Assess To Lift. Training manual. National Recognised Training Organisation 91574

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1 Assess To Lift Training manual National Recognised Training Organisation

2 CHANGING LP GAS BOTTLES 1. 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 value to be frozen open allowing liquid gas to escape when hoses are disconnected. Goggles should also be worn. 2. Turn off valves before attempting to disconnect hoses. 3. When liquid gas is released to 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 vital therefore 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 30meters. 4. LP Gas is heavier then air and will, if allowed to escape, gather in low lying areas such as drains, service pits in workshops, basement, sewers to name a few. Always change bottles in open, well ventilated areas. 5. 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 a sewerage system immediately notify your supervisor and be sure that the appropriate authorises are also notified. Mount and dismount the forklift correctly Three point of contact Forklift Tip Over If your forklift starts to tip over( DO NOT JUMP). Stay in you seat (tip with the forklift). Grip the wheel and brace you feet. 1

3 1. Can an employer let you do high risk licence work if you are not trained? -No. By law your employer must make sure you are trained and competent to do high risk work 2. You have a high risk work licence. Under WHS laws, what are your responsibilities while working? -You must work in a way that is safe. You must not risk the health and safety of yourself or others. 3. Name 3 Rules that apply when you are attempting to gain a HRW licence according to WHS Legislation.? -Be able to show name correct id and photograph for the licence. -Be able to show that you have completed the required training i.e. show Statement of Attainment. -do not provide false information to obtain the licence. -declare and WHS offences that you may have been penalized for. 4. You can be penalised for not doing high risk work safely. What might the penalty be? -You may have your licence suspended or cancelled. You may not be able to renew your 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 6. You have passed your high risk work license test. You must now apply for your photo ID high risk work licence. You must submit the notice of satisfactory assessment 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 put in your high risk work licence application 7. Once you have a high risk work licence you need to remain competent and up to date. Can you use your high risk work license if you are no longer experienced? -No you must undergo more training 8. You must renew your high risk work license 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? -People such as Your team leader or supervisor -Workmates -WHS representatives - Safety officers -Site engineers 11. Why is it dangerous to use internal combustion engines in restricted (confined) places? 2

4 -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 risk of a build-up of explosive gases 13. Should a forklift truck be refuelled by the engine is running? Explain your answer -No. The running engine could ignite the fuel 14. You need to plan for possible hazards before you use the forklift. Name 8 hazards. Powerlines Doorways Everything up high Bridges Railway lines Blind corners Obstructions People Other machinery Dangerous good Hazard 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 a hazard in the workplace. What are the six levels? Hierarchy of Hazard Control 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 (danerous) area. Engineering Control measures: Change the tools, equipment or enviroment to make it safer. Administrative Practices: Reduce the time the workers is exposed to the hazard by using training, job rotation,the timing of jobs, ect. Personal Protective Equipment (PPE): 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 will travel? 3

5 -You need to check the path for hazards and ensure appropriate controls are in place Will you need to reverse? Are there any ramps or slopes? When should you sound the horn? Where will you have to stop? Is there enough ventilation and fresh air? Where should you slow down? What is the safest speed to travel at? 17. When is the best time to choose your PPE and other safety equipment? -When you are planning your work 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 use in a restricted (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 will need to consider? -What are some of the problems or challenges at this site? ie: shift times, movement of people, etc -Communication -How will you plan your route? -What equipment do you need? -Is the equipment there? -Is the equipment suitable? -Do you need permits? -Does the forklift have enough capacity to carry the load? Check the data plate. -Is the load is stable and well balanced? 21. You are using a forklift near powerlines. Working near powerlines is very dangerous and can kill you. What are the minimum safe distance rules you must follow? -The minimum safe distance rules you must follow can be different for each state/territory. For example only some use safety observers. A safety observer is someone who helps you work closer to powerlines. Most state and territories follow the powerlines safe working distances in the Australian Standard. (Ausgrid electrical safety rules) Low voltage with a safety observer- 2m Low voltage without an observer- 3m High voltage with a safety obsever -3.5m High voltage without a safety obsever - 6m 22. Who could you talk to if you need to find out the voltage of overhead powerlines? -Your local power supply company 4

6 23. What are 4 ways you can work closer to powerlines than the minimum distances allowed? -You might be able to get permission from the electricity supply authority. They will make sure the power is turned off. -The power company may be able to turn off (disconnect) the power supply -If you can t turn the power off, the power lines will need to 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 powerlines. What are they for? -Tiger tails warn that powerlines are there. 25. Name 4 ways you can communicate and give information to other workmates on a site: -Written/verbal -Instructions -Signs -Hand gestures or signals -Listening and asking 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 that the data plate is missing or unreadable. What action would you take? -Take out the keys -Put a danger tag on the forklift so no one else can use it -Tell your supervisor 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 29. You have found a problem with your forklift truck. What should you do? -Take out the keys -Put a danger tag on the forklift so no one else can use it -Tell your supervisor 30. How should you get on and off your forklift truck? -You should get on and off the forklift from the left hand side. Three parts of your body should touch the forklift at the same time: both hands and one foot. Never jump off the forklift. 31. List 3 things you would check for on a forklift with solid rubber tyres? -Check the tyre wear is even -Check the outer tread is not worn down (Keep tread above the wear line) -Check no big pieces of rubber is missing 5

7 32. You need to do post-start checks to check the forklift is safe and working properly. List 7 post-start checks you should do after you have started the forklift truck? -Check the steering -Check the brakes -Make sure all hydraulic functions work correctly -Check that the forklift moves properly in all directions -Check warning devices (horn, beeper, etc) -Check the lights -Check the gauges 33. You are using the forklift and hear strange noises. What do you do? -Take out the keys -Put a danger tag on the forklift so no one else can use it -Tell your supervisor 34. When should pre-operation checks be conducted? -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 from fouling the mast and falling on the operator (Protect mast and operator) 37. Forklifts have safety guards to keep the operator safe. What safety guards do forklifts have? -Overhead guard -Load backrest -Foot guard 6

8 38. Why do all tyres need to have the right air pressure? - A flat tyre can make the forklift unstable and it could tip over sideways 39. Under what circumstances could an operator make minor repairs, alterations or adjustments to a forklift truck? -Only if the operator was a competent person and authorised by the employer 40. List 4 ways that you can find out the weight of a load? -Checking the weigh bridge note, consignment note or other information -Weigh the load -Calculate the weight of the load. For example: 50kg x 6 = 300kg (don t forget to add the weight of the pallet) -Reading the weight on the load 41. The forklift in attachment A are rated at 2000kg at 600mm load centre, which one is overloaded? Load A 42. A forklift truck in attachment B is rated at 4500kg at 600mm load centre distance. Which one of the loads is within the capacity of the forklift truck? Load C 7

9 43..You have to move a load of 44 bags of flour on a pallet. Each bag weighs 25kg. The pallet weighs 35kgs. What is the full weight of the load? Show how you worked it out. -44 x 25kg = 1100kg -Plus the weight of the pallet = 35kg -Total weight of load = 1135kg 44. What is meant by term Rated Capacity in relation to a forklift truck? -It is maximum load that a forklift is designed to carry at a certain load elevation at a specific load centre distance (maximum limits found on data plate) 8

10 USE THE DATA PLATE FOR THE NEXT 4 QUESTIONS Max capacity when mast is vertical Tilt Limited to : Forward 6 degrees Backwards 6 degrees Max Capacity in forward tilt position Length mm Height mm Load Centre mm Capacity Kg Length mm Height mm Load Centre mm Capacity Kg 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 forklift capacity and put it on a shelf. The shelf is 4200mm off the ground. Can you lift the load with this forklift? Why or why not? -Yes. It is less than maximum lift height. 47. You have to lift a load. You must tilt the mast forward. What is the heaviest load 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 s heavier than what the data plate of your forklift says it can lift up. Should you lift the load? -No. Never lift loads heavier than what the forklift data plate says it can lift 50. When should you set up your hazard controls? -Before you start the job. -As soon as you find a hazard 51. List 3 ways you can warn and direct pedestrians and workmates on site? -Barricades or safety fences to protect people -A flag person to direct people -Flashing yellow hazard lights to warn people 9

11 -Warning signs -Scaffolding, hoarding or gantry 52. List 3 ways you can warn and direct vehicles on site? - Barricades or safety fences to protect people -A flag person to direct people (you might need to be a licensed traffic controller) -Flashing yellow hazard lights to warn people -Warning signs -Scaffolding, hoarding or gantry -Vehicle exclusion zone 53. You are using a forklift in a dark place. What do you need to have? -You need 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, particularly for pedestrians 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 56. You are about to reverse the forklift truck. What should you do? -Check behind you- use the mirrors and look over your shoulders -If you cannot see ask someone to help guide you -Check the warning devices are working 57. What precautions should the operator take when operating the forklift truck on wet or slippery surfaces? -Reduce speed and proceed with caution 58. List 3 situations where you should use the horn on your forklift truck? -You want to warn someone that you are coming -You are going around a blind corner and someone may be around the corner -When going through doorways 59. You need to move a load up or down a ramp/ which direction should the forklift be moving? -When you move up the ramp the forklift must be going forward with the load facing uphill -When you move 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 sloping surface? -Because the lateral stability is affected and the forklift could overturn or the load could slide 10

12 61. Are you allowed to put more counterweights on a forklift truck without checking with the forklift manufacturer? -No. Forklifts are made to lift specific maximum loads. Changing the counterweights could cause an accident. (Check Data Plate) 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 or over people, it is dangerous and is against safe operating procedures 63. Some of your workmates want to ride on the forklift truck. Is this ok? -No, it is unsafe. To carry a passenger the forklift must be fitted with a passenger seat seatbelt, and footrest 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 drive a forklift in a straight line or turn a forklift with the load raised in the air? -Because it makes the forklift unstable and it could tip over. 66. Why does the side-shift attachment need to be in the middle when carrying a load? -To maintain balance and stop the forklift from tipping sideways 67. You have moved a load on the forklift. You can t see where to go. How can you move the load safely? -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 fork arm of the forklift truck? Explain your answer. -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 things 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 69 What should be provided for the gap between a truck and a loading dock before shifting a load? -You need to use secured bridge plates or secured dock plates to cover the gap. 11

13 70 What does load centre distance mean? -The load centre distance is measured from the vertical face of the forks to the centre of gravity of the load 71 How does increasing the load centre affect the capacity of the forklift truck? -It decreases the capacity (-As the load centre distance gets bigger, the weight that it can safely lift gets smaller.) 72 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 and could tip over. 73 Name 6 operating conditions that may cause a forklift truck 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 -Driving with a flat or uninflated tyre -Load shifting sideways -Driving too fast (loaded or unloaded) -Side shift not centred 74 Name 6 operating conditions that may cause a forklift truck 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_ 75 Where is the forward point of balance (fulcrum) on the forklift truck? -Where a line drawn vertically, passing through the centre of the front axle meets the ground 76 Is all the weight behind the point of balance acting as a counterweight? -Yes 77 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 78 List 2 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. 12

14 79 What would you do if you drove your forklift truck mast into powerlines? List 3 actions. -Warn other people to stay clear and not to touch the forklift -Try and break contact with powerlines by moving forklift is possible -Remain in or on the forklift until informed the conditions are safe -If you must leave the forklift, jump clear ensuring you don t contact the forklift and ground at same time (Jump without earthing yourself) 80 There has been an accident at your worksite. Which vehicles have the right of way in an emergency? -All emergency vehicles 81 You are looking for a place to park the forklift truck. List 4 places you should not park the forklift? -In front of fire fighting equipment, extinguishers or water hoses -In front of emergency exits -In front of doorways and exits -On ramps or slopes -On pedestrian walkways -In front of first aid stations -Less than two metre from train and rail tracks -Where the forklift can block other traffic or people 82 What are the normal 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*** 83 If your forklift truck must be parked on an inclined surface, what precautions would you take? -In addition to normal parking procedures, chock the wheels of the forklift 84 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 85 You have finished using the forklift truck. You should do some post-operational checks. Name 4 things you would check. 13

15 -Check the coolant (water) and oil -Check the tyres -Wipe the controls and seat -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 86 Why do you need to take out the ignition key when leaving the forklift unattended? -To stop the forklift truck being moved by someone who is unauthorised. 87 You are doing the post-operational checks. You find a problem with the forklift truck. What should you do? -Take out the keys -Put a danger tag on the forklift so no one else can use it -Write the problem in the logbook -Tell your supervisor 14

16 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 Load 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 materialspersonnel in area Other hazards unique to the workplace Applicant immediately removes hazards are eliminated by instigating appropriate action 15

17 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 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 fixed) 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 16

18 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 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 17

19 Remove keys Dismounts correctly Draft Mapping of Easy Guides Learning Resources To Assessment Instrument and Performance Criteria Of Training Package 18

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