Forklift Training and Assessment Centre

Transcription

1 Study Information Training for the Future Forklift Training and Assessment Centre RTO Training and Assessment Centre : Unit 5/83 Gavenlock Rd Tuggerah V Review 07/14

2 CHANGING LP GAS BOTTLES Always wear gloves when changing gas bottles. Liquid gas is extremely cold and will cause nasty frost burns if it contacts the skin. Because it is so cold it is possible for the shut off valve to be frozen open allowing liquid gas to escape when hoses are disconnected. Goggles should also be worn. Turn off the valve before attempting to disconnect hoses. When liquid gas is released into the atmosphere it will return to its gaseous form and increase in volume, many times. This can easily fill the workshop with explosive gas. It is therefore vital that no naked flames or electrical panels, where continually sparking contacts are present, are in the vicinity of gas bottle changing operations. No smoking within 30 meters. LP Gas is heavier than air and will, if allowed to escape, gather in low lying areas such as drains, service pits in workshops, basements, sewers to name a few. Always change bottles in open, well ventilated areas. If an escape of gas occurs, keep onlookers away and notify a supervisor immediately. Gas may be dispersed with high pressure air or water. If you suspect that gas has escaped into sewerage system immediately notify your supervisor and be sure that the appropriate authorities are notified. FORKLIFT TIP OVER Page 2 of 23

3 1. Can an employer let you do High Risk Work (HRW) if you are not trained? No. By law your employer must make sure that you are trained and competent to do High Risk Work 2. You have a HRW licence. Under WHS (Workplace Health and safety), what are your responsibilities while working? You must work in a way that is safe. You must not risk the health and safety of others or yourself. 3. Name 3 responsibilities when applying for a HRW licence according to WHS regulations. Enrolling in an approved course and provide the following information: Provide 100 points of Identification Declare you have never had a licence suspended or cancelled Give no false or misleading Information Declare you have never been fined under WHS legislation 4. You can be penalised for not doing high risk work safely. What might the penalties be? You may have your licence suspended or cancelled. You may not be able to renew you licence. 5. You are a trainee at a Registered Training Organisation (RTO). You are training to get a high risk work licence. Under WHS Regulations/Laws, what does trainee mean? A trainee is a person learning under a training plan or enrolled with an RTO in an approved course 6. You have passed your HRW licence test. You must now apply for your photo ID high risk work licence. You must submit the Notice of Satisfactory Assessment form from your RTO. How many days do you have to put this application in? From the time that you get your Statement of Attainment you have 60 days to lodge your HRW licence application 7. Once you have a HRW licence you need to remain competent and up to date. Can you use your HRW licence if you are no longer competent? No, you must undergo more training Page 3 of 23

4 8. You must renew your HRW licence after how many years? 5 years 9. Why is it important to communicate to Safety Officers and other workers prior to operation? To help you follow Safe Operating Procedures 10. Who might you talk to about hazards before you start the job? Supervisor, Workmates, WHS Representatives, Safety Officers, Site Engineers 11. Why is it dangerous to use internal combustion engines in restricted (confined) spaces? Persons in the restricted space could be overcome by the dangerous gas generated by the combustion engine. 12. Why must batteries be charged in a well-ventilated area? To reduce the build-up of explosive gases. 13. Should a forklift truck be refuelled while the engine is running? No, the running engine could ignite the fuel 14. You need to plan for possible hazards before you use the forklift. Name 8 hazards. Doorways Blind Corners Dangerous Material Overhead lighting Support Beams Other Machinery Obstructions Co-workers Page 4 of 23

5 Power lines Service Lines Railway Lines Uneven ground Buildings Weather Hazards unique to the workplace 15. The Hierarchy of Control is a list of actions that you can use to eliminate or lower the danger from hazards in the workplace. What are the six levels? ELIMINATION: if possible, remove (take away the hazard) SUBSTITUTION: Use a safer method if you can t remove the hazard ISOLATION: Stop access to the hazardous (dangerous) area ENGINEERING control measures: Change the tools, equipment, and environment to make it safer ADMINISTRATIVE Practices: Reduce the time the workers are exposed to the hazard by using training, job rotation etc. Safe Operating Procedures PPE: (Personal Protective Equipment) Use PPE if the above controls are not enough to remove the hazard 16. Why is it important to look after your work area and plan the path you would travel? You need to check the path for hazards and remove hazards if they are present. 17. When is the best time to choose your PPE and other safety equipment? When you are planning your work Page 5 of 23

6 18. When is the best time to check your PPE and other safety equipment? Before use 19. What is the most suitable type of forklift to be used in a confined space? A battery (electric) powered forklift 20. You are about to lift a load, list 6 things that are not site hazards that you would need to consider. Check the Data Plate to make sure the load is within the Rated Capacity Make sure the load is stable and well balanced Know the weight and the size of the load Make sure the entry and exit to the load are accessible Make sure the attachment is the right one and in good condition Make sure you have the right equipment and it is available Make sure you have the right permits for the task 21. You are using a forklift near power lines. Working near power lines is very dangerous and can kill you. What are the minimum distances you must follow? 3m < 132,000 volts 6m 132, ,000 volts 8m>330,000 volts ***Use a Safety Observer if you need to work closer than the minimum distance allowed*** 22. Who could you talk to if you needed to find out the voltage of overhead power lines? Your local power supply company Page 6 of 23

7 23. What are some ways that you can work closer to power lines than the minimum safe distances allowed? The power company may be able to turn the power off (disconnect) the power lines. The power lines may be covered by insulation Use a safety observer in the exclusion zone if you are allowed to in your State/Territory 24. Tiger Tails are black and yellow pipes that wrap around Power lines. What are they used for? Tiger tails warn that power lines are there 25. Name 4 ways you can communicate and give information to other workmates on sites Signs hand signals & gestures written and verbal Listen and asking instructions questions 26. Why should you look over your forklift and do a visual check before using it? You must make sure the forklift is safe for operation 27. During your pre-operational check you notice the data plate is missing or unreadable. What action would you take? 3T's Take the keys out Tag the machine Tell your boss 28. You should know all the controls on your forklift. Forklift controls may be different on each forklift. How do you learn about the controls? You should check the operator s manual or undergo induction training Page 7 of 23

8 29. You have found a problem with the forklift truck. What should you do? 3T's Take the keys out Tag the machine Tell your boss 30. How should you get off and on your forklift truck? Get on and off the left hand side. Use three points of contact. Never jump off the forklift. 31. List 3 things you would check for on a forklift with solid rubber tyres. Check that the tyre wear is even Check the outer tread is not worn down (keep above the wear line) Check no big pieces of rubber are missing and for cracks 32. You need to do a post start check to check the forklift is safe and working properly. List 7 post start checks you should make after you have started the forklift. Check the steering Check the brakes Make sure all hydraulics work correctly to their full extent Check that the forklift moves properly in all directions Check warning devices (horn, beeper, etc) Check the lights Check the gauges Page 8 of 23

9 33. You are using the forklift and hear strange noises. What do you do? 3T s - Take the key out, tag the machine and tell the boss 34. When should you do pre operational checks? Prior to use 35. List 7 different parts of the forklift that you would check prior to use 36. What important function does a load backrest (load guard) perform on a forklift truck? A load backrest stops the load fouling the mast and falling on the operator. (Protects mast and operator) 37. Forklifts have safety guard to keep the operator safe. What safety guards do they have? Overhead guard Load backrest Foot guard Page 9 of 23

10 38. Why do all tyres need to have the right air pressure? A flat tyre can make the forklift unstable and could tip over sideways 39. Under what circumstances could an operator make minor repairs, alterations or adjustments to the forklift truck? Only if the operator was a competent person and authorised by the employer 40. List 4 ways you can check the weight of a load Read the weight Check the weigh bridge Weigh the load Calculate the load of the load note or consignment note eg. 50(kg) x6 + 20kg for the pallet =320kg 41. The forklifts in attachment A are rated at 2000kg, with a 600mm Load Centre Distance. Which one is overloaded? Load A ATTACHMENT A Page 10 of 23

11 42. The forklifts in attachment B are rated at 4500kg, with a 600mm Load Centre Distance. Which one is within the forklifts capacity? Load C ATTACHMENT B 43. You have to move a load of flour there are 11 bags per row, 4 rows high on a pallet. Each bag weighs 25kg. The pallet weighs 35kg. What is the full weight of the load? Show how you worked it out. 11(bags) x4 (rows) = 44 bags 44 (bags) x 25 (kg) = 1100Kg 1100kg + 35kg (the weight of the pallet) Total weight of the load = 1135kg 44. What is meant by the term Rated Capacity in relation to a forklift truck? It is the maximum load that a forklift is designed to carry at different heights and different load centres Page 11 of 23

12 USE THE DATA PLATE FOR THE NEXT 4 QUESTIONS 45. You are about to lift a load. The load centre is 700mm. The weight of the load is 1900kg. Can you lift this load? Why or why not. No. The load centre is more than 600mm 46. You have to lift a load that is within the forklifts capacity and put it on a shelf. The shelf is 4200mm off the ground. Can you lift this load? Why or why not. Yes. It is less than the maximum lift height 47. You have to lift a load. You must tilt the mast forward. What is the heaviest you can lift? 1610kg 48. You have to lift a load. It has a 600mm load centre. You can use the mast vertically. What is the heaviest load you can lift? 1900kg 49. You are about to lift a load vertically, you find it is heavier than the data plate on your forklift says you can lift. Should you lift the load? No. Never lift loads that are heavier than what s listed on the data plate Page 12 of 23

13 50. When should you set up your hazard controls? Before you start the job, or as soon as you find the hazard 51. List 3 ways you can warn and direct pedestrians and workmates on site. Barricades or fences A flag person Flashing yellow hazard lights Warning signs Scaffolding, hoarding or gantry 52. List 3 ways you can warn and direct vehicles on site. Barricades or fences A flag person Flashing yellow hazard lights Warning signs Scaffolding, hoarding or gantry Vehicle exclusion zones 53. You are using a forklift in a dark place. What do you need to have? You need to have good lighting in the area so that you can see everything clearly and easily 54. Why is rear end swing dangerous on forklift trucks fitted with rear end steering? The rapid sideways movement at the rear of the forklift truck creates a hazard for people nearby. 55. Rear end swing is dangerous. Who is it most dangerous to? It can be dangerous to all the people in the area where the forklift is working Page 13 of 23

14 56. You are about to reverse the forklift truck. What should you do? Check behind you and look over both shoulders If you cannot see behind you get someone to guide you Check the warning devices are working 57. What precautions should the operator take when operating the forklift on wet or slippery surfaces? Reduce speed and proceed with caution 58. List 3 situations where you should sound the horn on your forklift truck? When you want to warn someone that you are coming When you are going around a blind corner When you are going through doorways 59. You need to move a load up or down a ramp. Which direction should the forklift be moving? When you are moving up the ramp the forklift must be going forward with the load facing uphill When you are moving down the ramp the forklift must be going in reverse with the load facing uphill 60. Why is it unsafe to turn a forklift on a ramp or a sloping surface? Because the lateral stability is affected and the forklift could tip sideways or the load could slide 61. Are you allowed to put more weight on a forklift truck without checking with the forklift manufacturer? No. Forklifts are made to lift specific maximum loads. Changing the counterweight could cause an accident. 62. Should a load be raised or lowered near or over people? Explain your answer No. Not under any circumstances. Loads must never be raised or passed over people, it is dangerous and against safe operating procedures. 63. Some of your workmates want to ride on the forklift truck. Is this ok? Only if it is designed for it (the forklift must be fitted with a passenger seat, seatbelt and footguard) Page 14 of 23

15 64. How does the seatbelt keep you safe? The seatbelt keeps you in the seat. If the forklift tips over it will hold you in 65. Why is it not safe to turn a forklift with the load raised in the air? Because it makes the forklift unstable and it could tip over sideways 66. Why does the side shift attachment need to be centralised before shifting a load? To maintain balance and stop the forklift from tipping sideways 67. You have to move a load on the forklift. You can't see where to go. How can you move the load safely? Travel in reverse or ask someone to walk beside the forklift to guide you 68. When you are moving the forklift, what is a safe height for the load? Axle height or as low as possible to the ground without scraping. 69. May a load be carried by only one arm of the forklift truck? No. The fork arm carrying the load may be overstressed and the lateral stability of the forklift truck will be seriously affected 70. You are stacking stock into shelves. What three things do you need to think about when you stack load on top of each other? Stack the goods on a solid and level surface The stack of goods should be stable and balanced Heavy goods need to be at the bottom 71. A Pallet appears to be unsafely loaded. What would you do before attempting to lift it? Restack it so it is safe Page 15 of 23

16 72. What should be provided for the gap between a truck and a loading dock before shifting a load? You need to use a secured bridge plates or a secured dock plates to cover the gap 73. What does Load Centre Distance mean? It s the distance from the vertical face of the forks to the loads centre of gravity 74. How does increasing the load centre affect the capacity of a forklift truck? It decreases the capacity. (As the load centre distance gets bigger, the weight that it can safely lift gets smaller) 75. If the load is not pushed right up against the heel of the fork arms, what might happen? The forklift can carry less and may be unstable 76. Name 6 operating conditions that may cause the forklift to tip over sideways. (lateral instability) Turning at speed Turning on a ramp Turning with a raised load Turning and braking Driving over uneven surfaces Unevenly distributed load to one side Driving with a flat or uninflated tyre Load shifting sideways Driving too fast (loaded or unloaded) Side shift not centred 77. Name 6 operating conditions that may cause the forklift to tip forward or backwards lengthways (longitudinal instability) Driving forwards downhill (especially with a heavy load) Braking too hard Overloading Not using the mast tilt correctly Load not pushed right up against the heel of the forks Load centre too far forward Shifting of load centre forward (centre of load is forward of the approved load centre) Page 16 of 23

17 78. Where is the forward point of balance or fulcrum for a forklift truck? Where a line drawn vertically, passing through the centre of the front axle meets the ground 79. Is all the weight behind the point of balance acting as a counterweight? Yes 80. Why should you keep checking your load while you are moving? To make sure people are safe, and to make sure the load is still stable 81. List 3 actions you should take if the forklift starts to tip sideways and you think it might tip over? Stay on the forklift. Do not jump off. Brace yourself and wait until the forklift stops, then get off 82. What would you do if you drove your forklift mast into power lines? List 3 actions Warn others to stay clear Try and break contact Stay on the forklift Jump with both feet with power lines if until it is safe together ensuring you possible Don t touch the ground and the fork at the same time Page 17 of 23

18 83. There has been an accident at your work site. Which vehicles have the right of way in an emergency? All Emergency vehicles 84. You are looking for a place to park the forklift truck. List 4 places where you would not park. Doorways and exits Fire equipment First Aid Stations Less than 2 meters from train tracks Pedestrian walkway Refuelling sites Ramp or slopes Emergency exits Blind Corners 85. What are the normal parking procedures when you park a forklift truck? Tynes (forks) should be flat on the ground Put park brake on Put forklift in neutral Take key out Follow any site specific safety procedures 86. If your forklift must be parked on an inclined surface, what precautions would you take? In addition to normal parking procedures, chock the wheels of the forklift Page 18 of 23

19 87. List 4 things you need to do when shutting down a forklift truck? Park the forklift away from hazards Put the fork arms on to the ground and use the forward tilt Put the forklift into neutral gear Put the handbrake on Turn off the engine Take out the key Get off the forklift using three points of contact Turn off the gas Charge the battery if required Update the logbook and do a post-operational (after) check on the forklift 88. You have finished using the forklift truck. You should do some post operational checks. Name 4 things you would check Make sure everything is closed off and turned off Look for leaks on and under the forklift Walk around the forklift and look for damage Make sure it is safe for the next person 89. Why do you need to take the key out of the ignition when leaving the forklift unattended? To stop the forklift truck being moved by someone who is unauthorised. 90. You are doing the post operational checks and you notice a fault on the forklift. What would you do? 3T s - Take the key out, tag the machine and tell the boss Page 19 of 23

20 IN THE EVENT OF AN EMERGENCY SITUATION Page 20 of 23

21 UNIT 1: CONDUCT ROUTINE CHECKS 1. Pre Start Checks Lift and tilt systems Mast assembly Tyre condition, wheel nuts and pressure Warning decals Warning devices e.g. (flashing lights) Engine oil Hydraulic oil Transmission oil Battery security, water level and cleanliness Brake fluid Coolant Power steering Air filter indicator (diesel) Seat adjusted and secured Seat belt condition and security Mirrors adjusted and clean Windscreen condition and clean Data plates Overhead guards condition and security Load back rest condition and security Security of LPG cylinder, in date and condition of system LPG compliance plate Condition and security of batteries Condition of fork arms or attachments Locking pins checked for security 2. INSPECTS SITE AND PLAN WORK Power lines Doorways Overhead service lines (inside/outside) Bridges Surrounding building(blind corners) Railway lines Obstructions Other equipment in area Dangerous materials Other hazards unique to the workplace Personnel in area Applicant immediately removes hazards are eliminated by instigating appropriate action Applicant immediately removes hazards are eliminated by instigating appropriate safeguarding measures Before operating applicant ensures that site personal are made aware of forklift operation and any access restrictions for pedestrians Applicant is wearing suitable protective clothing and explains why it is important to wear it Page 21 of 23

22 Forklift type is suitable for load and height limitations. Applicant explains the reason why Attachments and fitting are appropriate for load type 3. AFTER START CHECKS Mounts Correctly Adjusts seat Fastens seat belt (if fitted) Demonstrates correct start up procedures Check lights Checks warning devices Checks gauges Braking system while moving Steering systems while moving Operation of controls results in smooth and correct operation of function ( all functions to be tested to the full extent of their movement) Checks underneath for any leaks Checks clear for travel before moving Applicant clearly explains what action would be taken if a fault was discovered during the check UNIT 2 SHIFT LOAD 4. OPERATIONAL PERFORMANCE CRITERIA Assesses the weight of a load before lifting Follows & maintains agreed travel path Ensure travel direction clear Operator keeps left in aisles for two way traffic Gives way to other traffic before moving Maintains a safe distance from other vehicles Travels at safe speed No mishaps or near misses when operating Where forklift goes undetected by others, operator takes appropriate action by either stopping, slowing, using horn or flashing lights Looks in direction of travel, if reversing looks over both shoulders before forklift truck moves Does not travel with load until load is lowered to safe height Travel in reverse if load obstructs forward vision and must constantly look in the direction of travel No object in the path of the forklift is hit or knocked over Operator keeps all parts of the body within the forklift when traveling. However, when manoeuvring or positioning loads operator may lean out for a clearer view Correct hydraulic controls are selected Operation of controls is smooth Whilst manoeuvring in a confined area the applicant shunts or repositions forklift to access the load Inserts attachments without touching or scraping the rack, stack or pallet Load is correctly positioned relative to attachment before raising Page 22 of 23

23 Mast is vertical or on a slight back tilt to stabilise the load when raising from racks or stacks Forklift is moved clear of the racks or stacks and the load lowered to the correct travel height with operator checking for sufficient clearance before traveling While traveling, the attachment or load is high enough to just clear any bumps or rises in the floor Where fitted forks arms must be below axle height.with other fittings bottom of load is axle height and/or high enough to clear obstacles During travel the mast is tilted back slightly to ensure the load is laying towards the load backrest or carriage, the load must remain correctly positioned on the attachment Travels at a safe speed and maintains safe control of the forklift The load is correctly positioned relative to the rack or stack before placing the load The load is positioned squarely in racks or stacks before placing the load Operator ensures the load is being placed evenly on the rack or stack, before the attachment are withdrawn Attachment is withdrawn cleanly Applicant explain the correct use of the park brake when raising or lowering a load on an incline, as per manufactures recommendations UNIT 3 SHUT DOWN EQUIPMENT 5. SHUT DOWN Parks equipment in a suitable location away from danger areas Lowers fork arms/attachments to ground Appropriate gear, relevant to the forklift transmission type, is selected when parking vehicle Applies park brake Engine/ power is off LPG cylinder is turned off Batteries are connected to recharge 6. SECURE SITES Parks clear of Access ways Walkways Fire/emergency exits First aid facilities Refuelling sites Blind corners No less than 2 meters from nearest railway track Remove keys Dismounts correctly Page 23 of 23