High Risk Work Licence - Order-Picking Forklift (LO) cheat sheet

Primary duty: a person conducting a business or undertaking (PCBU) must ensure health and safety so far as is reasonably practicable; workers must take reasonable care for themselves and others and follow lawful instructions.

Officers owe a due diligence duty: acquire and keep current WHS knowledge, understand operations and hazards, ensure resources and processes exist, and verify they are used.

Order-picking forklift operation is high risk work; the operator must hold a current LO licence for the class of plant being operated, and the PCBU must verify it before allowing operation.

A licence is class-specific and person-specific: it cannot be lent, copied or transferred, and operating outside the licensed class or with a suspended licence is an offence.

Reasonably practicable weighs the likelihood and severity of harm against the cost, effort and availability of controls; the greater the risk, the stronger the required control.

Incident notification: a death, serious injury or dangerous incident (e.g. plant collapse, uncontrolled load drop, tip-over) must be reported to the regulator immediately, with written notice within the prescribed period.

Other duty holders: designers and manufacturers must eliminate risks in design; suppliers must provide information; persons installing or erecting plant must ensure it is stable and commissioned safely.

Worker consultation and representation duties require the PCBU to consult on matters that affect health and safety, including changes to plant, systems of work and hazard controls.

Hierarchy of control, highest to lowest: eliminate the hazard, substitute, isolate, engineering controls, administrative controls, then personal protective equipment as the last line.

Risk assessment ranks risk by likelihood of occurrence multiplied by severity of consequence; controls are prioritised for the highest-ranked risks first.

Common order-picking hazards: falls from height, tip-over, crush between mast and racking, pedestrian strike, falling loads, overhead services, floor edges and poor lighting.

Hazard identification sources: pre-start inspections, incident and near-miss records, workplace inspections, task analysis, manufacturer information and worker reports.

Engineering controls for order-picking include guarding, interlocked gates, racking protection, speed limiting, warning devices and designated pedestrian exclusion zones.

Administrative controls include traffic management plans, exclusion zones, permits, procedures, training, signage and scheduled maintenance.

Controls must be monitored and reviewed after an incident, a change in plant or layout, or at scheduled intervals to confirm they remain effective.

Residual risk is the risk remaining after controls; it must be documented and accepted by the person with authority before work proceeds.

An order-picking forklift (LO) is a high-lift machine where the operator's platform rises with the load, allowing picking at height; the operator remains on the platform during travel and lifting.

Stability triangle: the centre of gravity of the machine plus load must stay inside the triangle formed by the two front wheels and the centre of the steer axle, or the machine tips.

Load centre distance is measured from the vertical face of the forks to the load's centre of gravity; increasing it reduces the rated capacity.

Rated capacity is stated at a specific load centre and lift height on the data plate; capacity decreases as load centre, lift height or mast tilt increases.

Components include mast, carriage, forks or platform, hydraulic lift and tilt cylinders, chains, overhead guard, restraint or harness anchor, horn, lights and deadman pedal.

The overhead guard protects against falling objects; the operator restraint (harness or gate) protects against ejection during tip-over or sudden stops.

Mast sway and mast flex increase with lift height, so travel speed and load height must be reduced as the platform is raised.

Dynamic forces from braking, turning, accelerating and uneven floors add to static load and can move the centre of gravity outside the stability triangle.

Pre-start inspection is completed before each shift or use and covers the whole machine; the result is recorded and signed.

Check fluids and leaks: hydraulic oil level and leaks, engine oil, coolant, fuel, battery electrolyte and charge state, and any pooling under the machine.

Check tyres and wheels for pressure, cuts, chunking, loose wheel nuts and correct matching; check forks or platform for cracks, wear and heel distortion.

Check mast, chains and hydraulics: chain tension and equalisation, chain wear and lubrication, hose condition, cylinder leaks, and smooth operation through full lift and lower.

Check safety devices: horn, lights, flashing beacon, reverse alarm, deadman pedal, operator restraint or harness, gates, interlocks, brakes and parking brake.

Check data plate and decals are legible and the machine matches its rated capacity; unreadable plates must be replaced before use.

Defective plant must be tagged out, isolated and removed from service; the fault is reported to the supervisor and recorded, and the machine is not operated until repaired and re-checked.

Servicing follows the manufacturer's schedule; only competent persons perform repairs, and records of service and repairs are retained.

Read the load chart or data plate before lifting: capacity is valid only for the stated load centre, lift height and attachment, and must be de-rated for other conditions.

De-rating rule: as load centre distance increases beyond the rated value, capacity falls; as lift height increases, capacity falls; on uneven ground or with attachments, capacity also falls.

Estimate the load's centre of gravity: a long or irregular load has a centre further from the fork face than a compact load of the same mass, so it must be de-rated.

Never exceed the rated capacity; if the load mass is unknown, weigh it or obtain the documented mass before lifting.

Load restraint: loads must be secured against sliding and falling, using pallets in good condition, stretch wrap, strapping or racking stops as appropriate.

Keep the load low and the mast tilted back slightly during travel; the load and platform must not obstruct the operator's view, so travel in reverse if needed.

Distribute the load evenly across both forks and keep the load within the fork length; avoid lifting loads by the tips or with a single fork.

Check the load for stability, damaged packaging, overhang and loose items before lifting, and confirm the destination racking has adequate capacity.

Pick-up: approach square and slowly, level the forks, insert fully, lift clear, tilt back slightly, then lower to travel position before moving off.

Travel: keep the load low, look in the direction of travel, sound the horn at blind corners and doorways, obey speed limits and give way to pedestrians.

On ramps and slopes, travel with the load uphill; on the order-picker, keep the platform lowered when travelling on inclines and never turn on a slope.

Stacking: square up to the rack, raise to just above the beam level, move forward slowly, lower onto the beams, check seating, then withdraw the forks.

De-stacking: raise to clear the beam, withdraw slowly, lower to travel position, then check the load is stable before moving away.

Never allow anyone under a raised load or platform; keep hands, feet and body inside the operator compartment while the platform is elevated.

Shut-down: lower the platform and forks fully, neutralise controls, apply the parking brake, remove the key, park in the designated area and recharge or refuel as required.

Park clear of traffic, exits, fire equipment and racking; chock on slopes and follow the site's key control procedure.

The operator must remain inside the platform guardrails and wear the supplied restraint or harness attached to the designated anchor point whenever the platform is elevated.

Fall protection must be inspected before use: check harness webbing, stitching, buckles, lanyard and anchor for damage, and remove defective equipment from service.

Never climb on the guardrails, use ladders from the platform, or lean out to reach stock; reposition the machine instead.

Keep the platform clear of overhead obstructions and powerlines; maintain the legislated safe approach distance from energised electrical equipment.

Rescue planning: a written rescue procedure must exist before elevated work starts, with trained rescuers, equipment and a means of lowering the platform in an emergency.

Emergency lowering: know the manual descent or auxiliary pump procedure and where it is located; never attempt to catch a falling person.

Suspension trauma is a risk after a fall arrest; the casualty must be rescued promptly and kept still, with medical help called immediately.

Platform capacity, including operator, tools and stock, must not be exceeded; the platform is not a crane and must not be used to lift loads.

Traffic management separates pedestrians and plant using marked walkways, barriers, mirrors, speed limits, signage and designated parking and loading zones.

Before moving, check mirrors and blind spots, sound the horn if fitted, and make eye contact with nearby pedestrians; never assume you have been seen.

Hand signals and radio protocols must be agreed before the lift; only one designated spotter gives signals, and the operator stops if the signal is unclear.

Signage types: prohibition (red circle), warning (yellow triangle), mandatory (blue circle) and emergency information (green); obey all site and racking signs.

Racking signage states the bay's rated capacity and load configuration; never exceed it, and report damaged racking immediately.

Pedestrian exclusion zones apply whenever the platform is elevated or a load is being placed or retrieved at height.

Use the horn at blind corners, doorways, intersections and before reversing; keep the beacon and lights on where required.

Report near misses and unsafe acts so the traffic management plan and signage can be reviewed.

Tip-over response: stay in the seat or platform with restraint fastened, brace, do not jump; jumping is a leading cause of fatal crush injuries.

If a tip-over occurs, do not attempt to right the machine yourself; isolate it, keep people clear and call for competent assistance.

Hydraulic failure or sudden loss of lift: stop, lower the platform using the emergency lowering procedure, evacuate and tag out the machine.

Fire: isolate the power or fuel, evacuate to the assembly point, call emergency services, and only use an extinguisher if trained and safe to do so.

Load drop or racking strike: stop work, secure the area, check for injured persons, report to the supervisor and do not resume until the racking is inspected.

Contact with powerlines: stay in the machine, warn others away, and only leave if there is fire, jumping clear and shuffling away without touching machine and ground together.

Incident response: provide first aid, secure the scene, preserve evidence, notify the regulator where required, and record the incident and near misses.

Emergency plan knowledge includes exits, assembly points, first aid, spill kits, fire equipment locations and the site's communication channels.

Pre-operational checks, seatbelt or harness use, and correct mounting and dismounting (three points of contact, facing the machine) are assessed as part of practical competence.

Smooth control is assessed: progressive acceleration and braking, no harsh steering, correct use of the deadman pedal and parking brake.

Load handling is assessed for correct approach, square pick-up, full fork insertion, correct tilt, low travel height and accurate placement on the rack.

Observation and hazard awareness are assessed continuously: checking mirrors, blind spots, pedestrians, overhead obstructions and floor conditions.

Communication is assessed: horn use, eye contact, hand signals, radio use and response to a spotter.

Parking and shut-down are assessed for full lowering, neutral controls, brake applied, key removed and correct parking location.

The operator must demonstrate knowledge of the load chart, de-rating and the stability triangle during the practical assessment.

Any unsafe act, uncontrolled movement or breach of exclusion zones is a fail criterion regardless of task completion.

Primary duty: a person conducting a business or undertaking (PCBU) must ensure health and safety so far as is reasonably practicable; workers must take reasonable care for themselves and others and follow lawful instructions.

Officers owe a due diligence duty: acquire and keep current WHS knowledge, understand operations and hazards, ensure resources and processes exist, and verify they are used.

Order-picking forklift operation is high risk work; the operator must hold a current LO licence for the class of plant being operated, and the PCBU must verify it before allowing operation.

A licence is class-specific and person-specific: it cannot be lent, copied or transferred, and operating outside the licensed class or with a suspended licence is an offence.

Reasonably practicable weighs the likelihood and severity of harm against the cost, effort and availability of controls; the greater the risk, the stronger the required control.

Incident notification: a death, serious injury or dangerous incident (e.g. plant collapse, uncontrolled load drop, tip-over) must be reported to the regulator immediately, with written notice within the prescribed period.

Other duty holders: designers and manufacturers must eliminate risks in design; suppliers must provide information; persons installing or erecting plant must ensure it is stable and commissioned safely.

Worker consultation and representation duties require the PCBU to consult on matters that affect health and safety, including changes to plant, systems of work and hazard controls.

Hierarchy of control, highest to lowest: eliminate the hazard, substitute, isolate, engineering controls, administrative controls, then personal protective equipment as the last line.

Risk assessment ranks risk by likelihood of occurrence multiplied by severity of consequence; controls are prioritised for the highest-ranked risks first.

Common order-picking hazards: falls from height, tip-over, crush between mast and racking, pedestrian strike, falling loads, overhead services, floor edges and poor lighting.

Hazard identification sources: pre-start inspections, incident and near-miss records, workplace inspections, task analysis, manufacturer information and worker reports.

Engineering controls for order-picking include guarding, interlocked gates, racking protection, speed limiting, warning devices and designated pedestrian exclusion zones.

Administrative controls include traffic management plans, exclusion zones, permits, procedures, training, signage and scheduled maintenance.

Controls must be monitored and reviewed after an incident, a change in plant or layout, or at scheduled intervals to confirm they remain effective.

Residual risk is the risk remaining after controls; it must be documented and accepted by the person with authority before work proceeds.

An order-picking forklift (LO) is a high-lift machine where the operator's platform rises with the load, allowing picking at height; the operator remains on the platform during travel and lifting.

Stability triangle: the centre of gravity of the machine plus load must stay inside the triangle formed by the two front wheels and the centre of the steer axle, or the machine tips.

Load centre distance is measured from the vertical face of the forks to the load's centre of gravity; increasing it reduces the rated capacity.

Rated capacity is stated at a specific load centre and lift height on the data plate; capacity decreases as load centre, lift height or mast tilt increases.

Components include mast, carriage, forks or platform, hydraulic lift and tilt cylinders, chains, overhead guard, restraint or harness anchor, horn, lights and deadman pedal.

The overhead guard protects against falling objects; the operator restraint (harness or gate) protects against ejection during tip-over or sudden stops.

Mast sway and mast flex increase with lift height, so travel speed and load height must be reduced as the platform is raised.

Dynamic forces from braking, turning, accelerating and uneven floors add to static load and can move the centre of gravity outside the stability triangle.

Pre-start inspection is completed before each shift or use and covers the whole machine; the result is recorded and signed.

Check fluids and leaks: hydraulic oil level and leaks, engine oil, coolant, fuel, battery electrolyte and charge state, and any pooling under the machine.

Check tyres and wheels for pressure, cuts, chunking, loose wheel nuts and correct matching; check forks or platform for cracks, wear and heel distortion.

Check mast, chains and hydraulics: chain tension and equalisation, chain wear and lubrication, hose condition, cylinder leaks, and smooth operation through full lift and lower.

Check safety devices: horn, lights, flashing beacon, reverse alarm, deadman pedal, operator restraint or harness, gates, interlocks, brakes and parking brake.

Check data plate and decals are legible and the machine matches its rated capacity; unreadable plates must be replaced before use.

Defective plant must be tagged out, isolated and removed from service; the fault is reported to the supervisor and recorded, and the machine is not operated until repaired and re-checked.

Servicing follows the manufacturer's schedule; only competent persons perform repairs, and records of service and repairs are retained.

Read the load chart or data plate before lifting: capacity is valid only for the stated load centre, lift height and attachment, and must be de-rated for other conditions.

De-rating rule: as load centre distance increases beyond the rated value, capacity falls; as lift height increases, capacity falls; on uneven ground or with attachments, capacity also falls.

Estimate the load's centre of gravity: a long or irregular load has a centre further from the fork face than a compact load of the same mass, so it must be de-rated.

Never exceed the rated capacity; if the load mass is unknown, weigh it or obtain the documented mass before lifting.

Load restraint: loads must be secured against sliding and falling, using pallets in good condition, stretch wrap, strapping or racking stops as appropriate.

Keep the load low and the mast tilted back slightly during travel; the load and platform must not obstruct the operator's view, so travel in reverse if needed.

Distribute the load evenly across both forks and keep the load within the fork length; avoid lifting loads by the tips or with a single fork.

Check the load for stability, damaged packaging, overhang and loose items before lifting, and confirm the destination racking has adequate capacity.

Pick-up: approach square and slowly, level the forks, insert fully, lift clear, tilt back slightly, then lower to travel position before moving off.

Travel: keep the load low, look in the direction of travel, sound the horn at blind corners and doorways, obey speed limits and give way to pedestrians.

On ramps and slopes, travel with the load uphill; on the order-picker, keep the platform lowered when travelling on inclines and never turn on a slope.

Stacking: square up to the rack, raise to just above the beam level, move forward slowly, lower onto the beams, check seating, then withdraw the forks.

De-stacking: raise to clear the beam, withdraw slowly, lower to travel position, then check the load is stable before moving away.

Never allow anyone under a raised load or platform; keep hands, feet and body inside the operator compartment while the platform is elevated.

Shut-down: lower the platform and forks fully, neutralise controls, apply the parking brake, remove the key, park in the designated area and recharge or refuel as required.

Park clear of traffic, exits, fire equipment and racking; chock on slopes and follow the site's key control procedure.

The operator must remain inside the platform guardrails and wear the supplied restraint or harness attached to the designated anchor point whenever the platform is elevated.

Fall protection must be inspected before use: check harness webbing, stitching, buckles, lanyard and anchor for damage, and remove defective equipment from service.

Never climb on the guardrails, use ladders from the platform, or lean out to reach stock; reposition the machine instead.

Keep the platform clear of overhead obstructions and powerlines; maintain the legislated safe approach distance from energised electrical equipment.

Rescue planning: a written rescue procedure must exist before elevated work starts, with trained rescuers, equipment and a means of lowering the platform in an emergency.

Emergency lowering: know the manual descent or auxiliary pump procedure and where it is located; never attempt to catch a falling person.

Suspension trauma is a risk after a fall arrest; the casualty must be rescued promptly and kept still, with medical help called immediately.

Platform capacity, including operator, tools and stock, must not be exceeded; the platform is not a crane and must not be used to lift loads.

Traffic management separates pedestrians and plant using marked walkways, barriers, mirrors, speed limits, signage and designated parking and loading zones.

Before moving, check mirrors and blind spots, sound the horn if fitted, and make eye contact with nearby pedestrians; never assume you have been seen.

Hand signals and radio protocols must be agreed before the lift; only one designated spotter gives signals, and the operator stops if the signal is unclear.

Signage types: prohibition (red circle), warning (yellow triangle), mandatory (blue circle) and emergency information (green); obey all site and racking signs.

Racking signage states the bay's rated capacity and load configuration; never exceed it, and report damaged racking immediately.

Pedestrian exclusion zones apply whenever the platform is elevated or a load is being placed or retrieved at height.

Use the horn at blind corners, doorways, intersections and before reversing; keep the beacon and lights on where required.

Report near misses and unsafe acts so the traffic management plan and signage can be reviewed.

Tip-over response: stay in the seat or platform with restraint fastened, brace, do not jump; jumping is a leading cause of fatal crush injuries.

If a tip-over occurs, do not attempt to right the machine yourself; isolate it, keep people clear and call for competent assistance.

Hydraulic failure or sudden loss of lift: stop, lower the platform using the emergency lowering procedure, evacuate and tag out the machine.

Fire: isolate the power or fuel, evacuate to the assembly point, call emergency services, and only use an extinguisher if trained and safe to do so.

Load drop or racking strike: stop work, secure the area, check for injured persons, report to the supervisor and do not resume until the racking is inspected.

Contact with powerlines: stay in the machine, warn others away, and only leave if there is fire, jumping clear and shuffling away without touching machine and ground together.

Incident response: provide first aid, secure the scene, preserve evidence, notify the regulator where required, and record the incident and near misses.

Emergency plan knowledge includes exits, assembly points, first aid, spill kits, fire equipment locations and the site's communication channels.

Pre-operational checks, seatbelt or harness use, and correct mounting and dismounting (three points of contact, facing the machine) are assessed as part of practical competence.

Smooth control is assessed: progressive acceleration and braking, no harsh steering, correct use of the deadman pedal and parking brake.

Load handling is assessed for correct approach, square pick-up, full fork insertion, correct tilt, low travel height and accurate placement on the rack.

Observation and hazard awareness are assessed continuously: checking mirrors, blind spots, pedestrians, overhead obstructions and floor conditions.

Communication is assessed: horn use, eye contact, hand signals, radio use and response to a spotter.

Parking and shut-down are assessed for full lowering, neutral controls, brake applied, key removed and correct parking location.

The operator must demonstrate knowledge of the load chart, de-rating and the stability triangle during the practical assessment.

Any unsafe act, uncontrolled movement or breach of exclusion zones is a fail criterion regardless of task completion.