Forklift Training

Manual
Reading and learning the questions and answers contained in this
manual is step 2 of our 6 step forklift licensing course.

Licence to operate a Forklift Truck - TLILIC2001

Version V12 August 2018

AFT Forklift Training Manual V12 Aug 2018

 Forklift Licensing – 6 step process

Theory training - You do in your own time

1- Training videos 2 - Training manual 3 - Self-assessment

watch and learn read and learn theory quiz

 Fail - go back to step 1

 Pass - go to step 4

Practical training - You do with our trainer

4 - Practical forklift training 5 - Trial assessment

(Theory and practical)

Licence assessment – You do with our assessor

6 - Final licence assessment

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AFT Forklift Training Manual V12 Aug 2018
AFT Forklift Training Manual V12 Aug 2018
Forklift licence course - Frequently Asked Questions

Course outcomes:

Q. What licence class does this course lead to?

A. LF class = Forklift Truck

Q. What type of forklift can I operate with this licence?

A. All Forklift’s except for Order Picking Forklift Trucks

Course entry requirements:

Q. How old do I need to be to get a forklift licence?

A. 18 years of age

Q. Do I need to be a New South Wales resident to get a forklift licence in NSW?

A. Yes

Q. Can I do the forklift licensing course in a language other than English?

A. No

Q. What will happen to me if I forget my 100 points of identification (I.D) on my

final licence assessment day?
A. You cannot legally be assessed if you do not have 100 points of suitable I.D with you
at the start of the licence assessment.

Q. Do I need to bring my I.D to my training days or only the final licence

assessment day?
A. Only the final licence assessment day

Q. Can I have an interpreter help me with this course?

A. No

Q. Can I do the final licence assessment verbally if I cannot write my answers?

A. Yes, but you must pre-arrange for this to happen with our office. Please discuss this
option with your trainer or call our office on 8814 8640.

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Training course options:

Q. Why does Australian Forklift Training offer 3 training course options for the
same licensing course?
A. Each course option contains the same content the only difference is the duration and
fees. AFT offers the following course options:
 Express
 Standard
 Premium

Q. How do I know which training course option is right for me?

A. Each course has a suitability guide that you use to decide for yourself which course
is right for you. It is your responsibility to commence the most suitable course for you
and your skills and experiences. The entry requirements for these courses are:

1. Express course
 Experienced forklift operators only
 Must have above average reading and writing skills
 No verbal assessments

The Express course is the most difficult way to complete the forklift licence course. Do
not do this course unless you comply with both entry requirements. Only 10% of our
clients select this training course option

2. Standard course
 Must have good reading and writing skills
 No verbal assessments

The Standard course is our most popular course by far. 80% of our clients select this
training course option

3. Premium course
 Must be fluent in English with at least basic reading and writing skills
 Verbal assessments if required

The Premium course is a great course for people who speak English as a 2nd language
or who wish to attend the most thorough forklift training course possible

Q. What should I do if I feel that I have been booked into the incorrect course
option for me and my skills?
A. You must call our office immediately

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Licensing course – 6 step process:

Q. What are the 6 steps that make up this licensing course?

A. 1. On-line training videos
2. Training manual
3. Self-assessment theory quiz
4. Practical forklift training
5. Trial assessment
6. Final licence assessment

Q. What will happen to me if I arrive at my practical forklift training day (Step 4)

but I have not yet completed the theory training part of the course (Steps 1,2&3)?
A. The training day will run as per plan. If you fail the trial assessment then you will
need to book an additional training day

Licensing course – Terms and conditions:

Q. Will there be any additional fees if I do not pass either the trial assessment
with my trainer or the final licence assessment with the assessor?
A. Yes

Training Centre - Extra fees & charges

Extra training session (half day) $100
Extra training session (full day) $150
Extra licence assessment - theory $100
Extra licence assess - practical (includes half day training) $150
Saturday surcharge above charges plus $50

Workplace - Extra fees & charges

Extra training session 1 person $250
Extra training session 2 people $350
Extra training session 3+ people $500
Re assessment 1 person $250
Re assessments 2 people $350
Re assessments 3+ people $500

Q. Can I change the date of my booking at the last minute if I cannot make it?
A. No, you must give us at least 72 hour notice to re-schedule a booking

Q. What will happen if I turn up late to my forklift training?

A. You will pick up the training from where the group is up to. The training time that you
have missed will not be made up

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Q. What will happen if I turn up late to the final licence assessment?
A. Licence assessments must commence on time. If you are running late please call our
office on 8814 8640. Our office will let you know if you should continue to the
assessment or if you are simply too late and you must re-schedule for a later date

Q. What will happen if I am completing the licensing course in my workplace and I

lose my training logbook?
A. You must cease operating the forklift. Please contact our office to arrange a
replacement logbook. You must supply the logbook to the licence assessor as proof that
you have completed the training course. The licence assessment cannot begin if you
cannot supply your logbook.

Licensing course – General information:

Q. Why do I have to do a trial assessment?

A. The trial assessment is the best way to see if you are ready to attempt the final
licence assessment or if you still require additional study and/or practise time.

Q. Who will be my licence assessor?

A. Australian Forklift Training employ x5 people who are SafeWork NSW accredited
forklift licence assessors. You could be assessed by anyone of these gentlemen. It does
not matter which licence assessor you get as they all use the same SafeWork NSW
assessment instrument and they all get regularly audited to ensure consistency.

Q. Why was the wording of the questions in the licence assessment different to
the wording given to me in my training material?
A. We are strictly forbidden to give you a look at the actual licence assessment paper
prior to the assessment. SafeWork NSW believes that this rule prevents people from
cheating or memorising particular answers.

Q. What will happen if I fail the licence assessment?

A. You will need to complete a re-assessment of all parts that you were unsuccessful in.
You must wait at least 48 hours but no longer than 90 days to do this.

Q. Will I get my licence as soon as I pass the licence assessment?

A. Yes. Upon passing the licence assessment you will receive an interim forklift licence
on the spot. To convert this into your 5 year licence you must go to an Australian post
office within 60 days and lodge original copies of the following:

- Notice of Satisfactory Assessment (NSA) form

- Application form

You will keep the duplicate (pink) copy of the NSA form in your wallet until the plastic
licence card comes to you in the mail.

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The questions and answers on the following pages must read and learnt prior to your
trial assessment. You will attempt the trial assessment once you have developed
sufficient forklift operating skills with our forklift trainer.

Reading and learning these questions is step 2 in the forklift licensing – 6 step process.

1. On-line videos – watch and learn

2. Training manual – read and learn
3. Self-assessment theory quiz

Allow between 4-10 hours to complete steps 1, 2 & 3

IMPORTANT: The wording of the questions in the final licence assessment will differ
from the questions that you have been supplied with in the training. SafeWork NSW
have mandated that no applicant can see the licence assessment questions prior to the
assessment commencing to prevent possible cheating or just memorising answers. If
you can answer all of the questions that we have supplied to you in this training manual
then there is no reason why you will not be able to answer the licence assessment
questions successfully.

1. You have a high risk work licence (forklift licence). What are your legal
responsibilities whilst operating a forklift in the workplace?

You must work in a way that is safe. You must not risk the health and
safety of yourself or others

2. You can be penalised for not doing high risk work safely. What might the
punishment from the work health and safety regulator be? Name two (2)

- Suspend your licence

- Cancel your licence
- Refuse to renew your licence
- Order you to sit a licence re-assessment

3. You have passed your high risk work licence test. You must now apply for a
photo high risk work licence card at an Australia Post Office. How many days
do you have to put this application in?

- 60 days

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4. Your high risk work licence is valid for 5 years. If you let it expire by longer
than 12 months what will happen?

- You will not be able to renew it again

- You will need to re-do the licensing course

5. If you do not have a high risk work licence when can you legally operate a
forklift?

- Only once you have begun a high risk work licensing course and you are
operating under the supervision of a licensed person

6. What evidence could you provide to your employer to show them that you can
carry out work that requires a high risk work licence?

- A licence card
- A training record (logbook)

7. Part 1:
Who might you talk to about worksite hazards before you start working? Name
three (3) people

- Supervisor
- Workmate
- Safety officer
- Site engineer
- Manager

Part 2:
Why is it important to talk to these people about site hazards?

- So that you are aware of the workplace rules & procedures

8. It can be dangerous to use a forklift with an internal combustion engine in an

area with restricted air flow. Why?

- Exhaust fumes are dangerous and can poison you

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9. Part 1:
What is the most suitable type of forklift to use in a restricted air flow area?

- An electric forklift

Part 2:
Why should you charge a battery in an area with good air flow?

Batteries give off gasses which can explode. Good air flow helps to
remove the gasses

10. You need to refuel the forklift. The forklift uses diesel or petrol. What is the
risk if you leave the engine running while your refuel?

The fuel could catch on fire

11. You need to plan for possible hazards before you use a forklift. The hazards
could be inside or outside. Name seven (7) hazards you might have to plan
for?

- Overhead service lines

- Surrounding structures
- Doorways
- Obstructions
- Other equipment
- Other vehicles/machinery
- Pedestrians
- Dangerous materials

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12. The hierarchy of hazard control is a list of controls that you can use to
eliminate or lower the danger from a hazard in the workplace. What are the six
(6) levels in the hierarchy from the first choice to the last?

- Elimination: If possible, remove (take away) the hazard

- Substitution: Use a safer method if you can’t remove the hazard
- Isolation: Stop access to the hazardous (dangerous) area
- Engineering Control Measures: Change the tools, equipment or
environment to make it safer
- Administrative Practices: reduce the time the worker is exposed to the
hazards by using training, job rotation, the timing of jobs etc.
- Personal Protective Equipment (PPE): use PPE if the above controls are
not enough to remove the hazard

Note: In the assessment you will only need to write the underlined part of the answer.
However, you should have a good understanding of what each steps means

Learning tip: Remember the acronym. Every Sunday I Eat A Pie

13. When is the best time to set up hazard control measures?

- Before you start the job and also as soon as you identify a hazard

14. When is the best time to choose and check your PPE and other safety
equipment?

Before you start the job

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15. You are about to start forklift operations and lift a load. What are five (5)
requirements that you must plan for and consider (other than worksite
hazards) before you lift an unfamiliar load?

- Is the load stable?

- How heavy is the load?
- What is the rated lifting capacity of the forklift?
- What equipment do you need? Is the equipment there?
- Attachments required for the load?
- Where will you do the lift? What do you need to do?
- How will you get in and out?
- Who do you need to talk to and communicate with?
- Do you need any permits?
- Are there any blind spots caused by the size of the load?

16. You are using a forklift near electric lines. Working near electric lines is very
dangerous and can kill you. What are the minimum safe distance rules you
must follow?

- 3m up to 132,000 volts
- 6m Between 132,000 & 330,000 volts
- 8m above 330,000 volts

In the assessment you will only be required to write the metres from each voltage range

17. Who could you talk to if you needed to find out the voltage of overhead
electric lines?

Your local power supply company

18. What are two (2) ways you can work closer to electric lines than the minimum
distances allowed?

- You might be able to get permission from the electricity supply authority
- The electric lines will need to be covered by insulation
- A safety observer (spotter) may be allowed depending on your state or
territory legislation

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19. Tiger tails are black and yellow pipes that hang off electric lines. What are they
for?

Tiger tails are a visual system to warn that electric lines are there

20. Name three (3) ways you can communicate and give information to other
workmates on a site?

- Signs
- Written Instructions
- Speaking to people
- Appropriate workplace protocol

21. When should you look over your forklift and do a pre-start check?

Before operating the forklift

22. What are six (6) pre-start checks you should do before using a forklift?

- Data plate
- Seat,
- Seatbelt
- Overhead guard
- Mirrors
- Controls
- Tyre condition
- Leaks underneath forklift
- Mast assembly
- Lift and tilt system
- Hydraulic hoses
- Hose pulleys
- Warning decals
- Load backrest
- Fork arms
- Locking pins
- Brake fluid
- Hydraulic fluid
- Battery water
- Battery cables and security
- Coolant (if appropriate)
- Engine oil (if appropriate)
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 - Transmission fluid (if appropriate)
- Air filter indicator (if appropriate)
- Security of LPG cylinder (if appropriate)
- Compliance plate for the LPG installation (if appropriate)

23. You have found a problem with your forklift during the pre-start check. What
should you do?

- Take out the key

- Put a danger tag on the forklift
- Tell your supervisor
- Fill in the maintenance logbook

24. When checking the tyre condition on a forklift. What are four (4) things you
need to check for?

- The tyre wear is even

- The tread is not worn
- No big pieces of rubber are missing
- Wheels are secure
- Tyres are secure

25. You need to do a start-up check on the forklift to see if it is safe and working
properly. What are three (3) things you should check after you have started the
forklift?

- Gauges
- Lights
- Reversing light
- Warning devices / horn
- Brakes (including handbrake)
- Steering
- Mast and tilt functions

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26. Part 1:
A forklift has safety guards to keep the operator safe. Name two (2) of these
guards?

- Overhead guard
- Load backrest
- Foot guard

Part 2:

What is the function of these guards?

To protect the operator from falling objects

27. Why do all tyres need to have the right air pressure?

A flat tyre can make the forklift unstable and it could tip over

28. When are you allowed to fix a mechanical problem on the forklift?

Only if your employer allows you to and if you know how to fix the problem

29. What are the three (3) ways you can find out the weight of a load?

- Checking the weighbridge certificate, consignment note, or other

paperwork
- Weighing the load
- Calculating the weight of the load
- Reading the weight markings on the load

30. You have to move a load of 44 bags of flour on a pallet:

- Each bag weighs 25kgs
- The pallet weighs 35kgs

What is the total weight of the load? You can use a calculator but you must
show how you worked it out.

44 x 25kg = 1100kg
Weight of pallet = 35kg
Total weight of load = 1100 + 35 = 1135kg

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31. There is a load to be moved. The load is stacked cartons on a pallet:
- Four (4) cartons per layer
- Six (6) layers high
- One (1) carton = 25kg
- Pallet = 15kg

What is the total weight of the load? You can use a calculator but you must
show how you worked it out.

Total weight = 4 x 6 x 25 + 15
Total weight = 615kg

32. There is a load to be moved. It is 200 litre drums full of water:

Each drum weighs 13kgs when empty
Water = 1kg per litre

What is the weight of 6 drums full of water? You can use a calculator but
you must show how you worked it out.

Total weight = 213kg x 6

Total weight = 1278kg

33. What does the “rated lifting capacity” of a forklift truck mean?

It is the maximum weight a forklift can lift at a maximum load centre distance
and maximum load height

34. Where is the load centre distance measured between?

From the vertical face of the forks to the load’s centre of gravity

35. If you don’t insert the fork arms all the way into the pallet prior to lifting, what
effect will this have on you forklift?

The forklift’s lifting capacity will be reduced and it may make the forklift
unstable

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36. The x3 forklifts below are all rated at 2000kg with a 600mm load centre
distance. Which one is unsafely carrying a load outside of the rated lifting
capacity?

Answer = A

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 Look at the data plate to answer the following questions

37. Can a load weighing 1575kg with a load centre distance of 700mm be safely
raised by the forklift truck above?

No. The load centre distance is longer than the maximum allowed

38. Can a load weighing more than 1575kg be safely raised by the forklift above?

No. 1575kg is the maximum allowed

39. You have to lift a load. You must tilt the mast forward. What is the rated lifting
capacity with the mast tilted forwards?

900kg

40. You have to lift a load. You can use the mast vertically. What is the rated
lifting capacity if the mast can remain vertical?

1575kg
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41. Name three (3) hazard control measures that you could use if you are
operating in an area where there are pedestrians or other vehicles?

- Barricades
- A guide
- Flashing lights
- Warning signs
- Vehicle / pedestrian exclusion zones

42. You are using a forklift in a dark place. What do you need to have?

You need good lighting in the area

43. A forklift steers with the rear wheels. This causes “rear end swing”. Why must
you be careful of “rear end swing”?

Rear end swing is dangerous and could result in damage or harm

44. If your view is obstructed or blocked when operating a forklift, what are three
(3) things you could do to make this safe?

- Check the pathway is clear

- Check the mirrors
- Look over both shoulders if reversing
- Use the horn or flashing lights
- Use a guide

45. You are operating a forklift outside in wet weather. What are two (2) operating
precautions you should take to be safe?

- Slow down
- Operate cautiously
- Avoid inclines or ramps

46. You need to move a load up or down a ramp. Which direction should the load
face when travelling?

- Uphill

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47. It is unsafe to turn a loaded forklift when it is on a ramp or a sloping surface.
Name two (2) reasons why?

- The load can be lost

- The forklift might tip over

48. Are you allowed to put more counterweight onto a forklift without checking
with the manufacturer?

No

49. Are you allowed to raise or lower a load above people? Explain your answer.

No, because it is very dangerous. The load might fall on someone and kill
them

50. When is it allowable to carry a passenger on a forklift?

Only if the forklift is designed to carry more than one person

51. Why is a seatbelt needed on a counterbalanced forklift?

- It will hold you in the forklift in the event of a roll over

- It will hold you in the forklift in the event of a collision

52. Why is it not safe to drive a forklift with the load raised in the air?

Because it makes the forklift unstable and it could tip over

53. Why does the side-shift attachment need to be in the middle when carrying a
load?

To keep the forklift from tipping over sideways

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54. When you are moving a loaded forklift, what is a safe height for the load to be
carried?

Axle height or as low as possible

55. Carrying a load on only one fork arm can be dangerous. Name two (2) reasons
why?
- The forklift may tip over
- You may damage the fork arm

56. You are stacking loads on top of each other. What are three (3) things that you
need to think about when you stack loads on top of each other?

- Stack the goods on a solid, level surface

- The stack of goods must be stable and balanced
- Heavy goods need to be on the bottom

57. You are about to move a load. It doesn’t look like it has been loaded safely.
What should you do before moving this load?

Re-stack the load

58. There is a gap between the loading dock and the truck. What do you need to
cover this gap with?

A secured dock or bridge plate

59. Most of the time a forklift is safe and steady. What are five (5) things that can
make a forklift tip over sideways?

- Turning too fast

- Turning with the load raised
- Uneven surface
- Uneven load
- Driving with a flat tyre
- Driving too fast
- Side shift attachment not in the middle
- Turning on a ramp or slope
- Driving with the load in the air
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60. Most of the time a forklift is safe and steady. What are five (5) things that can
make a forklift tip over forwards?

- Overloading (Load too heavy)

- Load centre distance too long
- Braking severely (hard)
- Using the forward tilt with a raised load
- Load is not pushed right up against the vertical face of the fork arms
- Operating down a sloping surface load first
- Driving with the load in the air
- Driving too fast
- Uneven surface
- Uneven load

61. A forklift has a point of balance (fulcrum). Where is it?

It is where the front tyre touches the ground

62. Does all if the weight behind the point of balance work as a counterweight?

Yes

63. Why should you keep checking that your load remains stable whilst operating
a loaded forklift?

To make sure people are safe and to make sure the load is still stable

64. Part 1:
There is an evacuation emergency in your workplace. What information do you
need to communicate to people? Name three (3) things.

- That there is an emergency

- What the emergency is
- Where the emergency is located

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Part 2:

There is an evacuation emergency in your workplace. Who do you need to tell?

Name two (2) people.

- Other people in the area

- Safety officer
- Supervisor / management
- Emergency services

65. What should do you do if the forklift starts to tip sideways? Name two (2)
things.

- Stay on the forklift

- Brace yourself
- Wait until you stop moving, then get off

66. What should you do if your forklift hits electric lines? List the five (5) steps.

1. Warn other people to stay back

2. Try and break the contact with electric lines
3. Stay on the forklift truck if it is safe to do so. If you must get off, do not
touch the forklift truck and the ground at the same time. Jump off with both
feet together and continue to jump like this until you are 8 metres away.
4. Report the incident to your supervisor
5. The forklift must be checked over by a competent person before using it
again

67. There has been an accident on your work site. Which vehicles have the right
way in an emergency?

You must give way to all emergency vehicles

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68. You are looking for a place to park the forklift truck. Where are three (3)
places you should not obstruct when parking?

- Fire-fighting equipment (fire extinguishers, water hoses)

- Emergency exits
- Doorways
- Ramps or sloping surfaces
- Pedestrian walkways (walking places)
- Where the forklift can block other traffic
- Less than 2m from train tracks
- First aid stations
- Within the safe distances to electric lines

69. Where are normal procedures (things you have to do) when you park a
forklift?

- Fork arms should be flat on the ground

- Put the forklift in neutral
- Put on the park brake
- Follow the site specific safety procedures (your worksite’s rules)

70. What must you do when you park on a sloping surface or a ramp?

- Do the normal parking procedures and

- Chock the wheels of the forklift

71. Why do you need to take out the ignition key when leaving the forklift
unattended?

To stop the forklift being moved by someone who is unauthorised

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Practical exercise

Part 1: Hazard identification and hazard control measures

Part 1a) Name at least x8 of the following hazards

Overhead service lines (inside and or outside)

Surroundings buildings
Doorways
Obstructions
Other equipment in area
Pedestrians in area
Dangerous materials
Other hazards unique to the workplace (you will need to state a hazard)
Overhead Lighting
Other vehicles/machinery

Part 1b) Name ALL appropriate hazard control measures

Pedestrian walkways
Fire-Fighting equipment
First aid equipment
Barricades
Suitable racking
Appropriate signage

Part 2: Pre-Start safety checks (visual inspection)

You must inspect ALL of the following (unless not fitted to the forklift)

Data plate (state the rated capacity with the mast vertical and forward)
Seat
Seat belt
Overheard guard
Mirrors
Tyre condition
Mast assembly
Lift and tilt systems
Hydraulic lines
Hoses pulleys
Load backrest
Condition of fork arms
Locking pins
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 Underneath machine for any fluid leaks
Controls
Warning decals
Compliance plate for gas installation
Security of LPG gas cylinder, cylinder date and condition of system
Air filter indicator if Diesel
Brake fluid
Hydraulic oil
Battery: water, connections and security
Engine oil
Coolant
Transmission oil
Battery retaining plates, connector and cable

Part 3: Start-Up safety checks (test drive)

You must inspect ALL of the following (unless not fitted to the forklift)

Mounts correctly (three points of contract)

Adjust seat
Fastens seat belt
Demonstrate start up procedure
Gauges
Lights
Reversing light
Checks pathway clear for travel before moving
All warning devices eg. horn, beepers etc
Braking system whilst moving, including hand brake
Steering system whilst moving
Mast and tilt controls (to the full extent of their movement)

Part 4: Operating procedures

You must move loads from a low, medium and high level and negotiate an obstacle
course in a forward and a reverse direction

You must correctly demonstrate ALL of the following procedures

Assess the weight of the load before lifting

Ensures travel direction is clear
Keeps to the left in aisles or roadways for two-way traffic
Maintains a safe distance from other vehicles
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 Travels at safe speed and maintains control of forklift truck
Takes appreciate action if the forklift truck goes undetected by others
Looks in direction of travel when reversing
Does not travel with load until load is lowered to safe height
Does not hit or knock any object in the path of forklift truck
Keeps all parts of his/her body within the forklift truck when travelling
Selects correct hydraulic controls
Drives or re-positions forklift truck to access the load correctly
Correctly positions the tines relative to the rack or stack before raising
the load
Ensure the mast is vertical, or on a slight back tilt, to stabilise the load
when raising from a rack or stack
Moves the forklift truck clear of the rack or stack, and lower the load to a
safe travel height before reversing
Check over both shoulders before reversing
Ensure the load is at a safe height to clear any bumps or rises on the
floor while travelling
Ensure the mast is tilted back slightly to ensure the load is laying towards
the load backrest or carriage while travelling
Correctly position the load relative to the rack/stack/truck
tray/trailer/loading dock before placing the load
Place the load evenly on the rack/stack/truck tray/trailer of loading dock
prior to withdrawing the tines
Withdraw tines cleanly without disturbing load
Explain correct use of the brake when raising or lowering a load on an
incline

Part 5: Shut down procedures

You must correctly demonstrate ALL of the following procedures

Park forklift in a safe location

Lower fork arms / attachments to the ground
Place the forklift into neutral
Apply the park brake
Remove the key to prevent unauthorised use

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