TLILIC0003 TLILIC0003 Forklift Safety and Operations 2 — Questions and Answers
Question 1: When operating a forklift near pedestrians, what is the safest practice?
- Sound the horn once and continue at normal speed
- Stop the forklift and give way to pedestrians (Correct answer)
- Flash the overhead light and proceed slowly
- Increase speed to clear the pedestrian zone quickly
Correct answer: Stop the forklift and give way to pedestrians
Forklifts must stop and give way to pedestrians. Pedestrian safety is the highest priority in any forklift operating area.
Under SafeWork Australia's Code of Practice for Managing Risks of Plant in the Workplace, forklift operators must give way to pedestrians at all times. Physical separation (barriers, painted lanes, exclusion zones) is the preferred control, but where interaction is unavoidable, the forklift must stop. Sounding a horn is a supplement to, not a replacement for, stopping. Operators should also make eye contact with the pedestrian before proceeding.
Question 2: What does a forklift's data plate (capacity plate) show?
- The operator's licence class required to operate the forklift
- The rated load capacity at specified load centres and lift heights (Correct answer)
- The maximum speed permitted on public roads
- The service history and last maintenance date
Correct answer: The rated load capacity at specified load centres and lift heights
The data plate shows the forklift's rated load capacity at various load centre distances and lift heights, along with the model, serial number, and unladen weight.
The manufacturer's data plate (capacity plate) is fixed to the forklift and must not be removed or obscured. It displays the maximum rated load capacity (kg) at the specified load centre (mm) and maximum lift height (mm). If the forklift is fitted with an attachment such as a side-shifter or rotator, a revised data plate must be fitted reflecting the reduced capacity. Operators must refer to the data plate before lifting any load.
Question 3: Which hazard is MOST likely to cause a forklift to tip sideways?
- Travelling on a smooth, level concrete floor
- Turning at speed on a sloped or uneven surface with an elevated load (Correct answer)
- Operating in a temperature-controlled warehouse
- Lowering an empty pallet to floor level
Correct answer: Turning at speed on a sloped or uneven surface with an elevated load
Turning at speed on a slope or uneven surface while carrying an elevated load shifts the centre of gravity outside the stability triangle, creating a high risk of lateral tip-over.
Lateral tip-over is the most common and deadly type of forklift accident. Risk factors that combine dangerously include: speed (centrifugal force during a turn), elevated load (raised centre of gravity), uneven or sloped surface (displaces the base of support), and sharp turns. SafeWork Australia data consistently shows lateral tip-overs cause the majority of forklift fatalities. Operators must slow to a crawl before turning, keep loads low, and treat ramps with extreme caution.
Question 4: What action should you take if you discover a fuel leak on an LPG forklift during pre-operational checks?
- Add a small amount of fuel and monitor the leak during the shift
- Tag the forklift as out of service and report the fault immediately (Correct answer)
- Tighten the connection yourself and record it in the logbook
- Operate the forklift briefly to use the remaining fuel before reporting
Correct answer: Tag the forklift as out of service and report the fault immediately
A fuel leak is a serious fire and explosion hazard. The forklift must be tagged out of service and the fault reported immediately to a supervisor or maintenance personnel.
Under WHS regulations, defective plant must not be used. An LPG leak presents an immediate fire and explosion risk. The operator must: not start or continue operating the forklift, tag it out of service using the site's lock-out/tag-out (LOTO) procedure, record the fault in the logbook, and report it immediately to a supervisor or the PCBU. Only a licensed gas fitter or authorised maintenance person may repair the leak and return the forklift to service.
Question 5: What is the primary purpose of the counterweight on a forklift?
- To increase the forklift's top speed
- To balance the weight of a load on the forks and prevent forward tip-over (Correct answer)
- To improve braking performance on wet floors
- To provide additional ballast for operating on slopes
Correct answer: To balance the weight of a load on the forks and prevent forward tip-over
The counterweight is positioned at the rear of the forklift to counterbalance the weight of a load on the forks, preventing the forklift from tipping forward.
The counterweight is a heavy mass (typically cast iron or steel) bolted to the rear of the forklift chassis. It acts as a counterbalance to the load being carried on the forks. The front axle acts as the fulcrum (pivot point). When a load is placed on the forks, it creates a forward moment; the counterweight creates an opposing rearward moment. The forklift is designed so that at rated capacity the counterweight moment exceeds the load moment — but only when the load is within the rated load centre.
Question 6: Under WHS legislation, who is responsible for ensuring forklift operators hold a valid High Risk Work (HRW) licence?
- The forklift operator only
- The person conducting the business or undertaking (PCBU) (Correct answer)
- The state transport authority
- The equipment hire company only
Correct answer: The person conducting the business or undertaking (PCBU)
The PCBU has the primary duty to ensure that only workers holding a valid HRW licence for the class of forklift operate the equipment at their workplace.
Under the model WHS Act and the Work Health and Safety Regulation, a PCBU must not direct or allow a worker to carry out high risk work (including operating a forklift) unless the worker holds the appropriate High Risk Work licence. The relevant licence class for a standard counterbalance forklift in Australia is LF (Licence — Forklift Truck). The operator also has a duty not to perform the work without a current licence. Both the PCBU and the unlicensed operator can face significant penalties.
Question 7: What does 'stacking height' mean in relation to forklift operations?
- The maximum height the forklift mast can extend
- The safe maximum height to which loads may be stacked in racking or freestanding (Correct answer)
- The height at which the forklift's load backrest must be positioned
- The height restriction in the building where the forklift operates
Correct answer: The safe maximum height to which loads may be stacked in racking or freestanding
Stacking height refers to the safe maximum height to which loads may be stacked, determined by load weight, stability, racking ratings, and site-specific rules.
Stacking height is determined by multiple factors: the structural rating of the racking system, the stability of the load (irregularly shaped or unsecured loads may need lower stacking), the forklift's rated capacity at the required lift height (capacity decreases with height), and site-specific WHS risk assessments. Exceeding safe stacking height can cause racking collapse, load falls, and serious injuries. Operators must know and observe the stacking height limits set by the PCBU for each storage area.
TLILIC0003 TLILIC0003 Forklift Safety and Operations 2
When operating a forklift near pedestrians, what is the safest practice?