CSCS Counterbalance Forklift flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

PUWER 1998

UK regulations requiring work equipment to be suitable, maintained, inspected and used by trained people; they cover forklifts and apply to employers and operators.

LOLER 1998

UK lifting equipment regulations requiring thorough examination at least every 12 months, or 6 months for equipment lifting people, and planned lifting operations by a competent person.

Employee duty under HSWA

Section 7 of the Health and Safety at Work etc. Act 1974 requires employees to take reasonable care of themselves and others and cooperate with their employer on safety.

RIDDOR reporting

UK rules requiring employers to report work-related deaths, specified injuries, dangerous occurrences and over-seven-day incapacitations to the enforcing authority, including serious forklift incidents.

Fork heel wear

The heel is the curved bend where the fork blade meets the shank; check for cracks, thinning and wear, because a worn heel reduces strength and can fail under load.

Pre-shift inspection record

A documented check completed before each shift listing defects found; defective trucks must be tagged out of service and reported until repaired and re-inspected.

Mast chain check

Inspect chains for equal tension, kinks, corrosion and lubrication; uneven tension or damaged links can cause the carriage to bind or drop suddenly.

Data plate legibility

The capacity plate must be readable and match the truck and attachment; if missing or unreadable, the truck should not be used until the correct plate is fitted.

Rated capacity plate

Plate showing maximum load at a stated load centre and lift height, plus truck and battery weight; capacity falls as load centre or lift height increases.

Counterbalance principle

A counterweight at the rear offsets the load at the front; the combined centre of gravity must stay inside the stability triangle for the truck to remain upright.

Rear-wheel steering

Counterbalance trucks steer with the rear wheels, so the rear end swings outward when turning; this affects clearance and pedestrian safety in tight aisles.

Attachment derating

Fitting a clamp, rotator or side-shifter changes capacity and load centre, so the truck's data plate or attachment plate must be consulted before lifting.

Stability triangle

The area formed by the two front wheels and the centre of the rear steer axle; the combined centre of gravity must remain within it during travel, lifting and tilting.

Load centre distance

Horizontal distance from the vertical fork face to the load's centre of gravity, usually 500 mm or 600 mm; increasing it reduces the truck's safe lifting capacity.

Dynamic stability loss

Braking, accelerating, turning and uneven ground create forces that move the centre of gravity; these can tip a truck even when the static load is within capacity.

Travel position

Forks low, about 100–150 mm above the floor, mast tilted back, load stable; this keeps the combined centre of gravity low and improves forward visibility.

Capacity at new load centre

Approximate capacity = rated capacity × rated load centre ÷ actual load centre; for example 2,000 kg at 500 mm becomes 1,667 kg at 600 mm, though lift height also derates.

Stacking procedure

Approach square, forks level, lift the load clear of the stack, tilt back slightly, reverse before lowering; check overhead clearance and stack stability before placing.

De-stacking procedure

Check the stack and load, approach squarely, lift clear, tilt back, and reverse before lowering; never drag loads or lower while moving forward over the stack.

Uneven load risk

A load whose centre of gravity is off-centre or unstable shifts the combined centre of gravity sideways, reducing lateral stability and increasing tip-over risk during turns.

Ramp travel rule

Keep the load uphill: travel forward up a ramp when loaded and reverse up when unloaded, so the load stays on the uphill side and stability is maintained.

Parking procedure

Park in a designated area with forks flat on the floor, mast tilted forward, parking brake applied, controls neutral and key removed; never leave a running truck unattended.

Start-up sequence

Sit down, fasten the seat belt, check the parking brake and controls are neutral, start the engine, then test horn, steering and brakes before moving.

No riders rule

Only the operator may ride the truck; passengers must never be carried on forks, pallets or the chassis because they can fall and be crushed.

Pedestrian exclusion zone

A marked or agreed area around a working forklift where pedestrians must not enter; operators should stop work if someone enters the zone or cannot be seen.

Blind corner procedure

Slow down, sound the horn, use mirrors and proceed cautiously at blind corners, doorways and aisle intersections where pedestrians or other trucks may appear.

Rear-end swing hazard

Because rear-wheel steering swings the counterweight outward, the operator must check the rear clearance before turning near racking, walls or pedestrians.

Dock edge safety

Before entering a trailer, check the dock leveller, wheel chocks or vehicle restraint, trailer floor condition and lighting; never rely on trailer brakes alone.

LPG cylinder exchange

Change cylinders in a well-ventilated area with the engine off and no ignition sources; check hoses and connections for leaks and close the valve when parking.

Battery charging ventilation

Lead-acid charging releases hydrogen, so charge in a well-ventilated area with no flames or sparks, keep the battery cover open if specified and use acid-resistant PPE.

Battery counterweight

The traction battery is part of the truck's counterweight; removing or replacing it with a different weight changes stability and must follow the manufacturer's procedure.

End-of-shift handover

Park correctly, refuel or recharge, report defects, record the hour meter and complete the handover log so the next operator knows the truck's condition.