DOSH Forklift Operator flashcards

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

Stability triangle

The area bounded by the centre of the steer axle and the two front wheels. The combined centre of gravity of truck and load must stay inside this triangle or the counterbalance forklift will tip over.

Load centre distance

Horizontal distance from the vertical face of the forks to the centre of gravity of the load. Rated capacity is stated at a specific load centre, commonly 600 mm (24 in).

Load moment

Load weight multiplied by load centre distance from the front face of the forks. It must be balanced by the counterweight moment; increasing either factor reduces the safe capacity.

Fork heel wear limit

The heel thickness of a fork must not be reduced by more than 10 percent of its original thickness. Forks exceeding this limit, or showing cracks or bends, must be withdrawn from service.

Tip-over survival procedure

If a forklift starts to tip, stay seated with the seat belt fastened, brace your feet, hold the wheel and lean away from the fall. Do not jump; the overhead guard can crush you.

OSHA 1994 Section 15

The employer's general duty to ensure, so far as is practicable, the safety, health and welfare of employees at work, including providing safe plant, training and supervision for forklift operations.

OSHA 1994 Section 24

The employee's duty to take reasonable care for their own safety and that of others, and to cooperate with the employer and others in complying with safety requirements and instructions.

DOSH notification duty

Under OSHA 1994, employers must notify DOSH of accidents causing death or serious injury, dangerous occurrences, occupational poisoning and occupational diseases. Failure to report is an offence.

Travel with obstructed view

When a load blocks forward visibility, travel in reverse and look in the direction of travel, except when climbing a ramp where the load is kept uphill and travel is forward.

Ramp travel rule

Travel with the load on the uphill side: forward when climbing a loaded ramp, in reverse when descending. Never turn on a ramp and never park on one.

Rated capacity plate

The data plate states maximum load at a specified load centre and lift height for that specific truck. Attachments and increased load centres require derating per the manufacturer's chart.

Free lift

The height the forks can be raised before the mast sections begin to extend, allowing lifting inside containers or under low overhead clearance without exceeding the collapsed mast height.

Overhead guard purpose

A falling-object protective structure mounted above the operator compartment. It protects against falling loads and, with the seat belt, forms the survival envelope in a tip-over.

Pre-shift inspection scope

Check tyres, forks and heels, mast and chains, hydraulic hoses for leaks, overhead guard, seat belt, horn, lights, brakes, steering and parking brake. Record defects and tag out unsafe trucks.

Lockout tagout for defects

A forklift with a safety-related defect must be taken out of service, tagged or locked out, and reported to a supervisor. It must not be operated until repaired and re-checked.

Hydrogen gas during charging

Lead-acid battery charging releases hydrogen, which is explosive at roughly 4 percent concentration in air. Charge only in well-ventilated areas with no smoking, sparks or open flame.

Battery acid first aid

For acid contact with skin or eyes, flush immediately with large amounts of clean water for at least 15 minutes, remove contaminated clothing, and seek medical attention. Eyewash must be available.

LPG cylinder change

Change LPG cylinders with the engine off in a ventilated area, no ignition sources, wearing gloves and face shield. Close the valve, check the seal, and leak-test with soap solution.

Carbon monoxide hazard

LPG, diesel and petrol engines produce carbon monoxide, a colourless, odourless toxic gas. Never run them in confined or poorly ventilated spaces; symptoms include headache, dizziness and nausea.

Pedestrian right of way

Pedestrians in marked walkways have right of way. Operators must sound the horn at blind corners and doorways, slow down, and make eye contact before proceeding through shared areas.

Traffic management plan

A site plan defining one-way aisles, speed limits, pedestrian crossings, mirrors at blind corners, exclusion zones, and designated parking, charging and refuelling areas for forklifts.

Overhead power line clearance

Maintain the site-specified safe clearance from overhead power lines, typically several metres. Treat lines as live; contact can cause electrocution or arcing through the mast and operator.

Parking a forklift

Park in a designated area, lower forks to the floor, tilt the mast forward slightly, set the parking brake, neutralise controls and remove the key. Chock wheels if parking on a slope.

Trailer docking check

Before entering a trailer, confirm it is chocked or restrained, dock locks are engaged, the floor can support the load, and the trailer is not moving or detached from the dock.

Attachment derating

Side shifts, clamps, rotators and extensions add weight and move the load centre forward, reducing rated capacity. Use the attachment manufacturer's derated capacity plate, not the base truck rating.

Near-miss reporting

All near misses, property damage and minor incidents must be reported immediately. Near misses are leading indicators that reveal unsafe conditions before a serious injury occurs.

Emergency stop procedure

Stop the truck safely, lower the load, apply the parking brake and switch off. Evacuate by the designated route to the assembly point and do not re-enter until declared safe.

Fire extinguisher selection

Use CO2 or dry powder extinguishers for electrical and flammable liquid fires, including battery fires. Never use water on live electrical equipment. Only fight small fires if trained.

Operating without authorisation

Operating a forklift without a valid competency certificate or employer authorisation breaches both employer general duties and employee duties under OSHA 1994 and site rules.

Lifting persons on forks

Never lift a person directly on the forks. Use a purpose-built, rated and secured safety cage with a risk assessment, and ensure the truck is stationary with the brake set.

Carrying passengers

Passengers may ride only in a designed passenger seat fitted to the forklift. Riding on the forks, counterweight or mast is prohibited and is a common cause of serious injury.

Forklift stability during turns

Centrifugal force during a turn shifts the combined centre of gravity outward. Slow down before turning, keep the load low, and avoid sharp turns at speed to prevent lateral tip-over.