phw services qualification through competence

Counterbalance FLT Refresher Course Pack

Forklift Operator Refresher – Counterbalance (HSE L117 & NVQ-Aligned)
1

Course Overview

Course Title
Forklift Operator Refresher – Counterbalance
Provider
PHW Services
Course Type
Refresher / Re-test for Experienced Operators
Refresher Cycle
Every 3–5 Years

Standards & Alignment

  • HSE ACOP L117 – Rider-operated Lift Trucks: Operator Training and Safe Use (Approved Code of Practice)
  • PUWER 1998, Regulation 9 – Provision and Use of Work Equipment Regulations: Training requirement
  • Level 2 FLT Operations NOS – National Occupational Standards for Forklift Truck Operations

When Is a Refresher Required?

2

Target Learners & Entry Requirements

Who Is This Course For?

  • Existing counterbalance forklift operators with evidence of previous training (certificate, operator card, or employer records)
  • Operators due for refresher within the 3–5 year cycle
  • Operators referred following an incident, near miss, or observed unsafe behaviour
  • Operators returning after workplace changes affecting truck operations

Entry Requirements

  1. Previous training evidence – Certificate, operator log, or employer confirmation of prior competence
  2. Medical fitness – Employer confirms fitness to operate (FS19-style medical declaration or occupational health clearance)
  3. Minimum age 16 (employer premises only) or 18 (public roads / construction sites)
  4. Adequate English to understand theory content and safety instructions
Important

If a candidate cannot demonstrate evidence of previous training or competence, they must complete a full novice operator course (typically 3–5 days) rather than this refresher.

3

Duration & Ratios

Individual Candidate
~4.5 Hours (Half Day+)
Small Group (Max 3)
1 Full Day (Up to 6.5 Hours)

Trainer-to-Candidate Ratios

ComponentMax RatioNotes
Theory delivery1 trainer : 6–8 candidatesClassroom or meeting room setting
Practical assessment1 trainer : 1 candidate : 1 truckOne-to-one on the truck at all times
Practical rotationMax 3 candidates per truckRotate through practical whilst others do theory/quiz
Scheduling Tip

For groups of 3, run theory to the full group first, then rotate candidates through practical assessment whilst others complete the written test. This keeps everyone engaged and minimises downtime.

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Learning Outcomes

Knowledge Outcomes

On successful completion, the candidate will be able to:

  1. Legal duties – Explain operator responsibilities under HSWA 1974, PUWER 1998, and HSE ACOP L117
  2. Truck components & safety systems – Identify and describe the function of key counterbalance truck components and safety devices
  3. Stability principles – Explain the stability triangle, centre of gravity, load centres, the effects of gradients, and dynamic forces on stability
  4. Safe load handling – Describe correct procedures for assessing, picking, transporting, stacking, and de-stacking loads
  5. Site-specific hazards – Identify common workplace hazards and describe safe systems of work for forklift operations

Practical Outcomes (Mapped to NVQ Units)

UnitTitleKey Skills
FLT-01Prepare Truck for UseWalk-around pre-use inspection, identify defects, report faults, check fluid levels, test controls
FLT-02Operate & Manoeuvre SafelyStart-up, forward/reverse travel, cornering, confined spaces, observation, speed control, horn use
FLT-03Handle Loads SafelyLoad assessment, approach, pick-up, travel with load, stacking, de-stacking, racking, vehicle loading
FLT-04Secure & Shut DownCorrect parking procedure, post-operational checks, defect reporting, key removal, housekeeping
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Course Timetable

Session 1
45–60 min

Welcome, Legal & Standards

Introductions and course overview. Quick initial knowledge check (informal). Overview of HSWA 1974, PUWER 1998, L117 ACOP. Employer and operator duties. Consequences of non-compliance.

Session 2
60–75 min

Technical Refresh

Stability triangle and centre of gravity. Load centre and rated capacity (de-ration). Effects of forward/backward tilt. Operating on slopes and gradients. Cornering forces and speed. Truck components refresher. Discussion of real incidents.

Session 3
2–3 hours

Practical Skills Refresh

Pre-use inspection walkthrough (FLT-01). Manoeuvring: forward, reverse, tight turns, confined areas (FLT-02). Load handling: approach, pick, tilt, travel, stack, de-stack (FLT-03). Parking and shutdown procedure (FLT-04). One-to-one coaching and correction of bad habits.

Session 4
30–45 min

Theory Assessment

25-question closed-book written test covering all knowledge outcomes. Pass mark: 80% (20/25). Candidates who fail may have one resit opportunity at the trainer's discretion.

Session 5
30–45 min

Coaching & Action Plans

One-to-one feedback session. Review of theory and practical results. Identification of bad habits and development areas. Individual action plan agreed. Certificate issued (if competent).

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Theory Quiz – 25 Questions

Closed-book assessment. Pass mark: 80% (20 out of 25).

A. Health & Safety / Legal (Questions 1–5)
Question 1
What is the main legal duty of a forklift operator under the Health and Safety at Work Act 1974?
  1. Carry out repairs on the forklift
  2. Take reasonable care for own safety and others
  3. Write risk assessments for the workplace
  4. Inspect the truck monthly
Answer: (b) Take reasonable care for own safety and the safety of others who may be affected by their acts or omissions.
Question 2
Which regulation specifically requires that forklift operators receive adequate training before operating?
  1. COSHH 2002
  2. PUWER 1998
  3. RIDDOR 2013
  4. Manual Handling Operations Regulations 1992
Answer: (b) Provision and Use of Work Equipment Regulations 1998 (PUWER), specifically Regulation 9 – Training.
Question 3
During pre-use checks you discover a serious fault. What is your first action?
  1. Continue working carefully and report at end of shift
  2. Attempt to repair it yourself
  3. Report it immediately and take the truck out of service
  4. Ask a colleague to check it
Answer: (c) Report the fault immediately to your supervisor and take the truck out of service. Never operate a defective forklift. Tag or isolate the truck to prevent others from using it.
Question 4
Why should the operator's manual be kept with the forklift at all times?
Answer: The operator's manual contains the manufacturer's instructions, rated capacity data, tyre pressure specifications, and essential maintenance and safety information. It must be available for reference at all times as required by PUWER.
Question 5
Name four circumstances in which a refresher or re-test would be recommended.
Answer: (1) After an accident or near miss; (2) When unsafe habits are noticed by management; (3) When changing workplace, truck type, or operating conditions; (4) As routine refresher every 3–5 years. Also: returning after prolonged absence.
B. Pre-Use Inspection (Questions 6–10)
Question 6
Why is fork heel wear a critical item to check during pre-use inspection?
  1. It makes the forks look untidy
  2. It can weaken the forks, leading to bending or breaking under load
  3. It only affects the paint finish
  4. It reduces fuel efficiency
Answer: (b) Fork heel wear reduces the cross-section at the weakest point of the fork. This can lead to bending or catastrophic failure under load, causing the load to fall.
Question 7
What should you check on the mast lift chains during pre-use inspection?
Answer: Check that both chains are equal in length (no stretching), show no visible damage (cracked or worn links), have correct tension (not slack), and have no twists or kinks. Worn or damaged chains must be reported immediately.
Question 8
What could happen if there are different sized tyres fitted on the front (drive) axle?
  1. The truck will go faster
  2. Fuel consumption improves
  3. The forklift may not sit level, becoming unstable when lifting
  4. No effect at all
Answer: (c) Mismatched tyres cause the truck to lean to one side, affecting the centre of gravity and reducing stability, particularly when lifting loads at height.
Question 9
If a forklift develops a defect during the shift, who decides whether it is safe to continue working?
  1. The operator
  2. A competent person or authorised engineer
  3. Any colleague nearby
  4. Nobody – just carry on
Answer: (b) Only a competent person (trained engineer or designated authorised person) should assess the defect and decide whether the truck is safe to continue operating. The operator must not make this decision alone.
Question 10
List three items you would check on a daily pre-use walk-around inspection.
Answer: Any three from: tyres and wheels (damage, pressure, wear); brakes (footbrake, handbrake); steering (play, response); hydraulics (leaks, operation); mast and carriage (damage, smooth operation); forks (cracks, wear, alignment); chains (tension, damage); seatbelt (condition, function); warning devices (horn, lights, beacon); fluid levels (oil, coolant, battery).
C. Working Safely (Questions 11–15)
Question 11
Why is reversing a forklift considered particularly hazardous?
Answer: Reduced visibility to the rear, proximity to pedestrians who may not hear or see the truck, and the risk of striking people, objects, or racking. Reversing is involved in a high proportion of forklift incidents.
Question 12
Before reversing, what should the operator always do?
  1. Sound the horn and reverse immediately
  2. Check all mirrors, look over both shoulders, and ensure the route is clear
  3. Ask someone to walk behind
  4. Turn on hazard lights only
Answer: (b) Check all mirrors, look over both shoulders, and ensure the intended route is completely clear of people and obstacles before reversing. Sound the horn as an additional warning.
Question 13
When must the handbrake be applied during lifting operations?
  1. Only when parking up for the day
  2. Only when on a slope
  3. Every time the truck is stopped and hydraulics are being used
  4. Never – the footbrake is sufficient
Answer: (c) The handbrake must be applied every time the truck is stationary and hydraulic operations (lifting, lowering, tilting) are being performed. This prevents the truck from creeping or rolling.
Question 14
What is the minimum safe distance from overhead power lines supported on wooden poles?
Answer: 9 metres horizontal clearance from the line, plus the full height of the mast when extended. For metal pylons the clearance is 15 metres. Always check site-specific rules and consult the electricity supplier if in doubt.
Question 15
What must you do before leaving the operator's seat to manually adjust forks or attachments?
Answer: Apply the handbrake, put the controls in neutral, lower the forks fully to the ground, and switch off the engine/motor. Never reach between or under the mast with the engine running.
D. Lifting, Stability & Travelling (Questions 16–23)
Question 16
What does the rated capacity chart on a forklift tell you?
Answer: The rated capacity chart shows the maximum safe load the truck can handle at given lift heights and load centres. If the load centre exceeds the rated value, the capacity must be reduced (de-rated). It is the operator's responsibility to check and comply with the chart.
Question 17
Why can you not always judge a load's weight by its size alone?
  1. All loads weigh the same
  2. Different materials have different densities – a small load may be much heavier than a larger one
  3. Size is the only factor in weight
  4. The forklift compensates automatically
Answer: (b) Different materials have different densities. A small pallet of steel can weigh far more than a large pallet of foam. Always check load weight markings or documentation before lifting.
Question 18
What is the “load centre” and why does it matter?
Answer: The load centre is the horizontal distance from the vertical face of the forks to the centre of gravity of the load. The standard rated capacity assumes a 500mm load centre. If the load's centre of gravity is further out (larger or uneven load), the effective capacity is reduced and the truck may become unstable.
Question 19
What is the correct fork spacing for a standard palletised load?
  1. As close together as possible
  2. As wide as the mast allows
  3. Equidistant from the centre line, fully supporting the pallet and load
  4. It doesn't matter as long as they go in
Answer: (c) Forks should be spaced equally either side of the centre line, as wide as practical to fully support the pallet. This distributes the load evenly and maximises stability.
Question 20
What happens to stability when a load is raised to full height with full backward tilt applied?
  1. Stability improves because the load is secure against the carriage
  2. The centre of gravity moves upward and rearward, reducing forward stability
  3. There is no change to stability
  4. The truck becomes more stable in all directions
Answer: (b) Raising the load increases the height of the combined centre of gravity, and backward tilt moves it rearward. This reduces the truck's stability, particularly when cornering or on uneven surfaces. Only tilt back at low level; level the mast before raising to height.
Question 21
What are the rules for travelling on slopes when loaded and unloaded?
Answer: Loaded: travel forwards up the slope, reverse down the slope (keep the load on the uphill side). Unloaded: reverse up the slope, travel forwards down. In all cases: keep forks as low as possible, mast tilted slightly back, travel at walking pace, never turn on a slope.
Question 22
Why is it dangerous to travel with a raised load?
Answer: Travelling with a raised load raises the combined centre of gravity significantly, reducing the truck's stability. This greatly increases the risk of tipping over, especially when turning, braking, or travelling over uneven surfaces. Always travel with forks as low as possible (approximately 150–200mm ground clearance).
Question 23
What extra risks are involved when carrying a suspended (non-palletised) load?
Answer: A suspended load can swing during travel, braking, or turning, causing the centre of gravity to shift unpredictably. Wind can also affect the load. The swinging motion can exceed the stability limits of the truck, leading to tip-over. Extra caution, slower speeds, and a banksman may be required.
E. Parking & Post-Use (Questions 24–25)
Question 24
Describe the correct parking and shutdown sequence for a counterbalance forklift.
Answer: (1) Park in a designated safe area, away from traffic routes and fire exits; (2) Lower forks fully to the ground; (3) Tilt mast to neutral (vertical); (4) Apply the handbrake; (5) Select neutral; (6) Switch off the engine/motor; (7) Remove the key and keep it secure.
Question 25
Why is it important to keep work areas clean and free from debris?
Answer: Clean work areas reduce slip and trip hazards for pedestrians, improve tyre traction for the forklift, prevent obstructions that could cause collisions, and ensure clear sightlines. Debris on the floor (shrink wrap, broken pallet pieces, spillages) is a major cause of workplace incidents.
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Practical Assessment Sheet

Candidate Details

Candidate Name
Company
Date
Truck Type / ID

Score each item: C = Competent  |  ND = Needs Development  |  NYC = Not Yet Competent

FLT-01: Pre-Use Inspection (10 Items)

Assessment Item
C
ND
NYC
1. Approaches truck safely, checks for hazards around vehicle
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□
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2. Checks tyres and wheels (condition, pressure, damage)
□
□
□
3. Checks forks (cracks, heel wear, alignment, locking pins)
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□
□
4. Checks mast, carriage, and chains (damage, tension, lubrication)
□
□
□
5. Checks fluid levels (hydraulic oil, engine oil, coolant, fuel/battery)
□
□
□
6. Checks brakes (footbrake, handbrake/parking brake)
□
□
□
7. Checks steering (play, smooth operation)
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8. Checks warning devices (horn, reversing alarm, beacon, lights)
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9. Checks seatbelt and operator restraint (condition, function)
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10. Tests hydraulic controls (lift, lower, tilt, sideshift)
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FLT-02: Manoeuvring Assessment (8 Items)

Assessment Item
C
ND
NYC
1. Smooth starting and stopping (no jerky movements)
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□
□
2. Forward travel (correct speed, observation, fork height)
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□
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3. Reverse travel (all-round observation, mirrors, look over shoulder)
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4. Tight turns and cornering (appropriate speed, clearances)
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5. Confined space manoeuvring (awareness, precision)
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6. All-round observation maintained throughout
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7. Appropriate speed control for conditions
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8. Correct use of horn at junctions and blind spots
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FLT-03: Load Handling Assessment (10 Items)

Assessment Item
C
ND
NYC
1. Assesses load before lifting (weight, condition, stability)
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□
□
2. Correct approach to load (square on, forks level, correct height)
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□
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3. Forks fully inserted, correct spacing
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4. Correct use of tilt (back-tilt to secure load at low level)
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5. Travels with load low (150–200mm), mast back
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6. Stacking: approaches squarely, levels mast, places accurately
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7. De-stacking: checks stability, lifts clear, tilts back at low level
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8. Maintains safe clearances from racking and obstacles
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9. Correct technique for racking operations (beam clearance, alignment)
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10. Vehicle loading/unloading (dock safety, trailer security, load placement)
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FLT-04: Post-Operational Assessment (5 Items)

Assessment Item
C
ND
NYC
1. Parks in designated safe area
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2. Correct shutdown sequence (forks down, neutral, brake, engine off)
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□
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3. Reports any defects or concerns identified during operation
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4. Leaves work area clean and tidy (housekeeping)
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□
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5. Removes key and stores securely
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Overall Assessment Result

Theory Score
_______ / 25   (Pass: 20+)
Overall Practical Result
□ COMPETENT     □ NOT YET COMPETENT

Comments / Development Areas

Assessor Name & Signature
Date
Candidate Signature
Date
8

Certificate Template

PHW Services

Unit Achievement Certificate

Forklift Truck Operations – Counterbalance
Certificate No.PHW-CB-________
Candidate Name________________________________
Company________________________________
Date of Assessment________________________________
Refresher Due________________________________

Units Achieved

  • FLT-01: Prepare Truck for Use (Pre-Use Checks)
  • FLT-02: Operate and Manoeuvre Safely
  • FLT-03: Handle Loads Safely
  • FLT-04: Secure and Shut Down (Post-Operational Checks)

Aligned to Level 2 Forklift Truck Operations National Occupational Standards and PUWER 1998.

Assessor Name & Signature
Employer Authorisation
This is not a CPCS, NPORS, or RTITB accredited card. This certificate confirms unit achievement assessed by PHW Services in accordance with HSE ACOP L117 recommendations. Employer authorisation confirms the operator is permitted to operate within their workplace.
9

Trainer Notes

Structuring the Day

Recommended Flow
  • Start with theory – deliver Sessions 1 & 2 to the full group. This refreshes knowledge before they touch the truck.
  • Rotate practical – send Candidate 1 to the truck (Session 3) while Candidates 2 & 3 complete the written quiz (Session 4). Rotate through.
  • Finish with feedback – once all candidates have completed practical and theory, do individual coaching sessions (Session 5).
  • For individuals – run straight through Sessions 1–5 sequentially. Allow natural breaks between theory and practical.

Key Points to Emphasise

  1. Pre-use checks are non-negotiable – stress that skipping them is both dangerous and a legal liability. Many operators treat them as a box-ticking exercise; make it real with incident examples.
  2. Stability triangle – this is the most misunderstood concept. Use physical demonstrations (lean back in chair, stack books off-centre) to make it tangible.
  3. Seatbelts save lives – many experienced operators refuse to wear them. Show the FLTA lateral tip-over video (operator ejected vs restrained). Make it clear that the safest place in a tip-over is inside the cab with belt on.
  4. Speed kills – refresher candidates often drive too fast because they're experienced. Emphasise that pedestrian fatalities are the number one cause of forklift deaths in the UK.
  5. Hands and feet – never put hands between mast sections, never let anyone stand on forks, never walk under raised forks.

Common Bad Habits to Watch For

Bad HabitWhy It MattersCorrection
Skipping pre-use checksLegal requirement; defects cause incidentsWalk through the full check together; explain consequences
Not wearing seatbeltLateral tip-over = ejection = crush injury/deathShow incident footage; non-negotiable for assessment
One-hand steeringReduced control; risk of losing grip on uneven surfacesBoth hands on wheel at all times when travelling
Travelling with raised forksRaised CoG; tip-over risk; strikes overhead objectsForks 150–200mm off ground, tilted slightly back
Not looking direction of travelPedestrian strikes; collisions with racking/structuresEmphasise all-round observation; mirrors + head checks
Excessive speedLonger stopping distances; loss of control on turnsWalking pace in pedestrian areas; demonstrate braking distances
Tilting forward at heightLoad slides off forks; catastrophic instabilityOnly tilt at ground level; mast vertical before raising
Leaving keys in unattended truckUnauthorised use; liabilityKeys removed every time operator leaves the seat

Handling Failed Candidates

Process for “Not Yet Competent” Results
  1. Theory fail (below 80%) – offer one resit opportunity on the same day. If they fail again, recommend further study and a re-test on another date. Do not pass them.
  2. Practical fail – identify specific areas of weakness and provide targeted coaching. If minor issues, allow a second attempt after coaching. If fundamental competence concerns, recommend additional training hours (partial or full novice course).
  3. Document everything – complete the assessment sheet fully, noting specific areas of concern. This protects the training provider and gives the employer clear information.
  4. Communicate with the employer – explain the result professionally. Focus on the candidate's development needs, not personal criticism. Recommend a clear pathway to competence.
  5. Never pass a candidate who isn't competent – your signature on that certificate carries legal weight. If there's a serious incident, your assessment records will be examined.

Documentation Checklist

Complete all of the following for every candidate:

DocumentWhenRetain For
Candidate registration form (name, company, previous training evidence)Before course starts3 years minimum
Medical fitness declaration (FS19-style, signed by employer)Before practical3 years minimum
Theory test paper (marked, scored)During Session 43 years minimum
Practical assessment sheet (this document, Section 7)During Session 33 years minimum
Certificate (if competent) – copy retainedEnd of course3 years minimum
Action plan / development notes (if applicable)Session 53 years minimum
phw services qualification through competence

PHW Services – Counterbalance FLT Refresher Course Pack

Aligned to HSE ACOP L117, PUWER 1998, and Level 2 Forklift Truck Operations NOS

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