Forklift Training Manual

Transcription

1 Forklift Training Manual TLILIC Licence to operate a forklift truck OPEN 6 DAYS A WEEK PHONE (03)

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3 INTRODUCTION To drive a forklift truck in Australia you must hold a National Forklift Licence. This manual has been produced by START Training to assist you in gaining your Forklift Licence. All applicants must be 18 years of age or over. Current Photo Identification (Driver's Licence, Key Pass) is required at time of testing. If there is anything in this manual that you do not understand please feel free to contact one of our instructors on: Ph: (03) or info@starttraining.com.au Refund Policy Please note that 3 days notice is required for any cancellations or rebooking. If at least 3 days notice is given then a full refund will apply. If less than 3 days notice is given then the deposit paid is not refundable and the full cost of the course may apply. Forklift Training Manual Feb 2018 V9.docx 3

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5 Contents Introduction. 3 Contents. 5 Legislative requirements for High Risk Work... 7 Element 1 Plan Work.. 11 What is a Forklift.. 13 Duty of Care.. 16 Identifying hazards.. 18 Hazard prevention and control Data Plates.. 30 Load Centre Distance.. 31 Plan Work Summary.. 37 Element 2 Conduct Routine Checks.. 39 Daily Inspections.. 43 Controls.. 46 Starting your Forklift.. 52 Conduct Routine Checks summary 54 Element 3 Shift Load.. 55 Determining Load Weight.. 57 Hazard Control.. 62 Forklift Dynamics.. 64 Operating an Forklift.. 68 Emergency Situations and Procedures 80 Shift Load summary.. 83 Element 4 Shut down and Secure Forklift Truck Parking the Forklift.. 87 Securing the Forklift.. 88 Reporting and recording faults Shut down and secure Forklift summary.. 90 Appendix A Load calculations Appendix B Fitting a LPG gas cylinder.. 94 Forklift Training Manual Feb 2018 V9.docx 5

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7 Legislative requirements for High Risk Work (HRW) Forklift Training Manual Feb 2018 V9.docx 7

8 Legislative requirements for High Risk Work (HRW) licence applicants. When can I drive a forklift? To drive a forklift in Australia you need to have a forklift (LF) endorsed HRW (High Risk Work) Licence issued by WorkSafe. This is a nationally recognised and will allow you to drive a forklift in all states and territories in Australia. If you are asked to drive a forklift (perform high risk work) then you must show your employer evidence in the form of: a HRW Forklift licence or Written evidence that you are undertaking a registered training organizations (RTO) forklift licence course If you do not have a HRW (High Risk Work Licence) licence when can you under take High risk Work? Under the WHS Regulations you are considered under training when: You are enrolled in a course for HRW training and You are being supervised at a workplace by a person with a current HRW license for the work. How do I get a HRW forklift licence (LF?) You must enroll in a training course with a registered training organisation (RTO) that has been approved by WorkSafe. Upon completion of the training you will need to undertake and pass the National Forklift assessment. This National assessment has three parts to it: A theory assessment A calculations assessment A practical drive assessment Forklift Training Manual Feb 2018 V9.docx 8

9 Successful completion of assessment Once you have successfully completed your assessment you will be issued A Notice of Assessment (NOA) and a licence application form by the registered training organisation (RTO). You must take these to the Post Office to be processed within 60 days. The Notice of Satisfactory Assessment is your temporary licence for this 60 day period and allows you to operate the forklift until your licence arrives in the mail. The HRW licence needs to be renewed every five years. This can be done at any Australia Post outlet you need to provide the following: Current ID (100 points) Your existing HRW licence $45 licence renewal fee What happens if I let my licence expire? If you allow your licence to expire and you do not renew it within 12 months of the expiry date the licence cannot be renewed and you will have to: Complete a training course with an approved RTO and apply for a new licence or While continuing to work, be enrolled in a training course and work under supervision of a HRW licence holder Forklift Training Manual Feb 2018 V9.docx 9

10 Responsibilities of a HRW licence holder. As a HRW licence holder you need to take reasonable care of your own health and safety and not adversely affect the health and safety of others. Failure to do so could result in you being penalized under the WHS regulations. This may result in: Your licence being suspended or cancelled or The regulator (WorkSafe) may refuse to renew the licence. You may be directed to obtain a reassessment to determine competency. Forklift Training Manual Feb 2018 V9.docx 10

11 Element 1 Plan Work This Element covers the following Performance Criteria: 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. Forklift Training Manual Feb 2018 V9.docx 11

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13 What is a forklift truck? A forklift is a powered industrial truck used to assist the operator to pick/ lift and transport materials/goods in a warehouse. There are many different types of forklift trucks used in the workplace. The most commonly used forklift truck is the gas / petrol powered counterbalance style. This same style of forklift truck can also be electric powered. Forklift Training Manual Feb 2018 V9.docx 13

14 Other styles / types of forklift truck that you may be asked to operate are: Electric Reach Truck can operate in aisles much narrower than required by a counterbalance style Forklift and therefore allow much better use of the warehouse space. All Terrain Forklift These can be four wheel drive or two wheel drive and are designed to operate on rough and uneven ground. Container Forklift - Or Heavy duty Forklift. These can handle loads in excess of 45 tons. Forklift Training Manual Feb 2018 V9.docx 14

15 Double Reach Forklifts Are similar to a normal reach truck but are designed to place stock into a different style of racking that is much deeper than normal. Side Loader Forklifts Are designed to handle wide loads and not only drive forwards and backwards but can drive sideways as well. In this way they do not need as much space to turn and can still operate in narrow aisles. Forklift Training Manual Feb 2018 V9.docx 15

16 Identifying workplace hazards A hazard is anything or any situation with the potential to cause injury or harm. In other words it is anything or any action that can hurt or injure you or anyone around you. Under our Duty of Care we have a responsibility to act in a safe manner for ourselves and anyone around or near us. Duty of Care Definition. The duties under the Act are expressed in broad terms, for example: An employer must, as far as practicable, provide a work environment, in which employees are not exposed to hazards, Employees must take reasonable care for their own safety and health, and that of others, at work; and Self-employed persons must, as far as practicable, ensure the work does not adversely affect the safety and health of others. Such wide-ranging duties are called general duties or general duty of care the latter reflecting that a duty of care is owed in law by one person to another. Forklift Training Manual Feb 2018 V9.docx 16

17 What this means in simple terms is that: The Employer Must provide a safe workplace that is without risk to health. It means that the Employer must provide information, instruction, training and supervision as is necessary to enable employees to perform their work safely. It also means that equipment should be maintained in safe working order. The Employee All workers need to ensure that they work in a manner that is not harmful to their own health and safety and the health and safety of others. Employees must not place themselves or others at risk. Employees must comply with safe work practices, including making sure they hold license s, tickets or certificates of competency where necessary. Employees must carry out their tasks or use equipment according to any safety instruction. Employees must co-operate with their employer and follow all systems or procedures in the workplace to the extent necessary to allow compliance with the Act. Forklift Training Manual Feb 2018 V9.docx 17

18 The most common types of hazards we will encounter in most workplaces are: UP HIGH - Roller door clearances - Lighting/illumination - Electric lines - Overhead service lines - Bridges - Wind and bad weather conditions EYE LEVEL - Pedestrians - Plant and Equipment - Dangerous Materials - Obstructions - Facilities - Surrounding structures - Buildings - Access and Exit Points - Vehicle traffic; - Other equipment - Blind corners - Confined spaces - Poorly lit areas - Stock protruding from racking DOWN LOW - Wet surface condition, - Uneven surfaces, - Spills, - Debris, - Underground Services, - Weight bearing ability. - Slopes - Loading dock edges OTHER - Tidal areas - Chainsaws - Pressure washers - Safety tags - Records of incidents and injuries Forklift Training Manual Feb 2018 V9.docx 18

19 Hazardous work practices Not all hazards are environmental. We or other workers in the area sometimes cause them. These kinds of hazards may need to be reported or controlled. Working in inadequate light Stock badly stacked Driving equipment to fast Smoking near refueling stations Not using pedestrian walkways Not wearing protective clothing Hazards not barricaded off or contained Using petrol, gas or diesel equipment in poorly ventilated areas. If you feel the area is unsafe to work in DO NOT START WORK. Report the situation to your supervisor or manager. Forklift Training Manual Feb 2018 V9.docx 19

20 Planning for the job Apart from hazards we also need to consider a number of other things before commencing work (SPACE): Specifics of the task Permits required for the task Availability of Equipment Capacity of the forklift Equipment required for the task Characteristics of the load Location of task Attachments Communication (safe and adequate) Blind spots due to corners, the mast or the load. Forklift Training Manual Feb 2018 V9.docx 20

21 Some common hazards / accidents that forklift trucks are involved in include: - Damage To: - Stock Equipment People Caused by: - Not planning your route. Not allowing for rear end swing (see next page). Load falling from forklift. Not barricading the area that is being worked in. Not taking hazardous ground conditions into consideration. Pedestrians in the work area. Driving too fast. Forklift Truck Tip Over Caused by: - Operating across a ramp or sloped surface. Turning too quickly. Braking too hard (whilst turning and in a straight line). Overloading the forklift. Having the load centre too far forward. Driving down a ramp forwards. Speeding. Driving and/or turning with the load in the air. Being overcome by petrol, diesel or LPG fumes If there forklift truck has an internal combustion engine (petrol, diesel or LPG) and is being operated in an area with restricted airflow then the operator may be overcome by the forklift s exhaust fumes. You must use an electric fork in areas with restricted airflow. Forklift Training Manual Feb 2018 V9.docx 21

22 What is Rear End Swing Many accidents in the warehouse can be attributed to Forklift rear end swing or tail swing. It is the action of the rear wheels of the forklift truck swing outside the line of the front wheels whilst turning. This rapid sideways movement presents a hazard to people close by, structures, plant and equipment that may be struck by the rear of the machine. It also is a major factor in roll over of forklift trucks. Most rollovers occur on unloaded machines as they are at their most unstable when operating without a load. If full lock is used when turning a Forklift truck, you should remember that the rear of the machine may swing up to 3 ½ times faster than the front of the machine. If you are travelling at 3kph then the rear of the machine will swing at 10kmh. Note that on order pickers and reach forklifts the rear wheels are nearly in the middle of the machine so that front end swing is nearly as fast and dangerous as rear end wing. Poor Ventilation As many Forklift Trucks are petrol, gas or diesel powered you need to understand that if you are working in an area with restricted airflow then you may be overcome by the exhaust fumes. This can be fatal. The following areas would be considered as a having restricted airflow areas and an electric forklift should be used: A freezer A cold storage room A container A shed A store room Any other small area Forklift Training Manual Feb 2018 V9.docx 22

23 Power line clearances As Forklift Trucks often work outside near electric lines, WorkSafe requires you to know the legal requirements for working around electric lines. In Victoria the regulations state that you cannot work within: Power Poles 3 metres with a spotter 6.4 metres without a spotter Towers 8 Metres with a spotter 10 metres without a spotter Power Poles Towers In other States these clearances may change. If working interstate you need to check these clearances with the relevant authority. If you need to work closer than these clearances you need to: Seek an exemption from the relevant authority. Where possible have the electrical supply shut off. If this is not possible, the electric lines must be insulated by an authorised/competent person. The use of a spotter within the exclusion zone may also be appropriate, dependent on legislation within the state/territory. To determine the voltage of electric lines in your work vicinity you need to contact the local power authority for advice. Forklift Training Manual Feb 2018 V9.docx 23

24 In Victoria Tiger Tails are used as a visual system to warn people about power lines If you come into contact with electric lines you need to: Warn others to stay away Try to break contact with the power lines If safe to do so stay on the forklift. If you must leave the machine, jump clear ensuring you don t have contact with the vehicle and the ground at the same time, landing with your feet together and then continue to jump or shuffle with your feet together until you are at least 8 metres clear of the vehicle. Repot to management, power company and safety regulator. Do not use the forklift until it has been checked. Forklift Training Manual Feb 2018 V9.docx 24

25 Hazard prevention and control Once you have identified hazards in your workplace you need to decide how to deal with them before you start work. In some cases it might be as simple as clean up the mess or move the hazard. In other cases though you may need to consult with and report the hazard to: Safety officer Workplace Engineers (where applicable) Supervisor Other workers Managers who are authorised to take responsibility for the workplace operations. The reason for this is so that you understand any workplace policies and/or site specific procedures that need to be adhered to so that the correct hazard controls will be used. Depending on your workplace you may have to fill out paperwork to show how you will control hazards. This may include: Job Safety Analysis (JSA) Safe Work Method Statement (SWMS) Or other paperwork. Regardless of what paperwork needs to be done hazard control methods must be put into place before you start work to prevent injury/harm to personnel or damage to equipment and/or property. Forklift Training Manual Feb 2018 V9.docx 25

26 Hierarchy of hazard control To help us in the formal process of dealing with hazards in the workplace there is a system that is referred to as the hierarchy of hazard control. There are six levels to the Hierarchy of Hazard control. Most Effective Elimination Substitution Isolation Engineering Administration Least Effective PPE Forklift Training Manual Feb 2018 V9.docx 26

27 Hierarchy of Hazard control The hierarchy of hazard control is a list of control measures that can be used to eliminate or minimize the exposure to a hazard in the workplace. The diagram above shows the 6 levels in the hierarchy from most effective to least effective control. The six steps are: 1. Elimination If possible remove the hazard completely. e.g. Use electric forklifts or order pickers inside instead of petrol powered machines. 2. Substitution If you cannot completely remove the hazard then you should consider a safer method to be used. E.g. Use a spotter to warn the forklift operator that there are people nearby or use an Electric Forklift in confined spaces rather than a petrol forklift. 3. Isolation Lower the risk of exposure or injury by restricting or preventing access to the hazard. For example separate pedestrians and forklifts by the use of exclusion zones and the use of barriers and walkways. 4. Engineering This is where equipment and work processes are improved through engineering solutions to reduce risk. E.g. Use lights, reverse beeper, speed limiters, barriers or horns to warn people nearby. 5. Administration Administrative measures and safe work practices such as the use of signs, line marking, induction programs and training can all help reduce hazards and exposure to risks. 6. Personal Protective Equipment. (PPE) The use of PPE to control a hazard is always the last choice and least effective measure of control. It should always be used in conjunction with the other above listed methods of control. PPE is such things as safety boots, Hi-visibility clothing, eye protection etc. When using PPE make sure it is appropriate for the conditions, that fits correctly and you have been given adequate instruction in its use. Forklift Training Manual Feb 2018 V9.docx 27

28 Personal Protective Equipment PPE (Personal Protective Equipment) is common in nearly all workplaces these days. PPE is an item of clothing or piece of equipment that is worn on the body to protect you from certain hazards. It cannot totally eliminate the hazard or potential injury but it will help in reducing the risk of injury and assist in keeping you safer. The most common form of PPE in most warehouses are safety boots and hi-visibility clothing but as a Forklift truck operator you may also be required to wear other PPE as deemed appropriate by your employer. What PPE is required needs to be decided at the planning stage of the work and the PPE should be inspected prior to commencing work. Other forms of PPE that you may have to wear may include the following: Forklift Training Manual Feb 2018 V9.docx 28

29 Hazard control measures are in place Some examples of hazard control measures that may need to be implemented in the workplace for pedestrian, other workers, vehicles or mobile plant safety are: Flag person Flashing hazard lights Hoardings, gantries or scaffolding Pedestrian barricades and warning signs Pedestrian exclusion zone If you find a hazard in your work area that you cannot control you need to report it immediately to a supervisor. All risk control measures need to be in place before commencing work or as soon as a hazard is identified whilst working. Selection of equipment As mentioned earlier there are a number of types of forklift commonly used. So before commencing work you need to decide which type is appropriate for the work to be done and does it require any special attachments for the intended task. You also need to know if the forklift is capable of handling the loads you are required to lift and to the height you need to operate. To determine this there are a number of things we need to understand regards the machines capabilities. Forklift Training Manual Feb 2018 V9.docx 29

30 Data Plate (Load Plate) All forklift trucks in Australia are required by law to have a legible data plate attached to the machine. This is so that the operator can easily and quickly determine the load capacity of the machine they are about to operate. If the forklift does not have a data plate, or is unreadable, do not use it. The Data Plate gives us numerous important facts about the machine. It tells us the machines rated capacity. This is dependent on: The maximum load that can be carried To what height can that load be carried and/or lifted and, At what load center as shown on the data plate (load chart). It may also tell us other information such as: What attachments can be used Tyre Pressure Weight of the machine Weight of the battery The model and year of manufacture of the machine. Note: It is illegal and very dangerous to exceed the rated capacity on the data plate. Forklift Training Manual Feb 2018 V9.docx 30

31 Load Centre Distance To properly understand what the data plate is saying in regards to the machines lifting capacity we must understand the concept of Load Centre Distance. Load Centre is defined as The distance measured from the vertical face of the forks to the loads center of gravity All forklift trucks in Australia are re-rated at a 600mm Load Centre when they are imported into Australia because the standard size pallet used throughout Australia is based on a chep pallet. They are approximately 1200mm x 1200mm in size thus having a load center distance of 600mm. Forklift Training Manual Feb 2018 V9.docx 31

32 Load Centre Distance (continued) Most palletized loads are square and evenly stacked in which case the load center will be in the center of the load. Therefore if the load is picked up hard against the vertical face of the forks, the Load Centre distance will be half the length of the load. (This is 600mm in the case of a chep pallet). But, if the load is unusually shaped, has been stacked heavier at the front than the back or the pallet is not hard up against the vertical face of the forks then the loads center of gravity will be moved forward thus increasing the load center distance which may reduce the forklifts capacity. or affect the stability of the forklift Forklift Training Manual Feb 2018 V9.docx 32

33 Travel Route / Path of Movement It is important to inspect your work area for potential hazards and decide on the safest path to take when moving your load and operating the forklift truck. This will help prevent accidents, injury to other personnel or damage to machinery, equipment and stock. Things to consider will include: What hazards are present? (People, stock on the floor etc). Where will you have to stop/ relocate the load to? Where should you slow down? Where should you sound the horn? Will you need to reverse? Is ventilation adequate? Is there adequate lighting? What is a safe speed Is the ground surface suitable Do you have room to move / can you see? In planning your path you need to consider if you need to move things out of the way and do you have adequate clearance overhead and sufficient lighting in the areas you are about to move through. Effective traffic management Whilst operating the forklift truck it is important to reduce the risks to people working around you. So you will need to let people know you are working in the area. This can be done by: Posting signs Erecting barriers / barricades Using a flag person to control the flow of traffic. Forklift Training Manual Feb 2018 V9.docx 33

34 Communication In every workplace communication is very important in reducing hazards and risk of injury. There are a number of ways in which people may communicate with you or other site personnel. They may include: Verbal (listening and asking questions) Written instructions (such as JSA s or operating procedures) Signage Appropriate worksite protocol Verbal communication This the most used form of communication in the workplace. Your manger, supervisor or workmates may give you verbal instructions; listen carefully on how to do your job safely and properly. It is very important that if you don t understand the instructions that you ask questions and clarify what you were asked to do. Don t guess at what you have been asked to do. It is not foolish to ask a question. It may prevent you from having an accident. If you are asked to do something or use a machine that you have not been trained to use then you are entitled to ask for help and your employer has a duty of care to provide you with the necessary training. If you are unsure ask for help from an experienced operator or competent person. Forklift Training Manual Feb 2018 V9.docx 34

35 Written Instructions Written instructions come in many forms. They may be: Signage Company policies or work instructions These will include site and emergency procedures. These are rules and guidelines, which are put into place to ensure work is carried out properly and safely. It is important that you are familiar with how your company expects you to work and what you need to do in an emergency. If you don t know contact your manger or OH&S representative. An operating manual Each forklift truck comes with an operating manual. You need to take the time to read it and become familiar with that particular type of forklift. Material Safety Data Sheets or MSDS s contain information on how to handle and transport chemicals and what to do if there is an accidental spill. Work Permits set out the safety control measures that are required prior to commencing work and are used to ensure workers understand the site conditions and offer guidelines of what they shouldn t do. They are sometimes referred to as an induction onto the machine or the area. Every workplace will have safety signs posted around the work area. These signs are important because they remind you of any restrictions, hazards or special requirements (such as PPE) for the work site. You must follow the instructions on these signs as they are posted to keep you and your co-workers safe. Forklift Training Manual Feb 2018 V9.docx 35

36 Appropriate worksite protocols In some cases the company you work for may have their own specific forms of communication. An example of this is the use of hand signals. You have to use hand signals to communicate. It may be because the work area is very noisy or you may have someone guiding you because your vision is limited because of a large load. Always make sure you understand what the hand signals you and your assistant are using mean before you start work. HAND & WHISTLE SIGNALS Based on AS Motion Hand signal Whistle Motion Hand signal Whistle 1 long 1 short 1 long 2 short Turning left Turning right 3 short 4 short Luffing boom up 1 short N/A Stop Travel and traverse Creep speed: appropriate hand signal for motion is clenching and unclenching hand Forklift Training Manual Feb 2018 V9.docx 36

37 SUMMARY Plan work Make a thorough check of your workplace before you start work to identify any hazards or risks. Put in place any hazard control measures that you can. Report any hazards that cannot be controlled to your supervisor, manager etc. Use PPE when necessary Make sure you use the correct type of Forklift Truck for the job/work conditions Check the forklift trucks data plate before lifting anything. Set a travel plan or path to prevent accidents Understand the different ways in which your job instructions and requirements may be communicated to you i.e. verbal, written, signs or hand signals. Forklift Training Manual Feb 2018 V9.docx 37

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39 Element 2 CONDUCT ROUTINE CHECKS This element covers the following Performance Criteria: 2.1 Prior to operation, forklift is visually checked for any damage or defects. 2.2 All signage and labels are checked to ensure they are visible and legible, according to the appropriate standard. 2.3 All controls are located, identified and confirmed. 2.4 Pre-start operational checks are carried out accordance with manufacture specification and workplace procedures. 2.5 Forklift truck is started accordance with manufacturer specification and workplace procedures, and is checked for any abnormal noise. 2.6 Post- start operational checks are carried out in accordance with manufacture specifications and workplace procedures. 2.7 All forklift truck functions and safety devices are tested to their maximum in accordance with manufacture specifications and workplace procedures. 2.8 Issues, defects and damage identified during routine checks are reported and recorded accordance with workplace procedures, and appropriate action is taken. Forklift Training Manual Feb 2018 V9.docx 39

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42 Forklift truck safety guards There are three safety guards on the forklift truck to protect you. Overhead guard Protects the operator from falling objects Load guard / Backrest Stops the load from hitting the mast and protects the driver Foot guard Protects the operators feet Forklift Training Manual Feb 2018 V9.docx 42

43 Daily inspection checklist As an operator you will be required to check the forklift on a daily basis before use and complete a daily check sheet to record any faults that you may find. Daily check sheets allow you to: Record defects Record routine maintenance Record any other work that needs to be done. Forklift Training Manual Feb 2018 V9.docx 43

44 Daily inspections For your safety it is important to make sure the forklift is in proper working condition and safe to use before attempting to use it. There are two forms of checks that must be done. They are: 1. Pre-Start checks (Visual walk around and fluids check) 2. Start-up checks (Once on the forklift) Details of what operational checks can be found in the: Operators Manual Manufacturers Handbook Pre-start check Before starting your Forklift it is important to walk around the machine and do a visual check. Things you should check are: No Danger/ out of order tag is attached Tyres/wheels are ok Any attachments All guards (load guard/backrest, foot guard and overhead guard) Battery There are no leaks Forks are not damaged or cracked Mast and Hydraulics are not damaged or leaking There is no structural damage The data plate is attached and readable The operators manual and logbook are available Fuels Fluids (oils and water) Forklift Training Manual Feb 2018 V9.docx 44

45 If during your visual check you notice any major faults such as hydraulic leaks, structural damage or missing data plates you must (STIRR): Stop do not operate Tag out of service Isolate it so it cannot be used (Remove key) Record the fault in the log book. Report the fault to an authorized person. As part of your visual check you had to make sure the data plate was attached and readable. This is very important, as this is what tells you how much load the forklift can carry, at what load centre and to what height you can operate the machine. If there is no data plate attached or it is unreadable it is illegal to drive the machine. You must (STIRR): Stop do not operate Tag out of service Isolate it so it cannot be used (Remove key) Record the fault in the log book. Report the fault to an authorized person. Forklift Training Manual Feb 2018 V9.docx 45

46 Controls Although most forklifts have a similar layout for their controls there are a number of machines on the market that have very different layouts and control functions. It is important to consult the operator s manual for your particular forklift before operating it. Below is an example of the control layout for a typical Counter balance Forklift Truck. Steering Wheel Up / down lever Handbrake Gear lever Tilt Lever Side shift lever Brake pedal Accelerator Pedal Forklift Training Manual Feb 2018 V9.docx 46

47 Fluids (Pre-Start checks) On a forklift there are a number of fluids that need to be checked: 1. Brake Fluid 2. Hydraulic Fluid/ Power steering fluid 3. Battery Electrolyte level in each cell 4. Gas / petrol / diesel 5. Transmission fluid 6. Engine Oil 7. Coolant Battery A large number of forklifts are battery operated. It is important to maintain the battery in a good condition, as they are expensive to replace. When doing your visual checks you need to make sure that the battery is: Not damaged or leaking. Is fully charged. The terminals are clean and undamaged. The electrolyte is at the correct level. The battery is secured properly. Note: Some employers will not want you to do anything with the battery unless you have received the appropriate training. Always wear the appropriate PPE when checking batteries. When connecting and disconnecting the battery from the charger always make sure that everything is turned off especially the charger as batteries give off explosive gases when they are being charged and these can build up in an enclosed space over time. DO NOT SMOKE NEAR A CHARGING BATTERY Forklift Training Manual Feb 2018 V9.docx 47

48 Gas bottle checks A lot of forklifts operate on LPG gas which is contained within a gas bottle mounted to the rear of the Forklift. It is important to check for: Any gas leaks. The general condition of the system. The security of the system. The tank is in date. The forklift has a gas compliance plate. The pressure relief valve is positioned at the top. Refueling / Changing gas bottles Only properly trained and authorised personnel are permitted to change gas cylinders and/or batteries, and to charge batteries. Fuel system checks If the forklift has a petrol or diesel engine you need to ensure that there are no fuel leaks. If a fuel leak is suspected or detected do not start the forklift. You must immediately: Stop do not operate Tag out of service Isolate effectively isolate it so it cannot be used (Remove key) Record the fault in the log book. Report the fault to an authorized person. If the machine is diesel operated you may need to consult the manual for information on further checking the fuel and exhaust systems e.g., air filter and fuel filter elements may need to be checked. NEVER REFUEL A RUNNING FORKLIFT it could ignite the fuel and result in a fire. Forklift Training Manual Feb 2018 V9.docx 48

49 Tyre and wheel checks It is important to the stability of the forklift that all tyres are inflated to their correct pressure, in good condition and free of punctures. What do we check? No large pieces of rubber missing. Tyre not worn down. Wear is even. Ensure security of wheels To make sure tyres are securely fitted Wheel nuts must all be secured and rims must be in good condition free of dents and damage. Attachment checks Forklifts can be fitted with a variety of attachments to assist in moving various types of loads. Attachments must be: The right type for the forklift and loads and should be stated on the Data Plate. That it is correctly fitted and secured to the forklift by a suitable locking device or pins. Forklift Training Manual Feb 2018 V9.docx 49

50 Some common attachments used on forklifts are: Fork tines Carpet spike/ Roll prong Safety cage / Work platform Drum clamp / Rotator Jib Fork extensions Bin tipper Load spreader Forklift Training Manual Feb 2018 V9.docx 50

51 Height checks Safety cage / Work platform If you are going to lift someone in a safety cage / work platform you must: Ensure that the safety cage is approved and has a data plate attached to it. That you remain at the controls of the forklift whilst someone is in the safety cage. That the forklift be in neutral with the handbrake applied whilst the safety cage is raised. That you do not drive with the safety cage in the air. It must be lowered each time you need to move to another position. You are not allowed to use a stepladder or other device inside the safety cage to gain extra height. It is important to know the Overall extended height and collapsed height of your forklift before commencing work. Overall extended height is the height of the mast from the ground to the top of the backrest when the mast is fully extended. It is important for the operator to know this so that they are aware if the mast can hit the roof or other overhead hazards. It also tells the operator at what height they can place their loads. Collapsed height - is the height of the mast when fully lowered to the ground. This measurement allows the operator to know if the machine will be able to fit through the doorways, under any mezzanine floors or can be driven into a shipping container to unload it. Forklift Training Manual Feb 2018 V9.docx 51

52 Starting your forklift Getting on and off the forklift Most forklifts are mounted from the left side so as to avoid bumping the mast controls by accident. We also should use three bodily points of contact (foot, hand, hand) to avoid slipping or falling off. Starting the forklift Before starting your forklift: Make sure you have read the operators manual. Check it doesn t have an out of order tag on it. Check the battery has sufficient charge or there is enough fuel. Check the brake is applied. Visually check the forklift for damage, leaks and wear. Check the area is clear. Once you have started the forklift conduct you re start-up checks. Forklift Training Manual Feb 2018 V9.docx 52

53 Start-up checks When you have started your forklift there are a number of further checks that must be done. The following tests/ checks need to be performed: Warning devices (Flashing light, Horn and beepers) Lights if fitted Brakes are working. Hydraulics Steering is in working order. Gauges are working. Forward and reverse functions operate. If electric, the emergency cut out switch is working. Once you have started the forklift listen to see that there are no unusual noises or vibrations as this may indicate that there is a problem or fault. If you detect any fault or hear any abnormal noise you should: Stop do not operate Tag out of service Isolate effectively isolate it so it cannot be used (Remove key) Record the fault in the log book. Report the fault to an authorized person. If you are competent and authorised by your employer you may carry out minor repairs. Forklift Training Manual Feb 2018 V9.docx 53

54 Conduct Routine Checks Element 2 Summary Use daily inspection checklist to record maintenance and defects. Complete a visual check of the forklift for damage or defects. Check that all signage and labels are attached and readable. Make sure you know where all the forklift controls are and what they do. Pre-start operational checks are made including: Attachments Fluids Tyres Battery Warning devices Brakes Steering Faults and defects are recorded using the proper paperwork and reported to the appropriate person. Forklifts with faults have their keys removed and are tagged with an out of order tag so that others will not use the machine. Forklift Training Manual Feb 2018 V9.docx 54

55 Element 3 Shift Load This element covers the following Performance Criteria: 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 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 ensuring 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. Forklift Training Manual Feb 2018 V9.docx 55

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57 Determining load weight In our pre-operational checks we read the data plate on the forklift to determine how much weight the machine could carry. Before picking up or moving a load we need to also determine how much the load may weigh. This can be done in a number of ways: 1. By reading the consignment note or weighbridge docket that came with the load. 2. Weighing the load. 3. By calculating the weight of the load. 4. The load weight may appear on the load itself or on the packaging in which it is delivered and transported. Consignment Notes A consignment is usually sent with most deliveries and is issued by the carrier as a record of what ahs actually been sent. It will usually contain information on: Pallet control. Number of items. Description of items. Who is to receive the items? A place for the receiver to sign to say they have received the goods. The weight of the pallet load or the individual items. Weighbridge dockets A weighbridge docket can be used if the delivery truck has been over a weighbridge and had the load weighed. Weighbridge dockets are only useful if there is only one item (i.e. one large crate) on the truck as the docket only gives the total weight of the load, not individual pallet weights. Forklift Training Manual Feb 2018 V9.docx 57

58 Calculation Calculation is probably the most common method used by operators. It can be as simple as identifying the weight of one item on the pallet and multiplying that weight by the number of items on the pallet (if all are the same). Example 1. If one box on the pallet weighs 10kg and there are 20 boxes on the pallet then it is: 10kg x 20 = 200kg (plus the weight of the pallet) Example 2. If there are 4 drums of water on the pallet at 200litres in each drum and the drums weigh 10kg each then it is: Water weighs 1 litre = 1kg 4 x 200 = 800 for the weight of the water plus 4 x 10 for the weight of the drums = 40kg = 840kg (plus the weight of the pallet) Example 3. There are six cartons on each layer of the pallet and there are three layers and each carton is 15kg then the total weight is: Cartons 6 X 3 = 18 cartons Weight of the cartons is 18 X 15kg = 270kg Total pallet weight = 270kg plus the weight of the pallet Forklift Training Manual Feb 2018 V9.docx 58

59 Load Centre Distance Once we have determined how much the load weighs we then have to check our load centre distance to confirm that the load is within our rated capacity. As mentioned earlier Load Centre distance is defined as The distance measured from the vertical face of the forks to the loads center of gravity Remember: If you increase the Load Centre distance you will reduce the lifting capacity of the Forklift. Forklift Training Manual Feb 2018 V9.docx 59

60 Load Centre distance calculations The machines below are rated at 2000kg at a 600mm Load Centre a) If the load to be moved weighs 2400kg which forklift could move the load? None of the machines are capable of lifting the load as they are all rated at a 2000kg maximum. b) If the load to be moved was 2000kg which forklift can lift the load? B can lift the load as it has a load centre of 600mm and C can lift the load as it has a load centre of 500mm and they are rated to 2000kg at a 600mm Load Centre as. A cannot lift the load as the load centre is 700mm which is greater than the 600mm rating. c) If the load was 2000 kg can Forklift C lift the load? Yes, the load is within the 2000kg that the machine is rated for; the load has a load centre of only 500mm which is less than the rated load centre of 600mm so the machine can safely lift it. d) If the forklift is rated at 2200kg at a 600mm load centre and we try to lift up a 2200kg load with a load centre greater than 600mm what will happen to the forklift. The Forklift will be overloaded and possibly tip forward. It is important for your safety to understand load centre distance and how it affects the capacity of your machine. Forklift Training Manual Feb 2018 V9.docx 60

61 The longer the load the more the forklifts capacity is reduced Forklift Training Manual Feb 2018 V9.docx 61

62 Hazard control Before commencing work it is necessary to ensure that all hazard control measures are in place. If you are unsure what these are for your particular employer then you need to check with your supervisor or manager. Hazard controls will include: Putting barricades in place. Putting signage in place (if not already there). Letting other people know you are working in the area. Moving obstructions. Turning on additional lighting. Putting on your PPE. Getting someone to assist as a flagman (if required). Anything else necessary to do the job safely. What sorts of goods are you moving? Sometimes the load or goods you are moving may be comprised of dangerous goods such as chemicals, explosives (aerosols/ air bags for cars) and other dangerous goods. If you are handling times like these then you need to check the companies Material Data Safety Sheets (MSDS) to see what action you need to take when handling and packing them and what to do if there is a chemical spill. Forklift Training Manual Feb 2018 V9.docx 62

63 Safety devices When using the forklift you must always check that the warning devices are working correctly. E.g.: Horn Reverse beeper Flashing light This is particularly important when working around other people or equipment. Insufficient lighting If you are working at night in a darkened area such as: A store room A container Or other dimly lit areas You are required to obtain adequate lighting across the entire area, sufficient for the forklift to safely conduct its operations. Forklift Training Manual Feb 2018 V9.docx 63

64 Forklift dynamics Before we start moving our load and driving the forklift around there are some basic concepts that we need to understand. The Stability Triangle Forklifts have a 3-point suspension. The rear axle is supported by a pivot pin in the centre of the axle enabling some up and down movement of the rear wheels when working. The area between points A, B, and C in the diagram below is known as the stability triangle. If the centre of gravity moves outside the stability triangle, the forklift will start to tip over. Many accidents occur as a result of the forklift tipping over, either forward (longitudinally) or sideways (laterally). The centre of gravity moves about like a ball in a bowl of water and is affected by how the operator drives, brakes, accelerates turns and even moves across uneven ground. Understanding this will help you avoid tipping the forklift over. Forklift Training Manual Feb 2018 V9.docx 64

65 The Point of Balance (Fulcrum) The point of balance (fulcrum) is where the front tyre meets the ground. All the weight behind the point of balance acts as a counterweight. It is very important to understand these principals of balance, because if the load is not properly balanced, then the forklift can tip over. The forklift is like a seesaw. The weight behind the point of balance acts as a counter-weight and provided that the balance between the counter-weight and the load remain in favour of the forklift then everything will remain balanced and be OK. However, if the weight of the load exceeds that of the counter weight then the forklift will tip over. You are not allowed to add additional counter weights to the forklift without referring to the forklift manufacturer. Forklift Training Manual Feb 2018 V9.docx 65

66 Forward / backward (longitudinal) stability The forklift is an unbalanced machine with one end heavier than the other and should never be allowed to have more weight forward of the fulcrum than behind it. If the centre of gravity of the load and the machine combined, moves forward of the fulcrum, the machine is in danger of tipping forward. Some causes of tipping forward or backward while travelling are: Overloading. Load not positioned against the heel of the fork arms. Sever braking. Incorrect use of forward tilt (if fitted). Driving over uneven surfaces. Unevenly distributed load. Operating on a sloping surface. Driving too fast (loaded or unloaded), including reversing. Shifting of the load centre forward Sideways (lateral) stability As with forward stability, we have to consider the centre of gravity of the machine. If the centre of gravity of the machine shifts to far to one side, the forklift is in danger of tipping to that side. Some causes of tipping over sideways while travelling are: Unevenly distributed load. Operating across a slope. Turning at an unsafe speed. Driving over uneven surfaces. Driving too fast (loaded or unloaded). Side shift not centered. Driving with flat or under-inflated tyre. Turning with the load raised. Forklift Training Manual Feb 2018 V9.docx 66

67 If your forklift tips over If the forklift was to roll over sideways you need to: Remain in/on the forklift. Brace yourself until the forklift is stationary and safe to exit. All counterbalance forklifts are fitted with seatbelts with the important function of:- Stops the operator from falling out in the event of a rollover. Stops the operator being propelled into the forklift structure or out of the forklift in a collision Forklift Training Manual Feb 2018 V9.docx 67

68 Operating a forklift You must always wear a seat belt when operating a counter balance forklift. When operating the controls on the machine it is important that you: o Use the correct controls. o Use them in a safe and smooth way. You must raise the fork arms from the ground (high enough to avoid bumps in the ground but still below axle height) before driving off to avoid the load or fork tynes from scraping on the ground. You may need to tilt the mast back slightly whilst travelling to maintain load stability. Keep the side-shift centralised to maintain forklift and load stability. Forklift Training Manual Feb 2018 V9.docx 68

69 If you need to carry a passenger on the machine it needs to be specifically designed and equipped to carry more than one person. Keep all parts of your body within the forklift whilst travelling. Do not operate the machine if you: o Have been drinking alcohol. o Are taking illegal drugs. o Are over tired or stressed. o Are on medication that may make you drowsy. Obey all traffic signals, traffic management plans and workplace procedures. Give way to all emergency vehicles. Forklift Training Manual Feb 2018 V9.docx 69

70 People and forklifts Accidents between pedestrians and mobile plant within workplaces are very common so as a forklift operator it is very important to watch out for and be aware of people around you. Never raise your loads near or over people, if the load falls you could injure or kill someone. It is also against OH&S safe working procedures. Never lift someone or the bare fork arms or load as they may slip and fall, injuring them. This is also against OH&S safe working procedures. Use your horn and lights so that people are aware you are coming. Use your horn when turning corners to warn others of your approach. Use your horn when approaching doorways to warn others that you are coming through. Forklift Training Manual Feb 2018 V9.docx 70

71 Operate at a safe speed WorkSafe does not specify a safe speed for the operation of forklifts. It is up to you the operator to decide what a safe speed is for the forklift at the time. This will depend upon what is happening around you and what the environment is like. If the company has a set speed limit for that particular area it does not mean you can exceed the speed limit but it means that it may be sensible to drive much slower than the posted speed limit. Some things that will affect how fast you can drive are: Speed Limit signs People in the area Size load Surface condition Obstructions The physical space you have to operate in Other equipment in the area. Obstructed vision If your view is obstructed, before moving you need to: 1. Check the pathway is clear 2. Check the mirrors 3. Looking over each shoulder if reversing 4. Use warning devices such as horn and flashing lights. 5. Use a guide if required. Forklift Training Manual Feb 2018 V9.docx 71

72 Working with a load Often we are asked to pack loads onto or move pallets with the forklift. Always ensure: The pallet is not damaged (replace it if it is). The pallet is capable of supporting the weight of the load. If the load is poorly or unsafely stacked restack it and make it safe. Keep the loads centre of gravity towards the heel of the fork arms. When we are driving and moving a load we must constantly monitor the load on the Forklift to ensure: Safety to other people and Load and structural stability. Forklift Training Manual Feb 2018 V9.docx 72

73 Placing a load in a stack/rack If you are required to drive a Forklift then you will be required to move palletized loads in and out of racking. 1. Approach the stack squarely and stop 300mm from the stack Apply handbrake. 2. Raise the load; check the load is level with only minimal back tilt to safely clear the stack. This will avoid hitting the lower loads if working at height. 3. Release handbrake. Move forward slowly stop with the load lined up in the stack and is correctly positioned. Apply the handbrake. Lower the load carefully to the stack. Make sure it is settled and locked into the racking. 4. Make sure the fork arms are clear of the load. Release handbrake. Look over both shoulders before reversing to ensure the area is clear. Reverse away from the rack carefully about 300mm without scraping or touching the pallet, rack or stack. 5. Apply handbrake. Lower the fork arms as close as possible to the ground at a maximum of axle height. Release handbrake. Again look over both shoulders. Reverse / drive away from the racks. Do not turn with the forks raised. Remember: when placing loads on top of each other they should: Be stacked on a firm level site. Heavy goods must be placed at the bottom. The stack must not become unstable due to height. Forklift Training Manual Feb 2018 V9.docx 73

74 Removing a load from a stack 1. Approach the stack squarely and stop 300mm from the stack. Apply handbrake. 2. Raise the forks; check the forks are level with only minimal back tilt to safely clear the stack. This will avoid hitting the lower loads if working at height. 3. Release handbrake. Move forward slowly, ensuring that the forks are centrally located and fully inserted. Avoid touching, scrapping the rack, stack or pallet. Apply the handbrake. 4. Raise the load and check for clearance. Release handbrake. Look over both shoulders before reversing to ensure the area is clear. Reverse away from the rack carefully about 300mm. 5. Apply handbrake. Lower the fork arms as close as possible to the ground at a maximum of axle height. Release handbrake. Again look over both shoulders. Reverse / drive away from the racks. Do not turn with the load raised. Forklift Training Manual Feb 2018 V9.docx 74

75 Moving a load When moving a load you must remember: To look in the direction of travel before moving. Ensure you have enough height clearance before you move. You are clear of power lines or overhead lighting etc. Constantly be alert for pedestrians and other obstructions. Other vehicles. Always keep the heaviest part of the load against the backrest. Monitor the loads stability. Stay to the agreed travel plan or pathway. Forklift Training Manual Feb 2018 V9.docx 75

76 Moving a load When moving a load you must remember: Be aware of slippery conditions e.g. wet floor, oil spills. Reduce speed, proceed with caution and avoid ramps or other inclined pathways. Travel with the load at approximately axle height or as low to the operating surface as practicable. Drive up ramps with the load facing uphill. Drive down ramps in reverse with the load facing uphill. If the load is large and blocks your vision you must:- - Check the path is clear - Look over both shoulders - Check mirrors - Use a spotter if required If a load is stacked badly and unstable we must restack it and make sure it is stable before attempting to move it When operating in a loading dock a secured dock plate or bridge plate will be provided to fill the gap between the loading dock and the truck. Forklift Training Manual Feb 2018 V9.docx 76

77 Moving a load - Do not Drive with unbalanced, uneven or unstable loads as you may lose the load. Turn corners quickly and risk tipping the machine over. Braking to hard loaded or unloaded and risk tipping the machine forward. Drive forward down a ramp as the machine may tip forward or lose the load. Turn on a ramp as the forklift may become unstable and tip over or you may lose the load. Travel across a ramp or incline as the forklift may become unstable and tip over or you may lose the load. Forklift Training Manual Feb 2018 V9.docx 77

78 Moving a load - Do not Carry people on the bare fork arms or load it is unsafe and against safe operating procedures. Lift or lower the load over people as it can result in: injury or death to bystanders if the load or part of the load falls from the Forklift. Drive with the load on one fork arm as it may be unstable and place to much stress onto the fork arm. Operate in a straight line or whilst braking or turning with the load raised as it affects the stability of the forklift, creates a hazard and the forklift may tip over or lose its load. Forklift Training Manual Feb 2018 V9.docx 78

79 Conditions may change All the time you are operating your machine you must stay alert for any changes in conditions. Just because you have planned your travel route and completed all of your checks it does not mean that things cannot go wrong. Pedestrians may walk out in front of you. The load may move whilst you are travelling. The forklift may develop a fault while you are driving. Things may have been put along your travel path by other operators. Other vehicles may be blocking your path. Forklift Training Manual Feb 2018 V9.docx 79

80 Emergency situations and procedures If there is an emergency you should do everything you can to minimize damage and/or injury to yourself and those around you. You Must: Communicate three important things:- 1. There is an emergency situation 2. The nature of the emergency 3. Where the unsafe area or areas are. Who do we tell:- 1. Other people at the work place 2. Workplace safety officer 3. Management / supervisor 4. Emergency services Make sure that you understand your workplaces Emergency Response Procedures. If you don t, consult your Manger or OH&S representative. Emergency Isolator In some emergencies you may have to cut the power to the electric Forklift. To do this, use the Emergency Isolator / stop button located on the front control pane or beside the drivers seat. (Check the Operators manual for its exact location.) Forklift Training Manual Feb 2018 V9.docx 80

81 Emergency vehicle access In emergency situations you must give way to all emergency vehicles. This includes Police, Ambulance, Fire Trucks and SES vehicles. Types of emergencies Chemical spills In the event of a chemical spill or accident you should: Barricade off the area Consult the Material Data Safety sheets on how to: o Contain the spill o Clean up the spill. Contact with power lines or overhead lighting or electrical cabling. If your forklift comes into contact with electrical cabling or power lines you should: (see page 25) o Warn others to stay away Environmental Conditions - rain / lightning o Try to break contact with the power lines o If safe to do so stay on the forklift. If you must leave the machine, jump clear ensuring you don t have contact with the vehicle and the ground at the same time, landing with your feet together and then continue to jump or shuffle with your feet together until you are at least 8 metres clear of the vehicle. o Repot to management, power company and safety regulator. o Do not use the forklift until it has been checked. Forklift Training Manual Feb 2018 V9.docx 81

82 Most forklifts are capable of operating in the rain, but be aware that rain may make the ground conditions slippery or soft and unstable. No forklift should be used in stormy conditions where lightning may strike. Doing so may result in injury or death. Failure / loss of control If your brakes or steering fail on the forklift: Don t panic Come off the accelerator and let the fork roll to a stop Gently apply the brakes (if possible) If the brakes have failed, steadily apply the handbrake Tag out the machine and report the incident Failure of hydraulics If your hydraulics fail or start leaking badly on the forklift: Don t panic Stop the forklift Lower the forks to the ground Tag out the machine and report the incident Forklift Training Manual Feb 2018 V9.docx 82

83 Element 3 SUMMARY Shift Load Always check the weight of the load before trying to move it. Check that the data plate allows you to lift the load. Steps to prevent hazards / reduce risks are taken. All forklift controls should be used in a smooth manner according to operating procedures. The forklift is always used in a safe manner according to regulations and procedures. Don t speed on the forklift. Drive slowly and within the constraints of the workplace. Make sure pedestrians are clear of your work area. Pick up, place and move your load safely to avoid tipping. Know what to do in the case of an emergency. Forklift Training Manual Feb 2018 V9.docx 83

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85 Element 4 SHUTDOWN AND SECURE FORKLIFT TRUCK This Element covers the following Performance Criteria: 4.1 Forklift truck is parked to avoid hazards. 4.2 Forklift is shut down in accordance with manufacturer specifications and workplace procedures. 4.3 Routine post-operational forklift truck checks are carried in accordance with manufacturer specifications and workplace procedures. 4.4 Forklift is secured to prevent unauthorized 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. Forklift Training Manual Feb 2018 V9.docx 85

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87 Parking a forklift truck At the end of your work period you should park your forklift in a safe area where it will not get in the way of anything and block exits and doorway as these may need to be used in an emergency. Most work places will have designated parking areas. (Usually near the battery charger if the forklift is electric.) Do not park in front of: Emergency exits First Aid stations or emergency showers Near firefighting appliances Near doorways On sloping surfaces Access ways Walkways Within 2 metres of a railway track Where its obstructing traffic Under overhead electric lines with insufficient clearance. Parking on a slope If you have to park on a slope or incline you must in addition to normal parking procedures, chock the wheels of the forklift. Chocking the wheels means placing a brick, block of timber or a wheel chock behind the wheels of the forklift to stop it rolling down the slope. Forklift Training Manual Feb 2018 V9.docx 87

88 Shutting down the forklift Once you have parked the forklift safely you need to shut it down correctly. Check the operators manual as to the correct shut down procedure for the machine you are using. Most shut down procedures are similar to this: 1. Lower the fork arms to the ground. 2. Apply the handbrake (if fitted). 3. Forklift to neutral. 4. Adhere to any site specific safety procedures. Post-operational checks Now you have finished using the machine you should conduct a post-operational check to: Check for damage. Check for leaks. Check if the battery needs recharging. Connect the battery to a charger. Make sure it is safe for the next operator. Confirm everything is turned off. Update all records A post-operational check involves walking around the forklift to conduct the inspection. Securing the forklift Forklift Training Manual Feb 2018 V9.docx 88

89 Always remove the key when you have finished using the machine. This is to stop unauthorized use. Each workplace may have varying procedures as to where to put the key so check with your supervisor or manager. Make sure the LPG fuel valve is turned off so that there can be no gas leaks and the risk of explosion is eliminated. Reporting and recording faults If any defects or damage is found you need to (STIRR): Stop do not operate Tag out of service Isolate it so it cannot be used (Remove key) Record the fault in the log book. Report the fault to an authorized person. In some workplaces there will be an authorized person responsible for the servicing and repair of the forklift trucks. Check with your supervisor or manager as to your responsibilities as in some workplaces you may be required to carry out minor servicing or repairs if you are considered capable and have authorization from management. Forklift Training Manual Feb 2018 V9.docx 89

90 Element 4 Summary Shut down and secure a forklift truck Park the forklift in a safe/designated area. Shut down the forklift according to the correct procedures. Complete a post-operational check of the forklift after you have finished using it. Carry out any minor servicing if required (if you are authorized and competent). Check you have removed the key and secured the forklift according to company policy. Report and record any damage or faults you find to an authorized person. Forklift Training Manual Feb 2018 V9.docx 90

91 Appendix A Load calculations 69. If your forklift was rated at 2200kg at a 600mm load centre could it pick up a load of 2200kg at a 500mm Load Centre? (Page 59) YES 70. If the forklift is rated at 2200kg at a 600mm load centre and we try to lift up a 2200kg load with a load centre greater than 600mm what will happen to the forklift? (Page 59) It will become unstable, tip forward and lose the load. Forklift Training Manual Feb 2018 V9.docx 91

92 71. If there are 4 drums of water on the pallet at 200litres in each drum and the drums weigh 10kg each then it is? (Page 57) 1 litre = 1kg 200 X 4 = 800 Plus 10 X 4 = = 840 kg 72. There are six cartons on each layer of the pallet and there are three layers and each carton is 15kg, then the total weight is? (Page 57) 6 X 3 = X 15 = 270 kg Forklift Training Manual Feb 2018 V9.docx 92