forklift-training-manualv54 compress

FORKLIFT
TRAINING
MANUAL
TLILIC0003
Licence to operate a
forklift truck
START TRAINING GROUP
🕿
(03) 9756 0244
🖳
[email protected]
LF Forklift Training Manual Sep 2024 v5.4
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INTRODUCTION
To drive a forklift truck in Australia you must hold a National Forklift Licence. This manual has been
produced by Start Training Group to assist you in gaining your Forklift Licence.
● All applicants must be 18 years of age or over.
● Current Photo Identification (Driver's Licence, passport, Key Pass) is required at time of testing.
If there is anything in this manual that you do not understand please feel free to contact our student
welfare officer on:
Ph: (03) 9756 0244 or
Email: [email protected]
Refund Policy
Please note that 5 full business days’ notice is required for any cancellations or rebooking.
● If at least 5 days’ notice is given, then a full refund will apply.
● If less than 5 days’ notice is given, then the deposit paid is not refundable and the full cost of the
course may apply.
Please refer to the Student handbook for further information related to Start Training’s policies and
procedures.
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Table of Contents
Legislative requirements for High Risk Work (HRW)
7
Element 1 - Plan Work / Task
11
Before work can begin
13
What hazards are in the area
14
Hazard prevention and control
21
Communication
24
Element 2 - Prepare for work / task
28
Principal forklift parts
30
Daily inspection checklist
33
Starting your forklift
34
Element 3 - Perform work / task
45
Determining load weight
47
Load centre distance
49
Hazard control
52
Forklift dynamics
54
Operating a forklift
57
Emergency situations and procedures
70
Element 4 – Pack up
73
Parking the forklift
75
Shutting down the forklift
76
Securing the forklift
77
Reporting and recording faults
77
Appendix A
81
Appendix B
85
Appendix C
87
Appendix D
89
Appendix E
93
Appendix F
97
Appendix G
101
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Legislative requirements for High
Risk Work (HRW)
Legislative requirements for High Risk Work (HRW) licence applicants.
When can I drive a forklift?
To drive a forklift in Australia you need to have a forklift (LF) endorsed HRW (High
Risk Work) Licence issued by WorkSafe. This is a nationally recognized and will allow
you to drive a forklift in all states and territories in Australia.
How we safely operate the Forklift is controlled by several legal documents. Sources of workplace
safety information are:
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Legislation and regulations
Relevant Australian standards
Management plans
Noticeboards
Signage
Manufacturer’s instructions
Operations manual
OHS workplace representative
Site policies and procedures
When inspecting a new work environment, you might look for:
F
I
R
S
T
Fire fighting and first aid equipment
Information about job
Risk control measures; signage, barricades, exclusion zones
Suitable racking
Traffic management plan
You are a new HRW Forklift licence holder what does your employer have to provide before you can
start work with an unfamiliar forklift?
S
I
T
Supervision
Instruction / Information
Training
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Legislative requirements for High Risk Work (HRW) licence applicants.
Responsibilities of a HRW licence holder.
As a worker you have a “duty of care”. What does that involve?
While at work, an employee must look after the health and safety of themselves
and others.
This is achieved by the following:
● You must follow site policies and procedures
● You must not misuse anything provided in the workplace; like the forklift
Failure to do so could result in you being penalized under the WHS regulations. This may result in:
● Your licence being suspended
● Your licence being cancelled
● The regulator (WorkSafe) may refuse to renew the licence.
● You may be directed to obtain a reassessment to determine competency.
● prosecute
Responsibilities of your employer
To ensure the health and safety of workers, an employer must undertake the following actions:
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To provide a risk-free work environment
To provide safe, well-maintained forklifts
To provide safe site policies and procedures
Provide adequate facilities, e.g.: toilets, lunchroom
Ensure the safe use, handling and storage of plant, structures and materials
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Element 1 - Plan Work / Task
Planning - Before work can begin
Before work can begin
Before we can begin any forklift work, we need to understand several things that are not workplace
hazards: ●
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How much weight can I put in the racking? Is the racking suitable?
Are there any site procedures or company policies that I need to follow?
What is the availability of the forklift?
What is the nature of the load? How much does it weigh?
What type / capacity of the forklift and attachments do I need?
What is the method of attachment for the attachments?
Where are the emergency exits, first aid equipment and firefighting
equipment?
What hazards are in the area I am going to work in like?
How do I control those hazards?
Do I need to speak with any relevant site personnel?
How am I going to communicate in the workplace?
A good way to remember this is by thinking of the words FIRST CLASS:
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F
I
R
S
T
Firefighting and first aid equipment
Information about job
Risk control measures; signage, barricades, exclusion zones
Suitable racking
Traffic management plan
●
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C
L
A
S
S
Communication methods
Location of the task
Available forklifts
Specifics of the task
Site inspection
Some extra considerations:
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Characteristics of the load
Capacity of the forklift
Attachments required
Route of travel
Characteristics of the load
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Planning – What is the task I am going to do?
The first thing we need to understand is what type of work am I going to do: ●
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Will it be indoors or outdoors?
Will it be a concrete or dirt surface?
How big are the loads?
Am I loading into racking or onto a truck or something else?
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
Planning – What hazards are in the area I am going to work
What hazards are in the area
What is a hazard?
A hazard is anything or any situation that may cause injury or harm. In other words, it is ‘anything’ or
any action that can hurt or injure you or anyone around you.
What is a Risk?
A risk is the chance of a hazard hurting someone.
Under our ‘Duty of Care” we have a responsibility to act in a safe manner for ourselves and anyone
around or near us. (See Appendix D for more information)
Who in your workplace could you ask about workplace hazards?
Who:
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Supervisor
Safety officer
Other workers
Workplace Engineers (where applicable)
Managers who are authorised to take responsibility for
the workplace operations.
● Health and safety representatives
● Work Health and Safety Committee members
Why do we need to ask about workplace hazards?
● To understand any workplace policies and / or site-specific procedures
● To identify and be aware of any workplace specific hazards / ground conditions
● To identify hazards and controls
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Planning - What hazards are in the area I am going to work
The most common types of hazards we will encounter in most workplaces are:
UP HIGH
-
Roller door clearances
Electric lines
-
Overhead service lines
Wind and bad weather conditions
EYE LEVEL
-
Pedestrians
Dangerous materials
Buildings
Vehicle traffic
Blind corners
Poorly lit areas
-
Plant and equipment
Obstructions
Surrounding structures
Access and Exit points
Other equipment
Confined spaces
Stock protruding from racking
DOWN LOW
-
Underground services
- Spills
Debris
- Weight bearing ability
Slopes
- Loading dock edges
Surface condition: - (wet, concrete, dirt, bitumen, ice, backfilled
ground, railway tracks.)
OTHER
-
Environmental – (Extreme weather, wind, lightning, extreme heat,
UV exposure)
Pressure washers
chainsaws
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Planning - What hazards are in the area I am going to work
Hazardous work practices
Not all hazards are environmental. We or other workers in the area sometimes cause them. These
kinds of hazards may need to be reported or controlled.
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Working in inadequate light
Stock badly stacked
Driving equipment to fast
Smoking near refueling stations
Not using pedestrian walkways
Not wearing protective clothing
Hazards not barricaded off or contained
Using petrol, gas or diesel equipment in poorly ventilated areas.
Work area operating surface is not assessed to determine suitability for
operational use of forklift truck in accordance with workplace procedures
If you feel the area is unsafe to work in DO NOT START WORK.
Report the situation to your supervisor or manager.
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Planning - What hazards are in the area I am going to work
‘What is Rear End Swing’
Many accidents in the warehouse can be attributed to Forklift ‘rear end swing’ or ‘tail swing’. It is the
action of the rear wheels of the forklift truck swing outside the line of the front wheels whilst turning.
The rear end swinging fast has a higher chance of colliding with any surrounding structures,
equipment or pedestrians in the area.
If full lock is used when turning a Forklift truck, you should remember that the rear of the machine
could hit someone or something. If you are travelling at 3kph then the rear of the machine will swing
at 10kmh. Note that on order pickers and reach forklifts the rear wheels are nearly in the middle of
the machine so that ‘front end swing’ is nearly as fast and dangerous as ‘rear end wing”.
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Planning - What hazards are in the area I am going to work
Poor Ventilation
As many Forklift Trucks are petrol, gas or diesel powered you need to understand
that if you are working in an area with restricted airflow then you may be overcome
by the exhaust fumes. This can be fatal. This means you can die from breathing in
toxic fumes!
The following areas would be considered as a having restricted airflow areas and an electric forklift
should be used:
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A freezer
A cold storage room
A container
A shed
A storeroom
Any other small area
Weather
We need to obtain a weather forecast when planning the days operation?
● To help plan the work environment
● To help plan suitable risk control measures
● Helps to schedule work activities
Weather hazards that could affect forklift operations.
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Wet and slippery conditions
Heat and sun exposure
Strong winds
Smoke
Snow or ice
Limited visibility
Extreme heat
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Planning - What hazards are in the area I am going to work
Power line clearances
As Forklift Trucks often work outside near electric lines, WorkSafe requires you to know the legal
requirements for working around electric lines. In Victoria, the regulations state that you must use
a qualified spotter to work within the following distance:
● Power Poles – 3m up to 6.4m away with a qualified spotter. Outside 6.4m no spotter is required.
● Power Towers – 8m up to 10m away with a qualified spotter. Outside 10m no spotter is required.
Power Poles (Distribution)
Towers (Transmission)
In other States these clearances may change. If working interstate, you need to check these
clearances with the relevant authority.
Qualified Spotters
Qualified Spotters for overhead electrical lines will have completed an electrical spotter training
course by a registered training provider and be competent in the following areas:
●
the operation and uses of the equipment/plant being used
●
the hazards posed by overhead electrical assets.
The qualified spotter must also carefully position themselves so they can monitor the distance
between the equipment and the lines, and must provide early and effective warning to the
equipment operator of any potential encroachment on the No Go Zone.
Electric line voltages
To determine the voltage of electric lines in your work vicinity you need to
contact the local power authority for advice.
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Planning - What hazards are in the area I am going to work
In Victoria there are several things used as a visual system to warn people about power lines.
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Tiger Tails’
Safety warning / danger signs
Power line marker balls
Markers of different colours
Painting the lower section of the pole
If you come into contact with electric lines you need to:
1. Warn others to stay away
2. Try to break contact with the power lines
3. If safe to do so stay on the forklift. If unsafe you must leave the machine, jump clear
ensuring you don’t have contact with the vehicle and the ground at the same time, landing
with your feet together and then continue to jump or shuffle with your feet together until
you are at least 8 metres clear of the vehicle.
4. Repot to management, power company and safety regulator.
5. Do not use the forklift until it has been checked by a technician.
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Planning - Hazard prevention and control
Hazard prevention and control
Once you have identified hazards in your workplace you need to decide how to deal with them before
you start work. In some cases, it might be as simple as clean up the mess or move the hazard.
In other cases, though you may need to consult with and report the hazard to:
● Safety officer
● Workplace Engineers
(where applicable)
● Supervisor
● Other workers
● Managers who are
authorised to take
responsibility for the
workplace operations
Hierarchy of Hazard Control
The reason for this is so that
you understand any
workplace policies and/or
site-specific procedures that need to be adhered to so that the correct hazard controls will be used.
Once consultation with workplace person/s is established and maintained, use a clear workplan
consistent with site requirements in accordance with safe work procedures.
Depending on your workplace you may have to fill out paperwork to show how you will control
hazards. This may include:
● Job Safety Analysis (JSA)
● Safe Work Method Statement (SWMS)
● Or other paperwork.
Regardless of what paperwork needs to be done hazard control methods must be put into place
before you start work to prevent injury/harm to personnel or damage to equipment and/or property.
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Planning - Hazard control measures
In the workplace for pedestrian, other workers, vehicles or mobile plant safety are:
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Warning signs
Barricades
Pedestrian exclusion zones
Vehicle exclusion zones
Traffic management plan
Flashing hazard lights
Flag person
Travel Route / Path of Movement
It is important to inspect your work area for potential hazards and decide on the safest path to take
when moving your load and operating the forklift truck. In many workplaces they may already have a
Traffic Management Plan in place to control how traffic moves in the warehouse or work area
Traffic management plans will include:
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Work areas are assessed and managed in accordance with workplace procedures.
What hazards are present? (People, stock on the floor etc.)
Where will you have to stop/ relocate the load to?
Where should you slow down?
Where should you sound the horn?
Will you need to reverse?
Is ventilation adequate?
Is there adequate lighting?
What is a safe speed?
Is the ground surface suitable?
What hazard control measures need to be implemented and maintained in according to
workplace procedures
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Planning - Hazard control measures
Effective traffic management
Whilst operating the forklift truck it is important to reduce the risks to people working around you.
So, you will need to let people know you are working in the area and control their movements. This
can be done by:
● Posting signs
● Erecting barriers / barricades
● Using a flag person to control the flow of traffic.
Insufficient lighting
If you are working at night in a darkened area such as:
● A storeroom
● A container
● Or other dimly lit areas
You are required to obtain adequate lighting across the entire
area, enough for the forklift to safely conduct its operations.
If you find a hazard in your work area that you cannot control you need to report it immediately to a
supervisor (relevant person/s in accordance with workplace procedures).
Note: - All risk control measures need to be in place and reported before commencing work or as
soon as a hazard is identified whilst working (accordance with workplace procedures).
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Planning - Communication
Communication
In every workplace communication is very important in working safely and effectively. Your workplace
may have a communication procedure in place.
There are several ways in which people may communicate with you or other site personnel. They
may include:
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Eye contact
Verbal (listening and asking questions)
Written instructions (such as JSA’s or operating procedures)
Signage
Appropriate worksite protocols
Warning devices
Two-way radio
Prestart meeting
Hand signals
If you are given a signal by a co-worker and it is unclear or communication stops, what should you
do?
● Stop and ask for clarification of the signal
Planning - Forklift Capacities
Once we have decided what type of forklift is right for the task, we must determine that is has the
right capacity / capability to perform the task required. To decide this, we must understand what the
Data Plate on every forklift tells us.
Data Plate
The data plate is usually located beside the driver’s seat or on the
dashboard, where it can easily be read by the driver whilst operating the
machine.
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Planning - Forklift Capacities
All forklift trucks in Australia are required by law to have a legible data plate attached to the machine.
This is so that the operator can easily and quickly determine the load capacity of the machine they are
about to operate. If the forklift does not have a data plate, or is unreadable, do not use it.
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Stop, do not operate the forklift
Tag out of service
Isolate – take the key
Record in the forklifts’ logbook
Report to your supervisor
The Data Plate gives us numerous important facts about the machine. It tells us the machines rated
capacity. This means:
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The maximum load that can be carried
To what height can that load be carried and/or lifted and,
At what load center distance as shown on the data plate (load chart).
How much mast forward tilt can be used
It may also tell us other information such as:
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What attachments can be used
Tyre pressure
Weight of the machine
Weight of the battery
The model and year of manufacture of the machine
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Planning - Forklift Capacities
Load Centre Distance
To properly understand what the data plate is saying regarding the machines lifting capacity we must
understand the concept of ‘Load Centre Distance’.
Load Centre Distance is defined as “The distance measured from the vertical face of the forks to the
load’s centre of gravity.” Some forklift data plates may also have a load centre distance for height,
which is the distance measured from the bottom of the load to the load’s centre of gravity.
All forklift trucks in Australia are re-rated at a 600mm Load Centre when they are imported into
Australia because the standard size pallet used throughout Australia is based on a ‘chep’ pallet. They
are approximately 1200mm x 1200mm in size thus having a load center distance of 600mm.
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Planning - Forklift Capacities
Load Centre Distance (continued)
Most palletized loads are square and evenly stacked in which case the load center will be in the center
of the load.
Therefore, if the load is picked up hard against the vertical face of the forks, the Load Centre distance
will be half the length of the load. (This is 600mm in the case of a ‘chep’ pallet).
But, if the load is unusually shaped, has been stacked heavier at the front than the back or
the pallet is not hard up against the vertical face of the forks then the loads center of gravity will be
moved forward thus increasing the load center distance which may
● reduce the forklifts capacity.
● or affect the stability of the forklift
If your forklift is rated at 3,000kg at 600mm load centre, which of the following loads can be lifted
safely?
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Element 2 - Prepare for work /
task
Forklift Parts
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Principal forklift parts
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Forklift Parts
Principal forklift parts continued
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Principal Forklift Parts
Forklift truck safety guards
There are three safety guards on the forklift truck to protect you.
Overhead guard
Protects the
operator from
falling objects
Load guard / Backrest
Stops the load from
hitting the mast and
protects the driver
Foot guard
Protects the
operator’s feet
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Daily inspections
Daily inspection checklist
As an operator you will be required to check / accesses the forklift for safe operation prior to use in
accordance with manufacturers requirements and workplace procedures.
Before use complete a daily check sheet to record any faults that you may find and read the forklift
operators manual.
Daily check sheets allow you to:
● Record defects
● Record routine maintenance
● Record any other work that needs to be done.
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Daily inspections
For your safety it is important to make sure the forklift is in proper working condition and safe to use
before attempting to use it. There are two checks that must be done. They are:
1. Pre-Start checks (Visual walk around and fluids check)
2. Start-up checks (Once on the forklift)
Details of what operational checks can be found in the:
● Operators Manual
● Manufacturers Handbook
Starting your forklift
Pre-start checks
Before starting your Forklift, it is important to walk around the machine and do a visual check. Things
you should check are:
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Forks are not damaged or cracked
Mast and Hydraulics are not damaged or leaking
All guards (load guard/backrest, foot guard and overhead guard)
Tyres /wheels are ok
Seat / seatbelt are not damaged
The data plate is attached and readable
Battery not leaking or damaged
No Danger / out of order tag is attached
There are no leaks
The operator’s manual and logbook are available for the correct forklift
Fluids (oils and water)
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Daily inspections
If during your visual check you notice any major faults such as hydraulic leaks, structural damage or
missing data plates you must (STIRR):
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Stop, do not operate the forklift
Tag out of service
Isolate – take the key
Record in the forklifts’ logbook
Report to your supervisor
As part of your visual check, you had to make sure the data plate was attached and readable. This is
very important, as this is what tells you how much load the forklift can carry, at what load centre and
to what height you can operate the machine.
If there is no data plate attached or it is unreadable it is illegal to drive the machine. You must
(STIRR):
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Stop, do not operate the forklift
Tag out of service
Isolate – take the key
Record in the forklifts’ logbook
Report to your supervisor
Pre-start checks must be carried out and any damage and defects are reported, recorded and
appropriate action is taken in accordance with safe work procedures and manufacturer requirements
Do Not Use the forklift until it has been repaired and is safe to use.
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Daily inspections
Controls
Although most forklifts have a similar layout for their controls there are several machines on the
market that have very different layouts and control functions. It is important to consult the operator’s
manual for your forklift before operating it.
Below is an example of the control layout for a typical Counterbalance Forklift Truck.
Steering Wheel
Light switch
Gear lever
(Hidden from view)
Mast Up / down
lever
Mast Tilt Lever
Handbrake
Mast Side shift
lever
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Brake pedal
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Accelerator Pedal
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Daily inspections
Fluids (Pre-Start checks)
On a forklift there are several fluids that need to be checked:
1.
2.
3.
4.
5.
6.
7.
Brake Fluid
Hydraulic Fluid/ Power steering fluid
Battery Electrolyte level in each cell
Gas / petrol / diesel
Transmission fluid
Engine Oil
Coolant
Battery
Many forklifts are battery operated. It is important to maintain the battery in a good condition, as
they are expensive to replace. When doing your visual checks, you need to make sure that the
battery is:
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●
●
●
Note:
Not damaged or leaking.
Is fully charged.
The terminals are clean and undamaged.
The electrolyte is at the correct level.
The battery is secured properly.
Some employers will not want you to do anything with the battery unless you have received
the appropriate training. Always wear the appropriate PPE when checking batteries.
When connecting and disconnecting the battery from the charger always make sure that everything is
turned off – especially the charger as batteries give off explosive gases when they are being charged
and these can build up in an enclosed space over time. These gases must be ventilated to avoid build
up which may cause explosions.
DO NOT SMOKE NEAR A CHARGING BATTERY
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Daily inspections
Gas Bottle checks
A lot of forklifts operate on LPG gas which is contained within a gas bottle mounted to the rear of the
Forklift. It is important to check for:
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Any gas leaks.
The general condition of the system.
The security of the system.
The tank is in date.
The forklift has a gas compliance plate.
The pressure relief valve is positioned at the top.
Refueling / Changing gas bottles
Only properly trained and authorised personnel are permitted
to change gas cylinders and/or batteries, and to charge
batteries. (See Appendix B)
Fuel system checks
If the forklift has a petrol or diesel engine you need to ensure
that there are no fuel leaks.
If a fuel leak is suspected or detected do not start the forklift. You must immediately:
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Stop do not operate
Tag out of service
Isolate effectively isolate it so it cannot be used (Remove key)
Record the fault in the logbook.
Report the fault to an authorized person.
If the machine is diesel operated you may need to consult the manual for information on further
checking the fuel and exhaust systems e.g. air filter and fuel filter elements may need to be checked.
NEVER REFUEL A RUNNING FORKLIFT
it could ignite the fuel and result in a fire.
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Daily inspections
Tyre and wheel checks
It is important to maintain the stability of the forklift that all tyres are inflated to their correct
pressure, in good condition and free of punctures.
What do we check?
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No large pieces of rubber missing.
Tyre not worn down.
Wear is even.
No flat tyre
No damaged sidewall
To make sure tyres are securely fitted
Wheel nuts must be all secured
Underinflated tyre
Wheel nuts must all be secured, and rims must be in good condition free of dents and damage.
Attachment checks
Forklifts can be fitted with a variety of attachments to assist in moving various types of loads.
Attachments must be:
● The attachment is attached and used in accordance with the
Attachment Instructions and Instruction Manual. Follow the
Manual, and read the Instructions.
● The right type for the forklift and loads and should be stated on
the Data Plate.
● That it is correctly fitted and secured to the forklift by a suitable
locking device or pins.
Beware:
Fitting of an attachment may reduce the load capacity of the forklift because of increased
Load Centre Distance.
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Daily inspections
Some common attachments used on forklifts are:
Fork extensions
Carpet spike/ Roll prong
Safety cage / Work platform
Jib
Drum clamp / rotator
Fork tines
Bin tipper
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Daily inspections
Safety cage / Work platform
If you are going to lift someone in a safety cage / work platform
you must:
● Ensure that the safety cage is approved and has a data
plate attached to it.
● That you remain at the controls of the forklift whilst
someone is in the safety cage.
● That the forklift be in neutral with the handbrake applied
whilst the safety cage is raised.
● That you do not drive with the safety cage in the air. It
must be lowered each time you need to move to another
position.
● You are not allowed to use a stepladder or other device
inside the safety cage to gain extra height.
Jib
What hazards are associated with using a jib?
● Reduced stability from the load swinging / moving and
changing the loads centre of gravity
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Starting the Forklift
Getting on and off the forklift
Most forklifts are mounted from the left side to avoid bumping the
mast controls by accident.
We also should use three bodily points of contact (foot, hand, hand) to
avoid slipping or falling off
● Make sure you have read the operators manual.
● Check it doesn’t have an out of order tag on it.
● Check the battery has enough charge or there is enough fuel.
● Check the brake is applied.
● Visually check the forklift for damage, leaks and wear.
● Check the area is clear.
Once you have started the forklift conduct, your start-up checks.
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Starting the Forklift
Start-up checks
When you have started your forklift there are several further checks that must be done. The
following tests/ checks need to be performed:
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Lights if fitted
Sounds
Hydraulics
Levers
Forward and reverse functions operate.
Steering is in working order.
Brakes are working.
Gauges are working.
If electric, the emergency cut out switch is working.
Warning devices (Flashing light)
Reverse buzzer and horn
Once you have started the forklift listen to see that there are no
unusual noises or vibrations as this may indicate that there is a
problem or fault.
If you detect any fault or hear any abnormal noise you should:
●
●
●
Stop do not operate
Tag out of service
Isolate effectively isolate it so it cannot be used
(Remove key)
● Record the fault in the logbook.
● Report the fault to an authorized person.
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Element 3 - Perform work / task
Load weight
Determining load weight
In our pre-operational checks, we read the data plate on the forklift to determine how much weight
the machine could carry. Before picking up or moving a load we need to also determine how much
the load may weigh.
This can be done in several ways:
1. By reading the consignment note or weighbridge docket or other documentation that came
with the load.
2. Weighing the load.
3. By calculating the weight of the load.
4. The load weight may appear on the load itself or on the packaging in which it is delivered and
transported.
5. Check inventory systems
Consignment Notes
A consignment is usually sent with most deliveries and is issued by the carrier as a record of what has
been sent. It will usually contain information on:
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Pallet control.
Number of items.
Description of items.
Who is to receive the items?
A place for the receiver to sign to say they have
received the goods.
● The weight of the pallet load or the individual items.
Weighbridge dockets
A weighbridge docket can be used if the delivery truck has been over a weighbridge and had the load
weighed. Weighbridge dockets are only useful if there is only one item (i.e. one large crate) on the
truck as the docket only gives the total weight of the load, not individual pallet weights.
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Determining load weight
Calculation
Calculation is probably the most common method used by operators. It can be as simple as
identifying the weight of one item on the pallet and multiplying that weight by the number of items
on the pallet (if all are the same).
Example 1.
If one box on the pallet weighs 10kg and there are 20 boxes on the pallet, and your pallet weighs 30kg
- then the calculation looks like:
10kg x 20 = 200kg
200kg + 30kg = 230kg total weight
Example 2.
You have 4 drums of water on the pallet. Each drum weighs 135kg. The pallet weighs 30kg. The
calculation will look like:
4 x 135kg = 540kg
540kg + 30 = 570kg total weight
Example 3.
There are 6 cartons to a layer. There are 3 layers on the pallet. Each carton is 15kg. The pallet weighs
30kg. The calculation will look like:
6 x 3 = 18 cartons
18 cartons x 15kg = 270kg of cartons
270kg + 30kg (pallet) = 300kg total weight
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Load Centre
Load centre distance
Once we have determined how much the load weighs, we then must check our ‘load centre distance’
to confirm that the load is within our rated capacity.
As mentioned earlier Load Centre distance is defined as “The distance measured from the vertical
face of the forks to the loads center of gravity
Remember:
If you increase the Load Centre distance you will reduce the lifting capacity of the
Forklift.
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Load Centre Distance
Load Centre distance calculations
The machines below are rated at 2000kg at a 600mm Load Centre
a)
If the load to be moved weighs 2400kg which forklift could move the load?
None of the machines can lift the load as they are all rated at a 2000kg maximum.
b)
If the load to be moved was 2000kg which forklift can lift the load?
‘B’ can lift the load as it has a load centre of 600mm and
‘C’ can lift the load as it has a load centre of 500mm and they are rated to 2000kg at a 600mm
Load Centre as.
‘A’ cannot lift the load as the load centre is 700mm which is greater than the 600mm rating.
c)
If the load was 2000 kg can Forklift ‘C’ lift the load?
Yes, the load is within the 2000kg that the machine is rated for; the load has a load centre of
only 500mm which is less than the rated load centre of 600mm so the machine can safely lift it.
d)
If the forklift is rated at 2200kg at a 600mm load centre and we try to lift a 2200kg load with a
load centre greater than 600mm what will happen to the forklift.
The Forklift will be overloaded and possibly tip forward.
It is important for your safety to understand load centre distance and
how it affects the capacity of your machine.
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Load Centre Distance
Remember the weight and positioning of load needs to be assessed to ensure compliance with forklift
truck data plate requirements and in accordance with safe work procedures
The longer the load the more the forklifts capacity is reduced
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Hazard control - operating
Hazard control
Before commencing work, it is necessary to ensure that all hazard control measures are in place. If
you are unsure what these are for your employer, then you need to check with your supervisor or
manager.
Hazard controls will include:
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Putting barricades in place.
Putting signage in place (if not already there).
Letting other people know you are working in the area.
Moving obstructions.
Turning on additional lighting.
Assessing weather and environmental conditions.
Getting someone to assist as a flagman (if required).
Anything else necessary to do the job safely.
Operating in accordance to forklift manufacturers specifications.
Operating Forklift in accordance to safe work procedures.
What sorts of goods are you moving?
Sometimes the load or goods you are moving
may be comprised of dangerous goods such as
chemicals, explosives (aerosols/ air bags for
cars) and other dangerous goods.
If you are handling times like these then you
need to check the companies Material Data
Safety Sheets (MSDS) to see what action you
need to take when handling and packing them
and what to do if there is a chemical spill.
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Hazard control - operating
Safety devices
When using the forklift, you must always check that the warning devices are working correctly.
E.g.:
● Horn
● Reverse beeper
● Flashing light
This is particularly important when working around other people or equipment.
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Forklift dynamics
Forklift dynamics
Before we start moving our load and driving the forklift around there are some basic concepts that we
need to understand.
The Stability Triangle
Forklifts have a 3-point suspension. The rear axle is supported by a pivot pin in the centre of the axle
enabling some up and down movement of the rear wheels when working.
The area between points A, B, and C in the diagram below is known as the stability triangle. If the
centre of gravity moves outside the stability triangle, the forklift will start to tip over.
Many accidents occur as a result of the forklift tipping over, either forward (longitudinally) or
sideways (laterally). The centre of gravity moves about like a ball in a bowl of water and is affected
by how the operator drives, brakes, accelerates turns and even moves across uneven ground.
Understanding this will help you avoid tipping the forklift over.
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Forklift dynamics
The Point of Balance (Fulcrum)
● The point of balance (fulcrum) is where the front tyre meets the ground.
● All the weight behind the point of balance acts as a counterweight.
It is very important to understand these principals of balance, because if the load is not properly
balanced, then the forklift can tip over.
The forklift is like a seesaw. The weight behind the point of balance acts as a counterweight and
provided that the balance between the counterweight and the load remain in favour of the forklift
then everything will remain balanced and be OK. However, if the weight of the load exceeds that of
the counterweight, then the forklift will tip over.
● You are not allowed to add additional counterweights to the forklift without referring to the
forklift manufacturer.
Counterweight
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Forklift dynamics
Sideways (lateral) stability
As with forward stability, we must consider the centre of gravity of the machine. If the centre of
gravity of the machine shifts to far to one side, the forklift is in danger of tipping to that side.
Some causes of tipping over sideways while travelling are:
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Turning at an unsafe speed
Turning with the load raised
Turning on a ramp / slope
Unevenly distributed load
Operating across a slope
Driving over uneven surfaces
Driving too fast (loaded or unloaded)
Side shift not centered
Driving with flat or under-inflated tyre
Forward / backward (longitudinal) stability
The forklift is an unbalanced machine with one end heavier than the other and should never be
allowed to have more weight forward of the fulcrum than behind it. If the centre of gravity of the
load and the machine combined, moves forward of the fulcrum, the machine is in danger of tipping
forward.
Some causes of tipping forward or backward while travelling are:
● Overloaded
● Sever braking
● Driving too fast (loaded or unloaded), including reversing
● Load not positioned against the heel of the fork arms
● Incorrect use of forward tilt (if fitted)
● Driving over uneven surfaces
● Unevenly distributed load
● Driving down a ramp with the load downhill
● Shifting of the load centre forward
● Carrying the load to high
● Colliding with an overhead structure
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Forklift dynamics
If your forklift tips over
If the forklift was to roll over sideways you need to:
● Remain in/on the forklift.
● Brace yourself until the forklift is stationary and safe
to exit.
● Lean away from the point of impact
Operating a forklift
● You must always wear a seat belt when operating a counterbalance forklift
All counterbalance forklifts are fitted with seatbelts with the important function of: Stops the operator from falling out in the event of a rollover.
Stops the operator being thrown into the forklift structure or out of
the forklift in a collision
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Operating a forklift
● You must raise the fork arms from the ground (to at or
below axle height) before driving off to avoid the load
or fork tines from scraping on the ground.
● “Axle height” is to the centre of the front wheels, at the height the axle sits. (Dotted red line)
● You may need to tilt the mast back slightly whilst travelling to maintain load stability.
● Keep the ‘side-shift’ centralized to maintain forklift
and load stability.
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Operating a forklift
●
If you need to carry a passenger on the machine it needs to be
specifically designed to carry more than one person.
●
Keep all parts of your body within the forklift whilst travelling.
●
Do not operate the machine if you:
o
o
o
o
Have been drinking alcohol.
Are taking illegal drugs.
Are over tired or stressed.
Are on medication that may make you drowsy.
●
Obey all traffic signals, traffic management plans and workplace
procedures.
●
Give way to all emergency vehicles.
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Operating a forklift
People and forklifts
Accidents between pedestrians and mobile plant within workplaces are very common so as a forklift
operator it is very important to watch out for and be aware of people around you.
● Never raise your loads near or over people, if the load falls you
could injure or kill someone.
● Never lift someone on the bare fork arms or load as they may slip
and fall, injuring them. This is also against OH&S safe working
procedures.
● Use your horn and lights so that people are aware you are coming.
● Use your horn when turning corners to warn others of your approach.
● Use your horn when approaching doorways to warn others that you are
coming through.
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Operating a forklift
Operate at a safe speed
WorkSafe does not specify a safe speed for the operation of forklifts. It is up to you the operator to
decide what a safe speed is for the forklift at the time. This will depend upon what is happening
around you and what the environment is like. If the company has a set speed limit for that area it
does not mean you can exceed the speed limit, but it means that it may be sensible to drive much
slower than the posted speed limit.
Some things that will affect how fast you can drive are:
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Speed Limit signs
People in the area
Size load
Surface condition
Obstructions
The physical space you must operate in
Other equipment in the area.
Obstructed vision
If your view is obstructed, before moving you need to:
1. Operate in reverse
2. Use a guide if required.
3. Repack the load.
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Operating a forklift
Working with a load
Often, we are asked to pack loads onto or move pallets with the
forklift. Always ensure:
● The pallet is not damaged (replace it if it is).
● The pallet can support the weight of the load.
● If the load is poorly or unsafely stacked – restack it and
make it safe.
● Keep the loads centre of gravity towards the heel of the fork
arms.
When we are driving and moving a load, we must constantly
monitor the load on the forklift to ensure load stability.
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Operating a forklift
Placing a load in a rack
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Operating a forklift
Removing a load from a stack/rack
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Operating a forklift
Placing a load on a stack (without racking)
When stacking loads on top of each other without a rack, they should:
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●
Hard, flat ground
Heaviest goes on the bottom
Your stack must be stable at height
Make sure loads below can support the loads above
Moving a load
When moving a load, you must remember:
● To look in the direction of travel before moving.
● Ensure you have enough height clearance before you move.
● You are clear of power lines or overhead lighting etc.
● Constantly be alert for pedestrians and other
obstructions
● Be alert for other vehicles
● Always keep the heaviest part of the load against
the backrest
● Monitor the loads stability.
● Stay to the agreed travel plan or pathway.
Unstable surfaces include:
● Backfilled ground, soft soils
● Bitumen, concrete (damaged, cracked)
● Hard compacted soil
● Potholes
● Railway tracks
● Rough uneven or difficult terrain (sloping surfaces, uneven
surfaces, steel decks and grates, trench covers)
Avoid driving or turning on unstable surfaces, and report unstable surfaces to your supervisor.
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Operating a forklift
Moving a load
When moving a load, you must remember:
● Be aware of slippery conditions e.g. wet floor, oil spills.
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●
●
●
Reduce speed,
proceed with caution,
avoid sudden braking and
avoid ramps or other inclined pathways.
● Travel with the load at approximately axle height or as
low to the operating surface as practicable.
●
Drive up ramps with the load facing uphill.
●
Drive down ramps in reverse with the load facing uphill.
● If the load is large and blocks your vision you must: 1. Reverse
2. Use a spotter if required
3. Repack your load
●
If a load is stacked badly and unstable, we must restack it
and make sure it is stable before attempting to move it
●
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When operating in a loading dock a secured dock plate or
bridge plate will be provided to fill the gap between the loading
dock and the truck.
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Operating a forklift
Moving a load -
Do NOT
● Drive with unbalanced, uneven or unstable loads as you may
lose the load.
● Turn corners quickly and risk tipping the machine over.
● Brake to hard loaded or unloaded and risk tipping the
machine forward.
● Drive forward down a ramp as the machine may tip
forward or lose the load.
● Turn on a sloping as the forklift may become
unstable and tip over or you may lose the load.
● Travel across a ramp or incline as the forklift may
become unstable and tip over or you may lose the
load.
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Operating a forklift
Moving a load -
Do NOT
● Carry people on the bare fork arms or load – it is unsafe and against
safe operating procedures.
● Lift or lower the load over people as it can result in: –
injury or death to bystanders if the load or part of the
load falls from the Forklift.
●
Drive with the load on one fork arm as it may result in:
o The forklift being unstable and tipping over
o Damage the tines
o Damage to the mast or carriage
o Losing the load from the load being unstable
● It is dangerous to operate with the
load raised high as the Forklift may
tip over
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Operating a forklift
Conditions may change
All the time you are operating your machine you must stay alert for any changes in conditions. Just
because you have planned your travel route and completed all your checks it does not mean that
things cannot go wrong.
Pedestrians may walk out in front of you.
The load may move whilst you are travelling.
The forklift may develop a fault while you are driving.
Things may have been put along your travel path by other operators.
Other vehicles may be blocking your path.
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Emergencies
Emergency situations and procedures
If there is an emergency, you should do everything you can to minimize damage and/or injury to
yourself and those around you.
Make sure that you understand your workplaces Emergency Response Procedures. If you don’t,
consult your Manger or OH&S representative to follow safe work procedures.
Emergency Isolator
In some emergencies you may have to cut the power
to the electric Forklift.
To do this, use the Emergency Isolator / stop button
located on the front control pane or beside the
driver’s seat. (Check the Operators manual for its
exact location.)
Emergency vehicle access
In emergency situations you must give way to
all emergency vehicles. This includes Police,
Ambulance, Fire Trucks and SES vehicles.
Types of emergencies
Job specific information: Chemical spills
In the event of a chemical spill or accident you should follow your
workplace emergency procedures. If you are unsure about your
emergency procedures regarding dangerous goods, speak to your
employer.
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Types of emergencies
Contact with power lines or overhead lighting or electrical cabling.
If your forklift comes into contact with electrical cabling or power lines you should:
(See Page 20)
● Warn others to stay away
● Try to break contact with the power lines
● If safe to do so stay on the forklift. If you must
leave the machine, jump clear ensuring you don’t
have contact with the vehicle and the ground at
the same time, landing with your feet together and
then continue to jump or shuffle with your feet
together until you are at least 8 metres clear of the
vehicle.
● Repot to management, power company and safety
regulator.
● Do not use the forklift until it has been checked by
a technician.
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Types of emergencies
Environmental Conditions - rain / lightning
Most forklifts can operate in the rain but be aware that rain may make the
ground conditions slippery or soft and unstable.
No forklift should be used in stormy conditions where lightning may strike. Doing
so may result in injury or death.
Machine failure / loss of control / failure of hydraulics
If your brakes or steering fail on the forklift:
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Stop the forklift
Activate the emergency stop procedure as per
the manufacturer’s instructions
Return the Forklift to a lowered position using
applicable procedures
Lock and Tag out the Forklift
Report to management
Have the Forklift checked and repaired before
using it again
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Element 4 – Pack up
Parking a forklift truck
Parking the forklift
At the end of your work period you should park your forklift in a safe area where it will not get in the
way of anything and block exits and doorway as these may need to be used in an emergency. Follow
manufacturer requirements and workplaces procedures for designated parking areas. (Usually near
the battery charger if the forklift is electric.)
Do not park in front of:
●
●
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Emergency exits
First Aid stations or emergency showers
Near firefighting appliances
Near doorways
On sloping surfaces
Walkways
Where its obstructing traffic
Parking on a slope
If you must park on a slope or incline you must in addition to normal parking procedures, ‘chock’ the
wheels of the forklift. ‘Chocking’ the wheels means placing a brick, block of timber or a wheel chock
behind the wheels of the forklift to stop it rolling down the slope
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Shut down
Shutting down the forklift
Once you have parked the forklift safely you need to shut it down correctly. Check the operators’
manual as to the correct shut down procedure for the machine you are using.
Most shut down procedures are like this:
Fork arms lowered and tips to the
ground
Apply the handbrake (if fitted)
Forklift to neutral
Turn off the ignition
Remove key
Post-operational checks
Now you have finished using the machine you should conduct a post-operational check to:
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●
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●
●
●
●
Check for damage.
Check for leaks.
Check if the battery needs recharging.
Connect the battery to a charger.
Make sure it is safe for the next operator.
Confirm everything is turned off.
Update all records
A post-operational check involves walking around the forklift to conduct the inspection.
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Shut down
Securing the forklift
Always remove the key when you have finished using the machine. This is
to stop unauthorized access / use. Each workplace may have varying
procedures as to where to put the key so check with your supervisor or
manager, to follow manufacturer requirements and safe work procedures.
Make sure the LPG fuel valve is turned off so that there can be no gas leaks
and the risk of explosion is eliminated.
Reporting and recording faults
If any defects or damage is found, you need to (STIRR):
●
●
●
●
●
Stop do not operate
Tag out of service
Isolate it so it cannot be used (Remove key)
Record the fault in the logbook.
Report the fault to an authorized person.
In some workplaces there will be an authorized person responsible for the servicing and repair of the
forklift trucks. Check with your supervisor or manager as to your responsibilities as in some
workplaces you may be required to carry out minor servicing or repairs if you are considered capable
and have authorization from management.
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Appendix
Additional information
Appendix A
Planning - What type of forklift truck do I need?
A forklift is a powered industrial truck used to assist the operator to pick/ lift and transport
materials/goods in a warehouse. There are many different types of forklift trucks used in the
workplace.
The most used forklift truck is the gas / petrol powered counterbalance style.
This same style of forklift truck can also be electric powered.
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Planning - What type of forklift truck do I need?
Other styles / types of forklift truck that you may be asked to operate are:
Electric Reach Truck – can operate in aisles much
narrower than required by a counterbalance style
Forklift and therefore allow much better use of the
warehouse space.
All Terrain Forklift – These can be four-wheel drive
or two-wheel drive and are designed to operate on
rough and uneven ground.
Side Loader Forklifts – Are designed to handle wide
loads and not only drive forwards and backwards but
can drive sideways as well. In this way they do not
need as much space to turn and can still operate in
narrow aisles.
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Planning - What type of forklift truck do I need?
Container Forklift Or Heavy-duty Forklift. These can handle loads in
excess of 45 tons.
Double Reach Forklifts – Are like a normal reach
truck but are designed to place stock into a different
style of racking that is much deeper than normal.
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Appendix B
Fitting a new L.P. gas cylinder
Make sure you are authorized before attempting to change the gas bottle.
Gas forks are usually dual fuel and if operating on gas are driven until the gas bottle is completely
empty.
To change a gas cylinder, follow these steps:
1. Wear suitable PPE
2. Close the liquid service valve (turning clockwise).
3. Run the engine until fuel is depleted and the engine stops (this usually has already happened).
4. Unscrew the main feed coupling.
5. Release the strap connections securing the cylinder to the counterweight. Remove empty
bottle.
6. Fit new, full cylinder. Make sure it is correctly seated.
Ensure pressure release valve is facing upwards. Do up straps.
7. Examine the main feed coupling to make sure the rubber sealing washer is in place.
8. Screw this coupling onto the male half of the cylinder coupling (only needs to be hand tight).
9. Very slowly open the liquid service valve (turning anticlockwise), checking to see that no leaks
occur. You should initially hear the gas enter the hoses.
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NOTE: Always wear protective equipment such as gloves and face shield when changing L.P. Gas
tanks because sub-freezing liquid under pressure may result in serious physical harm e.g.
severe burns as the liquid escaping is at -40C.
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Appendix C
Charging a Forklift Battery
At the end of shift the amount of charge left in the Forklift battery needs to be checked to see that
there is enough charge to complete the next shift. If the charge is low, then the battery needs to be
placed on charge. To do this: 1. Wear appropriate PPE
2. Park the Forklift close enough to the battery charger that the cables will reach without causing
trip hazards or obstructions in the work area.
3. Ensure that the Forklift is turned off and the battery charger is also turned off.
4. Lift the seat / battery cover to gain access to the battery cables.
5. Unplug the battery cable on the Forklift and plug it into the matching cable on the battery
charger.
6. Turn on the charger. Depending on the type of charger either a green light should come on, on
the charger or the gauge on the charger should show how much current is being delivered to
the battery. If this is not happening, then check the connections and that the charger is turned
on.
7. The battery will take between 4 – 8 hours to charge to full capacity. This will depend on the
age / technology of the battery and charger combination
8. Once the battery is fully charged, turn off the charger before disconnecting it from the
battery. Failure to do this could result in a spark causing an explosion
Battery charger cable
Battery cable
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Appendix D
Hierarchy of hazard control
To help us in the formal process of dealing with hazards in the workplace there is a system that is
referred to as the hierarchy of hazard control.
There are six levels to the Hierarchy of Hazard control.
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Planning – Hazard control
Hierarchy of Hazard control
The hierarchy of hazard control is a list of control measures that can be used to eliminate or minimize
the exposure to a hazard in the workplace. The diagram above shows the 6 levels in the hierarchy
from most effective to least effective control.
The six steps are:
1.
Elimination
If possible, remove the hazard completely. e.g. Use electric forklifts or order pickers inside
instead of petrol-powered machines.
2.
Substitution
If you cannot completely remove the hazard, then you should consider a safer method to be
used. E.g. Use a spotter to warn the forklift operator that there are people nearby or use an
Electric Forklift in confined spaces rather than a petrol forklift.
3.
Isolation
Lower the risk of exposure or injury by restricting or preventing access to the hazard. For
example, separate pedestrians and forklifts using exclusion zones and the use of barriers and
walkways.
4.
Engineering
This is where equipment and work processes are improved through engineering solutions to
reduce risk. E.g. Use lights, reverse beeper, speed limiters, barriers or horns to warn people
nearby.
5.
Administration
Administrative measures and safe work practices such as the use of signs, line marking, induction
programs and training can all help reduce hazards and exposure to risks.
6.
Personal Protective Equipment. (PPE)
The use of PPE to control a hazard is always the last choice and least effective measure of control.
It should always be used in conjunction with the other above listed methods of control. PPE is
such things as safety boots, Hi-visibility clothing, eye protection etc. When using PPE make sure it
is appropriate for the conditions, that fits correctly, and you have been given adequate
instruction in its use.
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Planning – Hazard control
Personal Protective Equipment
PPE (Personal Protective Equipment) is common in nearly all workplaces these days.
PPE is an item of clothing or piece of equipment that is worn on the body to protect you from certain
hazards.
It cannot eliminate the hazard or potential injury, but it will help in reducing the risk of injury and
assist in keeping you safer.
The most common form of PPE in most warehouses are safety boots and hi-visibility clothing but as a
Forklift truck operator you may also be required to wear other PPE as deemed appropriate by your
employer.
What PPE is required needs to be decided before starting work and the
PPE should be inspected prior to commencing work.
Other forms of PPE that you may have to wear may include the following:
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Appendix E
Planning – Types of Communication
Verbal communication
This the most used form of communication in the workplace. Your manger, supervisor or workmates
may give you verbal instructions; listen carefully on how to do your job safely and properly.
It is very important that if you don’t understand the instructions that you ask questions and clarify
what you were asked to do. Don’t guess at what you have been asked to do. It is not foolish to ask a
question. It may prevent you from having an accident.
If you are asked to do something or use a machine that you have not been trained to use, then you
are entitled to ask for help and your employer has a ‘duty of care’ to provide you with the necessary
training.
Written Instructions
Written instructions come in many forms. They may be:
Company policies or work instructions
These will include site and emergency procedures. These are rules and guidelines, which are put into
place to ensure work is carried out properly and safely. It is important that you are familiar with how
your company expects you to work and what you need to do in an emergency. If you don’t know
contact your manger or OH&S representative.
An operating manual
Each forklift truck comes with an operating manual. You need to take the time to read it and become
familiar with that forklift.
Material Safety Data Sheets – or MSDS’s
Contain information on how to handle and transport chemicals and what to do if there is an
accidental spill.
Work Permits
Set out the safety control measures that are required prior to commencing work and are used to
ensure workers understand the site conditions and offer guidelines of what they shouldn’t do. They
are sometimes referred to as an induction onto the machine or the area.
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Planning – Types of Communication
Signage
Every workplace will have safety signs posted around the work area. These signs are important
because they remind you of any restrictions, hazards or special requirements (such as PPE) for the
work site. You must follow the instructions on these signs as they are posted to keep you and your
co-workers safe.
Appropriate worksite protocols
In some cases, the company you work for may have their own specific forms of communication. An
example of this is the use of hand signals. It may be because the work area is very noisy, or you may
have someone guiding you because your vision is limited because of a large load.
Always make sure you understand what the hand signals you and your
assistant are using mean before you start work.
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Planning – Types of Communication
Hand and whistle signals
HAND & WHISTLE SIGNALS
Based on AS2550.1.2002
Motion
Hand signal
Whistle
Motion
Hand signal
1 long
1 short
Turning left
Whistle
1 long
2 short
Turning right
3 short
4 short
1 short
N/A
Luffing boom up
Stop
Travel and traverse
Creep speed: appropriate hand signal for motion is clenching and unclenching hand
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Planning – Forklift terminology
Height checks
It is important to know the “Overall extended height and collapsed height” of your forklift before
commencing work.
Overall extended height – is the height of the mast
from the ground to the top of the backrest when the
mast is fully extended. It is important for the
operator to know this so that they are aware if the
mast can hit the roof or other overhead hazards. It
also tells the operator at what height they can place
their loads.
Collapsed height - is the height of the mast when
fully lowered to the ground. This measurement
allows the operator to know if the machine will be
able to ‘fit’ through the doorways, under any
mezzanine floors or can be driven into a shipping
container to unload it.
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Appendix F
Load calculations - workbook
68. If your forklift was rated at 2200kg at a 600mm load centre distance, could it pick up a load of
2200kg at a 500mm load centre distance?
YES
69. If the forklift is rated at 2200kg at a 600mm load centre distance and we try to lift a 2200kg
load with a load centre distance greater than 600mm what will happen to the forklift?
It will become unstable, tip forward and lose the load.
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70. If there are 4 drums of water on the pallet at 200litres in each drum and the drums weigh 10kg
and the pallet weighs 30kg each then the total weight of the load is?
1 litre water = 1kg
200 X 4 = 800kg water weight
10 X 4 = 40kg drum weight
Pallet = 30kg
800 + 40 + 30 = 870kg
71. There are six cartons on each layer of the pallet and there are three layers and each carton is
15kg, pallet weighs 30kg then the total weight is?
6 cartons per layer X 3 layers = 18 cartons
18 X 15 = 270kg
Pallet = 30kg
270 + 30 = 300kg
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Using the information on this data plate: Question 72
Forklift Load Chart
Model
Toyota
FBE15
Serial
No
12006
Max
Height
Tyres 700 x 12 x12
MAST VERTICAL
Length
mm
Forks
1065
Front
bar
Fork
Height
mm
4500mm
Load
Centre
mm
600mm
4500mm
Max Back Tilt
7
Working
Load
Limit
1250kg
6
Degrees
Rear 7 bar
MAST FORWARD TILT: 3 DEGREES
Length
Fork
Load
mm
Height
Centre
mm
mm
1065mm 4500mm 600mm
Working
Load
Limit
1050kg
Slippers
RAM
Paper
Grab
a) With the mast vertical what is the forklifts maximum WLL?
___________________ 1250kg __________________________
b) With the mast on forward tilt what is the WLL of the forklift?
______________________ 1050kg ________________________
c)
When the mast is vertical can the forklift lift a load of 1250kg with a Load Centre of 700mm?
_____________________ No _____________________________
d) When the mast is vertical can the forklift lift a load of more than 1250kg?
______________________ No _____________________________
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Load
Calculation / Reason
Load 1
A pallet 1185mm Length x
1185mm width with a height
of 1400mm and a total weight
of 1700kg
1700kg is less than the maximum
capacity of 6130kg
Is this load safe to
lift?
Yes
No
Yes
No
Yes
No
Load centre B is 1185 / 2 = 592.5mm
Load centre B is less than 915mm
Load centre C is 1400/2 = 700mm
Load centre C is less than 915mm
Load 2
A container with a tare weight
of 2100kg containing a load of
5000kg
With a size of 2.4 metres wide,
2.4 metres long, and 2.4
metres high
2100kg + 5000kg = 7100kg
Above the rated capacity
Load 3
Load centre B is 2400 / 2 = 1200mm
Load centre B is more than 915mm
The empty container outlined
in Load 2
Load centre B is 2400 / 2 = 1200mm
Load centre B is more than 915mm
Load centre C is 2400/2 = 1200mm
Load centre C is more than 915mm
The Forklift is overload
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Appendix G
How do I get a HRW forklift licence (LF)?
You must enroll in a training course with a registered training organisation (RTO) that has been approved by
WorkSafe. Upon completion of the training, you will need to undertake and pass the National Forklift
assessment. This National assessment has three parts to it:
● A theory assessment
● A calculations assessment
● A practical drive assessment
Successful completion of assessment
Once you have successfully completed your assessment you will be issued ‘A
Notice of Assessment (NOA)’. You must apply within 60 days either online at
myworksafe.vic.gov.au or at the post office to be processed and receive your
licence.
The ‘Notice of Satisfactory Assessment’ is your temporary licence for this 60day period and allows you to operate the forklift until your digital licence
arrives in your ‘my WorkSafe account’ or mailbox.
The HRW licence needs to be renewed every five years. This can be done online you need to provide
the following:
● Current ID (100 points)
● Your existing HRW licence
● A licence renewal fee
What happens if I let my licence expire?
If you allow your licence to expire and you do not renew it within 12 months of
the expiry date the licence cannot be renewed and you will have to:
● Complete a training course with an approved RTO and apply for a new
licence or
● While continuing to work, be enrolled in a training course and work
under supervision of a HRW licence holder
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