Forklift Operator Safety & Compliance Essentials

Posted on Sep 9, 2025 in Other subjects

High-Risk Work Licence & Renewal

1. How many days do you have to apply for a High-Risk Work Licence after assessment? 60 days.
2. What should you do if your High-Risk Work Licence expires? Retrain and sit an assessment with a Registered Training Organisation (RTO) as you cannot renew an expired licence.
3. Do you need to renew your High-Risk Work (HRW) Licence? Yes, every five years.

Forklift Components, Checks & Hazards

4. List common forklift components. Hoses, forks, mast, hydraulic arms, data plate, oils, battery.
5. What is meant by Load Centre Distance (LCD)? The distance from the heel of the forks to the centre of gravity of the load.
6. List essential items for a pre-start check. Lights, horns, reverse beeper, steering, brakes.
7. What three actions should you take if a fault is found on a forklift? Stop, tag, report.
8. List common tyre issues to check. Incorrect air pressure, tyres not securely fitted to rims, uneven tyre wear.
9. List common forklift safety guards. Overhead guard, foot guard, load guard.
10. Why is it dangerous to refuel a forklift near ignition sources? Fuel could ignite.
11. What is the primary purpose of correct load handling? To maintain stability.
12. List actions to take when visibility is obstructed. Use a spotter, restack the load, travel in reverse, ensure the pathway is clear.
13. What is crucial when stacking loads? The stability of the load.
14. What are potential consequences of improper load handling? Forklift tip-over, losing the load.
15. What is a hazard? A thing or situation with potential to cause harm.
16. What is risk? The chance of a hazard causing harm.

Work Health & Safety (WHS) Responsibilities

17. List potential consequences for breaching WHS regulations. Licence suspended, licence cancelled, refusal to renew licence.
18. List common workplace hazards. Power lines, trees, vehicles, pedestrians, other plant.
19. What three duties must all employers perform regarding health and safety? Provide safe plant and equipment, provide safe systems of work, provide adequate facilities.
20. List four key workplace safety documents. Code of Practice, Australian Standards, Regulations, Legislation.
21. Who are three people you should communicate safety issues to, and why? Other workers (for awareness), supervisor (for action), safety officer (for advice and recording).
22. What should be checked before commencing a task? Permits, location, access, communication, egress, required skills.
23. When carrying out work, what four things does your duty of care imply? Ensure your own health and safety, do not put others in danger, keep yourself safe, comply with WHS regulations.
24. What four things must be provided when using new equipment? Supervision, information, instruction, training.

Working Near Power Lines

25. What are the exclusion zones for power lines in Queensland? 3m, 6m, 8m (depending on voltage).
26. How do you confirm the voltage of power lines? Contact the local electrical authority.
27. List five ways to identify power lines. Tiger tails, marker balls, warning/danger signs, coloured markers, painted power poles.
28. List five steps to take if you make contact with electric power lines. Warn others to stay clear, break contact with lines (if safe), stay in the machine if safe (if not, jump clear without touching the machine and ground simultaneously, then jump 8m clear), report to an authorised person, check the machine before re-using.

Workplace Communication & Controls

29. When can a person ride on a forklift? Only if it has been designed with a seat to carry more than one person.
30. List six controls for working around mobile plant. Stop/go person, hazard lights, signs, barriers, exclusion zones, traffic management plan.
31. What equipment is needed when working in a dark area? Adequate lighting.
32. What four ways can you communicate with other workers? Verbal, written, signs, hand signals.
33. If a co-worker gives you an unclear instruction, what should you do? Stop and clarify.

Operational Safety & Stability

34. How can you plan for safe work? (3 ways) Prepare for suitable risk controls, plan the work environment, schedule work appropriately.
35. List four weather-related hazards. Heat, smoke, snow and/or ice, slippery conditions.
36. When operating on slippery surfaces, what two things can you do to stay safe? Reduce speed, avoid hard braking.
37. Why is raising a person on forklift forks dangerous? There is a risk of injury or death.
38. Why is it dangerous to operate internal combustion forklifts in confined spaces? The fumes could kill. What type of forklift should be used where airflow is restricted? Electric.
39. Why must batteries be charged in well-ventilated areas? Dangerous gases are produced and could explode.
40. What are the risks when using a forklift with uncontrolled movement? Injury to persons or damage to property.
41. When travelling on a slope with a load, which way should the load face? Uphill.
42. If the forklift starts to tip over, what two things should you do? Stay in the forklift, brace yourself until stationary.
43. List six causes of a forklift tipping over sideways. Uneven surfaces, uneven load, flat tyres, driving too fast, side shift not centred, turning on a slope.
44. List six causes of a load becoming unstable when moving. Overloaded, hard braking, driving too fast, uneven surfaces, mast tilted forward.
45. What is the important purpose of a seatbelt on a forklift? It will stop you from falling out.

Load Characteristics & Attachments

46. To maintain stability, the load should always be centred before travelling with a load.
47. When moving a load, at what height should the load be carried? At axle height, as low as possible.
48. Why is operating a forklift with a raised load dangerous? Increased height reduces stability.
49. Why is carrying an unbalanced load dangerous? Stability may be reduced, it may damage the forklift, or you may lose the load.
50. If the load exceeds the forklift’s rated capacity, what happens to the forklift? Stability and capacity are reduced.
51. List four ways to find out the weight of a load. Calculate weight, check the consignment note, weigh the load with scales, check for markings on the load.
52. What is the common load centre distance in Australia? 600mm.
53. What is the name of the equipment used to bridge gaps between a dock and a truck? Dock plates or bridge plates.
54. Where would you find the forklift’s rated capacity? On the data plate.
55. How would you determine if an attachment can be fitted to a forklift? Refer to the manufacturer’s instructions.
56. List five common forklift attachments other than fork tynes. Carpet spike, jib, work platform, fork extension, drum clamp.

Advanced Attachment & Stability Considerations

57. What are three effects of using a jib attachment? Swinging load, reduced stability, reduced load capacity.
58. What two things could happen if you use fork extensions? The capacity of the forklift will be reduced, and the Load Centre Distance (LCD) may increase.
59. What do you need to consider when stacking loads near each other? Ensure a flat, level surface; high loads may be unstable; place heavy and/or liquid goods at the bottom.
60. What is the fulcrum point on a forklift? The centre of the front wheel where the tyre touches the ground and pivots from.

Emergency Procedures & Parking

61. What four actions should you take if a forklift breaks down in any way? Stop operating, lower forks to the ground, tag out, report to an authorised person.
62. List seven areas where a forklift should not be parked. Emergency exits, doorways, near fire-fighting equipment, on sloping surfaces, near first aid stations, in walkways, near railway crossings.
63. What is the “normal” parking procedure for a forklift? Lower fork arms to the ground, apply park brake, select neutral, remove key.
64. When leaving a forklift unattended, why must you remove the ignition key? To prevent unauthorised use.

Key Forklift Stability Concepts

65. Indicate the meaning of these terms in relation to forklift stability:
    • COG (Centre of Gravity): The point where the entire weight of the forklift and its load is concentrated.
    • LCD (Load Centre Distance): The horizontal distance from the heel of the forks to the centre of gravity of the load.
    • FULCRUM: The pivot point, typically the centre of the front axle, around which the forklift and its load balance.