4 Hines road

Wingfield 5013
Ph: - (08) 8359 0099

abn 15794 402 123

enquiries@gnltruck.com.au

PO box 14
Welland 5008
fax: - (08) 8359 0095

Forklift Training Manual

TLILIC108A Licence to operate a forklift

Course start time: - 08.00, if you are later than 15 minutes you will not be allowed to attend and
will have to be rescheduled to another day at your expense.
Read this manual carefully, prior to attending the course.
Bring this manual with you to the course.
Please wear fully closed in shoes, i.e. work boots or sneakers, no sandals, thongs or high heels.
You must have some form of photographic ID on you to participate on the course.

INTRODUCTION
The forklift s a versatile workhorse used in many areas of industry, and is often taken for granted. Like any
piece of equipment, you must conduct regular maintenance checks, to decrease the potential of accidents
happening.
This course is designed to provide you with the knowledge and skills necessary to operate a forklift in an
efficient, safe, and competent manner. This course will also assist you to reach the level of competency
required to pass the theory and practical components required by SAFEWORK SA for you to obtain a forklift
licence.
ASSESSMENT To complete the course you must pass the Theory and Practical assessment, conducted by an
assessor registered with SAFEWORK SA. If you are assessed as competent, you will be issued with a Notice of
Satisfactory Assessment.
RE-ASSESSMENT If you are unsuccessful in your assessment, you will be required to attend further training
before you can be re-assessed. A period of 21 days (3 weeks) from the initial assessment date must elapse
before you can be re-assessed.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

OCCUPATIONAL HEALTH SAFETY & WELFARE ACT 1986

Section 19 - Duties of employers
An employer shall, in respect of each employee, provide and maintain so far as is reasonably practicable:
a) A safe working environment;
b) Safe systems of work;
c) Plant and substances in a safe condition;
d) Adequate facilities for the welfare of employees;
e) Such information, instruction, training and supervision as is necessary to ensure that
every employee is safe from injury and risks to health.
Section 21 - Duties of workers
An employee shall take reasonable care:
a) To protect their own health and safety at work;
b) To avoid adversely affecting the health or safety of any other person through any act,
or omission at work; and shall so far as is reasonable (but without derogating from any
common law right)
c) Use any equipment provided for health or safety purposes.
d) Obey any reasonable instruction that their employer may give in relation to health
or safety at work;
e) Comply with any policy that applies at the workplace published or approved by the
Minister;
f) Ensure that they are not, by the consumption of alcohol or a drug, in such a state
as to endanger their own safety, or the safety of any other personal at the work site.
Section 59 Aggravated Offence
Where a person contravenes a Provision of Part III:
a) Knowing that the contravention was likely to endanger seriously the health or safety of
another.
b) Being recklessly indifferent as to whether the health or safety of another was so
endangered, the person is guilty of an aggravated offence and liable upon conviction to a monetary
penalty not exceeding double the monetary penalty that would otherwise apply under Part III for that
offence or imprisonment for a term not exceeding five years or both.
An offence against this section is a minor indictable offence.
Regulations under the Act
The OHS&W Regulations 2010, which came into effect in September 2010, contain many requirements that
relate to the operation of forklift trucks. Some of those that will be most relevant to you in the day-to-day
operation of a forklift truck are listed below. This list is not exhaustive and is only intended as a guide. If
there is any doubt as to your responsibilities, you should refer to the OHS&W Regulations (the bracketed
numbers indicate relevant regulations for future reference) or the Department for Administrative and
Information Services.
Employees must do all such things as required by their employer to ensure compliance with the
regulations. (1.2.4)
Employers must ensure that:
(a) An employee does not operate a forklift truck unless they have been assessed as
competent by a registered assessor. (7.4.382)
Note: This requirement does not apply where the forklift is being operated:
- By an operator who complies with the requirements of the repealed regulations
(regulations in force prior to April 3 1995) as if those regulations were still in operation
- In an emergency to avert a serious and immediate threat to the safety of a person
- For training purposes under the direct supervision of a competent person.
(b) Plant operators receive adequate information and instruction. (3.6.103)
(c) Appropriate checks, tests and inspections are carried out on plant and records are kept of the
tests and inspections. (3.6.107 & 3.7.121)
(d) Unsafe plant is withdrawn from use. (3.6.107)
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

(e) An industrial lift truck is used in a manner, which minimises any risks arising from the work
practices or systems and the environment in which the industrial lift truck is used. (3.7.116)
(f) No passengers ride on an industrial lift truck unless in a seat specifically designed for the
purpose and fitted with appropriate seat restraints. (3.7.116)
(g) Any safety features or warning devices incorporated into plant are used in a proper manner and
in addition, are maintained and tested on a regular basis. (3.6.107)
(h) Industrial lift trucks are fitted with a warning device, which effectively warns people who are
at risk from the movement of the plant. (3.7.116)
(i) Plant designed to lift or move is equipped with appropriate lifting attachments. (3.7.116)
(j) Persons are not lifted by plant designed to lift or move unless a suitable and
adequate personnel box is used and securely attached to the plant. (3.7.116)
(k) So far as is reasonably practicable, loads are not suspended over, or travel over a
person. (3.7.116)
(l) A load that may become unstable is appropriately restrained. (3.7.116)
(m) So far as is reasonably practicable, no load is simultaneously lifted by more than one
plant. (3.7.116)
(n) Plant is used only for the purpose for which it was designed. (3.6.107)
(o) Appropriate controls are implemented to eliminate or minimise the risk of powered mobile plant
colliding with pedestrians or other powered mobile plant. (3.7.113)
(p) A person not operate a vehicle for work unless they are fit and competent to safely do
so. (2.16.79)
(q) Reasonable traffic control measures are put in place to minimise any danger
caused by the movement of vehicles. (2.16.79)
(r) If people are at risk from the movement of vehicles measures such as systems of work,
barriers, signs, warning devices, high visibility clothing etc. must be used to minimise the
risk. (2.16.79)
Reference:
Occupational Health and Safety Act 1986
Occupational Health Safety and Welfare Regulations 2010
National Guidelines for Occupational Health and Safety Competency Standards for the
Operation of Load Shifting Equipment and other Specified Equipment [NOSCH: 7019 (1992)]
TLILIC108A Licence to Operate a Fork Lift Truck
Australian Standards
2030.1 Gas cylinders Code
2210.1 Safety, protective and occupational footwear
2359.1 Powered industrial trucks
4602.1 High Visibility safety garments
Definitions
Plant includes
(a) Any machinery, equipment, appliance, implement, or tool;
(b) Any component, fitting, or accessory used in or in conjunction with any machinery,
equipment, implement or tool.
Industrial Lift Truck means powered mobile plant, designed to move goods, materials or
equipment, equipped with an elevating load carriage and, normally, a load handling attachment, but does not
include a mobile crane or earthmoving machinery.
Forklift Truck means a powered industrial truck equipped with a mast and elevating load carriage to
which is attached a pair of fork arms or another form of load holding attachment, and includes a truck on
which the operator is raised with an attachment for order picking, but does not include a pedestrian
operated industrial truck.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

The Forklift truck

Forklift Trucks transport and stack materials, freight, goods, and cargo. They are a short wheel
based truck with a vertical mast.
There are two (2) types, counterbalanced and non-counterbalanced forklift trucks.
Equipment Selection
Prior to starting your shift, it is important to select the correct forklift for the task you are going to
undertake. Some differences in forklifts are as follows:
Slick tyres generally used for inside activity.
Heavy tread tyres commonly used inside and outside
Reach truck forklifts are mostly used for inside work (These machines should not be used for
uneven ground or crossing railway lines)
Counterbalanced fork lift trucks, types and their uses
Counterbalanced Forklifts use the front wheel axle in the same way as the fulcrum of a lever. The load is
counterbalanced on one side by the weight of the machine on the other side. All the weight behind the
point of balance (fulcrum) acts as a counterweight. There are many different sizes and they use various
power applications. An electric forklift would be an ideal choice when working in confined spaces, such
as shipping containers. Telehandlers are an ideal choice if working on rough or un-stable ground
because of their large robust off road wheels and solid tyres. Duty of care training must be obtained
when operating Telehandlers.

Additional weight should never be added to the counterbalance system

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

Non-counterbalanced Fork Lift Trucks

In non-counterbalanced Forklifts, the centre of the load is behind the fulcrum point. They are known as
reach or straddle trucks.
This type of Forklift reaches out to deposit the load or straddles the stack for depositing the load.
They should not carry loads unless the reach is retracted. They are used for particular load stacking
functions and are more versatile than the counterbalanced type in warehouse locations.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

Conducting Routine Checks

It is the operators responsibility to ensure they have been given appropriate duty of care instruction on
any forklift they are not familiar. All controls should be pointed out and their use explained.
For example: Some forklifts will have the control levers fitted either on the dash board or on the bonnet to
the side of the driver, generally to the operators right hand side.
Some forklifts will only have 2 levers, the first to operate the mast, and the second to operate
the tilt of the mast.
Other forklifts will have additional levers for side shift and tyne spreaders and for other
attachments fitted to the machine. Side shift must be used to keep the load centred,
as an uneven load can affect load balance.
Your assessor will point these controls out to you in some more detail.
Prior to starting and then using any industrial equipment including forklifts, checks must be
performed to establish its condition.
3 checks must be conducted.
They are:
1. Physical checks
2. Electrical checks
3. Operational checks
We can look at these in more detail, starting with Physical checks.
1 - Physical Checks
A thorough physical check of the forklift should be made prior to operation. The first thing that
should be identified is the compliance or rating plate. This data plate will provide the operator with all the
information required to move and relocate a load safely.

Data Plate

LPG Plate

Once this rating plate has been found, it is now possible to continue with other checks. If the forklift has been
fitted with LPG (liquid petroleum gas) then the compliance plate for this work should also be found. This will
ensure a licenced and appropriately trained competent person has carried out the work
If for ANY reason, these data plates are missing or cannot be found, the equipment MUST NOT BE USED.
The KEY should be removed and reported to a manager or supervisor at once.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

All parts of the forklift should be checked. There is no set order when conducting these checks,
providing nothing is missed. Your trainer will show you a process; however the order of checks
below will enable you to consider what is best for you.
Tynes (or forks) should be checked for stress cracks and general condition. Pay particular
attention to the heels for cracks. Locking pins used when opening and closing the forks
should also be checked for free movement.
The backrest should be checked for condition, damage, and security to the forklift.
This device is designed to stop items falling through the mast assembly onto the
operator I.E. YOU.
Chains should be checked and signs of rust reported
The mast assembly should be checked for signs of damage and mask rollers checked for
condition, i.e. lubricated.
Hydraulic rams should be inspected for weeping seals (signs of oil should indicate this)
Front wheels and tyres should be inspected and obvious signs of damaged tyres reported.
Wheel nuts should be inspected as they can shear off. Remember some tyres do not have
OR have very little tread on them, this should be considered when driving on WET or
SLIPPERY floors.
The drivers seat should be securely fixed and the seat belt in working order/condition.
Rear wheels should be checked as per the front ones.
Rubbish and waste material (shrink-wrap) should be removed from the rear radiator housing.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

 LPG gas bottle bracket should be securely fixed. Check for fuel leaks
Overhead guide should be checked for damage, this is fitted to protect the operator from falling objects.
The operator is YOU.
The remaining checks are as before, i.e. rams, tyne assembly etc.
Mirrors, registration, and number plate should also be checked, and should be current and not damaged,
even if the operator does not intend using the equipment on the road.
If any of these checks expose a problem, then the equipment should be tagged out.
Under the bonnet, checks should now be made and they include:
1 - Liquid levels: Coolant or water (with the engine cold)
Engine oil
Hydraulic Oil
Battery levels (all cells)
Brake fluid
Wiper water bottle (if wipers/windscreen is fitted)
Additional checks should include hoses for splits and wear. Belts, for signs of wear and damage.
Checks for waste material should also be checked around the engine bay.
Repairs and maintenance
Any repairs to be made to any equipment should only be carried out by and authorised competent person.
Most forklift trucks are hired or leased and carry a compressive maintenance call-out arrangement.
MINOR repairs may include:
Replacing light bulbs
Fitting out of date registration disks (if road registered)
Tyre inflation
Filling liquid levels, i.e. coolant, oil etc. You MUST check on the policies and procedures
within your workplace.
2 - Electrical Checks
Electrical checks are important because the working conditions and environment can and often do
change quickly particularly with weather and lighting around the work sites.
The amount of checks will depend largely on the equipment being used. In other words, you have to check
the operators manual for a concise list of checks. Generic checks would
include the following:
Warning devices
Flashing warning light
Horn
Reversing Light
Indicators (if fitted)
Head Lights (if fitted)
Brake lights
Side lights (if fitted)
Gauges and console lights.
If indicators, side lights etc. are fitted then they have to be operational regardless of whether you
intend to use them.
3 - Operational Checks
Operational checks are the final stage, and are as important as the previous checks. All operating
parts should now have been checked in order to avoid any problems whilst moving, lifting or otherwise
relocating loads with the forklift.
With the engine running first listen for any unusual/abnormal noise. Once you are satisfied that there are no
unusual noises etc. the following checks should be made:
Elevate the mast to the full working height.
Tilt the mast forwards and then backwards.
With the mast in the lowered position, check side shift and tyne spreaders (if fitted)
Turn steering in the FULL lock position in both directions.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3 31st September 2011
8

 With the park brake (hand brake) applied check that it operates and works with the forklift in
forward and reverse gears.
Check the ground for any oil leaks.
Finally check both foot brakes in both forward and reverse directions.
If any damage or defects are detected then remove the key, and report the faults to a supervisor.
By removing the key, you are eliminating the chance of someone else using the faulty
equipment. Tag or other means of fault reporting should be used. Check the procedure on your
site so you are aware of it should it be required. Remember to ensure any leaks are cleaned up.
In conclusion, a pre-operational check sheet should be utilised so nothing is missed and there is a
record of your check.
If a fuel leak is identified
- Isolate Fuel
- Remove Key
- Tag the Forklift out
- Report to supervisor

If a hydraulic leak is identified

- Remove key
-Tag the forklift out
- Clean up oil
- Report to supervisor

Forklift Tyres
There are three basic types of forklift tyres used in industry. They are:
Pneumatic Rubber tyres, generally 10 or 12 ply, inflated to 550 - 690 Kpa. (80 100Psi.). Special care should be taken when working with pneumatic
forklift tyres as they are on split rims which can cause serious injury if
mishandled.
Solid These tyres are generally the same profile as pneumatic tyres
however they are constructed with solid rubber. These tyres are also
known as puncture proof.
Cushioned These tyres are made from a thin band of rubber on a rim and are
commonly found on electric forklifts.
The condition of the forklift tyres should be inspected as part of the safety check
carried out at the start of every shift. Pneumatic tyres should have their pressure
checked on a regular basis as uneven tyre pressures can result in the forklift tipping
over.
Do not work on any forklift tyres unless you are qualified to do so.
Post Operational Checks
Considering forklifts can be used for several hours at once, post operational checks should also be
considered as part of the operators shut down procedures. Similar checks to the ones already
highlighted should be conducted to ensure any damage or faults are clearly identified and the
appropriate repair/maintenance request made. Company policy may require keys to be removed
from the forklift. Check with you employer as to their policy and procedures. This practice will ensure no unauthorised or un-trained personnel are using the equipment.
Shut Down and Secure Forklift Truck
Ensure the following:
Forklift is parked to avoid hazards
Forklift is shut down according to procedures, which may include removing keys etc.
Routine checks are carried out, similar to those for the pre start checks
Report any faults that have been identified.
CARE SHOULD BE TAKEN WITH HOT ENGINE PARTS, AND RADIATORS
SHOULD NOT BE OPENED WHEN THE ENGINE HAS BEEN RUNNING.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

The Motor
Internal combustion engines
Internal combustion engines are powered by diesel fuel, petrol, or LP gas. An LP gas motor is a
petrol motor that has been converted to use gas instead of petrol.
Warning: Internal combustion engines produce the odourless but poison gas, carbon
monoxide. A person working in a confined space where carbon monoxide is present could
become seriously ill.
Carbon monoxide builds up in the body and can kill in minutes. Make sure there is adequate
ventilation where Forklifts with internal combustion engines are operating.
Do not refuel an internal combustion Forklift unless the motor has stopped and the ignition turned off.
Internal combustion diesel engines
Most diesel engines must warm up before they can start. When the ignition key is turned on, the
glow plug is activated. This warms up the motor so that it will fire.
There is a delay of several seconds from ignition until the starter motor turns on the engine. A light on the
dashboard indicates that the engine is warming. It goes out when the engine is ready to fire. Try to avoid
allowing a diesel engine to run out of fuel. Diesel engines fire on compressed vaporised fuel and will not fire
if there is air in the fuel lines. If a diesel engine runs out of fuel, a competent person must bleed the system of
air before it can be restarted.
Diesel engines also emit carbon monoxide gas. A badly tuned diesel engine can emit more carbon
monoxide than a petrol motor.
Remember that carbon monoxide is odourless, will build up and can kill.
Battery forklift will release toxic and flammable vapour when charging, and therefore should be charged in
a well-ventilated area. Smoking or naked flames should be avoided when charging or re-fuelling any forklift
equipment. Appropriate PPE must be utilised when re-fuelling with LPG.
Changing LP gas cylinders
LP gas is a highly volatile explosive. Change gas cylinders in a well-ventilated area well clear of a naked flame
or source of ignition. Only those trained and authorized to do so must change LP gas cylinders. Some
employers do NOT change over LPG cylinders they re-fill them. Check with your employer before
changing/filling these cylinders.
Beware of cold burns from escaping gas. Always wear appropriate gloves and safety glasses and
do not smoke while changing LP gas cylinders.
Take the following steps in the order below when changing LP gas cylinders:
1. Turn off cylinder valve
2. Use correct PPE i.e. gloves, goggles etc.
3. Switch off engine
4. Disconnect take off hose
5. Remove safety straps
6. Change the cylinder
7. Connect the safety straps
8. Re-connect take off hose
9. Turn on cylinder valve
10. Check for leaks-look, listen and smell.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

10

Fixed Liquid
Level Gauge

LP gas cylinders must be inspected and stamped by a competent person every 10 years.
All LP gas Forklifts must have an installers compliance plate.
Beware of exhaust fumes in confined space
Operator Responsibilities
As an operator of a forklift truck, you have certain responsibilities when operating a forklift in the work
place.
You must:
Drive the forklift safely at all times, taking into account all possible hazards that you may encounter
Have proficient knowledge of the rules of operation central to operation of the particular forklift you
will be operating.
Protect yourself and others by observing SAFEWORK SA practices at all times.
For you to effectively exercise your responsibilities as listed above then it is imperative that you take the
time for you to familiarise yourself with:
The forklift you will be required to operate e.g. controls, capacity and limitations, and other factors
that may affect stability.
The loads you will be required to carry e.g. stability, balance and contents
The areas in your working environment that may under certain conditions could be hazardous e.g.
ramps, blind corners, overhead obstructions, pedestrians etc.
Forklift Operating Speed
Forklifts are not designed for fast erratic driving styles. Therefore a brisk walking pace is
considered an appropriate speed for general operation. Some sites will govern or control via
computer or engine settings, the actual speed the forklift will be allowed to travel. In other words
depending on where you work will depend greatly on the speed allowed to for that site. You should
always check before starting at any new site. Stability will vary greatly depending on your style of
driving, the loads being carried, and the site the load is being carried over.
It is important to stop your activity if the pre-determined path has been blocked or changed. STOP, reevaluate the hazards, and continue with the activity if it is safe to do so. Plan your work, and work to
your plan.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

11

Planning the Work

Many hazards associated with the use of forklift trucks can be eliminated with suitable planning prior to
commencing work.
As part of your working shift, it is important to check for hazards around your worksite, and to
check which path you will travel by avoiding hazards. There could have been changes to hazards at
any time during the previous shift or working day. A good method of communication is to hold short
but informative tool box talks, during which supervisors can pass on any relevant information that
may affect your shift. If these are not currently utilised on your site, perhaps you could suggest this
to a manager or OHS rep.
A thorough Worksite Inspection, before commencing work of the area you will be working in allowing
you to identify any potential hazards.
These can include:
power lines
overhead obstructions
blind corners
blind alleyways with cross traffic
doorway clearances
ramps/inclines
wet or slippery surfaces
variation in lighting levels
recently filled trenches/holes
underground cavities
other vehicles
people
timber waste on the floor
types of load, flammable, fragile. unstable or hot
excessive heat, especially where LP gas is used
the fumes produced by the forklift
other contractors on site
Hazard Control
Where a hazard has been identified, safety control measures must immediately be put into place.
Hazard control measures can include:
highlighting overhead obstructions
using fish-eye mirrors on blind corners
traffic control measures
barricades/bunting
signs
Where PPE (Personal Protective Equipment) is used, it should be appropriate and meet the
required standard and fit the operator correctly.
When deciding how to control a hazard the hierarchy of control measures should be applied in the
order listed below.
Hierarchy of Control
Elimination - Eliminate the hazard from the workplace.
Substitution - Substitute the activity, substance etc. for one less hazardous.
Isolation Separate people from the hazard by distance, barriers etc.
Engineering Controls - Use machinery, equipment or processes, e.g. exhaust ventilation.
Administration (Safe Work Practices) - Control the way people do the job, e.g. work permits,
washing to remove contamination.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

12

Personal Protective Equipment - Use personal protective equipment, e.g. respirators, gloves, eye
protection (personal protective equipment should only be used as a last resort).
Example: An LPG powered forklift operating in an enclosed area may present a hazard due to
the production of carbon monoxide (CO).
This hazard could be controlled by using exhaust ventilation to remove the carbon monoxide
(engineering control), restricting the time people may work in the area (safe work practice), requiring
everyone in the area to wear breathing apparatus (personal protective equipment) etc.
The best method would be to eliminate the hazard by using a battery-powered forklift or preventing the
forklift from entering the area.
Pedestrian Safety
The safety of pedestrians may be compromised by their own actions or the actions of forklift
operators. When pedestrian workers are at risk from the movement of a forklift truck measures
must be taken to eliminate or minimise that risk.
Hazard control measures may include:
Erection of barriers, bunting etc.
Posting of signs
Fitting warning devices to the forklift, e.g. flashing light, reversing beeper etc.
Use of a flag person to control the movement of pedestrians and other vehicles
(particularly when working on roads or other areas open to the public)
The operator of a forklift truck should warn any personnel who may be at risk from the operation of the
forklift truck.
Overhead Hazards & Dangers
When working with forklifts the collapsed height (the height measured from the ground to the
top of the mast accessibly) should be factored into lifting operations, and the extended height (the
measurement from the ground to the top of the mast OR the back rest if fitted) must be taken into account
when working in un-familiar sites.
Work Permits
In some situations, it may be necessary to obtain a work permit before commencing particular tasks in
certain areas such as working in a potentially explosive environment.
Work permits are required to ensure that adequate safety control measures are in place.
Forklifts and electricity
Keep a safe distance from electric power lines. Find out where all power lines are located in your
workplace. Do not unload a truck under power lines. (To avoid the mast making contact with the
lines when the forks are raised).
Current Regulations from the Office of the Technical Regulator in conjunction with SAFE Work SA sets the
following distances that operators of forklifts must stay clear of overhead power lines:
Stay at least
6.4 meters away from distribution lines on poles.
10 meters away from transmission lines on towers.
These distances are quoted in Australian standard AS 2550.1
Cranes, safe use-general requirements. One precaution is the requirement to have appropriate earthing
systems fitted and in contact with the ground.
Constant vigilance and an authorised spotter are required whilst working or travelling near live electrical
apparatus. If you do not know the voltage stay, at least 10 meters clear of power lines.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

13

If you do make contact with power lines

1. Stay on the machine.
2. Do not leave the Forklift until the power has been turned off.
3. If help fails to arrive, apply the handbrake, place the controls in neutral, and switch the Forklift off.
4. Jump well clear and stand a safe distance from the Forklift until help arrives.
5. Do not make contact with the ground and the Forklift at the same time.

Never work within 3 meters of low voltage lines and 8 meters of high voltage power lines with a
Spotter.
Never work within 6.4 meters low voltage and 10meters high voltage without a spotter.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

14

Stability
Forklifts are unstable by design. They have no springs and even four wheel counterweighted
Forklifts only have 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 on uneven ground.
The 2 rear wheels are attached in the centre to the main body of the machine allowing the rear to
hinge sideways affecting the lateral (sideways) stability of the machine. All Forklifts have a high centre of
gravity and a narrow wheelbase, which adds to their lateral instability.
Forklifts have 3-point suspension formed from the front drive axle A & B and the steering axle point at the
rear of the base C The area between points A, B & C on the diagrams below are known as the stability
triangle. If the centre of gravity moves outside the stability triangle the forklift will start to tip over.

Many forklift accidents occur as a result of the forklift tipping over either forward (longitudinally) or
sideways (laterally). An understanding of what causes this will help you to avoid the same thing happening
to you.
Be aware of the factors listed below which can affect longitudinal (Forward) instability.
The forklift is an unbalanced machine (one end is heavier than the other is), and should never be allowed to
have more weight forward of the fulcrum (centre of the front axle) than behind. If the centre of gravity of the
machine and load combined moves forward of the fulcrum the machine is in danger of tipping forward.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

15

Some causes of forward instability are:

Overloading
Violent stopping and starting
Incorrect use of the mast tilt (especially with the load carried at high levels)
Load not positioned against the heel of the fork arms
Shifting the load centre forwards
Lifting a load with a jib with the mast tilted forward
Picking up an over width load
Fitting slipper forks
Driving with reach extended.
Rough use of hoist and tilt levers
Driving on an incline
Be aware of the factors listed below which can affect lateral (sideways) instability.
As with forward stability, we have to consider the centre of gravity of the machine. If the centre of gravity of
the machine shifts too far to one side then the machine is in danger of tipping to the side.

Some causes of sideways instability are:

Turning at speed
Driving over uneven surfaces
An unevenly distributed load
Driving with a flat or under inflated tyre
Travelling with the load raised
Braking too hard when turning
Side shift not centred
Lifting a load on one fork arm
Driving sideways across a slope
Turning on an incline
Poor ground surface

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

16

Rear-end or Tail swing can be up to 3.5 times faster than the forward speed of the forklift. Many forklift
accidents can be attributed to the effect of rear-end swing. Rear-end swing is caused by the rear wheels of
the forklift swinging outside the line of the front wheels when a forklift turns whilst travelling forward.

This feature presents a hazard to pedestrians who may be struck by the rear of the machine and is
responsible for many forklifts rolling over when cornering too fast.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

17

Safe working load

Most Forklifts have 2 safe working loads (SWL) stamped on the load rating plate (Data Plate). They are the:
Mast vertical SWL
Mast forward tilt SWL
The load rating plate is usually found next to the drivers seat. If attachments are fitted a separate
load-rating notice needs to be displayed. To prevent an accident the weight of the load needs to be checked
against the specifications of the Forklift.
SWLs must not be exceeded. If the load weight is too great, the Forklift can tip over. As the mast is tilted
forward, the centre of gravity moves away from the fulcrum so that the SWL decreases.
Some other information often found on a data plate is the weight of the machine, tyre pressure, degrees of
forward and backward tilt and sometimes information relating to particular attachments. these data plates
are generally one or two types as outlined in the diagrams A and B below.
Diagram A

Diagram B

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

18

Operators must be able to understand the load plate and the conditions of loading at all times. The
load rating is taken from the front face of the load backrest to the centre of gravity of the load.
It is the responsibility of the owner to ensure a load plate has been fitted and that it displays the
lifting capacity of the machine under all lifting conditions. Do not use a Forklift that does not have a load
plate.
Understanding Load Centre Distance
Load centre is defined as:
The distance from the vertical face of the forks to the centre of gravity of the load. Most
palletised loads are square and evenly stacked in which case the load centre will be in the centre of the load.
Therefore, if the load is picked up hard against the vertical face of the forks the load centre measurement will
be half the length of the load. Unusually shaped loads will have varying load centres.

Using the diagrams below, study the load plates and determine whether they may be safely lifted.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

19

Capacity Decreases as the Load Centre Increases

If the load centre measurement increases past the rated measurement then you must decrease the weight of
the load in order to maintain stability. Using the load plate below determine whether or not the loads maybe
safely lifted.

Know your workplace

Each workplace has conditions that can contribute to dangerous situations. Operators should
inspect the workplace for any potential hazards and make sure they are eliminated or minimized
before operating the Forklift. On some sites, it may be necessary to obtain a work permit to operate a Forklift
as a safety control measure.
Be aware of:
The direction of traffic flow
Blind corners
Blind alleyways with cross traffic
Inclines
Ceiling clearance, including low pipes etc.
Doorway clearances
Types of load- flammable, fragile, unstable or hot
Excessive heat, especially where LP gas is used
The road surfaces
The fumes produced by the Forklift
Electric overhead wires
Forklift Selection
Ensure that the forklift you are going to use is suitable for the task and environment.
Issues to consider include:
Forklift capacity and limitations.
Refer to the load plate for forklift capacity, lift limit etc. and make certain that it is adequate for the
job.
The operating area.
Most forklift trucks are designed to operate on a smooth surface such as is found in most
warehouses. Many will not negotiate inclines or spoon drains without bottoming out. If you need to
operate on rough or unstable terrain, then a rough terrain or 4-wheel drive forklift may be required.
The fuel source.
If you are going to operate around foodstuff, or in confined areas, then a battery powered forklift
would be more suitable than one powered by an internal combustion engine.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

20

Make sure the floor can support the weight of your Forklift
Other workers and pedestrians should be aware of the need to keep clear of a Forklift while loading and
travelling. In particular, no one should walk behind a Forklift while it is loading or stacking or walk under an
elevated load. If these dangerous practices happen, you should report them to management.
Safety signs, barriers and using the horn and warning lights are methods of warning
personnel about Forklift operations. These precautions must be taken when operating over
roadways, footpaths and other public and work areas.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

21

ASSESSING THE LOAD

To reduce the possibility of an accident while lifting, transporting and stacking goods, it is important to
consider the following in relation to the load:
Weight and Load centre. Check that the load is not outside the limits of the forklift. This
information can often be found on consignment notes, weighbridge certificates or may be marked on
the load. It may be possible to calculate the weight of the load. If you are unsure do a test lift.
Contents. Check that the load will not be a danger to yourself or others in your working
environment. Are there special requirements such as the need to keep dry or store away from heat?
Stability. Check that the load is stable enough to be transported and stacked safely. If the load does
not look secure, restack it before moving. Is the pallet in good condition?
Balance. Check that the load is evenly balanced. Beware of goods in creates and unusually shaped
loads, e.g. machinery.
Handling Instructions. Look for and follow any handling instructions on the load. Beware of old
loads, creates etc. that are being re-used as old information may still be present.
Physical make-up of the Load. Consider whether the load consists of a solid, liquid, or gas. Liquids
are particularly dangerous as they a shifting centre of gravity. Some gases are stored and transported
in liquid form and may pose the same problem.
Consignment Notes
Consignment notes or con notes will display all the required information on it. This is
because all freight is moved and charged on weight due to the nature of the transport system in
Australia. If you have been asked to sign for freight being delivered onto your site, a possible solution
would be to mark the pallet load weight on the boxes or fright on the pallet.
This is only a suggested method; check with you employer and their procedures.
Load Weights
The correct identification of load weights should never rely on guess work. It should be considered
vital in the lifting, moving and re-locations of loads. The information that follows allows you to work
out the weight of some common loads, and therefore allow you to work out if the forklift you are
using is able to safely lift and carry those loads.
Simple calculations
Example 1
5 layers, 4 cartons per layer, each carton weighs 20kg
5x4x20kgs PLUS pallet weight i.e. 60kgs TOTAL load weight 460kgs
Example 2
A rectangular block of concrete solid mass 2,400kgs
Height 1.0 meters
Width 1.5 meters
Length 2.0 meters
Height x Width x Length = 1.0 x 1.5 x 2.0 x 2.400kg = 7.200kg
Example 3
The container weighs 500 kg
The container holds 3,000 litres 1 litre of water weighs 1kg
Weight of container + weight of liquid 500+3,000 = 3,500 kg

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

22

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

23

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

24

Tips for handling the load safely.

The following are recommendations that should be followed any time you carry a load:
Do not handle a load on only one tyne as this could place undue strain on the tyne and affect the
stability of the forklift
Do not lift a load that appears unstable. Restack if necessary.
Ensure that you have adequate fork spread to stabilise the load (approx.. 70% of the width of the
load)
Carry the load as near as possible to the backrest. Avoid undercutting the load.
Lift the tynes, loaded or unloaded, only as high as necessary to travel safely over the surface without
scraping or catching. Vary height as necessary.
Use only as much back tilt as is necessary to stabilise the load.
Keep the tynes tilted back when travelling whenever possible.
Avoid lifting and lowering when travelling.
Only lift when close as possible to the set down point

To avoid this, drive with the forks as

low as possible, which should be at
least below the height of the front
axle hub.
When working around other people,
never raise loads above
people.

Safe Operation
Forklift trucks should only be used on hard level surfaces. Four-wheel drive or rough terrain type
should be used on unstable terrain.

When raising the load

Carry loads as low as possible at all times.
Hydraulic controls should be eased in. If the controls are plugged or pushed quickly the
operation will be jerky.
Make sure that the forks are centred when they are entering a pallet.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

25

Do not put slings around forks

Do not enter the pallet with the mast tilted back or forwards (this will bind the forks).
The load should always rest against the heel of the fork arms. This will ensure the load centre is in
the right place.
If the load weight is unevenly distributed on the pallet, put the heavy end of the load against the heel
of the fork arms.
Make sure the forks are centred on either side of the mast.
A properly constructed hardwood pallet weighs 60 kg and has a SWL of 2000kg.
Do not overload pallets.
Do not allow more than a third of the top section of an unwrapped load to stand above the top of the
load backrest extension. A load not backed by the load apron can fall back and tangle with the mast,
or if the load is very high, can topple back onto the driver.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

26

Do not raise a load with just one fork.

Some situations that would affect your driving speed would include:
Wet floors or outside weather conditions
Driving with the forks or tynes too high off the ground.
Other fork lifts working in the area.
Other traffic, including people, cars or vehicles
Layout of the work site.
Workplace policy and procedures
Speed limits signs.
The size of the load being moved.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

27

When tilting the load:

Raise the load clear of the stack before tilting the load backwards
Always travel with the load tilted backwards and close to the ground.
When putting the load down, always bring the load over the stack before tilting forwards.
Deposit the load with the mast vertical or tilted forward slightly

Only begin to tilt forward when the

load is over the stack

Travelling
Forklifts are one-person vehicles. Do not carry a passenger unless an approved seat and
footrest that places the passenger under the overhead guard are fitted.
You can only lift people in an approved work platform manufactured to an Australian Standard 2359
Stay left in two-way traffic aisles

Do not lift or carry passengers.

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

Do not attempt to turn a Forklift when it is on a sloping surface. (This could affect lateral
stability and cause it to tip over sideways).

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

28

Forklifts and flammable liquid stores

Flammable liquid stores and areas where flammable liquids are used are usually zoned as having a
hazardous atmosphere. Forklifts must be modified or flame proofed before they can be used in a
hazardous atmosphere and in addition must have a compliance plate to that effect.
Flame proofed diesel powered Forklifts have an exhaust water wash box, which must be flushed out and
refilled every shift. Flame proofed battery powered Forklifts must not be connected to the battery charger
near any area where flammable liquids are handled in open containers.
Petrol and LP gas forklifts are never flame proofed because of their spark ignition system.

Handling Dangerous Goods

Dangerous Goods can be defined as:

"Substances which by their nature or their quantity constitute a hazard, from explosion, fire or poisoning or
by nature of their corrosive effect." Forklift operators are often required to load, unload or transport
dangerous goods and are likely to encounter packages that are leaking or damaged. For this reason it is
important that you have the ability to recognise containers of dangerous goods by their markings and have
an appreciation of the hazards involved in handling these substances. If a spill or a fire occurs, a basic
understanding of the action necessary is essential.
The HAZCHEM Emergency Code
This Code is taken from the "HAZCHEM" system developed by the United Kingdom Fire Service. The Code
characters (numerals and letters) are intended to inform emergency services of the best response action to
minimise the hazards to personnel.

Interpretation of the HAZCHEM Code

The Number - Designates the medium suitable for fighting a fire or
dispersing a spill. You may use the medium indicated by the number
shown or a higher number.
The First Letter - Indicates the following:
V
There is a risk of violent or explosive reaction.
BA
Wear breathing apparatus plus protective gloves.
FULL
Wear full body protective clothing and BA.
DILUTE
May be diluted with large quantities of water.
CONTAIN
Prevent spillage from entering drains or watercourses.
The Second Letter The letter E is added if evacuation of the area of the
accident should be considered as a first priority.

Example: The HAZCHEM Code 3 Y E is interpreted as follows:

3 - Means that you can use a foam (3) or a dry agent (4) extinguisher.
Y - Means that there is a chance of a violent or explosive reaction.
- Breathing apparatus plus protective gloves are required.
- Any spillage must be contained.
E - Means that evacuation of the area should be considered as a first priority.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

29

Have someone guide you when driving up a hill with a bulky load that blocks clear vision.
When travelling up OR down a hill your load should always face up hill.

Look over both shoulders before reversing

When reversing LOOK behind you. Do not rely on rear vision mirrors.

Blow the horn and drive slowly when approaching a blind corner
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

30

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

Do not drive across a slope, or when crossing railway tracks. Use a 45-degree angle to
ensure a smooth crossing.

Do not turn sharply at speed. Forklifts overturn very easily. They are narrow wheelbase
vehicle with a high centre of gravity.
Do not jump out if your Forklift is overturning. Stay seated, and brace yourself. Make
sure that no part of your body is outside the Forklift frame. (If you try to jump out, the
frame can cut you in half).
Lean away from the direction of the fall.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

31

Simple rules for inclines

Loaded Forklift. For increased stability keep the load on the uphill side. Not only is the load more secure on
the forklift but a load that is pointing downhill will cause the centre of gravity to shift further away from the
pivot point (front axle) and make it more likely for the forklift to tip forward.
Unloaded Forklift. When negotiating an incline on an unloaded forklift the tynes should be pointed downhill.
This will increase the amount of weight on the brake wheels (front) and make them work more efficiently.
Break wheels with little weight on them tend to lock up more easily.

Face the load uphill when travelling up a slope.

Face the load uphill and look behind when reversing down an incline.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

32

Watch out for rear end swing. Forklifts steer from the rear and the rear end will swing out on
the side opposite to the direction of the turn. When travelling forward on a forklift and turning
the steering wheel the speed of the rear end swing can be up to 3.5 times that of the
forward speed of the forklift. Stay as close as possible to the inside of narrow corners
when turning and watch out for pedestrians or objects.

Do not allow the Forklift to run out of fuel. Power steering and brakes will immediately
malfunction if the fuel runs out.
Gravity alone lowers the load. Revving the engine makes no difference.
Do not drive reach trucks with the reach out as this alters the load centre.
Give way to police, ambulance or other emergency vehicles at all times.
Always cross railway lines on a 45-degree angle, this will allow for a smoother crossing.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

33

Loading trucks
Ensure correct bridge plate is used.
Ensure drivers keys are removed and the driver is in a safe zone
Always, load pallets alternately on both sides of a truck. A truck can overturn if one side is
empty and the other side has a full load.
Make room by shifting the truck if there is no room to load both sides.
Loading Pantech (Large enclosed vans or trailers)
Make sure:
The mast is not too high to enter the van.
There is sufficient ventilation.
The truck will support the combined weight of the Forklift and the load.
The bridge plate is in place and secure.
The van wheels are chocked.
The driver of the van has removed the keys from the ignition and has left the cabin during loading.
The load is kept low during loading.
Lifting loads with two Forklifts.
Lifting a load with 2 Forklifts is very hazardous. The precautions listed below must be followed when lifting
with two Forklifts:
Only use counter balance forklifts for duel lifts.
Dual lifts should only be carried out by experienced operators.
The operation must be controlled by an experienced 3rd person who has responsibility.
Each Forklift must not lift more than 75% of its rated capacity given stability, position of load
centre and other factors affecting the Safe Working Load.
The load must be only carried the distance necessary to clear the load carrier.
Loads must be raised and lowered simultaneously.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

34

If one Forklift lowers more quickly than the other does, the load becomes uneven. In the diagram it shows
Forklift B lowering more quickly than Forklift A causing:
The weight to move immediately to the tip of the fork arms on A.
Pressure put on the mast of Forklift B that could cause it to bend or break.
The load slips along the fork arms changing the position of the load centre

Parking
Always find a level out-of-the way place to park.
Park clear of fire and emergency exits, power switches, fire fighting appliances, first aid
facilities, gas refuelling stations and fuel pumps.
Park with the tips of the forks on the ground and with the tilt forward.
Turn the ignition off and remove the key
Engage handbrake.
If the tips of the forks cannot be lowered to the ground, park so that the forks do not create a tripping
hazard.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

35

Work Platforms
Many workplaces use maintenance platforms to perform certain tasks. Work platforms should only be used
when the use of another method such as scaffolding is impracticable. When platforms are used they should
comply with Australian Standard 2359.1 1985
The following are recommended work practices, which should be followed when elevating people on these
platforms.
Use of only an approved platform.
Choose a forklift with solid tyres if possible.
Ensure that the platform is securely attached to the tynes.
Run the platform up to the working height while empty to ensure safe operation.
Leave the mast in the vertical position to keep the platform level.
The forklift should be on a hard level surface.
the forklift should be in neutral gear, with the handbrake applied.
the operator should stay with the forklift at all times.
Persons using the platform should stand firmly on the floor and not use ladders or steps to gain extra
height (unless the steps are an approved fixture).
Do not move the platform with a person on the platform regardless of short the distance to be
travelled or how low the platform is.
Remember, you, the operator are in control of the forklift and platform. Dont be pressured into
doing anything dangerous

Communication
Workplace communication should also be established in your workplace. In particular when using a safety
cage for example, methods of communication must be determined prior to elevating anyone.
Hand signals can and should be used for noisy sites, two way radios are also an option including verbal
commands.
Whichever method is used ALWAYS discuss them before starting any job.
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

36

Attachments
All attachments must comply with an Australian standard. Attachments can include: Drum Grabs (used to move 200 litre drums etc.)
Jib attachments
Safety personnel cages (used to lift personnel for short durations) Safety personnel cage should be
securely attached. Operator to remain in the forklift at all times. Park brake and neutral gear should
be applied. Only lifting and lowering should be used.
Tarp spreaders (used to lay tarpaulins over flatbed trailer loads)
Bale Grabs.
Carpet Spikes
Crane jib
Bin tipper
Side shift
Rotating head
Regardless of the type, each attachment must have a standards plate fixed to it, and the forklift
being used must be able to have the attachment fitted to it. If you are using an attachment for the
first time, seek extra training from a competent person. Jibs attachments must have a SWL (safe workload)
stamped on the attachment.
Jib Attachment
Keep the jib centred over the load before lifting (to ensure a clean lift with no sideways movement) and level
when being carried as low to the ground as possible. Drums etc. can swing whilst being moved and cause
some sideways instability.
Other attachments include carpet spikes, great care should be taken when using these
spike. Longitudinal stability can be affected, and great care should be taken with turns and turning
around blind corners. Always use the horn when approaching these situations. Ensure the attachment is
compatible with the forklift being used.

Paper grabs must

not be rotated
(turned) whilst
moving. It will
affect the stability
of the
forklift and a roll
over may occur.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

37

When using an attachment

Do not revolve the load while moving if a load revolve mechanism is fitted.
Use caution: jib attachments are more unstable than forks because they have a higher centre of
gravity.
The Forklift should be operated as if it is partially loaded even if there is no load on the jib
attachment.
The jib should be kept as low as possible and the mast should be kept vertical or tilted
backwards.
Do not lift a load with a jib attachment if the mast is tilted forward.
Do not tilt the mast forward when a loaded jib is attached.
The load should be kept as low as possible.
Travel at low speeds and make turns slowly.
Make sure that jib attachments are properly fitted with the locking bolt housed.
Slings should be inspected before being used for lifting
Centre the hook directly over the load before lifting to ensure stability.
The Safe Working Load must be displayed on all jib attachments above the lifting points
where a lifting hook is attached.
Hooks must be able to move at least 15 in all directions and swivel freely.
Do not rotate the load on attachments when the Forklift is moving.
"Slipper forks" are often used and can alter the load centre.
In all cases, the Forklift must be approved to use attachments. Safe Working Loads will be stamped
on the data plate for each approved attachment.
Chains, Shackles, and Synthetic slings should only be used by competent and authorised
personnel
All Multi-leg Lifting chains must be labelled (Tag) with the SWL.
All Shackles must have a SWL marked on them.
Discard any Shackle with more than 10% wear in the crown or the pin.
Each Synthetic sling must be labelled with a (Tag) with the SWL or identified by colour coding
All Shackles and Slings must be inspected before each use.
Using The Forklift As A Crane
Before using a jib attachment to lift a load check that the attachment:
is in good order and condition
is properly secured to the forklift
is fitted with a swivel (not fixed) hook
is of suitable capacity for the task (the SWL must be clearly marked on the
attachment at each hook position).
When travelling with a slung load:
travel and turn at low speed
keep the load as low to the ground as possible
keep the jib attachment as low to the ground as possible (use slings that are as short as practicable).
keep the mast vertical or on back tilt.
Only attach lifting gear to a jib attachment specifically designed for the purpose.Never hook slings
over or wrap around the tines of a forklift.
Ensure that slings and fittings are of adequate capacity for the task. The capacity of synthetic
webbing slings is indicated by way of colour coding and a tag attached to the sling. The capacity of
chains and flexible steel wire ropes is indicated by a stamp on the ferrule or a tag on the sling.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

38

Ensure that the lifting gear (slings, shackles, etc.) are in good condition. Inspect slings and other
fittings for wear and damage. The maximum amount of wear permissible in a shackle is 10% (it
should then be discarded).
Ensure that the load is correctly slung and secure before lifting
Ensue that the forklift is on solid, level ground, before lifting.
Lift the load slowly and smoothly. Do not jerk the load.
Ensure that the hook is centred directly over the load so that the load does not swing. A swinging
load can affect the stability of the loader.
Use tag lines (minimum of 16 mm diameter and made of dry, natural fibre rope) where necessary to
guide the load.
If there is any sign that the load has become unstable, lower it immediately.
Never raise a load over or near other people.
It is good practice to mouse/secure the pin of a shackle to prevent it unscrewing.

Rule Of Thumb Formula

Rule of thumb is a method for calculating the approximate WLL of flexible steel wire rope (FSWR), chain and
fibre rope when no charts are available.
Rule of Thumb - FSWR
To calculate the WLL of FSWR apply the formula:
WLL (in kilograms) = diameter2 (in millimetres) x 8
Example: Rope diameter is 20mm
WLL = 20 x 20 x 8
WLL= 3200 kg
Rule of Thumb - Chain
To calculate the WLL of chain apply the formula: WLL = diameter 2 x Grade x 0.3
Example: Chain diameter, 15mm. Grade, 80.
WLL = 15 x 15 x 80 x.3
WLL = 5400 kg
Rule of Thumb - Fibre Rope
To calculate the WLL of fibre rope apply the formula: WLL diameter2
Example: Fibre rope diameter, 15mm.
WLL = 15x 15
WLL = 225 kg
Load Factors
The WLL of a sling is the maximum weight that may be lifted with a straight lift. The
load factor for a straight lift is 1. Different methods of slinging and the angle
between the legs of slings will change the lifting capacity of a sling.
Included Angle
The angle of a sling also has an effect on its capacity. Increased angle between the
legs of a sling will reduce its capacity because of horizontal tension being added to
vertical tension. In most instances a longer sling will solve the problem by reducing
the sling angle.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

39

A rule of thumb for a safe angle is to ensure that the distance between the points of
attachment of the load is no longer than the length of the slings. If the distance
between the points of attachment is the same as the length of the slings the angle
will be 60.

Reeve Factor
The method used to sling a load will alter the lifting capacity of the sling. For
example:
- A reeved sling around a round load will reduce the lifting capacity of the
sling by 25%. The load factor is 0.75.
- A reeved sling around a square load will reduce its lifting capacity by 50%.
The load factor is 0.50.
Any person involved in the slinging of a load must be familiar with load factors for
each method of slinging.
WLL tables are available for all types of slings. You should refer to the correct table
before lifting a load.
Care Of Slings
Do not allow slings to lie upon ashes, the ground, wet or damp surfaces, rusty steel, near corrosive
substances or where a reaction between two metals may occur.
Do not drag slings from beneath loads.
Use adequate packing to prevent slings coming in to contact with sharp corners or edges.
Do not overload or shock load slings.
Ensure that slings are not heated or damaged during cutting or electric welding operation.
Do not leave slings exposed to the weather or salt water.
Take care to prevent twists from developing.
Do not expose to excessive heat.
Don't cross twist kink or knot any sling.
Inspection Of Slings
Proper inspection of slings is very important and should be done prior to use.
Inspect for:
FSWR
Core Slippage (where the outer strands of wire slip over the inner core)
Bird caging
Kinks
High stranding
Excessive wear
Corrosion from exposure to corrosive substances, salt air etc.
Crushed or jammed strands
Signs of stretching
Broken Wires
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

40

Number of Broken Wires Permitted in FSWR

If broken wires are found, count the number of broken wires in a length of wire times the diameter of the
rope. Discard the rope if the number of broken wires exceeds 10% of the total number of wires in the rope.
Example: 6/24 FSWR, diameter 12mm.
Length of rope to be inspected: 12mm x 8 = 96mm
Total number of wires in rope: 6 x 24 = 144 wires
10% Of 144 = 14.4
15 broken wires over a length of 96mm would mean that the rope should be discarded.
Note: One broken wire below a metalled socket indicates serious fatigue below the socket. The rope should
not be used unless repaired.
Chain
Twists, kinks or knots
Stretched links
Links locked or do not move freely
Gouged, pitted or cut links
Links crushed more than 10% of the original diameter
More than 10 % wear in the diameter of the link
Cracks
Wear is likely to occur at the link ends or on the outer side of the link from being dragged.
Synthetic Slings
Label present
External damage such as abrasions, cuts or contusions
Internal damage indicated by variation in the thickness of the sling
Damage to stitching
Damage to cleave or protective coating
Signs that the sling is damaged due to contact with a corrosive substance
Cuts and tears
Damage to eyes or end fittings
Fibre Ropes
An excessive amount of broken fibres
Signs of rot of mildew (you will smell and see this problem)
High stranding (one strand in the rope lays higher than the rest)
Unlaid or fraying strands
Signs of contact with acid or other corrosive agents
Sun rot (this normally affects synthetic ropes more)
Knots
Cuts
If any of the above are found the sling should be withdrawn from service and safety
tagged.
General safety rules summarised
When work platform is elevated, the driver of the forklift must remain at the controls at all times.
Park brake applied, gear selection in neutral with engine running.
In the event of a fault being revealed at any time or if the forklift becomes unsafe in anyway.
Shut the forklift off (do not operate until fault rectified)
Remove the ignition keys
Tag the forklift off
G&L FORKLIFT TRAINING MANUAL
TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

41

Report the matter immediately to your supervisor to be fixed.

Do not make repairs, alterations, or adjustments to any forklift unless authorised and qualified.
Do not allow anyone to stand or pass under elevated fork or attachments, whether loaded or empty.
Do not use supplementary counterweights or additional personnel to increase the load capacity of
any forklift.
Always approach rail tracks at a 45 degrees angle and slow down.
Do not operate a forklift unless a compliance plate (data plate) is fitted.
Do not operate a forklift on a public road unless the forklift is registered, has lights, turning
indicators and warning devices fitted. Have appropriate class of drivers licence covering the Gross
Vehicle Mass of the forklift.
Never lift unstable loads (restack pallet if required).
Check load weights and handle only within the rated capacity of your forklift truck.

First Aid
Forklift operators work in a high-risk industry. Not only are there many minor injuries but also there are
also serious injuries where the injured person will need first aid to restore breathing, heartbeat or to stem
blood flow.
Know the location of the first aid room and the nearest first aid kit. Refer to the code of practice in relation to
the amount of first aid kits per site. South Australia has approved OH&S standards relating to this.
The standard first aid symbol in Australia is a white cross on a green background.
First aid kits on worksites should have a carrying handle. There must be a notice near to the first aid room
with the name(s) of those in the workplace that hold an approved occupational first aid certificate.
It is recommended that Forklift operators take the time to obtain an approved first aid certificate.

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

42

NOTES

G&L FORKLIFT TRAINING MANUAL

TLILIC108A-LICENCE TO OPERATE A FORKLIFT
G&L Version 1.3

31st September 2011

43