High Risk Work Licence - Forklift Truck (LF) cheat sheet

Model WHS Act duties: PCBU must ensure health and safety so far as reasonably practicable; workers must take reasonable care and comply with instructions; officers exercise due diligence.

A forklift is 'high risk work' plant; the operator must hold a current LF licence for the class of truck being operated, and must carry or produce it on request.

Licence classes are set by truck type and capacity: LO (order-picking forklift), LF (forklift truck), and related WP classes for boom-type elevating work platforms.

Licences are issued by the regulator, valid for 5 years, and must be renewed before expiry; operating on an expired or suspended licence is an offence.

RTO training and assessment must be completed before applying; the assessor lodges results, and the licence application must be made within 60 days of assessment.

Duty to report notifiable incidents to the regulator immediately: death, serious injury or illness, or a dangerous incident such as a load drop or tip-over.

PCBU must provide information, training, instruction and supervision; generic induction does not replace task-specific training on each site and truck.

Workers have the right to cease unsafe work and must not be directed to operate an unsafe forklift; consultation on WHS matters is required.

Hierarchy of control, highest to lowest: eliminate, substitute, engineering controls, administrative controls, PPE; PPE is the last line of defence.

Risk score = likelihood × consequence; controls are applied until residual risk is rated low or acceptable under the site's risk matrix.

Common forklift hazards: tip-over, falls from height, crushing between truck and structure, pedestrian strike, load drop, and collision with racking.

Hazard identification sources: pre-start inspections, incident and near-miss reports, workplace inspections, worker consultation, and safe work method statements.

Engineering controls for forklifts include speed limiters, reverse alarms, blue spotlights, overhead guards, and racking protection barriers.

Administrative controls include traffic management plans, exclusion zones, designated walkways, and competency-based authorisation for each task.

Risk assessment must be reviewed after an incident, a change in layout or load type, or new plant is introduced.

Hazardous substances and confined spaces near forklift operations require separate risk assessment and control measures.

Counterbalance trucks carry the load ahead of the front wheels; the load moment must be balanced by the truck's counterweight and wheelbase.

Stability triangle: the centre of gravity of the combined truck and load must remain inside the triangle formed by the two front wheels and the centre of the steer axle.

Load centre is measured from the vertical face of the forks to the centre of gravity of the load; rated capacity applies only at the stated load centre.

Increasing load centre or lift height reduces capacity; the data plate states capacity at a specific load centre and lift height.

Attachments such as sideshift or clamps reduce rated capacity; the reduced rating must be shown on an updated data plate.

Longitudinal stability is lost by overloading, load centre too far out, or tilting forward with a raised load; lateral stability is lost by turning too fast or travelling with a raised load.

Truck types include counterbalance, reach truck, order picker, pallet truck, rough terrain, and telehandler; each has a different licence class or rating.

The data plate shows model, serial number, rated capacity, load centre, lift height, and tyre type; never exceed any stated limit.

Pre-start check items: tyres, forks and heels, mast chains, hydraulic hoses, fluid levels, battery or fuel, lights, horn, alarm, brakes, and seat belt.

Fork heel wear limit is typically 10 percent of the original fork thickness; excessive wear, cracks, or bent forks require the truck to be taken out of service.

Mast chain tension must be equal on both chains; slack or broken chains indicate a fault that must be reported before use.

Defects are recorded in the pre-start checklist and reported to the supervisor; safety-critical defects require tagging out and isolation.

Planned maintenance is scheduled by hours or calendar interval; the operator must not perform repairs beyond their competence.

Daily checks are recorded and retained; a truck without a current inspection record must not be operated.

Battery charging areas require ventilation, no smoking, eyewash, and correct PPE; refuelling areas require fire extinguishers and spill kits.

Any incident, near miss, or damage to the truck or racking must be reported and the truck inspected before returning to service.

Confirm the load weight from documentation, markings, or a weighbridge; never guess a weight that may exceed the truck's rated capacity.

Calculate the load moment: weight × load centre distance; compare with the truck's rated moment from the data plate.

Load centre increases when the load is deeper, off-centre, or when an attachment extends the distance to the load's centre of gravity.

Distribute loads evenly across both forks; avoid single-fork lifts, which cause lateral instability and fork damage.

Check the load is stable, stacked correctly, and secured; shrink wrap or strapping prevents load shift during travel.

Do not lift a load that exceeds the capacity at the required lift height; the capacity chart applies at the actual lift height, not just ground level.

Loads must be carried low, with the mast tilted back, and the load must not obstruct the operator's forward view.

Estimate weight using known references such as pallet type, material density, and labelled carton weights; if uncertain, weigh the load.

Travel with the load low, approximately 100-150 mm above the ground, mast tilted back, and forks trailing when unladen.

Observe the site speed limit; travel at a speed that allows stopping within the visible clear distance.

Sound the horn at blind corners and intersections; slow down and check mirrors and blind spots before turning.

When travelling with a load that restricts forward view, travel in reverse, except when ascending a ramp, where the load leads.

On ramps, drive up and down with the load uphill; never turn on a ramp or travel across a slope.

Approach the pick or place position squarely, stop, apply the park brake, and then raise or lower the load.

When stacking, raise the load just above the racking level, move forward slowly, lower onto the beam, tilt back slightly, and withdraw the forks.

Never allow anyone to stand under or near a raised load; never lift people on the forks unless in an approved work platform with the correct controls.

A traffic management plan defines vehicle routes, pedestrian walkways, exclusion zones, speed limits, and crossing points.

Physical separation of pedestrians and forklifts is the primary control; barriers and marked walkways take priority over signage alone.

Operators and pedestrians should make eye contact before either moves; a wave or nod confirms the pedestrian has been seen.

Pedestrians must never walk under raised forks, behind a reversing forklift, or within the truck's operating radius.

Use mirrors, reversing cameras, and blue spotlights; sound the horn when reversing or approaching a blind corner.

Designated loading and unloading zones must be marked, kept clear, and separated from walkways and storage areas.

Communication protocols include two-way radio, hand signals, and stop-work authority for anyone who sees an unsafe act.

Site induction covers traffic rules, exclusion zones, and emergency assembly points for all workers and visitors.

If a tip-over occurs, stay in the seat, brace against the wheel, and do not jump; jumping is the leading cause of fatal crush injuries.

If a load starts to fall, do not attempt to catch it; move clear and warn others.

On detecting fire or smoke, stop the truck in a safe location, shut down, isolate the battery or fuel, and raise the alarm.

Emergency stops and isolation points must be known before operating; the key must be removed and retained when leaving the truck.

Incident response: make the area safe, provide first aid, notify the supervisor, preserve the scene, and report notifiable incidents to the regulator.

Spills of hydraulic fluid or fuel require containment, absorbent material, and reporting; do not operate a leaking truck.

Shutdown procedure: lower forks to the ground, neutral gear, park brake, key off, remove key, and chock wheels on a slope.

Emergency assembly points, first aid officers, and evacuation routes must be identified during site induction.

Pre-use: complete the pre-start checklist, adjust the seat and mirrors, fasten the seat belt, and test the horn, lights, and brakes.

Operate smoothly: avoid sudden starts, stops, and turns; use the inching pedal for precise positioning.

Park in a designated area, not in walkways or in front of fire equipment; lower forks flat to the ground and apply the park brake.

Post-operational: refuel or recharge as required, record hours, complete the shutdown checklist, and report defects.

Handover must include any defects, incidents, or near misses and the truck's condition and fuel or charge level.

Secure the truck against unauthorised use by removing the key and locking the cab where fitted.

Clean the truck of debris and spills; check for hydraulic leaks before parking.

Complete the post-operational inspection record and file it with the shift documentation.

Rated capacity is valid only at the stated load centre and lift height; any increase in either reduces capacity.

Derating formula: new capacity = rated capacity × (rated load centre ÷ actual load centre) for the same lift height.

Attachments reduce capacity by their own weight and by shifting the load centre forward; use the attachment data plate.

Lift height reduces capacity because the mast and carriage raise the combined centre of gravity.

Tyre type and inflation affect stability; solid tyres and correct pressure are required for rated capacity.

Dynamic forces from braking, turning, and lowering add to the static load moment; reduce speed and load when manoeuvring.

The stability triangle must contain the combined centre of gravity at all times; it shrinks when the load is raised or shifted.

Never use counterweight additions or unauthorised modifications to increase capacity; they void the rating.

Signage types: speed limits, pedestrian crossings, no-go zones, load limits, and hazard warnings; all must be obeyed.

Exclusion zones are set around operating forklifts, especially when loads are raised or oversized.

Use a spotter for oversized loads, blind lifts, or reversing into tight spaces; the spotter must remain visible to the operator.

Hand signals must be agreed before the lift; stop signals override all other signals.

Two-way radio communication is required for coordinated lifts and for blind corners on large sites.

Pedestrians must use designated walkways and crossings; jaywalking through vehicle areas is a hazard.

Barricades and cones mark temporary hazards; they must be removed when the hazard is cleared.

Report damaged or missing signage to the supervisor for replacement.

Load moment = load weight × distance from the front wheel or fork face to the load's centre of gravity.

Rated moment = rated capacity × rated load centre; the actual moment must not exceed the rated moment.

Example: rated capacity 2000 kg at 500 mm load centre; a load at 750 mm load centre reduces capacity to about 1333 kg.

Estimate weight from volume × density; steel is about 7850 kg/m³, water 1000 kg/m³, and timber 500-800 kg/m³.

Pallet weight must be added to the load weight; standard pallets are 15-25 kg.

Check container markings and delivery dockets for declared weights; weigh if the declared weight is missing or doubtful.

Off-centre loads shift the combined centre of gravity and reduce effective capacity; centre the load on the forks.

Never exceed the data plate rating, even if the truck appears to lift the load; overloading causes tip-over and structural failure.

Check racking for damage before placing loads; report bent beams, missing clips, or damaged uprights.

Place loads squarely on the racking beams; do not overhang or bridge beams.

Do not exceed the racking's rated load per bay or per beam level.

Stack loads so they are stable, with heavier items at the bottom and within the racking's height limits.

Keep the mast vertical when entering and leaving the racking; tilt back only after the load is clear.

Never push or drag loads with the forks; this damages racking and the load.

Ensure the load is fully seated on the forks before lifting; check the load's stability after lifting clear of the ground.

Report and tag out damaged racking immediately; do not load a damaged bay.

Refuel only in designated areas with the engine off and no ignition sources; use a fire extinguisher and spill kit.

Battery charging requires ventilation to disperse hydrogen gas; no smoking or open flames.

Use PPE for battery work: face shield, acid-resistant gloves, and apron.

Isolate the battery before maintenance; follow lockout/tagout procedures.

Hydraulic systems store energy; relieve pressure before disconnecting hoses.

Do not operate a truck with a leaking hydraulic hose or fuel line; tag out and report.

Spills must be contained and cleaned with absorbent material; report to the supervisor.

Only trained and authorised personnel may refuel or change batteries.

Notifiable incidents include death, serious injury or illness, and dangerous incidents such as tip-over or load drop.

Notify the regulator immediately by phone, then provide written notice within the required timeframe.

Preserve the scene; do not disturb equipment until the regulator or investigator authorises it.

Record witness statements, photographs, and the truck's inspection and maintenance history.

Investigate root causes using a method such as 5 Whys or fishbone; identify contributing factors.

Implement corrective actions and verify their effectiveness.

Report near misses; they are leading indicators of future incidents.

Keep records of incidents, investigations, and corrective actions for the required retention period.

Common attachments: sideshift, fork positioner, clamp, rotator, and drum handler.

Attachments add weight and shift the load centre forward, reducing capacity; use the attachment data plate.

Clamps require sufficient clamping force to hold the load without damage; test the clamp before lifting.

Rotators must be secured before travel; never travel with a raised rotator load.

Attachments must be compatible with the truck and fitted by a competent person.

Inspect attachments before use for cracks, wear, and hydraulic leaks.

Never modify attachments or the carriage without engineering approval.

Operators must be trained on each attachment type before use.

On ramps, travel with the load uphill; reverse down the ramp when the load is uphill.

Never turn on a ramp or travel across a slope; this causes lateral tip-over.

Reduce speed and load on slopes; the gradient reduces effective capacity.

Rough terrain trucks have higher ground clearance and traction tyres; still observe gradient limits.

Check the ramp surface for traction, debris, and edge protection.

Keep the load low and tilted back when ascending or descending.

Use a spotter when the ramp is narrow or visibility is restricted.

Never exceed the truck's rated gradient; consult the data plate or manual.

Pedestrians must never walk under raised forks or within the truck's turning radius.

Make eye contact with the operator before crossing a vehicle path.

Use designated walkways and crossings; do not cut through storage areas.

Wear high-visibility clothing in vehicle areas.

Keep walkways clear of obstructions and debris.

Report unsafe pedestrian behaviour and near misses.

Visitors must be inducted and escorted in vehicle areas.

Operators must stop when pedestrians are in the path and wait until they are clear.

The combined centre of gravity must remain inside the stability triangle at all times.

Raising the load raises the combined centre of gravity, reducing lateral stability.

Tilting forward with a raised load shifts the centre of gravity forward, risking longitudinal tip-over.

Turning at speed creates centrifugal force that can move the centre of gravity outside the triangle.

Braking sharply shifts the load forward; brake smoothly and progressively.

Carrying the load low and tilted back keeps the centre of gravity low and within the triangle.

Overloading moves the centre of gravity forward beyond the triangle.

Attachments and off-centre loads shift the centre of gravity laterally as well as forward.

Site induction covers traffic rules, emergency procedures, hazards, and reporting.

Operators must be authorised for each truck type and task; a licence alone does not authorise all tasks.

Competency is verified by observation and assessment on the specific truck and task.

Refresher training is required after incidents, long absences, or changes in equipment.

Records of training and authorisation must be kept and available for inspection.

Visitors and contractors must be inducted before entering vehicle areas.

Authorisation can be withdrawn for unsafe behaviour.

Report any change in health or fitness that affects the ability to operate safely.

Loads must be stable and secured before lifting; use shrink wrap, strapping, or banding.

Do not lift a load that is loose, unbalanced, or stacked unevenly.

Check that the load is fully seated on the forks and against the carriage.

Use the correct pallet type for the load weight and dimensions.

Never lift a load by one fork or by the pallet's edge.

Secure tall loads to prevent tipping during travel.

Inspect restraints before use for wear and damage.

Report loads that cannot be safely secured.

Defects are classified as safety-critical or non-critical; safety-critical defects require immediate tag-out.

Tag-out procedures include locking the controls, attaching a defect tag, and notifying the supervisor.

Only competent persons may repair forklifts; operators must not attempt repairs beyond their training.

Maintenance records must be kept and include the date, defect, action taken, and person responsible.

Pre-start checks are recorded daily and reviewed by the supervisor.

Scheduled maintenance follows the manufacturer's intervals and includes brakes, steering, hydraulics, and mast.

A truck with an unresolved safety-critical defect must not be returned to service.

Report recurring defects for root cause investigation.

Check overhead clearance before raising the mast; watch for sprinklers, lights, and doorways.

Reduce speed in aisles and warehouses; maintain a safe stopping distance.

Use mirrors at aisle intersections and sound the horn.

Keep the load low and within the aisle width when turning.

Do not enter a confined space with a forklift unless authorised and assessed.

Ensure ventilation when operating LPG or diesel trucks indoors; carbon monoxide is a hazard.

Keep fire exits and extinguishers clear at all times.

Report damaged racking, lighting, or flooring immediately.

The data plate shows rated capacity at a specific load centre and lift height.

Capacity charts show derating for increased load centre and lift height.

Attachments require a revised data plate showing the reduced capacity.

Tyre type and pressure affect the rated capacity; use the specified tyres.

Never exceed the rated capacity at the actual load centre and lift height.

The load moment must not exceed the rated moment.

Consult the manufacturer's manual for capacity at non-standard configurations.

Report a missing or illegible data plate; the truck must not be operated.

Check the load for dangerous goods markings and labels before lifting.

Follow the safety data sheet for handling, PPE, and spill response.

Do not lift damaged containers; report leaks or damage immediately.

Use spark-free equipment in flammable atmospheres.

Keep spill kits and fire extinguishers accessible.

Segregate incompatible dangerous goods during storage and transport.

Report spills to the supervisor and follow the site's spill response plan.

Only trained personnel may handle dangerous goods.

Maintain the safe approach distance from overhead powerlines; consult the site's exclusion zone.

Use a spotter when operating near powerlines.

Never raise the mast under powerlines or overhead structures.

If contact occurs, stay in the cab and warn others to stay clear; call emergency services.

Do not touch the truck and the ground at the same time if contact occurs.

Report any contact or near contact immediately.

Check overhead clearance before raising the mast.

Use non-conductive equipment where required.

Cold store operation requires appropriate PPE and limited exposure time.

Battery performance drops in cold temperatures; monitor charge levels.

Check for ice on floors, ramps, and forks; ice reduces traction and stability.

Use cold-rated hydraulic fluid and lubricants as specified.

Ensure ventilation and emergency exits are clear.

Report condensation, ice build-up, or equipment faults.

Follow the site's cold store entry and exit procedures.

Maintain communication with others outside the cold store.

Check the dock leveller and trailer restraint before entering a trailer.

Ensure the trailer is chocked or restrained and the wheels are locked.

Check the trailer floor for damage and load capacity.

Use dock lights and mirrors for visibility.

Do not enter a trailer that is not restrained.

Keep the load low and centred when entering and exiting.

Report damaged dock equipment immediately.

Never stand between the forklift and the dock edge.

Oversized loads require a risk assessment and a spotter.

Check the load's dimensions against aisle and doorway clearances.

Reduce speed and avoid sharp turns.

Ensure the load is secured and balanced.

Use a tag line where required.

Do not travel with the load raised above the safe travel height.

Report any contact with structures or equipment.

Plan the route before moving the load.

Public areas require additional controls: barriers, signage, and spotters.

Reduce speed and maintain a safe distance from pedestrians.

Use a spotter when reversing or turning in public areas.

Ensure the load is secured and does not overhang.

Comply with local council and road rules for forklifts on roads.

Report any near misses with the public.

Use high-visibility clothing and lights.

Plan the route to avoid crowded areas.

Use explosion-protected forklifts in flammable atmospheres.

Check the area's hazardous zone classification before entering.

Ensure ventilation and gas monitoring where required.

Do not use spark-producing equipment in flammable atmospheres.

Follow the site's permit-to-work system.

Report any gas leaks or unusual odours.

Keep fire extinguishers accessible.

Only trained personnel may operate in hazardous atmospheres.

Monitor hydraulic fluid and engine temperatures; overheating can cause failure.

Check coolant and oil levels before use.

Take breaks in shaded areas and stay hydrated.

Inspect tyres for heat damage and correct pressure.

Report overheating or unusual noises immediately.

Ensure ventilation in enclosed areas.

Follow the manufacturer's temperature limits.

Keep fire extinguishers accessible.