What is the difference between a reach truck and a counterbalance forklift?

A reach truck has outriggers (legs) that extend forward to provide stability, allowing it to operate in narrower aisles. It uses a reach mechanism to extend the forks forward to retrieve or place loads. In contrast, a counterbalance forklift has a heavy counterweight at the rear and does not have outriggers, requiring more space to manoeuvre. Reach trucks are ideal for high-level racking in warehouses, while counterbalance trucks are better for loading/unloading vehicles and outdoor use.

How often do I need to renew my forklift licence?

The City & Guilds Level 2 Award does not expire, but employers typically require refresher training every 3-5 years or when operating conditions change. The Health and Safety Executive recommends that operators undergo periodic assessment to ensure competence. Some industries may require more frequent renewal, so check with your employer.

Can I operate a side loader without additional training if I have a reach truck licence?

No, a reach truck licence does not cover side loaders. Side loaders have different controls, stability characteristics, and load handling procedures (e.g., carrying loads on the side deck). You must complete specific training and assessment for side loaders to be certified. However, some skills are transferable, so training may be shorter.

What should I do if I find a defect during the pre-use inspection?

If you find a defect, do not operate the truck. Report the issue to your supervisor or manager immediately, and tag the truck as 'out of service' to prevent others from using it. The defect must be rectified by a qualified technician before the truck can be used. Never attempt to repair it yourself unless you are authorised.

How do I calculate the safe working load if the load centre is different from the rated centre?

Use the formula: Actual capacity = (Rated load centre ÷ Actual load centre) × Rated capacity. For example, if the rated capacity is 1500 kg at 500 mm load centre, and your load has a centre at 600 mm, the actual capacity is (500 ÷ 600) × 1500 = 1250 kg. Always refer to the truck's load capacity plate for the rated values.

What are the key safety rules for operating an order picker?

Order pickers are designed for picking stock at height, so the operator must always wear a safety harness and lanyard attached to the platform. Never exceed the platform's maximum load capacity. Keep the platform fully lowered when travelling, and only raise it when stationary at the picking location. Ensure the area below is clear of pedestrians and obstacles.

Select, transfer and position loads using a fork lift truck

CITY AND GUILDS OF LONDON INSTITUTE

vocational

This element focuses on the practical skills and underpinning knowledge for selecting appropriate loads, transferring them safely, and positioning them accurately using a reach truck, side loader, or order picker. Learners must demonstrate the ability to assess load stability, operate controls smoothly, and adhere to safe working practises while navigating varied workplace environments.

Learning Outcomes

Assessment Guidance

Key Skills

Key Terms

Assessment Criteria

Assessment criteria

City & Guilds Level 2 Award In Land-Based Forklift Truck Operations (Reach Truck, Side Loader and Order Picker Types) (QCF)

Topic Overview

The City & Guilds Level 2 Award in Land-Based Forklift Truck Operations covers the safe and efficient operation of reach trucks, side loaders, and order pickers in land-based environments such as agriculture, horticulture, and forestry. This qualification is essential for anyone seeking to operate these specialised forklift types in settings like farms, nurseries, garden centres, or estates where materials handling involves uneven terrain, narrow aisles, or delicate loads. The course combines theoretical knowledge of health and safety regulations, load handling principles, and machine maintenance with practical skills in manoeuvring, stacking, and de-stacking loads.

This award is part of the wider Motor Vehicle & Transport suite but focuses specifically on land-based applications, distinguishing it from general forklift operations. It prepares students for roles such as warehouse operator, stock handler, or agricultural materials handler, and is often a prerequisite for employment in sectors requiring certified forklift operation. Mastery of this qualification demonstrates competence in risk assessment, pre-use inspections, and adherence to the Approved Code of Practice (ACOP) L117, ensuring both personal safety and workplace compliance.

Understanding this topic is crucial because improper forklift operation is a leading cause of workplace accidents in land-based industries. The course emphasises stability factors, load centre calculations, and the unique challenges of operating on slopes or soft ground. By the end, students will be able to confidently handle reach trucks for high-level storage, side loaders for long loads like timber, and order pickers for picking stock at height, all while maintaining safety and efficiency.

Key Concepts

Core ideas you must understand for this topic

→Stability triangle and load centre: The stability of a forklift depends on the load's centre of gravity relative to the stability triangle formed by the wheels. Exceeding the load centre distance or lifting uneven loads can cause tipping.
→Pre-use inspection: Daily checks of tyres, forks, hydraulic systems, brakes, and safety devices (e.g., horn, lights, seatbelt) are mandatory. Any defects must be reported and rectified before operation.
→Safe load handling: Principles include keeping the load low during travel, tilting the mast back for stability, and avoiding sudden movements. For reach trucks, the reach mechanism must be used only when stationary.
→Site-specific risk assessment: Operators must identify hazards such as uneven ground, overhead obstructions, pedestrians, and confined spaces. The speed and route should be adjusted accordingly.
→Battery safety and charging: For electric trucks, correct charging procedures, water levels (for lead-acid batteries), and ventilation are critical to prevent gas explosions or acid spills.

Learning Objectives

What you need to know and understand

know how to select, transfer and position loads using a fork lift truck, be able to select, transfer and position loads using a fork lift truck

Assessment Criteria

Key criteria assessors look for in your portfolio

Award credit for correctly assessing load weight, dimensions, and stability before handling.
Look for evidence of selecting the correct forks or attachment for the specific load type.
Expect smooth, controlled hydraulic operations with no abrupt movements during lifting, tilting, or stacking.
Assess the ability to position loads precisely without excessive shunting or corrections.
Check that the operator maintains clear visibility and uses all-around observation throughout the transfer.

Assessment Guidance

Guidance for achieving higher grades

💡Always complete a pre-shift inspection before starting any practical assessment; examiners will note this.
💡Narrate your actions during the assessment to demonstrate your awareness of safety procedures and load assessment.
💡Prioritise slow, deliberate steering and hydraulic control over speed—accuracy scores higher than haste.
💡Use the truck's horn when reversing or approaching blind corners to show your commitment to workplace safety.
💡If placing a load at height, pause and verify alignment before final positioning to avoid multiple attempts.
💡In the practical assessment, always perform a thorough pre-use inspection and verbalise your checks. Examiners look for systematic approach and attention to detail, such as checking tyre pressure and fork condition.
💡When demonstrating manoeuvres, maintain a smooth, controlled pace. Avoid jerky movements or sudden stops, as these indicate poor load control. Use the horn at blind corners and keep the load as low as possible while travelling.
💡For the theory test, memorise key load centre values for common loads (e.g., 500mm for standard pallets) and understand how to calculate safe working loads when the load centre differs from the rated centre. Practice interpreting load capacity plates.

Common Mistakes

Common errors to avoid in your coursework

Failing to adjust fork spread to match the load width, leading to instability.
Travelling with the load raised too high, which can cause the truck to tip.
Not tilting the mast back sufficiently to secure the load during transit.
Underestimating the turning radius of the truck, causing collisions with racking or obstacles.
Neglecting to check the load capacity plate and attempting to handle loads beyond the truck's rated capacity.
Misconception: The forklift can carry any load as long as it fits on the forks. Correction: The load must be within the truck's rated capacity and load centre. Overloading or shifting the load centre forward reduces stability and can cause tipping.
Misconception: Side loaders and reach trucks can be operated the same way as counterbalance forklifts. Correction: Side loaders require the load to be carried on the side deck, not lifted high during travel. Reach trucks need the reach mechanism retracted when moving, and the outriggers must be fully lowered before lifting.
Misconception: Pre-use inspections are optional if the truck was used earlier in the day. Correction: A pre-use inspection must be conducted at the start of every shift or after a change of operator. Even if the truck appears fine, hidden defects like hydraulic leaks or worn brakes can develop.

Frequently Asked Questions

Common questions students ask about this topic

Before You Start

Prior knowledge that will help with this topic

•Basic understanding of health and safety regulations in the workplace, such as the Health and Safety at Work Act 1974 and PUWER 1998.
•Numeracy skills to interpret load capacity charts and calculate load centres.
•Physical fitness and coordination to safely operate forklift controls and perform manual handling tasks.

Key Terminology

Essential terms to know

know how to select, transfer and position loads using a fork lift truck, be able to select, transfer and position loads using a fork lift truck

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Select, transfer and position loads using a fork lift truck

Assessment criteria

Topic Overview

Key Concepts

Learning Objectives

Assessment Criteria

Assessment Guidance

Common Mistakes

Frequently Asked Questions

Before You Start

Key Terminology

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