Forklift Operations Manual

Transcription

1 Forklift Operations Manual

2 ALL RIGHTS RESERVED No part of this publication may be reproduced or resold in any form without the prior written consent of the publishers, NATIONWIDE TRAINING PTY LTD. 13 Collingwood Street Osborne Park WA 6017 Phone: (08) Fax: (08) Web: Thank you for choosing NATIONWIDE TRAINING Our Nationally Accredited Courses include: Dangerous Goods Licence / Refresher Dangerous Goods Awareness Dangerous Goods Storage and Handling Dangerous Goods Class 3 & 9 Transport of Explosives by Road Safe Load Program (AIP) Safety and Health for Managers and Supervisors Driver Fatigue Management Safety Awareness Safety Representatives / Refresher OH&S Procedures Manual Handling Load Restraints Gantry Operation Certificate IV in Warehousing Operations Certificate IV in Business Certificate IV in Retail Management Certificate IV in Training and Education Certificate IV in Business Frontline Management Certificate IV in Occupational Health and Safety Every effort has been made to ensure that this publication is free from error or omissions. It must be noted that the information it contains is a guide for Operators only. Operators are referred to relevant publications as listed for further information relating to the Forklift Operator s responsibilities. NATIONWIDE TRAINING, the editor or their representatives, agents or employees shall not accept responsibility for injury, loss or damage occasioned to any person acting or refraining from action, as a result of material in this publication whether or not such injury, loss or damage is in any way due to any neglect, act of omission, breach of duty or default on the part of NATIONWIDE TRAINING, the editor or their representatives, agents or employees. Nationwide Training Pty Ltd Page 2 6 th Edition June 2013

3 ACKNOWLEDGEMENTS NATIONWIDE TRAINING would like to thank the following for their advice, cooperation and expertise in the development of this Forklift Operator Training Course: WorkSafe Australia Department of Labour Victoria Training conducted in this course complies with Australian Standard National High Risk Licensing requirements PURPOSE The purpose of the FORKLIFT OPERATOR TRAINING COURSE is to ensure Operators have the appropriate knowledge and skills to perform their duties and responsibilities in a safe, efficient, accurate and professional manner thereby avoiding injury to self and others, damage to goods, property and the environment and unnecessary costs to the community. This course is Accredited by the Training Accreditation Council. DEFINITIONS: The introduction of the new Work Health and Safety Act and Regulations, 2011 have changed the definitions of: Employer to Persons conducting business or undertaking Employee to Worker. OHS or OH&S to WHS (Work Health and Safety) Use the terms interchangeably in this document. Where ever possible, terms as per the WHS legislation have been applied. Nationwide Training Pty Ltd Page 3 6 th Edition June 2013

4 Section 1 Legal Requirements - Australian Standards Work Health and Safety Act and Regulations, 2011 Know your worksite - WHS Personnel - Site emergency procedures - Site communication - Four steps to managing hazards - Equipment Pedestrians and fork trucks - Segregation of pedestrians Operating near power lines Know your workplace and identify potential hazards Hazardous Loads Power, Fuels and Refueling Nationwide Training Pty Ltd Page 4 6 th Edition June 2013

5 Legal Requirements AUSTRALIAN STANDARD An Operator of a forklift must: Be a minimum of 18 years of age. Have no physical disabilities that would impair the safe operation of an industrial truck or endanger the safety of others. Be specially trained in the operation of each industrial truck that will be used. Be sufficiently fluent in the use of the English language for communication purposes. Conform to any relevant requirements of the statutory authority. Have adequate knowledge of the NOHSC: to allow implementation of its requirements. An Employer Has a duty of care under the Australian Standards to ensure that only persons who are qualified (as listed above) are authorised to operate industrial trucks. Licence Whenever operating an industrial truck, the operator shall either carry the licence on his/her person or display the licence on the industrial truck. Training of Operators New operators, including those with previous experience, shall be instructed on the following items for each type of industrial truck used: User's policies. Safety practices and rules. Operating conditions in all areas of operation, including any special or hazardous conditions i.e. bumpy ground. Control positions and functions. Servicing, maintenance and repair responsibilities. A Licence does not entitle the holder to automatically operate any machinery within that category unless they have received the appropriate training in the safe use of that machinery and have adequate supervision as required. Nationwide Training Pty Ltd Page 5 6 th Edition June 2013

6 Legal Requirements As an Operator of a forklift you are required to comply with the guidelines prescribed by National Occupational Safety and Health Competency Standards for the Operation of load shifting equipment and other types of specified equipment. Work Safety and Health Act and Regulations, 2011 The main object of the Act is to provide a balanced and nationally consistent framework to secure the health and safety of workers and workplaces. Work Safety and Health The law applies to you if you are: A person conducting business or undertaking A person is a worker if the person carries out work in any capacity for a person conducting a business or undertaking. Including work as: a) An employee; or b) A contractor or subcontractor; or c) An employee of a contractor; or d) An employee of a labour hire company; or e) An outworker; or f) An apprentice or trainee; or g) A student gaining work experience; or h) A volunteer; or i) A person of a prescribed class. Duties of persons conducting business or undertaking Section 19 WHS Act 2011 To ensure, as far as is reasonably practicable, a) The provision and maintenance of a work environment without risks to health and safety: and b) The provision and maintenance of safe plant and structures; and c) The provision and maintenance of safe systems of work; and d) The safe use, handling and storage of plant, structures and substances; and e) The provision of adequate facilities for the welfare at work of workers f) The provision of any information, training, instruction or supervision that is necessary to protect all persons from risk g) The health of workers and the conditions at the workplace are monitored for the purpose of preventing illness or injury of workers Nationwide Training Pty Ltd Page 6 6 th Edition June 2013

7 Persons conducting business or undertaking (employer) must provide: A safe work environment Maintenance systems in place A safe system of work Information, instruction/ training PPE and safety equipment Reporting and monitoring mechanisms Duties of workers Section 28 WHS Act 2011 While at work, a worker must: a) Take reasonable care for his or her own health and safety and: b) Take reasonable care that his or her acts or omissions do not adversely affect the health and safety of other persons: and c) Comply, as far as the worker is reasonably able with any reasonable instructions that is given by the person conducting business d) Co-operate with any reasonable policy or procedure, relating to health or safety at the workplace that has been notified to workers. A worker must: Take care of themselves, firstly Follow safety instructions and information, so you do not put your fellow workers in danger/harm Follow all instructions / Take care information of one s self Co-operate with others in the workplace Nationwide Training Pty Ltd Page 7 6 th Edition June 2013

8 Know your Worksite It is your responsibility to ensure that you have undertaken a site induction. Ensure that you know who the WHS personnel are on your site, understanding and abide by all WHS policies and procedures for Fire and Emergency, Safe systems of work and undertake any duties as directed by WHS personnel. WHS personnel may be, but not limited to: Managers ( i.e. Transport / Distribution / Production ) Safety Officer Health and Safety Representative Site foreman Supervisors Team leaders Site Engineers Other nominated colleagues or managers who have been authorised to take responsibility for the workplace or operations. Workplace communication Effective communication in the workplace is just as important as abiding by all safety requirements. Ensure you are aware of the methods of communication used in your workplace, especially if you work in an isolated area, extremes in conditions, use machinery and equipment. Communication in the workplace, is not only by verbal means, in your workplace you will see many examples of - Written instructions, information - Signs (Signage) - Opportunity ( required ) to listen to verbal instructions, information - Opportunity to question instructions, information. Examples of Written instructions, information: Consignment notes, Standard Operating Procedures, Log books Signs: Caution, Hazardous substances, Mandatory PPE required Listening: Being attentive and listening to Tool box meetings, site WHS meetings, general meetings Questioning: Being involved in tool box meetings, information or instructional briefs, and asking questions to confirm knowledge of new instructions or Nationwide Training Pty Ltd Page 8 6 th Edition June 2013

9 requirements. Workplace Emergency Information: Do you know where the - Muster point is - Location of first aid facilities - Who is a First aid officer - Where fire extinguishers are, and how to use them effectively Ensure you have been inducted, and are aware of the workplace protocols, that in the event of an emergency, that you are able to: - Alert personnel to the emergency - Communicate the nature of the emergency - Inform and advise personnel of unsafe areas, location of emergency - Assist emergency personnel During the course of an emergency, Emergency Services Personnel may take command of the site/location, you are to ensure that you undertake all direction and commands as issued by them, and ensure that all vehicles give way to emergency services vehicles. A HAZARD is defined as: An object, condition or event that has the Potential to cause Injury or Loss Nationwide Training Pty Ltd Page 9 6 th Edition June 2013

10 The Four steps to Managing Hazards Four steps should be taken to ensure a safe and healthy workplace. They are based on the concept that the workplace should be modified to suit people and not vice versa. The four steps are: Identify Identifying hazards, what are the hazards in a particular workplace? Are they: Pedestrians and personnel Other plant and equipment Vehicle traffic Electrical power lines Obstructions Lighting / illumination Overhead / underground services Weather conditions Dangerous / Hazardous materials / substances Surrounding structures Non ground weight bearing surfaces / pressures Stress Vibration Assess Assess the risk of each hazard. You must consider the Likelihood of the event occurring and the Consequence of the harm, injury or ill health, costs to the business, if the event does occur. Risk assessment requires good judgment and awareness of potential risks of work processes, you can only best estimate on the information available to you. However you can use a systematic approach in order to assess a priority rate for each hazard. Control Once you have identified the hazards in your workplace and analysed the level of risk, the next step is to determine the control measures. In some instances a combination of control measures may be appropriate. Control measures should be designed to : Eliminate or reduce risks of hazardous work process s and To minimise the effects or injury or disease Nationwide Training Pty Ltd Page 10 6 th Edition June 2013

11 Hierarchy of Control Always start at the top of the pyramid and work down. Elimination Eliminate or remove the hazard Substitution Substitute or replace a hazardous work practice or substance, material. Isolation Isolate or separating the hazard or hazardous work practice from people not involved in the work or direct work area. Engineering Controls Engineer out the hazard by incorporating guarding / cages / grating or modification to machinery or equipment. Administrative Controls Undertake additional training, implementation JHA s, signage, updates at tool box meetings (regularly) Personal Protective Equipment Undertake the use of PPE. Personal protective equipment (PPE) such as face mask, respirators, gloves, goggles, lumbar supports etc, should be used in conjunction with other methods of control and only used as a last resort when other control methods are not practicable. When PPE is provided it must be suitable and properly maintained. Personnel must be trained in the correct use, storage and maintenance of the equipment. Nationwide Training Pty Ltd Page 11 6 th Edition June 2013

12 Monitor Constant review of control measures is important to ensure they continue to prevent or control exposure to hazards or hazardous work practices. Ensure that the control measure undertaken has been effective and has not created an additional hazard. Identifying and managing hazards in the workplace, is everyone s priority. Ensure that you are aware of your organisational policies and procedures for Identifying and Reporting Hazards in the workplace. Equipment Undertaking preoperational checks of equipment at the commencement of your shift should take priority. Pre operational checks should be undertaken on all mechanical / electrical equipment and noted in official Log Books, but it is also the workers responsibility to inspect all Personal Protective Equipment (PPE) at the commencement of a shift or task and report defects as per organisational policies and procedures. Nationwide Training Pty Ltd Page 12 6 th Edition June 2013

13 Operating near Electric/Power Lines Western Australian, Occupational Health and Safety Regulations state: Western Australian, Occupational Safety and Health Regulations 1996 Regulation 3.64: a) 0.5 metre of a live insulated overhead power lines not more than 1,000 volts b) 1.0 metre of uninsulated overhead power lines of not more than 1,000 volts c) 3.0 metres of either insulated or uninsulated overhead power lines exceeding 1,000 volts but not more than 33,000 volts. d) 6.0 metres of either insulated or uninsulated overhead power lines exceeding 33,000 volts Tiger tails A warning device indicating the presence of overhead power lines. If, you must work closer than the prescribed minimum distances, you will be required to seek an exemption from the relevant authority ( i.e. Power company ie Western Power) and or have the electrical power shut off. If this is not possible the power lines must be insulated by an authorised/competent person. Refer to relevant local authority. Always contact the local power authority ie Western Power, to determine the voltage of overhead power lines, prior to conducting any forklift operations. Actions to take if your forklift truck comes in to contact with power lines? When possible, and without endangering yourself (operator), attempt to break the forklifts contact with the power lines by moving the forklift clear by lowering the forklift arms or moving the forklift mast. i.e. Reverse out If this is not possible to break contact, REMAIN in the forklift, if safe to do so. Nationwide Training Pty Ltd Page 13 6 th Edition June 2013

14 If it is unsafe to remain on the forklift, check that the ground around the forklift is clear (of water or obstacles). If safe, jump clear of the forklift without touching the metal parts of the forklift and the ground at the same time. When moving away from the equipment, you should hop or shuffle (with both feet together) until you are at least eight (8) meters from the forklift, as the ground may be electrified. Under no circumstances, should you run or walk from the forklift, as the ground may be electrified. Once safely away from the forklift, warn all other people to keep eight (8) meters clear from the forklift, until the electricity supply has been isolated and the site made safe. Follow site incident reporting procedure. Do not use the forklift until it has been checked. Segregation of Pedestrians Pedestrians and Forktrucks Pedestrians should, where possible, be segregated from vehicle routes by a physical barrier, otherwise pedestrian walkways should be clearly marked. Where it is not possible to provide separate means of access and exit for pedestrians, other arrangements, such as the use of audible or visual warning devices, use of hi-visibility vests and defined walkways, should be made to ensure their safety. Pedestrians must give way to Operators at all times. Segregation/ Identification of pedestrian methods may include, but not limited to: Barricades Safety Signs Flag Person Cones Use of hi-visibility vests Defined pathways Vehicle exclusion zones Nationwide Training Pty Ltd Page 14 6 th Edition June 2013

15 Damaged Pallets Do not use damaged pallets, report as per organisational policies and procedures, if in doubt ask your Supervisor. PPE Personal Protective Equipment On some worksites you may need to wear Safety boots Hard hat/helmet Hearing protection Safety glasses/goggles Dust mask Gloves/overalls High visibility clothing It is your responsibility to check, utilise (wear), maintain all PPE, that is provided to you. Follow organisational policies and procedures where maintenance or replacement of equipment is required. Permits On some sites you may require a permit to undertake some activities, which meet Quality Systems and Safety Standards of the organisation. If a permit is required, it should be clearly identified prior to the task being undertaken and the process should have been identified in the site induction process, or advised by the supervisor concerned. Forklift with flashing lights and reverse warning siren s Must comply with manufacturer s guidelines and company policies and procedures. Environmental conditions Environmental conditions may effect the way in which a vehicle is operated or the operation of the vehicle. i.e cold/heat, dust, visibility. All operators are to ensure that they are aware of and abide by all operational policies and procedures when undertaking activities in different environmental conditions. Signs Black/White - Danger signs Yellow/Black - Caution Blue/White Mandatory requirement Green/White Safety signs Nationwide Training Pty Ltd Page 15 6 th Edition June 2013

16 Know your workplace and identify potential hazards As a forklift operator you should take the time to evaluate the area in which you work. By doing so, you will familiarise yourself with potential hazards and thereby reduce the risk of accident. Potential Hazards - things to be aware of other than site hazards: Restricted height or width Uneven surfaces of different floors and slopes Blind corners or doorways Characteristics of load Confined/ limited access spaces Dangerous loads Pedestrians Traffic flows and directions of travel Noise Damaged or worn equipment Location of task Specifics of task Permits required for task Availability of equipment Capacity of forklift Working at night or in darkened areas Safety starts with YOU Nationwide Training Pty Ltd Page 16 6 th Edition June 2013

17 Hazardous Loads At various times an operator may encounter hazardous/dangerous loads. The following are guidelines to your responsibilities and some examples of HAZCHEM symbols. Before loads are moved they need to be identified to ensure safety procedures are followed. Hazardous cargo must be identified using the appropriate labels (see Class Labels) and moved according to the standard procedures required for handling hazardous goods. SEGREGATION If required to move various hazardous loads together or to be stored together, be sure it is safe to do so. As it can be dangerous if certain chemicals are stored together especially in the event of a spillage or an accident when moving loads. Refer to organisational policies and procedures for specific instructions or your supervisor prior to undertaking any tasks. These tasks need to be undertaken by qualified personnel. CLASS LABELS TO BE UPDATED IN NEXT REVISION Advised explosive, oxidizer and miscellaneous are incorrect. T Trim Nov 2012 TOXIC CLASS LABELS Nationwide Training Pty Ltd Page 17 6 th Edition June 2013

18 Power, Fuels and Refuelling Forklifts can be driven by 4 (four) types of power sources - they are: Petrol Diesel Liquid Petroleum Gas (L.P.G.) Battery (Electric) BATTERY (ELECTRIC) ONLY TRAINED AND AUTHORISED PERSONNEL MAY TOP UP, RECHARGE OR CHANGE BATTERIES AND WITHIN THE DESIGNATED AREA ONLY Precaution is required to be undertaken when handling machine batteries. When commencing activities, ensure that the vehicle is secured and the isolator switch is turned off: Smoking or open flames are prohibited during charging/topping up operations Charging/topping up must always take place in a well-ventilated area Protective clothing, safety gloves, apron, glasses MUST be worn. Resources required to be contained in charging area: Eye wash station First aid kit Baking soda (Neutralizes acid spill) Fire fighting equipment Do not operate vehicle with a leaking battery. Batteries being charged produce Hydrogen gas, which is highly explosive. The liquid within the battery is Sulfuric acid and is highly corrosive. Contact with skin or eyes MUST be AVOIDED Nationwide Training Pty Ltd Page 18 6 th Edition June 2013

19 Fuels and Refueling PETROL AND DIESEL (Internal Combustion engines) Extreme caution must be taken as fuel spilling onto hot surfaces may ignite. Exhaust gases are very toxic. Operation of a machine in confined spaces such as freight containers or cool rooms should be avoided. Fuelling to be in designated area i.e. outside. LIQUID PETROLEUM GAS (L.P.G.) Gas is stored in a liquid form and under pressure and is highly explosive. The use of gloves for protection is essential as, in liquid form, the fuel will cause severe cold burns. Because of its highly volatile nature, avoid gouging, denting or otherwise damaging the cylinder surface as this will weaken the cylinder structure. Filling bottles for L.P.G. powered forklifts must only be carried out in designated areas, by trained operations utilizing appropriate PPE. If a leak is suspected, close off the supply valve and inform the appropriate person immediately. ONLY TRAINED AND AUTHORISED PERSONNEL MAY UNDERTAKE REFUELLING, REFILLING OR CHANGING OF GAS CYLINDERS Nationwide Training Pty Ltd Page 19 6 th Edition June 2013

20 Section 2 Parts of the Forklift Alternate Forklifts Balance of a Forklift Safe Working Loads (SWL) - Capacity / Data Plate Reading a load chart Human Error Instability - Longitudinal - Lateral Attachments Forklift platforms Nationwide Training Pty Ltd Page 20 6 th Edition June 2013

21 Parts of a Forklift Overhead Guard Mast Hydraulic lifting cylinders Counterweight Load Backrest Fork / Tine Heel Front Wheels Foot Guard Rear wheels 1. Overhead Guard - prevents loads, items falling on to the operator 2. Counter weight - balances the forklift when loaded 3. Rear wheels - steer the forklift 4. Foot Guard - prevents operators foot from touching the tyres when entering or alighting 5. Front wheels activates the forward and reverse movement and provides braking 6. Heel the right angle of the tine 7. Fork / Tine - carries pallets / goods 8. Load Backrest- prevents load from falling on to mast and or operator 9. Hydraulic lifting cylinders - enables fork tines to lift the load 10. Mast holds the load backrest/tines and enables the assembly to be lifted vertically. Nationwide Training Pty Ltd Page 21 6 th Edition June 2013

22 Alternate Forklift Trucks 1. Industrial counterbalanced fork truck 2. Industrial Reach truck 3. Rough terrain counterbalanced fork truck 4. Telescopic materials handler 5. Side loading lift truck 6. Pedestrian controlled lift truck Nationwide Training Pty Ltd Page 22 6 th Edition June 2013

23 Balance of a Forklift The fulcrum or pivot of a forklift runs along the front axle and all the lifting and turning of the forklift is based on this point. Load Counter weight Fulcrum The load centre is the Centre of Gravity of the load you are carrying, and is measured from the heel of the fork/tines to the centre of the load. This load centre is crucial to the lifting capacity of the forklift. Load centre of 600mm Load centre of 800mm The capability of the forklift is greatly reduced, if the load centre of the object being carried is further from the vertical face of the forks. Nationwide Training Pty Ltd Page 23 6 th Edition June 2013

24 Safe Working Loads (S.W.L.) By law every forklift must have a Compliance Plate affixed and legible This may also be referred to as the Data Plate or Capacity Plate. You MUST not operate a forklift, where the Compliance plate has been removed or is obscured. Follow your organisational policies and procedures and tag out the forklift and report to the appropriate person (i.e. Supervisor). Sample Compliance Plate: The first line shows the Safe Working Load (S.W.L.) with the mast fully elevated and vertical 1360 kg with the load centre being 600 mm or less. How do you determine the weight of a load? Determine the weight of the load by: Reviewing Consignment paperwork (Con Note) Checking load for packaging labels Estimating the weight, if similar loads previously loaded Refer to a supervisor for information Weigh the load Nationwide Training Pty Ltd Page 24 6 th Edition June 2013

25 Reading a Load Chart LOAD TABLE 1800 KG AT 600 MM LOAD CENTRE 4 meter lift LOAD CENTRE LIFTING CAPACITY mm inches kgs lbs It is important to remember that a forklift truck can safely lift its recommended maximum load if the centre of gravity of the load does not extend beyond its rated load centre. Nationwide Training Pty Ltd Page 25 6 th Edition June 2013

26 Human Error HUMAN ERROR IS THE GREATEST CAUSE OF FORKLIFT ACCIDENTS In the past thirteen (13) years approximately 2,400 people have been injured (approx 200 per year) and eleven (11) have been killed in Western Australia in forklift accidents. DO NOT LET YOURSELF BECOME A STATISTIC Forklifts don t roll over on there own!!! They roll over due to driver error combined with certain conditions Forklifts may tip sideways due to: Turning at speed Driving over uneven surfaces Uneven distributed load Driving with flat or under inflated tyre Turning with load raised Side shift not centered Operating incorrectly on a sloping surface Forklifts may tip over frontwards or backwards- Load not positioned at heel of fork tine Shifting of the load centre forward Incorrect use to the mast tilt (especially if the load is being carried at a high level) Overloading Driving to fast (loaded or unloaded) Driving over uneven surfaces FORKLIFT ROLL OVER Should you consider that the forklift is about to roll over: Do not attempt to jump clear Remain inside the cab area Brace yourself for the impact Seat belts and side restraints must be used Nationwide Training Pty Ltd Page 26 6 th Edition June 2013

27 The most common cause for deaths with forklifts is when an Operator attempts to jump clear and is crushed by either the overhead guard or the mast assembly. FACTORS CONTRIBUTING COMMON INJURIES TO HUMAN ERROR Lack of training Being struck by a moving forklift Inexperience Forklift tipping over or overturning Poor judgment Collision with stationary objects or other Not enough care vehicles Unfamiliar with workplace surroundings Parts of the Operator s body protruding from the cab and striking an object Poor communication Forklift losing its load Stress Injury Distractions Death Carelessness Unfamiliar with forklift characteristics and safe working load Unnecessary rushing to complete a task. Nationwide Training Pty Ltd Page 27 6 th Edition June 2013

28 Instability A Counterweight X X CENTRE OF GRAVITY B C Load Carriage 3 Point Suspension System Stability Triangle Nationwide Training Pty Ltd Page 28 6 th Edition June 2013

29 Instability LONGITUDINAL Some examples of causes: The load is too heavy Tilting a heavy load forward when lifting or in an elevated position Load is incorrectly placed i.e. too far along the forks. Harsh braking when carrying a load Uneven surfaces Incorrect direction of travel when on slopes Unsecured loads LATERAL Some examples of causes: Turning with the load raised Driving across slopes Driving on uneven surfaces Turning too sharply Driving too fast Operating with a flat tyre Driving into potholes or over obstructions Incorrect position of mast For safe operation the vehicle manufacturer s specifications must be adhered to. An Operator must avoid: Excessive engine revs Harsh braking Erratic steering Transmission abuse Aggressive use of levers and controls - hand and foot Instability of a forklift may also be affected by the inflation level of the tyres. Ensure the tyres are Filled to the correct operating pressure as per the manufactures guidelines, For solid tyres, no pieces of rubber missing Outer sides of tyre not worn Wear is even For optimum stability and operation. Nationwide Training Pty Ltd Page 29 6 th Edition June 2013

30 Attachments Fitting an attachment may alter the characteristics of the forklift and is likely to reduce the capacity of the forklift. This is called Derating. Fitting of attachments, should only be carried out by a forklift engineer or authorised person. It may be necessary to use a forklift with a larger capacity. Wherever possible the manufacturer or authorised supplier should be consulted regarding suitability of the attachment for the forklift and the necessary derating. At the start of each shift, the security of any attachment should be checked and any defects must be reported immediately. If defects are found, do not use the forklift until defects are rectified, report as per organisational polices and procedures. A wide range of removable attachments are available for use with forklifts. Shown below are some examples of the more common ones currently in use though no description is made of more specialised attachments used with telescopic materials handlers such as bale grabs and silage forks. Side Shift Carriage May be mounted either on existing fork carriage or in place of it. Enables horizontal sideways movement of the fork arms to allow precise positioning. Rotator and Clamp This is mounted on the fork carriage and usually used in conjunction with another attachment Allows load to be rotated vertically about an axis parallel to the longitudinal axis of the forklift Some rotators can tilt the load forward from the vertical to the horizontal and beyond - known as tipplers Nationwide Training Pty Ltd Page 30 6 th Edition June 2013

31 Attachments Fork Positioner Hydraulically operated Allows operator, whilst remaining in the operating position, to change the position of the fork arms relative to each other. The fork arm centres can be adjusted to accommodate different load widths. Clamps These attachments are designed for a variety of purposes such as lifting reels, drums or bales. May be used in conjunction with a rotator. May be faced with rubber or other material to improve the grip. Self Dumping Hoppers Usually carried on fork arms. Fitted with a mechanism which causes the hopper to roll forward and discharge the contents. Once empty the hopper returns to its normal position and re-engages the holding mechanism. Nationwide Training Pty Ltd Page 31 6 th Edition June 2013

32 Attachments Crane Jib May be mounted directly on the fork carriage on the fork arms May be of a fixed length or extendible or embody a number of lifting points. It is possible to vary the end of the jib from horizontal. Fitting of this attachment is subject to additional requirements covering the test and examination of cranes. Booms / Carpet spikes These attachments usually consist of a circular section pole mounted on the fork carriage They come in a variety of diameters and lengths Designed for lifting rolls of carpet, coils of wire or similar cylindrical loads. Working Platforms Working platforms must not be used for order picking. In order to prevent inadvertent operation, the operator of the forklift should lock out the tilt mechanism when the machine is being used as a work platform. Suitable means of communication i.e. two-way radio between the forklift operator and the person on the platform. When manual signals are being used, clear and unambiguous signals should be agreed before commencement of work. All Attachments must have a Capacity plate. Nationwide Training Pty Ltd Page 32 6 th Edition June 2013

33 Section 3 Operational Pre-Start Checks After Start Checks Shutdown and Parking Breakdown or Accident Procedures Nationwide Training Pty Ltd Page 33 6 th Edition June 2013

34 Operational Pre-operational checks are generally undertaken by an authorised operator at the commencement of their shift. These may include, but not limited too: Prior to commencing Pre start Check ensure: Hand brake applied Transmission in neutral Check log book for previous entry in case of defects Capacity plate fitted and legible. Structural checks: Check forklift for cracks, damage and distortion Mast assembly Backrest Chains tension, greased Overhead guard Seating area Tyres wear, damage, pressure, wheel nuts. Fluid levels: Engine Transmission Hydraulic reservoir Radiator Brakes Fuel Battery No Fluid Leaks: Oil Water Fuel Hydraulic Battery Brake Accessories: Lights, indicators working Horn Warning devices Attachments secure Gas bottle or battery pack secure Operator restraint if fitted Battery charger switched off and charge leads disconnected Fire extinguisher if fitted, the operator must be competent in its use If any defects are identified, complete the pre-operational check with details and follow organisational policies and procedures for tagging out of equipment and reporting. Nationwide Training Pty Ltd Page 34 6 th Edition June 2013

35 Post Starting Checks After starting (post starting) checks: Engine running smoothly Brake operation hand and foot All gauges functional All lights and warning devices functional Lifting, tilting and manipulation systems Transmission forward and reverse Steering and travel. If any defects are identified, complete the operational checklist with details and follow organisational policies and procedures for tagging out of equipment and reporting. Forklift operators and other staff members are only able to conduct maintenance on equipment if they are competent and authorised to do so. ALL OPERATIONAL CHECKS MUST BE IN COMPLIANCE WITH MANUFACTURERS SPECIFICATIONS COMPANY POLICIES AND PROCEDURES Nationwide Training Pty Ltd Page 35 6 th Edition June 2013

36 Prestart Checklist OPERATOR FORKLIFT No. DATE.. SHIFT 1. Visual Checks CHECKS 1.1 Front of forklift OK EXPLAIN BELOW IF NOT OK OR ANY ACTION TO BE TAKEN no leaks and obstructions (ie timber, wire etc., under the forklift) forklift is not leaning because of a flat tyre or dips etc.,. condition & security of forks/attachments mast for any damage load backrest hydraulic hoses/couplings chains no obstruction in mast area. 1.2 Right side of forklift right front tyre & wheel tyre pressure wheel nuts general condition body damage safety cage right hand rear steer wheel hydraulic steering for leaks/damage 1.3 Rear of forklift radiator/exhaust not covered with flammable material body damage/conditions towing pin is secure 1.4 Left side of the forklift left hand rear steer wheel left hand front wheel & tyre hydraulic steering leaks/damage turn on gas bottle (if fitted) check gas line for leaks/fitting gas level. Nationwide Training Pty Ltd Page 36 6 th Edition June 2013

37 Prestart Checklist CHECKS 1.5 Engine compartment OK EXPLAIN BELOW IF NOT OK OR ANY ACTION TO BE TAKEN oil & water level fan belt leaks/damage/obstructions battery (water level, loose connections) 1.6 Drivers compartment free of obstacles adjust seat etc., for driver comfort check manufacturers dataplate for load, rating mast extension etc., seat belt operational 2. Operational checks gauges/warning lights lights (if fitted) revolving warning light (if fitted) brake lights horn indicators (if fitted) controls park brakes transmission steering & footbrake Remarks or additional explanation or suggestions. Operators signature.... Nationwide Training Pty Ltd Page 37 6 th Edition June 2013

38 Shutdown and Parking Procedure Where applicable, park in designated area. Park on level ground and ensure that the forklift has not blocked: Emergency exits Fire hoses Emergency equipment First aid stations Public access/doorways Or On sloping surfaces Where if may obstruct other traffic No closer than two meters from the nearest rail of a rail track. Parking procedure - Apply main park brake securing system i.e. hand brake / park brake Gears in neutral Fork tines are lowered and flat on the ground Switch off motor or turn off gas valve, if LPG Remove key - return to allocated location or person Follow any other site specific procedures. Nationwide Training Pty Ltd Page 38 6 th Edition June 2013

39 Breakdown or Accident Procedures / Defects APPLY MAIN BRAKE - If it has failed, chock the wheels. The following may vary slightly dependent on the type of forklift being driven. The manufacturer s manual together with company policies and procedures must be consulted. In a breakdown or accident situation, the operator shall ensure: Gears in neutral Turn the forklift off and remove key If a load is in an elevated position it must be returned to ground level, unless the breakdown / defect will not allow. In this case, the Operator must make the area safe from further accident or damage through one or more of the following: Have a responsible person on duty to warn others Place clearly visible warning signs Erect barriers Place an OUT OF SERVICE tag / sign on the forklift Report to a supervisor and fill in logbook as required. Out of Service Tag can only be removed by Authorised Personnel and only after repairs have been affected. Authorised Personnel : may be the Technician/Mechanic who repaired the equipment or Supervisor who has confirmed repairs. Nationwide Training Pty Ltd Page 39 6 th Edition June 2013

40 Section 4 Basic operating procedures Loading and Stacking Rear End Swing Counterbalanced Forklifts Stacking De-stacking Inclines and Declines Uneven / wet / slippery surfaces High Loads The use of a bridge plate Nationwide Training Pty Ltd Page 40 6 th Edition June 2013

41 Basic operating procedures Basic operating procedures Prior to moving / shifting a load, an operator shall: Ensure preoperational check on machine has been undertaken Load has been identified - Load structure - Load stability - Destination of load determined, path of travel has been identified and obstacles identified (if any) Prior to moving out, the operator shall: 1. Check behind using mirrors/and or looking over both shoulders to ensure it is safe to move out. 2. Ensure all warning devices are operational 3. If the load is obscuring the vision of the operator, employ the services of a responsible person to assist. 4. The operator shall ensure that during the movement of the goods, that the fork tines are kept at a safe travelling height. Ideally the safe travelling height is axle height or as low as the operating surface, will allow. During the course of travel, the operator shall, Constantly be checking (visually) the load for signs of instability Maintain correct driving practices (speed, traffic management principles) Vigilant for pedestrians and or other vehicles Not carry additional personnel on the forklift, unless designed to do so, Not raise or lower a load in or around pedestrians Nationwide Training Pty Ltd Page 41 6 th Edition June 2013

42 Loading and Stacking CORRECT POSITION OF FORKS INCORRECT POSITION OF FORKS Side shift - most common cause of incorrect position of forks whilst operating. Forks must be returned to centre of carriage before next lift. Where the load is secure, but is packed toward one side. That side (heavy side) must be loaded toward the load carriage of the forklift. Once loaded, tilt mast back The use of only one fork is illegal and the fork will become overstressed, compromising the stability of the forklift. Nationwide Training Pty Ltd Page 42 6 th Edition June 2013

43 Read End Swing The steering of a forklift is specially designed to maneuver within restricted areas. Operators must make themselves aware of their surroundings before reversing or making a turn, particularly in narrow aisles. The turning angle is as seen below, pivoting on either left or right wheel X Pivot point of forklift The acute angle of turn swings the rear of the forklift very quickly and could cause damage or injury if the operator is not attentive to the surroundings. It is estimated that the rear end swing is three times the speed of the forward movement of the forklift. Example Forward movement = 10kph Rear end swing = 30kph Nationwide Training Pty Ltd Page 43 6 th Edition June 2013

44 Counterbalanced Forklifts When stacking loads in to racking, or on top of other pallets, you must ensure: 1. That the load to be stacked on, is firm and level. 2. If the load is uneven, restack to ensure evenness and stability 3. Heavier pallets are stacked at the bottom of the stack, and not in the middle or top. 4. Adhere to workplace procedures with regard to load labeling requirements. STACKING Step 1 Approach the stack with the load low and tilted backwards. Step 2 Slow down and stop at the face of the stack. Apply the park brake. Reduce backward tilt to just sufficient to stabilise the load. Look up and check for obstructions. Raise the load to the stacking height. Step 3 When the load is clear of the top of the stack, move slowly forwards. Take care not to dislodge loads in adjacent stacks. Nationwide Training Pty Ltd Page 44 6 th Edition June 2013

45 Counterbalanced Forklifts Step 4 When the load is over the stack, stop. Apply park brake. Bring mast to vertical position. Carefully lower the load onto the stack. Step 5 When the load is securely stacked, lower fork arms until free of pallet or dunnage strips. Look behind to check all is clear. Reverse watching front and rear. Slight forward tilt of fork arms may be of assistance. Step 6 When clear of stack apply park brake. Tilt fork arms backwards. Lower to just above ground level. Check if direction of travel is clear before moving. Nationwide Training Pty Ltd Page 45 6 th Edition June 2013

46 Counterbalanced Forklifts DESTACKING Step 1 Halt at face of stack Apply park handbrake Bring mast to vertical position If necessary, adjust for spread to suit the width of load Ensure weight of load is within capacity of the forklift. Step 2 Look upwards Raise fork arms to a position permitting clear entry into pallet or dunnage strips. Step 3 Fully insert fork arms by slowly driving forward until load guard gently touches load or pallet base. Apply park brake. Nationwide Training Pty Ltd Page 46 6 th Edition June 2013

47 Counterbalanced Forklifts Step 4 Lift load clear of stack. Carefully apply backward tilt sufficient to stabilise load. Step 5 When load is clear of the top of the stack, check that direction of travel is clear. Move slowly backwards until load and fork arms are clear of stack. Take care not to dislodge loads on adjacent stacks. Apply park brake. Step 6 Carefully lower load to correct traveling position applying further backward tilt. Check if direction of travel is clear before moving. Nationwide Training Pty Ltd Page 47 6 th Edition June 2013

48 Inclines and Declines NEVER TRAVEL SIDEWAYS As the angle of the forklift and its load may exceed the centre of gravity point as explained on page 18 and cause the forklift to roll over, or the load to shift. Never travel downhill with a load as it may become dislodged, fall off or destablise the forklift. Centre of gravity On a decline: Travel in reverse with mast tilted back. this will ensure a secure load and clear vision On an incline: Travel forward with mast tilted back. this will ensure a secure load and clear vision. Nationwide Training Pty Ltd Page 48 6 th Edition June 2013

49 Uneven / Wet / Slippery Surfaces When working (driving over) uneven, wet or slippery surfaces ensure to Reduce speed Proceed with caution High Loads Where a load exceeds the height of the load backrest: Ensure it is secure and will not fall onto the driver. If the height is such that the driver s vision is obscured, employ the services of a responsible person to assist. This person must position him/herself so as to be clearly visible to the driver for directional purposes and to provide warning to others. Or where practical, drive in reverse. Nationwide Training Pty Ltd Page 49 6 th Edition June 2013

50 The use of a Bridge Plate As the name implies, the bridge plate is used to bridge the gap between two platforms or surfaces for load purposes. The example below shows the use between a semi-trailer bed and a loading dock. An operator must: Always use a bridge plate where movement may occur between loading surfaces Ensure bridge plate complies with safe working regulations Ensure the bridge plate is anchored securely and free of oil or grease. DO NOT ALLOW PEOPLE TO WALK UNDER THE BRIDGE PLATE ALWAYS DRIVE SLOWLY LOADING RAMP Ensure the braking system for securing the semi trailer has been applied. Wheel chocks may also be used to further secure the trailer Always chock wheels in case the braking system is faulty or has not been applied i.e. worn handbrake or truck driver error A ramp of this type must be secured to the trailer by chains. Nationwide Training Pty Ltd Page 50 6 th Edition June 2013

51 Section 5 Calculations Pallet weight Load capacity Load chart Nationwide Training Pty Ltd Page 51 6 th Edition June 2013

52 Pallet Weight Calculations Five (5) layers on a pallet Four (4) boxes to a layer Pallet Each box weighs 10kg Four (4) boxes per layer Five (5) layers per pallet Pallet weight is 12kg Total of boxes and pallet = 212kg Show all calculations: Boxes = 4 x 5 x 10kg = 200kg Weight of the Boxes 200kg 4 x 5 = 20, 20 x 10kg = 200kg Boxes plus the pallet 200kg + 12kg = 212kg Nationwide Training Pty Ltd Page 52 6 th Edition June 2013

53 Calculations Question1: The load to be moved is cartons, stacked on a pallet Four (4) layers high Six (6) cartons to a layer Each carton weights 15 kg Standard pallet size, weight 15kg What is the combined weight of the pallet to be moved? kg Show all calculations: Question 2: The load to be moved are bags of flour, which are stacked on a pallet. 82 bags on a pallet Each bag is 20 kg The pallet is a standard size and weighs 35kg. What is the total weight of the bags on the pallet. kg Show all calculations: Nationwide Training Pty Ltd Page 53 6 th Edition June 2013

54 Question 3: The load to be moved is drums stacked on a pallet: Four drums on the pallet Each drum is 220kg Standard size pallet weighing 40kg What is the combined weight of the drums and pallet? kg Show all calculations: Nationwide Training Pty Ltd Page 54 6 th Edition June 2013

55 Load Capacity The forktrucks in the above diagram are rated at 5000kg at 600mm load centre. Which of the loads are withing the capacity of the forktruck? Circle: A B C Nationwide Training Pty Ltd Page 55 6 th Edition June 2013

56 Load Chart Calculations Using the Load Chart LF Question 1 Question 2 Identify the maximum fork height of the mast. mm What is the maximum WLL the fork can lift with the mast tilted at 3 degrees. Nationwide Training Pty Ltd Page 56 6 th Edition June 2013

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58 Appendix Pallet weight calculations Answer 1 375kg Answer kg Answer 3 920kg Load Capacity: Answer C Load chart calculations Answer mm Answer Nationwide Training Pty Ltd Page 58 6 th Edition June 2013