Driven Machinery Regulations, 1988

National Code of Practice for the Evaluation of Training Providers for Lifting Machine Operators

Appendix 1.1: Standard Obstacle Course for Lift Truck Operators.

The standard lift truck course and procedure was developed to standardise the assessment of operators and thus ensuring an equitable benchmark regardless of location. The obstacle course tests the competence of the operator through various generic manoeuvres. Modifications to the obstacle course maybe necessary depending on the lifting machine and accessories fitted.

Stacking Heights

See drawing / sketch Appendix 1.2 for the minimum physical heights required.

Critical Dimensions

1. Procedure to determine dimensions marked “X”. Refer to drawing / sketch Appendix 1.2. Park the lift truck at right angles to the racking with the forks or pallet touching the rack. Whilst in the stationery position turn steering wheel to the full lock position. Move the truck to a 45-degree position. Stop the lift truck and measure a distance of 300 mm from the corner of the counter weight (or furthest projecting part) to the opposite racking. Please note that this procedure should be repeated for the opposite side as the turning radius differs on some lift trucks.

2. Chicane aisles are to be constructed in such a manner that the loaded lift-truck will have only 100 mm clearance at all critical points when passing through the chicane.

3. The maximum clearance allowed between pallets or other objects when stacking is 75mm for both width and height distances.

4. The distance from chicane to the test racking position is to be twice the length of the lift truck. Allow the operator two opportunities to align lift-truck in the test aisle before performing the first task.

Test Route Preliminaries

1. Before testing may take place, the facilitator must complete the test route twice to ensure that it is practical and to familiarise himself with the sequences and the pallet positions.

2. A marking control sheet must be used, see Appendix 7 for a recommended sheet. The sheet is to be completed during the assessment to record faults as and when they occur.

3. It is important to walk all learners through the route explaining both the requirements of the practical test and the criteria and method of marking.

4. As a safety measure, ensure that no other persons including other learners are in the immediate vacancy of the obstacle course, during the actual assessment of a learner.

Practical Test Procedure

1. The learner is to perform the following whilst being assessed -

1. At the parked position carry out, without the use of a written checklist, the pre-operational checks required for the lift-truck, which is to be used during the assessment;
2. Answer 5 questions regarding the pre-operational checks;
3. Mount the lift-truck and carry out the start-up and operational checks;
4. Drive to station "A" and pick up the pallet;
5. Drive forwards through the chicane and deposit the pallet at station "B" at the high level;
6. Drive to station "C" and collect the pallet at eye level;
7. Drive to station "D" and deposit at the low level;
8. Drive to station "B" and collect the pallet at the high level;
9. Drive to station "C" and deposit at the eye level;
10. Drive to station "E1" and collect the stillage** at the eye level;
11. Drive to station "E2" and deposit the stillage** at the eye level;
12. Drive to station "D" and collect the pallet at the low level;
13. Drive in reverse through the chicane;
14. Drive to station "A" and deposit the pallet within the identified position;
15. Drive to "Park" position and park correctly; and
16. Perform close down checks.

Note -

1. ** Stillages maybe substituted with a stack of pallets that is packed within a maximum tolerance of 50 mm on a minimum of two sides.
2. Where training and practical assessments are conducted on machines restricted to particular areas (i.e. warehouses), this must be conducted in a clearly demarcated area, by means of danger tape or barriers.
3. In the case of order pickers (Code 8 & 9) the word "pallet" shall be interpreted to describe a parcel or component.

Close Down Checks

The normal close down checks associated with the completion of the days work is to be carried out and any problems reported.