TLID1007C - Operate a Forklift - Learner Guide

TLID1007C

Operateaforklift

Armstrong’sDriverEducation

LearnerGuide

TLID1007C Operate a forklift

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© Australian National Training Authority 2003


Contents What this Learner’s Guide is about........ about ................ ................. ................. ............... ....... 2 Planning Planning your learning learning ................ ........................ ................. ................. ................ ................ .......... .. 3 How you will be assessed assessed........ ................. ................. ................ ................ ................. ............. .... 6 Section 1.......................... 1... ....................... ...................... ..................... ....................... . 8 Before Before you drive the forklift ................ ........................ ................. ................. ................ ........... ... 8 Section 2......................... 2... ...................... ...................... ...................... ...................... 16 Types Types of forklifts forklifts and attachments attachments ................ ........................ ................. ............... ...... 16 Section 3............................. 3...... ....................... ...................... ..................... ................... 52 Forklift Forklift safety safety ................ ......................... ................. ................ ................ ................. ................. .............. ...... 52 Section 4............................ 4...... ...................... ...................... ...................... ................... 66 Driving Driving the forklift forklift ................ ......................... ................. ................ ................ ................. ................ ....... 66 Additional resources....................... resources ....................... ..................... ...................... ..... 94 Feedback Feedback on activities activities ................. ......................... ................ ................. ................. ................ ................ .......... .. 96

© Australian National Training Authority 2003 Customised and Developed by Armstrong’s Driver Education July 2009

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What this Learner’s Guide is about ThisLearner’sGuideisabouttheskillsandknowledgerequiredto operateaforklift,includingcheckingforkliftcondition,drivingthe forklifttofulfiloperationalrequirements,monitoringsiteconditions andmonitoringandmaintainingforkliftperformance.Assessmentof thisunitwillusuallybeundertakenwithinalicensingexamination conductedby,orundertheauthorityof,therelevantstate/territory OHSAuthority. Personsachievingcompetenceinthisunitwillneedtofulfilallofthe relevantstate/territoryOHSregulatoryrequirementsconcerningthe safeoperationofforklifts. TheElementsofCompetencyfromtheunitTLID1007COperatea forkliftcoveredinthisLearner’sGuidearelistedbelow. Checkforkliftcondition Drivetheforklift Operateaforklifttohandleloads Monitorsiteconditions Monitorandmaintainforkliftperformance ThisunitofcompetencyisfromtheTransportandLogisticsTraining Package(TLI07).

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Planning your learning Itisimportanttoplanyourlearningbeforeyoustartbecauseyoumay alreadyhavesomeoftheknowledgeandskillsthatarecoveredinthis Learner’sGuide.Thismightbebecause: •

•

youhavebeenworkingintheindustryforsometime, and/or youhavealreadycompletedtraininginthisarea.

Togetherwithyoursupervisorortrainerusethechecklistsonthe followingpagestohelpyouplanyourstudyprogram.Youranswersto thequestionsinthechecklistwillhelpyouworkoutwhichsectionsof thisLearner’sGuideyouneedtocomplete. ThisLearner’sGuideiswrittenwiththeideathatlearningismademore relevantwhenyou,thelearner,areactuallyworkingintheindustry. Thismeansthatyouwillhavepeoplewithintheenterprisewhocan showyouthings,discusshowthingsaredoneandanswerany questionsyouhave.Alsoyoucanpractisewhatyoulearnandseehow whatyoulearnisappliedintheenterprise. IfyouareworkingthroughthisLearner’sGuideandhavenotyetfound ajobintheindustry,youwillneedtotalktoyourtraineraboutdoing workexperienceorworkingandlearninginsomesortofsimulated workplace.


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Section 1: Before you drive the forklift Areyouableto:

Yes

No

1. explainthecurrentlegalrequirementsfor youtobeabletodriveaforkliftinyour workplace? 2. listyourresponsibilitiesand‘dutyofcare’ as a forklift driver? 3. listyouremployer’sresponsibilities concerning forklift operations?

Section 2: Types of forklifts and attachments Areyouableto:

Yes

No

1. explainthedifferencebetweenthe counterbalance,straddle,orderpicker and side-loading forklifts? 2. listtheadvantagesanddisadvantagesof internal combustion and electric forklifts? 3. identify the major forklift components? 4. interprettheforkliftmanufacturer’sdata plate? 5. defineloadcenterdistanceandexplain how it affects forklift stability? 6. identify forklift attachments and their uses? 7. demonstratesafeuseofattachments including jibs and associated equipment?

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Section 3: forklift safety Areyouableto:

Yes

No

Yes

No

1. identifypersonalsafetyequipmentused while inspecting and operating a forklift? 2. explainthesafetystepsthataforklift driverneedstocompletebeforetheydrive the forklift? 3. stateforkliftsafetyrequirementswith regardstodrivingtheforklift,forkliftand forkliftequipment,loads,workplace environment,personalandworkplace safety?

Section 4: Driving the forklift Areyouableto: 1. conductapre-operationalforkliftsafety check? 2. conductapre-operationalworkareasafety check? 3. report the results of safety checks? 4. drive a loaded and an unloaded forklift? 5. stack and de-stack a load? 6. load and unload a truck? 7. refuel or recharge a forklift?


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How you will be assessed AssessmentofthisUnitofCompetencywillincludeobservationofreal orsimulatedworkprocessesusingworkplaceproceduresand questioningonunderpinningknowledgeandskills.Itmustbe demonstratedinanactualorsimulatedworksituationunder supervision. Youwillberequiredto: •

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completeanoralorwrittentheoryassessmentofforklift operation

•

driveaforkliftsafelyandcompetently

•

maintainalogbookofpracticeundertakenonaforklift




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Section 1 Before you drive the forklift

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Section outline Areascoveredinthissection

Legalrequirements Yourresponsibilities Youremployer’sresponsibilities


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What do you need to know about forklift legislation? Legislation refers to certain rules and conditions that you need to follow.

Thismaybe: •

beforeyouarelegallyqualifiedtodriveaforklift

•

whileyouaredrivingaforklift.

Althoughitisnotquitethesame,thinkofitassimilartothedriver’s licencesystem.Beforeyoucanlegallydriveacarontheroadyouhave tolearnwhattodoandthenbeexaminedondrivingthecar.Youneed tocompleteatheorytestandthenbeassessedonyourdrivingskills. Forkliftlegislationrequiresyoutodothesame. EachState/Territorymayhaveslightlydifferentlegislation.Insome States/Territoriesparticulartrainingneedstobeundertakenandin otherStates/Territoriesyouwillneedtoobtaina‘Certificateof Competency’beforeyoucandrivetheforklift.Howeveralltraining andlicenceswillreflecttheNationalGuidelinesforOccupationalHealth andlicenceswillreflectthe NationalGuidelinesforOccupationalHealth andSafetyCompetencyStandardsfortheOperationofLoadshifting EquipmentandOtherTypesofSpecifiedEquipment[NOHSC:7019 (1992)]. (1992)]. Therefore,itisessentialtoknowexactlywhatyourrequirementsare.

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Activity 1: What is the forklift legislation in my state/territory? As the forklift legislation differs in each state/territory, you need to find out what you need to do before you can drive a forklift in your workplace. Research into what the legislation requires you to do before you can drive a forklift in your your State/Territory. Find out what what regulations cover the use of a forklift in your State/Territory and then what requirements you need to do or fulfil before you can operate the forklift in the workplace. You can do this by obtaining information information from the following resources: •

Department for Industrial Affairs

•

Worksafe or Workcover Authority

•

Occupational Health & Safety Authority

•

the people you work with who operate that machinery

•

your workplace supervisor or trainer.

When you have completed this task take your answers to your trainer for checking. Forklift legislation In your own words, write down what you need to do before you can drive a forklift in your workplace. ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________


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What is ‘Duty of Care’? TheOccupationalHealth,SafetyandWelfareActapplicableinyour State/Territorynotonlyrequiresyoutofulfilcertainobligationsbefore youdriveaforklift,butalsowhileyouaredrivingaforklift. Theseobligationsarelegalobligationsandyouarerequiredtocomply withthembylaw.Failuretodosowoulddeemyouresponsibleand liableintheeventofanaccident. Workersarerequiredtoshowadutyofcareatalltimes.

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Activity 2: Define ‘Duty of Care’ Discuss the legal requirements and your Occupational Health, Safety and Welfare requirements with: •

your supervisor and trainer

•

your OHS committee

•

your workmates

•

Workcover Authority.

Then determine what the term ‘Duty of Care’ means to you, as a forklift driver. Think of it in terms of the following: Personal safety ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Safety of workmates ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Safe work practices ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________


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What are my employer’s responsibilities? Youremployeralsohaslegalresponsibilitiestocomplywith.Asthese responsibilitiesdirectlyaffectyou,itwillbehelpfulifyouareawareof theseresponsibilities.

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Activity 3: Employer responsibilities Think about the type of responsibilities your employer may have towards you, the forklift driver. Write these responsibilities responsibilities in the spaces provided below. Facilities ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Equipment ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Information ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Systems of work ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ ____________________________ __________________________________________ ________________________ __________ Refer to your OHSW Act to check your answers then discuss with your trainer.


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Section 2 Types of forklifts and attachments

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Typesofforklifts Powersourcesormodesofpropulsion Componentsoftheforklift Attachmentsthatcanbefittedtotheforklift


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What are the types of forklifts? Theforkliftisamaterialshandlingvehiclethatiswidelyusedinthe transportindustry.Itisinvaluableforitsabilitytomovealargeamount ofmaterialinaveryshorttimeusingaminimumoflabour. Therearefourmaintypesofforkliftthatyouarelikelytoseeinthe industry.Theyare: •

•

counterbalancedforklift straddleforkliftorreachtruck-alsoknownasnoncounterbalanced

•

orderpickers

•

sideloadingforklift.

Eachoftheseforkliftsareusedfordifferentpurposesinthe workplace.Theycanhoweverbeusedforavarietyoftasks.

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Activity 4: Identification of the types of forklifts Investigate the difference between the four main types of forklifts. You can gain this information from a variety of sources such as: •

sales brochures from retail outlets

•

materials handling magazines

•

transport and warehouse magazines

•

the Internet

•

libraries

•

books

•

previous knowledge and experience.

A worksheet is provided for your use and is located on the following pages. Counterbalance forklift What does a counterbalanced forklift look like? (draw or find a picture and place in the space opposite)

Why is it called a ‘counter balanced’ forklift?


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Where is the balance point or fulcrum of a counterbalanced forklift found?

List the two main power source options that you could find on a counterbalanced forklift.

Straddle forklift or reach truck What does a straddle forklift look like? (draw or find a picture and place in the space opposite)

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How is the weight of the load distributed on a straddle forklift?

What is a straddle forklift primarily designed for?

What is the primary power source for straddle forklifts?


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Order pickers What does an order picking forklift look like? (draw or find a picture and place in the space opposite)

Why is it called an ‘order picker’?

What is the difference between an order picker and a straddle forklift?

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Side loading forklift What does a side loading forklift look like? (draw or find a picture and place in the space opposite)

Why is it called a ‘side loading’ forklift?

What types of loads are handled by the side loading forklift?

Give two examples of workplaces that might use the side loading forklift.

There is feedback on this activity at the back of this Learner’s Guide.


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What are the power sources for forklifts? Powersourcesormodesofpropulsionforforkliftscanbedividedinto twomaintypes.Theyare: •

internalcombustion(fuels)

•

electric(battery).

Theinternalcombustionmotorinforkliftsissimilartothatusedin motorvehiclesandisdesignedtooperateonavarietyoffuelssuchas: •

petrol

•

diesel

•

LPG(LiquidPetroleumGas)

•

naturalgas.

Electricforkliftsarebatterypoweredforklifts.Abankofbatteriesor oneverylargebatteryisusedtopowertheforkliftinsteadoffuel substances.Electricpoweredforkliftsarebecomingmoreandmore popularwithinindustrybutelectricpoweredforkliftsalsohavesome disadvantages.

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Activity 5: Advantages and disadvantages of electric powered forklifts Discuss the advantages and disadvantages of electric forklift with one or more of the following: •

your trainer

•

your workmates

•

someone who drives an electric powered forklift

•

forklift distributors.

Then complete the worksheet on the next page.


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Advantages of electric powered forklifts

Disadvantages of electric powered forklifts


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What are the major components of a forklift? Just as a car has many features and components that you need to know before you drive it, so does a forklift. As you know, different cars have different features with components being in different places. places. For example, the handbrake in a Holden may be in a different place to the handbrake in a Ford. Forklifts are exactly the same, forklifts forklift s will have similar components but they may be located in different places.


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Activity 6: forklift components Match the components listed on the right-hand side of the page to the number shown on the forklift diagram.

Component

Number

Overhead guard Steering wheels Load Backrest Forks Mast Drive wheels Counterbalance Hoist chains Manufacturer’s data plate Parking brake


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Itisimportanttounderstandhowsomeofthesecomponentscan effectthesafeoperationoftheforklift.Forthisreasonyouwillneed toknowabout: •

typesanduseofdifferenttyres

•

typesofforks(tines)available

•

mastandliftingmechanism

•

forkliftcontrols.


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Activity 7: Components that can effect safe operations Research into the topics listed below: •

forklift tyres

•

forks

•

mast

•

forklift controls.

Research into the types available and their use in your industry. You can research into this by: •

discussing with your trainer

•

discussing with a forklift trainer

•

reading manuals and books.

A worksheet is provided to guide you in completing this activity.

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Component

Types available

Uses and limitations

Tyres

(Example) Pneumatic tyres

Kind to floor surfaces, possibility of puncture, common on counterbalance forklifts

Forks

Masts

Forklift controls


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What information is included on the Manufacturer’s Data Plate? Bylaw,everyforkliftisrequiredtohaveamanufacturer’sdataplate. Thisdataplateshouldincludethefollowinginformation: •

maximumsafeworkingload

•

loadcentredistance

•

maximumliftheight

•

make,modelandserialnumber

•

masttilt(indegrees)

•

tyretypeandrecommendedpressure

•

grossvehicleweight

•

attachmentdetails(ifoneisfitted).

Itiscriticalthatyouknowtheinformationonthemanufacturer’sdata platesothattheforkliftisdrivenandusedwithinthesafeoperating capacity.

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Activity 8: Data plate information Using the activity work sheet, complete the definition and then select one of your workplace forklifts and give actual data plate readings.

Information

Definition

Load centre distance

(you can indicate with a drawing)

Data plate information

Maximum safe working load

Maximum lift height

Mast tilt degrees



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What is load centre distance? Theloadcentredistanceisthemostimportantandmostdifficult concepttounderstandinforkliftdriving.Theloadcentredistance directlyaffectstheforklift’sstabilityandthereforeaffectssafetyas well. Tounderstandtheloadcentredistanceyouneedtoknowwhat ‘centreofgravity’isandhowtocalculatethecentreofgravityofan object. Yourtrainerwillhelpyouwiththisconcept,butingeneral,thecentre ofgravityofanobjectiswhereitwouldbalanceinalldirections(ifyou couldsuspendtheobjectfromthispoint).Forexample,fora basketballasitisperfectlysymmetrical,itwouldbeattheverycentre oftheball.Foraplate,itwouldbethecentreofitsbaseandhalfway throughthebase.Forabrick,itwouldbeatthepointwheretwo diagonallinesdrawnacrossthefaceofthebrickmeetandthenhalf waythroughthebrick.

Page 34



Activity 9: Centre of gravity Indicate where the centre of gravity is on the following shapes:

1200mm

2.2m 1800mm

1.8m

800mm diameter

1.5m

2.5m



Page 35 ADELG1011


Activity 10: Load centre distance The load centre distance, which is described on the manufacturer’s data plate is the distance between the centre of gravity of the load and the vertical face of the forks. Ask your trainer to explain this concept to you and to help you understand the concept, indicate on the diagram below t he load centre distance.


Page 36



How does load centre distance effect forklift stability? Astandardpalletissquareandhasthedimensions1200mmx1200mm asperthediagrambelow.

1200mm

1200mm

Asthemajorityofforkliftloadsarecontainedonpallets,forklift manufacturersdesignedtheforkliftwitha600mmloadcentre.This matcheswiththestandardstackedpalletcentreofgravity.For example,seediagram:

1200mm

600mm

Load centre


Page 37 ADELG1011


Activity 11: How to calculate load centre and forklift capacity Discuss with either your trainer or a licensed forklift driver how to calculate the load centre of a forklift load and how the load centre affects the capacity of the forklift. Then answer the following questions: Question 1 What happens to the capacity of the forklift if the load has a load centre greater than 600mm? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

Page 38



Question 2 Imagine that your forklift has the following specifications: •

Maximum safe working load or Capacity - 1000kg

•

Load Centre - 600mm

•

Max Height - 3500mm.

There are four different loads shown on the next page (drawings show side elevation). You are to determine and circle the loads which your forklift can safely lift. 900kg


Page 39 ADELG1011


Question 3 If the load centre of the load is less l ess than 600mm, will you be able to carry more than the maximum safe working load? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________


Page 40



Forklift attachments Aforkliftattachmentisanextrapieceofequipmentthatisusedonthe forkliftinplaceoftheoriginalforks.Sometimestheforksareremoved andtheattachmentisboltedtotheforkcarriage,andsometimesthe attachmentisfittedtotheforks. Therearemanytypesofforkliftattachments.Somearestandardtype attachmentsandcanbepurchasedfromadealer,e.g.drumclamps. Othersarespeciallydesignedandmadetodoaspecifictask. Mostattachmentshavespecialsafetyconsiderationsthatyouneedto takeintoaccountwhenyoudrivetheforklift.


Page 41 ADELG1011


Activity 12: Forklift attachments Forklifts can be fitted with attachments that make them safer to handle certain loads. However, these forklift attachments change the way the forklift handles, therefore it is essential to know how the attachments are used and any safety considerations that you need to know. The worksheets on the following pages are designed to help you through this process. You can find out the answers to these questions by:

Page 42

•

discussing them with your trainer

•

discussing them with a work mate

•

discussing with a forklift sales person

•

studying books, magazines, brochures or posters.



Drum clamp

What are drum clamps used for?

Drum clamps are used instead of transporting drums on pallets. Why?

Are they fixed to the forks or bolted on in place of the forks?

What are the safety considerations?

Roll clamps

What are roll clamps used for?

How do roll clamps work?



Page 43 ADELG1011


Push-pull attachment

What are push-pull attachments used for?

How do push-pull attachments work?


Carpet spike

What are carpet spikes used for?

How do carpet spikes work?


Page 44



Carton clamps

What are carton clamps used for?

How do carton clamps work?


Bale clamps

What are bale clamps used for?

How do bale clamps work?



Page 45 ADELG1011


Rotators

What are rotators used for?

How do rotators work?


Pantograph

What are pantographs used for?

How do pantographs work?


Page 46



Fork extensions

What are fork extensions used for?

How do fork extensions work?


Personnel lifts or work platforms

What are personnel lifts used for?

How do personnel lifts work?



Page 47 ADELG1011


Jib

What is a jib attachment used for?

List other associated equipment that is commonly used with jib attachments.

What are safety considerations when using jibs?

Page 48



Activity 13: Jib equipment safety When using a jib, heavy items will be carried and suspended by slings. The slings and associated equipment equipment need to be thoroughly checked each time they are used to ensure it is safe to do so. There are also certain safety requirements r equirements and procedures that you need to know before using jibs and slings on a forklift. For instance, one of the main safety considerations for operators using jibs is the moving centre of gravity, therefore, extreme care needs to be taken when determining a safe working load for the forklift. Complete the worksheet on the next page, stating relevant safety requirements when using jibs on a forklift.


Page 49 ADELG1011


Equipment type

Safety considerations

Slings (draw an example of a sling in this space)

Hooks (draw an example of a hook in this space)

Rings (draw an example of a ring in this space)

Shackles (draw an example of a shackle in this space)


Page 50




Page 51 ADELG1011


Section 3 Forklift safety

Page 52




Whattodobeforeyoudrivetheforklift Personalprotectiveclothing Forkliftsafetytips


Page 53 ADELG1011


What is required for forklift safety? Themostimportantaspectofforkliftdrivingissafety.Asaforklift driveryoumustbeawarethattherearealwayspeopleworkingaround youandiftherewasanaccidenttheymaybeinjured.Itwouldbea terribleburdentohaveonyourconsciencethatyourworkmatewas injuredbyanaccidentthatyoucouldhaveprevented. ForkliftsafetyhasaveryhighprofileinAustraliaasstatisticsshow‘one intenworkplaceaccidentsinAustraliainvolvesaforklift’(1993).These accidentscanbepreventedonlyifcompaniesandindividualsrealise theimplicationsoftheseaccidentsandtakestepstopreventthem fromhappening.

Page 54



Activity 14: Before you drive the forklift Before you even consider driving the forklift, forklift , you need to complete three tasks. They are: •

plan your work - inspect the work area

•

select the correct forklift

•

make your presence known.

Complete the worksheet on the next page by explaining what is involved in these three steps.


Page 55 ADELG1011


Steps

Questions

Plan your work

Why do you need to plan your work?

Why do you need to inspect the work area?

What do you look for?

What do you do when a hazard or a risk has been identified?

Page 56



Select the correct forklift

What do you need to consider when selecting a forklift to do a job?

Make your presence known

When do you need to let people know that you are about to drive a forklift in the area?

How can you alert people to the fact that a forklift is operating in the area?


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Personal protective clothing Thewearingofpersonalprotectiveclothingisanimportantfactorfor yourprotectionandisalegalOHSrequirement. Thetypesofpersonalprotectiveequipmentarevariedandtheiruseis determinedbythenatureofthetasksyouperform.Sometypesof personalprotectiveequipmentinclude:

Page 58

•

safetyhelmets

•

safetyglasses

•

safetybootsandshoes

•

gloves

•

aprons

•

overalls.



Activity 15: Personal protective clothing Different organisations have different personal protective clothing requirements for their forklift operators depending upon many factors. What protective clothing do you need to wear in your workplace while driving or inspecting the forklift? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

What protective clothing do you need to wear in a workplace while driving the forklift according to national and state regulations? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________


Page 59 ADELG1011


What are some causes of forklift accidents? Therearemanytypesofaccidentsthatcanhappentoaforklift operatororworkmate.Themorecommoncausesofaccidentsare: •

beinghitbyamovingforklift,includingfeetbeingrunover

•

operatorbeinghitbyafallingobject

•

otheremployeesbeinghitbyafallingobject

•

boardingorleavingtheforklift

•

forklifttippingover

•

collisionwithothervehiclesorobjects

•

partsoftheoperator’sbodyprotrudingoutsideofthecab andstrikinganobject.

Therearealsomanysafetyrulesthatneedtobeobservedwhile drivingaforklift.

Page 60



Activity 16: Safety considerations Discuss forklift safety with any two of the following people: •

your trainer

•

a forklift trainer

•

an experienced forklift operator.

Then look through the list of forklift safety tips provided to you on the following pages. Then categorise each of the tips into the given headings on the page following these tips.


Page 61 ADELG1011


1

Know your forklift and ancillary equipment

2

Inspect prior to use

3

Report damage or faulty equipment immediately

4

Do not operate the forklift until faults are corrected

5

Do not make repairs, alterations or adjustments to any forklift unless authorised to do so

6

For forklifts powered by an electric motor, know the location of the emergency isolator and know how to operate it

7

Use the attachments and ancillary equipment only for its intended use

8

Do not use the forklift for any purpose other than what it is designed to do

9

Do not allow internal combustion engines to idle unnecessarily in an enclosed or semi-enclosed area

10

Know your loads and how to carry them properly

11

Carry only those loads that are rated within the capacity of the forklift

12

Handle only stable loads

13

Centre the weight of the load between the forks

14

Be aware of rear end swing

15

Ensure that the forks are fully inserted and the load is up against the fork back rest

16

Always travel with the forks no more than axle height

17

Know the load centre distance of the load - be especially careful when using attachments

18

Do not use supplementary counterweights to increase the capacity of the forklift

19

Always lift and lower the loads with the forks tilted slightly back

20

Tilt the elevated load forward only when directly over the unloading position

21

Watch floor strength everywhere especially on loading ramps and bridge plates

22

Ensure that you travel in the correct direction when driving up and down inclines

23

Avoid bumps, dirt, wet spots, rough ground or anything that may cause the forklift to become unstable

24

Check all bridge plates for width, capacity and security before driving on

25

Ensure that truck wheels are chocked before attempting to load via a bridge plate

26

Do not obstruct emergency exits, aisles or thoroughfares when either using or parking the forklift

27

Cross railway lines diagonally - railway lines should be recessed or chocks put in place

28

Know critical clearance areas and locations of overhead pipes, wiring, doorways, etc.

Page 62



29

Never turn on an incline or a slope

30

Never take or carry a passenger - no riders

31

Keep yourself and others clear of the lifting mechanism

32

Always travel with the fork tips pointed slightly up - even when unloaded

33

Report all accidents immediately

34

Keep all hands, legs, head, etc. inside the operator’s compartment

35

Use only secured, approved safety platforms when lifting personnel

36

Never allow anyone to go under the load or forks

37

Make sure that nobody stands or walks between the forklift and a stationary object

38

When leaving the forklift, ensure that it is in a parked condition - forks lowered, park brake on, power shut off, etc.

39

Always follow proper refuelling procedures

40

Always give way to pedestrians, ambulances or police

41

Safeguard pedestrians at all times

42

Always sound horn at cross aisles and blind corners

43

If forward visibility is obstructed, travel in reverse

44

Always clean up any spilled fuel, oil or flammable liquids before starting engine

45

Travel slowly around corners

46

If you cant see, don’t go

47

Always concentrate on the job at hand - never be distracted

48

Avoid sudden stops and starts

49

Always carry the load with the centre of gravity directly in the middle of the forks

50

Know what the common handling symbols mean

51

Never elevate loads while on an incline

52

Ensure that all tyre pressures are correct and the same

53

Use only electric forklifts in enclosed areas

54

Make sure that you travel slowly when you have a load

55

Do not wear rings, wrist watches, jewellery or metal objects when battery charging as these may contact the electrical parts and cause arcing

56

Take extreme care when loading and unloading containers - they are an enclosed area

57

Take extreme care when driving over wet surfaces. The braking distance will be considerably more

58

Never alter the forks in any way, shape or form

59

USE COMMON SENSE


Page 63 ADELG1011


Place the number of the forklift safety tip next to the appropriate category. Driving the forklift e.g. 40 ________________________________________________________ ________________________________________________________________

Forklift and forklift equipment e.g. 52 ________________________________________________________ ________________________________________________________________

Forklift loads e.g. 12 ________________________________________________________ ________________________________________________________________

Workplace environment e.g. 21 ________________________________________________________ ________________________________________________________________

Personal safety e.g. 34 ________________________________________________________ ________________________________________________________________

Other peoples’ safety e.g. 30 ________________________________________________________ ________________________________________________________________


Page 64




Page 65 ADELG1011


Section 4 Driving the forklift

Page 66




Pre-operationalsafetycheckofforklift Pre-operationalsafetycheckofworkarea Reportingofchecks Drivingtheforklift Drivingaloadedforklift Stackingandde-stacking Loadingandunloading Refuellingandrechargingaforklift


Page 67 ADELG1011


Why are pre-operation safety checks completed? Beforeusinganyforkliftitisessentialthatyouconductapre-operation safetycheckonboththeforkliftandtheworksite. Thischeckistoensurethattheequipmentissafetouseandtheactual worksiteissafetoworkin. Notethatinrelationtothesafetycheckontheforklift: •

•

•

theextentofthesafetycheckwillbedeterminedby companyrequirementsandanyOHSregulations theremaybetheneedtocompleteachecklisttofulfil workplacepoliciesandregulationsbeforeusingthe equipment thecheckistoensurethattherearenofaultsordamage totheforkliftwhichmakeitunsafetooperate.

Notethatinrelationtothesafetycheckontheworksite: •

•

•

Page 68

thischeckistoensurethattheworksite(thepaththatyou willactuallybetakingwhenmovingtheload)isfreefrom obstaclesorsafetyhazards youshouldinformpeoplewhomaybeworkinginornear yourpath youshoulderectbarriersandsignstoinformotherpeople ofanypossibledanger(wherenecessary).



Activity 17: Pre-operational safety check equipment Watch your trainer or an experienced person demonstrate a preoperational safety check on the forklift. The pre-operational check will include a pre-start check and an operational check. The pre-start check is to check for safety features that can be checked before using the equipment; for example, flat tyres, worn slings, etc. The operational check is to determine if all forklift parts are working properly before using it on a job; for example, brakes, controls, etc. Whilst the person is performing the pre-operational safety check, ask them to tell you what they are checking so you can write it down to form a list. An activity worksheet is provided to help you and is located on the following pages. Decide if it is a pre-start check or an operational check and mark accordingly. Example: forklift (this example example is not complete)

Name of equipment

Forklift

Parts Checked - Pre start

Pre-start

Tyres for damage, pressure

✔

Wheel nut - not missing, tight

✔

Safety cage - damage, not loose

✔

Operational

Horn

✔

Park Brake

✔

Steering

✔

Etc. Etc.


Page 69 ADELG1011


Forklift Parts checked

Page 70

Pre-start

Operational



Forklift Parts checked


Pre-start

Operational

Page 71 ADELG1011


Activity 18: Check of work area Ask you trainer to give you an imaginary forklift task. Check out the work area where you would be using the forklift and identify any potential hazards or risk areas that might affect the safety of the operation. Write down areas that have potential hazards and any hazards or risks that you actually actually found. Then identify the actions that you would take (or actually took) to eliminate the hazard.

Hazard or risk

Action taken

Check out your answers with your trainer and then add any that you may have missed for future reference.

Page 72



Reporting of pre-operation check results Onceaninspectioniscomplete,theresultsofthatinspectionneedto bereported.Manyworkplaceshaveastandardchecklistand procedureforthereportingofforkliftpre-operationalchecks.All employeeswhousetheforkliftusethisstandardprocedure. However,someworkplacesexpectyou,theemployee,tobe responsibleforthisprocess. OccupationalHealthandSafetyregulationsinsomeStates/Territories requirethatyoudoapre-operationalcheckbeforeyouusetheforklift andequipment.Theresultsthenneedtoberecordedandreported. Therefore,itmaybeyourresponsibilitytodothis.


Page 73 ADELG1011


Activity 19: Pre-operational checklist First, find out if your workplace has a standard procedure for conducting the pre-operational check and for recording and reporting the results. If so, obtain a copy of the relevant documentation for your reference and use. If not, study the pre-operational checklist on the next page. Once completed, show the checklist to your trainer tr ainer and discuss what items need to be checked and if your organisation has any other requirements that you need to complete.

Page 74



Pre-operational checklist for counterbalanced forklift

Pre-start check - outside visual

Pre-start check - inside engine compartment

No leaks or obstructions under forklift

Liquid levels correct - engine oil, hydraulic oil, brake fluid, cooling water, transmission oil

Tyres - not flat, not damaged, wheel nuts not loose, tyre pressure

Fan belt - correct tension

Mast assembly - damage, obstructions, lubrication, chain tension

Battery - water level, connections and security

Forks/attachments - condition, secure, locking pins secure

Battery (electric forklifts) - sufficient charge, water levels

Load backrest -secure, not damaged

Condition - any leaks, damage or obstructions

Hydraulic hoses and couplings excessive leaking, not damaged Body damage

Operational Check

Safety cage secure

Gauges and warning lights - working

Check steering wheels and cylinders

Lights - check if working

Check for any loose wiring

Warning signals - revolving light, reverse beeper, indicators

Towing pin secure

Horn

Check manufacturers data plate

Mast controls

Driver compartment - free from obstacles, adjust seat, adjust mirrors

Park brake

Gas - turn on, check fittings secure, check for leaks, check level of gas

Foot brake

Steering

Name ________________________ ________________________

Signature _______________ ________________ _ Date _____________ _____________


Page 75 ADELG1011


Activity 20: Using the checklist Using your workplace checklist or the checklist shown on the previous page, practise using the list by checking the forklift and recording and reporting the results. Then report the results of the pre-operational check according to your workplace procedures. NOTE: Your state/territory legislation legislation may require you to be licensed before you you can use a forklift. If this applies in your your state/territory you will need to be supervised when conducting the operational check as this involves operating the forklift.

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Forklift start-up procedure Thispartoftheunitdealswiththeoperationoftheforklift.It isessentialthatyouoperatetheforkliftundersupervision whilstyouareintraining. Failuretodosowillhavebothyouandyouremployerliablein theeventofanaccident.


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Activity 21: forklift start-up procedure The forklift start-up procedure is similar to the start-up procedure of a car. There is a definite definite procedure to follow to ensure that everybody is safe and the equipment is safe to operate. Think about the procedure you are supposed to follow when you first get into a car and start the engine. Now relate this to the forklift. List the first five steps you would take when you get into a forklift. a. b. c. d. e.

Page 78



Travelling and parking the forklift Theforkliftcontrolsaredifferentfromthoseofacarormotorbikein thattheyonlyhaveoneforwardandonereversegear.Theyhaveno clutchbuttheydohaveabrakeandanaccelerator. Tooperatetheforklift,followthegivensequence: •

releasetheparkbrake

•

movethedirectionleverinthedirectionyouwishtotravel

•

takeyourfootoffthefootbrake

•

presstheacceleratorslowlyuntilmovementoccurs

•

adjusttheacceleratortothedesiredspeed.

Steering Theforkliftisdifferentfrommostothervehiclesinthatitissteeredby thebackwheelsandpoweredbythefrontwheels.Insteadofthe vehiclefollowingthefrontwheelsaroundacorner(asacardoes),the backoftheforkliftwillswingout,therebyturningthevehicle.Thisis commonlycalled‘TailSwing’.


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Activity 22: Tail swing The tail swing of the forklift occurs whenever the forklift is turned around a corner and is one of the main skills that you, as a forklift driver, need to master if you wish to become a competent forklift driver. Why do you think the forklift is designed and built with rear wheel steering? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

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Whenyoufirststartdrivingtheforkliftyouwillbeshownwherethe pivotpointisontheforklift.Thepivotpointisanimaginarypoint wheretheforkliftpivotswhilstturningacorner.Theforkliftisnotlike acarwhereaturningcircleisrequiredasaforkliftcanvirtuallyturnon apoint. Itisessentialtoknowwherethepivotpointoftheforkliftissothat youareabletomanoeuvreinverysmallspaces.Itdiffersslightly betweenforklifts. Youwilllearnmuchmoreaboutdrivingtheforkliftwhenyoubegin yourpracticaldrivingpartoftheunit. Whendrivingaforkliftyoumustalwaysbeconsciousofthesafety factor.Therearemanyrulesandsafetyprecautionsthatyoumust followwhenyouareinchargeoftheforklift.

Stopping and parking the forklift Manyaccidentscanoccurwhentheforkliftisbeingbroughttoahalt. Forkliftsshouldbebroughttoahaltgraduallyaswheelslidingand hardbrakingisdangerous,unnecessaryandharmfultotheforklift truck. Ifhardbrakingoccursthereisaveryhighpossibilityoftheloadtipping over,therebydamagingstock,wastingtimeandpossiblycausinginjury tosomebody. Afteryouhavebroughttheforklifttoahalt,itneedstobeparked correctly.Thecorrectparkingprocedureis: •

•

ensurethattheforkliftparkingpositionissuitable-e.g. not infrontofexits,levelground,notinwalkways makesurethatthetipsoftheforksaretouchingthe groundby: − tiltingthemastslightlyforward − loweringtheforksuntilthetipsaretouchingtheground

•

puttheforkliftinNEUTRAL

•

applytheparkingbrake

•

turnofftheforkliftandremovethekey(accordingtoyour companypolicy)


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•

Page 82

turnoffgas(ifgaspowered).



Activity 23: Shut down Answer the following questions. Why is it important to have the fork tips touching the ground? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

Why do you think this is necessary to conduct a post-operational check on the forklift? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

List the items that you think you would need to look at in the postoperational check. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________


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If you found a fault in conducting the post-operational check what do you need to do? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

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Refuelling/recharging Refuelling/rechargin g the forklift Aspartofyourdrivingskillsyouwillobviouslyneedtoknowhowto refueltheforklift. Itisimportanttofollowspecificinstructionswhenrefuellingthe forklift.Althoughtherearedifferentfuelsforforkliftsandtherefore differentrefuellingmethodsthefollowingrulesapplytoallforklifts whenrefuelling. Rules •

•

•

•

Beforerefuellingshutofftheengineandthelightsanddo notrestartengineuntilrefuellinghasfinished. Smokingisprohibitedinanyareawherethetruckisbeing refuelled. Refuellingshouldbedonewellawayfromwelding,open flamesandsparks. Ifyoudetectafuelleak,don’tstarttheforklift,pullit outsideandaskforhelp(fromyourtrainer,supervisoror maintenance).

WithLPGtherefuellingprocessinvolveschangingoveragasbottle, notsimplyfillingupthetankaswedowithmotorvehicles. ThefollowingprocedureshouldbefollowedwhenreplacingtheLPG gascylinderontheforklift. Beforechangeover •

•

•

•

Smokingisprohibitedinanyareawherethetruckisbeing refuelled. Keeptheenginerunning. Closethecylindershutoffvalveandlettheenginerun untilitstops. Whilechangingovercylinderalwayswearglovesanduse eyeprotection.

Conductingchangeover •

•

•

Unscrewthebottlefittingmakingsurethatyouare wearinggloves Removethecylinderandstoreemptycylinderuprightin thedesignatedarea(mustbeundercover). Connectupthenewcylinder.


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Afterchangeover •

•

Startforkliftandcontinuework. Ifaleakisdetectedinthefuelsystem,stopimmediately, turnoffisolatorvalve,putanappropriatesignonforklift andreportleaktosupervisor.

Batterycharging

Ifyouhaveanelectricforkliftyouwillobviouslyhavetorechargethe batteryratherthanrefueltheforklift. Whentheforkliftneedsit'sbatterychanged,theforkliftmustbe stationaryandmovedsothatitisintheproperparkedposition. Batteriesshouldbechargedinadesignatedareathatisfreefrom obstacles,weldingequipment,sparksandopenflames.Itshouldalso haveproperventilationasbatteriesduringcharginggiveoffhydrogen gasthatisextremelyflammable.Theareashouldalsobeanonsmokingasacigarettecouldcauseanexplosion. Tipsonbatterycharging •

•

•

•

•

•

•

Page 86

Parktheforkliftinthedesignatedareaandensurethe handbrakeison. Smokingisprohibitedinanyareawherethebatteryis beingrecharged. Openthebatterycompartmentandleavethisopenduring chargingoperation. Ensureventcapsarefunctioningproperlyandleavevent capsinplacetoavoidelectrolytespray. Donotwearrings,wristwatches,jewellery,orothermetal objectsastheymaycontactelectricalpartswhichwill causearcingandelectrocution. Keepallmetallicobjectsawayfromthetopofthebattery asthesemayalsocausearcing. Ifanyleakageofthebatteryelectrolyteoccursthenflushit away;reportanymajorspillage.



Activity 24: Battery charging Thefollowingdiagramshowsaforkliftdriverinvolvedinmanyunsafe practises.Listtheunsafepractisesthatyoucanidentify.

________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________


Page 87 ADELG1011


Loading and stacking Loadingandstackingisagainaverypracticalskillandwillneedtobe learntatyourpracticalsessions.Howeverthereissometheorythat youcanlearnbeforeyoudrivetheforklift. Asaforkliftdriver,youwilllift,stack,de-stackandmoveloadsevery dayandsotheseskillswillbecomesecondnaturetoyouintimeand withpractice.

Page 88



Activity 25: Lifting and carrying The following exercise lists the correct procedures for lifting and carrying a load. Fill in the missing words 1. Approach the load load ................ making sure that the forklift is square to the load and the forks are ...................... and at the correct height for sliding under the load. 2. Move forward slowly until the forks are entirely under the load and the load is ................... .............. ..... against the fork backrest. Ensure that the load is .................... ............. ....... and take care to ensure that the forks do not ..................... past the back of the load.

3. Raise the load until all .......................... are cleared. ............ the load backwards to ensure safe handling of the load. 4. To transport the load, the mast needs to be tilted slightly ..................... ....... to ensure ensure that the load is stable. Do not travel with the load raised higher than .......................... for adequate clearance. clearance. This is generally generally no higher higher than ...............


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5. To unload, first the load needs to be .................. slightly ..................... .... then lowered to the ground. It may then be necessary to tilt the mast further ....................... to ensure that the forks are smoothly withdrawn from the load.

6. ................. .... back away from the load ensuring that the forks do not catch on the load.


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Stacking a load Thefollowingisthecorrectproceduretousewhenstackingand unstackingaloadofpallets.Youshouldfollowthisprocedureatall times: •

Approachthestackwiththeloaddownandtilted backwards.

•

Haltatthebaseofthestackbyapplyingbrakes.

•

Raisetheloadtothedesiredstackingheight.

•

Driveforwarduntiltheloadisoverthestack.

•

Tiltmasttoaverticalposition.

•

Lowertheloadontothestack.

•

•

•

Whentheloadisstackedsecurely,lowertheforkarms untilfreeofthepallets. Movethetruckbackwardsmakingsurethattheforksare clearofthepallets.(Note:Itmaybebeneficialtotiltthe forksforwardasthetruckismovedbackwards). Whentheforksareclearofthestack,lowertheforksand tiltslightlybackwards.

De-stackingaload •

•

Haltatthebaseofthestack-remembertoensurethatthe loadiswithincapacityoftheforklift. Raisetheforkstothedesiredheight.Asyoudosotilt mastuntilitisvertical.

•

Insertforkstotheirfullextentbydrivingforward.

•

Liftloadclearofstackandcarefullyapplybackwardstilt.

•

•

Whentheloadisclearofthestack,movebackslowlyuntil itisclear-(remembertolook). Lowertheloadcarefullyandsmoothlytotravellingheight, applyfurtherbackwardtiltbeforemoving.

Reachtruckstacking

Thestackingandde-stackingwithareachtruckisthesameasa counterbalancetruckexceptthatthereachtruckhastheoptionto movetheforksforwardtopickandplacetheload.Thisensuresthat thereachtruckismorecompactandabletomoveinsmallerspaces.


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Remembertoalwaysbringtheloadwithinthewheelconfinesbefore movingtheload.

Loading and unloading vehicles Whenloadingvehiclesthefirstprioritywithanyloadistokeepthe loadwithinthelegalaxleloadrequirementsandwithinthepermissible loaddimensions. Tobeabletodothisyouneedtobeabletounderstandsome‘truckie’ terms. The‘truckie’termsthatyouwillneedtounderstandare: •

•

•

TARE-themass(weight)ofthevehiclewithoutitsload AGGREGATEMASS-themaximumallowableloadedmass ofaparticularvehicle GROSSCOMBINATIONMASS-theloadedmassofthe vehicleplustheaxleloadsofanytrailerbeingtowed (includessemitrailers).

Whenloadingvehiclesitisessentialtodistributetheloadtokeepthe centreofgravityaslowaspossibleandthevehicleevenlybalanced.If possible,itemsshouldbeplacedagainsttheheadboardofthevehicle sothattheycanbesecuredproperlyandtheyareinnodangerof movingduringbraking. Larger,heavieritemsshouldbeplacedatthebottomoftheload.The vehicleshouldbeloadedtogiveanevenweightdistributionoverits floorarea.Thismayrequirepackingsuchastimberplanksorblock wedges. Trytoalwaysdistributetheloadsothatlightcrushableobjectsarenot loadedinfrontoftheheavierlargeobjectsotherwisetheymightbe squashedduringbraking.Heavysoliditemsshouldalsobeloadedso thatpartoftheitemisovertheregionoftheaxles.Thiswillhelp distributetheloadevenly. Ifhighloadsneedtobetransportedalwaystrytouselowplatform vehiclesashighloadswillseriouslyaffectthecentreofgravityofthe loadandputitinseriousdangerofoverturningwhencornering.

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Activity 26: Loading trucks In the following exercise exercise an empty truck is drawn. There are also some loads on the ground next to the truck. Using these loads loads draw them onto the truck as it should be loaded according to the appropriate safety rules.

There is feed Learner’s Gui


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Activity 27: Driving the forklift During this activity you will be required to practise using the forklift within a variety of workplace situations. This activity must be done so under supervision according to any regulations or workplace and equipment policies. This activity only allows you to practise using the equipment. There will be separate assessment exercises that you need to complete. Your trainer will give you you different workplace tasks to do. They must include: •

using the forklift unloaded

•

using the forklift with a variety of loads l oads

•

using the forklift with long, wide loads

•

loading and unloading a truck

•

stack and de-stack a load (low and high stacks) in both narrow and wide aisles.

Each time you use the equipment, fill in the logbook contained in the Assessment Tasks section of this Learner’s Guide. Once you feel that you are competent in the use of this equipment in all of the above tasks, approach your trainer and request an assessment.

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Additional resources


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Websites:

• Workcover Authority of NSW http://www.workcover.nsw.gov.au/

• WorkSafe Victor http://www.workcover.vic.gov.au/wps/wcm/connect/WorkSafe

• WorkCoverQueensland http://www.workcover.qld.gov.au/

• WorkCover WA http://www.workcover.wa.gov.au/

• WorkCover SA http://www.workcover.com/home.aspx

• ACT WorkCover http://www.workcover.act.gov.au/

• WorkplaceStandardsTasmania http://www.wst.tas.gov.au/node/WST.htm

• NTWorkSafe http://www.worksafe.nt.gov.au/

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Feedback on activities The responses provided in this section are suggested responses. Because every workplace is different, your responses may vary according to your specific workplace procedures, the equipment available and the nature of the business.


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Activity 4: Identification of the different types of forklifts There are four main types of forklifts that you are likely to see within the road transport industry. These are discussed below:

Counterbalance forklift What does a counterbalance forklift look like? (draw or find a picture and place in the space opposite)

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Why is it called a ‘counter balance’ forklift?

Because the load being picked up is counter balanced by the weight of the vehicle chassis, engine, counterweight and body

Where is the balance point or fulcrum of a counterbalance forklift found?

A point on the ground vertically below the front axle

List the two main power source options that you find on counterbalanced forklifts.

internal combustion engine electric powered - battery



Straddle forklift or reach truck What does a straddle forklift look like? (draw or find a picture and place in the space opposite)

How is the weight of the load distributed on a straddle forklift?

The weight of the load is distributed between the four wheels of the forklift while moving. This dismisses the need for the forklift to counterbalance any load.

What is a straddle forklift primarily designed for?

The straddle forklift is primarily designed for use in the warehouse. They are designed to be manoeuvrable and to lift pallet loads to great heights.

What is the primary power source for straddle forklifts?

Most straddle forklifts are electric powered.


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Order pickers What does an order picking forklift look like? (draw or find a picture and place in the space opposite)

Why is it called an ‘order picker’?

It is called an order picker because that is its primary use. To lift the operator to high levels where he/she can select stock for picking a customers order.

What is the difference between an order picker and a straddle forklift?

The order picker and the straddle are quite similar in their looks but with an order picker the operator and the forklift controls are actually lifted to the desired height. With a straddle forklift it is only the load which is lifted to the desired height.

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Side loading forklift What does a side loading forklift look like? (draw or find a picture and place in the space opposite)

Why is it called a ‘side loading’ forklift?

Because unlike other forklifts the load is picked up from the side of the forklift rather than the front. This allows the forklift to be manoeuvrable with long awkward loads.

What types of loads are handled by the side loading forklift?

Usually long loads such as timber, pipes, metal bars, containers.

Give two examples of Timber yards, timber merchants. workplaces that Steel and pipe retailers. might use the side loading forklift? Anyone who moves long loads of timber, steel, plastic. Container storage areas.


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Activity 5: Advantages and disadvantages of electric powered forklifts

Advantages of electric powered forklifts

Disadvantages of electric powered forklifts

No exhaust fumes emitted, therefore suitable for enclosed spaces, cool rooms, warehouses, etc.

Batteries are bulky, very heavy and very expensive.

Very little engine noise. Virtually no vibration. Ongoing maintenance costs seem to be less than internal combustion.

The actual forklift is usually more expensive than an internal combustion forklift. Battery takes quite a few hours to recharge therefore there is either the need for an extra battery or a long wait between forklift use. Extra cost of battery recharging equipment.

Cost saving on fuel.

Less power than internal combustion. Relatively short operating time between recharges.

Activity 6: forklift components Component Overhead guard Steering wheels Load Backrest Forks Mast Drive wheels Counter weight Hoist chains Manufacturer’s data plate Parking brake

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No. 3 6 10 9 2 8 4 1 7 5



Activity 8: Data plate information Complete the chart by completing the definition and then selecting one of your workplace forklifts and give actual data plate readings.

Information

Definition


The distance between the centre of gravity of the load and the vertical face of the forks on the forklift. This is usually 600mm but may be 500mm on some forklifts.

Maximum safe working load

The maximum weight the forklift can safely carry.

Maximum lift height

The maximum height that the forklift can lift the maximum safe working load.

Mast tilt - degrees

The amount of forward and reverse tilt in the mast. The figure is in degrees. For example, 6 degrees.


Data plate information

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Activity 9: Centre of gravity Indicate where the centre of gravity is on the following shapes:

Centre of Gravity 1200mm 2.1m 600mm 700mm 900mm 1800mm 600mm

1.8m 800mm diameter

Dead centre

1.5m

1.25m

0.75m

2.5m

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Activity 10: Load centre distance The load centre distance, which is described on the manufacturer’s data plate is the distance between the centre of gravity of the load and the vertical face of the forks. Centre of Gravity of the load

Load backrest



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Activity 11: How to calculate load centre and forklift capacity Question 1 What happens to the capacity of the forklift if the load has a l oad centre greater than 600mm? If the load centre distance is greater than 600mm, the capacity of the forklift (the weight that it can carry) carry) will decrease. When the load centre is more than 600mm this will cause an effect where the load will appear heavier than what it actually is. Question 2 Imagine that your forklift has the following specifications Capacity - 1000kg Load centre - 600mm Max height - 3500mm There are four different different loads shown below. below. You are to determine determine which of the loads loads can be safely safely lifted with your forklift. Circle the loads that can be safely lifted.

900kg

Question 3 If the load centre of the load is less l ess than 600mm, will you be able to carry more than the maximum safe working load? No - The maximum weight at any time is the maximum safe working load.

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Activity 13: Jib equipment safety

Equipment type

Safety considerations

Slings

There are many different types of slings - wire rope, chain, webbing, natural fibre & synthetic. Check slings every time you use it - check for excessive wear, broken fibres or wires, weathering, mould, rot or sun damage, rust or cracks, cuts or gouges and stretching or bending of links. Ensure that the SWL (Safe working load) of the sling is never exceeded. All slings must have a label indicating either the SWL or the WLL (working load limit) - if the label is missing do not use the sling.

Hooks

Many different types. Ensure that it is an approved type of hook - never homemade. Ensure correct SWL - ensure that it is the same or less than the sling. Hooks used with jib attachments must always be the swivelling type - never the fixed type. Discard if more than 10% wear is evident.

Rings

Many different types. Ensure that it is an approved type of shackle - never homemade. Ensure correct SWL - ensure that it is the same or less than the sling. Discard if more than 10% wear is evident.

Shackles

Many different types. Ensure that it is an approved type of ring - never homemade. Ensure correct SWL - ensure that it is the same or less than the sling. Discard if more than 10% wear is evident.


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Activity 16: Safety considerations Driving the forklift

14,16,19,20,22,29,32,40,43,45,46,4 14,16,19,20,22,29,32,40,43,45,46,4 8, 51,54,59

Forklift and forklift equipment

1,5,6,7,18,52,58

Forklift loads

10,11,12,13,15,17,49,50,

Workplace environment

21,23,24,25,27,28,56,57

Personal Safety

2,3,4,8,31,33,34,39,44, 47,55,

Other peoples safety

9,26,30,35,36,37,38,41,42,53,

Note: many of these safety tips could be be grouped into a different category. The answers shown shown above are one option only. only.

Activity 25: Lifting and carrying 1. Approach the load slowly making sure that the forklift is square to the load and the forks are level and at the correct height for sliding under the load. 2. Move forward slowly until the forks are entirely under the load and the load is resting against the the fork backrest. Ensure that the load is centred and take care to ensure that the forks do not protrude past the back of the load. 3. Raise the load until all obstacles are cleared. Tilt the load backwards to ensure safe handling of the load. 4. To transport transport the load, load, the mast needs needs to be tilted slightly backwards to ensure that that the load is stable. Do not travel travel with the load raised higher than necessary for adequate clearance. This is generally no higher than 150mm (axle height). height). 5. To unload, first the load needs to be tilted slightly forward then lowered to the ground. ground. It may then be necessary to tilt the mast further forward further forward to ensure that the forks are smoothly withdrawn from the load.

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6. Slowly back away from the load ensuring that the forks do not catch on the load.

Activity 26: Loading trucks

Note: There are numerous numerous ways in which which the truck may may be loaded using these these loads. loads. This is one example. example. If your answer differs from the one shown above, consult your trainer to ensure that your answer is correct.


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TLID1007C - Operate a Forklift - Learner Guide

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