TLILIC2002A Licence to Operate an Order Picking Forklift Study Guide

Transcription

1 TLILIC2002A Licence to Operate an Order Picking Forklift Study Guide Page 1

2 Contents A note from the TAG team.3 Introduction.3 Legislative requirements.4 Fundamental principles 5 Planning your work 14 Conducting routine checks 23 Shifting a load safely. 32 Shutting down and securing the order picker. 38 Site inspection checklist.42 Pre-operational checklist 42 Post-start checklist.43 Shutdown and site security checklist 44 Evidence of identity guidelines.45 Study Tips Calculation Activities Page 2

3 A note from the TAG Team This course is a little differrent to most because you will need to be assessed by your trainer and then by a Workcover Accredited Assessor. In order to pass each assessment you will need to be able to conduct routine checks, operate a Order Picker safely and demonstrate a complete and thorough understanding of the principles covered within this booklet. You will also be required to complete basic calculations with the use of a calculator. Please do not hesitate to talk to your trainer or any of TRAINER ASSESSOR GROUP s friendly team members If you experience difficulties or feel that you have special requirements that will need to be catered to. It is extremely important that you use your time wisely and study your course material. In order to be ready for assessment by a Workcover Accredited Assessor you will need to know virtually everything contained within this document. When you allocate study time, try to study effectively. People learn in different ways. Some people need to read a document over and over while others need to hear it or be quizzed by a third party. Some people learn through visual stimulation such as pictures or video clips and others learn by having hands on experience. Try to use the study method best suited to your needs. The materials provided for this course have been designed to meet the needs of all learner types. Thank you for choosing Trainer Assessor Group Pty Ltd.as your training and assessment service provider. Introduction The order picking forklift is a specialised machine used to reach heights of up to 10 metres. Order Pickers are usually fitted with a pair of fork arms (also known as tynes,) and are used across many industries. Order Pickers can come in various shapes and sizes to suit a range of environments and purposes.they are mainly run by industrial sized batteries but can be fuelled by petrol, deisel, LPG. The most commonly used Order Picker is the counterbalance. In most cases, little variation exists between counterbalance Order Picker make and models and although this study guide is based on the safe use of a counterbalance, it can be easily adapted to suit a range of Order Picker types, and workplace envionments. The aim of this study guide is to inform you of what is required to safely and legally operate an Order Picker. If you have any questions or feel that you don t understand something contained in this booklet please talk to your trainer before you get behind the wheel. Page 3

4 Section 1: Legislative requirements Order Picker operations can be very dangerous if not conducted properly. For this reason it is now classed as High Risk Work (HRW.) For an employer to allow you to conduct HRW, they must first ensure that you are trained, competent, and hold a HRW licence to perform the task. Under WHS Regulations, if you want to learn how to drive an Order Picker you must first enrol into an approved course with a Registered Training Organisation (RTO.) Once you have built up the skills and knowledge required to safely operate an Order Picker, you can then apply to sit a HRW licence assessment with a Workcover Accredited Assessor. This will require for you to complete anapplication for a HRW licence form where you will need to: Provide 100 points of identification with a photo(refer to page 51) Declare that you have never had a HRW licence suspended or cancelled Declare that you have never been found guilty of breaking WHS/OHS laws Provide evidence of your formal training Provide honest answers only Once you have passed your Order Picker licence assessment, the Workcover Accredited Assessor will give you a document known as a Notice of Satisfactory Assessment (NSA.)If you wish to have your photo licence sent to you by Workcover,you must make sure that you lodge the NSA at the Post Office within 60 days of the date of issue. If you fail to lodge the NSA within 60 days, it will become null and void, and if you still want your licence you will need to go through the training and assessment process all over again. Once you have your HRW photo licence, it will be your responsibility to remain competent and up to date. This will ensure that you are able to fulfill yourresponsibility under WHS Laws to work in a way that is safe for you and others. If you ever find that you are no longer competent to safely complete order picker operations, it will be your responsibility to either hand your HRW licence back to Workcover Page 4

5 (or the WHS regulator in your state) or, organise to undergo further training to refresh your skills and knowledge. This is important as it will help to ensure the safety of yourself and others. If you were to be found working in a way that endangered either yourself or others, you could be penalised under WHS Laws. You could have your HRW licence suspended or cancelled, Workcover may refuse to renew your licence, you could be fined and if your actions were dangerous enough, you could even be inprisoned. As long as you do the right thing and remember your training you will be eligible to renew your HRW licence every five years. Make sure that you always have a current HRW licence avaliable for inspection whenever you carry out forklift operations. Section 2: Fundamental Principles Driving an Order Picker is not the same as driving a car. To be abe to operate an order picker safely you wll need to understand and be familiar with the fundamental principles explained in this section. Failure to comprehend any of these concepts can result in severe accidents. If you have difficulty understanding anything in this section please talk to your tainer BEFORE you attempt to operate an order picker. Forward point of balance (fulcrum) of an Order Picker The word fulcrum is just a fancy term used to describe the balance point of the forklift.the forward point of balance (or fulcrum)of an Order Picker is where a vertical line passing through the centre of the load bearing axle meets the ground. The fulcrum is very much like the axis of a see-saw. Each side of the see-saw can go up or down depending on the amount of weight resting on either side, but the axis always remains firmly positioned in the centre and touching the ground. When it comes to a Order Picker, all the weight behind the fucrum is acting as a counterweight (or anchor) for the load that you intend to lift. If the weight at the front of the fulcrum (the weight of the load) starts to exceed the weight behind the fulcrum (the counterweight,) the front tyre will start to lift up off the ground and the Order Picker will tip Backward. Your reat tyres will remain firmly planted on the ground. Page 5

6 Never add additional counterweights to a order picker without getting permission from the manufacturer. The counterweight has been carefully designed for that specific make of order picker and adding more weight can result in an accident. Load centre distance Order Pickers are a little bit like people. When we go to pick something up that is reasonably heavy we try to keep the weight as close to our bodies as possible. By holding the weight close to our bodies we find that we can safely manage the load. If we start to extend our arms out and move the weight forward away from our bodies, we start to struggle. All of a sudden the weight that was quite manageable, starts to put strain on our arms and our back and although the actual weight has not changed, that one action of moving the weight away from our bodies has caused us to overload ourselves. This same principle applies to Order Pickers but is instead known as load centre distance. Load centre distance is the distance measured from the vertical face of the loading platform to the centre of gravity of the load. To work out load centre distance, find the balance point of the load (this will be the load s centre of gravity) and measure the distance from this point back to the vertical face of the forks. Example A In this diagram, the total load length is 1400mm (shown across the top,) and the dotted line is indicating the centre of gravity of the load. If we measure the distance from the centre of gravity of the load back to the vertical face of the loading platform we will know that our load centre distance for this particular load is 700mm. Page 6

7 Example B In this diagram, the total load length is 1200mm (shown across the top,) and the dotted line is indicating the centre of gravity of the load. If we measure the distance from the centre of gravity of the load back to the vertical face of the loading platform we will know that our load centre distance for this particular load is 600mm. Example C In this diagram, the total load length is 1000mm (shown across the top,) and the dotted line is indicating the centre of gravity of the load. If we measure the distance from the centre of gravity of the load back to the vertical face of the loading platform we will know that our load centre distance for this particular load is 500mm. In the above examples, calculating load centre distance was as simple as halving the length of the load because the loads were evenly distributed and resting against the vertical face of the loading platform. Unfortunately you won t always have an evenly balanced load, sometimes one end of the load will be heavier than the other. The good news is that you can still measure the distance between the vertical face of the loading platform and the centre of gravity of the load to work out the load centre distance. Always position the heavier end against the vertical face of the loading platform to ensure maximum stability for your order picker and your load. It is very important that each load you pick up is resting against the vertical face of the loading platform. If the load is not positioned against the tynes correctly, the load centre distance will be increased. Just like people, moving the weight further out will result in the capacity to lift being reduced, and if the load is heavy enough, the order picker to become overloaded and tip Backward. Most standard wooden pallets are exactly 1200mm long, and most order pickers have a specified load centre distance of 600mm.This can be very helpful in determining load centre distance and working out whether or not the load is within the capacity of the order picker. Page 7

8 Rated capacity As mentioned previously, Order Pickers are similar to people when it comes to the ability to lift things. We cannot all lift the same amount of weight and our ability to lift and carry weight will vary according to the way we hold the load. For example, if I can safely carry 25kgs close to my body, that does not necessarily mean that I will be able raise and carry that same 25kg up above my head. The same principle would apply if I was to take the weight forward and away from my body, off to the side of my body or if I was to get up onto my tippy toes. Essentially, these are the same types of actions that can affect the lifting ability of a order picker. In most cases a order picker will have one standard hydraulic functions. That will be to raise the work platform and tynes up and down It is very important to know what your order picker is capable of lifting and under what circumstances. To determine what your order picker is capable of lifting look for a metal plate attached to it known as a data plate. The data plate will tell you the amount of weight that you can carry under different circumstances. Don t be tempted to just look at what your order picker can lift under ideal conditions, look at what it can carry under all possible circumstances otherwise you may end up having an accident. If the data plate is missing or unreadable you will need to take the key out of the machine, place an out of service tag on the order picker and tell your supervisor. Never operate a order picker if the data plate is missing or unreadable. The data plate for each order picker model will be formatted differently. Sometimes it may take a few minutes of looking at it before you understand what it s rated capacity is. DO NOT operate the order picker until you have worked out the maximum amount of weight that your order picker can carry at different heights, load centres and with the use of attachments fitted. Page 8

9 Example 1 Order Picker Data Plate Serial No: D MAXIMUM RATING WITH MAST IN VERTICAL POSITION WEIGHT LOAD HEIGHT CENTRE 2000kg 600mm 4000mm 1500kg 600mm 4500mm In the above example the rated capacity of the order picker can be affected by load centre distance and height. For example if this order picker was to lift a load that has a load centre distance of 600mm with the mast in a vertical position to a height of 4000mm the total amount of weight it can carry is 2000kg. If this same order picker was to lift a load that has a 600mm load centre distance and raised the load to a height of 4500mm in a vertical position, the order picker would only be able to carry 1000kg. The simple action of raising the loading platform to the full extent significantly reduced the order pickers ability to safely carry loads. Page 9

10 The stability triangle A forklift has a three point suspension system that is called the stability triangle. The stability triangle is formed by the front axle (drive wheels touching the ground) and the centre mount point in the middle of the rear (steer axle.) The centre of gravity in the stability triangle is like a ball floating in water and can therefore move with ease. The centre of gravity moves when the driver lifts, lowers, tilts, turns, accelerates, brakes and move over uneven surfaces. This movement is ok as long as it remains within the triangle. If any of these actions are done too quickly or incorrectly, the centre of gravity will move outside of the stability traingle, overbalancing the forklift, and causing it to tip.. If the centre of gravity moves forward and outside of the stability triangle, the order picker will tip lengthways (also referred to as longitudinal tipping.) Page 10

11 If the centre of gravity moves to the side and outside of the stability traingle the order picker will tip over sideways (also referred to as lateral tipping.) Preventing a backwards tip Always assess the weight of the load before lifting it. If the load is more than what the order picker data plate says that you can safely lift, you will overload the order picker and it will tip backwards. Don t be tempted to just look at the weght of the load, work out the load centre distance aswell. If the load centre distance is too great, the order picker may tip backwards. An increase in load centre can be due to the load being extra long, the load not being hard against the vertical face of the loading platform, the load being unbalanced or the load shifting backwards. All of these increases in load centre distance can cause your order picker to tip backwards. Always travel at a safe speed and avoid sudden braking. Most workplaces have a speed limit, this is not only to ensure the safety of pedestrians but also the safety of the operator.travelling at speed and/or heavy braking can cause the order picker to tip backward even if you are not carrying a load. Page 11

12 Make sure you use extreme caution when operating on sloping or uneven surfaces. If you are driving up or down a ramp, make sure that your fork tynes are facing uphill. If you drive the wrong way on a ramp, you could risk tipping your order picker backwards. Uneven surfaces can also cause the centre of gravity of the order picker to move outside the stability triangle, resulting in backward tipping so make sure you reduce your speed as necessary. Whenever the loading platform and tynes are rasied the stability of the order picker will be reduced. Travelling with raised loading platform and fork arms, particuarly with a load can not only result in a loss of load at heights but can also cause the order picker to tip backward. Travelling with a raised load Preventing a sideways tip It is important for the load to be evenly balanced on your order picker tynes as an unevenly distributed load can cause your order picker to tip over sideways. Uneven distribution can be caused by a load being poorly positioned on your fork arms, the load itself being unevenly distributed, a load shifting sideways, or the sideshift attachment not being centralised before travelling with a load Being silly enough to lift a load on one fork arm will also cause uneven load distribution.never attempt to pick up a load with only one of the fork arms. This can cause stress and damage to the fork arm and can cause the order picker to tip over sideways. Page 12

13 Travelling, turning and braking at a safe speed is important for maintaining the sideways stabiity of your order picker. If you travel too quickly either loaded or unloaded, turn too quickly or brake while turning you could risk tipping your order picker sideways. Make sure that you travel slowly and in a straight line when you are approaching a load, rack or stack with your tynes raised. The stability of the order picker is reduced when travelling with a raised loading platform and there is a risk of your order picker tipping sideways. Never turn with a raised load or tynes as this action could also cause your machine to tip sideways. Make sure you use extreme caution when operating on sloping or uneven surfaces. Turnng on a ramp or sloping surface can be cause for your load to shift and your order picker to tip over sideways. Travelling over uneven surfaces can also cause the centre of gravity of the order picker to move outside the stability triangle, resulting in sideways tipping. Always reduce your speed to suit the operating conditions. Although most order pickers use solid rubber tyres, there are a few that still use pnuematic (inflatable) tyres. If your order picker has pnuematic tyres make sure that you check that they are properly and evenly inflated as an underinflated or flat tyre can cause your order picker to tip over sideways. Page 13

14 Rear end swing Order Pickers steer with their front tyre, which is very helpful when handling heavy loads in tight spaces but can be very dangerous if the operator does not understand the principle of rear end swing. When you turn your steering wheel, everything behind the front axle will swing out. This is refered to as rear end swing. Rear end swing travels at almost three and a half times the speed of normal travel. The weight of the load at the back of the order picker combined with the speed of the sideways movement can result in a risk of people or property near the order picker being hit. It is therefore very important that you correctly judge how much space will be required when you want to make a turn and that you carefully control your speed and steering. Section 3: Plan Work In this section you will learn how to: Identify workplace hazards Apply hazard control measures that are consistent with legislative standards and workplace requirements Select a forklift that is appropriate for both the work environment and the loads to be moved Determine a suitable path of movement for the forklift and load Identify appropriate communication methods that are consistent with workplace procedures Hazard Identification A hazard is anything that has the potential to cause harm or damage within the workplace. It is important to identify any hazards before you start work so that you can take action to reduce any possible risks posed to you and your co-workers. Page 14

15 If you are unable to reduce the risk of a hazard on your own, try talking to different people at your work that might be able to help such as your supervisor, co-workers, safety officers, WHS representatives and/or site engineers. It is also important to know about the safe operating procedures in place at your worksite before you begin forklift operations. Usually an employer will put you though induction training prior to you commencing work so that you know what the safe operating procedures are for your particular workplace. If you work in an environment that is constantly changing (such as a construction site) or if you go from site to site as part of your work (such as a truck driver) make sure you talk to the person in charge of the site or a safety officer before starting work. These people can let you know what the safe operating procedures are for that particular environment. The easiest and most effective way for you to identify hazards each and every day is to inspect the site before you actually start to operate the forklift. This is very important as hazards may change from day to day and it will give you the opportunity to reduce the risk of harm or damage occurring. Page 15

16 Try to do your site inspection systematically so that you don t accidentally miss anything. The easiest way of doing this is to break your inspection up into zones so that you can find: Overhead hazards Outdoor hazards Hazards at an eye level Hazards at a ground level Hazard control It is not enough to just identify a hazard. Both you and your employer need to take action to try and reduce the risk of hazards prior to commencing operations and whenever one is found. The Hierarchy of Control is a prioritised list ofactions and methods available to reduce the risks of hazards in your workplace. It is in order of the most effective method through to the least effective method. When you find a hazard you should therefore always start at the top and only move down to the next level if you have no other options available to you.you will find that in most cases a combination of methods will be used together.the diagram above shows the six steps in order of effectiveness. Page 16

17 You have more than likely come across the application of the hierarchy of controls throughout your work life and probably even applied control measures in line with the guide without even realising it. Here are some basic examples to help you understand how it works: Elimination- Remove the hazard completely. By removing the hazard, you will be removing the risk. This can be as simple as picking up a broken pallet board and putting it in the bin or cleaning up a leak on the warehouse floor. These types of actions allow for you to eliminate the hazard and therefore eliminate the risk posed by it. Substitution- If you cannot remove the hazard, try to use substitution to reduce the risk. For example, internal combustion engines give off toxic carbon monoxide gas and can kill a person if used in an area that has limited or restricted air flow. If you were required to operate a order picker in a restricted space you could substitute your internal combustion engine order picker with a battery powered machine. By substituting the equipment you are using, you are removing the hazard and the risk. Isolation- If you cannot use elimination or substitution to control the risk of a hazard, you should try and isolate it. A vehicle and/or pedestrian exclusion zone marked with yellow paint, bollards or witches hats are prime examples of isolation. By isolating a hazard, exposure to the associated risk can be reduced. Engineering controls- If you cannot eliminate, substitute or isolate the hazard, try to use pieces of equipment or tools that have been specially designed to reduce the risk of the hazard. For example, guards around the base of pallet racking reduce the risk of the structure falling in the event of a collision. Conveyer belts help to reduce the risk of manual handling injuries. Reversing beepers, flashing lights and horns on order pickers help to prevent collisions with pedestrians and vehicles by alerting others to their presence. The order picker itself is an engineering control. It is a piece of load shifting equipment designed to reduce the risk of manual handling injuries. Page 17

18 Administrative controls- If you cannot eliminate, substitute, isolate or use engineering controls to reduce the risk of the hazard, try to use administrative controls. Essentially, administrative controls are safe work practices developed and taught to minimise the risk of a hazard. This option is heavily reduced in effectiveness as it does not remove the hazard, it only minimises the risk. For example, a company works hard to reduce the risk of manual handling injuries but some items must still be moved by hand. The company then teaches employees safe manual handling techniques. Virtually every safe operating procedure you have ever followed in the workplace is an administrative control. Personal Protective Equipment (PPE) The very last option available to you to control the risk of a hazard is PPE. For example, use ear muffs around noisy machinery, hard hats where there is a risk of falling objects, or safety vests when pedestrians are working around order pickers. Always choose your PPE and other safety equipment when you are planning your work and check that it is still in good condition before using it. Always make sure you use it as it was designed, otherwise it may not actually reduce the risk of the hazard. Controlling the risk of working near power lines There may come a time where you will have to work near power lines. This is very dangerous and the risks of this hazard need to be controlled prior to starting work. To begin with, you will need to contact the power company to determine the voltage of the lines. You will need to make sure that you don t get too close to live power lines as the electricity may arc and electrify your order picker even if you don t actually make contact with the lines. The distance that you will need to maintain will vary according to the voltage of the lines. In NSW you will need to make sure that your loading platform and mast stay at least: 3 meters away from lines that are under Volts 6 meters away from lines that are between Volts and Volts 8 meters away from lines that are Volts and over If you are required to work any closer than the distances shown above, you will need to make arrangements to have the power shut off or the lines covered with insulation prior to commencing work. In some states and territories it may also be legal for you to work within the exclusion zones if a certified safety observer is present to act as a guide. This is a state/territory specific law so make sure that you check with the relevant authority first. Insulation will prevent arcing Page 18

19 When you are working around power lines, tiger tails (black and yellow pipes) should be wrapped around the lines to increase visibility. Be aware that tiger tails are a warning device are not an insulation device and will not prevent the lines from arcing. If for some reason you happen to make contact with power lines take the following actions: Warn others to stay 8m away. Try to break contact with the lines by attempting to adjust the height of your loading platform, or moving your order picker in a forwards or reverse motion (this is safe to do as long as you do not touch any metal in the process.) Remain in the vehicle until conditions have been made safe. This is actually the safest place for you. If the conditions worsen and you have no choice but to the leave the vehicle, jump without touching the ground and the order picker at the same time (without earthing) and shuffle or hop 8m away with both feet together. Page 19

20 Controlling the movement of people, vehicles and mobile plant If you are working in an area that has people, vehicles, or mobile plant moving about, you should put control measures in place to warn and direct them before actually starting the work. Some of the things you could do to control the risks include: Setting up fences or barricades Erecting signs to notify others of the danger Setting up flashing yellow lights Getting a traffic controller to warn and direct other people, plant and vehicles Setting up scaffolding, hoarding or gantry Creating vehicle and/or pedestrian exclusion zones Page 20

21 Controlling the risk of working in restricted spaces Working within an area that has limited or no air flow can be dangerous if the correct equipment is not used. The use of order pickers that are fueled by either petrol, diesel or gas(which is very rare)these are called internal combustion engines and give off carbon monoxide gas which is toxic and can cause death within a restricted space in as little as twenty minutes. You should therefore only use electric (battery)powered order pickers in restricted spaces. Electric (battery) order picker You will also need to be careful when you recharge the battery in your electric order picker. The charging process produces hydrogen gas which can cause an explosion if it builds up. You should therefore only recharge batteries in well ventilated areas. Always check the electrolyte levels in the battery after it has come off charge and top up with water if need be. Things that are not site hazards that you need to consider when planning your work There are a range of things that are not necessarily site hazards that you may need to consider when you are planning your work. Some of these things may be: order picker capacity Make sure that you have checked the data plate on your order picker and that each load you plan to pick up is within the rated capacity of that particular vehicle. Page 21

22 Load characteristics Make sure that you assess each and every load before attempting to lift it. Don t just assess it against the rated capacity of your order picker, have a look at the height, width, stability and security of the load as well. You may find that you will have to approach the lift differently according these characteristics. If the load is badly packed, get off your order picker and re-stack it before you lift it. If the load is too high or wide and obscures your vision, you might find that you will need to reverse with the load or will need to find someone to safely guide you. Entry and exit points to and from the load Make sure that you can safely access the load. You need to be able to get in under the load, and get out from underneath the load once you have placed it into position. Move anything obstructing your access and plan your path of travel before you actually lift the load. Equipment needed to shift the load Sometimes your load will be prepared and ready for you to move without the assistance of any extra equipment. At other times you will need to collect the correct equipment yourself. You may need to collect extra pallets, shrink wrap or strapping, or you may need to get hold of communications or tracking equipment such as CB s or RF units (scanners.) Permits In some cases you may need to have a special permit to carry out the work. This may be because the work is being completed on a construction site or in a public place or it may be because of the nature or quantity of goods being moved (for example certain classes or quantities of dangerous goods or hazardous substances.) Communication You may need to communicate with other people prior to the commencement and throughout the course of you work for a variety of routine and non-routine reasons. This may be by way of signage, written instructions, hand signals and gestures,or listening and asking questions. Page 22

23 Section 3: Conduct Routine Checks In this section you will learn how to: Check harness and lanyard for damage and to appropriate standards Check the order picker for any damage or defects Identify and interpret labels and signage according to appropriate standards Locate and identify controls Conduct pre-start operational checks according to procedures Start the order picker and check for any abnormal noise Conduct post-start operational checks according to procedures Check all order picker functions and safety devices according to procedures Take appropriate action if damages or defects are found After you have inspected your work site, chosen the appropriate order picker and made any preparations required to complete your work safely, you will need to inspect your safety equipment and order picker. This process does not take a long a time and can be a key factor in reducing accidents, damage and even death within the workplace. Each order picker and harness will be different but the diagrams on the following pages can provide you with a general guide of what you should be visually checking before you put on the harness and start the machine. Page 23

24 Pre-start Checklist Guide This guide is in relation to the diagram on the next page. 1. Battery security and Electrolyte level 2. Beacon fitted 3. Hydraulic fluid 4. Emergency lower valve 5. Hoses, chains and pulleys 6. Mast assembly 7. Safety rails 8. Data plate 9. Controls 10. Tyres 11. Fork arms 12. Pallet grab 13. Overhead guard 14. Check for any leaks Also if fitted will have to check rear gates fitted and also check your harness and lanyard as shown in the diagrams on the following page. Page 24

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27 Safety equipment is identified and checked for workplace safety. Safety equipment is important to keep operators safe in case of any incident in the workplace. Here is a list of equipment we may need to use. Safety Harness Energy absorber Lanyard Anchor points Safety Boots PPE As a safe and responsible order picker operator you will be required to wear a safety harness at all times will performing order picker operations. Part of wearing a safety harness is to first visually inspect the harness for signs of damage before putting it on and also making sure it is fitting properly so it can do its job in case of an accident or fall from the platform. A few minutes of your time might just save your life so take the time to inspect your harness before each use and look for the following. Webbing Look for cuts, stretching, tears and abrasions Damage from heat, corrosive liquids or solvents Deterioration from rotting, mildew or exposure to the sun Attachment Hooks Corrosion or rust Distortion Broken or weak springs cracks or visible damage Hook swivel points Page 27

28 Buckles and Adjustments Cracks or visible damage Open rollers General distortion Bent or damaged Tongues Stitching and sewn areas Damaged, missing or loose stitching Cuts Frays Damage from heat corrosion or mildew D-Rings Vertical movement of the D-ring Cracks Distortion Physical damage Excessive wear of the D-Ring Also Check the expiry date of the Safety harness and Lanyard as they have a 10 year life span before the need to be re-tested. Try to do your pre-operational check systematically so that you don t accidentally miss anything. The easiest way of doing this is to break your inspection up into zones so that you can locate and check: Everything on the exterior (outside) of the vehicle Everything within the operator s cab Everything inside the engine bay Page 28

29 Checking the outside of the order picker If you begin at the front of your order picker and make your way around the vehicle until you get back to where you started you will be able to locate and check that: The beacon is fitted The battery retainer and electrolyte levels The hoses chains and pulleys The mast assembly Safety rails are fitted Data plate Controls The tyres are in good condition and the wheel nuts are secure. If the tyres are pneumatic you will need to check for inflation as an underinflated tyre can cause your order picker to tip sideways. If the tyres are made of solid rubber, you will need to check that there are no big chunks of rubber missing, there is enough tread, the tread is evenly worn and there are no cracks in them. Fork arms for any cracks, bends or sharp edges Pallet grab Overhead guard Warning decals (stickers) are on the order picker and you understand them. Check for any leaks You must mount the order picker on the side away from the traffic using three points of contact An example of a common warning decal found on forklifts Page 29

30 Do not start the machine if you find any damage or defects during your pre-operational check. Prevent others from starting it by removing the key and placing an out of service tag on the machine. Tell your boss what you have done and why. This process is often referred to as the 3T s. Anytime there is anything wrong with your order picker: Take the key out Tag as unsafe Tell the boss By following the three T s you will be able to isolate the machine, alert others to the dangers present and help to organise for the machine to be fixed as soon as possible. In cases where the repair required is minor you may be able to fix it yourself as long as you are competent to complete the task and your employer has given you permission to do so. Post-start checks Once you have completed your pre-operational checks you can go ahead and conduct what is referred to as post-start checks. The word post just means after, so post-start checks can be thought of as things that you must check after the machine has been started. Again, try to be systematic in your approach so that you don t miss anything. Climb in on the left hand side using three points of contact. Your left hand should be on the assist grip handle, your right should be on either the frame of the order picker or the safety rail. Your foot should be on the loading platform. Attach the harness to the anchor point and give a little pull to make sure it is secure. Check lights in the cabin to make sure they are working properly. Page 30

31 Turn on the key and make sure you are not standing on the dead man switch Check your gauges are all working and no warning lights flashing (Steering, Battery.) Check your dead man switch is working (try to move with it on and then try to move with it off.) Check your safety rails (try and move forwards and backwards with each rail lifted on its own.) Check the pallet grab opens and closes properly. Make sure your Horn and beacon are working properly. Check over both shoulders, beep horn twice then reverse backwards checking your steering to its full extent in both directions Have a look forward to see if there are any leaks on the ground where your order picker had been sitting Check that your reversing beeper comes on Now raise up till you hear the lift lockout (three Beeps and check if you can move forward and backwards at height. Check the full extent of all your hydraulic functions Now check your emergency disconnect on the way down (by pressing the button in whilst traveling down.) Do not continue to drive the machine if you find any defects or hear an abnormal sound during your post-start check. Prevent others from starting it by removing the key and placing an out of service tag on the machine. Tell your boss what you have done and why. In other words, do the 3T s. Take the key out Tag as unsafe Tell your boss Page 31

32 Section 3: Shift Load In this section you will learn how to: Assess the weight of a load to ensure compliance with the Order picker data plate specifications Apply appropriate hazard prevention/control measures and communicate with personnel in the work area Operate the forklift at a safe speed and according to procedures Monitor load movement, ensuring the safety of personnel, the load and structures Respond to unplanned and/or unsafe situations in line with procedures Assessing the weight of a load against the data plate specifications It is extremely important to assess the weight of a load and work out whether or not your forklift can carry it before you actually attempt to lift the load. If you don t do this you may find yourself in a situation where your forklift becomes overloaded and tips forward. Needless to say, this can cause severe injury and possibly death to either you or other people in the area. If you are unsure of the weight of the load, have a look to see if there is a label on it. Many palletised loads will have a label describing the contents and weight. If this isn t possible, have a look at the stock and see if you can calculate the total weight of the load by working out the weight of one of the cartons and multiplying the weight by the total number of cartons on the pallet. Don t forget to factor in the weight of the pallet. Sometimes you might need have a look at the paperwork that came with the load to find out the weight. You could look at consignment notes, weigh bridge certificates, invoices or packing slips. You could also look at what is listed in the company database. Some forklifts may also have a set of scales built into the fork arms. If this is the case, you may also have the option of weighing the load. In many cases, forklifts equipped with this function will prevent the operator from picking up any load that is too heavy for that particular forklift. Once you have worked out the weight of the load, you will need to assess it against the data plate specifications. Remember that it is important to not just work out the weight of the load but also it s load centre distance. Page 32

33 Load stability If you come across a poorly stacked load, don t be afraid to get off your forklift and re-stack it. The longer the unstable load sits around the workplace, the higher the risk to people working near it. Always monitor the load you are carrying. You want to make sure that theload remains stable, doesn t shift, and does not fall and hurt people near the forklift. If the load starts to shift, lower it to the ground straight away. This will hopefully stop it from collapsing completely and if you are working at full capacity, it will also stop the forklift from tipping as the load falls. Shifting a load Travel height of fork arms and/or load When travelling in a order picker you will need to make sure that your fork arms and/or load are as low to the ground as possible but make sure they are not so low that they will scrape the operating surface. You can use axle height as a rough guide while you are still learning. If you fail to have your fork arms at an appropriate travel height you will risk tipping the order picker either forwards or sideways. Choosing your path Make sure that you work out the path that you plan to travel ahead of moving. This way you can identify hazards and control them, avoiding possible accidents and/or damage. Some of the things that you may need to consider when choosing your path of travel could be: whether there are any ramps or sloping surfaces along the way, suitability of the path, whether your order picker and load will fit, whether there will be pedestrians along the way, whether you will have to go through doorways or whether there are any blind corners along the way. Page 33

34 Reversing safely Before reversing, make sure that you check over both shoulders before you actually move. When you do your shoulder checks, make sure that you actually look behind you and ensure that your path is clear.if you have mirrors fitted, check your mirrors but try not to rely on them-they often have blind spots. Also make sure that all of your warning devices are working correctly (your reversing beeper, the flashing yellow light, and the horn.) These devices help to alert others of your movements.if you find that you cannot see properly to safely reverse, ask somebody to guide you.in many cases, the difference between a safe operator and an unsafe operator is the ability to look prior to reversing. Using your horn Your horn is fitted so that you can use it as a warning device as you travel around the workplace. Make sure that you slow down and use your horn as you approach doorways and blind corners. The horn can also be used in the event that you want to warn pedestrians or other vehicles. Operating on ramps or sloping surfaces It is quite safe to operate on ramps or sloping surfaces as long as you take into account the reduction in your order pickers stability. When travelling up a ramp make sure that you travel in a reverse motion, and If you are travelling down a ramp, make sure that you travel in forward. As long as your fork arms always face uphill your order picker will remain stable. This is both if you are loaded or unloaded. You want all of the weight behind the fulcrum (the counterweight) to be on the decline. Never turn on a ramp or sloping surface, it can cause your order picker to tip sideways and/or the load to shift and fall. Page 34

35 Operating on wet or slippery surfaces If you are required to work on a wet or slippery surface make sure that you slow down. Take extra care and avoid heavy braking or sharp turns. If you can, avoid using ramps or operating on uneven surfaces. A order picker can lose traction on slippery surfaces which can result in a loss of control in the steering and brakes. Operating near pedestrians Never lift a load near or over people. It is extremely dangerous. If the load was to shift and fall, the people underneath would be killed. By the same token, do not allow for anybody else to rasie a load over the top of you. You have every right to tell them that this sort of practice is unacceptable, unsafe and against Regulations. Carrying a passenger on a order picker You can only legally carry a passenger on a order picker is if the machine has been specifically designed to do so. Order pickers designed for two people are extremely rare but will be specified by the manufacterer.it is not permissible for a person to hang off the side of a order picker, ride on the tynes of a order picker or be raised on the tynes of the order picker. Lighting Make sure that all of the areas you plan to work in have adequate lighting. The lights on the order picker will not usually be adequate to work in the dark, at night or in a dark area. Stacking loads (This is not done with your standard order picker) When you are stacking loads on top of each other you will need to make sure that you only stack loads on a solid, level surface. Make sure that the heavier goods are at the bottom of the stack and that the lighter stock is placed at the top. If you place heavy items on top of light items the stack will become unstable and will collapse. Make sure that you only ever stack loads in a way that is stable and balanced. If the loads are not positioned squarely on top of each other or if the stack becomes too high, it will become unbalanced and may fall. Page 35

36 These same rules will also apply if you are placing stock into pallet racking. Additionally, you will need to make sure that the pallet racking is able to safely hold the weight that you are putting into it. You can find the safe working load (SWL) of the rack by looking for a sign on the side of the racking uprights. Responding to unsafe situations If you have an issue with your steering, brakes or hydraulics Although pre-operational and post-start checks will reduce the likelihood of you having a problem with your brakes, steering or hydraulics, occassionally things can go wrong. It is always good to know what to do in an emergency situation ahead of finding yourself in that position. Electric order pickers Electric order pickers have an isolation or kill switch which the operator can press in order to cut the power to the machine. If you ever have a problem in an electric order picker this would be the most appropriate response. Once you have isolated the power, attempt to follow normal parking procedures, take the key, tag the machine as unsafe and tell your supervisor what has happened. Unfortunately not all order pickers are electric so if you are driving a order picker with an internal combustion engine you will need to use the following as a guide. Page 36

37 Loss of brakes If the brake pedal loses pressure or the brakes lock up and you find that you are unable to stop, gently apply the handbrake. In addition to normal parking procedures, take the key, tag the machine as unsafe and tell your boss. Steering If the order picker becomes difficult to steer or you lose control of the steering, stop the order picker. In addition to normal parking procedures take the key, tag the machine as unsafe and tell your boss. Hydraulics If the hydraulics stop working or become unresponsive stop the order picker. Try to lower the load. order pickers are usually fitted with a releasing system that will allow you to lower the tynes even if the machine is not running. If it is not possible to lower the fork arms, barricade the area so that people are unable to pass underneath the suspended load or fork arms. If you can, follow normal parking procedures and then take the key, tag the machine as unsafe and tell the boss. If your order picker starts to tip sideways If your order picker starts to tip sideways make sure you DON T jump. In most sideways tipping cases where severe injuries or death has occurred, it is because the operator jumped from the order picker and the vehicle rolled on top of them. You need to instead brace yourself by pushing your feet into the floor and holding onto the steering wheel. Try to lean in the opposite direction to the way the order picker is falling. If this is not possible lean over the steering wheel. Keep all of your body parts within the confines of the cab and wait until the order picker stops moving before you get out. Page 37

38 Responding to an emergency situation Workplaces will have their own policies and procedures for what communications should be made in an emergency situation and to whom they should be made. As a general rule you will need to alert and warn other workers in the area and let them know of any unsafe areas. You may also be required to alert your supervisor and emergency services and let them know what has happened, any possible unsafe areas, and what sort of assistance is required. Don t forget that in an emergency situation you are required to give right of way to all emergency services. Section 5: Shutdown and secure forklift In this section you wil learn how to: Park the order picker in a way that avoids hazards Shutdown the order picker according to procedures Conduct routine post-operational checks on the order picker according to procedures Secure the order picker to prevent unauthorised access and or/use Take action if any defects or damage is found Once you have finished operating your order picker you will need to follow standard shutdown procedures. Shutdown procedures include everything from finding a suitable place to park, through to conducting a post-operational check. Finding a suitable place to park Once you have finished operating your order picker you will have to find a suitable place to park. It is extremely important that you do not park infront of any area that may need to be accessed in an Page 38

39 emergency sitatuation, in places that may obstruct other traffic, or in places that may pose a risk to the safety of others. Although each workplace will be different, the following will give you a good idea of where you should not be parking your order picker: Infont of first aid stations Infront of fire fighting equipment Infront of emergency showers Infront of emergency exits In doorways On pedestrian walkways In areas that would obstruct other traffic On sloping surfaces Within 2 metres of the nearest rail of a railway track Although your should not park an internal combustion engine infront of refueling sites, an electric order picker may need to be parked infront of a refuelling site in order to connect the battery to the charger. If you ever find yourself in a situation where you have no choice but to park on a ramp or a sloping surface, make sure that in addition to following normal parking procedures you chock the wheels. Normal parking procedures Once you have found a suitable place to park, you will need to follow normal parking procedures. Although each order picker is different the following can be used as a guidline: Lower the loading platform and tynes so that they are resting flat on theoperating surface. Place your order picker controls into nuetral position. Apply your hand brake Remove the key from the order picker (this will prevent people who are unauthorised from using the order picker) Page 39

40 Post operational checks The word post just means after so post-operational checks are checks that you need to make after you have finished operating the order picker. After you have chosen a suitable place to park the order picker and followed the normal parking procedures, you will need to climb out of the order picker safely. Just like when you climbed into the order picker, dismounting will need to be done from the left hand side and with three points of contact. It is important to climb out facing the order picker itself as this will ensure that you can comfortably manage your own body weight and avoid injury. Again be systematic, start at the front and walk around your vehicle in a clockwise motion until you get back to where you started. As previously discussed, being systematic in your checks will ensure that your post-operational check is efficient and effective. During your post-operatational check you are just doing a visual inspection to ensure that: No damage occurred during the course of your shift No leaks are present All of your systems are shut off (a leaking LPG valve can cause an explosion and lights left on can drain a battery) The order picker is safe for the next user Page 40

41 If you find a defect or any damage during your post-operational check you will need to take the key out, tag the order picker as unsafe, and tell your supervisor.in other words, do the 3T s: Take the key out Tag as unsafe Tell your boss Depending on your workplace procedures and rules you may have additional responsibilities after conducting the post-operational checks. This may include updating the operator s logbook, connecting the battery up to a charger (if electric) or refuelling the machine for the next user. Page 41