Forklift

Operations
Manual
 ALL RIGHTS RESERVED

No part of this publication may be reproduced or resold in any form without the
prior written consent of the publishers, NATIONWIDE TRAINING PTY LTD.

13 Collingwood Street
Osborne Park WA 6017
Phone: (08) 9445 7766 Fax: (08) 9445 7756
E-Mail: info@[Link]
Web: [Link]

Thank you for choosing NATIONWIDE TRAINING

Our Nationally Accredited Courses include:

Dangerous Goods Licence / Refresher Driver Fatigue Management

Dangerous Goods Awareness Safety Awareness
Dangerous Goods Storage and Handling Safety Representatives / Refresher
Dangerous Goods Class 3 & 9 OH&S Procedures
Transport of Explosives by Road Manual Handling
Safe Load Program (AIP) Load Restraints
Safety and Health for Managers and
Gantry Operation
Supervisors

Certificate IV in Warehousing Operations Certificate IV in Training and Education

Certificate IV in Business Certificate IV in Business Frontline
Management
Certificate IV in Retail Management Certificate IV in Occupational Health and Safety

Every effort has been made to ensure that this publication is free from error or omissions. It must be noted

that the information it contains is a guide for Operators only. Operators are referred to relevant publications

as listed for further information relating to the Forklift Operator’s responsibilities. NATIONWIDE TRAINING,

the editor or their representatives, agents or employees shall not accept responsibility for injury, loss or

damage occasioned to any person acting or refraining from action, as a result of material in this publication

whether or not such injury, loss or damage is in any way due to any neglect, act of omission, breach of

duty or default on the part of NATIONWIDE TRAINING, the editor or their representatives, agents or

employees.

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 ACKNOWLEDGEMENTS

NATIONWIDE TRAINING would like to thank the following for their advice, co-
operation and expertise in the development of this Forklift Operator Training
Course:
• WorkSafe Australia
• Department of Labour – Victoria

Training conducted in this course complies with

Australian Standard 2359.2 – 1985
National High Risk Licensing requirements

PURPOSE

The purpose of the FORKLIFT OPERATOR TRAINING COURSE is to ensure

Operators have the appropriate knowledge and skills to perform their duties
and responsibilities in a safe, efficient, accurate and professional manner
thereby avoiding injury to self and others, damage to goods, property and the
environment and unnecessary costs to the community. This course is
Accredited by the Training Accreditation Council.

DEFINITIONS:
The introduction of the new Work Health and Safety Act and Regulations, 2011
have changed the definitions of:
Employer to Persons conducting business or undertaking
Employee to Worker.
OHS or OH&S to WHS (Work Health and Safety)

Use the terms interchangeably in this document.

Where ever possible, terms as per the WHS legislation have been applied.

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 Section 1

Legal Requirements
- Australian Standards 2359.2 1985 
- Work Health and Safety Act and Regulations, 2011 

Know your worksite

- WHS Personnel  
- Site emergency procedures 
- Site communication
- Four steps to managing hazards
- Equipment

Pedestrians and fork trucks

- Segregation of pedestrians

Operating near power lines

Know your workplace and identify potential hazards

Hazardous Loads

Power, Fuels and Refueling

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 Legal Requirements
AUSTRALIAN STANDARD 2359.2 - 1985

An Operator of a forklift must:

• Be a minimum of 18 years of age.

• Have no physical disabilities that would impair the safe operation of an
industrial truck or endanger the safety of others.
• Be specially trained in the operation of each industrial truck that will be used.
• Be sufficiently fluent in the use of the English language for communication
purposes.
• Conform to any relevant requirements of the statutory authority.
• Have adequate knowledge of the NOHSC:7019-1992 to allow
implementation of its requirements.

An Employer
Has a duty of care under the Australian Standards to ensure that only persons
who are qualified (as listed above) are authorised to operate industrial trucks.

Licence
Whenever operating an industrial truck, the operator shall either carry the
licence on his/her person or display the licence on the industrial truck.

Training of Operators
New operators, including those with previous experience, shall be instructed on
the following items for each type of industrial truck used:
 User's policies.
 Safety practices and rules.
 Operating conditions in all areas of operation, including any special or
hazardous conditions i.e. bumpy ground.
 Control positions and functions.
 Servicing, maintenance and repair responsibilities.

A Licence does not entitle the holder to automatically operate any machinery within that
category unless they have received the appropriate training in the safe use of that machinery
and have adequate supervision as required.

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 Legal Requirements
As an Operator of a forklift you are required to comply with the guidelines prescribed
by National Occupational Safety and Health Competency Standards for the
Operation of load shifting equipment and other types of specified equipment.

Work Safety and Health Act and Regulations, 2011

The main object of the Act is to provide a balanced and nationally consistent
framework to secure the health and safety of workers and workplaces.

Work Safety and Health

The law applies to you if you are:
 A person conducting business or undertaking
 A person is a worker if the person carries out work in any capacity for a
person conducting a business or undertaking. Including work as:
a) An employee; or
b) A contractor or subcontractor; or
c) An employee of a contractor; or
d) An employee of a labour hire company; or
e) An outworker; or
f) An apprentice or trainee; or
g) A student gaining work experience; or
h) A volunteer; or
i) A person of a prescribed class.

Duties of persons conducting business or undertaking

Section 19 WHS Act 2011

To ensure, as far as is reasonably practicable,

a) The provision and maintenance of a work environment without risks to
health and safety: and
b) The provision and maintenance of safe plant and structures; and
c) The provision and maintenance of safe systems of work; and
d) The safe use, handling and storage of plant, structures and substances;
and
e) The provision of adequate facilities for the welfare at work of workers
f) The provision of any information, training , instruction or supervision that
is necessary to protect all persons from risk
g) The health of workers and the conditions at the workplace are monitored
for the purpose of preventing illness or injury of workers

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 Persons conducting business or
undertaking (employer) must
provide:

 A safe work environment

 Maintenance systems in place
 A safe system of work
 Information, instruction/ training
 PPE and safety equipment
 Reporting and monitoring
mechanisms

Duties of workers
Section 28 WHS Act 2011

While at work, a worker must:

a) Take reasonable care for his or her own health and safety and:
b) Take reasonable care that his or her acts or omissions do not adversely
affect the health and safety of other persons: and
c) Comply, as far as the worker is reasonably able with any reasonable
instructions that is given by the person conducting business
d) Co-operate with any reasonable policy or procedure, relating to health or
safety at the workplace that has been notified to workers.

A worker must:
 Take care of themselves, firstly
 Follow safety instructions and
information, so you do not put
your fellow workers in
danger/harm
 Follow all instructions /
Take care of one’s self
information
 Co-operate with others in the
workplace

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 Know your Worksite

It is your responsibility to ensure that you have undertaken a site induction.

Ensure that you know who the WHS personnel are on your site, understanding
and abide by all WHS policies and procedures for Fire and Emergency, Safe
systems of work and undertake any duties as directed by WHS personnel.

WHS personnel may be, but not limited to:

 Managers ( i.e. Transport / Distribution / Production )
 Safety Officer
 Health and Safety Representative
 Site foreman
 Supervisors
 Team leaders
 Site Engineers
 Other nominated colleagues or managers who have been authorised to
take responsibility for the workplace or operations.

Workplace communication
Effective communication in the workplace is just as important as abiding by all
safety requirements. Ensure you are aware of the methods of communication
used in your workplace, especially if you work in an isolated area, extremes in
conditions, use machinery and equipment.

Communication in the workplace, is not only by verbal means, in your

workplace you will see many examples of
- Written instructions, information
- Signs (Signage)
- Opportunity ( required ) to listen to verbal instructions, information
- Opportunity to question instructions, information.
Examples of
 Written instructions, information:
Consignment notes, Standard Operating Procedures, Log books
 Signs:
Caution, Hazardous substances, Mandatory PPE required
 Listening:
Being attentive and listening to Tool box meetings, site WHS meetings,
general meetings
 Questioning:
Being involved in tool box meetings, information or instructional briefs,
and asking questions to confirm knowledge of new instructions or

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 requirements.

Workplace Emergency Information:

Do you know where the

- Muster point is
- Location of first aid facilities
- Who is a First aid officer
- Where fire extinguishers are, and how
to use them effectively

Ensure you have been inducted, and are aware

of the workplace protocols, that in the event of an
emergency, that you are able to:

- Alert personnel to the emergency

- Communicate the nature of the emergency
- Inform and advise personnel of unsafe areas, location of emergency
- Assist emergency personnel

During the course of an emergency, Emergency Services Personnel may take

command of the site/location, you are to ensure that you undertake all direction
and commands as issued by them, and ensure that all vehicles give way to
emergency services vehicles.

A HAZARD is defined as:

An object, condition or event that

has the Potential to cause
Injury or Loss

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The Four steps to Managing Hazards
Four steps should be taken to ensure a safe and healthy workplace. They are
based on the concept that the workplace should be modified to suit people and
not vice versa. The four steps are:

Identify
Identifying hazards, what are the hazards in a particular workplace?
Are they:

 Pedestrians and personnel  Dangerous / Hazardous

 Other plant and equipment materials / substances
 Vehicle traffic  Surrounding structures
 Electrical power lines  Non ground weight bearing
 Obstructions surfaces / pressures
 Lighting / illumination  Stress
 Overhead / underground services  Vibration
 Weather conditions

Assess
Assess the risk of each hazard. You must consider the Likelihood of the event
occurring and the Consequence of the harm, injury or ill health, costs to the
business, if the event does occur.
Risk assessment requires good judgment and awareness of potential risks of
work processes, you can only best estimate on the information available to you.
However you can use a systematic approach in order to assess a priority rate
for each hazard.

Control
Once you have identified the hazards in your workplace and analysed the level
of risk, the next step is to determine the control measures. In some instances a
combination of control measures may be appropriate.
Control measures should be designed to :
 Eliminate or reduce risks of hazardous work process’s and
 To minimise the effects or injury or disease
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 Hierarchy of Control

Always start at the top of the pyramid and work down.

Elimination Eliminate or remove the hazard

Substitution Substitute or replace a hazardous work practice or
substance, material.
Isolation Isolate or separating the hazard or hazardous work practice from
people not involved in the work or direct work area.
Engineering Controls Engineer out the hazard by incorporating guarding /
cages / grating or modification to machinery or equipment.
Administrative Controls Undertake additional training, implementation JHA’s,
signage, updates at tool box meetings (regularly)
Personal Protective Equipment Undertake the use of PPE.

Personal protective equipment (PPE) such as face mask, respirators, gloves,

goggles, lumbar supports etc, should be used in conjunction with other methods
of control and only used as a last resort when other control methods are not
practicable. When PPE is provided it must be suitable and properly maintained.
Personnel must be trained in the correct use, storage and maintenance of the
equipment.

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Monitor
Constant review of control measures is important to ensure they continue to
prevent or control exposure to hazards or hazardous work practices. Ensure
that the control measure undertaken has been effective and has not created an
additional hazard.

Identifying and managing hazards in the workplace, is everyone’s priority.

Ensure that you are aware of your organisational policies and procedures for
Identifying and Reporting Hazards in the workplace.

Equipment
Undertaking preoperational checks of equipment at the commencement of your
shift should take priority. Pre operational checks should be undertaken on all
mechanical / electrical equipment and noted in official “Log Books”, but it is also
the workers responsibility to inspect all Personal Protective Equipment (PPE) at
the commencement of a shift or task and report defects as per organisational
policies and procedures.

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 Operating near Electric/Power Lines
Western Australian, Occupational Health and Safety Regulations state:
Western Australian, Occupational Safety and
Health Regulations 1996

Regulation 3.64:

a) 0.5 metre of a live insulated overhead

power lines not more than 1,000 volts

b) 1.0 metre of uninsulated overhead

power lines of not more than 1,000 volts

c) 3.0 metres of either insulated or

uninsulated overhead power lines
exceeding 1,000 volts but not more than
33,000 volts.

d) 6.0 metres of either insulated or

uninsulated overhead power lines
exceeding 33,000 volts

Tiger tails – A warning device indicating the presence of overhead power lines.

If, you must work closer than the prescribed minimum distances, you will be
required to seek an exemption from the relevant authority ( i.e. Power company
ie Western Power) and or have the electrical power shut off. If this is not
possible the power lines must be insulated by an authorised/competent person.
Refer to relevant local authority.

Always contact the local power authority

ie Western Power, to determine the
voltage of overhead power lines, prior to
conducting any forklift operations.

Actions to take if your forklift truck comes in to contact with power lines?

 When possible, and without endangering yourself (operator), attempt to

break the forklifts contact with the power lines by moving the forklift clear
by lowering the forklift arms or moving the forklift mast. i.e. Reverse out

 If this is not possible to break contact, REMAIN in the forklift,

if safe to do so.

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  If it is unsafe to remain on the forklift, check that the ground around the
forklift is clear (of water or obstacles). If safe, jump clear of the forklift
without touching the metal parts of the forklift and the ground at the same
time. When moving away from the equipment, you should hop or shuffle
(with both feet together) until you are at least eight (8) meters from the
forklift, as the ground may be electrified. Under no circumstances, should
you run or walk from the forklift, as the ground may be electrified.

 Once safely away from the forklift, warn all other people to keep eight (8)
meters clear from the forklift, until the electricity supply has been isolated
and the site made safe.

 Follow site incident reporting procedure.

 Do not use the forklift until it has been checked.

Pedestrians and Forktrucks

Segregation of Pedestrians

Pedestrians should, where possible, be segregated from vehicle routes by a

physical barrier, otherwise pedestrian walkways should be clearly marked.
Where it is not possible to provide separate means of access and exit for
pedestrians, other arrangements, such as the use of audible or visual warning
devices, use of hi-visibility vests and defined walkways, should be made to
ensure their safety.

Pedestrians must give way to

Operators at all times.

Segregation/ Identification of pedestrian

methods may include, but not limited to:

 Barricades
 Safety Signs
 Flag Person
 Cones
 Use of hi-visibility vests
 Defined pathways
 Vehicle exclusion zones

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Damaged Pallets
Do not use damaged pallets, report as per organisational policies and
procedures, if in doubt ask your Supervisor.

PPE – Personal Protective Equipment

On some worksites you may need to wear
 Safety boots
 Hard hat/helmet
 Hearing protection
 Safety glasses/goggles
 Dust mask
 Gloves/overalls
 High visibility clothing
It is your responsibility to check, utilise (wear),
maintain all PPE, that is provided to you.
Follow organisational policies and procedures where maintenance or
replacement of equipment is required.

Permits
On some sites you may require a permit to undertake some activities, which
meet Quality Systems and Safety Standards of the organisation. If a permit is
required, it should be clearly identified prior to the task being undertaken and
the process should have been identified in the site induction process, or advised
by the supervisor concerned.

Forklift with flashing lights and reverse warning siren’s

Must comply with manufacturer’s guidelines and company policies and
procedures.

Environmental conditions
Environmental conditions may effect the way in which a vehicle is operated or
the operation of the vehicle. i.e cold/heat, dust, visibility. All operators are to
ensure that they are aware of and abide by all operational policies and
procedures when undertaking activities in different environmental conditions.

Signs
Black/White - Danger signs

Yellow/Black - Caution

Blue/White – Mandatory requirement

Green/White – Safety signs

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 Know your workplace and identify potential
hazards

As a forklift operator you should take the time to evaluate the area in which you
work. By doing so, you will familiarise yourself with potential hazards and
thereby reduce the risk of accident.

Potential Hazards - things to be aware of other than site hazards:

 Restricted height or width
 Uneven surfaces of different floors and slopes
 Blind corners or doorways
 Characteristics of load
 Confined/ limited access spaces
 Dangerous loads
 Pedestrians
 Traffic flows and directions of travel
 Noise
 Damaged or worn equipment
 Location of task
 Specifics of task
 Permits required for task
 Availability of equipment
 Capacity of forklift
 Working at night or in darkened areas

Safety starts with

YOU

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 Hazardous Loads

At various times an operator may encounter hazardous/dangerous loads. The

following are guidelines to your responsibilities and some examples of
HAZCHEM symbols.

• Before loads are moved they need to be identified to ensure safety

procedures are followed.

• Hazardous cargo must be identified using the appropriate labels (see Class
Labels) and moved according to the standard procedures required for
handling hazardous goods.

SEGREGATION
• If required to move various hazardous loads together or to be stored
together, be sure it is safe to do so. As it can be dangerous if certain
chemicals are stored together especially in the event of a spillage or an
accident when moving loads.

Refer to organisational policies and procedures for specific instructions or your

supervisor prior to undertaking any tasks. These tasks need to be undertaken
by qualified personnel.

CLASS LABELS TO BE UPDATED IN NEXT REVISION

Advised explosive, oxidizer and miscellaneous are incorrect. T Trim
Nov 2012

TOXIC

CLASS LABELS

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 Power, Fuels and Refuelling

Forklifts can be driven by 4 (four) types of power sources - they are:

• Petrol
• Diesel
• Liquid Petroleum Gas (L.P.G.)
• Battery (Electric)

BATTERY (ELECTRIC)

ONLY TRAINED AND AUTHORISED PERSONNEL MAY

TOP UP, RECHARGE OR CHANGE BATTERIES AND
WITHIN THE DESIGNATED AREA ONLY

Precaution is required to be undertaken when handling machine batteries.

When commencing activities, ensure that the vehicle is secured and the
isolator switch is turned off:

 Smoking or open flames are prohibited during charging/topping up

operations
 Charging/topping up must always take place in a well-ventilated area
 Protective clothing, safety gloves, apron, glasses MUST be worn.

Resources required to be contained in charging area:

 Eye wash station
 First aid kit
 Baking soda (Neutralizes acid spill)
 Fire fighting equipment

 Do not operate vehicle with a leaking battery.

 Batteries being charged produce Hydrogen gas, which
is highly explosive.
 The liquid within the battery is Sulfuric acid and is
highly corrosive.
 Contact with skin or eyes MUST be AVOIDED

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 Fuels and Refueling

PETROL AND DIESEL (Internal Combustion engines)

 Extreme caution must be taken as fuel spilling onto hot surfaces may ignite.
 Exhaust gases are very toxic. Operation of a machine in confined spaces
such as freight containers or cool rooms should be avoided.
 Fuelling to be in designated area i.e. outside.

LIQUID PETROLEUM GAS (L.P.G.)

 Gas is stored in a liquid form and under pressure and is highly explosive.
 The use of gloves for protection is essential as, in liquid form, the fuel will
cause severe cold burns.
 Because of its highly volatile nature, avoid gouging, denting or otherwise
damaging the cylinder surface as this will weaken the cylinder structure.
 Filling bottles for L.P.G. powered forklifts must only be carried out in
designated areas, by trained operations utilizing appropriate PPE.
 If a leak is suspected, close off the supply valve and inform the appropriate
person immediately.

ONLY TRAINED AND AUTHORISED PERSONNEL

MAY UNDERTAKE REFUELLING,
REFILLING OR CHANGING
OF GAS CYLINDERS

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 Section 2

Parts of the Forklift

Alternate Forklifts

Balance of a Forklift

Safe Working Loads (SWL)

- Capacity / Data Plate

Reading a load chart

Human Error

Instability
- Longitudinal
- Lateral

Attachments

Forklift platforms

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 Parts of a Forklift

Overhead Guard

Mast

Hydraulic lifting cylinders

Counterweight

Load
Backrest

Fork / Tine

Heel Front Wheels Foot Guard Rear wheels

1. Overhead Guard - prevents loads, items falling on to the operator

2. Counter weight - balances the forklift when loaded
3. Rear wheels - steer the forklift
4. Foot Guard - prevents operators foot from touching the tyres when
entering or alighting
5. Front wheels – activates the forward and reverse movement and
provides braking
6. Heel – the right angle of the tine
7. Fork / Tine - carries pallets / goods
8. Load Backrest- prevents load from falling on to mast and or operator
9. Hydraulic lifting cylinders - enables fork tines to lift the load
10. Mast – holds the load backrest/tines and enables the assembly to be
lifted vertically.

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 Alternate Forklift Trucks

1. Industrial counterbalanced fork

truck 4. Telescopic materials handler
2. Industrial Reach truck 5. Side loading lift truck
3. Rough terrain counterbalanced 6. Pedestrian controlled lift truck
fork truck

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 Balance of a Forklift

The fulcrum or pivot of a forklift runs along the front axle and all the lifting and
turning of the forklift is based on this point.

Load
Counter weight

Fulcrum

The load centre is the Centre of Gravity of the load you are carrying, and is
measured from the heel of the fork/tines to the centre of the load. This load
centre is crucial to the lifting capacity of the forklift.

Load centre of 600mm Load centre of 800mm

The capability of the forklift is greatly reduced, if the load centre of the object
being carried is further from the vertical face of the forks.

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 Safe Working Loads (S.W.L.)
By law every forklift must have a Compliance Plate affixed and legible
This may also be referred to as the Data Plate or Capacity Plate.

You MUST not operate a forklift, where the Compliance plate has been
removed or is obscured. Follow your organisational policies and procedures and
tag out the forklift and report to the appropriate person (i.e. Supervisor).

Sample Compliance Plate:

The first line shows the Safe Working Load (S.W.L.) with the mast fully elevated
and vertical – 1360 kg with the load centre being 600 mm or less.

How do you determine the weight of a load?

Determine the weight of the load by:

 Reviewing Consignment paperwork (Con Note)
 Checking load for packaging labels
 Estimating the weight, if similar loads previously loaded
 Refer to a supervisor for information
 Weigh the load

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 Reading a Load Chart

LOAD TABLE 1800 KG AT 600 MM LOAD CENTRE

4 meter lift

LOAD CENTRE LIFTING CAPACITY

mm inches kgs lbs
600 24 1800 4000
640 25 1690 3710
660 26 1640 3600
680 27 1590 3490
710 28 1520 3350
730 28 1480 3250
810 32 1330 2930
860 34 1260 2760
910 36 1190 2610
990 39 1090 2400

It is important to remember that

a forklift truck can safely lift its
recommended maximum load if
the centre of gravity of the load
does not extend beyond its
rated load centre.

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 Human Error

HUMAN ERROR
IS THE GREATEST CAUSE OF FORKLIFT ACCIDENTS

In the past thirteen (13) years approximately 2,400 people have been injured
(approx 200 per year) and eleven (11) have been killed in Western Australia in
forklift accidents.

DO NOT LET YOURSELF BECOME A STATISTIC

Forklifts don’t roll over on there own!!! They roll over due to driver error
combined with certain conditions –

Forklifts may tip sideways due to:

 Turning at speed
 Driving over uneven surfaces
 Uneven distributed load
 Driving with flat or under inflated tyre
 Turning with load raised
 Side shift not centered
 Operating incorrectly on a sloping surface

Forklifts may tip over frontwards or backwards-

 Load not positioned at heel of fork tine
 Shifting of the load centre forward
 Incorrect use to the mast tilt (especially if the load is being carried at a
high level)
 Overloading
 Driving to fast (loaded or unloaded)
 Driving over uneven surfaces

FORKLIFT ROLL OVER

Should you consider that the forklift is about to roll over:
• Do not attempt to jump clear
• Remain inside the cab area
• Brace yourself for the impact
• Seat belts and side restraints must be used

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 The most common cause for deaths with forklifts is when an Operator
attempts to jump clear and is crushed by either the overhead guard or the
mast assembly.

FACTORS CONTRIBUTING COMMON INJURIES

TO HUMAN ERROR
 Lack of training  Being struck by a moving forklift
 Inexperience  Forklift tipping over or overturning
 Poor judgment  Collision with stationary objects or other
 Not enough care vehicles
 Unfamiliar with workplace  Parts of the Operator’s body protruding
surroundings from the cab and striking an object
 Poor communication  Forklift losing its load
 Stress  Injury
 Distractions  Death
 Carelessness
 Unfamiliar with forklift characteristics
and safe working load
 Unnecessary rushing to complete a task.

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 Instability

Counterweight
A

X
CENTRE OF
X
GRAVITY

B C
Load Carriage

3 Point Suspension System

Stability Triangle

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 Instability
LONGITUDINAL
Some examples of causes:
• The load is too heavy
• Tilting a heavy load forward when lifting or in an elevated position
• Load is incorrectly placed i.e. too far along the forks.
• Harsh braking when carrying a load
• Uneven surfaces
• Incorrect direction of travel when on slopes
• Unsecured loads

LATERAL
Some examples of causes:
• Turning with the load raised
• Driving across slopes
• Driving on uneven surfaces
• Turning too sharply
• Driving too fast
• Operating with a flat tyre
• Driving into potholes or over obstructions
• Incorrect position of mast

For safe operation the vehicle manufacturer’s

specifications must be adhered to.

An Operator must avoid:

• Excessive engine revs
• Harsh braking
• Erratic steering
• Transmission abuse
• Aggressive use of levers and controls - hand and foot

Instability of a forklift may also be affected by the inflation level of the tyres.
Ensure the tyres are
 Filled to the correct operating pressure as per the manufactures
guidelines,
 For solid tyres, no pieces of rubber missing
 Outer sides of tyre not worn
 Wear is even
For optimum stability and operation.
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 Attachments
Fitting an attachment may alter the characteristics of the forklift and is likely to
reduce the capacity of the forklift. This is called Derating. Fitting of attachments,
should only be carried out by a forklift engineer or authorised person. It may be
necessary to use a forklift with a larger capacity. Wherever possible the
manufacturer or authorised supplier should be consulted regarding suitability of
the attachment for the forklift and the necessary derating.

At the start of each shift, the security of any attachment should be checked and
any defects must be reported immediately. If defects are found, do not use the
forklift until defects are rectified, report as per organisational polices and
procedures.

A wide range of removable attachments are available for use with forklifts.
Shown below are some examples of the more common ones currently in use
though no description is made of more specialised attachments used with
telescopic materials handlers such as bale grabs and silage forks.

Side Shift Carriage

 May be mounted either on existing fork carriage or
in place of it.
 Enables horizontal sideways movement of the fork
arms to allow precise positioning.

Rotator and Clamp

 This is mounted on the fork carriage and usually
used in conjunction with another attachment
 Allows load to be rotated vertically about an axis
parallel to the longitudinal axis of the forklift
 Some rotators can tilt the load forward from the
vertical to the horizontal and beyond - known as
“tipplers”

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 Attachments

Fork Positioner
 Hydraulically operated
 Allows operator, whilst remaining in the operating
position, to change the position of the fork arms
relative to each other.
 The fork arm centres can be adjusted to
accommodate different load widths.

Clamps
 These attachments are designed for a variety of purposes such as lifting
reels, drums or bales.
 May be used in conjunction with a rotator.
 May be faced with rubber or other material to improve the grip.

Self Dumping Hoppers

 Usually carried on fork arms.
 Fitted with a mechanism which causes the
hopper to roll forward and discharge the
contents.
 Once empty the hopper returns to its normal
position and re-engages the holding
mechanism.

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 Attachments

Crane Jib

 May be mounted directly on

the fork carriage on the fork
arms
 May be of a fixed length or
extendible or embody a
number of lifting points.
 It is possible to vary the end
of the jib from horizontal.
 Fitting of this attachment is
subject to additional
requirements covering the
test and examination of cranes.

Booms / Carpet spikes

 These attachments usually consist of a circular section pole mounted on the
fork carriage
 They come in a variety of diameters and lengths
 Designed for lifting rolls of carpet, coils of wire or similar cylindrical loads.

Working Platforms
 Working platforms must not
be used for order picking.
 In order to prevent inadvertent
operation, the operator of the
forklift should lock out the tilt
mechanism when the machine
is being used as a work
platform.
 Suitable means of
communication i.e. two-way
radio between the forklift
operator and the person on
the platform. When manual
signals are being used, clear
and unambiguous signals
should be agreed before
commencement of work.

All Attachments must have a Capacity plate.

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 Section 3

Operational

Pre-Start Checks

After Start Checks

Shutdown and Parking

Breakdown or Accident Procedures

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 Operational
Pre-operational checks are generally undertaken by an authorised operator at the
commencement of their shift.

These may include, but not limited too:

Prior to commencing Pre start Check ensure:

 Hand brake applied
 Transmission in neutral
 Check log book for previous entry in case of defects
 Capacity plate fitted and legible.

Structural checks:
Check forklift for cracks, damage and distortion
 Mast assembly
 Backrest
 Chains – tension, greased
 Overhead guard
 Seating area
 Tyres – wear, damage, pressure, wheel nuts.

Fluid levels: No Fluid Leaks:

 Engine  Oil
 Transmission  Water
 Hydraulic reservoir  Fuel
 Radiator  Hydraulic
 Brakes  Battery
 Fuel  Brake
 Battery

Accessories:
 Lights, indicators working
 Horn
 Warning devices
 Attachments secure
 Gas bottle or battery pack secure
 Operator restraint if fitted
 Battery charger switched off and charge leads disconnected
 Fire extinguisher – if fitted, the operator must be competent in its use

If any defects are identified, complete

the pre-operational check with details and
follow organisational policies and procedures
for tagging out of equipment and reporting.

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 Post Starting Checks

After starting (post starting) checks:

 Engine running smoothly

 Brake operation – hand and foot
 All gauges functional
 All lights and warning devices functional
 Lifting, tilting and manipulation systems
 Transmission – forward and reverse
 Steering and travel.

If any defects are identified, complete the operational checklist with details and
follow organisational policies and procedures for tagging out of equipment and
reporting.

Forklift operators and other staff members are only able to conduct
maintenance on equipment if they are competent and authorised to do so.

ALL OPERATIONAL CHECKS MUST BE IN COMPLIANCE WITH

MANUFACTURERS SPECIFICATIONS
COMPANY POLICIES AND PROCEDURES

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 Prestart Checklist
OPERATOR……………………………………………FORKLIFT No…………….

DATE………………………………………………….. SHIFT………………………

EXPLAIN BELOW IF NOT OK OR

CHECKS OK
ANY ACTION TO BE TAKEN
1. Visual Checks

1.1 Front of forklift

 no leaks and obstructions (ie

timber, wire etc., under the forklift)
 forklift is not leaning because of a
flat tyre or dips etc.,.
 condition & security of
forks/attachments
 mast for any damage
 load backrest
 hydraulic hoses/couplings
 chains
 no obstruction in mast area.

1.2 Right side of forklift

 right front tyre & wheel

 tyre pressure
 wheel nuts
 general condition
 body damage
 safety cage
 right hand rear steer wheel
 hydraulic steering for leaks/damage

1.3 Rear of forklift

 radiator/exhaust not covered with

flammable material
 body damage/conditions
 towing pin is secure

1.4 Left side of the forklift

 left hand rear steer wheel

 left hand front wheel & tyre
 hydraulic steering leaks/damage
 turn on gas bottle (if fitted)
 check gas line for leaks/fitting gas
level.

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 Prestart Checklist
EXPLAIN BELOW IF NOT OK OR
CHECKS OK
ANY ACTION TO BE TAKEN
1.5 Engine compartment

 oil & water level

 fan belt
 leaks/damage/obstructions
 battery (water level, loose
connections)

1.6 Drivers compartment

 free of obstacles
 adjust seat etc., for driver comfort
 check manufacturers dataplate for
load, rating mast extension etc.,
 seat belt operational

2. Operational checks

 gauges/warning lights
 lights (if fitted)
 revolving warning light (if fitted)
 brake lights
 horn
 indicators (if fitted)
 controls
 park brakes
 transmission
 steering & footbrake

Remarks or additional explanation or suggestions.

…………………………………………………………………………………………

…………………………………………………………………………………………

…………………………………………………………………………………………

…………………………………………………………………………………………

Operators signature……………………………………………...........………….

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 Shutdown and Parking Procedure
Where applicable, park in designated area.

Park on level ground and ensure that the forklift has not blocked:
 Emergency exits
 Fire hoses
 Emergency equipment
 First aid stations
 Public access/doorways
Or
 On sloping surfaces
 Where if may obstruct other traffic
 No closer than two meters from the nearest rail of a rail
track.

Parking procedure -
 Apply main park brake securing system i.e. hand brake / park brake
 Gears in neutral
 Fork tines are lowered and flat on the ground
 Switch off motor or turn off gas valve, if LPG
 Remove key - return to allocated location or person
 Follow any other site specific procedures.

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 Breakdown or Accident Procedures / Defects
APPLY MAIN BRAKE -
If it has failed, chock the wheels.

The following may vary slightly dependent on the type of forklift being driven.
The manufacturer’s manual together with company policies and procedures
must be consulted.

In a breakdown or accident situation, the operator shall ensure:

• Gears in neutral
• Turn the forklift off and remove key
• If a load is in an elevated position it must be returned to ground level, unless
the breakdown / defect will not allow. In this case, the Operator must make
the area safe from further accident or damage through one or more of the
following:
 Have a responsible person on duty to warn others
 Place clearly visible warning signs
 Erect barriers

• Place an OUT OF SERVICE tag / sign on the forklift

• Report to a supervisor and fill in logbook as required.

Out of Service Tag can

only be removed by
Authorised Personnel and
only after repairs have
been affected.

Authorised Personnel :
may be the
Technician/Mechanic who
repaired the equipment or
Supervisor who has
confirmed repairs.

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 Section 4

Basic operating procedures

Loading and Stacking

Rear End Swing

Counterbalanced Forklifts
• Stacking
• De-stacking

Inclines and Declines

Uneven / wet / slippery surfaces

High Loads

The use of a bridge plate

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 Basic operating procedures
Basic operating procedures –
Prior to moving / shifting a load, an operator shall:

 Ensure preoperational check on machine has been undertaken

 Load has been identified
- Load structure
- Load stability
- Destination of load determined, path of travel has been identified and
obstacles identified (if any)

Prior to moving out, the operator shall:

1. Check behind using mirrors/and or looking over both shoulders to ensure
it is safe to move out.
2. Ensure all warning devices are operational
3. If the load is obscuring the vision of the operator, employ the services of
a responsible person to assist.
4. The operator shall ensure that during the movement of the goods, that
the fork tines are kept at a safe travelling height. Ideally the safe
travelling height is axle height or as low as the operating surface, will
allow.

During the course of travel, the operator shall,

 Constantly be checking (visually) the load for signs of instability
 Maintain correct driving practices (speed, traffic management principles)
 Vigilant for pedestrians and or other vehicles
 Not carry additional personnel on the forklift, unless designed to do so,
 Not raise or lower a load in or around pedestrians

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 Loading and Stacking

CORRECT POSITION OF FORKS INCORRECT POSITION OF FORKS

 Side shift - most common cause of incorrect position of forks whilst

operating.

Forks must be returned to centre of carriage before next lift.

 Where the load is secure, but is packed toward one side. That side (heavy
side) must be loaded toward the load carriage of the forklift.

 Once loaded, tilt mast back

 The use of only one fork is illegal and the

fork will become overstressed, compromising
the stability of the forklift.

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 Read End Swing
The steering of a forklift is specially designed to maneuver within restricted
areas. Operators must make themselves aware of their surroundings before
reversing or making a turn, particularly in narrow aisles.

The turning angle is as seen below, pivoting on either left or right wheel

X Pivot point of
forklift

The acute angle of turn swings the rear of the forklift very quickly and could
cause damage or injury if the operator is not attentive to the surroundings.

It is estimated that the rear end swing is three times the speed of the forward
movement of the forklift.

Example Forward movement = 10kph Rear end swing = 30kph

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 Counterbalanced Forklifts

When stacking loads in to racking, or on top of other pallets, you must ensure:

1. That the load to be stacked on, is firm and level.

2. If the load is uneven, restack to ensure evenness and stability
3. Heavier pallets are stacked at the bottom of the stack, and not in the
middle or top.
4. Adhere to workplace procedures with regard to load labeling
requirements.

STACKING

Step 1
 Approach the stack with the load low
and tilted backwards.

Step 2
 Slow down and stop at the face of
the stack.
 Apply the park brake.
 Reduce backward tilt to just sufficient
to stabilise the load.
 Look up and check for obstructions.
 Raise the load to the stacking height.

Step 3
 When the load is clear of the top of
the stack, move slowly forwards.
 Take care not to dislodge loads in
adjacent stacks.

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 Counterbalanced Forklifts

Step 4
 When the load is over the stack, stop.
 Apply park brake.
 Bring mast to vertical position.
 Carefully lower the load onto the stack.

Step 5
 When the load is securely stacked,
lower fork arms until free of pallet or
dunnage strips.
 Look behind to check all is clear.
 Reverse watching front and rear.
 Slight forward tilt of fork arms may be of
assistance.

Step 6
 When clear of stack apply park brake.
 Tilt fork arms backwards.
 Lower to just above ground level.
 Check if direction of travel is clear
before moving.

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 Counterbalanced Forklifts

DESTACKING

Step 1
 Halt at face of stack
 Apply park handbrake
 Bring mast to vertical position
 If necessary, adjust for spread to suit the
width of load
 Ensure weight of load is within capacity of
the forklift.

Step 2
 Look upwards
 Raise fork arms to a position permitting
clear entry into pallet or dunnage strips.

Step 3
 Fully insert fork arms by slowly driving
forward until load guard gently touches load
or pallet base.
 Apply park brake.

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 Counterbalanced Forklifts

Step 4
 Lift load clear of stack.
 Carefully apply backward tilt
sufficient to stabilise load.

Step 5
 When load is clear of the top of the
stack, check that direction of travel is
clear.
 Move slowly backwards until load
and fork arms are clear of stack.
 Take care not to dislodge loads on
adjacent stacks.
 Apply park brake.

Step 6
 Carefully lower load to correct
traveling position applying further
backward tilt.
 Check if direction of travel is clear
before moving.

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 Inclines and Declines
NEVER TRAVEL SIDEWAYS

As the angle of the forklift and its load may

exceed the centre of gravity point as explained
on page 18 and cause the forklift to roll over,
or the load to shift.

Never travel downhill with a load as it may become

dislodged, fall off or destablise the forklift.

Centre of gravity

On a decline:

 Travel in reverse with mast tilted back.

 this will ensure a secure load and clear

vision

On an incline:
 Travel forward with mast tilted back.
 this will ensure a secure load and clear
vision.

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 Uneven / Wet / Slippery Surfaces

When working (driving over) uneven, wet or slippery surfaces ensure to

 Reduce speed
 Proceed with caution

High Loads

Where a load exceeds the height of the load backrest:

 Ensure it is secure and will not fall onto the driver.

 If the height is such that the driver’s vision is obscured, employ the
services of a responsible person to assist.

 This person must position him/herself so as to be clearly visible to the

driver for directional purposes and to provide warning to others.

 Or where practical, drive in reverse.

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 The use of a Bridge Plate
As the name implies, the bridge plate is used to bridge the gap between two
platforms or surfaces for load purposes.

The example below shows the use between a semi-trailer bed and a loading
dock.

An operator must:

 Always use a bridge plate

where movement may
occur between loading
surfaces
 Ensure bridge plate
complies with safe
working regulations
 Ensure the bridge plate is
anchored securely and
free of oil or grease.

DO NOT ALLOW PEOPLE TO WALK UNDER THE BRIDGE PLATE

ALWAYS DRIVE SLOWLY

LOADING RAMP
 Ensure the braking system for
securing the semi – trailer has
been applied.
 Wheel chocks may also be
used to further secure the trailer
 Always chock wheels in case
the braking system is faulty or
has not been applied i.e. worn
handbrake or truck driver error
 A ramp of this type must be
secured to the trailer by chains.

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 Section 5

Calculations
 Pallet weight
 Load capacity
 Load chart

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 Pallet Weight Calculations

Five (5) layers on a pallet

Four (4) boxes to a layer

Pallet

 Each box weighs 10kg

 Four (4) boxes per layer
 Five (5) layers per pallet
 Pallet weight is 12kg

Total of boxes and pallet = 212kg

Show all calculations:

Boxes = 4 x 5 x 10kg = 200kg Weight of the Boxes 200kg

4 x 5 = 20,
20 x 10kg = 200kg

Boxes plus the pallet

200kg + 12kg = 212kg

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Calculations

Question1:

The load to be moved is cartons, stacked on a pallet

 Four (4) layers high

 Six (6) cartons to a layer
 Each carton weights 15 kg
 Standard pallet size, weight 15kg

What is the combined weight of the pallet to be moved? __________kg

Show all calculations:

Question 2:

The load to be moved are bags of flour, which are stacked

on a pallet.

 82 bags on a pallet
 Each bag is 20 kg
 The pallet is a standard size and weighs 35kg.

What is the total weight of the bags on the pallet. __________kg

Show all calculations:

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Question 3:

The load to be moved is drums stacked on a pallet:

 Four drums on the pallet

 Each drum is 220kg
 Standard size pallet weighing 40kg

What is the combined weight of the drums and pallet? __________kg

Show all calculations:

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 Load Capacity

The forktrucks in the above diagram are rated at 5000kg at 600mm load centre.

Which of the loads are withing the capacity of the forktruck?

Circle: A B C

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 Load Chart Calculations

Using the Load Chart LF

Question 1

Identify the maximum fork height of the mast. _________________mm

Question 2

What is the maximum WLL the fork can lift with the mast tilted at
3 degrees. ___________________

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 Appendix

Pallet weight calculations

Answer 1
375kg

Answer 2
1675kg

Answer 3
920kg

Load Capacity:
Answer C

Load chart calculations

Answer 1
3708mm

Answer 2
1636

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