Professional Documents
Culture Documents
Forklift
Final Assessment Guide
TLILIC2001A
Licence to operate a forklift truck
TLI10 Transport and Logistics Training Package
Please take the time to read this Final Assessment Guide it tells you how each part of the
mandatory assessment (written, calculation and practical tests) work. A revision section of your
formal training session is included within this booklet and much of the information that you need to
pass the assessment is re-visited. It is certainly going to help you on the day if you have prepared in
advance. Remember if you fail to achieve competency WHSQ require another 6 business days for
re-assessment.
Some of the questions have multiple options i.e. Option 1 or Option 2. The Assessor is required
to choose these for you. It is not that some questions are harder than others; the Regulators
are just trying to limit the possibility of candidates cheating, each person undertakes a slightly
different test
You are given up to 15 minutes to read the exam and ask about the interpretation or meaning
of any of the questions
It is not multiple choice but a series of short statements or one word answers
It is a closed book assessment, i.e. you cannot take any learning materials or notes in with you
It is permissible to undertake the theory exam orally for students who struggle with written
English
The exam must be conducted in English therefore you must be able speak and understand
English easily
The exam should not take any more than 2 hours to complete
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The Assessor can ask you questions if any answer you have provided requires clarification, so
he can confirm your understanding
However clarification cannot be sought for answers that are clearly incorrect on the first attempt
Any critical questions answered incorrectly will result in you having to re-sit the written exam
again (further 6 day notification needed)
Any non-critical questions that were answered incorrectly within the permissible amount of up
to 4 wrong answers will be discussed with you
These questions will be asked again at the time of the practical assessment to confirm that you
now have the knowledge
If you got more than the permissible amount of non-critical questions wrong you will have to sit
the whole written exam again
You need to achieve competency in the written test before you can move on to the calculation
assessment
Your theory assessment will be retained by the Assessor
You are given up to 15 minutes to read the exam and ask about the interpretation or meaning
of any of the questions
It is a written exam
You must show the formulas (working out) for all your answers
The Assessor can ask you questions if any answer you have provided requires clarification, so
he can confirm your understanding
However clarification cannot be sought for answers that are clearly incorrect on the first attempt
You need to achieve competency in the calculation assessment before you can move on to the
practical assessment
If Assessment is to be conducted on site, please take a moment to review your workplace and ensure
it is suitable for training / assessment:
Be aware that a WHS Inspector maybe there at the time of assessment to audit the Trainee,
Re-assessments
If you fail part of your assessment, i.e. you have booked for your theory and calculations, you pass
the theory and fail the calculations, the following process will apply:
Providing it is done within 2 calendar months of failing the first time round, the trainee need
only successfully complete the calculations and the practical assessment to be deemed
competent
The competent result in the theory assessment will still be taken into consideration.
If more than 2 months elapse then the candidate must complete the entire assessment again
(theory, calculations and practical)
If more than 12 months elapses they must start the whole training course again from scratch.
All re-assessments are still subject to the 6 business day notification period required by WHSQ
of an Assessors intention to conduct a Trainees assessment
A Trainee is permitted 2 attempts at each of the challenge tests within their course fee. After
this a re-assessment fee of $150 may be charged for each assessment
Plan Work
Your employer has to provide you with a safe working environment and a safe working method
Where are you going?
Machine capable of doing the job (capacity)?
How are you going to do it?
Other equipment needed?
Is there enough light?
Ventilation?
Noise?
People?
Fumes?
Permits / inductions What do you need?
Paperwork what do you need?
Communication How will you communicate with supervisors and workers? (verbally,
emails, hand signals, forms etc.)
Traffic Management Plan Familiarise yourself (see next section)
Do you have to drive a forklift on the road / public access way? UD Licence
Characteristics of the Load itself. Are there chemicals or dangerous goods to deal with?
You must constantly consider the hazards involved and controls needed when planning how
you will operate the forklift and move the load
PPE - What do you need?
Hierarchy of Control
A priority list of dealing with hazards
Remove the hazard
e.g. Separate pedestrians and machines; change the layout of the
Eliminate worksite
Substitute
Isolate
Engineering Control
Administrative Control
Hazard controls should be applied prior to the commencement of work, then monitored and
implemented as new hazards emerge to prevent accidents injuries and damage to loads.
Admin control measures and PPE do not control the hazard at the source. They rely on human
behaviour and supervision and used on their own tend to be the least effective control measures to
minimise risks
Forklift Assessment Guide Version 1 valid from 1.1.13.docx
You must comply with State regulations working near power lines refer to Electrical Code of
Practice 2010 for working near exposed live parts.
Working near Power Lines
A safety observer or spotter is a person who has undergone specific training and is competent to
perform the role in observing, warning and communicating effectively; and who warns about
approach to exclusion zones. (Refer to Electrical Code of Practice 2010 for working near exposed
live parts).
Working with an authorised spotter can reduce the exclusion zone for working around electrical live
parts.
However, the best method is to eliminate the hazard by turning the power off, contact local supply
authority.
Actions on Hitting Power Lines
Stay calm and assess the situation
Warn other workers not to approach the forklift
Stay on the machine
Wait for the power supply to be isolated
If this is not possible, attempt to break contact by moving machine (do not take risks)
Jump clear without touching the forklift and the ground at the same time (be aware potential
difference in voltage)
Dont take unnecessary risks make a sensible, logical decision. You may be risking your life!
Tiger Tails
Tiger Tails (also known as Torapoli Pipes) are plastic covers used
to warn people they are in the presence of overhead power lines.
They are not insulators.
Load Calculation
Dont do trial lifts you may damage machine
Read labels / con notes / manifests
Contact supplier / manufacturer
Calculate
Weigh one box and multiply by number of boxes (dont forget to factor pallet / drum into
calculations)
Example:
If you have 11 boxes of nuts and bolts, each box weighs 70 kg
They are stacked on a Chep pallet which weighs 60 kg
How heavy is the load?
11 x 70 kg = 770 kg
Plus pallet = 60 kg
Total
830 kg
Pre-checks
Pre checks should be done daily before use
Or every 8-10 hours, whichever comes first
Records should be kept
Some of the benefits of having regular checks performed on each machine include:
Protects your own safety forklift is safe to use
Easy to find faults and repair them whilst still minor
More reliable machines and less chance of down time due to breaking down
Easier to identify bad drivers and staff causing damage
Protection against insurance problems, WHSQ fines and accidents
Pre-checks in a nutshell
Before starting the motor check do an overall visual check to ensure that there is no visible damage;
then check that:
There are no leaks under the machine
Overhead Safety Guard fitted and its condition
Load back rest extension fitted and its condition
Foot guard (metal plate immediately in front of the foot pedals.
Data Plate fitted details displayed for any attachments you are using
The wheels and tyres are in good condition
Wheel nuts are tight
Pneumatic (air filled) tyres have correct pressure for stability
Puncture Proof Tyres (solids) for good condition i.e. even wear, no big chunks of rubber
missing, not lifting away from the rims.
The forks are evenly spaced and without defects and the fork locking pins are in place.
Mast Guides and cylinders for any leaks or damage
The lifting chains are an even length, plus gaps between the plates.
The counterweight is secure.
There are no oil leaks from the hoses to the rams (dont use bare hands to feel)
Transmission oil
Engine oil level
Check the coolant level, visually in the header tank, do not take the top off the radiator only
do this when the engine is cold
Forklift Assessment Guide Version 1 valid from 1.1.13.docx
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Danger Tags
KTR = Keys, Tag, Report
K = Keys (Secure Machine and remove keys)
T = Tag (attach correct warning sign to forklift)
R = Report (report fault to supervisor)
Data Plates
Safe working load
Most Forklifts have two safe working loads stamped on the load rating plate. They are the:
Mast vertical SWL
Mast forward tilt SWL
The load rating plate is usually found next to the drivers seat.
Do not use a machine where data plate is missing or unreadable key tag, report
If attachments are fitted a separate load rating plate needs to be displayed.
To prevent accidents the weight of the load must always be checked against the
specifications of the Forklift.
Rated Capacity
Rated Capacity =
Normally in KGS
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2
3
How heavy?
How long?
How high?
Weight
Length (load centre of gravity)
Height
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Tyres
Air filled tyres (pneumatic) tyres must be kept at the correct even pressure to ensure good stability
of the forklift.
Solid rubber tyres should be checked for even wear and no chunks missing.
Post Start Operational Checks
Everything fitted should function
All warning / safety devices strobes, beepers, lights, horn, mirrors etc.
All hydraulic functions tested to their operational limits & to lubricate rams
Single acting lift rams / rust build up and wear ridges
Steering - hydraulic / electric
Brakes / inching and parking
Listen for noises
Any faults key, tag report
Components of a Forklift
Protective Structures
Overhead Guard Function of the overhead guard is to protect the operator from falling objects
and overhead hazards. Can fit Lexan cover as well
Backrest or Load Structure is positioned between the mast and the fork arms. Function is to
Apron
protect the operator from falling objects and stop fouling of the mast.
Foot Guard
Function is to stop objects falling on the operators feet and stop any fouling of
the foot pedals, slippy pedals are dangerous
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WHEN
LOADED LOAD
ALWAYS
FACES UPHILL
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Severe braking
Incorrect use of the mast tilt (especially with the load carried at a higher level)
Load not positioned against the heel of the fork arms
Shifting the load centre forward
Dragging a load in from the front with the jib attachment fitted
Lifting a load with a jib with the mast tilted forward
Picking up an over-length load
Driving reach truck with mast extended forward.
Too heavy, too long and too high
In case of a rollover
If the forklift does tip over:
do not jump out
brace yourself
hold on
stay inside the forklift with your seat belt on
lean in the opposite direction to the overturn
Be very aware in reach trucks what is your safest option
DO NOT TURN AT SPEED OR WITH A RAISED LOAD
Seatbelts Must be Worn
Mandatory they are worn if fitted
Prevent you from falling out / jumping out when adrenalin kicks in
Prevent you from head-butting the overhead guard in an emergency stop or accident
On the spot fines can apply
Reach trucks safe procedure can vary refer to manual / supervisors recommendations
Fulcrum
ALL the weight behind the point of balance, pivot point or fulcrum (front axle) of the truck is acting as
the counterweight.
Counterweights
Do not put extra weights / people onto the back of forklifts in an attempt to increase its
capacity
Get a bigger forklift
If you want to increase a forklifts capacity refer to the manufacturer
Side Shift Attachments
A side shift attachment allows the operator to move the load to the left and right of centre.
This particularly useful when placing loads into tight spaces and when tier stacking goods.
However, when side shift is used the lateral stability of the forklift is compromised, for this
reason it is important that you ensure that the side shift has been centralized before
travelling.
Tier Stacking
If you are tier stacking a load (stacking a load on top of each other)
Ensure loading area is stable and flat
The Heaviest Load should be on the bottom to avoid crushing
Do not stack too high that the load becomes unstable (3 high is a general rule)
Bagged goods should be pyramid lock stacked onto pallets.
If you have to re-stack a pallet manually because a load is damaged or unstable, ensure that
you get trained in the correct manual handling technique from your employer.
Loading Large Vans (Pantechnicons)
Make sure:
A rated and secure bridging / docking plate is used to join the truck to the loading dock (no
gaps)
Forklift Assessment Guide Version 1 valid from 1.1.13.docx
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Rated means that the Bridging Plate is rated to cover the weight of the machine plus the load
That the mast is not too high to enter the van (collide with the roof).
There is sufficient ventilation.
That the truck will support the combined weight of the Forklift and load.
That the van wheels are chocked.
That the driver of the van has removed the keys from the ignition and has left the cabin
during loading.
The load is kept low during loading
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Parking
Do not park a forklift near:
Doorways passageways and walkways
First aid facilities
Re-fuelling zones
Blind corners
Within 2 metres of any rail track
Emergency exits
Overhangs
Power switches
Fire fighting appliances / hose reels
The site should be well away from other work activities ensuring that the machine will not
become a hazard to others
Never park a forklift on a slope except in case of a breakdown, wheels must be chocked
Shut Down
Handbrake on
Tynes on the ground (tips on the floor)
Equipment safety locks are in place
Turn the engine off
Put the forklift into a low or neutral gear (in accordance with operational manual).
Dismount the forklift in a safe manner, using the 3-point exit using the handrails and footrest.
Do not jump from the machine
Isolate fuel supply
Remove key (site specific)
Parking on a Hill (only done in an emergency, breakdown etc)
If you must park the forklift on an incline: Make sure the handbrake is applied and the wheels are chocked, to prevent the vehicle from
rolling forwards or backwards
You will need a third person to do this
It is a bad practice
Post Checks (after operation)
Post-operational checks need to be carried out, in order to:
Detect any structural damage
Fuel etc.) turned off
Any leaks (water, oil, other fluids etc.)
Safe for use by the next operator
If not safe, key tag report
To eliminate getting blamed for something you did not do!
Forklift Keys
Must be removed to prevent untrained or unauthorised people accessing machine
Can be site specific
Can affect insurance / fire regulations
Suggest using PIN codes etc.
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Task four: Operation of the forklift to the full range of its capability (safe moving of
loads)
Task four requires you to safely move a variety of loads using the forklift. You must maintain communication with other
workers where appropriate and required, and at the same time you will need to continually monitor the load, when visible,
as well as hazards in the working area. In addition, the assessor will check that you do not hit or knock over any objects in
you path, that you keep the mast in the correct position and that you ensure the load is correctly positioned at all times.
The assessor will ask you some questions about your knowledge.
The assessor will ask you to
demonstrate the following three lifts:
Lift one low level
Lift two medium level
Lift three high level
Your instructions, which the assessor will give to you orally, are as follows:
Pick up load at A, drive forward and place load at B.
Pick up load at B, drive forward and place load at C.
Pick up load at C, drive forward and place load at D
Pick up load at D, operate the forklift in reverse, place load at E.
Move forklift to point F.
Shutdown and secure forklift.
The assessor will show you where points A to F are in the assessment area.
You are now required to park the forklift and shut it down, safely and effectively. Secure the forklift in accordance with
procedures.
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c.
d.
e.
f.
g.
h.
i.
j.
k.
A third copy of your Assessment Summary is kept on your student file at The Operator School.
One original copy of your Statement of Attainment will be produced and issued to you following
a successful outcome of competency. This is for you to keep for your records. You no longer
need a copy to submit your application at the Post Office.
In the majority of courses done at The Operator School your Statement of Attainment will be
issued to you at the same time as your Assessment Summary, as this fits in with our
administration process. However we do have up to 14 days to get this document to you. If we
have delivered practical assessments on site, we need to come back to The Operator School to
complete the administration process.
You are not legal to operate a forklift in the workplace until you have lodged your licence
application at a Qld branch of Australia Post.
We suggest you staple the receipt from the Post Office to your Government paperwork as proof
of lodgement, this will act as your temporary interim licence until you receive written approval
from WHSQ that your licence has been issued.
If you are unable to get to the Post Office straight away, you must not operate a Forklift in the
workplace under any circumstances.
If you have applied for 2 classes of high risk work licences, i.e the Forklift and Order Picker,
both classes will appear on the one high risk work licence.
You must lodge your application for licence, in person, at any major Queensland branch of
Australia Post within 60 days of the issue of the Statement of Attainment together with the
appropriate Licence application fee (currently $77.00 for each licence). Certain branches of
Australia Post may require the applicant to make an appointment.
If an application for a licence to perform high risk work is not made within 60 days of the
issuance of the Statement of Attainment. Depending how overdue the licence
application is, you may be allowed to re-take the mandatory challenge tests. There is a $350
fee for this service. However, if several months have elapsed since you undertook your
assessment, you may have to complete the whole training process again and pay the cost of a
full training course. Please discuss this with us if you find yourself in this situation.
If the paperwork is issued but misplaced by yourself within 60 days, you will incur an
administration fee of $50 for re-issuing paperwork. Paperwork is re-issued with original dates
(you do not get extra 60 days) you will also need to be available to re-sign paperwork.
Where possible The Operator School will supply and assist you to complete the F1 application
for a Licence Form (Australia Post keep these forms for individual use and we are aware that at
times we will be unable to secure bulk copies)
You take to a Qld Post Office
F1 Licence Application Form
The Assessment Summary number (from the top left hand
corner of the yellow copy of your Assessment Summary)
One passport style photograph of yourself
(some Australia Post outlets can take photos for $14.95)
Required 100 points of Photo Identification
Payment for each Licence $77.00 (if cheque make payable
to Department of Employment and Industrial Relations or
Australia Post)
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