LEARNER GUIDE

Operate Counter-Balanced Lift Truck

Unit Standard 242981

NQF Level 2 Credits 4
 TABLE OF CONTENTS
TABLE OF CONTENTS....................................................................................... i
PERSONAL INFORMATION ............................................................................. 1
INTRODUCTION ............................................................................................ 2
Programme methodology ......................................................................................... 3
What Learning Material you should have .................................................................... 3
Different types of activities you can expect ................................................................ 5
Learner Administration ............................................................................................ 6
Assessments .......................................................................................................... 6
Learner Support ..................................................................................................... 7
Learner Expectations ............................................................................................... 8
UNIT STANDARD 242981 ............................................................................... 9
MODULE 1 – TYPES OF LIFT TRUCKS ............................................................ 11
Formative assessments ......................................................................................... 16
MODULE 2 – PARTS & FUNCTIONS OF LIFT TRUCKS ..................................... 17
Basic parts ................................................................................................... 17
Controls............................................................................................................... 19
Drive / steering / braking example .......................................................................... 20
Formative assessments ......................................................................................... 20
MODULE 3 – PRINCIPLES OF OPERATION .................................................... 21
Principles of a lever ....................................................................................... 21
Load capacity plates ...................................................................................... 23
Attachments................................................................................................. 24
Specification plate ......................................................................................... 25
Formative assessments ......................................................................................... 25
MODULE 4 – LIFT TRUCK SAFETY ................................................................. 26
Operational safety......................................................................................... 26
Lifting operation safety .......................................................................................... 27
Travelling ............................................................................................................ 27
General lift operations ........................................................................................... 28
Driving on public roads .......................................................................................... 28
Workplace operation record worksheet .................................................................... 31
Formative assessments ......................................................................................... 32
MODULE 5 – DAILY CHECKS ......................................................................... 33
Daily Checks ................................................................................................ 33
Pre Start checks ................................................................................................... 33
Operational startup check ...................................................................................... 34

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 Close down check ................................................................................................. 35
Lift truck operator: Daily check list.......................................................................... 36
Formative assessments ......................................................................................... 37
MODULE 6 –CHANGING BATTERIES ............................................................. 38
General safety practices ................................................................................ 38
Battery ................................................................................................................ 39
Using a hydrometer .............................................................................................. 41
Battery changing .................................................................................................. 42
MODULE 7 – MECHANICAL APPRECIATION .................................................. 43
Mechanical system ................................................................................................ 43
Hydraulic system .................................................................................................. 43
Tyre and wheel ..................................................................................................... 44
Controls............................................................................................................... 44
Braking ............................................................................................................... 44
Electrical system ................................................................................................... 45
Lift truck trouble shooting guide ..................................................................... 46
Formative assessments ......................................................................................... 47
MODULE 8 – LOG BOOKS .............................................................................. 48
Lift truck operator: Battery specific gravity daily log sheet ......................................... 48
Lift truck operator Accident report sheet .................................................................. 50
Lift truck operator: Lift truck defect report ............................................................... 52
Formative assessments ......................................................................................... 53
MODULE 9 – LOAD RECOGNITION ................................................................ 54
Pallet types .................................................................................................. 54
Common defects ................................................................................................... 57
Block stacking .............................................................................................. 58
Types of loads .............................................................................................. 59
Hazardous cargo ................................................................................................... 60
Documentation ............................................................................................. 61
Tremcard ............................................................................................................. 61
Consignment note ................................................................................................. 63
Pictorial labels ...................................................................................................... 64
Load handling ............................................................................................... 65
Correct procedure ................................................................................................. 65
Vehicle loading ..................................................................................................... 66
General safety signs ...................................................................................... 67
Types of racking ........................................................................................... 68
Pallet handling information ..................................................................................... 69
MODULE 10 – PRACTICAL LIFT TRUCK OPERATION ..................................... 71

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 General operations ........................................................................................ 71
Confined gangway stacking ............................................................................ 74
Loading and off loading ................................................................................. 76
Formative assessments ......................................................................................... 78
FORMATIVE ASSESSMENT WORKBOOK ........................................................ 79

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 PERSONAL INFORMATION
NAME

CONTACT ADDRESS

Code

Telephone (H)

Telephone (W)

Cellular

Learner Number

Identity Number

EMPLOYER

EMPLOYER CONTACT
ADDRESS

Code

Supervisor Name

Supervisor Contact Address

Code

Telephone (H)

Telephone (W)

Cellular

1
 INTRODUCTION
Welcome to the learning programme
Follow along in the guide as the training practitioner takes you through the material. Make notes
and sketches that will help you to understand and remember what you have learnt. Take notes
and share information with your colleagues. Important and relevant information and skills are
transferred by sharing!

This learning programme is divided into sections. Each section is preceded by a description of
the required outcomes and assessment criteria as contained in the unit standards specified by
the South African Qualifications Authority. These descriptions will define what you have to know
and be able to do in order to be awarded the credits attached to this learning programme. These
credits are regarded as building blocks towards achieving a National Qualification upon successful
assessment and can never be taken away from you!

2
 Programme methodology

The programme methodology includes facilitator presentations, readings, individual activities,

group discussions and skill application exercises.
Know what you want to get out of the programme from the beginning and start
applying your new skills immediately. Participate as much as possible so that the
learning will be interactive and stimulating.
The following principles were applied in designing the course:
 Because the course is designed to maximise interactive learning, you are encouraged and
required to participate fully during the group exercises
 As a learner you will be presented with numerous problems and will be required to fully
apply your mind to finding solutions to problems before being presented with the course
presenter’s solutions to the problems
 Through participation and interaction the learners can learn as much from each other as
they do from the course presenter
 Although learners attending the course may have varied degrees of experience in the
subject matter, the course is designed to ensure that all delegates complete the course
with the same level of understanding
 Because reflection forms an important component of adult learning, some learning
resources will be followed by a self-assessment which is designed so that the learner will
reflect on the material just completed.
This approach to course construction will ensure that learners first apply their minds to finding
solutions to problems before the answers are provided, which will then maximise the learning
process which is further strengthened by reflecting on the material covered by means of the self-
assessments.

Different role players in delivery process

 Learner
 Facilitator
 Assessor
 Moderator

What Learning Material you should have

This learning material has also been designed to provide the learner with a comprehensive
reference guide.
It is important that you take responsibility for your own learning process; this includes taking
care of your learner material. You should at all times have the following material with you:

3
Learner Guide This learner guide is your valuable possession:
This is your textbook and reference material, which provides
you with all the information you will require to meet the exit
level outcomes.
During contact sessions, your facilitator will use this guide and
will facilitate the learning process. During contact sessions a
variety of activities will assist you to gain knowledge and
skills.
Follow along in the guide as the training practitioner takes you
through the material. Make notes and sketches that will help
you to understand and remember what you have learnt. Take
and share information with your colleagues. Important and
relevant information and skills are transferred by sharing!
This learning programme is divided into sections. Each section
is preceded by a description of the required outcomes and
assessment criteria as contained in the unit standards
specified by the South African Qualifications Authority. These
descriptions will define what you have to know and be able to
do in order to be awarded the credits attached to this learning
programme. These credits are regarded as building blocks
towards achieving a National Qualification upon successful
assessment and can never be taken away from you!

Formative Assessment The Formative Assessment Workbook supports the Learner

Workbook Guide and assists you in applying what you have learnt.
The formative assessment workbook contains classroom
activities that you have to complete in the classroom, during
contact sessions either in groups or individually.
You are required to complete all activities in the Formative
Assessment Workbook.
The facilitator will assist, lead and coach you through the
process.
These activities ensure that you understand the content of the
material and that you get an opportunity to test your
understanding.

4
 Different types of activities you can expect
To accommodate your learning preferences, a variety of different types of activities are included
in the formative and summative assessments. They will assist you to achieve the outcomes
(correct results) and should guide you through the learning process, making learning a positive
and pleasant experience.

The table below provides you with more information related to the types of activities.

Types of Activities Description Purpose

Knowledge Activities You are required to These activities normally test

complete these activities your understanding and
on your own. ability to apply the
information.

Skills Application You need to complete These activities require you

Activities these activities in the to apply the knowledge and
workplace skills gained in the
workplace

Natural Occurring You need to collect These activities ensure you

Evidence information and samples get the opportunity to learn
of documents from the from experts in the industry.
workplace.
Collecting examples
demonstrates how to
implement knowledge and
skills in a practical way

5
 Learner Administration

Attendance Register
You are required to sign the Attendance Register every day you attend training sessions
facilitated by a facilitator.

Programme Evaluation Form

On completion you will be supplied with a “Learning programme Evaluation Form”. You are
required to evaluate your experience in attending the programme.
Please complete the form at the end of the programme, as this will assist us in improving our
service and programme material. Your assistance is highly appreciated.

Assessments
The only way to establish whether a learner is competent and has accomplished the specific
outcomes is through the assessment process. Assessment involves collecting and interpreting
evidence about the learners’ ability to perform a task.
To qualify and receive credits towards your qualification, a registered Assessor will
conduct an evaluation and assessment of your portfolio of evidence and competency.
This programme has been aligned to registered unit standards. You will be assessed
against the outcomes as stipulated in the unit standard by completing assessments
and by compiling a portfolio of evidence that provides proof of your ability to apply
the learning to your work situation.

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How will Assessments commence?

Formative Assessments
The assessment process is easy to follow. You will be guided by the Facilitator. Your responsibility
is to complete all the activities in the Formative Assessment Workbook and submit it to your
facilitator.

Summative Assessments
You will be required to complete a series of summative assessments. The Summative
Assessment Guide will assist you in identifying the evidence required for final assessment
purposes. You will be required to complete these activities on your own time, using real life
projects in your workplace or business environment in preparing evidence for your Portfolio of
Evidence. Your Facilitator will provide more details in this regard.
To qualify and receive credits towards your qualification, a registered Assessor will
conduct an evaluation and assessment of your portfolio of evidence and competency.

Learner Support
The responsibility of learning rests with you, so be proactive and ask questions and
seek assistance and help from your facilitator, if required.

Please remember that this Skills Programme is based on outcomes based education principles
which implies the following:
 You are responsible for your own learning – make sure you manage your study, research
and workplace time effectively.
 Learning activities are learner driven – make sure you use the Learner Guide and
Formative Assessment Workbook in the manner intended, and are familiar with the
workplace requirements.
 The Facilitator is there to reasonably assist you during contact, practical and workplace
time for this programme – make sure that you have his/her contact details.
 You are responsible for the safekeeping of your completed Formative Assessment
Workbook and Workplace Guide
 If you need assistance please contact your facilitator who will gladly assist you.
 If you have any special needs please inform the facilitator

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 Learner Expectations
Please prepare the following information. You will then be asked to introduce yourself to the
instructor as well as your fellow learners

Your name:

The organisation you represent:

Your position in organisation:

What do you hope to achieve by attending this course / what are your course expectations?

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 UNIT STANDARD 242981
This learning programme is aligned to the following unit standard:

Unit Standard Title

Operate defined purpose lift trucks

Unit Standard Id
242981

NQF Level
2

Credits
4

Specific Outcomes And Assessment Criteria

Specific outcome 1 Inspect and record the operational fitness of battery powered lift trucks.
 Appropriate measures (e.g. completion of pre and post operations check-sheet) are identified
and used to identify and/or prevent basic faults and defects in the mechanical function of the
heavy lift truck.
 Operational fitness of battery powered list trucks are inspected according to truck inspection
checklists.
 Operational fitness of battery powered lift trucks are recorded according to safety procedures.
Specific outcome 2 Identify and classify freight/loads.
 A minimum of five different categories of freight/loads are identified and explained with
examples.
 Common freight codes, from a handling perspective, are classified together and described
with examples.
Specific outcome 3 Handle load and store freight.
 Specific handling methods and attachments are identified and their use according to
particular commodities/freight described.
 The reasons for selecting a particular piece of lifting equipment are explained according to
particular type of freight.
 The specific selection of storage facilities for different freight types are explained according
to organisational storage procedures.
 Different freight types include but are not limited to dangerous goods, perishables,
foodstuffs, break-bulk, liquids.
Specific outcome 4 Achieve maximum work performance of battery powered lifting
equipment and attachments.
 The operating functions of the particular lift truck relevant for the job environment, and
different environmental conditions and freight types are identified and explained with
examples.
 Work performance of the equipment is evaluated against operating guidelines.
 Mechanical appreciation of the lifting equipment and attachments is described with examples.
 Lifting equipment is operated in accordance with manufacturers guidelines.
Specific outcome 5 Operate freight equipment.

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Outcome range Operating includes the actual checking, operating, shutting down and parking
of the lift truck, including load movement indicators and automatic guidance systems.
 The operating functions of the particular lift truck relevant for the work environment, and
different environmental conditions and freight types are explained according to
organisational operating functions.
 The effect of the environment and equipment constraints are identified according to safe
operating procedures and practices.
 Corrective actions required to prevent dangerous situations arising are explained and
implemented according to organisational policies and procedures.
 Dangerous situations could include but are not limited to weather, lighting conditions,
visibility, overloading.
Specific outcome 6 Access available emergency support systems and services.
 A range of support that may be accessed are identified according to emergency support
systems.
 The most appropriate course of action is identified in relation to potential hazards in the
working environment.
 The evacuation process is explained according to organisational evacuation procedures.
 Emergency escape procedures (via abseil) are demonstrated in accordance with safety
standards and procedures.

Unit standard essential embedded knowledge

The following embedded knowledge is addressed in an integrated way in the unit standard:
1. Occupational Health and Safety Act; Driven Machinery regulations; environment;
operating method; packaging, labelling, and personal protective equipment.
2. National Road Traffic Act where public roads are used.
3. The relevant attachments applicable to handling various categories of freight.
4. Basic mechanical appreciation.
5. Equipment dimensions/capacity and controls in relation to safety and maximum work
performance.
6. Product handling and storage principles and specifications.
7. Available support systems and emergency care services.
8. The different makes (manufacturers) and codes of lift trucks in the market.

Critical cross-field outcomes (CCFO):

 Identify and solve problems in the case of damaged packaging/labelling.
 Work efficiently with others and in teams by demonstrating initiative in selecting the most
appropriate means of communication with work colleagues to facilitate efficient and safe
freight handling.
 Manage and organise oneself by continually evaluating whether maximum work performance
of lifting equipment was achieved given the operating conditions, and based on this, gain
improved work performance consistently.
 Demonstrate initiative in selecting the most appropriate gear and equipment dependent on
lift truck codes, freight characteristics and environmental conditions.
 Demonstrate an understanding of the world as a set of related systems by understanding the
impact of safe working practices on people safety, the environment and cost effective
business operations.

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 MODULE 1 – TYPES OF LIFT TRUCKS
Learner outcomes
Compare various types of lift trucks and attachments to pick the right equipment for the load to
be handled

SO 3.1, 3.2, 4.1, 5.1 EEK 3, 6, 8 CCFO 1, 2

Lift trucks come in a variety of sizes and forms and are used for different specific purposes.
Attachments are pieces of equipment which can be fixed to the lift truck for handling different
types of loads. This means that for specific types of freight, the correct type of lift truck and
attachment must be used to maximise work efficiency and ensure that the freight being handled
is not unnecessarily damaged or carried in a dangerous manner. Let’s have a look at these
various types of lift trucks and attachments.

CODE F3
CODE F1 CODE F2 CODE F4
CAPACITY UP TO 15
CAPACITY UP TO 3000kgs CAPACITY UP TO 7000kgs CAPACITY >15 000kgs
000kgs

Forklift
 Load carried outside front wheels
 Can be pedestrian or rider operated
 Petrol, diesel, gas or electric
 Load centre’s:- heel of forks to centre of load
 Designed to lift
 Fulcrum points about front axle
 Aisle stacking

Reach truck
 Load centres vary behind & in
front of front wheels depending  Electric only
on mast position  Designed to lift
 Moving mast  High level warehouse
 Rider operated operations
CODE F5  Fulcrum point
UP TO A RATED CAPACITY OF 2  Pantograph
500kgs  Aisle stacking

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 CODE F7
ABOVE RATED CAPACITY OF 2000kgs

CODE F6
BELOW RATED CAPACITY OF 2000kgs

Pedestrian controlled lift truck

 Load carried inside front wheels
 Pedestrian operated  Electric only
 Front legs usually lift about 200mm  Designed to transport, and lift
 Fulcrum point to low level
 Aisle stacking

CODE F8
FIRST & SECOND LEVEL RACKING CODE F9
ALL RACKING LEVELS INCLUDING HIGH RISE

Order picker lift trucks

 Load & man inside front wheels
 Pedestrian operated low level order picker
 Rider operated high level order picker  Electric only
 Not normally used to stack pallets  Designed to lift
 Fixed mast  Manual lower override
 Fixed front legs  Safety rope descent in
 Fulcrum point emergency
 Aisle stacking – does not turn in aisle  Safety belts or interlocking
 Safety lower or means of descending when stuck at high barriers
level
 Side guide wheels

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 Side loader lift truck
 Load inside wheelbase
 Diesel or electric
 Automatic tilt compensation
 Designed to lift &
 Mast retracts from side into wheelbase
carry long loads
 Lower load onto platform to travel
 Often used without
 Used normally outdoors on rough
pallets with
terrain
cantilever racking
 Truck does not turn in aisle
 Side guide wheels on some electric
CODE F10
machines

Rough terrain / earthmoving/

agricultural equipment with lift truck
 Diesel or petrol
attachments
 Designed to lift
 Load carried outside front wheels  Large wheels for
 Rider operated rough terrain
 Load centres heel of forks to centre of  Be aware of
load actions over rough
 Fulcrum points about front axle ground &
 Sometimes has articulated body encountering
 Aisle stacking obstacles
CODE F11  Generally, as for larger counter
balanced trucks

Pallet lift truck

 Load carried over front
wheels  Electric
 Pedestrian operated  Designed to transport
 May lift to very low level
CODE F12

Code f13
Non-elevating cab, to service all levels

CODE F14
ELEVATING CAB, TO SERVICE ALL LEVELS

Very narrow aisle lift trucks  Electric only

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 Load inside wheelbase  Designed for high bay narrow
 Truck doesn’t turn in aisle aisle racking
 Turret head turns in aisle when required  Requires feeder trucks to
 Fixed mast similar to reach truck charge
 Fixed front legs  P & d stations at end of aisle
 Fulcrum point
For elevating cab
 Safety lower or means of descending when stuck at high
level with man up machine  Manual lower override
 Side guide wheels  Safety rope descent in
 Automatic aisle location systems emergency
 Wire guidance & automatic lift heights  Safety belts or interlocking
barriers

Code f15 rail mounted stacker lift truck, non-elevating cab

Code f16 rail mounted stacker lift truck, elevating cab

 Electric only
Rail mounted stacker lift trucks
 Designed for high bay narrow
 Load inside wheelbase aisle racking
 Truck doesn’t turn in aisle  P & d stations at end of aisle
 Turret head turns in aisle when required
For elevating cab
 Fixed mast
 Fixed front legs  Manual lower override
 Fulcrum point  Safety rope descent in
 Safety lower or means of descending when stuck at high emergency
level with man up machine  Safety belts or interlocking
 Side guide wheels barriers
 Automatic aisle location systems
 Wire guidance & automatic lift heights

Lift truck attachments

Roll clamp
Used for picking up rolls of various sorts

Tine clamps
Used for paper roll handling in the bilge
position

Bale clamp
Used to handle bales of various types

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 Forks
Used to carry various types of loads
resting on the forks and backrest

Load turning fork clamps

Used for various types of loads which
require turning during handling

Double pallet handler

Designed for carrying 2 pallets side by
side

Fork positioner
To allow mechanical fork adjustment
rather than manual adjustment

Push pull attachment

Designed for pushing or pulling a load
off or onto the forks

Carton clamps
For lifting of various types of cartons

Carpet ram
For lifting of carpet rolls

Coil booms
For handling steel coils, steel and
concrete pipes

Jib cranes
For lifting goods with appropriate
rigging

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Hydraulic bucket
For handling powdered or granulated
materials

Rotators
When attached with other attachments,
permits the attachment and load to be
rotated to required position

Load extenders
Used with other attachments to load or
unload trucks from one side

Formative assessments

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 MODULE 2 – PARTS & FUNCTIONS OF LIFT
TRUCKS

Learner outcomes
Name the parts and purpose of each part of a lift truck, for correct operation

SO 4.1 EEK 4, 5 CCFO 1, 4

The Lift Truck is a versatile vehicle, using forks or other attachments, for loading and offloading
purposes, or for transporting goods over short distances. There are many similarities to the
normal road going vehicles as far as controls and operation is concerned, while others are
peculiar to the lift truck only. Before starting with operations, let’s learn what all the important
parts of the Lift Truck are, along with the basic functions of these parts.

Basic parts
Basic Lift Truck parts are:

1. Tiller 2. Battery plug

3. Cover 4. Battery charger switch

5. Electric panel 6. Lift cylinder

7. Drive motor 8. Driving wheel

9. Reduction box 10. Stabiliser wheels

11. Load wheels 12. Fork arms

13. Battery 14. Motor – pump assembly

15. Panel

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18
1. Tiller 2. Mast
3. Lift cylinder 4. Initial lift cylinder
5. Forks 6. Rear load wheels
7. Wheel leg 8. Battery
9. Scr control 10. Side cover
11. Front support roller 12. Motor & pump unit
13. Distributing valve 14. Folding drivers platform
15. Dead man’s pedal 16. Gearbox with swivel booster
17. Traction wheel 18. Horn
19. Centre cover 20. Traction motor
21. Lateral guard 22. Electromagnetic brake
23. Lock button 24. Top cover
25. Battery plug

Controls

Pressing this control overrides speed and direction

1. Safety reversing device control, to be used only to prevent operator being
trapped in confined spaces
Thumb operated control determines speed and
2. Speed & direction control
direction
3. Horn push button Horn alert

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 4. Battery quick release lever For connecting battery to charger
5. Key switch To activate traction controls and hydraulics
6. Lift
Coloured push buttons for lowering and lifting.
7. Lower
8. Steering tiller Steers the truck.
Where fitted, operates mechanical broke on motor
9. Footbrake
drive shaft.

Drive / steering / braking example

1. Brake Cam
2. Parking Brake Cable
3. Brake Pad
4. Brake Disc
5. Steering Shaft
6. Drive Motor
7. Drive Unit Breather
8. Steering Gear
9. Drive Unit Lower Case
10. Drive Wheel
11. Coil Spring
12. Grease Fitting
13. Steering Chain
14. Power Steering Motor
15. Horn

Unlike a forklift truck which has driven and steering on different wheels/axles, these trucks have
driven, steering and brakes all on one wheel. Some trucks have an extra set of wheels known
as castors, in line with the drive/steer/brake wheels, but these have no function other than
providing a bit more stability and are freewheeling. In all these trucks, a single set of wheels
supplies the driving/steering & braking functions. The two wheels under the forks, known as
trailing or load wheels, are also freewheeling.

Formative assessments

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 MODULE 3 – PRINCIPLES OF OPERATION

Learner outcomes
Explain how a lift truck works, and how this affects operation in the workplace
Read the information from a load specification plate to decide on the load mass for the lift truck
being operated

SO 4.3 EEK 4, 5 CCFO 1, 3

Principles of a lever

Principles Effect of lever lengths Truck is not designed to

of a lever accept unauthorised
Effect of lifting load away from fork heels
additional weights
Capacity related to load centre’s
Could result in tipping of
Capacity reduction with attachments truck
Not to exceed load capacity
Counterweights provide force to balance load

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Fulcrum Position of truck fulcrum
Load & force on one side of fulcrum
Load & force on opposite sides of fulcrum

Load centre Where to obtain information Specification

plates
How to apply to lift truck

Counter Load carried outside front wheels Diesel, gas or

balanced electric
Can be pedestrian or rider operated
truck
Designed to lift
Load centre’s:- heel of forks to centre of load
Fulcrum point about front axle
Aisle stacking

22
De-rating with lift  The effect of height on the load capability Specification plates
height  Where to obtain information
 How to apply to lift truck

Attachments, 1. Side shift Contact manufacturer

characteristics for load specifications
2. Fork spreaders & positioners
3. Roll clamps
4. Bale clamps
5. Rotating heads
6. Push pull unit
7. Double pallet handlers
8. Fork extensions
9. Buckets & ploughs
10. Pantograph
11. Drum clamps
12. Block clamps
13. Pallet inverters
14. Crane jib
15. Carrying ram
16. Special attachments

Load capacity plates

Example : load capacity plates

LOAD CENTRE 60cm HEIGHT 550cm = LOAD CAPACITY OF 4 750kg

LOAD CENTRE 100cm HEIGHT 600cm = LOAD CAPACITY OF 3
300kg

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 Attachments

The effect of
attachments on load
centres and de-rating

Various  Effects on load capacity Contact manufacturer

attachments,  Reduction of load centre’s &capacity for load specifications
effect on the load (derating)
capacity of the  Reduced capacity from manufacturer
truck
 Operation of attachments
 Limitations
 Extra safety precautions
 Extra pre-start, start up and close down
checks

Hazards of lift  Effects of Centre of gravity of

truck operation,  Speed & cornering truck and load, both
importance of  Working on inclines forward/backward &
load plate sideways
 Slippery surfaces
information
 Overloading
 Over lifting
 Non centralised loads

The importance of  Combined effect of centre of gravity of load &

stability in terms truck
of the 3 point  Effect of load positioning
suspension of lift
trucks

24
 Specification plate
Specification plate example

Formative assessments

25
 MODULE 4 – LIFT TRUCK SAFETY

Learner outcomes
Discuss lift truck safety and how it affects the driving of a forklift in the workplace

SO 5.2, 5.3, 6.1, 6.2, 6.3, 6.4 EEK 1, 2 CCFO 2, 4

Safety when operating a lift truck is as important as any other aspect of safety in the workplace.
A lift truck handled in a careless manner is a danger to all people in the area, including the
driver, as well as presenting a danger of damaging or destroying costly equipment and materials.
By operating according to safety rules, you will lessen the chance of an accident and help the
company save on unnecessary costs.

Operational safety

Operational safely  Correct personal protective equipment for varying

conditions
 All working areas must be free of grease/oil
 Complete initial checks before boarding
 Check controls are in neutral before starting up or after shut
down
 Complete start up checks before moving off
 No loose objects/tools in cab
 Handbrake engaged

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 Lifting operation safety
Safely during lift  Requirements of OHS Act 85 of 1993,reg 18 sub reg 11 (See
truck operation Appendix)
procedure  No passengers on the lift truck
 No people lifted on forks unless appropriate and properly secured
cage used
 No working above people
 No people nearby during loading/off-loading operations
 Use correct truck for area of work
 Correct truck for hazardous areas
 Be aware of lift truck capabilities
 Operate controls only with which you are sure of their function
 Lift only loads within the rated capacity of the truck
 No stacking loads on an incline
 Chock wheels of vehicles being loaded/off-loaded to prevent
moving off
 Load and off-load to maintain loaded vehicles balance

Travelling
Operating 1. Grip steering firmly
safely during
2. Keep left
travelling
3. Be alert to other traffic & pedestrians
4. Expect the unexpected always
5. Keep forks + 200mm above ground except when negotiating ramps
6. Keep load against back rest
7. Keep mast tilted backwards
8. Ensure load is stable before moving off
9. Travel in correct direction
10. Ensure good visibility
11. Drive at speeds suitable to conditions
12. Observe road rules & signs
13. Sound hooter at blind corners
14. Observe floor loading restrictions
15. Watch for obstructions & debris in your path
16. Avoid fast/jerky stops/starts & quick turns
17. Don’t reverse up a ramp loaded
18. Don’t drive forwards down a ramp loaded
19. Watch for overhead obstacles
20. Never drive on unsecured plates
21. Drive slowly in hazardous areas
22. Watch for overhead cranes & power cables
23. Don’t drive over debris

27
 General lift operations

Operating  Don’t attempt any unauthorised repairs on the lift truck

safely in  Report defects to your supervisor as soon as possible
general lift  Report all accidents immediately (accident reporting procedure)
truck
 Don’t let engine idle continuously in an enclosed environment
operations
 Don’t place any part of your body outside of the driver’s compartment
 Be aware of rear track and wide load swing
 Place hazardous loads in correct areas
 Report damaged/leaking containers
 Report unusual smells
 Don’t enter movable vehicles lift without ensuring it is capable of handling
truck and load
 Confined spaces should be adequately lit
 Don’t remove components from the truck
 Cross railway lines diagonally & slowly

Driving on public roads

Driving on  Vehicle to be roadworthy & licenced
public  Driver to have appropriate drivers licence
roads  All road rules to be obeyed

28
 OHP 1 OHP 2

OHP 3 OHP 4

29
30
 Workplace operation record worksheet

TRUCK ANY UNSAFE

DATE TIME PLACE GENERAL COMMENTS
NO. ACTIONS?

31
Formative assessments

32
 MODULE 5 – DAILY CHECKS
Learner outcomes
Use the daily checklist to check the lift truck for safe operation in the workplace
Report any defects discovered during the daily checks.

SO 1.1, 1.2, 1.3 EEK 1, 4 & 7 CCFO 3, 4

As with most vehicles, the efficient and safe operation of the lift truck depends on the condition
of the vehicle, which can be monitored by proper and regular checks.

Daily Checks
Pre Start checks
Using the correct safety equipment

Checking the driver’s compartment

Inspecting the battery

Checking the electrolyte level

Checking traction battery condition

Checking engine oil level

Checking hydraulic oil level

Checking the brake fluid level

Checking the radiator cap

Daily pre-start
check on the Checking the water pump
lift truck
Checking the fan belts

Checking fan blades

Checking drive belts

Checking all hoses

Checking fuel/battery level

Checking fork condition

Checking load backrest

Checking tyre condition

Checking the wheel nuts

33
 Checking wheels

Checking overhead guards

Checking for engine & transmission leaks

Checking for hydraulic oil leaks

Checking for brake fluid leaks

Checking for petrol/diesel leaks

Checking for gas leaks

Checking for water leaks

Visually checking masts & chains

Visually inspecting all:

 Cylinders for damaged seals & leaks
 Rams for pitting
 Security of framework

Checking the air filter

Operational startup check

Checking shoes and clothing

Getting on to truck

Adjusting seat

Adjusting mirrors

Checking steering wheel

Checking all controls

Daily
operational
Checking the emergency isolator (on battery operated vehicle)
startup checks
on the lift truck
Ensuring parking brake is engaged

Turning on the ignition

Checking gauges & warning lights

Starting the engine

Checking gauges & warning lights

Checking hooter

34
 Checking lights & indicators

Checking forward gear

Checking reverse gear

Checking steering

Checking foot brake

Checking the park brake

Checking the tilt function

Checking the raise and lower function

Checking attachments

Close down check

Stopping the truck

Applying the parking brake

Lowering the forks

Tilting the mast forward

Selecting neutral on the gear shift

Switching off any activated lights

The daily close De-activating any attachments

down check on
the lift truck Operating the diesel cut-out

Switching off the key

Closing the gas tap

Removing the key from the ignition

Dismounting from the truck

Completing the necessary reports

Carrying out the required handing over procedure

35
 Lift truck operator: Daily check list

MACHINE TYPE: _________________________ DATE :

____________________

OPERATOR : _________________________ COMPANY NO.:

______________

PRE-START CHECKS Yes No Yes No

Safety Shoes/Boots Load Chart & Max Mass Load

Forks/Attachments Position of Forks

Load Backrest Tyre Condition & Pressure

Machine Condition Wheel Nuts

Battery Terminals Overhead Guards

Electrolyte Level Engine & Transmission Leaks

Engine Oil Level Hydraulic Oil Leaks

Hydraulic Oil Level Brake Fluid Leaks

Brake Fluid Level Petrol/Diesel Leaks

Radiator Water Level Gas Leaks

Radiator Cap Water Leaks

Water Pump Drivers Compartment

Fan Belts Mast & Chains

Fan Blades Hydraulic Cylinders

Drive Belts Hoses Condition

Fuel Level

OPERATIONAL CHECKS Yes No Yes No

Enter & Adjust Seat Gauges (before and after)

Control levers/pedals Ignition Key

Raise & lower Foot Brake

Tilt Front & Back Hand/Park Brake

Forward & Reverse Steering Operation

Horn Attachment controls

Lights/Indicators

36
CLOSE DOWN CHECKS Yes No Yes No

Stop the truck Operate diesel cut-out

Apply parking brake Switch off key

Lower forks Close gas tap

Tilt mast forward Remove key from ignition

Select neutral on gear shift Dismount from truck

Switch off any activated lights Complete necessary reports

De-activate any attachments Handing over procedure

HOUR METER READING START _________________ FINISH

___________________

COMMENTS :
_________________________________________________

_________________________________________________

OPERATOR’S SIGNATURE : ___________________________________

DATE : __________________

Formative assessments

37
 MODULE 6 –CHANGING BATTERIES

Learner outcomes
Change the battery on a lift truck in the safest possible manner

SO 1.2, 1.3 EEK 1, 4 & 7 CCFO 3, 4

All lift trucks require battery changes depending on the type of equipment being used. In all
instances where operators are required to perform this function, it is important that the correct
procedures and safety practices are properly followed. For those operators that are not required
to perform these functions, the knowledge of these correct practices and procedures will enhance
the mechanical appreciation of the operator for their respective equipment.

General safety practices

The following procedures are general safe practices, which should be used in conjunction with
the appropriate company procedures of the operator’s respective employer. (Refer to Module 4
Lift Truck Safety)

38
Battery

39
 Driving to recharging area

Stopping in correct position

Parking the truck

Positioning the fire extinguisher & eye wash bottle

Removing the battery access panels

Removing the battery cover

Unlocking & disconnecting plugs

Checking the specific gravity of all cells

Positioning the removing device

Securing the removing device in place

Removing the battery from the truck

Replacing the
battery in a
Positioning battery at the charger
battery powered
truck
Checking the electrolyte level (4 cells per day)

Connecting the battery to the charger

Switching on the charger

Checking & selecting a new battery

Removing the charged battery from the charger

Positioning the removing device

Securing the removing device in place

Moving battery to truck

Correctly positioning battery in truck

Securing the battery in position

Removing the removing device

40
Correctly fitting the plug

Correctly locating the battery lid

Locking the battery lid into place

Closing access panels

Checking the truck operations

Cleaning & tidying the area

Putting away the fire extinguisher

Moving off

Using a hydrometer

41
Battery changing

42
 MODULE 7 – MECHANICAL APPRECIATION

Learner outcomes
To recognise and report faults on a lift truck during checks and operations

SO 4.2, 4.3 EEK 4, 5 CCFO 3, 4

As an operator, it is important to know what the different parts of the machine are supposed to
do. The machine is a combination of a number of ‘systems’, and each ‘system’ has specific
purposes. Awareness of these systems will assist operators in operating the machine effectively
& safely, while also offering the opportunity to identify problems on the machine before complete
breakdown. (Refer to Module 2: Parts & Functions)

Mechanical system

 Body  Counter-
 Steering weight
 Controls
 Brakes
 Mast
The parts of the  Forks & carriage
mechanical system of  Load centre’s
a lift truck  Overhead guard
 Lift chains  De-rating
 Controls & steering
 Electric motors
 Lubricants
 Electrical system

Hydraulic system

 Reservoir
Parts of the hydraulic  Pump
system of a lift truck  Lift, tilt, reach & steering cylinders
 Hydraulic pressure & temperature gauges

43
 Tyre and wheel

 Tread wear
 Inflation
 Wall condition
 Nails, shavings etc.
Tyre & wheel
 Stones
condition
 Missing wheel nuts
 Damaged flanges or rims
 Correct tyres
 Oil/grease contamination

Controls

Respective functions  Lift / lower function See daily

 Tilt function checks &
The mast, operational
 Forks, locking pins and carriage controls
forks &
associated  Inner mast
controls  Lift cylinders & chains
 Check for hydraulic leaks even during
operations

Braking

Identify Checking the braking Effectiveness and efficiency See daily

function checks &
braking
operational
problems controls

44
 Electrical system

The battery Traction battery – casing condition, See

terminals & plates. Electrolyte – sg level, refuelling
traction motor, hydraulic pump motor,
emergency stop button, battery level
gauge – indicates charge of traction
battery

Warning lights &  Hour meter Never

gauges  Power indicator exceed 80%
 Battery discharge indicator discharge
 Brush wear indicator
Electrical  Brake fluid level indicator Indicator
system on  Steering direction indicator colours
battery
powered The charging system  Battery plugs Refer to
trucks  Built in charger refuelling
 Separate charger
 Battery removing systems

The fuses  Functional fuses Broken

 Steering fuses stop
 Lift controls functions
 Traction control
 Horn
 Hydraulic motor
 Traction motor

45
 Lift truck trouble shooting guide

The following repairs should only be carried out by trained mechanics. This guide is provided
for operators to be aware of the possible causes of breakdowns and the necessity of taking
appropriate action for the equipment to be properly repaired before continuing any work.

Trouble Possible cause Correction

Hydraulic system

Suction filter blocked Clean or replace filter

Inlet hose leak Tighten connections, check for

holes & cracks

Oil foams Check oil & top up if necessary

Unusual noises
Hydraulic pump or motor failure Have checked by service mechanic

Seals defective causing air intake Have checked by service mechanic

Incorrect oil viscosity Replace oil with correct viscosity oil

Low oil level in tank Top up oil tank

Pump inlet defective Change or fill up with oil

Pump failure, leakages Have checked by service mechanic

Pressure relief valves do not close Have checked by service mechanic

Low or no pressure
Valve seats damaged Have checked by service mechanic
in the system
Line broken or leaking Replace line &/or tighten
connections

Low viscosity oil causing high Change oil to correct viscosity

leakage losses

As per “Unusual noises” above As per “Unusual noises” above

Pressure relief or boost pressure Have checked by service mechanic

valves sticking
Oil pressure
Tight spots on lift & tilt cylinders Have checked by service mechanic
fluctuates
Mast does not extend fully Have checked by service mechanic

Mast retracts slightly after Top up with oil

extending

46
 Filter blocked – accompanied by Clean or replace filter
abnormal noises

Pump failure, leakages Have checked by service mechanic

Pressure relief valves do not close Have checked by service mechanic

Valve seats damaged Have checked by service mechanic

Low or no oil flow
Pipe rupture or leaks Replace pipe &/or tighten
connections

Valves blocked Have checked by service mechanic

Hydraulic system overheating Check oil & viscosity, clean oil

cooler

Hydraulic oil Pump failure Have checked by service mechanic

temperature too
high Oil level too low or oil cooler Check oil level, top up, clean oil
defective cooler

Formative assessments

47
 MODULE 8 – LOG BOOKS

Learner outcomes
Completing lift truck log books and check sheets accurately and correctly

SO 1.3, 4.2, 6.1, 6.2 EEK 1&7 CCFO 2, 3, 4

 Records use of company property (money)

 Indicates
abuse
waste
Using log books/sheets by theft
recognising their importance
level of maintenance
to the proper running of an
organisation  Proof of operator’s actions
 Establishes responsibility of persons in the proper
performance of the lift truck (management,
maintenance & operation)
 Protects both company and operator if actions are
correct & properly recorded

Record hour meter readings By correctly completing the hour meter log sheet and
submitting readings according to company procedure.

Record faults By correctly completing the daily check list and submitting
report according to company procedure. (see module 3,
daily checks)

Record problems By correctly completing the defect report and submitting

report according to company procedure.

Record accidents By correctly completing the accident report sheet and

submitting report according to company procedure.

Lift truck operator: Battery specific gravity daily log sheet

48
BATTERY
CELL TYPE VOLTAGE
MAKE

DISCHARGED
EXPECTED READINGS: CHARGED 1,28
1,14

Cell No. 1. 2. 3. 4. 5. 6. 7. 8.

Before
Charging

After Charging

Date / Sign

Cell No. 1. 2. 3. 4. 5. 6. 7. 8.

Before
Charging

After Charging

Date / Sign

Cell No. 1. 2. 3. 4. 5. 6. 7. 8.

Before
Charging

After Charging

Date / Sign

Cell No. 1. 2. 3. 4. 5. 6. 7. 8.

Before
Charging

After Charging

Date / Sign

Cell No. 1. 2. 3. 4. 5. 6. 7. 8.

Before
Charging

After Charging

Date / Sign

Supervisor’s name Date

49
Supervisor’s
signature

Lift truck operator Accident report sheet

NAME:

CO. NO.: DATE:

TIME OF ACCIDENT / INCIDENT:

LOCATION OF ACCIDENT /
INCIDENT:
DESCRIPTION OF ACCIDENT:

CAUSE OF ACCIDENT:

INJURIES (Include names):

DAMAGE TO VEHICLE /:

DAMAGE TO BUILDINGS/ EQUIPMENT:

50
COMMENTS:

SIGNATURE: DATE:

51
 Lift truck operator: Lift truck defect report

MACHINE TYPE: __________________________________________________

MAKE: _________________________________________________________

SERIAL NUMBER: _________________________________________________

HOUR READING: __________DEPARTMENT: __________________________

DATE: _________________LAST SERVICE HOURS: _____________________

OPERATOR’S NAME: ______________________________________________

DEFECTS / FAULTS

TIME SENT FOR TIME RECEIVED

REPAIR BACK
SUPERVISORS
SIGNATURE
NAME

WORKSHOP
REPORT
DATE RECEIVED TIME RECEIVED
DATE COMPLETED TIME COMPLETED

52
SUPERVISORS
SIGNATURE
NAME

Formative assessments

53
 MODULE 9 – LOAD RECOGNITION

Learner outcomes
To recognise different types of loads, labels, pallet designs and the type of lifting equipment to
use for safe handling and stacking

SO 2.1, 2.2, 3.1, 3.2, EEK 3, 6 CCFO 1, 4

3.3

Pallet types

Types of pallets

2 WAY ENTRY PALLETS NON Good condition

REVERSIBLE
 Top deck slatted or solid
 2, 3 or more main bearers
 Suitable for all rack depths
 Not suitable to block stack

2 WAY ENTRY PALLETS, BOTTOM Good condition

BOARDS, NON REVERSIBLE
 Top deck slatted or solid
No broken
 2, 3 or more main bearers bottom slats
 Usually 3 bottom slats
Not suitable for
 Rack depth to be pallet depth – 2 stackers
bearers
 Suitable to block stack on solid
loads only
 Not suitable for stackers

2 WAY ENTRY PALLETS Good condition

REVERSIBLE
 Top deck slatted or solid
Not suitable for
 2, 3 or more main bearers stackers
 Bottom deck same as top deck
 Suitable for all rack depths
 suitable to block stack
 Not suitable for pallet trucks or
stackers

54
4 WAY ENTRY PALLETS NON Good condition
REVERSIBLE
 Top deck slatted or solid
Suitable for
 3 secondary slats stackers on face
 9 blocks & 3 bottom slats without bottom
 Stack on rack bottom bearers bearers
 Rack depth to be pallet depth –
100/150 mm
 Suitable to block stack on solid
loads only
 Suitable for stackers on face
without bottom bearers

4 WAY ENTRY PALLETS Good condition

PERIMETER BASED
 Top deck slatted or solid
Not suitable for
 3 secondary slats stackers
 9 blocks & 3 bottom slats
 4 infill slats
 Stack on rack either way round
 Rack depth to be pallet depth –
100/150 mm
 Suitable to block stack
 Not suitable for stackers

4 WAY ENTRY PALLETS Good condition

REVERSIBLE
 Top deck slatted or solid
Not suitable for
 3 secondary slats stackers
 9 blocks & 3 bottom slats
 Bottom deck same as top deck
 Stack on rack with secondary
slats front to back
 Rack depth to be pallet depth –
100/150 mm
 Suitable to block stack
 Not suitable for stackers

55
POST PALLETS All posts in
position to stack
 4 legs with cups or plates
 Usually removable posts Feet to be located
over posts
 Usually steel construction
 Stack on rack with skid channels
or decks
 Rack depth same or larger than
pallet depth
 Suitable for block stack, load
carried by posts

PALLET CONVERTOR All posts in

position to stack
 Metal frame fitted to normal
wooden pallet Feet to be located
 Can be collapsible to occupy less over posts
space on return or storage
 Allows stacking of crushable load

DRUM PALLETS
 For carrying drums without using
drum attachment
 Permits stacking of drums

BULK BIN PALLET

PALLET COLLAR
WITH LID

56
 BULK BOX PALLET –
COLLAPSIBLE

Common defects

57
Block stacking

58
 STACKABLE STILLAGES Check specific
details before
Proprietary brands
use
Usually steel construction
Stack on rack with rack channels or
decks
Rack depth same or larger than pallet
depth
Suitable for block stack

Types of loads

Loads without bearers Load probably

deposited by crane
 Requires dunnage under to pick up
 Stack on rack with fork entry bars or dunnage
 Rack depth same or larger than pallet depth Correct size of
 Only block stack with loose dunnage dunnage
 May not be suitable to handle with straddle stacker

Large loads Check

 Loads with front to back dimensions larger than  Mass
twice load centre’s  Size
 Decrease lifting capacity of truck  Centre of gravity
 Are unstable on forks
Before attempting to
Various  Possible to use fork extensions lift
types of  Require larger stacking gangways
loads
Unbalanced loads Check
 Are unstable on forks  Mass
 Possible to use fork extensions  Size
 Load must be picked up under centre of gravity  Centre of gravity
 Require larger stacking gangways Before attempting to
lift

Long loads Check

 Are unstable on forks  Mass
 Use fork spreader bars  Size
 Load must be picked up under centre of gravity  Centre of gravity
 Require larger stacking gangways Before attempting to
lift

59
 Hazardous cargo

Explosives

Gas

Flammable
liquids

Flammable solids

Handling
All loads to be
hazardous
Oxidising agent / stored in specific
cargo with
organic peroxide and secure
hazchem
locations
labels

Poison

Radioactive
material

Corrosive

Other hazards &

any combination
of hazards

60
 Hazardous loads should be kept away from other loads.
Stacking
hazardous
cargo
Normally like products are kept together

Documentation
Tremcard
Example of a tremcard

TRANSPORT EMERGENCY CARD (Road) CEFIC TEC(R)-620

Revision: 01/2003
Class 3 ADR
Lt. 1a

LOAD
ACETALDEHYDE

Name of substance(s):

 Colourless liquid or paste – Usually with perceptible odour,

 Completely miscible with water.

See SABS 0232 (all parts)

See SABS 0232 (all parts)

NATURE OF DANGER

 Highly flammable
 May evaporate quickly.
 The vapour may be invisible. The vapour is heavier than air and spreads along the ground.
 May form explosive mixture with air, particularly in empty uncleaned receptacles.
 Heating will cause pressure rise, severe risk of bursting and subsequent explosion.
 Causes severe damage: to eyes.
 The vapour has irritant effect: on eyes, on air passages.
 The vapour has narcotic effect and causes giddiness.

PERSONAL PROTECTION

 Protective gloves
 Protective footwear.
 Eyewash bottle with clean water.
 Two self-standing warning signs, handlamp, warning vest.

GENERAL ACTIONS BY DRIVER

61
  Stop the engine.
 No naked lights. No smoking.
 Mark roads with self-standing warning signs and warn other road users or passers-by.
 Keep public away from danger area. Keep upwind.
 Notify police and fire brigade as soon as possible.

ADDITIONAL AND/OR SPECIAL ACTIONS BY THE DRIVER

 Any action only if without personal risk.

 Avoid direct contact with substance.
 Stop leaks if without risk.
 Use low sparking hand tools and explosion-proof electrical equipment.
 Prevent liquid from entering watercourses, sewers, basements and workpits. Vapour may create explosive
atmosphere.
 Contain or absorb leaking liquid with sand or other suitable material, using shovel or broom.
 Warn everybody – Explosion hazard.
 If substance has entered a watercourse or sewer, or been spilt on soil or vegetation, advise police.

FIRE (information for the driver in case of fire)

 Do not attempt to deal with any fire involving the load.

FIRST AID

 If substance has got into the eyes, immediately wash out with plenty of water. Continue treatment until medical
assistance is provided.
 Remove contaminated clothing immediately and wash affected skin with plenty of water.
 Seek medical treatment when anyone has symptoms apparently due to inhalation or contact with skin or eyes.

SUPPLEMENTARY INFORMATION FOR EMERGENCY SERVICES

 Drench with water

 If this is not practicable: Contain or absorb leaking liquid with sand or earth or other suitable material, using shovel
or broom.
 Sewers must be covered and basements and workpits evacuated.
 Keep container(s) cool by spraying with water if exposed to fire.
 Extinguish with waterspray, foam or dry chemical.
 Do not extinguish a leaking gas flame. Extinguish secondary fire.

Additional information EMERGENCY TELEPHONE: …………………..

UN No.: 1089
HI No.: 33

© CEFIC Prepared by CEFIC from the best knowledge available; no responsibility is accepted that the
information is sufficient or correct in all cases

APPLIES ONLY DURING ROAD TRANSPORT ENGLISH

Issued: 2008

62
 Consignment note

Example of a consignment note / dangerous goods declaration

(DGD)

DANGEROUS GOODS DECLARATION

Consignment
Note No: 101 11X Company Logo (optional)

OPERATIONAL DETAILS
R A Jones B Higgins
Jones Warehouse Higgins Road freight
Consignor: 100 High Rd, Operator: 200 South Ave,
Germiston Germiston
Tel: 011 100 1000 Tel: 011 200 2000

Product
manufacturer Vehicle Registration: XYZ 100 GP

Product owner Trailer Registration: XYZ 200 GP

ABC Chemical
Product custodian Consignee:
300 Marine Drive,
Durban
Tel: 031 300 3000
R A Jones
Party contracting Jones Warehouse Additional The package marked with UN 3226 shall be
information on
the operator: 100 High Rd, handling/transport/ shaded from sunlight and other goods must not
Germistion storage: be stacked on top of it.
Tel: 011 100 1000

GOODS DETAILS
Hazard Packing Volume/ gross mass
Shipping name UN No. Quantity & type of packaging Net mass kg
Class Group L/kg

2 fibreboard boxes, 4 x 5 L
Paint 1263 3 III 52 41.5
each

Self-reactive solid Type D

3226 4.1 II 1 fibreboard box 12 10
(Benzine sulfohydrazide)

DECLARATIONS
I hereby declare that the content of this consignment is fully
and accurately described above by the proper shipping name,
The consignment described above has been received into my
and is classified, packaged, marked and labelled/placarded and
vehicle. My vehicle is correctly placarded and I am in
in all respects in proper condition for transport in accordance
possession of all necessary transport documentation
with the relevant national legislation.
pertaining to the transport of dangerous goods, including
Where the consignor is not the manufacturer, the declaration
information to be followed in case of an emergency.
is based on information received.

63
Status of Consignor / party contracting the operator :
  
Name of
Product manufacturer Product owner Product custodian driver

Name of
Job title Place
Declarant

Place Date Date

Signature Signature

Pictorial labels

FRAGILE - HANDLE
USE NO HOOKS
WITH CARE

KEEP AWAY FROM

THIS SIDE UP
HEAT

TEMPERATURE LIMITS KEEP DRY

PICTORAL
LABELS CENTRE OF GRAVITY DO NOT ROLL

NO FORKS – USE
STACKING LIMITS
TROLLEY

CLAMP HERE SLING HERE

Pictoral labels are picture instructions which are used worldwide to advise people
handling the goods, that they must be handled in a certain way. These are
international symbols which require no language or translation, and have the
same meaning irrespective of the language of the people handling the freight.

64
 Load handling
Correct procedure
Setting the  set forks not to strike stringers Ensure loads
correct fork as stable as
 adjust as wide as possible
spacing possible.
 space forks evenly on carriage
Forks locked in
place.

Correctly  no pallet, what accessory to use & where to  clamps

setting up find it
 hooks
appropriate
 method of attaching to truck
attachments  slip sheets
 does it need to be done at the workshop

Handling Checking the  no damage to wrappings or strapping Report any

various load condition aspect which
loads using  strapping & wrappings not too tight /too
& stability could affect
the correct loose
the conveying
procedure  strapping & wrappings sufficiently securing of load or
load present a
danger
 no dampness, dents, smells or leaks
 will not overturn
 secure & will not separate

Checking the Check

load mass
 load itself
 load waybill
that load mass is within the lift truck’s capacity

65
 Vehicle loading

Loading/Unloading from/to ground level

The difference in height and gap between the platform of the lorry/trailer and the bay is usually
bridged with a motorized dock leveller. Depending on the dock leveller length you will get
various slope angels. The flatter the better, however, it should not exceed 7° upwards or
downwards. If steeper, there is a risk that the truck will hang on the bridge knuckle because
of the low ground clearance. You may get stranded downwards if forks are longer than 1150
mm if the angle is steeper than 7°.

66
Loading/Unloading from/to ground level
Inside the trailer – stacking/unstacking. If you have to stack or unstack load consider that
you need a stacker with freelift.
Is normally done with a counter balance truck!
However, you can use stackers and reach trucks provided the ground surface is hard and
strong enough and that you find space for the straddles underneath the vehicle.

General safety signs

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 Types of racking

CONVENTIONAL FLOW RACK

Adjustable pallet racking. Live storage system

HIGH DENSITY MOBILE

Manual mobile racking Powered mobile racking

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 NARROW AISLE PUSH BACK
Narrow aisle storage system Live storage system

Pallet handling information

Adjustable pallet racking Standard lift

truck operations
 storing unit loads & pallets
 access to all goods
 protects & supports goods
 can be to maximum lift truck height

Narrow aisle system Not for standard

lift truck
 for specially designed trucks
Identifying operation
different rack  higher storage & narrower aisles
types  more storage space
Characteristics
of racking Drive in racking Standard lift
truck operation
 continuous blocks of pallet storage
 drive in / drive through
 minimum floor space usage
 safe stable load storage
 for loads not requiring 100% selectivity
 pallets stored on support rails
 use standard lift trucks

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 Live storage systems Standard lift
truck operation
 for pallets & cartons
 loaded on to wheel tracks or rollers
 load moves under gravity from load face to unload face
Identifying  from 3 – 30m in length
different rack
 height determined by lift truck used
types
Characteristics Powered mobile pallet racking Ensure correct
of racking aisle spacing for
 high density storage with easy access
(cont) standard lift truck
 standard adjustable pallet racks mounted on wheels & operation
rails
 access to required rack obtained by moving entire
racking aisles
 use any conventional lift truck

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 MODULE 10 – PRACTICAL LIFT TRUCK
OPERATION

Learner outcomes
To drive a lift truck correctly and safely, whether loaded or unloaded, without error, under
varying conditions.

SO 3.1, 3.2, 3.3, 4.1, 4.4, EEK 1-8 CCFO 1, 3, 4

5.3, 6.2

General operations
Perform pre-start checks Adhering to the prescribed checks

Perform operational controls

Adhering to the prescribed checks
check

Checking front, rear and sides to ensure no obstructions &

Checking the route visually
people in path

Positioning mast & forks Lifting forks + 200mm off ground, with mast tilted backwards

 Selecting a gear
 Releasing the park brake
Selecting forward gear
 Press accelerator
 Moving forward

Checking front, rear and sides to ensure no obstructions &

Rechecking route
people in path

 Driving slowly forward to pallet front

 Aligning truck to pallet face
Approaching the pallet  Stopping in front of pallet
 Applying park brake
 Setting gear in neutral

Checking the pallet Visually inspecting the pallet condition

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Checking the load Visually inspecting stability & load mass

Setting the fork centre’s Adjusting to suit load & pallet

 Positioning mast vertically

 Setting height of forks
 Putting into forward gear
 Releasing park brake
Picking up the load
 Inserting forks at inching speed
 Inserting forks until heels reach pallet face
 Lifting load + 200mm from floor
 Tilting mast backwards

 Setting off smoothly in direction of travel

 Keeping a sharp lookout
Transporting the load
 Travelling at a suitable speed
 Obeying all safety rules

Steering the truck By safely & efficiently negotiating the course

Slowing & stopping the truck under control , using the foot
Stopping the truck
brake

Applying the parking brake Manipulating the parking brake control to the “on” position

 Selecting reverse gear

 Check over both shoulders
Selecting reverse  Releasing the park brake
 Press accelerator
 Moving backward

Checking front, rear and sides to ensure no obstructions &

Rechecking route
people in path

Steering the lift truck Safely & efficiently negotiating the course

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  Stopping at bottom of ramp
 Lifting forks sufficiently to clear slope
Driving up ramp
 Proceeding slowly forward with load up front
 Releasing accelerator as the rise is breasted

 Positioning truck to reverse down ramp

 Stopping at top of ramp
Driving down ramp  Lifting forks to clear slope
 Proceeding slowly down ramp
 Controlling speed with foot brake

Moving to pallet park position Driving truck to pre-determined position

Slowing & stopping the truck under control , using the foot
Stopping the truck
brake

Applying the parking brake Manipulating the parking brake control to the “on” position

 Selecting neutral gear

 Positioning mast vertically
 Lowering forks until pallet grounds
Setting down the load
 Removing forks at inching speed until clear of pallet
 Lift forks + 200mm from ground
 Tilting mast backwards

Moving to parking area Slowing & stopping truck under control using foot brake

Applying parking brake Manipulating the parking brake control to the “on” position

Carrying out complete close down checks in accordance with

Parking the lift truck
the close down check sheet

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 Confined gangway stacking
Checking the pallet Visually inspecting the pallet condition

Checking the load Visually inspecting stability & load mass

Setting the fork centre’s Adjusting to suit load & pallet

 Positioning mast vertically

 Setting height of forks
 Putting into forward gear
 Releasing park brake
Picking up the load
 Inserting forks at inching speed
 Inserting forks until heels reach pallet face
 Lifting load + 200mm from floor
 Tilting mast backwards

 Setting off smoothly in direction of travel

 Keeping a sharp lookout
Transporting the load
 Travelling at a suitable speed
 Obeying all safety rules

 Slowing down
 Sounding horn
Entering the gangway
 Keeping left
 Giving space for approaching trucks

Positioning the truck correctly Approaching stacking position from opposite side of gangway,
in the gangway allowing space for tail swing

Turning through 90°

Performing 90° turn  Missing load opposite
 Forks in line with deposit position

Checking
Check empty pallet slot  Space for depositing
 Beams not damaged

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  Beam configuration suitable for pallet
 Pallet dimensions will enter space

 Leave mast tilted backwards

 Operating lift control
Lifting the load  Lifting pallet 50mm above beam position
 Inching forward to approximate position
 Tilt mast forward until load symmetrically located on rack

 Lowering forks under control until pallet contacts beams

Depositing the load  Lowering 25mm to free forks
 Reverse at inching speed to original position

 Lowering forks to travel position

Returning to travel position  Tilting mast backwards
 Reverse left or right to position before executing 90° turn

Travelling empty to next

Driving smoothly & being alert
location

Positioning the truck correctly Approaching stacking position from opposite side of gangway,
in the gangway allowing space for tail swing

Turning through 90°

Performing 90° turn  Missing load opposite
 Forks in line with deposit position

Checking
 Pallet condition
Check pallet slot  Load stability
 Handling clearances
 Pallet orientation

 Moving the mast to vertical

Lifting the forks  Operating lift control
 Lifting forks 75mm above beam position

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Entering the pallet Inching forward until forks located in pallet without scraping

Lifting the load Lifting forks slowly until pallet is 50mm above beam

Retracting from the rack Reversing at inching speed to original position

 Lowering forks to travel position

Returning to travel position  Tilting mast backwards
 Reverse left or right to position before executing 90° turn

Move off with load Driving smoothly & being alert

Loading and off loading

Loading & offloading vehicles, carriages & containers
Observing

Checking jockey wheels &  Ground contact

landing legs of vehicle  Stable ground
 Locked in place

Locating load plates

Checking

Checking capacity & condition  Walls

of vehicle load space  Drop sides
 Stakes
 Securing ropes

Check
Checking vehicle parking
 Position
brake
 Engaged

Chocking the wheels of the

Placing chock blocks around vehicle wheels
vehicle

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Checking vehicle cannot be
Checking that a third party cannot change situation
driven away

Opening vehicle doors Releasing locks & opening doors

Positioning bridge plates &

Placing plat between vehicle & dock
dock levellers

Checking
 Floor solid & safe

Inspecting vehicle for  Walls & roof waterproof

suitability  No protrusions
 Door & seals secure
 Tyres adequately inflated

Checking
Planning the loading pattern  Vehicle capacity
 Load & vehicle size & deciding how to load

Planning off-loading pattern Maintaining vehicle balance & removing without damage

 Side shifting in containers

Depositing / picking up loads
 Aligning correctly
correctly
 No damage on pick up

 Correctly supporting loads above

Loading different levels
 Correctly choosing & placing dunnage

Placing dunnage Securing correctly & adequately supporting goods

Investigating whether load will be safe & will not move in

Checking load security
transit

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 Lifting off between dock & vehicle, without damage to goods or
Removing bridge plates
vehicle

Closing vehicle doors Closing doors & securing locks

Removing chocks etc. Removing from wheels & storing correctly

Formative assessments

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 FORMATIVE ASSESSMENT WORKBOOK

CHECK FORMATIVE ASSESSESSMENT WORKBOOK - LEARNER

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