ABN: 27 221 204 202

27 Technology Drive Arundel Qld 4214

Tel: 07 5537 9244 or 0418 156813
Fax: 07 5537 9245
email@theoperatorschool.com.au
www.theoperatorschool.com.au

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.

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Information about the Theory and Practical Assessments

Under the new Workplace Health and Safety Legislation, Assessors are required to submit details of
all upcoming assessments to Workplace Health and Safety Queensland at least 6 business days in
advance. Inspectors from Workplace Health and Safety Queensland have the authority to turn up
unannounced and undertake an audit of our Assessors, the trainee and the workplace at any time.
The tests must be completed in order: theory, calculation and finally practical. You have to achieve
competency in each one before being permitted to move on to the next. The exams are the same
wherever you go in Australia, they are mandatory and supplied by Safe Work Australia.
Theory assessment facts:
Written Test for the Forklift is made up of 66 Questions
Critical answers

i.e. you cannot get any of them wrong.

Any critical answers Trainee gets wrong result in immediate fail
Non Critical answers 41 you need to get a 90% pass rate to achieve final competency i.e.
allowed 4 wrong answers before a fail is recorded

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

It is not permissible to have an interpreter for the exam

The exam should not take any more than 2 hours to complete

25

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

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Calculations assessment facts:

Calculation Test for the Forklift is made up of 8 All questions are critical any wrong answers
Questions
will result in immediate fail

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

It cannot be delivered orally

Interpreters cannot be used

It is a closed book exam no learning material with you

You are allowed a basic calculator (not a complex, programmable one)

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

The exam should not take longer than 1 hour to complete

You need to achieve competency in the calculation assessment before you can move on to the
practical assessment

Your calculation assessment will be retained by the Assessor

Practical assessment facts:
Practical
assessment
is made up of
5 tasks:

Task 1 Hazard Identification and Hazard Prevention

Task 2 Conduct Pre-operational Checks (visual inspection)
Task 3 Conduct Post Start Checks (machine running)
Task 4 Operate machine to the full range of its capacity (safe movement of loads)
Task 5 Shut down and secure the machine
Can be conducted here at The Operator School using our machines and equipment or in the
Worksite
Your practical assessment will be conducted in the English language
No interpreters
The Assessor will give you verbal instructions on what you are required to do. You will be
asked questions at various points during your practical exam (when safe to do so) to confirm
your knowledge of the task at hand
Your answers to these questions are taken into consideration as part of your whole
assessment; they cannot solely make you competent or not competent.
You will be asked to stop immediately if the Assessor believes an unsafe act is about to occur
Evaluation of the worksite
Identify any hazards within the work area
Plan work, make sure machine capable of doing the job you are required to do
Select (or be wearing) correct Personal Protective Equipment i.e. safety boots (or enclosed
shoes at a minimum and a high visibility shirt plus any other item necessary to that worksite i.e.
hard hat if a construction site
No Personal Protective Equipment will mean that the Assessment will have to be cancelled and
another 6 business day notification period organised with WHSQ
The student must conduct a detailed pre operation check
Shift a series of 3 different types of loads by racking or stacking to the National Load Shifting
Standard
Forklift to be loaded to a minimum of 50% of the capacity of the machine at some point during
practical assessment
Lift one low level
Lift two medium level (not less than 25% of the machines height capacity)
Lift three high level (not less than 75% of the machines height capacity)
Negotiate obstacles and chicanes

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Demonstrate good safe operations at all times

Correct post operational checks and shut down procedures
If you got any non-critical questions wrong during your written assessment you will be asked
these questions at some point during your practical assessment, these answers too have to be
correct.
The exam should not take longer than 2 hours to complete, however it should be done in a
similar timeline that it would normally take in a workplace
A 100% pass mark is required for competency
Your practical assessment will be retained by the Assessor

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,

the Employer and the Assessor

Is area for assessment over 400m
Is capacity of machine over 1000 kg in good working order i.e. data plate, seatbelt, beepers,
manual
3 different loads (not less than 50% capacity of the machine)
Barriers, signs or other items to create control measures for pedestrian zones
Need High, Mid and Low racking Or stacks on site
Racking must be bolted to the floor and comply with Australian Standards
High lift for the forklift (could be mezzanine) must be at least 75% of the lift height of the
machine
Suitable area to perform practical assessment
Aware assessment may affect production
Any on site requirements, site induction, blue card that you need our assessor to comply with
Facilities to do necessary paperwork without interruption
Be aware test could take between 3-6 hours depending on notification time and how well
trainee progresses through assessment.

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

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Refresher Information from Formal Training Session

Significant information is written in bold

High Risk Work Licences

Your Responsibilities are:
You will need to provide a photo for your licence
100 points of photographic evidence to prove who you are
You must not give false or misleading information
You must not apply for a high risk work licence if you already hold an equivalent one issued
in another state by another regulator
You are required to declare any:
previous WHS convictions or offences,
if you have ever had an equivalent high risk licence, refused, suspended or cancelled
in Qld or any other State in Australia
details of any enforceable undertakings that you have entered into under the
Australian Workplace Health and Safety Act or Regulations
Application for the Licence
You are not legal to operate a forklift in the workplace until you have lodged your
licence application at a Qld Post Office
Stapling the receipt from the Post Office to the Government paperwork will act as your
temporary interim licence until such time as the application is approved by WHSQ and a
licence is issued.
Make sure you lodge your Forklift Licence Application Form at a Qld Post Office within 60
days.
If the timeframe goes to 61 days, you will have to re-take the exams - Do you really want to
do it again!
Licence Conditions
Under the current legislation
Your forklift licence - photographic 5 year renewable
No restriction on forklift size, style or make
Move house need to notify WHSQ within 14 days ($1,250 fine can apply)
Lose your licence a Replacement Licence costs $28.50
You must present your licence if asked by a WHSQ Inspector ($1,250 fine can apply)
It is YOUR responsibility to remain competent at all times.
Your employer should conduct refresher training
Learners and Logbooks
Basically, the only people who can operate a forklift are: A licenced operator (who is competent i.e. relevant recent experience)
A trainee. A trainee is a person on a training plan who has completed his formal
(theory) training allowing for a logbook to be completed in the workplace, under the
direct supervision of a current forklift licence holder
A trainee who has lodged a forklift licence application at a branch of Qld Australia Post and is
waiting to receive a Licence in the mail
Anyone else is illegal and uninsured
Due Diligence
Two of the underpinning principles of current OHS Legislation and terms that you will hear all
the time are Due Diligence and Reasonably Practicable both have similar meanings.
Translated into laymans terms Due Diligence (when applied to the operation of machinery)
means that you have exercised precaution, operated the machine in a safe manner and
done everything within your power to prevent an accident or an injury.
Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Basically it is a legal term.

It means that if there was a prosecution the courts would be looking to see if due diligence
was undertaken by every party involved before giving their verdict and handing down the
fines etc.

If you do not meet your Responsibilities

The Regulator can cancel, suspend, refuse to issue or refuse to renew a Licence
You may also be liable for prosecution and be issued with hefty fines.
Competent Framework
Under current Legislation, there is no off load of responsibility: Even when a person holds a current forklift licence, an employer must not allow them operate
if they do not think that they are competent.
The licence holder himself/herself must cease to do the work if they feel they are no longer
competent, i.e. not operated for a few years been behind a desk for a while
No room for complacency or stagnation under new laws
There should be a constant training and checking process taking place
Communication
Employers and employees should consult with safety officers, site engineers, supervisors,
workers, contractors and labour hire etc.. about: Hazards
Job requirements
Emergency procedures
Personal Protective Equipment (PPE)
Workplace specific paperwork and requirements
Types of Communication
Communication can be toolbox meetings, written, listening, questioning, signage, meetings,
memos, emails, etc.
Communication is necessary to comply with the rules and regulations of industry and the
work site.
Hazards in a Nutshell
Be aware of:
People
The direction of traffic flow in aisles etc.
Other plant and equipment
Blind corners and blind alley ways with cross traffic
Inclines / declines
Ceiling clearance, including low pipes etc.
Doorway clearances particularly roller doors, wall mounted fire hoses etc.
Types of load flammable, fragile, unstable or hot
Excessive heat and sparks (especially where LP gas is used)
The road surfaces and wet and dry areas
Weather, Noise and Lighting
Fumes produced by the Forklift
Electric overhead wires, light fittings, extension cables etc. (underground services)
Racking condition and strength
Loading docks and bridging plates
Security and Contents of Load
BEST THING TO DO WITH A HAZARD IS ELIMINATE IT

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

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

Swap the hazard for something safer

e.g. Replace forklifts with an automated conveyor system.

Isolate

Restrict access to the hazard

e.g. Fit barricades

Engineering Control

Administrative Control

Personal Protective Equipment

Use equipment to minimise the risk of the hazard,

redesign or enclose etc.
e.g. Install speed limiters
Using safe work practices, work in a safe way
by following rules and procedures
e.g. Create no-go zones that are clearly
marked, use signs
Wear protective clothing while you work
e.g. High visibility clothing, goggles, gloves
etc.

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

Preparing for Work

You should select and inspect what Personal Protective Equipment (PPE) you need prior to
commencing work
It is the responsibility of the employer to provide the necessary personal protective
equipment. (60 penalty units)
It is the responsibility of workers to inspect, wear and use the equipment properly, where and
when necessary. (36 penalty units)
Clothing should not be too loose, loose clothing can catch on controls. Long hair should be
tied back. Also be aware of Jewellery that can also catch on controls.
Forklifts and Electricity Exclusion Zones

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.

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Traffic Management Plans

A traffic management plan is essential to minimise the interactions of people, forklifts and
movement of loads.
Develop Practical Workable controls to minimise hazards
Consultation with employees and employers
Exclusion Zones 3 metres plus
Safety Zones for truck drivers
Safety barriers, fences and designated walkways
Workplace to be kept clean and tidy (no pallets etc. lying around)
LPG Petrol
Internal combustion engines produce the odourless but poisonous gas, carbon monoxide.
Carbon monoxide (CO) builds up in the body and can kill in 20 minutes
Make sure that there is adequate ventilation
Do not refuel when engine running could catch fire
Freeze burn 40C approximately
Where possible use a zero emissions battery electric forklift to do the job
Charging Batteries
Charge in a well-ventilated area
When charging batteries, the gas released during the charging process is hydrogen
Hydrogen is explosive
Sulphuric acid is highly corrosive (will burn flesh)
Electricity Supply can create sparks
Turn chargers off unless smart chargers are used
Wear gloves, rubber apron and full face shield
Care must be taken when filling and fitting batteries / security plates and pins correctly fitted
Refill batteries with water after charge cycle is complete to avoid overflow of the fluids /acid
and damage (fluid expands during charging process)
Do not opportunity charge batteries.
Refer to Manual for guidelines, normally deep cycle (let them run to a low state of charge
then fully re-charge)
Rear End Swing
The heaviest part of the forklift is at the back and it swings out.
Can hit someone or something
The rear end roughly spins 3 times faster than the front when going around a corner
Changing Gas Bottles
Well-ventilated area
Engine switched off ensure no naked flame or ignition sources
Select PPE i.e. goggles and gloves
Be aware of freeze burn (can be very severe) - 42 C
Get trained
10 year test date on bottles
Safe procedures must be followed if filling on site
Be aware of static nylon clothes
Mobile Phones should be away from the area
In Case of an Emergency
In the case of an emergency you must make sure that you alert personnel i.e. your immediate
supervisor, colleagues in the vicinity
Tell them the nature of the incident i.e. a spill, an accident, a near miss
Inform staff of all the unsafe areas i.e. get signs, barriers etc.
Provide directions to emergency services if required
Forklift Assessment Guide Version 1 valid from 1.1.13.docx

Give way to all emergency vehicles

Complete necessary paperwork
All Employers must have an emergency plan (60 penalty units)

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

10

The hydraulic oil level in the storage tank is correct.

The brake fluid level is correct.
Battery for cleanliness, fluid levels and security
Power steering fluid normally using hydraulic oil
Air filter (warning light)
The fuel level or the LP gas pressure is correct no leaks. Check Test date on bottle and
compliance plate (10 years) is fitted
The windscreen is clean, if fitted.
The seat and seatbelt are in good condition and properly adjusted.
If fitted, the mirrors are adjusted properly.
The controls are clearly marked.
Attachments for security and compliance

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

1
2
3

How heavy?
How long?
How high?

Weight
Length (load centre of gravity)
Height

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

11

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

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

12

Maintenance & Servicing

Similar to the situation with your car, basic maintenance can be done by an forklift operator i.e. oil,
tyres, water, battery etc. (pre-checks).
To undertake repairs
You must be qualified
You must competent
You must be authorised
Refer to supplier
Check hour meters / service stickers
Attachments also need to be maintained and serviced
Do not mess with machines
Check over both shoulders before reversing
Ensure warning devices are working
Clear path of travel
If you cannot see use a spotter
Driving up and down slopes Loaded

WHEN
LOADED LOAD
ALWAYS
FACES UPHILL

Sideways rollover (Lateral Instability)

Be aware of the factors listed below which can affect lateral instability (rolling over sideways):
Turning at speed
Driving over uneven surfaces
An unevenly distributed load
Driving with a flat or under inflated tyre
Driving too fast
Turning / travelling with a load raised bad practice / operators responsibility
Braking too hard when turning
Side shift not centred
Lifting a load on one fork arm
Driving sideways across a slope
Dragging a load sideways with a jib attachment
Approved Seats
A Forklift must not be used to carry a passenger unless the machine has been designed to do so.
The forklift needs to be fitted with an approved seat and seatbelt.
The seat must be located within the zone of protection that is provided by the operator protective
device required to be fitted to the forklift (Maximum penalty60 penalty units, $6,000 under current
Legislation).
Tip forward (Longitudinal Stability)
Be aware of the factors listed below which can affect longitudinal instability (tipping over
lengthways):
Overloading
Forklift Assessment Guide Version 1 valid from 1.1.13.docx

13

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

14

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

Load Centre Distance

Load centre distance is the horizontal distance measured along the fork arms from the
centre of gravity (C of G) of a load to the heel of the fork arms.
Most forklifts are rated as 600 mm as an Australian standard pallet is 1200 mm long. The
load must be against the heel of the forks or the capacity of the machine will be reduced
An increase in load centre reduces the forklifts capacity.
Travelling Safety Tips
Make sure that no one is in the way or standing next to you before driving away
Carry Loads as low as possible at all times 150 mm / front axle height
Always travel with the load tilted backwards & low to the ground
Stay left in two way traffic aisles
If the load is wide you might need to take a different route
If your load extends above the backrest extension height, band them together to reduce the
risk of falling
If you cant see clearly, drive backwards or use a spotter
Follow the travel path youve set out in the work plan.
Obey the speed limits
Read the signs, know what they mean and follow their direction
Look out for barriers; you dont want to hit them
Pay attention all the time. Things are constantly changing
Keep a safe distance from other forklifts
Allow enough distance and time, so that you can stop safely
Always keep your load lowered when youre driving
Use horns and lights to warn people youre in the area, when you drive in and out of doors
and when you go around corners
General Safety Rules
Blow the horn and drive slowly when approaching a blind corner and make a wide turn, treat
as a give way.
You could also do this when crossing aisles of traffic and in noisy environments. If you are in
doubt, lower load, switch off the engine, get off and check.
Use spotters
Do not put slings around forks to lift things
Do not raise a load with just one fork, it can damage fork and cause instability
Do not carry passengers on the forks
Note: a cage is used to raise and lower not travel
Slow down on wet and greasy surfaces avoid heavy braking and fast turns
Never turn on a slope
Always look in the direction of travel (when turning round dont use overhead guard for
leverage easy to lose a finger)
Mirrors should only be used for awareness or to see what is coming past you
Never lift loads near of over people, large risk of loads falling and killing or injuring
people

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

15

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.

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

16

Forklift Assessment 3: Performance Assessment

Instructions for candidates
1. You are required to undertake a performance assessment, which focuses on your performance in the practical area
of forklift operations.
2. The assessor will provide you with verbal instructions about what you are to do.
3. If you are unclear about what you have to do, ask the assessor.
4. The assessment may be stopped (when it is safe to do so) to allow questioning. Questions (non-critical) that were
identified as incorrect in the Knowledge Assessment will be included in this assessment.
5. All tasks/activities must be performed without assistance from another person. Some tasks may require interaction
with another person e.g. a crane operator when lifting a load.
6. You cannot use any references, books or course notes.
7. All tasks/activities must be satisfactorily demonstrated. If you do not satisfactorily demonstrate all tasks/activities then
you assessor is required to enter a result of Not yet competent.
8. You should be able to complete the assessment in two (2) hours. The time stated is a guide only. If you cannot
complete the assessment in the stated time then this will be considered when assessing overall competency.
Personal protective equipment (PPE)
You must wear safety clothing and equipment as required by the risk assessment of the workplace. Typically this will
include:
safety helmet (where required)
appropriate footwear
high-visibility vest or other similar clothing, and
other protective clothing and equipment as appropriate.
The Assessor is to confirm the availability of PPE when making arrangements to conduct the assessment. If you do not
have the appropriate equipment the assessment must not be undertaken.
IMPORTANT NOTE
If, at any time during the observation of the Performance Assessment, you act in a manner that endangers yourself,
others, equipment or property, the assessment will be stopped immediately. The assessor will point out the dangerous act
to you and re-schedule the assessment with you at a mutually agreeable time. You will be required to complete the whole
Performance Assessment again at that time.
The Assessor must provide the applicant with a selection of equipment, adequate for the following tasks:
Task one: Hazard identification and hazard prevention.
Task two: Conduct pre-operational checks (forklift visual inspection).
Task three: Conduct post-start checks.
Task four: Operate the forklift to the full range of its capacity (Safe moving of loads).
Task five: Shut down and secure the forklift.
The instructions and equipment required for each task are identified separately below.
Task one: Hazard identification and hazard prevention
Before using the forklift, the assessor will ask you to conduct visual hazard identification/risk assessment of the workplace.
You will need to apply hazard prevention controls where required, before using the forklift.
The assessor will ask you some questions to test your knowledge.
Task two: Conduct pre-operational checks (forklift visual inspection)
For Task two you are required to visually inspect the forklift, including:
all labels, signage and control identification
all oil and fluid levels
the condition of tyres, seats, gas cylinder, locking devices, mast assembly and any other relevant parts on the forklift
to ensure that it is safe to use, and
locating and checking the data plate.
The assessor will ask you some questions to test your knowledge.
Forklift Assessment Guide Version 1 valid from 1.1.13.docx

17

Task three: Conduct post-start checks

For Task three you are required to conduct post-start checks:
Start the forklift in accordance with policies and the manufacturers requirements.
Test (and inspect where practical) all limits, lights, gauges, warning devices, indicators, steering and braking systems,
mast and tilt controls to ensure that the forklift is safe to use.
The assessor will ask you some questions to test your knowledge.

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.

Task five: Shut down and secure the forklift

You are now required to park the forklift and shut it down, safely and effectively. Secure the forklift in accordance with
procedures.

Performance Assessment Course Template

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

18

Issuance of Forklift Licence

Reclassified on 1st July 2008 as a Photographic High Risk Work (HRW) Licence, renewable every 5
years. Listed below is the procedure to follow for the issuance of your Forklift Licence:a. The yellow copy of the Assessment Summary will be issued promptly after the conclusion of
your practical assessment.
The original copy will be retained by The Operator School to enter your details into the WHS
Queensland portal
You do not need the original copy to lodge your application at Australia Post. You simply
require the AS number from the top left hand corner of the Assessment Summary.
b.

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)

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

19

You keep for yourself

Yellow copy of Assessment Summary and receipt from

Australia Post
Your original Statement of Attainment
l.
Once an application is lodged with Australia Post you are authorised to carry out work until a
licence is issued or the application is refused.
m. Australia Post will then forward the application on your behalf to WHS Queensland
n. Workplace Health and Safety will notify you if there are any queries with your application
o. Your Licence should arrive in the mail at your postal address within four weeks; more complex
applications i.e. when other licences are also being renewed at the same time may take longer.
p. You must notify the regulator (WHSQ) of any changes to your personal details i.e. residential
address, contact details etc. within 14 days (can be done over the internet) 1300 369 915 or
http://www.justice.qld.gov.au/ There are hefty fines in place (up to $1,250) if you do not do this.
q. You must notify the regulator (WHSQ) as soon as reasonably practicable if your licence is lost,
stolen, damaged or destroyed. You must take the necessary steps to arrange for a
replacement licence. 1300 369 915 or http://www.justice.qld.gov.au/
r.
You are required to have your forklift licence available for inspection by a principal inspector of
WHSQ at any time that you are operating a forklift.
s. You must be aware that your Licence is renewable every 5 years and that you will need to
apply for a renewal if you still wish to operate a forklift.
t.
The regulator (WHSQ) may direct a licence holder to obtain a re-assessment of the
competency, if the regulator reasonably believes that the licence holder may not be competent
to carry of that work.
u. The regulator may suspend, cancel or refuse to issue or renew a licence if the licence holder
refuses or fails to provide sufficient reasons in response to a written notice of proposal to
suspend cancel or refuse to issue or renew a licence.
v. I must not perform work under the conditions of my licence unless I believe I am competent to
operate the plant. I must comply with any reasonable instructions given by my employer
If you have other competencies that need to be transferred to a High Risk Work Licence i.e. crane
tickets etc. please discuss it with us and we will endeavour to assist you in understanding the
process.
The issue of this licence is the minimum legal requirement of training and assessment standards to
operate a specific piece of high risk equipment without supervision. It does not qualify as
experience. Your employer will need to ensure ongoing training is undertaken to meet workplace
regulatory requirements. Licences are recognised throughout Australia. You do not have to change
your licence if you are working interstate.

Forklift Assessment Guide Version 1 valid from 1.1.13.docx

20