TLILIC2001 LICENCE TO OPERATE A FORKLIFT TRUCK. Student Learning Materials. Version 2.6

Transcription

1 TLILIC2001 LICENCE TO OPERATE A FORKLIFT TRUCK Student Learning Materials Version 2.6

2 Disclaimer Any provider using this material should independently ensure that instructional material is customised and covers all applicable State, Territory and Federal regulatory licencing requirements. The information within the material does not comprise professional advice and must be customised and delivered by a suitably qualified professional Provider. The material (as a single source) should not be relied upon in any important matter without obtaining appropriate advice from subject matter experts relevant to your circumstances. Publication Published by the Civil Contractors Federation SA ABN: CCF SA Branch 1 South Road Thebarton SA, 5031 Phone: Fax: First published November 2012 Copyright 2014 Civil Contractors Federation SA All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, scanning, recording, or any information storage and retrieval system, without permission in writing from the Civil Contractors Federation SA. No liability is assumed with respect to the use of information contained herein. While all due care has been taken in preparing this book, the publisher, the distributor and authors assume no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Feedback If you have any suggestions for improving this workbook, please send to: courses@ccfsa.com.au 1

3 Version Control: Date Changes Version By 19/11/12 Change of format Updated information: V2 P. Wanders and V. Griffith To include learning checks To be appropriate for the new calculations assessment Inclusion of the hierarchy of control and duty of care Updated diagrams for Load centre distance and stability triangle Inserted example of data plate to explain rated capacity 22/03/12 Update information V2.1 P. Wanders Assessment re-sit timeline changed Added legislation (pg. 11) Inserted section 1: Legislation Changes some wording to sections: 7, 8, 9, 12, 13 (plus addition of tiger tails), 15, 16. Inserted calculation methodology (section 17) 03/05/13 Minor change page numbers and contents corrected V2.2 V. Griffith 08/01/14 Review content and wording: V2.3 S.Young and Paul Minor changes for WHS terminology throughout Wanders Re-formatted and page number update Pg. 11 minor wording change Section 3 - changed wording and examples of hierarchy of control Section 6 change of wording Section 7 change of wording Section 8 change of wording Sections 9 and 10 minor word change 12.2 removed (when tilting the load) 12.2 (v2.3) change of wording Addition of 12.3 (placement of load) Section 13 change of wording Section 14 change of wording Addition of Communication (now section 15). Section 17 (v2.3) change of wording 18/11/14 Added to lists in section 6.1 Additions to learning checklists 1 and 2 Addition of 24 question pre-assessment check Removed 9.1 (slings, chians and shackles) 1/7/16 Changed TLILIC2001A to TLILIC2001, updated to align with the Standards for Training Packages Changed feedback contact from: support@civiltrain.sa.gov.au to: courses@ccfsa.gov.au Changed spacing Section 1.1 between legislation.regulations to legislation. Regulations. Changed spacing Section 1.2 between workare to work are. Changed Section 3, Personal Protective Equipment (PPE) spacing between haveproven and relieson to have proven and relies on. Changed Section 12.2, Travelling, paragraph 17. Changed start of paragraph if to If and changed.grab to. Grab. Added three additional calculations for learner Formatted and updated Self Check Questions, 25 questions. 29/3/17 Updated unit of competency information on pages 9-12 V2.4 S.Young M.Williams V2.5 M.Blackborough V2.6 V.Griffith 2

4 Contents What is the Civil Construction Industry?... 5 What is the Civil Contractors Federation?... 5 Personal Requirements... 6 How will I be assessed?... 6 Resources... 6 Legislative Requirements... 7 Personal Protective Equipment (PPE)... 7 Assistance with Learning... 7 Learning Symbols... 8 UNIT OF COMPETENCY... 9 IMPORTANT INFORMATION TO ALL PERSONS APPLYING FOR ANY CLASS OF HIGH RISK WORK LICENCE (HRWL) INTRODUCTION Legislation, Regulations and Codes of Practice Organisational and workplace standards THE FORKLIFT TRUCK Counterbalanced forklift trucks Non- counterbalanced forklift trucks (reach trucks) HIERARCHY OF CONTROL Identify the hazard Assess the risk Control the risk Review and update DUTY OF CARE PRE-OPERATIONAL CHECKS ORGANISATIONAL AND WORKPLACE STANDARDS, POLICIES AND PROCEDURES Work place rules and procedures STABILITY TRIANGLE AND CENTRE OF GRAVITY Learning Check RATED CAPACITY ATTACHMENTS AND EFFECTS

5 10. THE MOTOR Internal combustion engine (I.C.E.) Changing gas cylinders Internal combustion diesel engines Electric forklifts FORKLIFTS AND FLAMMABLE LIQUID Learning Check SAFE OPERATION When raising the load Travelling Placement of Loads Loading trucks Loading Pantech s (large enclosed vans) Loading loads with two forklifts Parking Learning Check FORKLIFTS AND ELECTRICITY FIRST AID COMMUNICATIONS GENERAL SAFETY RULES LOAD CENTRE DISTANCE CALCULATIONS Learning Check PRE-ASSESSMENT CHECK ASSESSMENT

6 What is the Civil Construction Industry? Australia s national prosperity is dependent on functional, efficient and cost effective civil infrastructure. Healthy, well-functioning and productive countries depend on infrastructure that civil contractors construct and maintain, whether this is in moving freight on our roads, shipping our products and resources through our ports or building communities where people live and work. Transport and utilities infrastructure, construction and maintenance includes, roads, bridges, marine structures, dams, cable and pipelines, tunnels and site works for commercial, industrial and housing development. Civil contractors play a prime role in working with both public sector and private clients in infrastructure delivery. This is the business of civil construction. What is the Civil Contractors Federation? The Civil Contractors Federation or CCF is Australia s largest representative body of the civil construction industry which is responsible for the delivery of Australia s infrastructure needs such as roads, streets, subdivisions, bridges, airports, water, sewerage, drainage and telecommunications. The Civil Contractors Federation is a nation-wide federation of civil construction interests. It has fully representative Branches established in all States and Territories of Australia and a membership base of over 2,000 contracting and industry linked companies. Under its banner of Constructing Australia s Infrastructure, the Civil Contractors Federation is charged with ensuring the industry is well placed to respond to a fast changing and challenging external environment. This responsibility extends from assisting the industry in the planning, delivery and management of the nation s infrastructure assets through to the development and retention of a skilled workforce. Civil Train is the training arm of the Civil Contractors Federation. All Civil Train units are Registered Training Organisations delivering qualification and short courses to provide Australia with the skilled workers to build its infrastructure. 5

7 Personal Requirements To be successful in this occupation you should: Enjoy practical and manual work Be physically fit Enjoy working outdoors Have good communications skills Be able to work in a team environment Be alert and observant Be willing to keep up with modern developments in civil construction. How will I be assessed? You will be assessed on evidence that you can perform the work to industry standards collected from a range of activities including: Completion of all workbook activities Theory (knowledge) assessment Calculations assessment Performance assessment. Resources You will be provided with the following resources: Student Learning Materials workbook Knowledge, calculations and performance assessments Your trainer or employer will provide access to the following documents as required: State or Territory Workplace Health and Safety Act State or Territory Workplace Health and Safety Regulations Relevant standards Relevant operations quality documentation. 6

8 Legislative Requirements Like all aspects of modern work, you will be subject to and have to know legislative requirements such as safety, workplace relations and environmental protection. These will be explained when you learn the various tasks which make up this unit. Personal Protective Equipment (PPE) Your State or Territory workplace safety legislation designates that you must use PPE as supplied and trained. Correct PPE may include: Safety boots Safety helmet Safety vest (reflective at night) or high visibility clothing Safety glasses Safety gloves Ear muffs or plugs Close fitting clothing Wet weather gear Respirator and filter mask Hat Sunscreen (SPF 30+) Assistance with Learning If at any time while studying this unit you experience learning difficulties or require assistance and advice, you can get support by contacting your Trainer. 7

9 Learning Symbols Find out Discuss Learning Check Theory Assessment Practical Assessment 8

10 UNIT OF COMPETENCY ELEMENT PERFORMANCE CRITERIA 1. Plan work 1.1 Potential workplace hazards are identified 1.2 Risk control measures are identified consistent with regulatory requirements and the hierarchy of control 1.3 Appropriate forklift truck is selected in accordance with load and workplace conditions 1.4 Working area is inspected to determine appropriate paths for moving loads and forklift truck in accordance with workplace conditions 1.5 Methods for communicating are identified and confirmed in accordance with workplace procedures 2. Conduct routine checks 2.1 Prior to operation, forklift truck is visually checked for any damage or defects 2.2 All signage and labels are checked to ensure they are visible and legible, in accordance with the appropriate standard 2.3 All controls are located, identified and confirmed 2.4 Pre-start operational checks are carried out in accordance with manufacturer specifications and workplace procedures 2.5 Forklift truck is started in accordance with manufacturer specifications and workplace procedures, and is checked for any abnormal noise 2.6 Post-start operational checks are carried out in accordance with manufacturer specifications and workplace procedures 2.7 All forklift truck functions and safety devices are tested to their maximum in accordance with manufacturer specifications and workplace procedures 2.8 Issues, defects and damage identified during routine checks are reported and recorded in accordance with workplace procedures, and appropriate action is taken 3. Shift load 3.1 Weight of load is assessed to ensure compliance with forklift truck data plate specifications 3.2 Appropriate hazard prevention/control measures are implemented and communicated to personnel in the work area 3.3 Forklift truck is operated at a safe speed in accordance with manufacturer specifications and workplace procedures 3.4 Loads are moved and placed to ensure stability of material and avoidance of hazards 3.5 Load movement is monitored constantly to ensure safety of personnel and load, and structural stability 3.6 Unplanned and/or unsafe situations are responded to in accordance with workplace procedures and emergency plans 4. Shut down and secure forklift truck 4.1 Forklift truck is parked to avoid hazards 4.2 Forklift truck is shut down in accordance with manufacturer specifications and workplace procedures 4.3 Routine post-operational forklift truck checks are carried out in accordance with manufacturer specifications and workplace procedures 4.4 Forklift truck is secured to prevent unauthorised access/use 4.5 All defects and damage are reported and recorded in accordance with manufacturer specifications and workplace procedures, and appropriate action is taken 9

11 Performance Evidence: A person who demonstrates competency in this unit must provide evidence of safely operating a forklift truck and satisfy all of the unit elements, performance criteria and foundations skills requirements on at least one occasion including: applying risk assessment and hazard control strategies, including hierarchy of control as applied to safely operating a forklift truck carrying out post-start operational checks, which must ensure: attachment movements and control functions are smooth and comply with operating requirements hazard warning systems (e.g. lights and horns) are functional safety devices are checked, including deadman s switch emergency descent device (hydraulic) reversing beepers start-up is in accordance with procedures steering, transmission and brake functions comply with operating requirements carrying out pre-start operational checks, which must include: battery charge checks, as required ensuring availability of logbook, records, handbook and/or operating manuals fitting and interpreting forklift truck data plate fluid checks forklift truck attachment security checks identifying approved modifications and/or attachments fitted, to manufacturer specifications in accordance with forklift truck or attachment data plate locating, identifying and confirming all controls safety equipment checks signage and label visibility and legibility checks updating records as required communicating with other workplace personnel through using appropriate worksite protocols listening making and interpreting hand signals questioning to confirm understanding signage verbal and non-verbal language written instructions complying with Commonwealth, state and territory work health and safety (WHS)/occupational health and safety (OHS) legislation and regulations conducting and monitoring safe forklift truck operations that include moving loads safely, driving and manoeuvring, picking up and placing loads at various stack heights and carrying out all functions to the maximum height and load capacity driving a forklift truck with load in forward and reverse, while maintaining visibility planning and preparing for forklift truck operations including: conducting a workplace risk assessment identifying hazards associated with operating a forklift truck, which must include forklift truck instability (e.g. due to overloading, poor load placement, irregular loads) ground conditions (e.g. condition of pavement, slopes) insufficient lighting overhead hazards (e.g. electric lines, service pipes) traffic (e.g. pedestrians, vehicles, other plant) and the risk of collision with people, moving plant and fixed structures 10

12 weather conditions (e.g. wind, lightning, rain) selecting hazard prevention strategies in accordance with the hierarchy of control putting in place effective controls for identified hazards visually checking a forklift truck for any damage or defects prior to operation including evidence of damage leaks structural weaknesses (including paint separation or stressed welds) receiving and interpreting workplace instructions, safety information and emergency procedures shutting down a forklift truck in accordance with manufacturer specifications and workplace procedures including parking in a suitable location away from dangerous areas correctly positioning fork arms (tips down, tilted forward, lowered to ground) selecting appropriate transmission/gear for parking (relevant to transmission type) applying hand/parking brake turning off engine power removing ignition key as required shutting off LPG gas cylinder valve as required securing equipment in accordance with manufacturer specifications and against unauthorised operation securing site ensuring access ways are clear identifying and segregating defective equipment and reporting to authorised personnel connecting batteries to charger as required verifying problems and equipment faults, and implementing appropriate response procedures to unplanned and/or unsafe situations including environmental conditions (e.g. wind, lightning, storms) failure/loss of control (e.g. brakes and steering) failure of equipment (e.g. hydraulic system) forklift truck instability (e.g. due to deterioration of ground condition, overloading, poor load placement, irregular loads). 11

13 Knowledge Evidence Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of: Australian and industry standards relevant to operating a forklift truck Commonwealth, state or territory WHS/OHS legislation and approved codes of practice in relation to one s own responsibilities forklift truck characteristics and capabilities (including use of load data plates) forklift truck operations and safe operating techniques hierarchy of control: elimination substitution isolation engineering controls administrative controls personal protective equipment (PPE) methodology to determine weight of a load including the estimation or determination from labels, markings or load paperwork such as: control labels forklift data plates/labels forklift warning decals organisational and workplace standards, requirements, policies and procedures for operating a forklift truck procedures for recording, reporting and maintaining workplace records and information relevant Australian and industry standards, codes of practice and guidelines to safely operate a forklift truck risk control measures including: barricades and traffic control (e.g. traffic management plan) compliance with permit condition requirements from electrical supply authority, including adequate illumination disconnected power excavation safeguards insulated electric lines maintaining safety observer zone movement of obstructions observing limits of approach pedestrian control (barricades, signs, etc.) power disconnection or compliance with electrical supply authority requirements safety tags on electrical switches/isolators using safety observer inside exclusion zone using personal protective equipment selecting forklift truck to suit load and workplace conditions typical routine problems encountered operating a forklift truck and equipment, and adjustments required for correction. 12

14 IMPORTANT INFORMATION TO ALL PERSONS APPLYING FOR ANY CLASS OF HIGH RISK WORK LICENCE (HRWL) High Risk Work (HRW) was introduced in South Australia in September With its introduction came specific legal requirements including who can deliver and assess HRW training and who may apply for it. It affects 29 different licence classes. The new licence is a small plastic card with photo identification (similar to a driver s licence) with a list of all the classes of high risk work that the holder is authorised to perform. Unlike previous Certificates of Competency or tickets, the licence requires renewal every five years. At this time the licence holder will need to provide evidence that they have maintained their skills and are still fit, healthy and competent to perform that class of HRW. Any person deemed to not meet these requirements may have their HRWL revoked, suspended or have a 5 year renewal request denied. It is also up to the HRWL holder to notify SafeWork SA of any changes to their health or level of competence and be re-trained accordingly or surrender their licence if deemed necessary by SafeWork SA. Some of the responsibilities that apply to HRW applicants are: Each applicant must be aged 18 years or older to obtain the new licence and must be able to offer identification that will confirm this. Each applicant will be asked to sign a declaration stating their age and physical fitness is appropriate, that each applicant has not previously been issued with the same licence class or failed an assessment for the same licence class in a period of not less than 7 days. That each applicant agrees to SafeWork SA sharing personal information with other relevant authorities and that giving false or misleading information can result in action from SafeWork SA. After training applicants will need to prove their knowledge by way of theoretical assessments and prove their operational skills by way of a performance assessment. Successful applicants will be deemed as competent and issued a temporary Notice of Satisfactory Assessment (NSA) and a Tax Invoice. The NSA will be valid for a period of sixty days where by the successful applicant must produce both to Service SA or an Australia Post Photo Capture Centre for processing with the stated fee and 100 points of ID. The new High Risk Work Licence will then be processed and posted to the applicant. After training and assessment, applicants deemed to be Not Yet Competent must wait a mandatory 7 days before being reassessed for the same class of licence. All HRWL holders must work safely, responsibly and with due care to all. Failure to do so may result in a HRWL being revoked, suspended or a 5 year renewal request denied. According to WHS Regulations, no unlicenced person, under any circumstance, shall perform any class of HRW. Persons are only considered to be under training when being supervised by a competent licenced operator or by being enrolled on a training course with a Registered Training Organisation (RTO). 13

15 1. INTRODUCTION 1.1 Legislation, Regulations and Codes of Practice Regulations are rules that provide details on how to meet the minimum requirements set by the legislation. Regulations require that employees carrying out work which is identified as being hazardous are required to be trained to operate in a competent manner. This training program has been designed to examine the hazards associated with working with forklift trucks and initiate safe work procedures so as to eliminate unsafe work practices in accordance with: The National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment [NOHSC:1006(1995)], The Work Health and Safety Act (WHS) 2012 (SA) The Work Health and Safety Regulations 2012 (SA) The National Standard for Licensing Persons Performing High Risk Work 2006 The Construction Work Code of Practice may be relevant dependent upon the working environment 1.2 Organisational and workplace standards Safe systems of work are the total set of methods adopted for carrying out the operations required in a particular workplace. They cover all aspects of the employment situation, including site specific rules and regulations, safety and emergency procedures, the organisation of work processes, the methods of using machinery, plant and equipment and training and instruction about associated hazards and their management. We will examine aspects of operation which include: pre-operational checks post start operational checks why and how to plan work machine selection set-up and shut down procedures hazard identification and hazard control Fault finding and recording procedures Log book, specifics entry 14

16 2. THE FORKLIFT TRUCK Forklift trucks transport and stack materials. They are a short wheel based truck with a vertical mast. There are two types; counterbalanced and non-counterbalanced forklift trucks. The LF (forklift) licence entitles an operator to use both machines. 2.1 Counterbalanced forklift 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. 15

17 2.2 Non- counterbalanced forklift trucks (reach trucks) In non-counterbalanced forklift trucks, the centre 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 load stacking functions and are more versatile than the counterbalanced type in warehouse locations. 16

18 3. HIERARCHY OF CONTROL The purpose of a risk assessment is to reduce or eliminate the potential for injury to personnel whilst at work. This is a systematic method of identifying, assessing, and reducing hazards. To complete a risk assessment correctly we need to: Identify the hazard Always consider the task to determine whether there is any risk of a person injuring themselves or others when carrying out the work. Assess the risk How likely could an injury occur? How often will we be exposed? What injuries could occur e.g. grazes, bruising, broken leg, fatality etc.? Control the risk What control(s) could be put in place to reduce or eliminate the incident occurring? (HAZARD CONTROLS MUST BE APPLIED AT THE PLANNING STAGE) 17

19 Control the Risk with the use of Hierarchy of Control: The Hierarchy of Control is a six step approach to controlling hazards in the workplace. Elimination is always the preferred option but not always possible. ELIMINATION Wherever possible the hazardous item or substance or work practice should be removed. For example: noisy grinding or cutting, purchase pre-cut materials. SUBSTITUTION Replace the hazardous system or process with one that presents less risk. For example: lift smaller packages, use a less toxic chemical, vacuum in place of sweeping. 18

20 ISOLATION Place the hazardous system or process in a separate area where the exposure is reduced. For example: place barriers around a spill until cleaned up, place heat producing objects in separate well vented rooms. ENGINEERING Structural changes to the work area, or process that forms additional protective barriers between hazards and workers. For example: provide a trolley to move heavy loads or surround moving parts with a guard. ADMINISTRATION Reduce exposure to hazards via procedures, instructions and training. For example: job rotation, shorter shifts, maintenance programs, instruction and training. PERSONAL PROTECTIVE EQUIPMENT (PPE) Where workers are exposed to hazard and other measures have proven ineffective or non-viable. The last line of defense relies on correctly selected, fitted and maintained PPE. For example: provide hearing and eye protection, gloves, sun cream, masks etc. until a more suitable solution can be found. Review and update During a job things may change which require the risk assessment to be reviewed e.g. weather changes, additional work needed, changes in the work group etc. We must ensure that the risk assessment is still current and valid by identifying the changes and reviewing the risk assessment. 19

21 Level of Risk Urgency of Action Needed 18 to 25 High Immediate action required 10 to 17 Significant Senior management attention needed urgently 6 to 9 Moderate Management responsibility must be specified and actioned 1 to 5 Low Manage by routine procedures Impact/Consequences Likelihood Insignificant Minor Moderate Major Catastrophic Almost certain Likely Possible Unlikely Rare DUTY OF CARE Your duty of care or due diligence means you must take reasonable care to ensure that you and others are not harmed by your actions or omissions. This applies to employers and employees. 20

22 5. PRE-OPERATIONAL CHECKS It is a legal and mandatory requirement that the first person to use the plant on any given day conducts a pre-operational inspection to ensure not only the operator s safety but the safety of those around them. Here is an example of a standardised pre-operational inspection checklist used for counterbalanced internal combustion engine (I.C.E.) forklifts. 21

23 6. ORGANISATIONAL AND WORKPLACE STANDARDS, POLICIES AND PROCEDURES Each workplace has conditions that can contribute to dangerous situations. Operators should inspect the workplace for any potential hazards and consult with a supervisor, site engineer, OHS rep or leading hand to ensure the hazard has been eliminated or minimised before starting work/ operating the forklift. On some sites it may be necessary to obtain a work permit to operate a forklift as a safety control measure. 6.1 Work place rules and procedures By notifying the appropriate people we can access the correct information needed to instigate our own safe work procedures and become aware of the particular rules and procedures that affect the site we are on. Each work site or organisation will have its own policies and procedures as to how it will work to meet legislative and regulatory requirements. Take time to ensure you have access to these and that you understand the processes. Remember, policies and procedures need to be reviewed regularly to ensure they are current, relevant and compliant. Be aware of: Soft or sloping ground Blind corners Blind alleyways with cross traffic Inclines Ceiling clearance, including low pipes etc. Doorway clearances Pedestrians Excessive heat, especially where LP gas is used The road surfaces The fumes produced by the forklift Electric overhead wires You must also consider Non-Site related hazards such as but not limited to: * Load characteristics (weight, height) * Rated capacity of the plant you are using * Availability of the plant * Access and egress * Signs, Barriers * PPE 22

24 Other workers and pedestrians should be aware of the need to keep clear of a forklift while loading and travelling. In particular, no one should walk behind a forklift while it is loading or stacking or walk under an elevated load. Precautions must be taken when operating over roadways, footpaths and other public areas. The rear end swing of a forklift can be particularly dangerous as the rear end can swing out in a very wide arc and can travel extremely fast when turning. 23

25 7. STABILITY TRIANGLE AND CENTRE OF GRAVITY Forklifts have 3-point suspension formed from the front drive axle (a and b) and the centre of the rear axles (c) and are unstable by design. All objects have a natural centre of gravity (C.O.G), as do forklifts. The centre of gravity on a forklift can change position pending the load you are carrying, the way you drive and other varying factors. If the centre of gravity shifts outside the safe working area, known as the Stability Triangle, the forklift will most likely tip over, either sideways (laterally) or forwards (longitudinally). Forklifts have no suspension but three contact points which form the stability triangle. The two rear wheels are attached in the centre of the rear axle via a pivoting pin. This pin allows the rear axle to rock up and down to allow movement over uneven surfaces. This can affect the lateral (sideways) stability of the machine. All forklifts have a high centre of gravity (C. O. G) and a narrow wheel base, which adds to their lateral instability. Note the change in the centre of gravity in the following diagrams. 24

26 Be aware of the factors listed below which can affect lateral instability or sideways tipping: Turning at speed Turning with an elevated load Driving over uneven surfaces An unevenly distributed load Driving with a flat or underinflated tyre Turning on an incline Travelling with the load raised Braking too hard when turning Side shift not centred Lifting a load on one fork arm Driving sideways across a slope 25

27 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). Be aware of the factors listed below which can affect longitudinal instability or forward tipping: Overloading Increasing load centre distance Severe braking Load not positioned against the heel of the fork arms Lifting a load with the mast tilted forward Driving with reach extended Travelling with the wrong way up or down a ramp Uneven loads, forward Rapid reversing with heavy loads Jerky hydraulic control movements 26

28 Learning Check 1 1. What is the lowest level of control measure on the hierarchy of control? 2. Name two things that can affect longitudinal (forward) instability: i) ii) 3. Name two things that can affect lateral (sideways ) instability: i) ii) 4. Name 2 hazards and their control measures when operating a forklift: i) ii) 27

29 8. RATED CAPACITY Operators must know a forklift s rated capacity. It can be found on the vehicles Data Plate and comprises the maximum lifting weight, height and load centre distance of that vehicle. These three elements combine together to form rated capacity and determine what the forklift can lift. Each of these elements may be affected by altering another. The data 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. Methods of determining load weights may include; Weighing individual items then adding the totals together, Checking the load for attached labels Asking to see con-notes, manifests, invoices, delivery dockets etc. Rated capacity must not be exceeded. Operators must be able to read and understand the data plate and the conditions of loading at all times. It is the responsibility of the forklift owner to provide a data plate on each vehicle that displays the lifting capacity of the machine under all lifting conditions. It is illegal to use a forklift without a data plate or one that is illegible. Do not use a forklift that does not have a load or data plate. 28

30 9. ATTACHMENTS AND EFFECTS Attachments are working aids that are added to a forklift for certain tasks. Some are permanently attached and hydraulically powered while others are only attached when required and removed afterwards. All attachments add weight to a forklift and can therefore affect the stability and reduce the safe working (SWL) of a forklift. Make sure all attachments are suitable for load and forklift and have their own data plate before use. They must be attached securely to forks with chains and/or pins if removable. Do not rotate the load while moving if a load rotator mechanism is fitted. Make sure the forklift data plate allows the attachment to be used on that forklift. The use of any attachment will reduce the lifting capacity of all forklifts. If asked to use an attachment you are unfamiliar with, ask for training or advice from a competent person first. 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. 29

31 10. THE MOTOR 10.1 Internal combustion engine (I.C.E.) Internal combustion engines are powered by diesel fuel, petrol or LPG or CNG. An LP gas motor is a petrol motor that has been converted to use gas instead of petrol. WARNING: Internal combustion engines produce the odourless, but poisonous gas, called carbon monoxide. A person working in a confined space where carbon monoxide is present could become seriously ill or die from inhalation. Carbon monoxide builds up in the body and can kill in twenty minutes. Make sure there is adequate ventilation where forklifts with internal combustion engines are operating. Do not refuel an internal combustion forklift unless the motor is stopped and the ignition is turned off. If not, there is a chance of explosion Changing gas cylinders The gas cylinder must be within its ten year use by date, must be correctly positioned within its mounting cradle and must be in good mechanical condition. Gas is a highly volatile explosive. Change gas cylinders in a well-ventilated area, well clear of a naked flame or a source of ignition. Only those trained and authorised to do so should change gas cylinders. Beware of burns from escaping gas. Always wear gloves and safety glasses and do not smoke whilst changing LP gas cylinders. Take the following steps in the order below when changing gas cylinders: 1. Turn off cylinder valve 2. Switch off engine 3. Disconnect take-off hose 4. Remove safety straps 5. Change the cylinder 6. Connect the safety straps 7. Re-connect take-off hose 8. Turn on cylinder valve 9. Check for leaks look, listen and smell Gas cylinders should be inspected and stamped by a competent person every ten years. All LPG forklifts must have an installer s compliance plate. 30

32 10.3 Internal combustion diesel engines Most diesel engines must warm up before they can start. When the ignition key is turned on, the glow plug is activated. This warms up the fuel so it will fire. There is a delay of several seconds from ignition until the starter motor turns on the engine. A light on the dashboard indicates that the fuel is warming. It goes out when the engine is ready to fire. Try to avoid allowing a diesel engine to run out of fuel. Diesel engines fire on the compressed vaporised fuel and will not fire if there is air in the fuel lines. If a diesel engine runs out of fuel, a competent person must bleed the system of air before it can be restarted. Diesel engines also emit carbon monoxide gas. A badly tuned diesel engine can emit more carbon monoxide than a petrol motor. Remember that carbon monoxide is odourless, will build up and can kill. 31

33 10.4 Electric forklifts Electric forklifts are quieter than I.C.E vehicles so greater care must be taken when operating as pedestrians are less likely to hear one approaching. Recharging of electric forklifts must take place in well-ventilated areas as the batteries produce a poisonous, odourless, flammable gas during the recharge process. This gas is known as hydrogen and is extremely dangerous when allowed to build up. Hydrogen is highly explosive and extremely harmful if inhaled. 32

34 11. FORKLIFTS AND FLAMMABLE LIQUID Flammable liquid stores and other areas where flammable liquids are used are usually zoned as having a hazardous atmosphere. Forklifts must be modified or flame proofed before they can be used in a hazardous atmosphere and have a compliance plate to that effect. Flame proofed diesel powered forklifts have an exhaust water wash box, which must be flushed out and refilled every shift. Flame proofed battery powered forklifts must not be connected to the battery charger near to any area where flammable liquids are handled in open containers. Petrol and LP gas forklifts are never flame proofed because of their spark ignition system. 33

35 Learning Check 2 1. Why should you use an electric machine in a confined space? Name three types of forklift motor: i) ii) iii) 34

36 12. SAFE OPERATION Forklift trucks should only be used on hard level surfaces. Four-wheel drive or rough terrain type should be used on unstable terrain When raising the load Carry loads as low as possible at all times, never higher than the front axle. Hydraulic controls should be eased in. If the controls are plugged or pushed quickly, the operation will be jerky Make sure the forks are centred when they are entering a pallet and do not contact the pallet until you are ready to lift Do not enter the pallet with the mast tilt back or forwards (this will bind the forks). Forks must be level and mast vertical The load should always rest against the heel of the fork arms. This will ensure the load centre is in the right place If the load weight is unevenly distributed on the pallet, put the heavy end of the load against the heel of the fork arms Make sure the forks are centred on either side of the mast if side shift is attached or side tipping may occur A properly constructed hardwood pallet weighs 60kg and has a SWL of 2000kg. Do not overload pallets Do not move damaged pallets. Loads should be repacked to undamaged pallets wherever possible 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 backed by the load backrest can fall back and tangle with the mast, or if the load is very high, can topple back onto the driver Unsafely or unevenly packed pallets should be repacked. Do not raise a load with just one fork as this can destabilise the forklift and the load or cause damage to the lifting mechanism. Always raise the load before tilting the load backwards 35

37 12.2 Travelling Always travel with the load tilted backwards and close to the ground Never travel with the load or the forks above front axle height Forklifts are one-person vehicles. Do not carry a passenger unless specified as acceptable by the manufacturer and displayed on the data plate You can only lift people in an approved work platform Understand your site s traffic requirements Reduce speed and proceed with caution on wet or greasy surfaces Do not attempt to turn a forklift when it is on a sloping surface (this could affect lateral stability and cause it to tip over sideways) Always drive up and down inclines slowly (check manufacturers specifications for any special features that the forklift you are operating has for operating up and down hills) Face the load uphill when travelling up a slope Face the load uphill and look behind you when reversing down a slope Have someone guide you when driving up a hill with a bulky load that blocks clear vision Before reversing check over both shoulders, check mirrors (if fitted) check path is clear Blow the horn and drive slowly when approaching a blind corner Make sure that no one is in the way or standing next to you before driving away Do not drive across a slope or side tipping may occur Do not turn sharply at speed. Forklifts overturn very easily. They are narrow wheelbase trucks with a high centre of gravity If your forklift is overturning. Grab the steering wheel, brace your feet, lean in the opposite direction of the fall and do not attempt to jump clear. Watch out for rear end swing. Forklifts steer from the rear and the rear end will swing out very wide. When travelling and turning the rear end, swing will be three times that of the forward speed of the forklift. Stay as close as possible to the inside of narrow corners when turning and watch out for pedestrians or objects Revving the engine when lowering a load makes no difference; lowering is gravitational. Do not drive reach trucks with the reach out as this alters the vehicle s C.O.G. Give way to police, fire, ambulance or other emergency vehicles at all times. 36

38 12.3 Placement of Loads When putting the load down, always bring the load over the stack before tilting forwards Deposit the load with the mast vertical If placing loads into stacks or racks make sure the heaviest item is at the base of the stack Make sure loose items are not stacked high, (wrap or strap loose items) Ensure shelves or racks are weight rated and know the weight of your loads Never stack too high as this will create an unstable stack Make sure ground is firm, dry and level Always try to stack neatly, neat stacks are safe stacks 12.4 Loading trucks 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 Make room by shifting the truck if there is no room to load both sides Loading Pantech s (large enclosed vans) 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 and secure That the van is 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 37

39 12.6 Loading loads with two forklifts Lifting a load with two forklifts is very hazardous. The precautions listed below must be taken when lifting with two forklifts: Dual lifts should only be carried out by experienced operators The operation must be controlled by an experienced third 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 (SWL) The load must be only carried the distance necessary to clear the load carrier Loads must be raised and lowered simultaneously Order pickers must not be used for dual lifts If one forklift lowers more quickly than the other, the load becomes uneven. The diagram on the previous page 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. 38

40 12.7 Parking 1. Always find a level, out of the way, place to park. If you must park on an incline, you must also chock the wheels before leaving the forklift. 2. Park clear of fire and emergency exits, power switches, firefighting appliances, first aid facilities, gas refuelling stations and fuel pumps. 3. Engage handbrake and select neutral gear 4. If the tips of the forks cannot be lowered to the ground, park so that the forks do not create a tripping hazard 5. Turn the ignition off and remove the key to prevent unauthorised use 6. Isolate the power source if at the end of a shift i.e. LP gas should be turned off to prevent leakage 7. Make sure you always park clear of: Doorways Emergency exits 3m from train lines Flammables/hazardous materials First aid stations Blind corners Pedestrian walkways 39

41 Learning Check 3 1. Circle true or false for each of the following statements. You must never: Load with one fork tyne Use order pickers for dual lifts Use two forklifts to carry a load Park hard up against another forklift Jump out if your forklift is overturning True or False True or False True or False True or False True or False 2. When raising the load, you should rest the load against the of the fork. 3. What should you do when driving towards a blind corner? 40

42 13. 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). Current regulations from the Office of the Technical Regulator in conjunction with Safe Work SA, sets the following distances that operators of forklifts must stay clear of overhead lines: Stay at least 6.4m away from distribution lines on poles (low voltage) and at least 10m away from transmission lines on towers (high voltage). These distances are quoted in Australian Standard AS Cranes, safe use general requirements. One precaution is to have appropriate earthing systems fitted and in contact with the ground. 41

43 If a spotter is used: 3m away for low voltage 8m away for high voltage If required to work closer than these distances you must first contact the supply company for permission. The supply company can either de-energise the lines, insulate them or provide an approved spotter when working nearby. SA Power Networks Constant vigilance and a spotter are required whilst working or travelling in the vicinity of live electricity. If unsure of voltages contact the supply company for more information. If you do make contact with power lines: 1. Stay on the machine and warn others to stay clear 2. Try to break contact if the engine is still running 3. Do not leave the forklift until the electricity has been turned off 4. If help fails to arrive, apply the handbrake, place the controls in neutral and switch the forklift off 5. Then jump well clear of the forklift 6. Do not make contact with the ground and the forklift at the same time. 7. Warn all others to remain no less than 8m away from the forklift 8. Forklift must be fully inspected before it can resume working REMEMBER TO CONTACT RELEVANT AUTHORITIES TO WORK CLOSER THAN THESE DISTANCES. IF UNSURE OF VOLTAGE LEVELS, ALSO CONACT SA POWER NETWORKS FOR ADVICE. Tiger Tails (as shown below) are a simple black and yellow plastic sleeve that can be attached to power lines. They are a visual aid used to highlight the location of live wires in relation to where the work will be carried out. Tiger Tail 42

44 13. FIRST AID Forklift operators work in a high risk industry. Not only are there many minor injuries, but there are also serious injuries where the injured person will need first aid to restore breathing, heartbeat or to stem blood flow. According to WorkCover statistics, between 1985 and 2003, 49 people have been killed in forklift incidents. Know the location of the first aid room and the nearest first aid kit. There must be a first aid kit on every floor of a multi-story building site or within 100m of any part of the workplace. The standard first aid symbol in Australia is a white cross on a green background. It is recommended that forklift operators take the time to obtain an approved first aid certificate. In the case of an emergency it is of critical importance to remain calm and communicate accurate descriptive information to the necessary people. This process can vary from site to site however in most cases you will be required to inform supervisors, other workers and emergency services; The nature of the emergency (if known) The exact location of the emergency (including directions if required) How many people are involved 43

45 14. COMMUNICATIONS Understanding how to use communication devices correctly is an important part of work place procedures and safety. Many companies will adopt varying methods of communication such as: Two way radios Mobile phones Verbal or written instruction Hand signals Whistle blows It is of vital importance that communication techniques and devices are checked for suitability and functionality prior to the work commencing. 44

46 15. GENERAL SAFETY RULES 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 any fault being revealed at any time or if the forklift becomes unsafe in any way: Remove the ignition keys to stop unauthorised use Turn off the gas to prevent leaks Tag the forklift as defective Report the matter immediately to your supervisor to be fixed 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 use additional counterweight to increase the load capacity of any forklift unless approved by the manufacturer. Always approach rail lines and speed humps at a 45º angle and slow down. Do not operate a forklift unless a compliance plate (data plate) is fitted. Do not operate a forklift on a public road unless the forklift is registered, has lights, turning indicators and warning devices fitted. Have 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 operate only within the rated capacity of your forklift truck. 45

47 16. LOAD CENTRE DISTANCE Load centre distance is defined as: The distance from the heel (or vertical face) of the forks to the centre of gravity of the load Most palletised loads are square and evenly stacked in which case the load centre will be in the centre of the load. Lifting loads that are not against the heel means the Load Centre Distance will be increased which in turn will lower the forklifts height and weight capacity. By increasing the load centre, you decrease the capacity of the forklift. Load centre distance (L.C.D) increase = height & weight decrease. 600mm is the Australian standard load centre distance although it is illegal in Australia to use a forklift with an LCD rated below 500mm. Always check the data plate for the rated capacity before use. 46

48 17. CALCULATIONS As part of this course you will need to demonstrate that you can: Calculate the weight of the load you will be carrying Read and understand load charts to calculate which loads are within the capacity of the forklift Read and understand load charts to calculate maximum working loads with the mast in different positions Example: The load to be moved is bags of sand stacked on a pallet. 40 bags on the pallet Each bag is 20kg The pallet weighs 30kg What is the combined weight of the bags and the pallet? (40 x 20) + 30 = 830kg Learning Check 4 1. The load to be moved is a precast block secured on a pallet. Precast block 730kg The pallet weighs 43kg What is the combined weight of the precast block and the pallet? Show all calculations. 47

49 2. The load to be moved is four drums stacked on a pallet. Four drums on the pallet Each drum s tare weight is 9.8kg Each drum s capacity is 208L (filled with water) The pallet weighs 34kg What is the combined weight of the drums, contents of the drums and the pallet? Show all calculations. 3. The load to be moved is an IBC filled with water. Tare weight of IBC is 56kg The amount of water is 1000L (1000kg) What is the combined weight of the IBC and the water? Show all calculations. 48

50 18. PRE-ASSESSMENT CHECK (This must be complete before the Final Assessment) 1. Before you start work who should you communicate with about site hazards? List 10 common hazards you should be aware of before operating a forklift truck It is important to confirm your work conditions and responsibilities before commencing work, other than site hazards what other conditions and responsibilities should you be aware of before you start work. List 6 examples

51 4. The Hierarchy of control is a six step approach to controlling hazards in the workplace. What are the six steps, starting with first consideration and working to the last step/level of control? Demonstrate knowledge of power line safety distances for South Australia, Low voltage with a spotter Low voltage without a spotter High Voltage with a spotter High Voltage without a spotter m m m m 6. Do Tiger Tales allow you to work closer than the distances given because they provide isolation and protection when working near powerlines? Explain your answer. 50