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ATC TLILIC0003 Training Manual

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Forklift
Training Manual
Training Manual
TLILIC0003 Licence to Operate a Forklift
Start time: 7.45am
Participants must read this manual prior to attending the training program and are required to bring the
manual to the training program.
It is strongly recommended that participants complete the Practice Questions at the back of this Training
Manual.
Participants must wear fully enclosed safety foot wear, long pants and long sleeve shirt.
It is a mandatory requirement that participants must bring photo Identification to training session i.e.
Australian Drivers licence or passport (must contain photo, date of birth & signature). Failure to provide
IDENTIFICATION will result in exclusion from the course.
Document Name:
TLILIC0003 Licence to Operate a Forklift Truck – Training Manual
Last Modified Date:
05/08/2024
Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800
Previous Modified Date:
08/04/2024
Document No: LF-TM-001
Page 1 of 70

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Summary of Contents for ATC TLILIC0003

  • Page 1 Australian Drivers licence or passport (must contain photo, date of birth & signature). Failure to provide IDENTIFICATION will result in exclusion from the course. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 2 Training Manual © 2024 Access Training Centre. All Training Manuals and associated course material remain the property of Access Training Centre. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 3: Table Of Contents

    Checking Signage, Labels and Data Plate ..................... 32 Pre Start Checks – Visual ........................33 Guards ................................33 Tyres .................................. 34 Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...
  • Page 4 Changing LP Gas Cylinders ..........................56 Appendix A – Legislative Framework ..................57 FORKLIFT PRACTICE QUESTIONS ..................59 Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 5: Introduction

    Forklift Training Manual Introduction This training course is based on the Unit of Competency TLILIC0003 Licence to operate a forklift from the Transport and Logistics Training Package and the National High Risk Work Licence. Course Overview During this course, you will learn about:...
  • Page 6 – Forklift Training Manual Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 6 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...

  • Page 7: Forklifts

    Steering and Lever Controls Hydraulic Tilt Ram Drive Wheels Rear/Steering Wheels Counter Balance Operator’s Seat Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 7 of 70...

  • Page 8: Forklift Characteristics And Capabilities

    Can be designed to work on rough terrain. • Can be powered by LPG. Petrol or battery. Types of Forklifts Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 9: Work Health And Safety Requirements

    ❖ AS2359 – Powered Industrial Truck Other Codes and Standards that are referred to in this Manual are listed in Appendix A. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 10: Other Documented Sources Of Workplace Safety Information

    Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 11: Duty Of Care

    • Training • Instruction • Supervision Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 11 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...

  • Page 12: Worker Duty Of Care

    A person under training is a person enrolled in a course of HRW and being supervised at a workplace by a person with a current HRW licence for the work. (WHS Regulation 82) Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 13: Applying For The High Risk Work Licence (Hrwl)

    Whether or not they have ever previously had an equivalent HRW licence refused, suspended or cancelled under the WHS Act or the WHS regulations in any jurisdiction in Australia. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 14: Safework Sa Portal

    Stop doing the work Retrain to become fully competent, OR Return the HRW licence to the WHS regulator. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 15: Plan For Forklift Operations

    You can also speak with your WHS workplace representative for more information about workplace safety. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 16: Consultation

    Where the emergency is and how to get their vehicles to the correct location? Every worker and vehicle gives way to all emergency vehicles at all times Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 17: First Aid

    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. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 18: Planning Operations

    Work permits are required to ensure that adequate safety control measures are in place. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 19: Hazard Identification And Controls

    Risk Control measures must be put in place before starting any type of work or as soon as a hazard is identified during Forklift operations. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 20: Risk Assessment

    The Hierarchy of Control is the name given to a range of control methods used to eliminate or control hazards and risks in the workplace. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 21 The best method would be to eliminate the hazard by using a battery powered forklift or preventing the forklift from entering the area. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 22: Safe Work Method Statements

    They assist in effectively coordinating the work, the materials required, the time required and the people involved to achieve a safe and efficient outcome. • They are a quality assurance tool. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 23: Hazard Identification

    Bridges Slopes and ramps Non-load bearing surfaces Loading docks Causes of Forklift instability Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 23 of 70...

  • Page 24: Power Lines

    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. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 25: Power Line Identification

    Steel decks and grates There is a risk that the load could be bumped or fall if driving too fast over uneven surfaces. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 26: Weather Conditions

    Wet and/or slippery conditions Strong winds Heat and sun exposure Smoke Limited visibility Snow and/or ice Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 26 of 70...

  • Page 27: Rear End Swing

    Passengers may only be carried on the forklift if it has been designed and equipped to carry more than one person. (eg: with an extra seat and seatbelt) Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 28: Forklift Selection

    The best method to eliminate this hazard is to use an electric powered forklift or to provide enough ventilation for the fumes to escape. Beware of Exhaust Fumes in Enclosed or Confined Spaces Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 29: Risk Controls

    Collisions Risk: Serious injury or death Control/s: Adequate lighting to provide sufficient lighting across work area Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 29 of 70...

  • Page 30: Communications

    Report unserviceable or damaged PPE to your supervisor and obtain a replacement. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 31: Inspection Of The Forklift

    Forklift. The Operator Manual will also be required for a maintenance person top access relevant and operational safety procedure information. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 32: Checking Signage, Labels And Data Plate

    Do not use the forklift if the data plate is damaged or illegible. Tag the Forklift and report it as per workplace procedures. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 33: Pre Start Checks - Visual

    Load Backrest (Load Guard) Stops the load from hitting the mast Protects the operator Helps to keep the load stable Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 34: Tyres

    Avoid grabbing controls to gain leverage to access the cabin, use the bar grips where possible. Do not stretch or twist your body when accessing the forklift. Never jump from the forklift. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 35: Seatbelt

    Other forklifts will have additional levers for “side shift” and “fork spreaders” and for other attachments fitted to the machine. Side shift should be used to keep the load centered, as uneven load can affect load balance. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 36: Start The Forklift

    If indicators or side lights are fitted, then they have to be operational regardless of whether you intend to use them. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 37: Fault Reporting

    An Out of Service Tag can only be removed by an authorised person (qualified person) once the repairs or schedule maintenance have been completed or the Forklift has been deemed safe to use. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 38: Stability Of The Forklift

    Gravity Combined Centre of Gravity Stability Triangle Forklift Centre of Gravity Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 38 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...

  • Page 39: Load Position

    Check the pallet that the load is sitting on. If it is too damaged to lift, re-stack the load onto a new pallet. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 40: General Forklift Operations

    DO NOT carry the load on only one fork arm, as: 1. Stability of the forklift and/or load may be affected 2. Damage potential to the fork tyne and/or mast/carriage Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 41: Forklift Travel Speed

    If loading onto a truck from a loading dock make sure there are secured dock plates or bridge plates in place. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 42: Travelling On Ramps

    Heavy goods are placed at the bottom The stack does not become unstable due to height The load below can support loads above Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 43: When Raising The Load

    Have a third person who is responsible and experienced control the operation Ensure that the load applied to each forklift truck is no more than 75% of its rated capacity Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 44: Forklift Attachments

    Be careful when turning the forklift and make sure you have enough room to move properly. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...
  • Page 45 Use with caution, as persons can be seriously injured by crushing or shearing if caught between the load arms and in other moving parts. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 46 The Working Load Limit must be displayed on all jib attachments above the lifting points where a lifting hook is attached. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 47: Forklift Loads

    The weight of the pallet must be included when calculating the total weight of the load to be lifted. Do not lift a load on a pallet that is damaged. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 48: Calculating The Load Weight

    Weight = bricks per layer) x (layers) x (brick weight) + Pallet = 70 x 6 x 2 + 40kg = 880kg Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...

  • Page 49: Load Centre Distance

    Often additional rated capacities for different load centre distances or heights are added to the data plate to provide specific ratings for restricted mast heights or different dimension pallets. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...
  • Page 50 B. Vertical= 1500 mm 4400 2800 (Width) (Length) Forklift approach Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 50 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...
  • Page 51 7800kg 7800 kg is over the maximum Rated Capacity The tare weight of the container is 3000kg Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024...

  • Page 52: Rated Capacity

    3. Can a load weighing 1850kg with a load centre of 900mm be lifted? 4. Can a load weighing 2230kg with a load centre of 500mm be lifted? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 53: Operational Issues

    The side-shift attachment must be returned to the central position before moving the forklift to maintain stability of the Forklift and the load. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...

  • Page 54: Forklift Roll Over Procedure

    ‘Lock out’ and ‘Tag out’ the forklift Report to management Have the machine checked and repaired before reuse Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 55: Complete Forklift Operations

    If a Fault or defect is present: Tag out of Service Record in Logbook Report to Supervisor Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024...

  • Page 56: Refueling / Recharging Forklift

    8. Re-connect take off hose 9. Turn on cylinder valve 10. Check for leaks - look, listen and smell Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...

  • Page 57: Appendix A - Legislative Framework

    • 2550.1 Cranes, safe use-general requirements Unit of competence • TLILIC0003 Licence to operate a forklift Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 57 of 70...
  • Page 58 – Forklift Training Manual THIS PAGE HAS INTENTIONALLY BEEN LEFT BLANK Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 58 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...

  • Page 59: Forklift Practice Questions

    6. List three (3) people you should talk to about workplace hazards before starting work. 7. Why is it important to consult with others about workplace hazards? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 60 - The relevant voltages for Distribution lines (poles) and Transmission Lines (towers) 14. List two (2) visual indicators that can identify overhead electric powerlines. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 61 23. If you were working in a restricted space with poor ventilation (e.g. cold room), what type of powered forklift would you use? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 62 31. What can happen to a forklift if air-filled tyres are not inflated to the correct pressures indicated on the data plate? 32. What defects may be found when inspecting the forklift wheels and tyres? List four (4) defects. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...
  • Page 63 43. What can happen if you turn or travel sideways with a load on a sloped surface? List two (2). 44. Which direction should the load face when travelling up a slope / ramp? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...
  • Page 64 52. Calculate the weight of the following load including the pallet. 6 drums on a pallet Each drum weighs 110 kg Pallet weighs 40 kg Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...
  • Page 65 900 mm a) What is the total weight of the load? b) Can this Forklift safely lift this container? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date:...
  • Page 66 2000mm long 1650mm wide 1800mm high The tare weight of the container is 3000kg Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 66 of 70...
  • Page 67 What is the rated capacity of the Forklift if the mast is vertical? d) Can a load weighing 2000 kg with a load centre distance of 650mm be lifted safely by this Forklift? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 68 67. List four (4) places not to park your forklift on shutdown. 68. List three (3) steps for parking a forklift. Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024...
  • Page 69 70. Does refueling with the engine running create a risk? Why? 71. Why must batteries be charged in a well ventilated area? Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date:...
  • Page 70 – Forklift Training Manual THIS PAGE HAS INTENTIONALLY BEEN LEFT BLANK Document Name: TLILIC0003 Licence to Operate a Forklift Truck – Training Manual Document No: LF-TM-001 Last Modified Date: 05/08/2024 Previous Modified Date: 08/04/2024 Page 70 of 70 Access Training Centre 7 LaSalle St Dudley Pk SA 5008 Ph 08 8169 9800...

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