TLILIC2001A LICENCE TO OPERATE A FORKLIFT TRUCK ACTIVITY BOOK

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1 TLILIC2001A LICENCE TO OPERATE A FORKLIFT TRUCK ACTIVITY BOOK STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 1 of 12

2 TLILIC2001A LICENCE TO OPERATE A FORKLIFT TRUCK ACTIVITY BOOK RTO to retain as evidence of training and competency Name: Learner Details: Name: Trainer Details: Company: RTO: STES #50091 Training Location: Date of Training: REVIEW LOG Version Number Date Updated Details of Updates Version 4H Released June, 2012 Version 4HR1 Supersedes previous version Released December, 2012 Terminology in questions/activities updated to reflect learner guide content. STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 2 of 12

3 MODULE 1 QUESTIONS 1. List the 4 main types of WHS/OHS legislation, requirements and guidelines. 2. What are the 3 stages of risk management? 3. What is a hazard? 4. List 3 hazards that might exist in a workplace with forklifts. 5. Number the hierarchy of hazard controls in order from most effective to least effective: Isolation Personal Protective Equipment Safe Work Practices Elimination Engineering Controls Substitution STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 3 of 12

4 6. List 3 types of forklift. 7. What information is found on a forklift load plate? 8. What are 3 factors that may cause the forklift s centre of gravity to move outside the stability triangle? 9. Why should you check the path of movement before you start? 10. List 3 types of instructions that you might come across in your day to day work as a forklift operator. 11. List 3 communication methods that you could use during forklift operations. STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 4 of 12

5 MODULE 1 PRACTICAL ACTIVITIES Activity Competency Demonstrated 1. Locate an example of each of the following documents and explain how they affect the way you would operate the forklift: Work instructions/swms/jsa. Legislative requirements. Organisational requirements. 2. Inspect the work area and identify and explain the following: a) Hazards and potential hazards in the area. b) Appropriate control measures for identified hazards and how you would implement them (including consultation with appropriate personnel/workers). c) The type of load to be shifted and its destination. d) The most appropriate choice of forklift and attachments. e) Appropriate communication techniques to be used throughout the forklift work. STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 5 of 12

6 MODULE 2 QUESTIONS 1. List 3 examples of visual checks that you would make while inspecting the forklift. 2. What are 3 fluid levels that need to be checked before using the forklift? 3. What should you do if the forklift load chart is missing or you cannot read it? 4. What safety devices should be installed on the forklift you intend to operate? 5. How should you climb onto the forklift to start it and check for any abnormal noise? STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 6 of 12

7 6. List 3 examples of operational checks that need to be made before using the forklift. 7. What should you do if you find a fault with the forklift during your pre-start checks? 8. How could you determine the weight of a load? 9. List 3 hazard control measures that may be implemented before starting forklift operations. 10. List 3 factors that would influence the speed of the forklift. 11. Where should the heaviest part of the load be positioned? STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 7 of 12

8 12. What is the correct way to travel on a ramp? 13. What should you do if the load blocks your view? 14. What should you always do before reversing the forklift? 15. When is it acceptable to use forward tilt? 16. What should you do if the forklift tips over? 17. List 3 places where you would NOT park the forklift. 18. How should the fork arms be positioned when parking the forklift? STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 8 of 12

9 19. Why should you remove the keys from the forklift after you have finished using it? 20. Why should you conduct post-operational checks? 21. What should you do if you find a fault with the forklift? STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 9 of 12

10 MODULE 2 PRACTICAL ACTIVITIES Activity Competency Demonstrated 1. Conduct an inspection of a forklift and record the results in the service logbook / daily inspection checklist: a) Pre-start visual checks. b) Demonstrate the correct procedure for mounting and starting the forklift. c) Operational checks: Locate and identify all controls. Test all movements and functions to their full extent. 2. Demonstrate the correct procedure for reporting faults in accordance with procedures including: Reporting the fault. Recording the fault in the logbook. Isolating defective equipment. 3. Determine the weight of an unmarked load selected by your trainer. 4. Determine if the forklift can lift the load by referring to the load chart. 5. Select attachments relevant to the load to be lifted. 6. Implement hazard control measures as required for the job and site. STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 10 of 12

11 7. Demonstrate how to operate the forklift: a) Position the forklift to access the load to be shifted. b) Pick up and travel with the load ensuring: Communication is maintained at all times with relevant personnel/workers. All instructions and directions are followed. The forklift does not collide with anything during travel. The forklift is operated at a safe speed appropriate to workplace conditions. Visibility is maintained at all times during travel. Safety devices are used in accordance with site procedures. The stability of the load and forklift is monitored at all times and adjustments are made to correct any problems. Mast tilt is applied appropriately and safely. Forklift is operated in forward and reverse according to work space restrictions. c) Place the load according to directions from your trainer. 8. Demonstrate the correct procedure for responding to a simulated emergency situation described by your trainer. 9. Park the forklift in the designated area away from hazards. 10. Demonstrate the correct shut down procedure for the forklift. Refer to the manufacturer s instructions for the correct shut down procedure. 11. Conduct post-operational checks on the forklift, secure the forklift and report any defects you find. STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 11 of 12

12 FORKLIFT INSPECTION CHECKLIST Forklift Inspection Checklist Date: Company Name: Machine Number: Site: Operator Name: Item to be checked by operator: Fault Report Data/Load plate Warning decals Forks, attachments, load backrest, carriage, pallet grab Mast assembly, hose pulleys Tilt and lift systems Hydraulic lines Steering chains Tyre pressure and condition Structure and overhead guard Fluid levels: engine oil, hydraulic oil level, transmission oil, brake fluid, coolant, power steering fluid Battery security, water level and connectors Air filter indicator (if diesel) Compliance plate, gas cylinder (if applicable) Leaks under forklift Seat and seat belts Mirrors Horn and/or backup alarm Lights, gauges and instruments All brakes All movements Steering Tag Attached? Yes / No Action Taken to Repair Forklift: Name: Return to Service Authority by Supervisor Supervisor Name: Signature: Comments: Date: Date of Repair: STES STES TLILIC2001A Licence to operate a forklift truck - activity book V1 01 Page 12 of 12

13 HAZARD REPORT FORM (To be completed by the person who identifies hazard) * Date: * Time: * Issue raised by: Details of Hazard: Description of Hazard: Location of Hazard: Further actions recommended: Out of Service tag required Yes No Supervisor notified verbally Yes No * Signature of person reporting: STES STES Hazard Report Form V1 01 Page 1 of 1

14 Forklift Operator Training Notes * Name: * Date: Power Line Clearance Zone R3.64 (1996) WA (a) Insulated overhead power line <(less than) 1000volts (b) Non-insulated overhead power lines <1000volts (c) Ins/n.ins overhead power line between ,000volts (d) Ins/n.ins overhead power line >(greater than) 33,000volts metres metres metres metres Load Centre Distance = Invisible distance drawn between the and the of of the. Point of Balance = Front Is all of the weight behind the Point of Balance acting as a counterweight? (circle) YES or NO Name three conditions that can cause a forklift to tip sideways? What is the safe travel height for a load? Below the. What direction must a load face when travelling up a ramp? When travelling up a ramp why must the load face uphill? What direction must a load face when travelling down a ramp? Additional Notes & Questions: for personal or group discussion You must ask questions where you are unsure at any time except during theoretical assessment activities. Your assessor will give you instructions. WARNING: Use of these written notes or any other documents including learning materials during the theoretical assessment may result in an instant ruling of Not Yet Competent. All assessments are conducted in accordance with Work Safe WA regulations and guidance material. STES STES Operator Training Notes V /08/2015

15 Learning the Controls and Pedals Sheet (10min) Group Activity PEDALS Awareness YES NO The first thing to understand about most forklift trucks is that they have an automatic gearbox meaning the machine is similar to an automatic motor car in that you will have a pedal for acceleration and a pedal for braking, to slow the machine to a stop. GEARS Awareness YES NO Most forklift trucks will only have a single gear ratio for forward motion and a reverse gear for travelling backwards. TRAVEL FORWARD Awareness YES NO As a result of automatic transmission, you only need to push the gear stick (small electronic stalk located to left of steering column) one position forward to travel in a forward motion. TRAVEL IN REVERSE Awareness YES NO As a result of automatic transmission, you only need to push the gear stick (small electronic stalk located to left of steering column) one position backward to travel in reverse motion. AT NO TIME does the operator engage the pedal on the far left to use as a manual gear for gear changes. This pedal is a CLUTCH BRAKE and does not need to be engaged for the purpose of changing gears. Awareness YES NO CHANGING GEARS (from forward into reverse or vice versa) Awareness YES NO Stop the machine by engaging either the far left clutch brake or the middle primary brake. BOOSTING Awareness YES NO An industry term used to describe the elevation (lifting upwards only) of a heavy load by use of additional hydraulic pressure caused by engaging the clutch brake whilst still in forward gear and then pushing gently down on the accelerator. Used when the operator chooses to remain in the forward gear position without use of the handbrake. This is a permissible industry practice that recognizes technology and efficiency as the machine is built for you to disengage the main drive power at the transmission when the machine is halted by pressing down on the clutch brake, thus allowing an operator to perform a lift without the need to return the forklift to a neutral gear position and apply the handbrake. Avoid use of clutch brake as an inching pedal although this is a name given to this pedal by the manufacturer. Do not use clutch brake (when inching forward) as though it were a manual clutch pedal in a motor car as you apply acceleration, as this may cause the machine to suddenly move forward a few centimetres or more. This is not good practice if holding a heavy load up high in front of a racking system. Do this instead When needing to ensure a smooth take off every time engage both brake pedals (both clutch brake on far left and primary brake in middle of layout) then slowly release the far left pedal (clutch brake) followed then by the slow release of the primary brake pedal. This will ensure a smooth take off as you gently apply pressure to the accelerator whilst in either forward or reverse gear position. I have sampled the above basic forklift controls, pedals and manoeuvres and understand the need to operate smoothly at all times without applying unnecessary acceleration during boosting or during take off. * Name: Date: * Signature: STES STES LF Controls and Pedals Sheet V /08/2015

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