorough Examination

• Checks should be made for any damage or faults on the tail lift

• The loading area ground conditions should be level and firm and capable of supporting pallet truck

movement

• Loads should be secured and arranged to prevent movement during transport

• Any available safety/fall prevention equipment, such as handrails or barriers, must be deployed

• The tail lift SWL should be clearly marked and should indicate safe capability to lift the truck, its load

and any attachments.

• Prior to loading or unloading, the vehicle must be correctly positioned and secured

• The vehicle must be secured against movement during any loading/unloading operation

• The vehicle keys should be removed and the driver must be made aware of the loading activities

being conducted. (Where it is not possible to remove vehicle keys, ensure that other robust methods

to prevent vehicle drive away are actioned.)

• The trailer access point dimensions (height, width etc) should be checked to ensure they are

compatible with the size of the load and pallet truck to be used


• The trailer load deck should be assessed for debris/condition/integrity prior to loading

• Prior to accessing the tail lift, ensure the pallet truck is raised sufficiently to clear any changes in

floor height

• Explain that the truck must enter the tail lift with the load leading and that it must be parked away

from the sides before operation of the lift commences

• Once the truck and load are positioned on the tail lift, the truck must be secured, the load must be

lowered to the tail lift floor

• The tail lift must be raised level to the trailer load bed

• Consideration should be made for load positioning in order to aid the unloading operation

• All loads/pallets should be in good condition prior to loading

• When releasing load restraints and during unloading, care must be taken to ensure that load

movement or damage has not occurred during transportation

• Risk assessments must be completed and followed for all vehicle loading/unloading activities

including appropriate measures to prevent falls from trailers with open sides.

There is a high risk of vehicle drivers accidentally driving away too early, this is a frequent and dangerousoccurrence in the industry. Therefore safeguards must be put in place to reduce this risk. Examples include:

• Traffic lights

• Use of vehicle or trailer restraints

• Steering wheel clamps

• Key custody arrangements that can be enforced while loading/unloading is taking place

• Ensuring that the driver is out of the cab during the operation

• Safeguards are especially important where there could be communication problems, e.g. where

foreign drivers are involved or if ambient noise is loud

• Stress that the safety of the driver is important and that they should remain in an appropriate

waiting area whilst loading or unloading is taking place.

Further information on safe loading and unloading can be found on the HSE website in the ‘Vehicles at work’ section. Further information on securing vehicles can be found on the HSE website in the ‘Site-based ways to stop vehicles from moving’ section.



Where a rider platform is fitted to pedestrian trucks, prior to starting stacking/de-stacking operations the platform should be placed in the correct stowed position.

Pallet orientation on the trailer should also be considered, in order to maximise load bed capacity (the wide face should be placed across the trailer- subject to machine/pallet compatibility). Pallets should also be deposited side by side as this assists with even load weight distribution.

Loading

Explain and demonstrate safe vehicle loading practices, ensuring that your explanation/demonstration includes:

• Carrying out the required safety/security procedures necessary to ready the vehicle before loading

• Entering the tail lift load leading and travel central. Once pallet and truck are positioned on the tail

lift, rotating the truck so it is positioned at 900 to the vehicle, securing the pallet truck and carrying

out all-round observations

• Lowering the load to position it securely on the tail lift floor

• Carrying out the correct lift operation whilst maintaining all-round observations and checking for

crush hazards and pinch points

• Once positioned at correct height, raising and rotating the truck to facilitate entering the vehicle

with forks trailing

• Rotating the truck/load and positioning correctly. Great care must be taken when working on open

-sided vehicles during the rotating of the truck to prevent falls

• Disengaging from the pallet and rotating the pallet truck to exit the load bed with the forks leading

• Once the pallet truck is on the tail lift, rotating and securing the pallet truck so it is positioned at 900

to the vehicle, whilst carrying out all-round observations

• Lowering the truck to position it securely on the tail lift floor

• Lowering the platform until it makes contact with the ground.

Trailer SafetyExplain that the stability of the trailer can be adversely affected by the movement of the truck and its operation. It is therefore important to minimise the risks involved including:

• Checking load bed integrity

• Maintaining awareness of working at height risks when working with curtain-sided or open trailers

• Maintaining awareness of trailer suspension movement.

Sequence of Loading and UnloadingExplain that trailers should be loaded with pallets placed tight to one another, starting at the headboard, to help prevent the load from moving whilst in transit, especially under braking.


Unloading

• Carrying out the required safety/security procedures necessary to ready the vehicle for unloading

• Entering the tail lift forks leading and travel central, once the truck is positioned on the tail lift,

rotating the truck so it is positioned at 900 to the vehicle, whilst carrying out all-round observations

at all times

• Lowering the truck and position it securely on the tail lift floor

• Raising the platform until level with the trailer load bed

• Accessing the load bed centrally with the forks trailing. Once on the load bed rotate 1800, select

and enter the pallet, taking great care of the associated fall risk when working on open-sided trailers

• Rotate the truck 1800 for load leading on exit

• Once the load is positioned on the tail lift, slowly rotate the truck/load 900 whilst maintaining all

round observations

• Lowering the load to position it securely on the tail lift floor

• Carrying out the correct lowering operation of the tail lift whilst maintaining all-round observations

and checking for crush hazards

• Once tail lift is at ground level, raising and rotating the truck to enable it to exit the tail lift.

Ensure that throughout the session, each candidate is given sufficient time to practise the manoeuvres taught. Ask questions to confirm learning and encourage active participation.


Basic Operating Skills Test

(Assessment)



IntroductionThis test has been developed by the Accrediting Bodies Association for Workplace Transport (ABA) as a means of ensuring national, uniform standards for the testing of Electric Pallet/Stacker Truck operators. Only currently qualified RTITB lift truck instructors and examiners who have been trained in its application should carry out this testing process.

Continuous assessment of Novice, Existing, Refresher and Conversion Electric Pallet/Stacker Truck operators’ progression will naturally be undertaken during training by instructors, and subsequently by immediate supervisors at the operators’ workplaces. This is routine and would normally be conducted fairly informally.

Ideally, a suitably qualified RTITB instructor who has not been involved in the delivery of training to the candidates should conduct the assessment. This is to ensure objectivity and to protect the integrity of the assessment process.

The HSE Approved Code of Practice and supplementary guidance Rider-operated lift trucks: Operator training and safe use L117 gives advice to employers concerning lift truck operator training and testing. RTITB operator training follows this guidance and has applied it to Electric Pallet/Stacker Trucks as per the ACoP and Guidance in L117. Successful completion of Basic Operator training should be followed by Specific Job and Familiarisation training, as well as supervision, as described in the ACoP and guidance.

This assessment can be used as:

a. Validation of a course of Basic training (including refresher and conversion)

b. Confirmation of existing standards

c. Pre-employment assessment

d. Post-incident assessment

Successful completion of this test without prior training does not indicate that training, as described in the ACoP and guidance has been provided, nor does it mean that accredited training has been provided.


Many training providers/instructors now train and test non-English speakers. You must ensure that in such cases all applicable legal requirements are met. If you are unsure what those requirements are, you should seek specialist legal advice.As Basic training covers technical information, there is a need to ensure that all candidates are equipped with the underpinning knowledge relevant to all operation and safety requirements relating to the category of equipment. It is therefore essential that all candidates, regardless of their language, are able to recall and discuss this important information and that evidence of this is recorded.

A translator can be provided for the purposes of testing. The chosen translator must not be a candidate from the course and must not alter the sense of any of the answers given by the candidate. Disciplinary sanctions may be taken in the event of any material changes made by the translator to the candidate’s responses. Thismay include revocation of any certificates awarded or the operator registrations. Additional sanctions may also be taken against the instructor/training provider.

The Accrediting Bodies Association (ABA) strongly recommends that an accredited translator is used during this test and that all responses provided by the candidate are translated and written onto the applicable answer sheet(s). Furthermore, the translator must print and sign their name and record their accrediting organisation



Test ObjectivesThe overall objective of this formal test is to verify a candidate’s ability to meet the minimum basic safety standard. Candidates must pass all elements of the test in order to be successful overall.

Individuals who do not meet the required standard in any of the elements that make up this test will be eligible for retest in the elements in which they refer after further remedial training.

The test requires candidates to:

a. Demonstrate understanding of pre-use checks, identifying faults and deficiencies and

taking the appropriate reporting/remedial action

b. Undertake a practical test:

• Manoeuvring a laden and unladen Electric Pallet/Stacker Truck, forward and reverse

• Carrying out a series of stacking and de-stacking exercises within the main aisle

• Manoeuvring twice in each direction, laden, through a chicane

• Culminating in depositing a load and parking the Electric Pallet/Stacker Truck correctly.

c. Undertake an associated knowledge test, written or oral.


Pre-use Inspection of the Electric Pallet/Stacker TruckThe candidate will be required to carry out a pre-use inspection of the equipment and clearly demonstrate understanding of the process. The pre-use check is a visual and functional safety check. It must be carried out in accordance with the equipment manufacturer’s recommendations and any relevant company procedures. During the pre-use check the candidate will be expected to answer questions about the process and various equipment components.

MarkingThe examiner will assess whether the candidate meets the minimum standards necessary to carry out a pre-use check correctly and efficiently.

A candidate pre-use check sheet and examiner marking sheet are included later in this section. Each sheet provides a list of the components that should be checked during every pre-use inspection. 14 of the components that should be included in the pre-use inspection have been deemed safety critical and if missed/not checked there may be a significant risk to the health and safety of the operator/other persons and infrastructure in the location of the truck. The following list of components are deemed as mandatory component checks. The candidate must carry out a full and correct check of these items – failure to adequately carry out checks on these components will result in a referral in this element of the test (these items have MC written against them on the examiner's marking sheet).

• Fork arms/attachment

• Carriage plate*

• Mast*

• Mast rollers/slides*

• Lift chains*

• Chain pulleys*

• Hydraulic systems

• Wheels

• Tyres

• Rated capacity plate

• Repel pad

• Hydraulic controls

• Drive and braking

• Steering

* Not found on A1/A2



The remaining elements described and listed on the inspection sheet are still required to be appropriately inspected and the examiner will decide if the overall inspection is adequate and will pass/refer as appropriate.

The list of items on the pre-use inspection sheet should not be considered complete or finite. It is important to remember that all pre-use inspections are to be carried out in accordance with the truck manufacturer's recommendations. The examiner pre-use inspection sheet must be retained for future reference and the result must be recorded on the final assessment document.

All marking must be carried out using the examiner’s marking sheet.

See the "Explanation of Criteria" overleaf for the methods of inspection criteria that can be applied to each component.


Pre-use Inspection of the Electric Pallet/Stacker TruckExplanation of CriteriaThe candidate will be observed carrying out a pre-use inspection of the equipment. The instructor/examiner will ask questions at planned intervals to ensure that the candidate understands the item under inspection. These explanatory notes will assist the instructor/examiner when questioning the candidate during the testing process.

The following list of items must be fully and comprehensively understood by the candidate. Failure to do so will result in an automatic referral.

• Fork arms/attachment

• Carriage plate*

• Mast*

• Mast rollers/slides*

• Lift chains*

• Chain pulleys*

• Hydraulic systems

• Wheels

• Tyres

• Rated capacity plate

• Repel pad

• Hydraulic controls

• Drive and braking

• Steering

* Not found on A1/A2

Note:

1. The pre-use checklist provided has been determined as the minimal number of items to be

checked before operation and is not definitive

2. All pre-use checks and additions must be carried out in accordance with the specific

instructions published in the manufacturer’s operating handbooks.



A1-A2No.

A3-A7No. CRITERIA EXPLANATORY NOTES

1 1 Fork Arms/Attachment Mandatory Component

Each fork arm should be checked for wear, cracks and distortion. Check for wear causing thin, jagged edges at the fork tip. Particular attention should be paid to the fork hooks and carriage plate, constant movement between these points causes wear and fracture. The fork arms should be equally spaced on the carriage with the fork retaining pins engaged and secure.

Any attachment fitted must be attached appropriately and secure on the carriage plate (if applicable). Locking pins, welded joints, pivots should not be worn, cracked or seized. The attachment must not be bent, twisted or distorted and must be in good, functional working order. For A1, A2 fixed fork tyres, where the wheels locate on these forks, check for debris at the tip end and the hole that allows the wheels to retract into.

N/A 2 Carriage plate Mandatory Component

The carriage plate should have no obvious damage and sit square to the mast. The end stop bolts must be engaged and secure. The fork locking pins must fully engage into the castellations.

N/A 3 Backrest extension The back rest extension or load guard should be attached securely to the carriage plate, retaining bolts should be in place and adequately fastened, the guard should be free from distortion and allow for any load to fully heel up, welded joints should be crack free.

N/A 4 MastMandatory Component

Checks should be made to the outer mast sections for damage, distortions and cracks. In addition the inner mast channels or runners must be inspected for undue wear, scoring, excessive dirt or any debris which may be fouling the mechanism.

N/A 5 Mast rollers/slidesMandatory Component

The mast guide rollers, including reach channel rollers must not show signs of uneven wear, incorrect tracking, flat spots and scoring. Mast slides must be intact and not loose.


A1-A2No.


N/A 6 Lift chainsMandatory Component

Check lift chains for evidence of deterioration, loose or worn pins, damaged pin rivet heads, worn, cracked or missing links and signs of rust on link plates.

Chain anchor points must be inspected for damage, even adjustment and security of the locking nuts or retaining pins.

N/A 7 Chain pulleysMandatory Component

Chain pulleys should have no obvious damage, uneven wear and flat spots. The chains running over pulleys should show signs of tracking correctly between the riveted end of the chain pins and the walls of the pulley flanges.

2 8 Hydraulic Systems Mandatory Component

All hydraulic rams, seals and couplings must be checked for damage and leaks. Particular attention should be given to where the piston emerges from the outer cylinder for any oil, corrosion and scoring on the piston. Examine all visible hydraulic hoses/pipes for kinks, damage, crushing, abrasion leaks or signs of fouling which could result in a possible hydraulic leak. Any hose reel mechanisms (if fitted) should be undamaged and running freely with no evidence of hydraulic oil leaks.

3 9 WheelsMandatory Component

There should be no obvious missing or loose wheel nuts. The wheel rim and hub should be examined for damage, cracks and scoring. Inspect the stub axles and steering assembly for excessive dirt or any foreign bodies especially polythene shrink wrap, banding etc. which may be fouling the mechanism.

4 10 TyresMandatory Component

Individual tyres should be checked for punctures and pressures [pneumatics], adequate and even tread across the same axle, damage, flat spots and deep cuts. All swarf, nails, flints, etc. should be removed from the tread. Incorrect wheel alignment results in uneven wear of the tyres and if the fault is great the steering ability of the truck is affected. Check the tyre side wall for evidence of deterioration and cracks.



A1-A2No.


5 11 External condition Examine the general condition of the machine’s overhead guard, battery or engine covers/access panels should be complete, damage free and secure. Inspect the bodywork for damage, rust, broken hinges, or locks, which could be detrimental to the truck's safe operation. Mirrors (if fitted), lights, and warning devices should be in working order, clean, and free from damage. When walking around the truck, the operator should check on top of the mast section, tie bars, overhead guard or cab, for articles which may have been left there which could fall when the truck is operated. The linkages that connect the lifting wheel to the front wheels (if applicable).

In addition the operator should ensure there are no water, oil, fuel or any other types of fluid leaks. The trucks reach legs, channels or pantograph should be free from damage and debris, any wheel guards or covers must not be in contact with the tyres. The tiller arm should be spring loaded and capable or returning to its non-operational position.

6 12 Rated capacity plateMandatory Component

The rated capacity plate must be fitted, it must be secure, clear and legible and display, at least, the maximum weight the lift truck can pick up, the load centre and the maximum lift height, appropriate to the lift truck and or any attachments fitted.

7 13 Operating position The floor and cockpit area should be dry and clear of dirt or any foreign bodies, which may be fouling the operating controls, safety switches or devices. Foot and hand operated controls and instruments should be intact, undamaged and functional. Side support arms should lower into the correct place and be able to be stowed correctly. Visual gauges, decals and instruments should be unobstructed, clean and intact.

8 14 Fold-down platform Should be able to lock into position both up and down, check any interlocks, platform distortion. Check any non-slip surfaces, side support arms should lower into the correct place and be able to be stowed correctly.


A1-A2No.


9 15 Operator’s seat Check anchor points, runners/slides and end stops are engaged, secure and undamaged . Ensure that under the seat is clear of any foreign bodies which may be fouling the adjusters and any safety interlock switches and weight function indicators. Check the seat and back rest adjusters to ensure they are intact, damage free and functional.

10 16 Starting procedure - Electric Trucks

The traction battery is secure and the power supply cable is intact, connected and secure. Confirm adequate charge. Ensure the on/off key switch system activates the power and the isolator switch [if fitted] functions correctly. Physically and visually check any additional interlocks or gauges to ensure they are functioning in accordance with the specific manufacturer’s operating handbook.

11 17 Repel padMandatory Component

The repel pad is located on the top of the tiller arm and is to reduce the risk of the operator becoming trapped between the truck and an obstacle (e.g. racking). To fully test the pad, stand to one side of the truck and operate the directional control so the truck is travelling repel pad first. Place one hand onto the pad to simulate the body. The truck should stop and move a short distance in the opposite direction before stopping. Do not try this against a body.

12 18 Lights Any service lights fitted should be in working order. This includes direction indicators, reversing lights, brake lights, flashing beacons, road lights, presence lights, spot/working lights etc. Lenses should be free from damage, clear of debris, secure and be able to be seen at a reasonable distance by others.

13 19 Audible warnings The machine must not be operated if the horn is defective. If there is an audible warning device, check that it activates and can be heard, e.g. if you leave the cockpit without switching off the power or fail to apply the parking brake, selecting reverse gear, height, weight and pressure limit switches, etc.



A1-A2No.


14 20 Hydraulic controlsMandatory Component

All hydraulic driven parts (mast height, reach carriage, tilt mechanisms etc.) must be run to their end positions, to lubricate all the moving parts, checking for their serviceability, smooth operation, obvious leaks and that there is sufficient oil in the tank.

15 21 Drive and brakingMandatory Component

Forward and reverse should be engaged to ensure their smooth operation and positive response to the accelerator pedal, as well as the tiller arm thumb control switches. The parking brake should be tested by slowly driving and then apply the brake, the truck must stop. The efficiency of the footbrake should be tested in both directions, braking must be even. The brake pedal should not travel to the cockpit floor. Lift trucks may be fitted with hydrostatic, rheostatic regenerative or opposite direction braking systems, in addition to mechanical brakes, these must be checked to ensure they are functional in accordance with the manufacturers operating handbook.

16 22 SteeringMandatory Component

Check for excessive play in the steering wheel before starting the truck. Check the tiller arm has a full range of motion and all thumb controls are fully functional. Avoid turning the wheels of the truck whilst stationary, this may subject the steering mechanism and tyres to unnecessary wear or strain. The operator should move the truck in both directions checking the steering operation fully on both locks. 180 and 360 degree steering systems should function correctly and any steering instrument indicators should correlate to the wheel position.

17 23 Fault reporting procedure

The candidate must satisfactorily explain the action to be taken in the event of discovering a fault on the truck at the start or during any operating period, i.e. isolating the truck, displaying of warning signage, any company policies and procedures, reporting to managers, supervisors etc, completion of documentation.


Practical Test of Basic Operating SkillsIntroductionThis test has been devised to examine the critical skills required of a pallet/stacker truck operator, which are:

• Starting and stopping the truck

• Driving forward and in reverse, including braking

• Steering accuracy

• Correctly placing a load on the forks

• Using hydraulic controls correctly and sympathetically

• Judging the position of fork tips at varying heights, laden and unladen

• Stacking and destacking accurately at various heights

• Observation of the working environment and judgement of speed, height, width and distance

from within the confines of the machine.

The test is based on the safe application of these operations at a reasonable working pace. Care has been taken to design a course which covers all the critical skills, while being easily constructed on most company premises. The course selected will depend on whether it is a stacking or non stacking variant.

Setting up the Practical Test CourseTest Course Materials

The course has been designed to take advantage of pallets, loads, stacks, racking and permanent constructions, subject to critical dimensions and machine type. All loads handled by the truck during the test should be identical width, height, length and weight to simulate what the candidate will realistically encounter in their workplace.

Where candidates work requires it, undercutting, with appropriate de-rating, may be necessary.

The height of the load is not critical, but should be high enough to restrict the candidate’s vision, requiring them to judge the position of the base of the pallet whilst manoeuvring and during stacking and de-stacking.

Chicane

The chicane should consist of one left and one right turn in either sequence, (see guidance on how to build a chicane) and it should be constructed using suitable barriers, hurdles, existing features or empty pallets. Care should be taken during construction to create the right distance between each turn to be negotiated (see the diagram of the course). Traffic cones and other materials which permit large voids between corners and intrude on to the chicane are not suitable for this purpose. The distance from the chicane to the test aisle is not critical; however, care should be taken to allow sufficient separation to allow the candidate, when emerging from the chicane, to position the truck correctly prior to undertaking the first stacking operation.



How to Build the Chicane

Position the truck at a 45° angle.45o

50 - 75mm (2-3 inches) clearance

Maintain 50 - 75mm (2-3 inches) clearance

Pivot point

50 - 75mm(2-3 inches) clearance

Travel load trailing whilst maintaining a 50-75mm (2-3 inches) gap, stopping when the pivot point reaches the 45° point of the turn.

Build the outside corner nearest the main aisle and leave a 50-75mm (2-3 inches) gap at the two critical points.

Build the inside of the turn, leaving a50-75mm (2-3 inches) gap at the pivot point.

Build the chicane corridor, ensuring it is at least 1.5 truck lengths from inside corner to inside corner and its width is consistent along its length.

At the end of the corridor repeat the process, to build the opposite corner.


If using empty pallets to construct the chicane, care must be taken to ensure they are intact, free from projecting nails and other protrusions, and are secure and stable once upended.

The width of the chicane will be the practical minimum manoeuvring width for a laden truck plus a clearance of 75mm (3 inches) at the critical points (pivot point, truck and load extremities) of each turn (see the diagram of the course).

Main Aisle

The width of the main aisle will be the manufacturer’s minimum 90° working aisle width for that particular truck, including any load overhang (from the fork tips to the front leading edge of the load), plus 300mm (12 inches) for pedestrian operated trucks and 200mm (9 inches) for fixed platform rider operated trucks.

The minimum 90° main aisle width may be obtained from the manufacturer if not already published in the manufacturer’s handbook.

The manufacturer’s minimum 90° working aisle relates to the use of standard forks and a 1000mm or 800mm x 1200mm pallet, with either the 1200mm or 1000mm face along the fork length (600mm or 500mm load centre). Use of a non-standard attachment and/or pallet will affect this measurement.

Loads along the main aisle should be stacked or racked in line at the appropriate levels with 75mm (3 inches) space between the loads or the racking uprights where applicable. Each location must have either racking upright(s) or load(s), ideally of identical width, height and length on both sides to simulate the candidate’s work.

Loads can be arranged to allow handling from either face (subject to pallet configuration and truck design); however, a consistent approach should be maintained for the whole duration of the test.

Stacking Positions and Heights

On completion of the low level test the candidate will have stacked and destacked at low level. On completion of the medium level test the candidate will have stacked and destacked at low level and medium level. On completion of the high level test the candidate will have stacked and destacked at low, medium and high levels.

Load at ‘A’ - The height of the load is not critical, but should be high enough to obscure candidate’s vision, thus requiring them to make blind judgements of positioning while negotiating the chicane during stacking and de-stacking operations in the main aisle, and when depositing the load at the vertical face.

When conducting the assessment with a straddle truck, the gap between the pallets or the upright should measure 75mm (3 inches) from the trucks outrigger leg.



The part of the course forming the vertical face should be of sufficient height and width to permit the candidate to see it clearly when approaching it load leading.

The first load at "A’"should be positioned squarely within 150mm of, but not touching, the vertical face.

Low-level - this stacking position is for truck types with limited lifting height capability. For trucks limited to this height capability, the stacking positions "B", "C" and "D" should be positioned at low-level to a maximum height of 300mm.

Medium-level - refers to the stacking position which requires the forks to be inserted at a height corresponding to the level which is between 301mm and 2999mm stacking height. For trucks limited to this height capability, the stacking positions "B" and "C" should be positioned at medium-level and the load positioned at "D" should be at low-level.

High-level - defined as a height of 3000mm (9ft 10 inches) and above. For the purpose of the test the high-level stacking position must be either the maximum stacking height normally found in the candidate’s working environment for the lift truck and loads in use on the test. The load at "B" should be positioned at high-level, the load at "C" at medium-level and the load at "D" at low-level.

Alternative Test Construction

Every effort should be made to construct the course in one continuous area. However, where the area is insufficient to construct a complete test course, the chicane may be entirely separate from the main aisle, effectively dividing the test into two parts, as described below.

Part 1

Will start at the position shown on the course plan and will comprise picking up the load from the vertical face, driving through and exiting the chicane, load leading and load trailing twice, depositing the load close to the vertical face and finally parking the truck at the finishing point. The examiner must record the time taken to complete this part accurately.

Part 2

Covering the various stacking and de-stacking operations will begin at the point where the end of thechicane nearer the main aisle might otherwise have been sited.

In situations where the maximum stacking height is less than 3000mm (9ft 10 inches) the certificate must be restricted clearly showing the maximum stacking height used in the test.


Administration and Testing ProcedureTest DurationCandidates are tested not just on their ability to operate correctly and skilfully but also on their ability to operate at a reasonable pace without hesitancy or excessive speed. Examiners should therefore determine a “fair and reasonable” time for completion of this part of the assessment.

This will be affected by a number of factors which may include: actual stacking heights, lift speed, general manoeuvrability of the truck being used, distances between stacking positions, chicane and the main aisle, etc.

The examiner should carry out the complete test at a normal working pace, making careful note of the time taken. For the purpose of the test time penalties, this will be referred to as the rehearsed time.

Testing ProcedurePrior to the test, the examiner must complete the various sections of the marking sheet, i.e. candidate’s details, description of the truck, capacity, etc. (see the Practical Skills Test Marking Sheet).

During the test, only the candidate and the examiner should be in the immediate vicinity of the test area. This will eliminate any potential distractions or hazards to the examiner and candidate.

Before the test begins the examiner must ensure that the:

• Lift truck is correctly parked, in a secure state at a distance from the first load that requires the lift truck to be placed into the travel position and travel to the first load

• Tiller arm or steering wheel of the truck are in the straight line position• Spread of the forks is both equidistant and suitable for the loads to be used, if applicable• If fitted with a fold-down platform,this is only to be used to and from the drive to pallet A from the

start/finish point

Walk through the test courseBefore the test, the examiner will walk the candidate through the course, giving a brief explanation of each operation to be carried out during the test. They should be told that these instructions will be repeated, a step at a time, while the test is in progress. The test is undertaken to assess their operating skills and is not intended to check their memory.

Explanation of the Marking SheetThe examiner must explain how the marking system works: why some faults are more heavily weighted than others, areas of disqualification and the pass/fail cut off criteria. The examiner will explain that where a candidate commits in excess of 3 faults (i.e. 4 or more) in any one fault area where the penalty award is 5 points then that candidate will have not met the required test standard and will have been deemed to have failed the practical element of the test.

The examiner will direct the candidate through the course giving stage-by-stage directions on the operation to be carried out.During the practical skills test the examiner must maintain a position where the candidate can be continuously observed without causing a distraction or hazard. The practical skills test should be carried out according to the test course plan and route (see plan of course A or B).



MarkingIt is important that faults should be carefully and quickly recorded as they occur during the test, and the test must be administered by an examiner who is well acquainted with the faults list on the marking sheet (see the marking sheet and explanation of faults).

Reference to the marking sheet will show that a penalty has been allocated to each of the faults listed. Those faults deemed to be more serious for the purpose of the test have been allocated weighted penalties accordingly.

On each occasion when a candidate commits a fault, a cross should be marked against the appropriate fault. At the end the examiner must:

• Multiply the number of crosses recorded against each fault by the allocated penalty and enter the

result in the award column

• Add up the recorded penalties and enter the total

• Add to this any time penalties incurred to arrive at the final total of penalties.

Where a candidate commits in excess of 3 faults (i.e. 4 or more) in any one area where the penalty award is 5 points then that candidate will have not met the required test standard and will have been deemed to have failed the practical test.

Time PenaltiesThe set time for completion of the test without time penalties, will be 2 x rehearsed time (twice the time recorded by the examiner taken to complete the test course when operating at a normal working pace).

Clearly, it would be unfair for candidates to be judged against an exceptionally quick test drive by the examiner. Equally, an over-cautious test drive would be undesirable, as it would effectively produce a set time for candidates which is too generous.

If the test drive is properly conducted, the resulting set time will closely match the time subsequently taken by an average candidate.

Examiners must monitor this aspect of their test results carefully. Wherever a wide variation occurs consistently between the set time and candidate’s performance times, it would be wise to investigate whether a test drive conducted at above or below normal working pace is a contributory factor.

Candidates who take in excess of the set time will incur one penalty for each full or part minute in excess of the set time. Time lost through interruption of the test will not incur penalties.

The maximum test time allowed before disqualification will be 3 x rehearsed time.

Example: Rehearsed time = 15 minutes (examiner’s time) Set time = 30 minutes (2 x rehearsed time) Disqualification time = 45 minutes (3 x rehearsed time)


Should hesitancy or lack of confidence be shown by a candidate undergoing the test (even if the disqualification time has not been exceeded) examiners should consider referring the candidate.

Explanation of Practical Operating Test Result

The examiner will explain to the candidate:

• Faults that occurred and why

• Time taken

• Pass/refer result and any remedial training that might be required

Pass/Fail Criteria

The cut off for the practical skills test at basic operator level is 40 penalty points for high level, 30 penalty points for medium level and 20 penalty points for low level. Where penalties are incurred in excess of these figures (according to machine type), candidates will be deemed to have failed the test.

• Low level testing up to a maximum lift height of 300mm • Medium level testing between 301mm - 2999mm

• High level testing 3000mm and above

In addition, candidates will be disqualified for:

• Operates dangerously – If, at any point, the examiner feels it necessary to intervene on safety grounds then the candidate will be disqualified. Examiners must be vigilant and protect the safety of the operator and others in the vicinity.

• Exceeds maximum time – The candidate cannot exceed 3 times the examiner’s test run time (rehearsal time). See the discussion on ‘time penalties’ earlier in this section.

• Dismounts unnecessarily – The candidate must remain inside the vehicle during the test (in a rider-operated scenario). If the candidate leaves the 'fixed platform' during the test they should be disqualified.

• Exceeds more than three 5 point penalties in one area – If a candidate receives more than three marks in any 5 point fault they will be disqualified from the practical test.

• Violent collision - If, at any point during the test, the candidate collides the equipment with infrastructure fixings, other vehicles or pedestrians, the test will be halted and the candidate disqualified.

• Unsafe stacking – Where examiners anticipate that a load or stack is about to be left in a potentially unsafe state, they should act immediately to overcome the problem and disqualify the candidate.

Where failures occur, it would be sensible to study the marking sheet for evidence of any particular areas in which the candidate might be given further tuition prior to undertaking the test in the future. Any retest should not be made too soon, ample time should be allowed for the candidate to be effectively retrained before undergoing a further test.



Test Sequence AElectric Pallet Truck (Low-level) - A1, A2

1. The candidate shall take control or mount the truck at the start position

2. If a fold-down platform is used the candidate will lower the platform, mount the machine

and drive to load A and dismount. Then stow the fold-down

3. Drive forward, forks leading and pick up load at low level A

4. Drive through the chicane with load leading

5. Deposit the load at position B

6. Withdraw from the load and reverse with forks trailing towards the chicane

7. Pick up the load from position C

8. Withdraw from the load and reverse with load trailing from the main aisle through the

chicane to the start/finish line

9. Drive forward through the chicane into the main aisle and deposit the load at position C

10. Withdraw from the load and reverse with forks trailing towards the chicane

11. Pick up the load from position B

12. Withdraw and reverse with load trailing through the chicane

13. Place the load squarely at low level A within 150mm of, but not touching, the vertical face

14. Withdraw the forks and reverse the truck until the fork tips are behind the start/ finish line


and reverse to the start/finish line. Dismount, then stow the fold-down

16. Park the truck correctly

17. Dismount from the truck (where applicable)

Notes

a. All elements of the test must be completed for the appropriate truck type

b. Throughout the practical test course, critical dimensions and layout must be maintained.

c. Each time candidates have to withdraw the truck from a stacking or destacking position in

the main aisle, they should be instructed to drive forks/load trailing towards the chicane, this

is to ensure both left and right hand approaches are included in the test. Upon successful

completion, the test course must be restored to its original state, ready for further use without

re-arrangement, except if loads need to be tidied up


MAINAISLE 75mm

(3 inches)

C

D

75mm(3 inches)

B

A

50 - 75mm(2-3 inches)clearance

Minimum1.5 truck lengths

Start / Finish


A maximum of150mm (6 inches)

gap between pallet Aand vertical face

Test Course AElectric Pallet Truck (Low-level) - A1, A2

Not to Scale



Test Sequence BElectric Pallet Truck (Low-level) - A1, A2


2. If a fold-down platform is used. The candidate will lower the platform, mount the machine

and drive to load A, and dismount. Then stow the fold-down



5. Deposit the load at position B

6. Withdraw from the load and reverse with forks trailing away from the chicane

7. Pickup the load from position C

8. Withdraw from the load and reverse with load trailing from the main aisle through the

chicane to the start/finish position

9. Drive forward through the chicane load leading

10. Deposit the load at position C

11. Reverse with forks trailing away from the chicane

12. Pick up the load from position B

13. Withdraw and reverse with load trailing through the chicane to the start/finish position

14. Place the load within 150mm of, but not touching, the vertical face at A


and reverse to the start finish line. Dismount, then stow the fold-down





Test Course BElectric Pallet Truck (Low-level) - A1, A2

Not to Scale

MAINAISLE

75mm(3 inches)

C

B

D

A



Start / Finish






Test Sequence AElectric Pallet/Stacker Truck - A3, A4, A5, A6, A7


2. If a fold-down platform is used the candidate will lower the platform, mount the machine and drive to load A and dismount then stow the fold-down



5. Stack the load at high level B

6. Withdraw from the stack and reverse with forks trailing towards the chicane

7. Destack the load from medium level C

8. Reverse with load trailing towards the chicane

9. Stack the load at low level D squarely and in line with the adjacent stack


11. Destack the load from high level B

12. Withdraw from the stack and reverse with load trailing from the main aisle through the chicane to the start/finish line

13. Drive forward through the chicane into the main aisle and stack the load at medium level C


15. Pick up the load at low level D

16. Withdraw and reverse with load trailing through the chicane (where applicable)

17. Place the load squarely at low level A within 150mm of, but not touching, the vertical face


19. If a fold-down platform is used the candidate will lower the platform, mount the machine and reverse to the start/finish line. Dismount, then stow the fold-down



Notes

a. All elements of the test must be completed for the appropriate truck type

b. Throughout the practical test course, critical dimensions and layout must be maintained.

c. Each time candidates have to withdraw the truck from a stacking or destacking position in the main aisle, they should be instructed to drive forks/load trailing towards the chicane, this is to ensure both left and right hand approaches are included in the test. Upon successful completion, the test course must be restored to its original state, ready for further use without re-arrangement, except if loads need to be tidied up.


MAINAISLE 75mm

(3 inches)

C

MediumLevel

HighLevel

D

75mm(3 inches)

B

HighLevel

HighLevel

A



Start / Finish




Test Course AElectric Pallet/Stacker Truck - A3, A4, A5, A6, A7

Not to Scale



Test Sequence BElectric Pallet/Stacker Truck - A3, A4, A5, A6, A7



and drive to load A, and dismount. Then stow the fold-down



5. Stack the load at high level B

6. Withdraw from the stack and reverse with forks trailing away from the chicane

7. De-stack the load from medium level C

8. Reverse the load trailing towards the chicane

9. Stack the load at low level D squarely and in line with the adjacent stack

10. Withdraw from the stack and reverse with forks trailing away from the chicane

11. De-stack the load from high level B

12. Withdraw from the stack and reverse with load trailing from the main aisle through the

chicane to the start/finish position

13. Drive forward through the chicane load leading

14. Stack the load at medium level C

15. Reverse with forks trailing away from the chicane

16. Pick up the load at low level D

17. Withdraw and reverse with load trailing through the chicane to the start/finish position

18. Place the load within 150mm of, but not touching, the vertical face at A


and reverse to the start/finish line, dismount, then stow the fold-down





MAINAISLE

75mm(3 inches)

C

MediumLevel

HighLevel

B

HighLevel

D

A



Start / Finish




Test Course BElectric Pallet/Stacker Truck - A3, A4, A5, A6, A7

Not to Scale



Practical Test of Basic Operating Skills Explanation of FaultsThe safe operating procedure must comply with, and be assessed in accordance with, the specific instructions published in the manufacturer’s operating handbook for the equipment used.

Mandatory DisqualificationsThe following explanations relate to grounds for mandatory disqualification from the practical test. In general, mandatory disqualification should be exercised for dangerous operating practices. The following examples are for guidance purposes and the examiner may feel that additional scenarios or actions are grounds for bringing the test to a halt and disqualification of the candidate.

• Operates dangerously – If, at any point, the examiner feels it necessary to intervene on safety

grounds then the candidate will be disqualified. Examiners must be vigilant and protect the safety

of the operator and others in the vicinity.

• Exceeds maximum time – The candidate cannot exceed 3 times the examiner’s test run time

(rehearsal time). See the discussion on ‘time penalties’ earlier in this section.

• Dismounts unnecessarily – The candidate must remain inside the vehicle during the test (in a

rider-operated scenario). If the candidate leaves the 'fixed platform' during the test they should be

disqualified.

• Exceeds more than three 5 point penalties in one area – If a candidate receives more than three

marks in any 5 point fault they will be disqualified from the practical test.

• Violent collision - If, at any point during the test, the candidate collides the equipment with

infrastructure fixings, other vehicles or pedestrians, the test will be halted and the candidate

disqualified.

• Unsafe stacking – Where examiners anticipate that a load or stack is about to be left in a potentially

unsafe state, they should act immediately to overcome the problem and disqualify the candidate.


ABA Category A1 and A2

FAULTNo.

FAULT DESCRIPTION EXPLANATORY NOTES

1 Mounts/dismounts incorrectly

Inserts key or turns the power on before mounting, fails to use secure and appropriate hand or foot holds correctly, holds steering wheel or a control lever, fails to look all round before dismounting and alights in the incorrect manner e.g. jumps off. Mounting and dismounting should be conducted facing the lift truck. A penalty should be awarded each time any of these faults occur.

2 Limbs outside the confines of the truck

Drives with a limb outside confines of the truck. Fingers, hands, arms, legs and feet must always remain inside the confines of the machine. Where an operator has to lean outside the confines of the lift truck for the purpose of observation or alignment, the truck must be secured and an all round visual check carried out before.

3 Fails to check all round Fails to check all round before moving off and whilst operating. A thorough check all round is essential before moving off. Whilst manoeuvring observation of the rear end, fork and load swing and when operating the hydraulic controls e.g. raising/lowering tilting reaching etc. A perfunctory glance, i.e. merely ‘going through the motions’ is not sufficient and should result in a penalty.

4 Fails to look in the direction of travel

Fails to look in the direction of travel whilst the truck is moving. Travelling with forks/load leading, this is self explanatory. When travelling with fork/load trailing, operators should be looking in the direction of travel with the occasional glance at the forks/load for possible fouling and to ensure load security.

5 Fails to use appropriate safety device

The lift truck horn should be used whenever there is a requirement to warn others of the lift truck presence if the operator suspects that they may not have seen or if the lift truck has to pass through a blind corner or entrance.

Safety devices such as presence lights, flashing beacons should all be activated. Safety rails and bars are to be correctly deployed and locked into the correct position.

6 Travels in wrong direction

Unintentionally selects wrong direction control and moves under power before correcting.



FAULTNo.


7 Brakes harshly/erratically

Emergency type braking where it is not necessary.

8 Fails to release parking brake

Attempts to move the truck without releasing the parking brake in either direction. This will not apply on lift truck types that have ‘auto release’ type parking brakes.

9 Operates hydraulic controls when moving

Whenever the hydraulic controls are operated the lift truck is to be placed in a secure state i.e. parking brake applied and in neutral or tiller arm raised. Where the configuration of the lift truck does not facilitate neutral no penalties are to be awarded. Penalties are to be awarded for any adjustment of the hydraulic controls whilst the truck is in motion.

10 Selects wrong hydraulic control

Selects and operates wrong hydraulic function [operates wrong lever or operates lever/switch in wrong direction]. Fault to be recorded whenever the hydraulic pump motor is energised or mechanical movement of the mast/fork occurs.

11 Excessive use of the hydraulic controls

Operators should not be penalised for failing to judge correct height of fork tips at first attempt during depositing operations. One adjustment is allowed per operation, but where more than one adjustment is made i.e. either by lowering or raising the forks etc. Faults should be recorded for each additional adjustment at each operation. Only record adjustments when movement actually occurs.

12 Rough use of hydraulic controls

Uses hydraulic controls roughly or unsympathetically. Harsh application, pumping with the levers and continuing to hold the lever in the engaged position (motor engaged) when the operation is complete.

13 Fails to hold the steering control/ tiller when moving

The steering control, assister or tiller (if fitted) must be held firmly by at least one of the operators hands whenever the truck is moving. Penalties should not be awarded if the candidate releases the steering wheel/assister when the lift truck is in a secure state i.e. park brake applied and in neutral.

14 Forks/load too high when travelling

Travels or turns with the forks/load above correct travel height. This refers to travelling [not inching forwards or reverse for alignment at face of stack] with heels of forks/ load more than 100mm above the height recommended for the truck in use (e.g. a recommended 100/150mm plus 100mm = 200/250mm).


FAULTNo.


15 Forks/load too low when travelling

Travels or turns with forks/load below the height recommended for the truck in use, where there is a risk of the forks/load coming into contact with the ground.

16 Touches course, racking or load

Minor contact with or touches any part of the test course, due to a steering/judgement error. To be interpreted as making contact with any part of the truck/load however slight between:

a) sides of chicane or the working aisle b) racking uprights or beams (above and below) c) adjacent stacks or supporting stacks.

(see disqualification for violent collision)

17 Shunts in chicane Shunts to negotiate chicane. A ‘shunt’ occurs when the operator’s progress through the chicane is interrupted by the truck being manoeuvred in both directions in order to assist in alignment. A fault should be recorded for each shunt, regardless of distance travelled in opposite direction to that of the overall manoeuvre.

18 Incorrect personal positioning

The delegate walks in front of the tiller or crosses from one side of the machine to the other without firstly bringing it to a stop (this is in the forks trailing position).

19 Fails to use fold down platform

The delegate fails to use the fold-down platform to drive from start to position A or from position A to the start position.

20 Fails to dismount from fold down platform

The delegate fails to dismount from the fold-down prior to picking up the load at position A or when completing the test and arriving at the finish point.

21 Incorrect set down at vertical face

Fails to deposit load correctly at vertical face. The load must be deposited square on to the vertical face and within 150mm, but not touching. (See plan of course).

22 Shunts when stacking/ destacking

At each stacking/destacking operation, operators should not be penalised for failing to line up correctly on the first attempt. One ‘shunt’ is to be allowed per operation, however where more than one adjustment is made i.e. where the truck moves away from the stack and then moves toward the stack, faults should be recorded for each additional shunt at each stacking/destacking operation.



FAULTNo.


23 Fails to secure truck Fails to apply parking brake and place direction controls in neutral when operating the hydraulic controls. Holding the truck on the footbrake or inching pedal is not acceptable. Where the lift truck has automatic parking brakes or the configuration of the lift truck does not facilitate neutral, no penalties are to be awarded. The lift truck manufacturer's handbook should be consulted for specific instructions on operating procedure.

24 Fork arms not central under load

Fork arms more than 40mm off centre when lifted. This fault can only be recorded when the operator engages the load by lifting it off the floor, stack or racking beam/shelf.

25 Fork arms rubbing (entry/withdrawal)

Wooden pallets: this refers to the forks rubbing against the top or bottom deck, fouling the dividing timbers or blocks. Corner post pallets/stillages/plastic boxes: applies to the forks rubbing against the underside of the pallet or the top of the lower pallet and/or its load, fouling the corner posts and cupped feet.

26 Fork arms not fully inserted

Load not housed as close as possible against the heel of both fork arms (see disqualification operating dangerously).

27 Fork tips touch stack/load

Tips of the fork arms or load make contact with pallet, rack, stack or vertical face This refers to the operator's weakness in judging distances between the tips of the forks and a) the leading edge of a load b) pallets, racking, stacks or the vertical face.


28 Load incorrectly stacked/ deposited

This applies when a load has been actually deposited and the operation completed. When placed into a racking systems all loads must be uniformly distributed on the load bearing beams. Faults should be recorded when the load is:

a) stacked out of alignment with the racking b) placed out of alignment with the adjacent stacks

29 Wheels/tiller not straight

On completion of the turn in the aisle prior to any hydraulic functions being performed any steering lock must be removed and the steering axle wheels aligned for straight ahead before attempting pallet engagement and pallet depositing.


FAULTNo.


30 Fails to secure truck When preparing the lift truck for parking, the park brake and neutral must be applied. Where the lift truck has automatic parking brakes or the configuration of the lift truck does not facilitate neutral, no penalties are to be awarded. The lift truck manufacturer’s hand book should be consulted for specific instructions on operating procedure.

31 Fails to lower forks/fork arms

As far as reasonably practicable, after being tilted forward the forks should be lowered until full ground contact has been made with the chamfered underside of the forks. The heels of the forks should be as low as reasonably practicable. No penalty will be awarded in situations where the heels do not touch the ground but the fork chamfer is in full ground contact.

32 Fails to switch off/remove key

This must be completed before the operator dismounts. Penalty to be awarded in full if the operator switches off but fails to remove the key. Where key card or other electronic control systems are in use the lift truck must be shut down in accordance with the manufacturer’s instructions prior to the operator dismounting.

33 Wheels/tiller arm not straight

Fails to leave wheels in a straight ahead position.



ABA Category A3, A4, A5, A6 and A7

FAULTNo.


1 Mounts/dismounts incorrectly

Inserts key or turns the power on before mounting, fails to use secure and appropriate hand or foot holds correctly, holds steering wheel or a control lever, fails to look all round before dismounting and alights in the incorrect manner e.g. jumps off. Mounting and dismounting should be conducted facing the lift truck. A penalty should be awarded each time any of these faults occur.

2 Limbs outside the confines of the truck

Drives with a limb outside confines of the truck. When aligning the truck or its load in a confined area etc, fingers, hands, arms legs and feet must always remain inside the confines of the machine. Where an operator has to lean outside the confines of the lift truck for the purpose of observation or alignment, the truck must be secured and an all round visual check carried out before.

3 Fails to check all round Fails to check all round before moving off and whilst operating. A thorough check all round is essential before moving off. Whilst manoeuvring observation of the rear end, fork and load swing and when operating the hydraulic controls e.g. raising/lowering tilting reaching etc. A perfunctory glance, i.e. merely ‘going through the motions’ is not sufficient and should result in a penalty.

4 Fails to look in the direction of travel

Fails to look in the direction of travel whilst the truck is moving. Travelling with forks/load leading, this is self explanatory. When travelling with fork/load trailing, operators should be looking in the direction of travel with the occasional glance at the forks/load for possible fouling and to ensure load security.

5 Fails to use appropriate safety device

The lift truck horn should be used whenever there is the requirement to warn others of the lift truck presence if the operator suspects that they may not have seen or if the lift truck has to pass through a blind corner or entrance. If fitted seat belts should be worn, safety devices such as presence lights, flashing beacons should all be activated. Safety rails and bars are to be correctly deployed and locked into the correct position.

6 Travels in wrong direction

Unintentionally selects wrong direction control and moves under power before correcting.


FAULTNo.


7 Brakes harshly/erratically

Emergency type braking where it is not necessary.

8 Fails to release parking brake

Attempts to move the truck without releasing the parking brake in either direction. This will not apply on lift truck types that have ‘auto release’ type parking brakes.

9 Rides footbrake Rides footbrake unnecessarily. No faults should be recorded whenever the truck requires to be controlled in this manner during tight manoeuvres. No more than one fault should be recorded under this heading at each stage of the test, irrespective of whether the fault occurs frequently during the stage.

10 Operates hydraulic controls when moving

Whenever the hydraulic controls are operated the lift truck is to be placed in a secure state i.e. parking brake applied and in neutral or tiller arm raised. Where the configuration of the lift truck does not facilitate neutral no penalties are to be awarded. Penalties are to be awarded for any adjustment of the hydraulic controls whilst the truck is in motion.

11 Selects wrong hydraulic control

Selects and operates wrong hydraulic function [operates wrong lever or operates lever/switch in wrong direction]. Fault to be recorded whenever the hydraulic pump motor is energised or mechanical movement of the mast/fork occurs.

12 Excessive use of the hydraulic controls

Operators should not be penalised for failing to judge correct height of fork tips at first attempt during depositing operations. One adjustment is allowed per operation, but where more than one adjustment is made, faults should be recorded for each additional adjustment at each operation. Only record adjustments when movement actually occurs. Penalties are to be awarded where a candidate uses one hydraulic control simultaneously.

13 Rough use of hydraulic controls

Uses hydraulic controls roughly or unsympathetically. Harsh application, pumping with the levers and continuing to hold the lever in the engaged position (motor engaged) when the operation is complete.

14 Fails to hold the steering control/ tiller when moving

The steering control, assister or tiller (if fitted) must be held firmly by at least one of the operators hands whenever the truck is moving. Penalties should not be awarded if the candidate releases the steering wheel/assister when the lift truck is in a secure state i.e. park brake applied and in neutral.



FAULTNo.


15 Fork arms/load too high when travelling

Travels or turns with the forks/load above correct travel height. This refers to travelling [not inching forwards or reverse for alignment at face of stack] with heels of forks/ load more than 100mm above the height recommended for the truck in use (e.g. a recommended 100/150mm plus 100mm = 200/250mm).

16 Forks/load too low when travelling

Travels or turns with forks/load below the height recommended for the truck in use, where there is a risk of the forks/load coming into contact with the ground.

17 Incorrect tilt when travelling

Fork arms/load not tilted correctly for travel. Whilst travelling with an unladen lift truck the fork arms should be adequately tilted back from the horizontal as recommended for the lift truck in use. On trucks which have above average available back tilt it is not always necessary to apply full tilt. Whilst travelling with a laden truck the amount of back tilt must be adequate and appropriate as recommended for the type of load being transported and the environment in which the truck is operating.

18 Touches course, racking or load

Minor contact with or touches any part of the test course, due to a steering/judgement error. To be interpreted as making contact with any part of the truck/load however slight between:

a) sides of chicane or the working aisle b) racking uprights or beams (above and below) c) adjacent stacks or supporting stacks.


19 Shunts in chicane Shunts to negotiate chicane. A ‘shunt’ occurs when the operator’s progress through the chicane is interrupted by the truck being manoeuvred in both directions in order to assist in alignment. A fault should be recorded for each shunt, regardless of distance travelled in opposite direction to that of the overall manoeuvre.

20 Incorrect personal positioning

The delegate walks in front of the tiller or crosses from one side of the machine to the other without firstly bringing it to a stop (this is in the forks trailing position).

21 Fails to use fold-down platform

The delegate fails to use the fold-down platform to drive from start to position A or from position A to the start position.

22 Fails to dismount from fold-down platform

The delegate fails to dismount from the fold-down prior to picking up the load at position A or when completing the test and arriving at the finish point.


FAULTNo.


23 Incorrect set down at vertical face

Fails to deposit load correctly at vertical face. The load must be deposited square on to the vertical face and within 150mm, but not touching. (See plan of course).

24 Shunts when stacking/ destacking

At each stacking/destacking operation, operators should not be penalised for failing to line up correctly on the first attempt. One ‘shunt’ is to be allowed per operation, however where more than one adjustment is made i.e. where the truck moves away from the stack and then moves toward the stack, faults should be recorded for each additional shunt at each stacking/destacking operation.

25 Fails to secure truck Fails to apply parking brake and place direction controls in neutral when operating the hydraulic controls. Holding the truck on the footbrake or inching pedal is not acceptable. Where the lift truck has automatic parking brakes or the configuration of the lift truck does not facilitate neutral, no penalties are to be awarded. The lift truck manufacturers hand book should be consulted for specific instructions on operating procedure

26 Fork arms not central under load

Fork arms more than 40mm off centre when lifted. This fault can only be recorded when the operator engages the load by lifting it off the floor, stack or racking beam/shelf.

27 Fork arms rubbing (entry/withdrawal)

Wooden pallets: this refers to the forks rubbing against the top or bottom deck, fouling the dividing timbers or blocks. Corner post pallets/stillages/plastic boxes: applies to the forks rubbing against the underside of the pallet or the top of the lower pallet and/or its load, fouling the corner posts and cupped feet.

28 Fork arms not fully inserted

Load not housed as close as possible against the heel of both fork arms (see disqualification operating dangerously).

29 Mast base touches stack/load (this includes load arms and straddle legs)

If the mast base or reach mechanism including the reach legs comes into contact with any loads or racking systems whilst conducting stacking or de-stacking operations then a penalty should be awarded.




FAULTNo.


30 Fork tips touch stack/load

Tips of the fork arms or load make contact with pallet, rack, stack or vertical face This refers to the operator's weakness in judging distances between the tips of the forks and a) the leading edge of a load b) pallets, racking, stacks or the vertical face.


31 Load/fork arms not level Fork arms not level during insertion or withdrawal. When laden the load must be level prior to depositing onto the floor/load bearing beams or structure. Faults are to be recorded at the point of actual deposit or lift.

32 Load incorrectly stacked/deposited

This applies when a load has been actually deposited and the operation completed. When placed into a racking systems all loads must be uniformly distributed on the load bearing beams. Faults should be recorded when the load is:

a) stacked out of alignment with base load b) stacked out of alignment with the racking c) placed out of alignment with the adjacent stacks

33 Wheels/tiller not straight

On completion of the turn in the aisle prior to any hydraulic functions being performed any steering lock must be removed and the steering axle wheels aligned for straight ahead before attempting pallet engagement and pallet depositing.

34 Fails to secure truck When preparing the lift truck for parking, the park brake and neutral must be applied. Where the lift truck has automatic parking brakes or the configuration of the lift truck does not facilitate neutral, no penalties are to be awarded. The lift truck manufacturer’s hand book should be consulted for specific instructions on operating procedure.

35 Fails to apply forward tilt (where applicable)

The forks are to be tilted forward so that the chamfered underside of the forks is substantially parallel to the ground. If the lift truck configuration does not allow for sufficient forward tilt movement, full forward tilt available should be applied. Tilt must be applied prior to lowering the forks.

36 Fails to lower forks/fork arms

As far as reasonably practicable, after being tilted forward the forks should be lowered until full ground contact has been made with the chamfered underside of the forks. The heels of the forks should be as low as reasonably practicable. No penalty will be awarded in situations where the heels do not touch the ground but the fork chamfer is in full ground contact.


FAULTNo.


37 Fails to switch off/remove key

This must be completed before the operator dismounts. Penalty to be awarded in full if the operator switches off but fails to remove the key. Where key card or other electronic control systems are in use the lift truck must be shut down in accordance with the manufacturer’s instructions prior to the operator dismounting.

38 Wheels/tiller arm not straight

Fails to leave wheels in a straight ahead position.

39 Lowers load onto reach legs

This refers to when the operator unintentionally lowers the load/pallet onto the reach legs, before reaching out or when returning to the travel position with a laden truck after completing a destacking operation. When this occurs as a result of selecting the wrong hydraulic control (see item 11). Record under one fault heading only.

40 Travels with reach extended

The mast must be fully retracted during unladen or laden travel. This fault does not refer to inching with the reach extended when:

a) carrying out minor adjustments for fork/load alignmentb) ensuring fork arms are fully inserted.



Associated Knowledge ExaminationTime allowed: 30 minutes

IntroductionThe associated knowledge theory test consists of 5 open questions and 20 multiple choice questions designed to determine a candidate’s knowledge of their role as an electric pallet/stacker truck operator.

AdministrationQuestion papers for Electric Pallet/Stacker Truck categories A1, A2, A3, A4, A5, A6 and A7 have been supplied for use with this course – you will find them on the USB card supplied with this guide.

Each question paper consists of 5 open questions and 20 multiple choice questions – the first 5 multiple choice questions will be mandatory questions (printed in bold text), and must be answered correctly by candidates to pass the test. If a candidate provides an incorrect answer to a mandatory question, they will refer the test (even if they achieve the required 80% to pass). Candidates who refer this test will be required to retake it after any necessary remedial tuition has been provided.

MarkingCandidates must achieve 80/100 to pass the test and must answer all mandatory questions correctly.

Multiple choice questions are worth 4 points. Open questions are worth a maximum of 4 points also, but are scored in proportion to the accuracy of the answer given – for example, if the question requires 4 responses and 3 suitable answers are given, then 3 points will be awarded; if a question requires 2 examples and 1 is given, 2 points should be awarded.

Candidates who do not achieve the required pass mark, must undergo appropriate remedial tuition prior to undertaking a different set of associated knowledge questions.

Candidates should mark their answers with a tick in the appropriate box for each question, and open question responses should be written in the space provided. If candidates wish to revise a given answer then they should place a single line through the incorrect response and place a new tick or write a new response. Candidates must work on their own and are not permitted to communicate with each other. Reference materials are not allowed and all phones and digital devices must be switched off.


Feedback on performance must be given to all candidates. Feedback should be given regarding questions that were answered incorrectly, even if a pass mark was achieved in the test.

Candidates who do not achieve the required pass mark, must undergo appropriate remedial tuition prior to undertaking a new question paper containing 25 questions.

Examiners should accept suitable and appropriate answers for an Open question that is not in the list of model answers provided.

All candidates answer sheets must be retained for audit purposes.

Examiners should accept suitable and appropriate answers should a candidate provide an answer for an open question that is not in the list of model answers provided.

Electric Pallet/Stacker Truck

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