Training Manual. TLILIC2001 Licence to Operate a Forklift

Transcription

1 TLILIC2001 Licence to Operate a Forklift Training Manual TLILIC2001 Licence to Operate a Forklift PLEASE NOTE: Students who are completing the 1 Day assessment Please ensure that you complete the homework questions on pg s and bring them on the day of your training. Start time: 7.45am Participants must: Read this manual prior to attending the training program Participants must wear safety footwear (i.e. fully enclosed steel cap foot wear), shirt (high visibility if available) and long pants. It is a mandatory requirement that participants must bring photo Identification to training session i.e. Australian Drivers Licence or passport (must contain photo, date of birth & signature). Failure to provide IDENTIFICATION will result in exclusion from the course.

2 TLILIC2001 Licence to Operate a Forklift Document Name: Forklift Training Manual Document No: LF-TM-001 Last Modified Date: 29/01/2018 Access Training Centre 7 LaSalle St Dudley Park SA 5008 Ph

3 TLILIC2001 Licence to Operate a Forklift 2015 Access Training Centre. All Training Manuals and associated course material remain the property of Access Training Centre. Contents INTRODUCTION... 1 Forklift Definition... 1 Course Overview... 1 Types of Forklifts... 2 WHS LEGISLATION... 3 WHS Act and Regulations... 3 New Terms from WHS Act and Regulations 2012 (SA)... 4 Duty of Care... 4 High Risk Work Training... 4 High Risk Licence Expiry... 5 Processing HRW Licence... 5 High Risk Licence Application... 6 HAZARD IDENTIFICATION AND CONTROLS... 6 Hazards and Risks... 6 Site Hazards... 7 Other Considerations... 7 Consultation... 8 Hierarchy of Controls... 9 PLAN WORK Selecting and Inspecting Equipment Communication Emergency Situations First Aid Power Lines Forklift Operator Responsibilities Safe Operation of the Forklift Protecting Pedestrians and Vehicles Rear End Swing Using Forklifts in Enclosed Spaces FORKLIFT FAMILIARISATION Counterbalanced Fork Lift Trucks Non-counterbalanced Fork Lift Trucks Parts of the Forklift Forklift Operational Parts Forklift Passengers and Work Platforms Attachments FORKLIFT PRINCIPLES Point of Balance Load Centre Distance Rated Capacity Safe Working Load Stabilising Loads FORKLIFT ROUTINE INSPECTIONS... 31

4 TLILIC2001 Licence to Operate a Forklift Visual Checks Electrical Checks Operational Checks Fault Reporting FORKLIFT LOADS AND CALCULATIONS Load Weights Calculations FORKLIFT OPERATIONS Travelling with a Load Sideshift Feature Stability Forklift Surfaces Other Operations FORKLIFT SHUT DOWN Post Operational Checks Parking Post start checks may include the following: Shut Down and Secure Forklift Truck Refuelling the Forklift Repairs and Maintenance Appendix A Legislative Framework Appendix B Table of Masses FORKLIFT PRACTICE QUESTIONS... 55

5 INTRODUCTION This training course is based on the National High Risk Licence unit of competence TLILIC2001 Licence to operate a forklift from the Transport and Logistics Training Package. The National Standard for Licensing Persons Performing High Risk Work (April 2006) aims to facilitate the operation of nationally uniform, competency based licensing system for persons performing certain types of high risk work. Forklift Definition A Forklift Truck is defined in the WHS Regulations 2012 (SA) as a powered industrial truck equipped with a mast and an elevating load carriage to which is attached a pair of fork arms or other attachment that can be raised 900mm or more off the ground Course Overview This unit is based on licensing requirements in the WHS Regulations 2012 (SA) and requires the operator to be able to: Plan Work Conduct Routine Checks on the Forklift Shift Loads in a Safe Manner Shut Down and Secure the Equipment This unit in its current form meets state and territory licensing requirements. Any alteration will result in a unit which is not acceptable to regulators for the purpose of licensing. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 1

6 Types of Forklifts TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 2

7 WHS LEGISLATION WHS Act and Regulations South Australia's work health and safety legislation, adopted on 1st January, 2013 includes: Work Health and Safety Act 2012 (SA) The main object of the Act is to provide for a balanced and nationally consistent framework to secure the health and safety of workers and workplaces Work Health and Safety Regulations 2012 (SA) The Work Health and Safety Regulations 2012 (SA) identifies the control measures that must be applied to specific work activities and hazards that occur in the workplace Codes of Practice This legislation is supported by Codes of Practice which provides practical information, or guidance, on how to meet the requirements of the regulations. Codes of practice are not mandatory but provide information to help workplaces achieve safe systems of work. Australian Standards Australian Standards set out specifications and procedures designed to ensure products, services and systems are safe, reliable and consistently perform the way they were intended to. They also act as guidance material to achieve compliance requirements with WHS legislation. Overview of Legislation Act Duties of workplace parties Regulations Compliment and support the general duties as well as procedural and administrative matters under the WHS Act. Codes of Practice Are practical guides to achieving the standards of health and safety required under the WHS Act and Regulations.Codes of practice are admissable as evidence in court proceedings. Regulator guidance material, Australian Standards / Industry Standards, other WHS material Further guidance to assist complaince with WHS legislation. To provide 'state of knowledge' along with codes of practice. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 3

8 New Terms from WHS Act and Regulations 2012 (SA) PCBU The PCBU (person conducting a business or undertaking) is an individual or organization conducting the business. This can include, but not limited to, company bodies, trustees, government departments and partnerships. Worker A worker includes all employees, contractors, sub-contractors, employees of a labour hire company and volunteers. High Risk Work High Risk Work (HRW) applies to licence classes for specific occupations throughout the workforce. To participate in HRW a person needs to be licensed and competent to do so. Due Diligence A Worker or PCBU s due diligence includes investigating all required information, implementing all safety measures and taking all steps where possible to provide a safe working environment. Duty of Care Duty of Care means to take all necessary steps to work safely and provide a safe work place for yourself and others. Under the new WHS legislation, PCBU s and workers can be heavily fined or even imprisoned for not acting with Duty of Care. PCBU Duty of Care Provide a safe work place for all workers Provide training to all employees to work safely Make sure hazards and risks are controlled in the workplace Worker Duty of Care Follow policies and procedures of your workplace Comply with reasonable safety instructions from your PCBU or Supervisor Wear and take care of protective equipment and plant / machines Stop work if you think there is a hazard that will be a risk to your health and safety High Risk Work Training TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 4

9 Employers also must not allow a person to carry out HRW unless they are licensed and competent to do so. The only exception that allows a person to carry out high risk work is if they under direct supervision of a licensed person as a trainee and enrolled in formal training of that licence class. A person under training is a person enrolled in a course of HRW and being supervised at a workplace by a person with a current HRW licence for the work. While conducting HRW, licence holders have a responsibility to take reasonable care and not adversely affect the health and safety of other persons when performing the HRW. Failing to work safely may result in: WHS Regulators penalising licence holders by suspending or cancelling their licence, If the matter arises at renewal, the regulator may refuse to renew the licence. Fines may be imposed High Risk Licence Expiry High Risk Licenses are valid for five (5) years and holders must show that their skills are current and that they remain competent to carry out the high risk work when applying for renewal. If you have not been participating in this class of work for a period of time or are no longer competent in the required skills, you must not carry out high risk work. You can: Enrol in a training course to refresh your skills and work under supervision until your skills have been assessed If you are no longer competent and do not undertake retraining, you should return your High Risk Work Licence to the regulator Processing HRW Licence On successful completion of a High Risk assessment, a candidate will be issued with a notice of satisfactory assessment (NSA) and an invoice. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 5

10 The NSA and invoice remain valid for only 60 days from the date of issue for the purpose of making an application for a HRW licence. The invoice will need to be presented to a Service SA centre or Post Office (with photo facility) who will process your HRW Licence and mail to your address on the application High Risk Licence Application When applying for a High Risk Licence applicants have responsibilities under WHS regulations. These include providing the following information: Their name, evidence of identity (100 points) and a photograph with any application for a (HRW) licence. A copy of a certificate that they have successfully completed a unit of competency relevant for the class applied for with any application for a HRW licence Not give false or misleading information Make a declaration that they do not hold an equivalent high risk licence granted corresponding WHS law by another WHS regulator. Make a declaration as to whether or not they have ever been convicted or found guilty of any offence under the WHS act or the WHS regulations in any jurisdiction in Australia, and if so, provide the details of conviction or finding of guilt. Make a declaration as to whether they have ever entered into an enforceable undertaking under the WHS act or the WHS regulations in any jurisdiction in Australia, and if so provide details of any enforceable undertaking. Make a declaration as to whether they have ever previously had a HRW licence refused, suspended or cancelled under the WHS act or regulations in any jurisdiction in Australia and, if so, provide details of the refusal, suspension or cancelation. IMPORTANT NOTICE PLEASE ENSURE THAT YOUR NAME & ADDRESS DETAILS ARE CORRECT AS THIS IS WHERE YOUR LICENCE WILL BE MAILED HAZARD IDENTIFICATION AND CONTROLS Hazards and Risks Hazard A hazard is a thing or situation that causes injury, harm or damage. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 6

11 Risk A risk is the chance or a hazard hurting you or somebody else or causing some damage It is important to identify all hazards in the work place before work begins. Once the hazards are identified, you need to decide how great the risk is that an injury or damage will be done. If you can remove or at least control the hazard, you can reduce the risk involved. As part of your working shift it is important to check for hazards around your worksite, and also to check which travel path you will use by avoiding hazards. There could have been changes to hazards at anytime during the previous shift or working day. A good method of communication is to hold short but informative tool box talks, during which supervisors can pass on any relevant information that may affect your shift. If these are not currently utilised on your site, perhaps you could suggest this to a manager or WHS representative. Site Hazards Prior to commencing work you should carry out an inspection of the worksite to identify possible hazards. These can include: Electrical Power Lines Underground services Pedestrians and personnel Ground bearing pressure Plant and other equipment Obstructions Potential non weight bearing surfaces Wind and bad weather conditions Lighting/ illumination Overhead service lines Bridges Surrounding structures( including bridges and buildings) Dangerous materials Vehicle traffic Working At Night or In Darkened Areas When working in darkened areas adequate lighting across the entire working area must be sufficient to allow the forklift to safely conduct its operations. Other Considerations Other than site hazards, other things that need to be considered when planning tasks include; TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 7

12 Characteristics of the load Communications Entry and exit of worksite Location of task Specifics of task Permits required Equipment required Availability of equipment Blind Spots Capacity of the forklift Type of load eg: flammable, fragile unstable or hot Road surfaces Work Permits In some situations it may be necessary to obtain a work permit before commencing particular tasks in certain areas such as working in a potentially explosive environment. Work permits are required to ensure that adequate safety control measures are in place. Know Your Workplace Each workplace has conditions that can contribute to dangerous situations. Operators should inspect the workplace for any potential hazards and make sure they are eliminated or minimized before operating the Forklift. Consultation The following people need to be consulted about site hazards before commencing work in order to ensure that workplace policies and site specific procedures are adhered to. Safety officers Site engineers (where applicable) Supervisors Colleagues Managers authorised to take responsibility for workplace operations TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 8

13 It is important to consult with relevant workplace personnel and safety officers before commencing work in order to ensure that workplace policies and or site specific procedures are adhered to. Hierarchy of Controls Where a hazard is identified measures must be put in place to control the hazard prior to commencing the task and as soon as a hazard is identified during operation. Control measures, which make the workplace safe, are likely to be more effective than measures which protect employees from a hazardous worksite. When deciding how to control a hazard the hierarchy of control measures should be applied in the order listed below. When adopting measures to control a hazardous risk, the management or consultative team is responsible for selecting the controls to be implemented. Measures from the top of the control hierarchy give better results and should be adopted wherever possible. Measures from the bottom of the hierarchy are more difficult to maintain and should be regarded as interim measures until preferred ones can be implemented. Most of the time a range of controls selected from the hierarchy of control is needed to bring the level of risk down to an acceptable level. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 9

14 1. ELIMINATION Elimination completely removes the hazard and is the ideal control solution. Examples of elimination include removing the hazard completely (for example: backfilling holes and trenches promptly), ceasing to use a hazardous substance or changing a process to remove the need for a hazardous action. 2. SUBSTITUTION Substitution is where a hazard is replaced by a less hazardous alternative. For example, instead of using a hazardous item of plant or equipment, substitute it for a less hazardous item that serves the same purpose, such as; using scaffolding instead of working from ladders, using electric or approved LPG powered plant in areas with limited ventilation, etc. 3. ISOLATION Isolation involves separating the hazard from people by the use of physical barriers to contain / enclose the hazard or segregate by distance. Barricades, fencing Keeping hazardous materials out of the lunch room Segregating defective equipment 4. ENGINEERING CONTROL MEASURES The next preferred control measure is engineering control, which can include: TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 10

15 Modification of tools and equipment like guarding Local exhaust ventilation Using water to suppress dust on materials and haul roads is a common form of engineering control Providing adequate fresh air to all workers through appropriate and effective ventilation Placing and securing covers to voids 5. ADMINISTRATIVE PRACTICES Administrative control involves the introduction of safe work practices that reduce risk by limiting the exposure to the worker from the hazard. This includes measures such as; Reducing the number of workers exposed by relocation Reducing the period of exposure, Rotating workplace activities, Special procedures to be followed for the use of chemicals Evacuation procedures Placing signs Effective training Documentation such as risk assessments and work plans, policies and procedures 6. PERSONAL PROTECTIVE EQUIPMENT Personal protective equipment must be used where all other control measures have not been fully effective. Practicable efforts to remove health and safety risks using measures higher up in the control hierarchy chain should continue. It is often difficult to fully protect the worker with personal protective equipment and is generally difficult to properly maintain a personal protection program as workers can be required to wear several items of PPE simultaneously which affect comfort and restrict performance and this reduces acceptance of the equipment. Where protective equipment is used, the employer should ensure that it fits the worker correctly, that training is provided on its need and use, its limitations and that it is serviced regularly and properly stored. Where personal protective equipment is used, it must: be appropriate for the job meet the required standards fit the operator correctly come with training for the operator on its need, use and maintenance Be serviced regularly, by appropriately trained staff. The WHS Act requires that an employee shall, so far as is reasonable, use any equipment provided for health and safety purposes Example: TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 11

16 A petrol powered forklift operating in an enclosed area may present a hazard due to the production of carbon monoxide (CO). This hazard could be controlled by using exhaust ventilation to remove the carbon monoxide (engineering control), restricting the time people may work in the area (safe work practice), requiring everyone in the area to wear breathing apparatus (personal protective equipment) etc. The best method would be to eliminate the hazard by using a battery powered forklift or preventing the forklift from entering the area. PLAN WORK Selecting and Inspecting Equipment Selection of all equipment and PPE needs to be done during the planning stage of the job. You need to ensure the equipment is available when you need it and that it is appropriate to the task. Hazard Controls must be put in place before work begins. If a new hazard is identified during operation, the control measures should be applied straight away. All equipment must be inspected and tested by a competent person before use. Any faults or damage need to be reported straight away and the equipment tagged as faulty and removed from service. Communication Communication is a fundamental component in carrying out safe operations of Forklifts. As indicated previously in the training program risk assessment will identify the risks and how those risks are to be managed to ensure safe operation. Communicating information amongst all directly and indirectly affected by the work is important and required by law. Safe work procedures are required and must be available to all that are involved in the elevation process Appropriate communications methods must be selected during the planning stage and communications checked prior to commencing the task Certain factors will dictate how communication is carried out or achieved. What type of work is carried out? What type of Forklift is used? What hazards arise from the work? Communication may include but not limited to: Verbal And Non-Verbal Language TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 12

17 Written Instructions Signage Hand Signals Listening Questioning To Confirm Understanding of Appropriate Worksite Protocol Fixed 2 Way Radios Emergency Situations If there is an accident or emergency at your workplace, you may be required to communicate about the situation. You need to make sure : workers are aware of the emergency, be able to give clear details to your supervisor of the nature of the emergency advise of any unsafe areas. You may need me required to contact the emergency services (ambulance, fire or police). The Emergency Services will need to know: What has happened? When it happened? What emergency services are required? Where the emergency is and how to get their vehicles to the correct location? Every worker and vehicle gives way to all emergency vehicles at all times First Aid Forklift operators work in a high-risk industry. Not only are there many minor injuries but also there are also serious injuries where the injured person will need first aid to restore breathing, heartbeat or to stem blood flow. Know the location of the first aid room and the nearest first aid kit. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 13

18 Refer to the code of practice in relation to the amount of first aid kits per site. South Australia has approved WH&S standards relating to this. The standard first aid symbol in Australia is a white cross on a green background. First aid kits on worksites should have a carrying handle. There must be a notice near to the first aid room with the name(s) of those in the workplace that hold an approved occupational first aid certificate. It is recommended that Forklift operators take the time to obtain an approved first aid certificate. Power Lines Forklifts and Electricity Keep a safe distance from electric power lines. Find out where all power lines are located in your workplace. Do not unload a truck under power lines. (To avoid the mast making contact with the lines when the forks are raised). TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 14

19 Current Regulations from the Office of the Technical Regulator in conjunction with SafeWork SA sets the following distances that operators of forklifts must stay clear of overhead power lines: When working near Power Lines, you need to maintain at least: Low Voltage 6.4 metres away (no spotter) 3 metres away when approved by the regulator and a Spotter is used High Voltage 10 metres away (no spotter) 8 metres away when approved by the regulator and a Spotter is used These distances are quoted in Australian standard AS Cranes, safe use-general requirements. One precaution is the requirement to have appropriate earthing systems fitted and in contact with the ground. The best way to determine the voltage of power lines is refer to the local power authority for advice. Always try and have your transport vehicle park clear of power lines. Most modern transport hubs have been designed to eliminate this dangerous hazard. If you are required to go closer than the minimum safe distances you must Seek an exemption from the relevant authority Where possible, have the electrical power shut off if this is not possible the lines must be insulated by an authorised and competent person The use of a spotter within the exclusion zone may also be appropriate, depending on legislation within the state/ territory Tiger Tails When working near overhead power lines, whether using machinery such as a crane or erecting a scaffold, it is recommended that you contact SA Power Networks to have Tiger Tails installed on the low voltage power lines. These Tiger Tails are a visual indicator only and do not reduce the prescribed safe working clearances. Constant vigilance and an authorised spotter are required whilst working or travelling in the vicinity of live electrical apparatus. If you do not know the voltage stay at least 10 meters clear of power lines. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 15

20 If You Do Make Contact with Power Lines 1. If possible and without endangering yourself as the operator (as the controls may be electrified) attempt to break the forklifts contact with the power lines by moving the forklift clear, lowering the forklift arms or moving the forklift mast. 2. If it is not possible to break contact with the overhead power lines you should remain on the forklift if it is safe to do so, do not touch any metal parts of the forklift and call for assistance 3. Warn other workers to stay at least 8 metres away from the machine until the power has been isolated and the area made safe 4. If it is not safe to stay in the forklift due to fire or other life threatening situation, check the ground around is clear of any water or other obstacles. If it is safe to do so jump clear of the forklift without touching any metal parts of the forklift and ground at the same time. 5. When moving away you should hop or shuffle away from the forklift (with both feet together) until at least 8 metres clear from the nearest part of the forklift. Under no circumstances should you run or walk from the forklift as the ground may be electrified. Follow the site incident reporting procedure and do not use the forklift until it has been checked. Electricity Distances TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 16

21 TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 17

22 Forklift Operator Responsibilities TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 18

23 As an operator of a forklift truck you have certain responsibilities when operating a forklift in the workplace. You must: Drive the forklift safely at all times Be aware of possible hazards Understand the rules of operating the forklift in your workplace Protect yourself and others by observing safe work practices at all times. Safe Operation of the Forklift If you are to effectively exercise your responsibilities as listed above then it is important that you take the time to familiarise yourself with; The forklift you will be required to operate e.g. controls, capacity and limitations, factors affecting stability The loads you will be required to carry e.g. stability, balance, contents The areas in your working environment that may, under certain conditions, present a hazard e.g. ramps, blind corners, overhead obstructions etc Protecting Pedestrians and Vehicles The safety of pedestrians may be compromised by their own actions or the actions of forklift operators. When pedestrian workers are at risk from the movement of a forklift truck measures must be taken to eliminate or minimise that risk. Hazard control measures may include: Flag person Flashing hazard lights Hoarding, gantries or scaffolding Warning signs and barriers Pedestrian / vehicle exclusion zones Rear End Swing The rapid sideways movement at the rear end of the forklift truck creates a hazard called rear end swing. Rear end swing can be up to 3.5 times that of the forward speed of the forklift and could TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 19

24 catch people un-aware, strike them or objects. Stay as close as possible to the inside of narrow corners when turning and watch out for pedestrians or objects. Pedestrian and other workers are a risk form rear end swing. No one should walk behind a Forklift while it is loading or stacking or walk under an elevated load. If these dangerous practices happen you should report them to management. Using Forklifts in Enclosed Spaces Your job may involve you using a forklift in a small area. This may be in a small room, a shipping container, on a ship or in an underground mine. A petrol or LPG gas operated forklift will produce fumes of carbon monoxide. When working in an enclosed area, these fumes build up and reduce the amount of oxygen in the area. The best method to eliminate this hazard is to use an electric powered forklift or to provide enough ventilation for the fumes to escape. Beware Of Exhaust Fumes in Confined Spaces FORKLIFT FAMILIARISATION TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 20

25 Forklift Trucks transport and stack materials, freight, goods and cargo. They are a short wheel based truck with a vertical mast. There are two types, counterbalanced and noncounterbalanced forklift trucks. Counterbalanced Fork Lift Trucks Counterbalanced Forklifts use the front wheel axle in the same way as the fulcrum of a lever. The load is counterbalanced on one side by the weight of the machine on the other side. All the weight behind the point of balance (fulcrum) acts as a counterweight. There are many different sizes and they use various power applications. An electric forklift would be an ideal choice when working in confined spaces, such as shipping containers. Telehandlers are an ideal choice if working on rough or un-stable ground because of their large robust off road wheels and solid tyres. Duty of care training must be obtained when operating Telehandlers, or any other equipment you are not familiar with. Counterbalanced Non Counterbalanced Non-counterbalanced Fork Lift Trucks In non-counterbalanced Forklifts the center of the load is behind the fulcrum point. They are known as reach or straddle trucks. This type of Forklift reaches out to deposit the load or straddles the stack for depositing the load. They should not carry loads unless the reach is retracted. They are used for particular TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 21

26 load stacking functions and are more versatile than the counterbalanced type in warehouse and tight, narrow locations. Parts of the Forklift Forklift Operational Parts A forklift is designed to lift and move loads safely. The forks are attached to a mast that moves up and down to lift the load. There are several important parts of the forklift that allow these moving parts to operate. Tyres The tyres on the forklift may be air filled or solid. It is important to keep tyres filled to their correct air pressure as they play a large part in the stability of the forklift. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 22

27 Check solid tyres for: Uneven wear on tread Any large chunks of rubber missing Total tread has not worn down Fuel There are a variety of fuels that may power a forklift. Different fuels are suitable to different working environments because of the hazard of the fumes when operating. Data Plate The data plate on the forklift must be readable. It provides important information about the 'Rated Capacity" of the forklift. The data plate will show the maximum weight / load that can be lifted at the specified Load Centre distance when: The mast is vertical The mast is tilted forward The mast is at maximum height (also noted on data plate) Fluids Like all vehicles, forklifts have operational fluids that need to be checked before starting the forklift: Engine Oil Transmission Oil Water or coolant Hydraulic fluid Brake fluid Wiper fluid (if wipers are fitted) Battery cell levels (if electric forklift) TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 23

28 The hydraulic fluid is used to power the operation of the mast and the forks. Mast and Forks The lifting part of the forklift is the mast and the forks. The back rest separates the load sitting on the forks and the chains that operate the mast. The forks are sometimes referred to as "tynes". The backrest may be referred to as the "load rest" or the "load guard". Forklift Passengers and Work Platforms Most forklifts are designed for only one person as a seatbelt must be worn at all times of operation. If a forklift is fitted by the manufacturer with 2 seats, 2 seatbelts and 2 foot rests, all under the overhead guard, then a second person may travel on the forklift in that seat. At no time should you lift a person using the forks or allow another person to travel on any part of the forklift without a seatbelt. The only way a person can be lifted using the forks is if they inside a specifically designed work platform. The work platform must meet the Australian Standard, have a clearly labelled data plate and attached securely to the forklift. The person must be attached to the work platform by a harness at all times and the Forklift Operator must always be at the controls below. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 24

29 A work platform (refer to Australian Standard 2359) must be fitted to the forklift to allow a person to be lifted by a forklift. Attachments All attachments must comply with an Australian standard. Attachments can include:- Drum Grabs (used to move 200 liter drums etc) Jib attachments Safety personnel cages (used to lift personnel for short durations) Safety personnel cage should be securely attached. Operator to remain in the forklift at all times. Park brake and natural gear should be applied. Only lifting and lowering should be used. Tarp spreaders (used to lay tarpaulins over flat bed trailer loads) Bale Grabs. Carpet Spikes Regardless of the type, each attachment must have a compliance plate fixed to it, and the forklift being used must be able to have the attachment fitted to it. If you are using an attachment for the first time, seek extra training from a competent person. Jib Attachment Jibs attachments must have a S.W.L (safe work load) stamped on the attachment. Keep the jib centered over the load before lifting (to ensure a clean lift with no sideways movement) and level when being carried as low to the ground as possible. Drums etc can swing whilst being moved and cause some sideways instability. Use Caution: Jib attachments are more unstable than forks because they have a higher centre of gravity TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 25

30 Other attachments include carpet spikes and great care should be taken when using these spikes. Longitudinal stability can be affected, and great care should be taken when turn and turns around blind corners. Always use the horn when approaching these situations. Ensure the attachment is compatible with the forklift being used. Use Caution: Jib attachments are more unstable than forks because they have a higher centre of gravity Jib Attachment Paper Grab Attachment Paper grabs must not be rotated (turned) whilst moving. It will affect the stability of the forklift, and a roll over may occur. When Using an Attachment Do not revolve the load while moving if a load revolve mechanism is fitted. Use caution: jib attachments are more unstable than forks because they have a higher centre of gravity. The Forklift should be operated as if it is partially loaded even if there is no load on the jib attachment. The jib should be kept as low as possible and the mast should be kept vertical or tilted backwards. Do not lift a load with a jib attachment if the mast is tilted forward. Do not tilt the mast forward when a loaded jib is attached. The load should be kept as low as possible. Travel at low speeds and make turns slowly. Make sure that jib attachments are properly fitted with the locking bolt housed. Slings should be inspected before and after being used for lifting. Centre the hook directly over the load before lifting to ensure stability and ensure the hook should be able to swivel The Safe Working Load must be displayed on all jib attachments above the lifting points where a lifting hook is attached. Hooks must be able to move at least 15 in all directions and swivel freely. Do not rotate the load on attachments when the Forklift is moving. Slipper forks are often used and can alter the load centre. In all cases, the Forklift must be approved to use attachments. Safe Working Loads will be stamped on the data plate for each approved attachment. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 26

31 Chains, Shackles and Synthetic Slings Chains, Shackles and Synthetic slings should only be used by competent and authorised people All Multi-leg Lifting chains must be labeled (Tag) with the SWL All Shackles must have a SWL marked on them Discard any Shackle with more than 10% wear in the crown or the pin or equipment that looks to be in poor condition Each Synthetic sling must be labeled with a (Tag) with the SWL or identified by colour coding All Shackles and Slings must be inspected before each use FORKLIFT PRINCIPLES Point of Balance The point of balance (also referred to as the fulcrum), is the point that balances the weight of the forklift and the weight of the load. On a counter balanced forklift this would be at the front wheel. The front wheels of the Forklift act as a fulcrum, with the forks on one side and the machine body on the other. If the weight at the fork ends is heavier than the counterweight it will cause longitudinal instability (the fork will tip up). TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 27

32 FULCRUM The counter weight is always every part of the forklift that is behind the point of balance and is used to balance the load that the forklift is carrying. Additional weight should never be added to the counterbalance system Load Centre Distance Load centre is defined as: The distance measured from the vertical face of the forks to the loads centre of gravity. Most palletised loads are square and evenly stacked in which case the load centre will be in the centre of the load. Therefore if the load is picked up hard against the vertical face of the forks the load centre measurement will be half the length of the load. Unusually shaped loads will have varying load centre distance. If the load is not hard up against the forks, the load centre distance increases. If the load centre distance is increased the capacity the forklift truck capacity is reduced. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 28

33 Rated Capacity The Rated Capacity of a Forklift is the maximum weight that the forklift can lift to a given height at a given load centre distance when the mast is fully extended. This weight will change when the mast is tilted forwards or backwards. You cannot safely operate the forklift without knowing this information. Do not use a Forklift that does not have a data plate. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 29

34 Mast Vertical The maximum weight that can be lifted with the mast vertical Forward Tilt The maxim weight that can be lifted if the mast is tilted forward Lift Height The maximum height that a load can be lifted Load Centre The forklift cannot be used to lift a load with a greater load centre than 600mm Safe Working Load The rated capacity is the maximum load that a forklift is designed to carry at a specified load height at a specific load centre distance. Most Forklifts have 2 safe working loads (SWL) stamped on the load rating plate (Data Plate). They are the: Mast vertical SWL Mast forward tilt SWL The load rating plate is usually found next to the driver s seat. If attachments are fitted a separate load rating notice needs to be displayed. To prevent accidents the weight of the load needs to be checked against the specifications of the Forklift. SWL s must not be exceeded. If the load weight is too great, the Forklift can tip over. As the mast is tilted forward, the centre of gravity moves away from the fulcrum so that the SWL decreases. It is the responsibility of the owner to ensure a load plate has been fitted and that it displays the lifting capacity of the machine under all lifting conditions. Stabilising Loads If you have multiple objects on a pallet the load centre distance will change depending on how they are stacked. If the heavier weight is nearest to the outer edge of the pallet, the load centre will increase and this will reduce the amount of weight that the forklift can lift. You would need to rearrange the objects closer to the backrest to safely lift the load. Load Centre of the Forklift below = 600 mm TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 30

35 The forklift cannot move the load when stacked this way Same load on the forklift with the load restacked. Heaviest items are closest to the backrest. Do not allow more than a third of the top section of an unwrapped load to stand above the top of the load backrest extension. A load not supported by the back rest can fall back and tangle with the mast, or if the load is very high, can topple back onto the driver. FORKLIFT ROUTINE INSPECTIONS It is the operator s responsibility once licensed, to ensure they have been given appropriate duty of care instruction on any forklift they are not familiar with. All controls should be pointed out and their use explained. For example:- Some forklifts will have the control levers fitted either on the dash board or on the bonnet to the side on the driver. Generally to the operators right hand side. Some forklifts will only have 2 levers, the first to operate the mast, and the second to operate the tilt of the mast. Other forklifts will have additional levers for side shift and fork spreaders and for other attachments fitted to the machine. Side shift should be used to keep the load centered, as uneven load can affect load balance. Prior to starting and then using any industrial equipment including forklifts, visual and operational checks must be performed prior to use to establish its condition and ensure that the plant is safe to use. Three checks should be conducted. They are; 1. Physical checks 2. Electrical checks 3. Operational checks We can look at these in more detail, starting with Physical checks. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 31

36 Visual Checks A thorough physical check of the forklift should be made prior to operation. The first thing that should be identified is the compliance or data plate. This data plate will provide the operator with all the information required to move and relocate a load safely. Data Plate L.P.G Plate Once this rating plate has been found, it is now possible to continue with other checks. If the forklift has been fitted with L.P.G (liquid petroleum gas) then the compliance plate for this work should also be found. This will ensure the work has been carried out by a licensed and appropriately trained competent person. If for ANY reason, these data plates are missing or cannot be found, the equipment should MUST NOT BE USED. The KEY should be removed and reported to a manager or supervisor at once and a Tag out fitted to warn others of the problem identified. All parts of the forklift should be checked in order to ensure the equipment is safe. There is no set order when conducting these checks, providing nothing is missed. Your trainer will show you a process; however the order of checks below will enable you to consider what is best for you. Tynes (or forks) should be checked for stress cracks and general condition. Pay particular attention to the heels for cracks. Locking pins used when opening and closing the forks should also be checked for free movement. The load back rest (load guard) should be checked for condition, damage and security to the forklift. This load backrest stops the load from fouling the mast and prevents the load falling onto the operator. Chains should be checked and signs of rust reported. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 32

37 The mast assembly should be checked for signs of damage and mast rollers checked for condition, i.e. lubricated. Hydraulic rams should be inspected for weeping seals (signs of oil should indicate this) Front wheels and tyres should be inspected and obvious signs of damaged tyres reported. Ensure solid rubber tyres wear is even, the outside of tyres is not worn down and no large pieces of rubber are missing. Wheel nuts should be inspected as they can shear off. Remember some tyres do not have OR have very little tread on them, this should be considered when driving on WET or SLIPPERY floors. Rear wheels should be checked as per the front ones. Air filled tyres should be checked and inflated to the correct operating pressure to assist in maintaining the stability of the forklift. The driver s seat should be securely fixed and the seat belt in working order/condition. Rubbish and waste material (shrink wrap) should be removed from the rear radiator housing. L.P.G gas bottle bracket should be securely fixed. Check for fuel leaks. All guards should be checked for damage including Roll over Protection (ROP) and Falling Object Protection (FOP). Overhead guards are fitted to protect the operator from falling objects. Foot guard should be checked. This is the third guard on a forklift to protect the operator. The remaining checks are as before, i.e. rams fork assembly etc. Mirrors, current registration and number plate should also be checked for and should be current and not damaged, even if the operator does not intend using the equipment on the road. If any of these checks expose a problem, then the equipment should be tagged out and reported Under the bonnet checks should now be made and they include: Liquid levels: Coolant or water (with the engine cold) Engine oil Hydraulic Oil Battery levels (all cells) Brake fluid Wiper water bottle (if wipers/windscreen is fitted) TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 33

38 Additional checks should include hoses for splits and wear. Belts for signs of wear and damage. Checks for waste material should also be checked around the engine bay. Electrical Checks Electrical checks are important because the working conditions and environment can and often do change quickly particularly with weather and lighting around the work sites. The amount of checks will depend largely on the equipment being used. In other words you have to check the operator s manual for a concise list of checks to be made. Generic checks would include the following: Warning devices:- Flashing warning light Horn Reversing Light Indicators (if fitted) Head Lights (if fitted) Brake lights Side lights (if fitted) Gauges and consol lights. If indicators, side lights etc are fitted then they have to be operational regardless of whether you intend to use them. Operational Checks Operational checks are the final stage, and are as important as the previous checks. All operating parts should now be checked in order to avoid any problems whilst moving, lifting or otherwise re-locating loads with the forklift. While the engine is running listen for any unusual/abnormal noise. Once you are satisfied there are no unusual noises etc the following checks should be made: Elevate the mast to the full working height. Check steering Check brakes Check warning devices Check lights Check all gauges Sideshift (if fitted) Fault Reporting TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 34

39 If any damage or defects are detected, or abnormal noises are heard after starting the forklift, By removing the key you are eliminating the chance of someone else using the faulty equipment. Tag or other means of fault reporting should be used. Check the procedure on your site so you are aware of it should it be required. Remember to ensure any leaks are cleaned up. In conclusion, a pre-operational check sheet should be utilised so nothing is missed and there is a record of your check. If a fuel leak is identified, Isolate Fuel Remove Key Tag the Forklift out Report to a supervisor If a hydraulic leak is identified, Remove Key Tag the Forklift out Clean up oil/or bund the spill from entering waterways Report to a supervisor FORKLIFT LOADS AND CALCULATIONS Load Weights The correct identification of load weights should never rely on guess work. It should be considered vital in the lifting, moving and re-locations of loads. The information that follows allows you to work out the weight of some common loads, and therefore allow you to work out if the forklift you are using is able to safely lift and carry those loads. Methods of determining the weight of a load: Obtaining content or weighbridge notes or other information Weighing the load Estimating by calculation TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 35

40 The loads weight may appear on the load itself or on the packaging in which it is delivered/transported Consignment Notes Consignment notes or con notes will display all the required information on it. This is because all freight is moved and charged on weight due to the nature of the transport system in Australia. If you have been asked to sign for freight being delivered onto your site, then a possible solution would be to mark the pallet load weight on the boxes or freight on the pallet. Pallets A standard packing pallet in Australia is 1200mm x 1200mm and weighs approximately 40kg. The weight of the pallet must be included when calculating the total weight of the load to be lifted. Do not lift a load on a pallet that is damaged. Calculations Example 1 5 layers, 4 cartons per layer, each carton weighs 20kg s 5 x 4 x 20kgs PLUS pallet weight i.e. 60kgs TOTAL load weight 460kg s TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 36

41 Example 2 A cubic metre of concretes solid mass is 2,400kg s Height Width Length 1.0 meters 1.5 meters 2.0 meters Height x Width x Length = 1.0 x 1.5 x 2.0 = 3 Cubic Metres 3 Cubic Metres x 2.400kg (Per cubic metre of Concrete) = 7.200kg Example 3 The container weighs 500kg s The container holds 3,000 liters 1 litre of water weighs 1kg Weight of container + weight of liquid 500+3,000 = 3,500kgs TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 37

42 FORKLIFT OPERATIONS Travelling with a Load When travelling forwards or backwards, with or without a load, it is important to keep the forks as low to the ground as possible. This is at about the height of the axle. When working around other people, never raise loads above people. Travelling with a raised load puts bystanders at risk of injury or death if the load or part of the load falls forms the forklift truck. A load should always be monitored while being lifted and while travelling with the forklift to ensure the forklift and load remain stable. There is a danger that part of the load may fall and injure a person. If the load falls on the forklift it may damage it or it may cause the rest of the load to become uneven and affect the stability of the forklift. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 38

43 Travelling or turning the forklift with the load raised affects the stability of the forklift and may cause it to tip or the load may fall when braking. Loads must be carried using both fork arms. The forklift will become unstable if only one fork arm is used and damage may be caused to the fork arm. If the load is small or an odd shape, you will need to pack the load onto a pallet or on a flat surface that can be picked up with both fork arms. Sideshift Feature Some forklifts are fitted with a side shift feature which allows you to move the forks to the side to pick up a load. When the forks are moved over, this affects the stability of the forklift and load by changing the point of balance. The forks must be returned to the central position before moving the forklift. Stability Forklifts are unstable by design. They have no springs and even four wheel counterweighted Forklifts only have 3-point suspension. The 2 rear wheels are attached in the center to the main body of the machine allowing the rear to hinge sideways affecting the lateral (sideways) stability of the machine. All Forklifts have a high center of gravity and a narrow wheelbase, which adds to their lateral instability. Side shift attachments should be centralised before travelling with a load to maintain the stability of the forklift and load. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 39

44 Forklifts have 3-point suspension formed from the front drive axle (a & b) and the steering axle point at the rear of the base (c) Forklift Stability Sideways Be aware of the factors listed below which can affect lateral (sideways) instability: Turning at speed Driving over uneven surfaces Unevenly distributed load Driving with a flat or under inflated tyre. Driving too fast (Loaded or unloaded) Turning with the load raised Side shift not centered Lifting a load on one fork arm Operating on a sloping surface Forklift Stability Forwards The counterweight of the forklift is used to balance the load on the front but there are situations that can cause the forklift to be unbalanced and tip forwards Driving over uneven surfaces Unevenly distributed load Driving too fast (loaded or unloaded) TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 40

45 Overloading Severe braking Incorrect use of the mast tilt (especially with the load carried at high levels) Load not positioned against the heel of the fork arms Shifting the load centre forward (centre of load is forward of the approved load centre) Lifting a load with a jib with the mast tilted forward Picking up an over width load Fitting slipper forks Operating on a sloping surface Seatbelts Seatbelts are an important safety feature on the forklift. If the forklift does tip, you are safest inside the cabin of the forklift. Do not attempt to jump out: Brace your feet Grip the steering wheel Stay inside the cabin of the forklift Forklift Operating Speed Forklifts are not designed for fast erratic driving styles. Therefore a brisk walking pace is considered an appropriate speed for general operation. Some sites will govern or control via computer or engine settings the actual speed the forklift will be allowed to travel. In other words depending on where you work will depend greatly on the speed allowed to for that site. You should always check before starting at any new site. Stability will vary greatly depending on your style of driving, the loads being carried and the site the load is being carried over. Some situations that would affect your driving speed would include: Wet floors or outside weather conditions Driving with the forks or tynes to high off the ground. Other forklifts working in the area Other traffic, including people, cars or vehicles Layout of the work site Workplace policy and procedures TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 41

46 Speed limits signs The size of the load being located When Tilting The Load: Raise the load clear of the stack before tilting the load backwards Always travel with the load tilted backwards and close to the ground When putting the load down, always bring the load over the stack before tilting forwards Deposit the load with the mast vertical or tilted forward slightly When raising the load Carry loads as low as possible at all times and no higher than axel height Operating with the forks raised either loaded or unloaded can affect the stability of the forklift and cause it to overturn Hydraulic controls should be eased in. If the controls are plugged or pushed quickly the operation will be jerky and loads could be dropped or damaged Make sure that the forks are centered when they are entering a pallet Load movement must be constantly monitored to ensure the safety of personnel and to ensure load and structural stability If the operators view is obstructed a spotter must be used Forklift Surfaces Forklift trucks should only be used on hard level surfaces. Four-wheel drive or rough terrain type should be used on unstable terrain. There are times you may need to travel on other surfaces and you need to know how this may affect the Forklift. Uneven Surfaces When travelling on uneven surfaces you need to take extra care as this may change the point of balance of the forklift or cause it to slide. Surfaces may include: Rough ground or loose gravel Potholes Cracked concrete Speed humps TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 42

47 Ramps When travelling on a ramp with a load, the point of balance changes on the forklift. You must always travel up a ramp with the load infront of you and the forks pointing up the ramp. reverse down a ramp with the load still on the front of the forklift and the forks pointing up the ramp. Slippery Surfaces Rain may have caused the surface you are travelling on to become slippery or you may be travelling on a polished concrete floor. Always reduce your speed and proceed with caution. Avoid ramps where possible when the surface it wet. Railway Crossing You may need to cross railway tracks with your forklift. Always cross the tracks on a 45 degree angle at a slow speed. Always give way to trains. Docking Plates If unloading a truck from a loading dock, you will need to fit a Docking or Bridging plate from the edge of the truck to the edge of the dock. This will give the forklift a flat surface to travel over when removing loads from the back of the truck. Temporary ramps must be fixed properly and sturdy enough for the forklift to travel over safely with a load. Travelling in Reverse There are times when you will need to travel in reverse on a forklift: If a load is too big for you to see past and therefore it is not safe to travel forwards If there is limited space for you to turn the forklift around safely If you are travelling up a ramp without a load Whether you are travelling forwards or in reverse, if your load it too large or wide, it is safest to use another person to guide you. When reversing: Check behind using mirrors and or looking over each shoulder to ensure that it is safe to reverse Ensure warning devices are operational If the operators view is obstructed, a guide is required TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 43

48 Unloading the Forklift When it is time to place the load down, you need make sure that it is not in a place where it will become an obstruction for other workers and vehicles. If unloading onto racking, you must make sure there is enough clearance (height and width) for the load and that the racking and shelf are in good order. Stacking Loads If you are stacking loads on top of each other, you need to make sure the loads are stacked level and onto a firm base. The heaviest loads need to be at the bottom and the loads need to be stacked securely to make sure they do not become unstable if the racking is bumped. General Safety Rules Summarised When a work platform is elevated, the driver of the forklift must remain at the controls at all times. Park brake applied, gear selection in neutral with engine running. In the event of a fault being revealed at any time or if the forklift becomes unsafe in anyway. Shut the forklift off (do not operate until fault rectified) Remove the ignition keys to isolate the machine Tag the forklift off and remind others not to use the machine Report the matter immediately to your supervisor to be fixed so repairs and maintenance can be organized. Do not make repairs, alterations or adjustments to any forklift unless authorised and qualified. Do not allow anyone to stand or pass under elevated fork or attachments, whether loaded or empty. Do not add additional counterweights or additional personnel to increase the load capacity of any forklift. Always approach rail tracks at a 45 degrees angle and slow down. Do not operate a forklift unless a compliance plate (data plate) is fitted TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 44

49 Do not operate a forklift on a public road unless the forklift is registered, has lights, turning indicators and warning devices fitted. You have an appropriate class of driver s Licence covering the Gross Vehicle Mass of the forklift. Never lift unstable loads (restack pallet if required). Check load weights and handle only within the rated capacity of your forklift truck. Other Operations This picture shows how easily loads can become lost if the operator does not travel in the correct way. Consider this picture and see if you can identify what this driver is doing that is wrong, and what damage and injuries could occur. It is important to stop your activity if the pre-determined path has been blocked or changed. STOP, re-evaluate the hazards and continue with the activity if it is safe to do so. Plan your work, and work to your plan. Loading Trucks Dock Plates or Bridge plates should be provided for the gap between the truck and the loading dock before shifting a load TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 45

50 Ensure drivers keys are removed and the driver is in a safe zone Always load pallets alternately on both sides of a truck. A truck can overturn if one side is empty and the other side has a full load. If a pallet appears to be unsafely loaded fix the stability of the load by repacking it. Make room by shifting the truck if there is no room to load both sides. Loading Large Enclosed Vans or Trailers Make sure: That the mast is not too high to enter the van That there is sufficient ventilation That the truck will support the combined weight of the Forklift and the load. That the bridge plate is in place, secure and load rated That the van wheels are chocked That the driver of the van has removed the keys from the ignition and has left the cabin during loading The load is kept low during loading Lifting Loads With Two Forklifts. Lifting a load with 2 Forklifts is very hazardous. The precautions listed below must be followed when lifting with two Forklifts: Only use counter balance forklifts for duel lifts. Dual lifts should only be carried out by experienced operators. The operation must be controlled by an experienced 3 rd person who has responsibility. Each Forklift must not lift more than 75% of its rated capacity given stability, position of load centre and other factors affecting the Safe Working Load. The load must be only carried the distance necessary to clear the load carrier. Loads must be raised and lowered simultaneously If one Forklift lowers more quickly than the other, the load becomes uneven. In the diagram it shows Forklift B lowering more quickly than Forklift A causing: The weight to move immediately to the tip of the fork arms on A. Pressure put on the mast of Forklift B which could cause it to bend or break. The load slips along the fork arms changing the position of the load centre. TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 46

51 FORKLIFT SHUT DOWN Post Operational Checks Considering forklifts can be used for several hours at once, post operational checks should also be considered as part of the operators shut down procedures. Similar checks to the ones already highlighted should be conducted to ensure any damage or faults are clearly identified and the appropriate repair/maintenance request made. Company policy may require keys to be removed from the forklift. This practice will prevent unauthorised movement of the forklift truck. Parking When parking the forklift ensure that you follow normal parking procedures. Always find a level out-of-the way place to park. Fork arms lowered and flat on the ground Forklift to neutral Park brake applied Site specific safety procedures must be adhered to Turn the ignition off and remove the key. Chock wheels if parking on an inclined surface(ramp) Ensure that the forklift is not parked in the following areas; Near first aid stations Near firefighting equipment Near doorways On sloping surfaces On or near pedestrian walkways Emergency exits Where it is obstructing traffic No closer than two metres from the nearest rail of a rail track TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 47

52 Post start checks may include the following: Check the forklift to the full extent of its movement ability(unloaded) Check steering Check brakes Check warning devices Check lights ( if fitted) Check all gauges Shut Down and Secure Forklift Truck Ensure the following: Forklift is parked to avoid hazards Forklift is shut down according to procedures; which may include removing keys etc Routine checks are carried out, similar to those for the pre start checks If any faults are identified you should cease operation, tag out of service and report to the appropriate person. CARE SHOULD BE TAKEN WITH HOT ENGINE PARTS, AND RADIATORS SHOULD NOT BE OPENED WHEN THE ENGINE HAS BEEN RUNNING Refuelling the Forklift Battery Operated Forklift The batteries on an electric operated forklift will need to be charged between use. This must be done in a well ventilated area as the batteries give off explosive gasses and may cause an explosion. Changing LP Gas Cylinders LP gas is a highly volatile explosive. Change gas cylinders in a well-ventilated area well clear of a naked flame or source of ignition. Only those trained and authorised to do so must TLILIC2001 Operate a forklift TM Last Modified 6/4/ Access Training Centre 48