Welcome to your

Counterbalance FLT
Course Instructor:
 Counterbalance Fork Lift Truck Training Course

Agenda:

■ House Keeping and Refreshments ■ Driving on Inclines

■ Certification ■ Pre-use checks and defect reporting
■ The Importance of Training ■ Battery care & Refuelling
■ Health and Safety at Work Act 1974 ■ Pallet and Load Assessment
■ PUWER 1998 ■ Vehicle Loading
■ LOLER 1998 ■ Pallets
■ Personal Risk assessment ■ Racking
■ Accidents and associated risks ■ Use of seat belts
■ Personal Protective Equipment ■ Public Highway
■ Basic Engineering Principles ■ Safe Driving Rules
■ Rated Capacity and Load Centres ■ Operators Manual
■ Stability Factors ■ Video
■ Full Practical training and testing

2
House Keeping and Refreshment

■ Introductions
■ Mobile Phone Use
■ Fire Exits
■ Toilets
■ Coffee and Lunch Breaks
■ Any Questions

3
Certification

On successful completion of this course you will receive a certificate which will
allow you to operate the machine as described on this course.

Refresher Training
• HSE Guidance recommends a refresher on
MHE being 3 - 5 years to ensure operators kept
up to date with legislation and any other
changes.

4
The Importance of Training

■ Reduce accidents
To Be Safe
■ Safe Environment

Legal Requirement
■ Untrained Operators are a risk
■ The LAW has no excuses

■ Reduce damage
Benefits! ■ Improve your efficiency
■ Personal development

5
 Health and Safety at Work Act 1974

The act was established to protect everyone and there is no hiding

from it.

■ Employers
■ Employees
■ Contractors
■ The public

6
Health and Safety at Work Act 1974

7
Health and Safety at Work Act 1974

8
Health and Safety at Work Act 1974

9
Provision and Use of Work Equipment Regulations 1998

PUWER Regulations apply to all work equipment

Overhead Crane

Cherry Picker

10
Provision and Use of Work Equipment Regulations 1998

Regulations 9 of PUWER relates to training:

■ All operators must receive training in the safe use of work

equipment.

■ All supervisors of work equipment must receive training in

its safe operation.

11
Lifting Operations and Lifting Equipment Regulations 1998

12
Lifting Operations and Lifting Equipment Regulations 1998

LOLER is responsible for the following:

■ Maintenance
■ Inspection (6 months or 12 months intervals)
■ Safe Use of Lifting Equipment

If a truck does not have an in-date LOLER then it should not be used!

13
Management of Health & Safety at Work Regulations 1999

MHSWR is there to protect the well-being of employees and other

persons who may be affected by the employers undertaking.

■ Regulation 3 – Risk Assessment.

■ Regulation 14 – Employees duties / Responsibilities.

14
Personal Risk Assessment

15
 Personal Risk Assessment

■ When performing any task, it is always important that you perform your own risk
assessment.

■ Understand the task and everything that is involved?

■ Am I competent and trained in the required task?

■ Do I have the right tools and eqiupment, are they safe to use for the task?

■ What are the possible hazards and who is at risk from performing this task?

■ Failsafe's, do we have any countermeasures in place to reduce or stop the hazard?

■ Is there a manager I can refer to for help/guidance?

16
Accidents and Associated Risks

Why do accidents happen?

■ Operator at Fault
■ Workplace Conditions
■ Other workforce
■ Environment (Weather)
■ Poorly Maintained Equipment
■ Complacency

17
Accidents – What is the REAL cost

In the event of an accident, what are the results of this

■ Personal Injury – loss of earnings

■ Emotional Damage

■ Legal Costs

■ Repair or Replacement costs

18
Personal Protective Equipment

Commonly know as PPE, what is PPE and why is it used?

■ Different PPE Types

■ Site Requirement for PPE
■ Wearing & Maintaining PPE
■ Inspecting and replacing PPE
■ Wearing relevant PPE is a legal
requirement!

19
Equipment Introduction

Counterbalance
Lift Truck

20
Equipment Introduction

Different Counterbalance Trucks

■ 3 wheel and 4 wheeled

■ Diesel / Gas(LPG) / Electric

■ Lifting Capacity
B1 (up to and including 5 ton) B2 (5 to 15 ton) B3 (15 ton +)
(A different certificate of competence is required to operator each
category).

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Parts of the Truck

Counterweight

22
Parts of the Truck

Operator
Protection

23
Parts of the Truck

Wheels

■ Steer wheels

24
Parts of the Truck

Wheels

■ Load bearing wheels

25
Parts of the Truck

Forks

26
Parts of the Truck

Carriage
Plate

27
Parts of the Truck

Mast

28
Parts of the Truck

Load
Chain/s

29
Parts of the Truck

Tilt Ram

30
Parts of the Truck

The cab
■ Cabs can vary from dependant on
model.

31
Parts of the Truck

Steering Wheel

32
Parts of the Truck

Operators Seat

33
Parts of the Truck

Emergency Power
Cut-Off

34
Parts of the Truck

Foot Pedals

35
 Hydraulics

What are Hydraulics?

■ The use of fluidic force under pressure to transfer power to the mast and carriage.

■ Lifting – The hydraulic pump action is controlled.

■ Lowering – The release valve is controlled.

36
Hydraulics

Hydraulics System

37
Questions

38
Principles of Counterbalance

A Stable Truck and Load

39
Principles of Counterbalance

Unstable Excessive Weight

40
Principles of Counterbalance

Stable Truck and Load

41
Principles of Counterbalance

Unstable Extended Load Centre

42
Load Centre

43
Lift Height

Below is an example of the Lift Height and Load Limit

■ Every truck should have this fitted on the machine.

44
Rated Capacity

Below is an example of a capacity plate

■ It is an offense to exceed the trucks rated capacity.

45
Questions

46
Stability of the Truck

The Stability Triangle

47
Stability Triangle

48
Stability Triangle

49
Stability Triangle

50
Stability Triangle

51
Stability Triangle

52
Stability Triangle

53
Stability Pyramid

54
Stability Pyramid

55 Footer: Insert > Header & footer

Stability Pyramid

Footer: Insert > Header & footer

3 Wheel v 4 Wheeled

Which is more stable?

57
3 Wheel v 4 Wheeled

Both are equally stable!

• In the event of a lateral tip, the

counter weight would touch the
floor.

• If anything, it could be argued that a

3 wheel truck offers better lateral
stability than a 4 wheel. This is
because the 3 wheel truck has
additional emergency support in the
form of the counterweight which
would touch the floor first in the
event of a tip. See the red circle.

58
Examples of Instability

■ Overloading

Exceeding a trucks rated capacity

is illegal.

59
Examples of Instability

■ Harsh acceleration

Always accelerate gradually.

60
Examples of Instability

■ Harsh Braking

Always brake gradually.

61
Examples of Instability

■ Incorrect Load Lowering

Use hydraulic controls smoothly.

62
Examples of Instability

■ Incorrect Use of Tilt

Take care when applying the

forward tilt.

63
Examples of Instability

■ Undercutting

Make sure forks are at least 2/3rds

of the way in.

64
Examples of Instability

■ Live Load

Take care when handing live

loads.

65
Examples of Instability

■ Ground Conditions

Ensure you can see clearly and

avoid obstacles.
If your view is impaired by the
load, drive in the reverse.

66
Examples of Instability

■ Turning at Speed

An unladen truck will tip over

even more readily than a
laden truck.

67
Examples of Instability

■ Turning with an Elevated Load

Always carry the load as low as

practically possible.
Never turn with an elevated load.

68
Examples of Instability

■ Damaged Tyre

Never drive a truck with a

damaged or flat tyre.

69
Examples of Instability

■ Carrying Load Off Centre

Ensure the load is carried

with equal weight on each
fork.

70
Driving on Inclines

■ When Laden, the load must face up the incline

■ When unladen, the load should face down the incline

71
Safe Driving Rules

■ Only qualified operators can use the

machine.
■ Site specific PPE must be worn.
■ Pre-use checks must be completed.
■ No additional passengers on vehicle.
■ Follow the on site driving rules.
■ Ensure good visibility when operating
the truck and hydrauic system.
■ Sound horn.
■ Check clearances when operating.

72
Questions

73
Pre-use Checks

Under Regulation 8 of LOLER it States that Pre-Use Checks must be

carried out.

Why?

■ A pre-use check is there for you to find

faults on the truck which mean it could be
potentially dangerous to use.

■ If any faults or defects are found they must

be reported so appropriate action can be
carried out, in some cases taking the truck
out of action.

74
 Pre-use Checks
What is checked?

■ Capacity plate ■ Operating position

■ Forks ■ Operators seat
■ Carriage plate ■ Overhead guard
■ Backrest extension ■ Lights
■ Mast ■ Directional indicators
■ Mast rollers and slides ■ Audible warnings
■ Lift chains and pulleys ■ Drive and Braking
■ Hydraulics ■ Steering
■ Hydraulic controls ■ Mirrors
■ Wheels and tyres ■ Fault reporting procedure
■ External truck condition
■ Fluid levels

75
 Battery Care and Maintenance

Battery care is very important!

Electricity (Shocks).

■ Always use the correct charger.

■ Isolate all mains supply before
checking the battery.
■ Only use insulated tools.
■ Remove all jewellery.
■ Connect charger to truck before
switching on electricity supply.
■ Disconnect electricity supply
before disconnecting the
charger from truck.

76
 Battery Care and Maintenance

Sulphuric Acid (Burns).

■ Wear appropriate safety equipment.

■ Acid contact with skin.
■ Acid contact with eyes.
■ Acid contact with clothes.
■ Do not overfill batteries.
■ Clean up any spills.

77
 Battery Care and Maintenance

Hydrogen and Oxygen.

■ Expose the battery.

■ Remove Metal Jewellery.
■ Use insulated tools.
■ Top up with distilled/de-ionised water.

NO SMOKING OR NAKED FLAMES – HIGHLY EXPLOSIVE!

78
 Refuelling (Diesel)

■ Park correctly.
■ Adequate ventilation.
■ Fire extinguisher present.
■ Wear PPE.
■ Use correct fuel.
■ Do not overfill.
■ Clear away any spills.

NO SMOKING OR NAKED FLAMES – HIGHLY EXPLOSIVE!

79
 Refuelling (Gas)

■ Park correctly.
■ Fire extinguisher present.
■ Wear PPE.
■ Follow the correct procedure.

NO SMOKING OR NAKED FLAMES – HIGHLY EXPLOSIVE!

80
Questions

81
 Attachments

There are various different types of attachments that can be used on a Counterbalance.
The most common are forks, but there is a wide variety of attachments available.

Its important to be aware that operators using different attachments require specific
training in the safe use of these attachments, including the following:

■ Operator training.
■ Truck and attachment compatibility.
■ Good attachment condition.
■ Secure fitting to the truck.
■ Attachment weight and SWL.

82
Attachments

Extended Forks

■ Used in matched pairs.

■ Fit over existing forks.

■ Used for handling loads with

increased load centres.

83
 Attachments

Reel / Barrel Clamp

■ Clamp consists of jaws that

open and close together to
allow loads to be picked up.

■ Used for handling reels such as

paper.

■ Some also rotate.

84
Attachments

Carpet Boom

■ The boom is a long metal

pole which is attached the
carriage plate.

■ Used for handling rolls of

carpet or steel coils.

85
 Attachments

Work Platform Attachment (Cage)

Can be used for a variery of tasks at

height to be undertaken in a safer
way then using ladders.

Important Notice
HSE guidance says that a non
integrated platform (as displayed)
should only be used for unplanned
tasks.

86
 Attachments

Jib Crane Arm

■ Jib crane arms is used to
handler awkward loads
with the aid of slings and
chains.

■ Dependant on type, they

can be fitted to the
carriage plate or slid onto
forks.

■ Operators should
undergo further training
before using this
attachment.

87
 Load Assessment

Before picking up a load ensure you know:

■ The weight of the

load.
■ Load Centre.
■ Condition of Pallet.
■ Condition of Load.
■ Size of Load.
■ Fork length and
spacing.

88
 Racking

Racking should be inspected and any damage reported

■ Uprights are securely

fastened to the floor.
■ Uprights and cross
members are free from
damage.
■ Racking beam securing pins
are in place.
■ Pallets are correctly located.
■ Pallets are safely loaded.
■ Pallets are free from
damage.

89
Racking

■ SWL
Safe Working Load.

■ UDL
Uniformly Distributed Load.

90
Questions

91
 Vehicle Loading and Unloading

Follow these basic rules:

Vehicle safely parked with engine

off and key removed.
Driver Aware and in a position of
safety.
Suitable access to both sides of
vehicle.
Vehicle bed in good condition.

92
Vehicle Loading and Unloading

When loading a vehicle always

position pallets tightly against each
other to prevent movement during
transit and to maximise the load.

93
Vehicle Loading and Unloading

When loading a vehicle always

position pallets tightly against each
other to prevent movement during
transit and to maximise the load.

94
Vehicle Loading and Unloading

When loading a vehicle always

position pallets tightly against each
other to prevent movement during
transit and to maximise the load.

95
 Vehicle Loading and Unloading

■ The Driver of the vehicle is the one who is responsible for the safety and security of
their load.

■ Therefore the lift truck operator should take instruction from the vehicle driver
when loading and unloading to avoid axle weight and stability issues.

■ Take care when entering a vehicle

via a bridging plate, or dock
leveller.

■ Understand the vehicles

capabilities.

96
Questions

97
 Using a FLT on a Public Highway

■ Taxed
■ Tested
■ Insured
■ Number plate
■ Qualified Driver

98
Seatbelts

Seatbelts should be worn at all times on a counterbalance truck up to 10

ton lifting capacity, unless a robust risk assessment says otherwise.

Tip over Procedure:

Stay on the truck.
Hold on tightly.
Brace feet against floor.
Lean away from point of impact.

99
Safe Driving Rules

The “Common Sense” approach should be taken with

most driving rules, but ever in doubt, stop and ask
your supervisor.
Over the next few slides we will explain some of the more common
unsafe runs.

100
Safe Driving Rules

No eating, drinking,
use of mobile phone etc.

101
Safe Driving Rules

■ Never carry passengers on a Fork Lift Truck.

■ Always make all round observational checks before moving.

102
 Safe Driving Rules

■ Ensure sufficient overhead

clearance for doorways, pipes,
lights cable etc.

■ The driver must have at least one

hand on steering wheel at all
times, whilst truck is in motion.

■ Always travel at a safe speed

suited to the load and general
conditions.

■ Avoid making sharp turns or

sudden stops.

103
 Safe Driving Rules

It is the drivers responsibility to ensure pedestrians safety.

Be aware of pedestrians, they may not be aware of the front and end swing of a fork lift.

Never allow any part of the body outside the truck cab whilst the truck is moving.

104
 Safe Driving Rules

When approaching a blind corner, slow

down manoeuvre slowly, be prepared to
stop.
Be aware of potential hazards in the
area.

Obey all signs and travel directions

restrictions.

Always operate the hydraulic controls

smoothly. A jerky movement could tip the
truck.

105
 Safe Driving Rules

Never Drive forward with a load obscuring your view, travel in reverse instead (unless you
are going up a slope, in this case you need someone to guide you).

Never lift a load using only one fork arm.

106
 Safe Driving Rules

Do not become involved in horseplay of any

type. Concentrate on the job in hand.

Leave a minimum separation gap of 3 truck

lengths when following another truck in an
aisle.

If the truck has side shift facility, return it to the

central position after use.

107
 Safe Driving Rules

Do not push or drag loads along the ground.

Do not carry divisible loads that are higher than the carriage or load backrest extension.

It is the responsibly of the operators to ensure safety of pedestrian when they are operating
the truck.
(Keep a look out for them at all times and give them space, stop if they get too close).

108
 Safe Driving Rules

When parking ensure the truck is parked safely and the parking brake applied
The key / transponder must be removed.

Do not obstruct:
Blind spots.
Doors.
Loading Bays.
Emergency Exits.
Fire Fighting Equipment.
Electric panels.

Do not park on an incline.

109
 Safe Driving Rules

Do not add extra counterweight to

the truck, so it can lift more than
itated on the capacity rating plate.

When crossing speed bumps,

drive slowly, cross diagonally one
wheel at a time.

Do not operate insecure or unsafe

loads.

Do not use defective pallets or

stillage's.

110
 Safe Driving Rules

Always look up to ensure sufficient clearance before raising the forks/load.

Take extra care when the forks project beyond the pallet.

Face the truck when mounting and dismounting, use handgrips and steps provided, look all
around for hazards, get on and off the truck under control. DO NOT JUMP OFF.

111
 Safe Driving Rules
Always look in the direction of travel.

If a load has to be repositioned by physically getting off the truck and manually adjusting it,
the truck should first be placed in a safe parked position switched off and the key
removed before dismounting.
If debris is encountered on the floor, stop, park safely and remove it.
The next driver may not spot it resulting in an accident.

112
 Safe Driving Rules

Do not allow anyone to be raised

by the lift truck unless they are
trained, and are using an
approved work platform which is
correctly secured to the truck.

113
 Safe Driving Rules

You will be trained to handle

palletised loads on this course.

If you are required to handle

unusual loads, consult your
supervisor and ensure they load
can be made safe for handling.

114
 Safe Driving Rules

Take Extra care in adverse conditions:

Bright Sunlight (Dazzle).

Ice.
Snow.
Rain.
Poor Light.

115
Operators Manual

Every truck should have a operators manual.

Please refer to this if you are ever not sure, and/or refer to a supervisor
for assistance.

Follow the instructions and be safe in your operation.

116
Video

■ I hope you have been paying attention?

We will now play a training video to complete the theory

session.

117
Questions

118