Forklift Course Pre-Reading Information. Version 2.0. March 2011

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1 Forklift Course Pre-Reading Information Version 2.0 March 2011 Reading through this manual prior to sitting your forklift course will assist you in preparing for your in-class theory session and written theory assessment. Definitions: Rear-End Swing: Rear-end swing is the rapid sideways movement of the rear end of the forklift when turning the machine. The rear of the machine will swing out to the opposite side to which you are turning. The speed of rear end swing will be approximately three times that of the forklift s forward speed, so it can cause serious damage. Rated Capacity: Is the MAXIMUM weight a forklift can carry at a given height and a given load centre. Data Plate: Stability: A metal plate affixed to the forklift by the manufacturer that contains information such as the weight of the vehicle. The ability of a forklift to remain upright. Stability is the most important factor necessary for avoiding accidents. Lateral Stability: The ability of a forklift to remain upright and not tip over sideways. A load that is out of balance or on an uneven travelling surface can affect lateral stability. Longitudinal Stability: A forklift s ability to resist tipping forward. When the weight exceeds the capacity of the forklift, longitudinal stability generally exists and the forklift will tip forward. Load Centre Distance: Is the distance from the vertical face of the fork arms to the centre of gravity of the load (see diagram below). Forklift/Current/Pre-Reading Manual v1.0

2 Duty of Care: The Occupational Safety and Health Act requires that employers, employees, contractors and others exercise a duty of care toward each other. This means that EMPLOYERS must provide and maintain a working environment in which workers are not exposed to safety and health hazards. Similarly, EMPLOYEES must take reasonable care of their own safety and health, and that of others. Parts of a Forklift: Mast: Load Backrest: Overhead Guard: Data Plate: The vertical portion of the lift mechanism that raises the load into the air. The backrest of the forklift that prevents the load from falling backwards onto the driver. The overhead guard protects the operator from falling loads. A metal plate affixed to the vehicle by the manufacturer that contains information such as the weight of the vehicle and it s maximum lifting capacity.

3 Counterbalance forklift s 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 acts as a counterweight. Pre-Start Safety Checks: Before operating a forklift, operators need to conduct a pre-start check at the beginning of each shift. This includes: Parts of the forklift (e.g. brakes, seat belt, steering, warning devices, lights, tyres, attachments); and Liquid levels e.g. hydraulic oil, brake fluid and water.

4 Safe Operation of a Forklift: All forklifts must be operated in a safe and responsible manner and within the manufacturer s guidelines as set out on the Data Plate; A seat belt must be worn at all times; Operators should always check the adjustment of rear view mirrors before moving off and then check mirrors regularly for potential hazards (e.g. pedestrians and other objects); Travel in a forwards direction wherever possible, unless for example the load on the forklift is blocking your view; Use the horn when turning around blind corners to warn people in the nearby area; Loads should always be carried as near to the ground as practicable. Turning the forklift with the load raised can cause the forklift to tip over; Always operate forklifts with the load firmly against the backrest with the mast tilted back sufficiently to prevent the load from slipping or falling; All loads that have the potential to slip or fall must be appropriately restrained with straps or shrink wrapping etc; Gas forklifts should only be used in well ventilated areas to prevent the build-up of fumes that could cause an explosion; Gas forklifts should never be refuelled whilst the engine is running as it could cause the fuel to ignite; Batteries for electric forklifts should be charged in a well ventilated area to stop the build-up of explosive gases. Similarly, you should never smoke when changing forklift batteries as the gases may ignite; When using a forklift over a roadway, footpath or public area you should use signs, barricades and safety personnel to prevent an accident from occurring; You should never raise or lower a load near or over people as it could cause an accident; The handbrake should be applied when raising or lowering the load; Make sure that the forks are centred when they are entering a pallet; Always put the heavy end of a load against the heel of the fork arms; People should only ever be raised on a forklift truck in an approved safety cage; Using attachments on forklifts are likely to reduce the lifting capacity of the machine. As such, all attachments need to be securely fastened to the forklift. The supplier of the attachment needs to then determine the lifting capacity of the forklift with the attachment fitted To avoid tipping over sideways (also known as lateral instability), operators should: - ensure loads are centred; - secure the load in appropriate manner (i.e. with straps or shrink wrapping); - carry loads as close the ground as practicable; - ensure tyres are correctly inflated (where applicable); - exercise extreme care when driving across uneven, sloping or wet surfaces. When leaving a forklift, the operator needs to ensure: - the fork arms are fully lowered, tilted slightly forward so the tips of the fork arms touch the ground; - the controls are in neutral;

5 - power is shut off; - park brakes are applied; and - the keys are removed, to prevent unauthorised use When you have finished using your forklift you should always undertake a post-operational check, to check for damage, leaks and to make sure all systems are shut down. If you suspect a problem with your forklift (e.g. missing or unreadable Data Plate, a leak in your fuel system or a crack in the heel of the Fork Arms), you should never attempt to repair it yourself, but instead you should remove the key, Tag the machine Out of Service, Isolate the machine and Report the problem to your supervisor. Electricity: The minimum distance you should keep your forklift and load away from powerlines is as follows: 0.5 metre from a live INSULATED overhead powerline of LESS than 1,000 volts; 1.0 metre from a live UNINSULATED overhead powerline of LESS than 1,000 volts; 3.0 metres from a live overhead powerline between 1,000 and 33,000 volts; 6.0 metres from a live overhead powerline greater than 33,000 volts. In the event of a forklift contacting a power line the operator should: If practical, stay in the cab and keep others away; Wait until the power is shut off before leaving the forklift; and If safe and practical, move the forklift off the power line. Data Plate Sample:

6 Stability Triangle: Forklifts have a stability triangle. A vertical line extending from the center of gravity of the vehicle and load combination must be inside of the stability triangle to prevent the forklift from tipping forward, falling sideways or dropping its load, as shown in the diagram below. The following can affect the centre of gravity and cause it to shift outside of the Stability Triangle, causing the forklift to tip over: - Load exceeding the rated capacity; - Unevenly stacked load; - Travelling down a ramp with the load facing downhill; - Raising a load on one fork only; - The addition of attachments; or - Slinging loads beneath the forks.

7 When travelling up a ramp, always ensure the load is facing uphill to ensure the load doesn t slip or fall and to maintain forklift stability at all times. When travelling down a ramp, always ensure the load is facing uphill to ensure the load doesn t slip or fall and to maintain forklift stability at all times.

8 Always use your horn around blind corners to ensure the safety of yourself and others. When travelling with a large load that obscures your vision, you should either travel in reverse, or use an experienced person as a spotter to guide you. Examples of some common forms of attachments used on forklifts:

9 Example of Load Centre calculation: The following forklifts are rated at 2,000kgs at a load centre of 600mm. Load centre is calculated by dividing the length of the load by two. Therefore, Forklift A has a load centre of 700mm (i.e divided by 2), Forklift B is 600mm (1200 divided by 2) and Forklift C 500mm (1000 divided by 2) Forklift A is overloaded, as it s Load Centre is 700mm, which is 100mm in excess of the rating of the forklift.