TLILIC0003 LICENCE TO OPERATE A FORKLIFT TRUCK · 2019-07-15 · 10.6 Electric forklifts ......

TLILIC0003 LICENCE TO

OPERATE A FORKLIFT TRUCK

Learning Materials

Version 3

1

TLILIC0003 Licence to operate a forklift truck Version 3

Disclaimer

Any provider using this material should independently ensure that instructional material is

customised and covers all applicable State, Territory and Federal regulatory licencing

requirements. The information within the material does not comprise professional advice and

must be customised and delivered by a suitably qualified professional Provider. The material

(as a single source) should not be relied upon in any important matter without obtaining

appropriate advice from subject matter experts relevant to your circumstances.

Publication Published by the Civil Contractors Federation SA

ABN: 65 484 720 549

CCF SA Branch

1 South Road

Thebarton SA, 5031

Phone: 08 8111 8000

Fax: 08 8111 8002

First published November 2012

Copyright © 2014 Civil Contractors Federation SA

All rights reserved. No part of this publication may be reproduced or transmitted in any form

or by any means, electronic or mechanical, including photocopying, scanning, recording, or

any information storage and retrieval system, without permission in writing from the Civil

Contractors Federation SA. No liability is assumed with respect to the use of information

contained herein. While all due care has been taken in preparing this book, the publisher, the

distributor and authors assume no responsibility for errors or omissions. Neither is any liability

assumed for damages resulting from the use of the information contained herein.

Feedback If you have any suggestions for improving this workbook, please send to:

[email protected]

Version Control:

mailto:[email protected]

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Date Changes Version By

19/11/12 Change of format

Updated information:

• To include learning checks

• To be appropriate for the new calculations assessment

• Inclusion of the hierarchy of control and duty of care

• Updated diagrams for Load centre distance and stability

triangle

• Inserted example of data plate to explain rated capacity

V2 P. Wanders and

V. Griffith

22/03/12 Update information

• Assessment re-sit timeline changed

• Added legislation (pg. 11)

• Inserted section 1: Legislation

• Changes some wording to sections:

7, 8, 9, 12, 13 (plus addition of tiger tails), 15, 16.

• Inserted calculation methodology (section 17)

V2.1 P. Wanders

03/05/13 Minor change – page numbers and contents corrected V2.2 V. Griffith

08/01/14 Review content and wording:

• Minor changes for WHS terminology throughout

• Re-formatted and page number update

• Pg. 11 – minor wording change

• Section 3 - changed wording and examples of hierarchy of

control

• Section 6 – change of wording



• Sections 9 and 10 – minor word change

• 12.2 removed (when tilting the load)

• 12.2 (v2.3) – change of wording

• Addition of 12.3 (placement of load)



• Addition of ‘Communication’ (now section 15).

• Section 17 (v2.3) – change of wording

V2.3 S.Young and

Paul Wanders

18/11/14 • Added to lists in section 6.1

• Additions to learning checklists 1 and 2

• Addition of 24 question pre-assessment check

• Removed 9.1 (slings, chians and shackles)

V2.4 S.Young

M.Williams

1/7/16 • Changed TLILIC2001A to TLILIC2001, updated to align with

the Standards for Training Packages

• Changed feedback contact from:

[email protected] to: [email protected]

• Changed spacing Section 1.1 between

“legislation.Regulations” to legislation. Regulations.

• Changed spacing Section 1.2 between “workare” to work

are.

• Changed Section 3, Personal Protective Equipment (PPE)

spacing between “haveproven” and “relieson” to have

proven and relies on.

• Changed Section 12.2, Travelling, paragraph 17. Changed

start of paragraph “if’ to If and changed “.grab” to . Grab.

• Added three additional calculations for learner

• Formatted and updated Self Check Questions, 25 questions.

V2.5 M.Blackborough

29/3/17 • Updated unit of competency information on pages 9 -12 V2.6 V.Griffith

18/12/17 • Reword section 1 on HRWL and inserted Learning Check 1

• Extracted power lines information (will provide separate

handouts for SA and NT from respective regulators)

• Add NT WHS legislation to 2.1

• Changed 60kg to 35kg in 13.1

V2.7 V.Griffith

08/01/19 • Re-install safe working distances from electricity V2.8 V.Griffith

4/07/19 • Updated resource to meet TLILIC0003 requirements V3 M. Blackborough



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Contents

INTRODUCTION ......................................................................................... 5

UNIT OF COMPETENCY ............................................................................. 8

1. APPLYING FOR A HIGH RISK WORK LICENCE (HRWL) ...................... 13

Learning Check 1 .................................................................................. 15

2. INTRODUCTION.................................................................................. 16

2.1 Legislation, Regulations and Codes of Practice ......................... 16

2.2 Organisational and workplace standards ................................... 16

3. THE FORKLIFT TRUCK .......................................................................... 17

3.1 Counterbalanced forklift trucks .................................................. 17

3.2 Non- counterbalanced forklift trucks (reach trucks) ................ 18

4. HIERARCHY OF CONTROL ................................................................... 19

4.1 Identify the hazard .......................................................................... 19

4.2 Assess the risk ................................................................................... 19

4.3 Control the risk ................................................................................. 19

4.4 Review and update ........................................................................ 21

5. DUTY OF CARE ..................................................................................... 21

6. ORGANISATIONAL AND WORKPLACE STANDARDS, POLICIES AND

PROCEDURES ........................................................................................... 22

6.1 Work place rules and procedures ................................................. 22

6.2 Working in bad weather ................................................................. 23

6.3 Lightning (electrical storms) ........................................................... 23

6.4 Extreme heat exposure .................................................................. 23

6.6 Unstable ground conditions ........................................................... 25

6.7 Planning for forklift operations ....................................................... 26

7. STABILITY TRIANGLE AND CENTRE OF GRAVITY ................................. 26

Learning Check 2 ................................................................................... 29

8. RATED CAPACITY ................................................................................ 30

9. ATTACHMENTS AND EFFECTS ............................................................. 31

9.1 Common forklift attachments: ...................................................... 31

9.2 Work Box/Personnel work platforms .............................................. 32

9.3 Lifting and suspended loads .......................................................... 34

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10. THE MOTOR ........................................................................................ 35

10.1 Internal combustion engine (I.C.E.) ............................................ 35

10.2 Gas cylinders.................................................................................. 36

10.3 Procedure for changing propane (LPG) cylinders ................... 38

10.4 Gas compliance plate ................................................................. 38

10.5 Internal combustion diesel engines ............................................ 39

10.6 Electric forklifts ............................................................................... 39

10.7 Battery changing procedures for electric forklifts. .................... 40

11. FORKLIFTS AND FLAMMABLE LIQUID................................................. 41

Learning Check 3 ................................................................................... 41

12. PRE-OPERATIONAL CHECKS ........................................................... 42

13.1 When raising the load ................................................................... 43

13.2 Travelling ......................................................................................... 44

13.3 Placement of Loads ...................................................................... 45

13.4 Loading trucks ............................................................................... 45

13.5 Loading Pantech’s (large enclosed vans) ................................. 45

13.6 Loading loads with two forklifts.................................................... 45

13.7 Parking ............................................................................................ 46

Learning Check 4 ................................................................................... 47

14. FORKLIFTS AND ELECTRICITY ............................................................ 48

15. FIRST AID ............................................................................................ 50

16. COMMUNICATIONS .......................................................................... 51

17. TRAFFIC WARNING SYSTEMS ............................................................. 51

18. TRAFFIC MANAGEMENT PLANS ........................................................ 52

19. GENERAL SAFETY RULES .................................................................... 53

20. LOAD CENTRE DISTANCE .................................................................. 54

21. CALCULATIONS ................................................................................. 55

Learning Check 5 ................................................................................... 55

22. PRE-ASSESSMENT CHECK .................................................................. 58

23. ASSESSMENT ...................................................................................... 64

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INTRODUCTION

What is the Civil Construction Industry?

Australia’s national prosperity is dependent on functional, efficient and cost effective

civil infrastructure. Healthy, well-functioning and productive countries depend on

infrastructure that civil contractors construct and maintain, whether this is in moving

freight on our roads, shipping our products and resources through our ports or building

communities where people live and work.

Transport and utilities infrastructure, construction and maintenance includes, roads,

bridges, marine structures, dams, cable and pipelines, tunnels and site works for

commercial, industrial and housing development.

Civil contractors play a prime role in working with both public sector and private

clients in infrastructure delivery.

This is the business of civil construction.

What is the Civil Contractors Federation?

The Civil Contractors Federation or CCF is Australia’s largest representative body of

the civil construction industry which is responsible for the delivery of Australia’s

infrastructure needs such as roads, streets, subdivisions, bridges, airports, water,

sewerage, drainage and telecommunications.

The Civil Contractors Federation is a nation-wide federation of civil construction

interests. It has fully representative Branches established in all States and Territories of

Australia and a membership base of over 2,000 contracting and industry linked

companies.

Under its banner of Constructing Australia’s Infrastructure, the Civil Contractors

Federation is charged with ensuring the industry is well placed to respond to a fast

changing and challenging external environment. This responsibility extends from

assisting the industry in the planning, delivery and management of the nation’s

infrastructure assets through to the development and retention of a skilled workforce.

Civil Train is the training arm of the Civil Contractors Federation.

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Personal Requirements

To be successful in this occupation you should:

• Enjoy practical and manual work

• Be physically fit

• Enjoy working outdoors

• Have good communications skills

• Be able to work in a team environment

• Be alert and observant

• Be willing to keep up with modern developments in civil construction.

How will I be assessed?

You will be assessed on evidence that you can perform the work to industry standards

collected from a range of activities including:

• Completion of all workbook activities

• Theory (knowledge) assessment (closed book)

• Calculations assessment

• Performance assessment

Resources

You will be provided with the following resources:

• Learning Materials workbook

• Knowledge and performance assessments

• Log book or work diary (as required)

Your trainer or employer will provide access to the following documents as required:

• State or Territory Workplace Health and Safety Act

• State or Territory Workplace Health and Safety Regulations

• Relevant standards

• Relevant operations quality documentation.

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Legislative Requirements

Like all aspects of modern work, you will be subject to and have to know legislative

requirements such as safety, workplace relations and environmental protection.

These will be explained when you learn the various tasks which make up this unit.

Personal Protective Equipment (PPE)

Your State or Territory workplace safety legislation designates that you must use PPE

as supplied and trained. Correct PPE may include:

• Safety boots

• Safety helmet

• Safety vest (reflective at night) or high visibility clothing

• Safety glasses

• Safety gloves

• Ear muffs or plugs

• Close fitting clothing

• Wet weather gear

• Respirator and filter mask

• Hat

• Sunscreen (SPF 30+)

Assistance with Learning

If at any time while studying this unit you experience learning difficulties or require

assistance and advice, you can get support by contacting your Trainer.

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UNIT OF COMPETENCY

1. Plan

work/task 1.1 Task requirements are identified from work orders or equivalent and confirmed with relevant

people and site inspection is conducted in accordance with workplace procedures

1.2 Work area operating surface is assessed to determine suitability for operational use of forklift

truck in accordance with workplace procedure

1.3 Suitability of forklift truck and attachment working load limit (WLL) is determined for the load/s

and work/task requirements in accordance with manufacturer requirements and workplace

procedures

1.4 Working area is inspected and appropriate paths for operating the forklift truck and moving and

placing load/s in work area are assessed and managed in accordance with workplace procedures

1.5 Hazard and risk control measures are identified and reported to relevant person/s in accordance

with workplace procedures

1.6 Traffic management plan implementation is confirmed in accordance with workplace procedures

1.7 Appropriate communication procedures are identified with relevant people in accordance with

workplace procedures

1.8 All work is confirmed to ensure coverage of work/task requirements for the relevant work area is

in accordance with workplace procedures

2. Prepare

for

work/task

2.1 Consultation with workplace person/s is maintained to ensure workplan is clear and consistent

with site requirements in accordance with safe work procedures

2.2 Weather and work environmental conditions are assessed to determine any impact on forklift

truck operations in accordance with manufacturer requirements and safe work procedures

2.3 Risk control measures for hazards identified are checked for implementation in accordance with

safe work procedures

2.4 Forklift truck is accessed in a safe manner in accordance with manufacturer requirements and

workplace procedures

2.5 Forklift truck logbook is checked in accordance with manufacturer, regulatory requirements and

safe work procedures

2.6 Pre-start checks are carried out and any damage and defects are reported, recorded and

appropriate action is taken in accordance with safe work procedures and manufacturer

requirements

2.7 Forklift truck is set up correctly with any relevant attachments as per work plan in accordance

with relevant manufacturer requirements including data plate and safe work procedures

2.8 Operational checks are carried out and any damage and defects are reported, recorded and

appropriate action is taken in accordance with manufacturer requirements and safe work

procedures

2.9 Hazard and risk control measures are checked for implementation and communicated to people in

the work area in accordance with safe work procedures

3. Perform

work/task

3.1 Weight and positioning of load is assessed to ensure compliance with forklift truck data plate

requirements and in accordance with safe work procedures

3.2 Forklift truck is operated safely in accordance with manufacturer requirements and safe work

procedures

3.3 Loads are monitored constantly when lifting, moving, lowering and placing to ensure stability of

load and avoidance of hazards in accordance with safe work procedures

3.4 Unplanned and unsafe situations are responded to in accordance with safe work procedures

3.5 Loads are picked up, transported and placed using all forklift truck movements in accordance

with safe work procedures

3.6 Forklift truck is parked, switched off and isolated appropriately in accordance with manufacturer

requirements and safe work procedures

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4. Pack Up 4.1 Forklift truck shutdown procedures are carried out in accordance with manufacturer requirements

and safe work procedures

4.2 Forklift truck is secured to prevent unauthorised access/use in accordance with safe work

procedures

Performance Evidence:

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all the requirements of the

elements and performance criteria on at least one occasion and include:

• applying safe operating procedures for a forklift truck including:

o maintaining safe operating speed

o travelling with load lowered to an appropriate height for the terrain, operating surface and

visibility in relation to

direction of travel

• applying relevant forklift truck manufacturer requirements and data plate information and approved

modifications

to attachments fitted are in accordance with manufacturer requirements

• carrying out pre-start checks, including visual inspection which must include:

o battery charge as required by manufacturer requirements

o checking and interpreting data plate/s are relevant to the attachment and the forklift truck

o checking for signs of paint separation and stressed welds indicating potential structural weakness

o document evidence of damage

o engine / mechanical fluid level checks including fuel as required by manufacturer requirements

o ensuring availability of correct forklift truck logbook and updating records as required

o ensuring forklift truck tynes or other attachment/s are securely fitted

o ensuring seat and mirrors are adjusted appropriately and seat belt is functional

o fluid leaks

o lights are working effectively

o safety equipment checks

o signage and labels to ensure they are visible and legible

o wheels and tyres for damage/correct inflation if applicable

• conducting and applying risk and hazard assessment strategies including:

o insufficient lighting

o other specific hazards including dangerous goods

o overhead hazards and fixed structures, roof beams and doorways

o restricted and poorly ventilated areas

o surface suitability based on forklift truck and task requirements

o the risk of collision with people, moving plant and fixed structures

o weather conditions

• complying with Commonwealth, State and Territory Work Health and Safety (WHS)/Occupational Health

and Safety (OHS)/Occupational Safety and Health (OSH) legislation, regulations safe work and workplace

procedures

• conducting operational checks, which must ensure:

o all controls are located, identified and tested for functionality

o all hydraulic functions operated to maximum extension and ensuring attachment (if fitted)

movements and control functions are smooth and comply with operating requirements

o hazard warning systems (e.g. reversing beepers, lights and horns) are functional

o recording and maintaining accurate information relating to forklift truck operations

o safety devices as fitted

o start-up is in accordance with manufacturer requirements

o steering, transmission and brake functions comply with operating requirements

o there are no unusual noises

• confirming and following traffic management plan procedures relevant to their role in the work area

• conducting relevant procedures for refuelling and isolating fuel/power source as per manufacturer

requirements using appropriate PPE

• determining relevant lifting attachment to perform work/task

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• determining lift requirements including:

o positioning of unusually balanced/shaped loads

o centre of gravity

o dynamic nature of load

o tyne/attachment positioning

o weight

• ensuring risk control measures within the work area are effective as per workplace procedures

• identifying, isolating and tagging out defective equipment and reporting to authorised person/s

• interpreting and confirming relevant documentation, workplace instructions, safety information,

emergency procedures for the work task and relevant area

• interpreting workplace procedures in relation to various environmental conditions

• maintaining communication with other workplace personnel through using worksite procedures including:

o audible and visual warning devices

o signage

o two-way radio

o verbal instructions

o written instructions

• maintaining three points of contact whilst accessing and egressing forklift truck and ensuring rungs / steps

are free of hazards

• operating and monitoring safe forklift truck operations using minimum 250kg dynamic and non-dynamic

loads that include:

o aligning tynes/attachment to load

o carrying out a lift to 75% of the maximum height

o conducting trial lift to ensure forklift truck and load are stable, and load is safe to move

o correctly using horns and mirrors in workplace

o correctly positioning and using an observer to assist when operating with a load that may restrict

vision or be placed out of vision of the operator

o driving applicable to conditions and moving loads safely

o driving a forklift truck safely with load in forward and reverse, while maintaining visibility

through an obstacle course including:

▪ an 'S' bend with a minimum 90 degrees left and right turn

▪ ensuring load/s remains stable through pick up, transport and placement

▪ forklift truck speed is appropriate to load and surroundings

▪ lowering dynamic and non-dynamic loads to appropriate height for travel in forward and

reverse

o picking up, driving, manoeuvring and placing dynamic and non-dynamic loads safely at various

heights within a compliant racking system

o picking up, driving, manoeuvring and placing dynamic and non-dynamic loads safely into/onto

an elevated, flat, stable area

o tilting mast (or forks if applicable) to ensure balance of load

o using gluts/dunnage appropriately and lowering load safely

o using tilt and side shift (where fitted) safely to manoeuvre dynamic and non-dynamic loads into

allocated space

• reporting to relevant person/s on site risk control measures that are not in place or are deficient

• setting up an exclusion zone

• securely parking forklift truck and isolating in appropriate position including:

o minimising possible access by unauthorised person/s

o tynes/attachment lowered to required position in accordance with manufacturer requirements

o park brake applied

o switching off, isolating fuel/power source and removing key according to workplace procedures

• shutting down a forklift truck in accordance with manufacturer requirements and workplace procedures

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Knowledge Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of

the elements and performance criteria and include knowledge of:

• Australian and industry standards, codes of practice and guidelines to safely operate a forklift truck

• communication procedures including:

o audible and visual warning devices

o hand signals

o questioning techniques

o signage

o traffic warning systems

o two-way radio

o written instructions

• forklift truck characteristics and capabilities, manufacturer requirements and instructions for any

attachments

• impact of the following on the operation of the forklift truck including:

o failure/loss of control including brakes and steering

o failure of equipment during forklift truck operations

o forklift truck instability causes including:

▪ deterioration of ground condition

▪ overloading

▪ pick up and placement of load

▪ irregular loads

o operating on ramps and uneven surfaces and in restricted spaces

o use of forklift truck data plate and attachment data plate and appropriate methodology to

determine weight of a load is appropriate for forklift truck and any attachment if fitted including

the estimation or determination from:

▪ labels on the actual load

▪ markings on the actual load

▪ paperwork such as consignment notes, running sheets and weighbridge dockets

▪ weighing a carton and calculating load

• manufacturer requirements, instructions and operator's manual

• problems, and appropriate response procedures to unplanned and/or unsafe environmental conditions

including:

o wind

o lightning

o water/ice impacted surface/ground

o rain

o extreme heat

o Ultra violet (UV) exposure

• problems and equipment faults, and implementing appropriate response procedures to unplanned and/or

unsafe situations including:

o lock out and tag out procedures

• relevant procedures for refuelling and recharging forklift truck using appropriate PPE including:

o gas bottle

o connecting battery to charger and disconnecting battery from charger and reconnecting to forklift

truck

o refuelling

• procedures for recording, reporting and maintaining workplace records and information

• risk assessment process including hierarchy of control:

o elimination

o substitution

o isolation

o engineering controls

o administrative controls

o personal protective equipment (PPE)

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• safe use and compliance of different types of attachments including:

o bale clamps

o carpet spike for carpet rolls

o drum carrier

o jib attachment

o paper roll clamps

o personnel work platforms

o rotators

o slippers/fork extensions on tynes

• suitability and lifting capability of the attachment to be used

• shut down procedures for a forklift truck in accordance with manufacturer requirements

• traffic management plan procedures and requirements

• typical routine problems encountered operating a forklift truck and associated equipment, and adjustments

required for correction

• workplace procedures including work plan which may be verbal, documented/written, or electronically

generated

• work area operating surface suitability including issues with:

o backfilled ground

o bitumen (damaged, cracked)

o concrete (damaged, cracked)

o hard compacted soil

o potholes

o railway tracks

o rough uneven or difficult terrain including sloping surfaces, uneven surfaces, steel decks and

grates

o soft soils

o trench covers

• Work Health and Safety (WHS)/Occupational Health and Safety (OHS)/Occupational Safety and Health

(OSH) requirements, safe work and workplace procedures

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1. APPLYING FOR A HIGH RISK WORK LICENCE (HRWL)

A High Risk Work Licence is a small plastic card with photo identification (similar to a driver’s

licence) with a list of all the classes of high risk work that the holder is authorised to perform.

SOUTH AUSTRALIA

In South Australia, High Risk Work (HRW) is regulated by SafeWork SA.

Each applicant must be aged 18 years or older to obtain a HRW licence.

Some of the responsibilities that apply to HRW applicants under the WHS legislation are to:

• Provide name, evidence of identity and photograph with application for HRW licence

• Provide a copy of certificate that they have successfully completed the unit of

competency relevant to the class of HRWL being applied for

• Not give false or misleading information

• Declare that they do not hold an equivalent licence issued by another WHS regulator

• Declare whether they have been found guilty of an offence under the WHS law

anywhere in Australia

• Declare if they have ever had a HRW licence cancelled, suspended or refused.

According to the WHS Regulations, a person is considered under training for a HRW licence

when:

o They are enrolled in a course of HRW training AND

o Being supervised at a workplace by a person with a current HRW licence for the work

An employer cannot allow a person to perform HRW if they know they are not fully competent

to do so (unless the person is enrolled in a course of HRW training and is supervised at the

workplace by a person with a current HRWL for that work).

After training, applicants will need to prove their knowledge by way of theoretical assessments

and prove their operational skills by way of a performance assessment.

After training and assessment, applicants deemed to be ‘Not Yet Competent’ must wait a

mandatory seven (7) days before being reassessed for the same class of licence.

‘Competent’ applicants will be issued with a Statement of Attainment and a temporary Notice

of Satisfactory Assessment (NSA) which is only valid for a period of sixty (60) days for the

purpose of making an application for a HRW licence. This needs to be taken, with the tax

invoice provided by the assessor, to Service SA or an Australia Post Photo Capture Centre for

processing with the stated fee and 100 points of ID. The new High Risk Work Licence will then

be processed and posted to the applicant.

A HRW Licence requires renewal every five years.

If a HRW licence holder becomes no longer competent to do the work they hold the licence

for, they must:

• NOT perform the HRW AND

• Retrain to become fully competent OR

• Return the HRW licence to the regulator.

When undertaking High Risk Work, the HRW licence holder must take reasonable care and not

adversely affect the health and safety of other persons whilst performing the HRW.

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If a HRW licence holder fails to exercise proper diligence when performing HRW they can be

penalised under the WHS Regulations by:

• Having their licence suspended or cancelled or

• If the matter arises at renewal, the regulator refusing to issue the new licence

NORTHERN TERRITORY

In the Northern Territory, HRW is regulated by NT WorkSafe.

Each applicant must be aged 18 years or older to obtain a HRW licence.

You can only conduct High Risk Work if you do not hold a HRW licence when you are:

• Enrolled in a registered training organisation course of HRW training to be able to

apply for the relevant High Risk Work class AND

• Being supervised at a workplace by a person with a licence for the relevant High Risk

Work class

Before you can carry out High Risk Work you must show the employer written evidence that:

- You hold the relevant High Risk Work Licence OR

- That you are undertaking a registered training organization coursed of High Risk Work

training

It is the legal duty of a HRW Licence holder to take reasonable care of their own health and

safety and ensure that their acts or omissions do not adversely affect the health and safety of

others.

If a HRW licence holder fails to work safely when performing HRW in their licence class, NT

WorkSafe can:

• Suspend their licence

• Cancel their licence

• Refuse to renew their licence if the matter arises at licence renewal

• Direct the licence holder to obtain a reassessment to determine competency

A High Risk Work Licence requires renewal every five years.

If a person does not renew their HRW licence within twelve (12) months of the date of expiry

date:

• The HRW licence cannot be renewed

• The person will need to complete a registered training organsiation course of training

to be able to apply for a new HRWL

• If continuing to undertake High Risk Work, the person must enrol in a registered training

origination’s course of training AND be supervised at work by a person with a licence

for that class of HRW.

Once you have successfully completed your training you will be issued with a Statement of

Attainment from the RTO. The assessor will also provide you with a completed HRWL

application which you need to take (with the licence fee and supporting documents) to the

Territory Business Centre. Note, you have to apply for your HRW licence within sixty (60) days

of completing the assessment.

15


Learning Check 1

1. What is the renewal period for a High Risk Work Licence?

2. Within what time frame must you apply for your High Risk Work Licence after being

deemed competent?

3. Under what circumstance can someone conduct High Risk Work without a High Risk

Licence?

4. What is the legal duty/responsibility of someone undertaking High Risk Work?

5. List 2 ways a HRW Licence holder may be penalised for failing to work safely?

a)

b)

6. SA trainees - What are three things you are responsible for when applying for your

HRW licence? (responsibilities of a HRW applicant)

a)

b)

c)

16


2. INTRODUCTION

2.1 Legislation, Regulations and Codes of Practice

Regulations are rules that provide details on how to meet the minimum requirements

set by the legislation. Regulations require that employees carrying out work which is

identified as being hazardous are required to be trained to operate in a competent

manner.

This training program has been designed to examine the hazards associated with

working with forklift trucks and initiate safe work procedures so as to eliminate unsafe

work practices in accordance with:

• The National Occupational Health and Safety Certification Standard for Users

and Operators of Industrial Equipment [NOHSC:1006(1995)],

• The Work Health and Safety Act (WHS) 2012 (SA)

• The Work Health and Safety Regulations 2012 (SA)

• (National Uniform Legislation) Work Health and Safety Act and Regulations

2011(NT)

• The National Standard for Licensing Persons Performing High Risk Work 2006

• The Construction Work Code of Practice may be relevant dependent upon

the working environment

2.2 Organisational and workplace standards

Safe systems of work are the total set of methods adopted for carrying out the

operations required in a particular workplace. They cover all aspects of the

employment situation, including site specific rules and regulations, safety and

emergency procedures, the organisation of work processes, the methods of using

machinery, plant and equipment and training and instruction about associated

hazards and their management.

We will examine aspects of operation which include:

• pre-operational checks

• post start operational checks

• why and how to plan work

• machine selection

• set-up and shut down procedures

• hazard identification and hazard control

• Fault finding and recording procedures

• Log book, specifics entry

17


3. THE FORKLIFT TRUCK

Forklift trucks transport and stack materials. They are a short wheel based truck with a

vertical mast.

There are two types; counterbalanced and non-counterbalanced forklift trucks.

The LF (forklift) licence entitles an operator to use both machines.

3.1 Counterbalanced forklift trucks

Counterbalanced forklifts use the front wheel axle in the same way as the

fulcrum of a lever. The load is counterbalanced on one side by the weight of

the machine on the other side.

All the weight behind the point of balance (fulcrum) acts as a counterweight.

18


3.2 Non- counterbalanced forklift trucks (reach trucks)

In non-counterbalanced forklift trucks, the centre of the load is behind the

fulcrum point. They are known as ‘reach’ or ‘straddle’ trucks.

This type of forklift reaches out to deposit the load or straddles the stack for

depositing the load. They should not carry loads unless the reach is retracted.

They are used for particular load stacking functions and are more versatile than

the counterbalanced type in warehouse locations.

19


4. HIERARCHY OF CONTROL

The purpose of a risk assessment is to reduce or eliminate the potential for injury to

personnel whilst at work.

This is a systematic method of identifying, assessing, and reducing hazards.

To complete a risk assessment correctly we need to:

4.1 Identify the hazard

Always consider the task to determine whether there is any risk of a person injuring

themselves or others when carrying out the work.

4.2 Assess the risk

How likely could an injury occur?

How often will we be exposed?

What injuries could occur e.g. grazes, bruising, broken leg, fatality etc.?

4.3 Control the risk

What control(s) could be put in place to reduce or eliminate the incident occurring?

HAZARD CONTROLS MUST BE APPLIED PRIOR TO OPERATING THE FORKLIFT

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Control the Risk with the use of Hierarchy of Control:

The Hierarchy of Control is a six step approach to controlling hazards in the

workplace. Elimination is always the preferred option but not always possible.

ELIMINATION

Wherever possible the hazardous item or substance or work practice should be

removed.

For example: noisy grinding or cutting, purchase pre-cut materials.

SUBSTITUTION

Replace the hazardous system or process with one that presents less risk.

For example: lift smaller packages, use a less toxic chemical, vacuum in place of

sweeping.

ISOLATION

Place the hazardous system or process in a separate area where the exposure is

reduced.

For example: place barriers around a spill until cleaned up, place heat producing

objects in separate well vented rooms.

ENGINEERING

Structural changes to the work area, or process that forms additional protective

barriers between hazards and workers.

For example: provide a trolley to move heavy loads or surround moving parts with a

guard.

ADMINISTRATION

Reduce exposure to hazards via procedures, instructions and training.

For example: job rotation, shorter shifts, maintenance programs, instruction and

training.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

Where workers are exposed to hazard and other measures have proven ineffective

or non-viable. The last line of defense relies on correctly selected, fitted and

maintained PPE.

For example: provide hearing and eye protection, gloves, sun cream, masks etc.

until a more suitable solution can be found.

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4.4 Review and update

During a job, things may change which require the risk assessment to be reviewed

e.g. weather changes, additional work needed, changes in the work group etc. We

must ensure that the risk assessment is still current and valid by identifying the changes

and reviewing the risk assessment.

5. DUTY OF CARE

Your duty of care or due diligence means you must take reasonable care to ensure

that you and others are not harmed by your actions or omissions. This applies to

employers and employees.

Score Level of Risk Urgency of Action Needed

18 to 25 High Immediate action required

10 to 17 Significant Senior management attention needed

urgently

6 to 9 Moderate Management responsibility must be

specified and actioned

1 to 5 Low Manage by routine procedures

Impact/Consequences

Likelihood Insignificant Minor Moderate Major Catastrophic

Almost

certain

10 16 20 23 25

Likely 7 11 17 21 24

Possible 4 8 12 18 22

Unlikely 2 5 9 14 19

Rare 1 3 6 13 15

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6. ORGANISATIONAL AND WORKPLACE STANDARDS,

POLICIES AND PROCEDURES

Each workplace has conditions that can contribute to dangerous situations.

Operators should inspect the workplace for any potential hazards and consult with a

supervisor, site engineer, OHS rep or leading hand to ensure the hazard has been

eliminated or minimised before starting work/ operating the forklift. On some sites it

may be necessary to obtain a work permit to operate a forklift as a safety control

measure.

6.1 Work place rules and procedures

By notifying the appropriate people we can access the correct information needed

to instigate our own safe work procedures and become aware of the particular rules

and procedures that affect the site we are on.

Each work site or organisation will have its own policies and procedures as to how it

will work to meet legislative and regulatory requirements. Take time to ensure you

have access to these and that you understand the processes. Remember, policies

and procedures need to be reviewed regularly to ensure they are current, relevant

and compliant.

Be aware of the following HAZARDS:

• Blind spots - (corners, alleyways with cross traffic, the mast or load)

• Surrounding structures - (buildings, ceiling clearance, i.e low pipes etc)

• Doorway clearances

• Pedestrians

• Other vehicles - (Mobile plant and equipment)

• Obstructions

• Unsafe environmental conditions - (Extreme heat, Ultra violet (UV))

• The road surfaces - (deteriorated, damaged)

• The fumes produced by the forklift

• Dangerous materials - (load is flammable, combustible and explosive)

• Overhead Services

• Underground Services - (pit covers)

• Electric Lines/cables Power sources

• sloping ground and ramps

• Bad weather conditions - (wind, lightning, ice)

• Unsuitable ground conditions

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6.2 Working in bad weather

If you work outside, you’re at risk of exposure to bad weather conditions including

storms, wind, rain, and lightning. Your workplace must have measures in place to

manage the risks to your health and safety caused by bad weather, including:

• working indoors (where possible)

• postponing outside work

• providing access to shelter

• securing structures and objects and turning power off, and

• providing protective equipment, like eye protection.

Eliminating exposure to bad weather is the best protection.

6.3 Lightning (electrical storms) Lightning (electrical storms) are one of nature's most spectacular displays, but they

can also have catastrophic consequences — triggering fires, destroying buildings,

disrupting air traffic and in the worst-case scenario, causing death.

It is estimated that there are five (5) to ten (10) deaths a year from lightning strikes in

Australia and more than 100 people are seriously injured annually.

Recommended precautions to be taken if working outdoors during a thunderstorm

include:

• Seek shelter immediately in an enclosed car or substantial building;

• Never shelter under trees because your body is a better conductor of electricity

than the tree;

• If boating or engaged in other aquatic activities, head for shore straight away;

• Avoid touching, handling and proximity to any metallic objects that may

become part of the discharge path, for example towers, the metal parts of

vehicles or mobile plant, power lines, pipes and rails;

• Do not handle fishing rods, umbrellas, golf clubs or any other metal objects and

stay clear of sheet metal, wire fences, clotheslines and so on; and

• If caught in the open, crouch down with your feet together. Do not lie down –

the idea is to be as low as possible, but with minimal contact with the ground.

• In addition, using wired electrical equipment, hand-held tools, appliances or

landline telephones should also be avoided during thunderstorms.

6.4 Extreme heat exposure

Extreme Heat or a Heatwave is when there are three or more days of unusually high

maximum and minimum temperatures. Extreme heat is more than just ‘hotter than

usual’ weather.

When temperatures are hotter than 35°C, your body may not be able to cool you

down enough for you to stay healthy, especially if you are an older person or if you

are taking certain medicines.

In extreme heat, you are more likely to develop a heat-related illness and become

unwell much faster than you would when in warm or hot weather.

https://www.safeworkaustralia.gov.au/glossary#risks

https://www.sahealth.sa.gov.au/wps/wcm/connect/public+content/sa+health+internet/protecting+public+health/emergency+management/extreme+heat

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Everyone is at risk of heat-related illness, here are simple steps that may assist to stay

healthy in the heat:

• Drink plenty of water

• Stay cool with a fan or air-conditioner

• Avoid going out in the hottest part of the day

• Keep curtains, blinds and windows closed during the day to keep your home

cool

• Cool off with a shower or bath

• Look out for family, friends and the elderly

• Check the weather forecast so you know when hot weather is coming

• If you go outside during the day, wear loose-fitting, long-sleeved and light-

coloured clothing, a hat, sunglasses and SPF30+ sunscreen.

6.5 Ultra violet (UV) exposure

Ultraviolet (UV) radiation is a type of energy produced by the sun and some artificial

sources, such as solariums.

UV radiation isn’t like the sun’s light or heat, which we can see and feel. Your senses

cannot detect UV radiation, so you won’t notice the damage until it has been done.

Sun exposure is well established as the major cause of skin cancer in Australia. It is

the ultraviolet (UV) radiation component of sunlight which is harmful; and the level of

UV radiation is not directly related to temperature or brightness of sunlight.

This means that harm can still occur on cool or cloudy days during the peak UV

periods of the year. Exposure to UV Index levels of 3 or above can contribute to skin

cancer. (The UV index is a measure of UV radiation and the higher the index value

the greater the potential for damage to skin. In addition to skin cancer, solar UV

exposure is a major cause of eye damage including photoconjunctivitis and

photokeratitis, cataracts and pterygia. UV damage also causes sunburn, tanning,

and premature ageing.

Here are simple steps that may assist to avoid over exposure to UV radiation:

• Work in shaded areas or temporary shade where possible

• move jobs where possible to shaded areas

• consider applying window tinting to work vehicles

• modify reflective surfaces where possible

• uterlise indoor areas or shaded outdoor areas for rest/meal breaks

• schedule outdoor work tasks to occur when levels of solar UVR are less

intense, such as earlier in the morning or later in the afternoon

• schedule indoor/shaded work tasks to occur when levels of solar UVR are

strongest, such as the middle part of the day

• rotate between indoor/shaded and outdoor tasks to avoid exposing any one

individual

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• use of appropriate sun protective PPE in line with SunSmart guidelines

including:

o sun protective work clothing

o sun protective hats

o sunglasses

o sunscreen

6.6 Unstable ground conditions

Ensuring there is adequate ground stability to support the load is a fundamental step

in planning for mobile plant use. Procedures for ensuring that plant does not

collapse into the ground or tip over are well documented in manufacturers’

instructions. Ground conditions can vary dramatically from one workplace to

another and from one part of the workplace to another. Failure to address poor

ground conditions (ground bearing pressures/potential non-weight bearing

surfaces) to ensure mobile plant stability can lead to the plant overturning, with

serious injury or death to the plant operator and others nearby.

Unstable ground conditions relate to: • Rough terrain – unstable driving and load could become unstable

• Soft soils – as forklift can sink and become unbalanced

• Backfilled ground – may not be compacted properly to hold forklift weight and

equipment can sink and become unbalanced

• Deterioration of ground conditions

o Damaged and or cracked bitumen – rough, unstable and possible raised

material

o Damaged and or cracked concrete – rough, unstable, possible raised

material and possible of exposed steel/reinforcement.

• Hard compacted ground – IF not managed and continually monitored, as the

operations can dry out soil and it can break-up, crumble and turn to powder/dust.

With eminent weather (rain) it can could become soft, this includes operations

nearby that uterlise large amounts of water. May have crust on its surface, but the

ground underneath could be soft and unstable.

• Steel decks, grates and trench covers – not designed to withstand forklift weight

and could fall through.

• Railway Tracks - incoming trains, getting stuck or snagged on the line and rail

ballast (loose large aggregate). Ensure appropriate permits and authorisation is

obtained, especially working inside the rail corridor. When parking and leaving

unattended ensure the forklift is at least three metres away from rail line.

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6.7 Planning for forklift operations

Other than hazards you must plan before you operate. This

includes considering Non-Site related hazards that will have an

impact on your operations, such as but not limited to:

• Load characteristics (weight, height)

• Rated capacity of the plant you are using

• Availability of the plant

• Communications (Safe and adequate – i.e. UHF Radio

• Permits required for your task

• Equipment required for the task (Signs, Barriers, PPE and additional tools)

• Specifics of the task (timeframes, location)

7. STABILITY TRIANGLE AND CENTRE OF GRAVITY

Forklifts have 3-point suspension formed from the front drive axle (a and b) and the

centre of the rear axles (c) and are unstable by design.

All objects have a natural centre of gravity (C.O.G), as do forklifts. The centre of

gravity on a forklift can change position pending the load you are carrying, the way

you drive and other varying factors. If the centre of gravity shifts outside the safe

working area, known as the Stability Triangle, the forklift will most likely tip over, either

sideways (laterally) or forwards (longitudinally).

Forklifts have no suspension but three contact points which form the stability triangle.

The two rear wheels are attached in the centre of the rear axle via a pivoting pin. This

pin allows the rear axle to rock up and down to allow movement over uneven

surfaces. This can affect the lateral (sideways) stability of the machine. All forklifts

have a high centre of gravity (C. O. G) and a narrow wheel base, which adds to their

lateral instability.

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Note the change in the centre of gravity in the following diagrams.

Be aware of the factors listed below which can affect lateral instability or sideways

tipping:

• Turning at speed

• Turning with an elevated load

• Driving over uneven surfaces

• An unevenly distributed load

• Driving with a flat or underinflated tyre

• Turning on an incline

• Travelling with the load raised

• Braking too hard when turning

• Side shift not centred

• Lifting a load on one fork arm

• Driving sideways across a slope

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The front wheels of the forklift act as a fulcrum, with the forks on one side and the

machine body on the other. If the weight at the fork ends is heavier than the

counterweight it will cause longitudinal instability (the fork will tip up).

Be aware of the factors listed below which can affect longitudinal instability or

forward tipping:

• Overloading

• Increasing load centre distance

• Severe braking

• Load not positioned against the heel of the fork arms

• Lifting a load with the mast tilted forward

• Driving with reach extended

• Travelling with the wrong way up or down a ramp

• Uneven loads, forward

• Rapid reversing with heavy loads

• Jerky hydraulic control movements

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Learning Check 2

1. What is the lowest level of control measure on the hierarchy of control?

……………………………………………………………………………………………………………

2. Name two things that can affect longitudinal (forward) instability:

i) ………………………………………………………………………………………………

ii) ………………………………………………………………………………………………

3. Name two things that can affect lateral (sideways) instability:

i) ………………………………………………………………………………………………

ii) ………………………………………………………………………………………………

4. Name 2 hazards and their control measures when operating a forklift:

i) ………………………………………………………………………………………………

ii) ………………………………………………………………………………………………

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8. RATED CAPACITY

Operators must know a forklift’s rated capacity. It can be found on the vehicles Data

Plate and comprises the maximum lifting weight, height and load centre distance of

that vehicle. These three elements combine together to form rated capacity and

determine what the forklift can lift. Each of these elements may be affected by

altering another.

Rated capacity = maximum load that a forklift truck is designed to carry at a load

height and specified load centre distance shown on load chart/data plate.

On this data plate: Max load 1400kg at 4310mm height with a 600mm load centre

The data plate is usually found next to the driver’s seat. If attachments are fitted a

separate load rating notice needs to be displayed. To prevent accidents, the

weight of the load needs to be checked against the specifications of the forklift.

Methods of determining load weights may include;

• Weighing individual items then adding the totals together,

• Checking the load for attached labels

• Asking to see con-notes, manifests, invoices, delivery dockets etc.

Rated capacity must not be exceeded.

Operators must be able to read and understand the data plate and the conditions

of loading at all times.

It is the responsibility of the forklift owner to provide a data plate on each vehicle that

displays the lifting capacity of the machine under all lifting conditions. It is illegal to

use a forklift without a data plate or one that is illegible.

Do not use a forklift that does not have a load or data plate.

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9. ATTACHMENTS AND EFFECTS

Attachments are working aids that are added to a forklift for certain tasks. Some are

permanently attached and hydraulically powered while others are only attached

when required and removed afterwards.

All attachments add weight to a forklift and can therefore affect the stability and

reduce the safe working (SWL) of a forklift.

Make sure all attachments are suitable for load and forklift and have their own data

plate before use.

They must be attached securely to forks with chains and/or pins if removable.

Do not rotate the load while moving if a load rotator mechanism is fitted.

Make sure the forklift data plate allows the attachment to be used on that forklift.

The use of any attachment will reduce the lifting capacity of all forklifts.

If asked to use an attachment you are unfamiliar with, ask for training or advice from

a competent person first.

In all cases, the forklift must be approved to use attachments. Safe working loads will

be stamped on the data plate for each approved attachment.

9.1 Common forklift attachments:

The number of forklift attachments that are available today has increased over the

years and their quality has improved as well, mainly because they offer businesses a

great deal more functionality and added features.

Side Shifters are one of the most common attachments used today; most forklifts

come with this attachment as standard. This attachment allows you to shift the forks

(tynes) from side to side allowing for small adjustments to be made by the operator;

enabling alignment with pallets without manoeuvring the entire forklift.

This handy attachment allows:

• Movement of loads in tight spaces without

moving the whole truck

• Precision of movement with loads

• Accurate alignment with pallets

• Reduced damage to pallets, loads and

racking

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It’s important to note though that when you have to attach a side shifter to a forklift,

this will reduce the overall load capacity of the truck because:

• The tool ads weight to

the equipment

• The load centre is

shifted outward

If you have just picked up a load using side shift you should centre the side shift

before travelling with the load to maintain the stability of the load and forklift.

Other attachments include:

9.2 Work Box/Personnel work platforms

Some industrial lift trucks are designed to lift people. For example, an ‘order-picking

industrial lift truck’ has an elevating platform that allows the operator to load shelves

as well as control platform height and steer the industrial lift truck. If you use a

separate work platform or box fitted to an industrial lift truck to lift people then you

must ensure people in a work box:

• are securely attached

• stay largely within the workbox

• wear a safety harness if there is a risk of falling from a height, and

http://www.proliftequipment.com/blog/2012/08/10/defining-forklift-load-center/

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• can safely exit from the workbox and the industrial lift truck in the event of a

failure in its normal operation.

Forklift trucks may be used to provide a safe work platform (see figure below). Work

platforms and boxes should only be used to raise people performing occasional

tasks and must be securely attached to the industrial lift truck. The industrial lift truck

operator should perform an initial trial lift without a person in the work box to check

the work box has a clear path and will not make contact

with overhead power lines or other overhead obstructions.

The following risk control measures should be put in place when using work platforms

or boxes (safe use):

• The industrial lift truck is to be stabilised at all times while lifting people and

preferably only used on a hard, even and level surface.

• Before work starts make sure the parking brake is set, the vehicle drive

controls are in neutral, the mast is vertical and hydraulic controls are off

except lift and lower.

• Workers are trained to use work boxes safely including emergency

procedures so occupants can be rescued if an incident or breakdown

happens.

• Workers stand on the floor of the work box, not on a ladder or other object.

• Where possible, work boxes are not used to transport people.

• The operator of the industrial lift truck stays at the controls at all times.

• instructions or those of a competent person. Each fall arrest anchorage point

should be located so a lanyard can be attached to it before the person using

the lanyard moves into a position where they could fall. Installed anchorage

points should be tested and approved by manufacturer.

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• For compliance and safety:

o Work boxes should only be attached to a compliant industrial lift truck

with a load capacity data plate that says which attachments may be

used.

o The work box safety gate is self-locking and kept shut when in the

raised position.

o Work box fall arrest anchorage points should meet the requirements of

the work box manufacturer’s

o Industrial lift trucks are equipped with flow restrictors or similar i.e. the

valves in the hydraulic lines to prevent free fall in the event of a hose

failure.

9.3 Lifting and suspended loads

You must ensure that the industrial lift truck is equipped with lifting attachments that

are right for the load to be lifted or moved by the truck. The attachment should be

securely connected to the industrial lift truck prior to operation to prevent it

separating from the lifting media. Many specialised attachments are available for

industrial lift trucks including slippers, bin lifters, carpet spikes, jibs, spreaders and

drum handlers (see figure below).

Attachments like jibs have more than one lifting point and the load chart should

show the lifting capacity for each point. If an attachment is fitted to an industrial lift

truck, ensure you have access to information on the de-rated capacity of the

industrial lift truck.

By using the industrial lift truck load chart and the information with the attachment,

often found on the attachment’s load rating plate, the de-rated capacity of the

industrial lift truck can be calculated.

In addition, the Australian standards dictate additional capacity reductions for

forklifts used with suspended loads:

• When a suspended load is carried (i.e. a jib attachment is used) the rated

capacity calculated for the forklift must be reduced by 20%.

35


• When two forklifts carry the same load, the load applied to each truck shall

not exceed 75% of that truck’s capacity.

Each of the de-ration factors stated here are cumulative. That is, the lifting capacity

at a given load centre is calculated, the self-mass of the jib and slings is subtracted

from this, then the 20% de-ration for suspended loads is applied, then (if two trucks

are used together) the 25% reduction is applied. This may result in a lower than

expected lifting capacity for a forklift.

Holes should not be drilled or cut through attachments or lifting media, for example

fork arms, as this can weaken and destroy the integrity of the attachment. Changes

should not be carried out unless they have been specified by a competent person,

for example a mechanical engineer

10. THE MOTOR

10.1 Internal combustion engine (I.C.E.)

Internal combustion engines are powered by diesel fuel, petrol or LPG or Compressed

natural gas (CNG). An LP gas motor is a petrol motor that has been converted to use

gas instead of petrol.

WARNING: Internal combustion engines produce the odourless, but poisonous gas,

called carbon monoxide. A person working in a confined space where carbon

monoxide is present could become seriously ill or die from inhalation.

Carbon monoxide builds up in the body and can kill in twenty minutes. Make sure

there is adequate ventilation where forklifts with internal combustion engines are

operating.

Do not refuel an internal combustion forklift unless the motor is stopped and the ignition

is turned off. If not, there is a chance of explosion.

Refuelling using a fuel pump/bowser

1. Remove the filler cap. Avoid dust getting into the fuel tank.

2. Ensure the area is well ventilated when fuelling vehicles or equipment.

3. Once started, note the pressure uptake in the fuel hose.

4. Immediately report any leaks that are observed. Turn off pump if required.

5. Keep the metal fill nozzle in contact with the lip of the tank to eliminate any static

accumulation.

6. Adjust the nozzle trigger to suit the particular fuel flow requirements.

7. Always check the fuel flow at regular intervals during normal operation.

8. Never kink the fuel hose to restrict or cut off the flow of fuel.

9. Report any fuel spills immediately and begin use of spill response/ recovery kit.

10. If fuel splashes onto clothing, remove and allow for fuel to evaporate completely

outdoors before washing. Thoroughly wash clothing before re-use

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Re-fuelling with a jerry can/fuel container

1. Use a proper fuelling nozzle or funnel to avoid splashing fuel on the engine or frame

of the equipment.

2. Fill slowly and listen to air coming out of the can as the fuel pours in. As the can

nears the full level, air will

come out faster, and the pitch will get higher. Stop before the tank is full. Leave 5

percent empty to allow for expansion of the tank.

3. When the tank is full, let the fuelling nozzle drain for a few seconds before removing

it from the fuel port to

prevent dripping.

4. Replace the filler cap.

10.2 Gas cylinders

Every cylinder must be inspected by an authorised LPG test station at least once every

10 years. The last inspection date should be clearly stamped on the cylinder collar,

neck or footing

If any leakage is detected or suspected from a cylinder, turn it off immediately and

refer to emergency procedures

Gas is a highly volatile explosive. Change gas cylinders in a well-ventilated area, well

clear of a naked flame or a source of ignition. Only

those trained and authorised to do so should

change gas cylinders.

Beware of burns from escaping gas. Always wear

gloves and safety glasses and do not smoke whilst

changing LP gas cylinders.

Test date: 10/17 = Oct 2017

Retest date: Oct 2027 (10 years)

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Handle cylinders

carefully Take care when handling cylinders to avoid impact damage.

DO NOT drop cylinders off vehicles or docks when unloading or allow heavy objects

to fall on them.

Impact damage can potentially reduce the cylinder wall thickness, which could lead

to premature cylinder rupture.

Barcodes are to alert the fillers and operators when the cylinders are due for re-test,

and for identification purposes. DO NOT under any circumstances tamper with or

remove these.

Cylinders need to be kept cool

DO NOT store cylinders at temperatures greater than 65°C.

On extremely hot days every effort should be made to keep the cylinders in the shade.

Excessive heat – results in an increase in internal pressure.

Excessive heat can reduce the strength of the cylinder resulting in localised bulging

at the source of the heat and in extreme cases cylinder rupture. Care must be taken

with an oxy-fuel gas torch when in use. DO NOT allow the flame from an oxy-fuel gas

torch or other appliance to point onto cylinders.

Some suppliers like BOC fit a plastic Test Date Tags (TDTs) on the cylinder valve inlet

connection which will distort or melt at a predetermined temperature when heat-

affected. This is to alert BOC (and customers) of any heat damage to the cylinder.

Any heat-affected cylinders are sent to a BOC cylinder test shop to determine if they

are safe to be returned back into gas service or if they are to be scrapped.

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10.3 Procedure for changing propane (LPG) cylinders Take the following steps in the order below when changing gas cylinders:

1. Wear eye protection and insulated, loose fitting gloves such as leather (dry)

or insulated neoprene.

2. Close the valve on the cylinder.

3. Run the engine until it stops. This ensures that the connection hose is empty.

4. Shut off the engine.

5. Open the connecting nut and inspect valves for leaking. Do NOT use metal

tools.

6. Disconnect the hose.

7. Disconnect the holding straps.

8. Remove the empty cylinder.

9. Inspect the replacement cylinder for damage.

10. Replace with a full cylinder in the proper position.

11. Connect the holding straps.

12. Tighten the connecting nut (wiggle hose).

13. Open the valve on the cylinder slowly and check for leaks. (can use solution

of soap and water). Smell – listen – look.

14. If the valve leaks:

1st time - Tighten the nut and continue.

2nd time - Change the cylinder.

3rd time - Change the hose.

15. Open the valve fully (slowly).

16. Check that the hose is turned inward.

17. Secure the hose downward.

18. Secure the cylinder.

19. Start the engine and resume operation.

10.4 Gas compliance plate All LPG forklifts must have an installer’s compliance plate.

Certification

On completion of any aftermarket installation work, the owner/hirer of the industrial

equipment will be supplied a certificate of compliance in accordance with

AS/NZS4983:2010 Gas fuel systems of forklifts and Industrial engines, which will also

give an installation date and the serial number(s) of any fixed container(s).

Compliance plates

An LP gas/CNG compliance plate should be securely attached to a permanent

part of the industrial equipment and must be clearly visible.

The compliance plate should take the form

shown in figure (right of page) and all

applicable information should be provided by

the installer. The information must be

permanently inscribed, where applicable,

and clearly legible.

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10.5 Internal combustion diesel engines

Most diesel engines must warm up before they can start. When the ignition key is

turned on, the glow plug is activated. This warms up the fuel so it will fire.

There is a delay of several seconds from ignition until the starter motor turns on the

engine. A light on the dashboard indicates that the fuel is warming. It goes out when

the engine is ready to fire.

Try to avoid allowing a diesel engine to run out of fuel. Diesel engines fire on the

compressed vaporised fuel and will not fire if there is air in the fuel lines. If a diesel

engine runs out of fuel, a competent person must bleed the system of air before it can

be restarted.

Diesel engines also emit carbon monoxide gas. A badly tuned diesel engine can emit

more carbon monoxide than a petrol motor. Remember that carbon monoxide is

odourless, will build up and can kill.

10.6 Electric forklifts

Electric forklifts are quieter than I.C.E vehicles so greater care must be taken when

operating as pedestrians are less likely to hear one approaching.

Recharging of electric forklifts must take place in well-ventilated areas as the batteries

produce a poisonous, odourless, flammable gas during the recharge process. This gas

is known as hydrogen and is extremely dangerous when allowed to build up.

Hydrogen is highly explosive and extremely harmful if inhaled.

40


10.7 Battery changing procedures for electric forklifts.

Battery charging safety precautions:

o Be sure the charger is OFF before connecting or disconnecting the

battery.

o Do not disconnect the battery plug when there is current going through,

as this may cause arcing and damage the plug.

o Battery chargers should be in a well-ventilated area and should be easily

accessible.

o Battery chargers should not be in a wet or damp area, and never stand in

water when connecting battery to charger.

o Always match the correct charger for the battery.

o Do not smoke, use power tools or do anything that will create sparks

around the battery charger area. Charging batteries gives off explosive

flammable gases which easily ignite when coming into contact with a

spark.

o Contact your supervisor if the battery, battery charger cables or

connectors show any bare wires, melting or damage. The connectors

should have a snug fit and should not be damaged from arcing.

o Check to make sure that the power supply cable to the charger is in good

condition.

o Do not touch battery terminals or the cell connectors on top of the battery

to prevent getting an electrical shock.

o Do not place any tools or any other metal objects on top of a battery.

o Equalize batteries on the last day of the week, last shift of the day - to fully

charge battery.

o If you suspect any abnormal battery or charger condition, turn off the

power supply and inform your supervisor immediately.

Battery Charging Procedure:

1. Disconnect the battery from the forklift

2. Check cable and connectors for damage (do not charge if damaged)

3. Check the battery lid is open before charge (dissipate gases during charge)

4. Do not open or remove the vent caps unless topping up (watering battery)

5. Plug the battery into charger

6. Turn on the charger (generally switch on front panel)

7. Take note of any charge indicators signifying start of charge cycle

(lights/voltage needles)

8. Always allow a complete charge cycle (do not interrupt)

9. Check if charge complete (charge indicator)

10. Un-plug battery (do not unplug by pulling cables, use the plug)

11. Check water level

Watering a battery:

o Always water (top up) the battery after charging

o Never over-fill the battery (maximum 10mm above plates)

o Water the battery at least once per week

o Always use clean water (preferably distilled/deionised)

o Xtreme fast charging (XFC) and gel batteries do not require

watering

41


11. FORKLIFTS AND FLAMMABLE LIQUID

Flammable liquid stores and other areas where flammable liquids are used are

usually zoned as having a ‘hazardous atmosphere’.

Forklifts must be modified or ‘flame proofed’ before they can be used in a hazardous

atmosphere and have a compliance plate to that effect.

‘Flame proofed’ diesel powered forklifts have an exhaust water wash box, which must

be flushed out and refilled every shift.

‘Flame proofed’ battery powered forklifts must not be connected to the battery

charger near to any area where flammable liquids are handled in open containers.

Petrol and LP gas forklifts are never flame proofed because of their spark ignition

system.

Learning Check 3

1. Why should you use an electric machine in a confined space?

....................................................................................................................................................

2. Name three types of forklift motor:

i) ………………………………………………………………………………………………

ii) ………………………………………………………………………………………………

iii) ………………………………………………………………………………………………

42


12. PRE-OPERATIONAL CHECKS

It is a legal and mandatory requirement that the first person to use the plant on any

given day conducts a pre-operational inspection to ensure not only the operator’s

safety but the safety of those around them.

Here is an example of a standardised pre-operational inspection checklist used for

counterbalanced internal combustion engine (I.C.E.) forklifts.

PRE -

START

CHECKS - Before

you turn

key and

start-up

forklift)

POST-

START

CHECKS – (checking

functional

operations

before you

commence

work.)

43


13. SAFE OPERATION

Forklift trucks should only be used on hard level surfaces. Four-wheel drive or rough

terrain type should be used on unstable terrain.

13.1 When raising the load

• Carry loads as low as possible at all times, never higher than the front axle.

• Hydraulic controls should be ‘eased in’. If the controls are plugged or pushed

quickly, the operation will be jerky

• Make sure the forks are centred when they are entering a pallet and do not

contact the pallet until you are ready to lift

• Do not enter the pallet with the mast tilt back or forwards (this will bind the

forks). Forks must be level and mast vertical

• The load should always rest against the heel of the fork arms. This will ensure

the load centre is in the right place

• If the load weight is unevenly distributed on the pallet, put the heavy end of

the load against the heel of the fork arms

• Make sure the forks are centred on either side of the mast if side shift is attached

or side tipping may occur

• A properly constructed hardwood pallet weighs 35kg and has a SWL of 2000kg.

Do not overload pallets

• Do not move damaged pallets. Loads should be repacked to undamaged

pallets wherever possible

• Do not allow more than a third of the top section of an unwrapped load to

stand above the top of the load backrest extension. A load not backed by

the load backrest can fall back and tangle with the mast, or if the load is very

high, can topple back onto the driver

• Unsafely or unevenly packed pallets should be repacked.

• Do not raise a load with just one fork as this can destabilise the forklift and the

load or cause damage to the lifting mechanism.

• Always raise the load before tilting the load backwards

44


13.2 Travelling

• Always travel with the load tilted backwards and close to the ground

• Never travel with the load or the forks above front axle height

• Forklifts are one-person vehicles. Do not carry a passenger unless specified as

acceptable by the manufacturer and displayed on the data plate

• You can only lift people in an approved work platform

• Understand your site’s traffic requirements

• Reduce speed and proceed with caution on wet or greasy surfaces

• Do not attempt to turn a forklift when it is on a sloping surface (this could affect

lateral stability and cause it to tip over sideways)

• Always drive up and down inclines slowly (check manufacturers specifications

for any special features that the forklift you are operating has for operating up

and down hills)

• Face the load uphill when travelling up a slope

• Face the load uphill and look behind you when reversing down a slope

• Have someone guide you when driving up a hill with a bulky load that blocks

clear vision

• Before reversing check over both shoulders, check mirrors (if fitted) check path

is clear

• Blow the horn and drive slowly when approaching a blind corner

• Make sure that no one is in the way or standing next to you before driving away

• Do not drive across a slope or side tipping may occur

• Do not turn sharply at speed. Forklifts overturn very easily. They are narrow

wheelbase trucks with a high centre of gravity

• If your forklift is overturning. Grab the steering wheel, brace your feet, lean in the

opposite direction of the fall and do not attempt to jump clear.

• Watch out for rear end swing. Forklifts steer from the rear and the rear end will

swing out very wide. When travelling and turning the rear end, swing will be

three times that of the forward speed of the forklift. Stay as close as possible to

the inside of narrow corners when turning and watch out for pedestrians or

objects

• Revving the engine when lowering a load makes no difference; lowering is

gravitational.

• Do not drive reach trucks with the reach out as this alters the vehicle’s C.O.G.

• Give way to police, fire, ambulance or other emergency vehicles at all times.

Other workers and pedestrians should be aware of the need to keep clear of a

forklift while loading and travelling. In particular, no one should walk behind a forklift

while it is loading or stacking or walk under an elevated load.

Precautions must be taken when operating over roadways, footpaths and other

public areas.

The rear end swing of a forklift can be particularly dangerous as the rear end can

swing out in a very wide arc and can travel extremely fast when turning.

45


13.3 Placement of Loads

• When putting the load down, always bring the load over the stack before

tilting forwards

• Deposit the load with the mast vertical

• If placing loads into stacks or racks make sure the heaviest item is at the base

of the stack

• Make sure loose items are not stacked high, (wrap or strap loose items)

• Ensure shelves or racks are weight rated and know the weight of your loads

• Never stack too high as this will create an unstable stack

• Make sure ground is firm, dry and level

• Always try to stack neatly, neat stacks are safe stacks

13.4 Loading trucks

• Always load pallets alternately on both sides of a truck. A truck can overturn if

one side is empty and the other side has a full load

• Make room by shifting the truck if there is no room to load both sides.

13.5 Loading Pantech’s (large enclosed vans)

Make sure:

• That the mast is not too high to enter the van

• That there is sufficient ventilation

• That the truck will support the combined weight of the forklift and the load

• That the bridge plate is in place and secure

• That the van is chocked

• That the driver of the van has removed the keys from the ignition and has left

the cabin during loading

• The load is kept low during loading

13.6 Loading loads with two forklifts

Lifting a load with two forklifts is very hazardous. The precautions listed below must be

taken when lifting with two forklifts:

• Dual lifts should only be carried out by experienced operators

• The operation must be controlled by an experienced third person who has

responsibility

• Each forklift must not lift more than 75% of its rated capacity given stability,

position of load centre and other factors affecting the safe working load (SWL)

• The load must be only carried the distance necessary to clear the load carrier

• Loads must be raised and lowered simultaneously

• Order pickers must not be used for dual lifts

46


If one forklift lowers more quickly than the other, the load becomes uneven. The

diagram on the previous page shows forklift B lowering more quickly than forklift A

causing:

• The weight to move immediately to the tip of the fork arms on A

• Pressure put on the mast of forklift B which could cause it to bend or break

The load slips along the fork arms changing the position of the load centre.

13.7 Parking

1. Always find a level, out of the way, place to park. If you must park on an incline,

you must also chock the wheels before leaving the forklift.

2. Park clear of fire and emergency exits, power switches, firefighting appliances,

first aid facilities, gas refuelling stations and fuel pumps.

3. Engage handbrake and select neutral gear

4. If the tips of the forks cannot be lowered to the ground, park so that the forks

do not create a tripping hazard

5. Turn the ignition off and remove the key to prevent unauthorised use

6. Isolate the power source if at the end of a shift i.e. LP gas should be turned off

to prevent leakage

7. Make sure you always park clear of:

• Doorways

• Emergency exits

• 3m from train lines

• Flammables/hazardous materials

• First aid stations

• Blind corners

• Pedestrian walkways

47


Learning Check 4

1. Circle true or false for each of the following statements.

You must never:

Load with one fork tyne True or False

Use order pickers for dual lifts True or False

Use two forklifts to carry a load True or False

Park hard up against another forklift True or False

Jump out if your forklift is overturning True or False

2. When raising the load, you should rest the load against the ……………………

of the fork.

3. What should you do when driving towards a blind corner?

……………………………………………………………………………………………………………

……………………………………………………………………………………………………………

48


14. FORKLIFTS AND ELECTRICITY

Keep a safe distance from electric power lines. Find out where all power lines are

located in your workplace. Do not unload a truck under power lines (to avoid the

mast making contact with the lines when the forks are raised).

You MUST know and remember the safe distances when working near power lines.

To determine voltage of the lines, you must consult with the relevant authorities.

Prescribed distances are dependent on the voltage of the powerline. In addition,

Australian Standard AS2550 (Cranes, hoists and winches – Safe use), describes the

operation of cranes and other elevating working platforms in proximity to powerlines.

This standard provides general guidance regarding safe working practices for

machinery near powerlines, with clearances depending on whether the work is

conducted with or without a spotter.

With Spotter:

3m away for low

voltage

Without Spotter:

at least 6.4m

With Spotter:

8m away for low

voltage

Without Spotter:

at least 10m

49


Stay at least 6.4m away from distribution lines on poles (low voltage) and at least 10m

away from transmission lines on towers (high voltage).

If a spotter is used:

• 3m away for low voltage

• 8m away for high voltage

If required to work closer than these distances you must first contact the supply

company for permission. The supply company can either de-energise the lines,

insulate them or provide an approved spotter when working nearby.

Procedure if accidental contact is made with power lines:

1. Stay on the machine and warn others to stay clear

2. Try to break contact if the engine is still running

3. Do not leave the forklift until the electricity has been turned off

4. If safe, jump well clear of the forklift

5. Do not make contact with the ground and the forklift at the same time.

6. Warn all others to remain no less than 8m away from the forklift

7. Forklift must be fully inspected before it can resume working

Tiger Tails (as shown below) are a simple black and yellow plastic sleeve that can be

attached to power lines. They are a visual aid used to highlight the location of live

wires in relation to where the work will be carried out.

Remember, if there is a requirement to get closer than the recommended minimum

safe distances, regulatory authorities must be notified prior to the work commencing.

DO NOT GUESS

ELECTRICITY IS DANGEROUS, INVISIBLE AND IT WILL KILL

50


15. FIRST AID

Forklift operators work in a high risk industry. Not only are there many minor injuries,

but there are also serious injuries where the injured person will need first aid to restore

breathing, heartbeat or to stem blood flow.

According to WorkCover statistics, between 1985 and 2003, 49 people have been

killed in forklift incidents.

Know the location of the first aid room and the nearest first aid kit. There must be a

first aid kit on every floor of a multi-story building site or within 100m of any part of the

workplace.

The standard first aid symbol in Australia is a white cross on a green background.

It is recommended that forklift operators take the time to obtain an approved first aid

certificate.

In the case of an emergency it is of critical importance to remain calm and

communicate accurate descriptive information to the necessary people.

This process can vary from site to site however in most cases you will be required to

inform supervisors, other workers and emergency services;

• The nature of the emergency (WHAT)

• The exact location of the emergency (WHERE)

• How the incident occurred (HOW)

51


16. COMMUNICATIONS

Understanding how to use communication devices correctly is an important part of

work place procedures and safety. Many companies will adopt varying methods of

communication such as:

• Two-way radios

• Verbal questioning and listening to confirm understanding

• written instruction

• Hand signals

• Audible and visual warning devices

It is of vital importance that communication techniques and devices are checked

for suitability and functionality prior to the work commencing.

17. TRAFFIC WARNING SYSTEMS

A person conducting a business or undertaking with management or control

of powered mobile plant at a workplace must ensure it does not collide with

pedestrians or other powered mobile plant. If there is a possibility of collision, I.E the

brakes and steering fail on the forklift the plant must have a warning device alerting

person who may be at risk from its movement.

workplaces can be designed with vehicle and pedestrian routes that are separated.

Mobile plant can be designed so the operator can see easily and the plant can

be fitted with speed limiters and traffic warning devices. Common warning devices

fitted include:

• Audible – horn

• Visual warning devices – flashing beacon/strobe light

• Alert systems –

o Collision Awareness Forklift Look Out Sensor

o Overhead Forklift Door Monitor with Sensor

o Worker Alert System Vibration Unit

52


18. TRAFFIC MANAGEMENT PLANS If you have a large workplace with a high volume of traffic a traffic management

plan can help you communicate how you are managing traffic risks in your

workplace.

A traffic management plan may include details of:

• the desired flow of pedestrian and vehicle movements

• the expected frequency of interaction of vehicles and pedestrians

• illustrations of the layout of barriers, walkways, signs and general arrangements to

warn and guide traffic around, past, or through a work site or temporary hazard,

and how short term, mobile work and complex traffic situations will be managed.

A traffic management plan could also set out:

• responsibilities of people managing traffic in the workplace

• responsibilities of people expected to interact with traffic in the workplace, and

• instructions or procedures for controlling traffic including in an emergency.

Example of traffic control measures for truck loading and unloading

Clearly designated pedestrian

walkway protected by physical barriers with

staggered barriers to control approaching

pedestrians.

Pedestrian exclusion zone has been

established for a distance equal to the height

of the load from the ground plus an additional

allowance for the type of load.

Beam from pedestrian-sensing

device.

Barriers, bollards, witches hats or

paint marking the pedestrian exclusion zone.

Warning light activated by

pedestrian sensors.

Establish a safety zone for the driver and

other pedestrians. The driver should be in full

view of the forklift operator. Stop the loading

and unloading activities if the driver cannot be

seen or needs to enter the exclusion zone.

Alternatively, if it is safe to do so the system of

work can provide for the driver to stay in the

cabin during loading and unloading. Effective

communication systems between the plant

operator and the driver should be used such as

a system of hand signals or two-way radios.

53


19. GENERAL SAFETY RULES

• When a work platform is elevated, the driver of the forklift must remain at the

controls at all times. Park brake applied, gear selection in neutral with engine

running.

• In the event of any fault being revealed at any time or if the forklift becomes

unsafe in any way:

▪ Remove the ignition keys to stop unauthorised use

▪ Turn off the gas to prevent leaks

▪ Tag the forklift as defective

▪ Report the matter immediately to your supervisor to be fixed

• Do not make repairs, alterations or adjustments to any forklift unless authorised

and qualified.

• Do not allow anyone to stand or pass under elevated fork or attachments,

whether loaded or empty.

• Do not use additional counterweight to increase the load capacity of any

forklift unless approved by the manufacturer.

• Always approach rail lines and speed humps at a 45º angle and slow down.

• Do not operate a forklift unless a compliance plate (data plate) is fitted.

• Do not operate a forklift on a public road unless the forklift is registered, has

lights, turning indicators and warning devices fitted. Have appropriate class of

driver’s licence covering the gross vehicle mass of the forklift.

• Never lift unstable loads (restack pallet if required).

• Check load weights and operate only within the rated capacity of your forklift

truck.

• When operating a forklift on wet or slippery surface you should take the

following evasive actions to minimise the risk of losing control.

• Reduce speed

• Avoid using ramps or steep inclined pathways

• Take wide turns (slowly)

• Proceed with care - (after there’s been an

interruption keep going, safely avoiding harm or

danger)

54


20. LOAD CENTRE DISTANCE

Load centre distance is defined as:

‘The distance from the heel (or vertical face) of the forks to the centre of gravity of the

load’

Most palletised loads are square and evenly stacked in which case the load centre

will be in the centre of the load. Lifting loads that are not against the heel means the

Load Centre Distance will be increased which in turn will lower the forklifts height and

weight capacity.

By increasing the load centre, you decrease the capacity of the forklift.

Load centre distance (L.C.D) increase = height & weight decrease.

600mm is the Australian standard load centre distance although it is illegal in

Australia to use a forklift with an LCD rated below 500mm. Always check the data

plate for the rated capacity before use.

55


21. CALCULATIONS

As part of this course you will need to demonstrate that you can:

• Calculate the weight of the load you will be carrying

• Read and understand load charts to calculate which loads are within the

capacity of the forklift

• Read and understand load charts to calculate maximum working loads with the

mast in different positions

Example:

The load to be moved is bags of sand stacked on a pallet.

• 60 bags on the pallet

• Each bag is 20kg

• The pallet weighs 30kg

What is the combined weight of the bags and the pallet?

(50 x 20) + 30 = 1230kg

Learning Check 5 1. Using the calculated load (above) and the data plate (below) answer the

following questions – (circle answer)

Can your forklift truck lift the load? YES NO

Can you lift the load with your mast tilted forward? YES NO

Can you lift 1820kg with a load centre of 800mm? YES NO

56


2. Your forklift requires some minor repairs; under what circumstances can the

operator make the repairs?

A. All HRW licence operators can.

B. If the supervisor says it’s ok.

C. Only if they are authorised and competent to do repairs.

3. You have just picked up a load, why should you centre the side shift before

travelling with the load?

A. A. So the load looks tidy.

B. B. To maintain the stability of the load and forklift.

C. C. So the operator can see properly.

4. What does the term, “load centre distance” mean?

A. The distance to the middle or the forklift blades.

B. From the mast to the middle of the forklift blades.

C. From the vertical face and the horizontal face of the fork tynes to the load

centre of gravity.

5. If your fork lift truck has a 600mm LCD and a SWL of 3000kg which load is within

tolerance? (circle your answer)

57


6. The load to be moved is a precast block secured on a

pallet.

• Precast block 730kg


What is the combined weight of the precast block and the pallet?

Show all calculations.

……………………………………………………………………………………………………………

……………………………………………………………………………………………………………

…………………………………………………………………………………………………………

7. The load to be moved is four drums stacked on a pallet.

• Four drums on the pallet

• Each drum’s tare weight is 9.8kg

• Each drum’s capacity is 208L (filled with water)


What is the combined weight of the drums, contents of the drums and the pallet?


……………………………………………………………………………………………………………

……………………………………………………………………………………………………………

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

…………………………………………………………………………………………………………

8. The load to be moved is an IBC filled with water.

• Tare weight of IBC is 56kg

• The amount of water is 1000L (1000kg)

What is the combined weight of the IBC and the water?


……………………………………………………………………………………………………………

……………………………………………………………………………………………………………

58


22. PRE-ASSESSMENT CHECK

(This must be complete before the Final Assessment)

1. Before you start work who should you communicate with about site hazards?

2. List 10 common hazards you should be aware of before operating a forklift

truck

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

3. It is important to confirm your work conditions and responsibilities before

commencing work, other than site hazards what other conditions and

responsibilities should you be aware of before you start work. List 6 examples.

1.

2.

3.

4.

5.

6.

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4. The Hierarchy of control is a six step approach to controlling hazards in the

workplace. What are the six steps, starting with first consideration and working

to the last step/level of control?

1. ____________________

2. ____________________

3. ____________________

4. ____________________

5. ____________________

6. ____________________

5. Demonstrate knowledge of power line safety distances for South Australia,

Low voltage with a spotter m

Low voltage without a spotter m

High Voltage with a spotter m

High Voltage without a spotter m

6. Do Tiger Tails allow you to work closer than the distances given because they

provide isolation and protection when working near powerlines?

Explain your answer.

7. When you have to move a load with your forklift from one location to

another, what would you consider in determining the travel route before you

carry out your task?

60


8. If you are going to operate a forklift in an area that allows pedestrians to

enter your work area, what control measures could be used to control their

movements?

9. If you had to operate a forklift in a warehouse that had very poor lighting and

blackened areas, what would you require to be able to work safely?

10. What is produced when charging batteries for an electric forklift?

11. Why is the rear end of a forklift dangerous when travelling and turning? (a)

Who is at most at risk? (b)

a)

b)

12. Why must the operator ensure the forklift truck is turned off when refuelling?

13. Name 3 communication styles you could use whilst operating a forklift truck?

1.

2.

3.

14. In an emergency list 3 people you would contact and what would you

communicate to them?

1.

2.

3.

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15. When assessing a load how would you determine the weight of a load?

List 3 examples

1.

2.

3.

16. Name 8 pre-start checks that you would make before starting your forklift?

1.

2.

3.

4.

5.

6.

7.

8.

17. If during your prestart checks you found that the Data Plate was missing or

unreadable or the machine is not in acceptable working order, what would

be your responsibility?

18. Where can you find a forklifts Rated Capacity and what are the three

elements that form it?

Can be found:

Element 1:

Element 2: _____________

Element 3:

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19. Whilst travelling up or down a ramp without a load in which direction must the

forklift face? (a)

Is this method different when travelling up or down a ramp with a load? (b)

a)

b)

20. What are the risks if a person is under a raised load whilst you are operating

the forklift?

21. What is the optimum load travel height?

22. What is the likely outcome of travelling with a load raised?

23. List 7 things that could change your forklifts centre of gravity and result in the

forklift tipping sideways?

1.

2.

3.

4.

5.

6.

7.

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24. Give 4 examples of areas considered unacceptable as a parking place for

forklift trucks?

1.

2.

3.

4.

25. Calculate the following:

The load to be moved is paving stones stacked on a pallet.

• 144 paving stones on the pallet

• Each paving stone weighs 2kg


What is the combined weight of the paving stones and the pallet?


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23. ASSESSMENT

Your trainer will explain the methods of assessment to you to demonstrate

competency of TLILIC003 Licence to operate a forklift truck.

Theory Assessment

You will need to undertake:

• Two (2) knowledge assessments

• One (1) calculations assessment

Practical Assessment

You will need to undertake:

• a performance assessment on the forklift

Ask your trainer if you have any questions about the assessment process for this unit.

GOOD LUCK WITH YOUR ASSESSMENTS

TLILIC0003 LICENCE TO OPERATE A FORKLIFT TRUCK · 2019-07-15 · 10.6 Electric forklifts ......

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Transcript of TLILIC0003 LICENCE TO OPERATE A FORKLIFT TRUCK · 2019-07-15 · 10.6 Electric forklifts ......