TLID1107C - Conduct Special is Ed Forklift Operations - Learner Guide

8/14/2019 TLID1107C - Conduct Special is Ed Forklift Operations - Learner Guide

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TLID1107C

Conductspecialisedforklift

ArmstrongsDriverEducation

LearnerGuide


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TLID1107C Conduct specialised forklift operations

Page 2 Australian National Training Authority 2003ADELG1017 Customised and Developed by Armstrongs Driver Education P/L April 2008


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Page 4 Australian National Training Authority 2003ADELG1017 Customised and Developed by Armstrongs Driver Education P/L July 2009


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Australian National Training Authority 2003 Page 5Customised and Developed by Armstrongs Driver Education P/L July 2009 ADELG1017

What this Learners Guide is about

ThisLearnersGuideisabouttheskillsandknowledgerequiredtooperateaforkliftwithspecialisedattachmentsorall-terrainequipment,includingcheckingattachmentsandworksiteforsuitability,selectingthetypeofforkliftandaccessoriesforrequiredloadshiftingtasks,andshiftingloadandcompletingworkinaccordancewithoperationalrequirements.Assessmentofthisunitwillusuallybeundertakenwithinalicensingexaminationconductedby,orundertheauthorityof,therelevantstate/territoryOHSAuthority.

Personsachievingcompetenceinthisunitwillneedtofulfilalloftherelevantstate/territoryOHSregulatoryrequirementsconcerningthe

safespecialisedoperationofforklifts.

TheElementsofCompetencyfromtheunitTLID1107CConductspecialisedforkliftoperationscoveredinthisLearnersGuidearelistedbelow.

Checkattachmentsandworksiteforsuitability

Selecttypeofforkliftandaccessoriesfortherequiredworkplacetask

Shiftloadandcompletework

ThisunitofcompetencyisfromtheTransportandLogisticsTrainingPackage(TLI07).


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Planning your learning

ItisimportanttoplanyourlearningbeforeyoustartbecauseyoumayalreadyhavesomeoftheknowledgeandskillsthatarecoveredinthisLearnersGuide.Thismightbebecause:

youhavebeenworkingintheindustryforsometime,and/or

youhavealreadycompletedtraininginthisarea.

Togetherwithyoursupervisorortrainerusethechecklistsonthefollowingpagestohelpyouplanyourstudyprogram.Youranswerstothequestionsinthechecklistwillhelpyouworkoutwhichsectionsof

thisLearnersGuideyouneedtocomplete.

ThisLearnersGuideiswrittenwiththeideathatlearningismademorerelevantwhenyou,thelearner,areactuallyworkingintheindustry.Thismeansthatyouwillhavepeoplewithintheenterprisewhocanshowyouthings,discusshowthingsaredoneandansweranyquestionsyouhave.Alsoyoucanpractisewhatyoulearnandseehowwhatyoulearnisappliedintheenterprise.

IfyouareworkingthroughthisLearnersGuideandhavenotyetfoundajobintheindustry,youwillneedtotalktoyourtraineraboutdoingworkexperienceorworkingandlearninginsomesortofsimulatedworkplace.


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Section 1: Types of forklifts and attachments

Areyouableto: Yes No

1. explainthedifferencebetweenthecounterbalance,straddle,orderpickerandside-loadingforklifts?

2. listtheadvantagesanddisadvantagesofinternalcombustionandelectricforklifts?

3. identifythemajorforkliftcomponents?

4. interprettheforkliftmanufacturersdataplate?

5. defineloadcentredistanceandexplainhowitaffectsforkliftstability?

6. identifyforkliftattachmentsandtheiruses?

7. demonstratesafeuseofattachmentsincludingjibsandassociatedequipment?

Section 2: Forklift safety


1. identifypersonalsafetyequipmentusedwhileinspectingandoperatingaforkliftwithattachments?

2. explainthesafetystepsthataforkliftdriverneedstocompletebeforetheydrivetheforkliftwithattachments?

3. stateforkliftsafetyrequirementswithregardstodrivingtheforklift,andforklift

equipment,loads,workplaceenvironment,personalandworkplacesafety?


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Section 3: Driving the forklift with attachments


1. conductapre-operationalforkliftsafetycheck?

2. conductapre-operationalworkareasafetycheck?

3. reporttheresultsofsafetychecks?

4. drivealoadedandanunloadedforkliftwithattachments?

5. stackandde-stackaload?

6. loadandunloadatruck?

7. refuelorrechargeaforklift?


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How you will be assessed

Assessment of this Unit of Competency will include observation ofreal or simulated work processes using workplace procedures andquestioning on underpinning knowledge and skills. It must bedemonstrated in an actual or simulated work situation undersupervision.

You will be required to:

demonstrate the safe and correct operation of a counterbalance forklift with attachments in a work situation.


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Section 1

Types of forklifts and attachments


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Section outline

Areascoveredinthissection

Typesofforklifts

Powersourcesormodesofpropulsion

Componentsoftheforklift

Attachmentsthatcanbefittedtotheforklift


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What are the types of forklifts?

Theforkliftisamaterialshandlingvehiclethatiswidelyusedinthe

transportindustry.Itisinvaluableforitsabilitytomovealargeamountofmaterialinaveryshorttimeusingaminimumoflabour.

Therearefourmaintypesofforkliftthatyouarelikelytoseeintheindustry.

Theyare:

counterbalancedforklift

straddleforkliftorreachtruck-alsoknownasnon-

counterbalanced orderpickers

sideloadingforklift.

Eachoftheseforkliftsareusedfordifferentpurposesintheworkplace.Theycanhoweverbeusedforavarietyoftasks.


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Activity 1: 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 followingpages.


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Straddle forklift or reach truck

What does a straddle forkliftlook like? (draw or find a pictureand place in the space opposite)

How is the weight of theload distributed on astraddle forklift?

What is a straddle forkliftprimarily designed for?

What is the primary power

source for straddle forklifts?


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Order pickers

What does an order pickingforklift look like? (draw or finda picture and place in the spaceopposite)

What is an order pickingforklift primarily designedfor?

Why is it called an orderpicker?


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What is the differencebetween an order pickerand a straddle forklift?

Side loading forklift

What does a side loadingforklift look like? (draw or finda picture and place in the spaceopposite)

What is a side loadingforklift primarily designedfor?


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Why is it called a sideloading forklift?

What types of loads arehandled by the side loadingforklift?

Give two examples ofworkplaces that might usethe side loading forklift.

There is feedback on this activity at the back of this LearnersGuide.


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What are the power sources for forklifts?

Powersourcesormodesofpropulsionforforkliftscanbedividedinto

twomaintypes.Theyare:

internalcombustion(fuels)

electric(battery).

Theinternalcombustionmotorinforkliftsaresimilartothatusedinmotorvehiclesandaredesignedtooperateonavarietyoffuelssuchas:

petrol

diesel

LPG(LiquidPetroleumGas)

naturalgas.

Electricforkliftsarebatterypoweredforklifts.Abankofbatteriesoroneverylargebatteryisusedtopowertheforkliftinsteadoffuelsubstances.Electricpoweredforkliftsarebecomingmoreandmorepopularwithinindustrybutelectricpoweredforkliftsalsohavesomedisadvantages.


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Activity 2: Advantages and disadvantages of electric poweredforklifts

Discuss the advantages and disadvantages of electric forklifts with:

your trainer

your workmates

someone who drives an electric powered forklift

or forklift distributors.

Advantages of electric poweredforklifts

Disadvantages of electric poweredforklifts



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What information is included on themanufacturers data plate?

Bylaw,everyforkliftisrequiredtohaveamanufacturersdataplatewhichhasinformationaboutattachmentdetails(ifonecanbefitted).Thisdataplatealsoincludesthefollowinginformation:

maximumsafeworkingload

loadcentredistance

maximumliftheight

make,modelandserialnumber

masttilt(indegrees)

tyretypeandrecommendedpressure

grossvehicleweight

attachmentdetails(ifoneisfitted).

Itiscriticalthatyouknowtheinformationonthemanufacturersdataplatesothatyouchoosetheappropriateforkliftandattachmentsneededforsafeoperation,andtheforkliftisdrivenandusedwithinthesafeoperatingcapacity.


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Activity 3: Data plate information for attachments

Using the activity work sheet, complete the definition and then

select one of your workplace forklifts and give actual data platereadings.

Information Definition Data plateinformation

Attachment details (you can indicate with a drawing)

Maximum safeworking load

Maximum lift height

Mast tilt - degrees



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Forklift attachments

Aforkliftattachmentisanextrapieceofequipmentthatisusedonthe

forkliftinplaceoftheoriginalforks.Sometimestheforksareremovedandtheattachmentisboltedtotheforkcarriage,andsometimestheattachmentisfittedtotheforks.

Therearemanytypesofforkliftattachments.Somearestandardtypeattachmentsandcanbepurchasedfromadealer,e.g.drumclamps.Othersarespeciallydesignedandmadetodoaspecifictask.

Whendecidingwhatattachmenttouse,youwillneedtotakeintoconsideration:

Thetypeofloadthatyouwanttomovee.g.barrels,bulkmaterials

weightoftheload

sizeoftheload

companypolicy

safetyconsiderationse.g.dangerousgoods.


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Activity 4: Forklift attachments

Most attachments have special safety considerations that you need

to take into account when you drive the forklift.

Forklifts can be fitted with attachments which make them safer tohandle certain loads. However, these forklift attachments changethe way the forklift handles, therefore it is essential to know how theattachments are used and any safety considerations that you needto know.

The worksheets on the following pages are designed to help youthrough this process.

You can find out the answers to these questions by: discussing them with your trainer

discussing them with a work mate

discussing with a forklift sales person

studying books, magazines, brochures or posters.


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Drum clamp What are drum clamps used for?

Drum clamps are used instead of transporting drumson pallets. Why?

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

What are the safety considerations?

Roll clamp What are roll clamps used for?

How do roll clamps work?



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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?



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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?



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Rotator What are rotators used for?

How do rotators work?


Pantograph What are pantographs used for?

How do pantographs work?



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Fork extension What are fork extensions used for?

How do fork extensions work?


Personnel lift or work platform What are personnel lifts used for?

How do personnel lifts work?



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Activity 5: Jib equipment safety

When using a jib, heavy items will be carried and suspended by

slings. The slings and associated equipment need to be thoroughlychecked each time they are used to ensure it is safe to do so.

There are also certain safety requirements and procedures that youneed to know before using jibs and slings on a forklift. Forinstance: one of the main safety considerations for operators usingjibs is the moving centre of gravity, therefore, extreme care needsto be taken when determining a safe working load for the forklift.

Complete the worksheet on the next page, stating relevant safetyrequirements when using jibs on a forklift.


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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)



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Section 2

Forklift safety


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What is required for forklift safety when usingattachments?

Themostimportantaspectofforkliftdrivingissafety.Asaforkliftdriveryouareawarethattherearealwayspeopleworkingaroundyouandiftherewasanaccidenttheymaybeinjured.Whenusingattachmentsitisimportanttomakesurethattheappropriateequipmentisselectedandsecuredtoensuresafetyandprotection


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Activity 6: Before you drive the forklift

Before you even consider using attachments with a forklift, you

need to complete the following tasks.

They are:

plan your work - inspect the work area

select the correct forklift

select appropriate attachments

store removed attachments

fit the appropriate attachments

make your presence known.

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


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Select the correctforklift

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

Select theappropriateattachment

What do you need to consider when selecting attachments?

Store removedattachments

What do you need to consider when storing attachments?

Fit the appropriateattachments

What do you need to consider when fitting attachments.


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Make your presenceknown

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

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


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Section 3

Driving the forklift withattachments


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Section outline

Areascoveredinthissection

Pre-operationalsafetycheckofforklift

Pre-operationalsafetycheckofworkarea

Reportingofchecks

Refuellingandrechargingaforklift

Fittingattachmentstotheforklift

Lifting,carryingandsetting-downloads

Lifting,carryingandsetting-downloadswithattachments

Drivingtheforkliftwithattachments


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Conduct advanced forklift operations

Fitting attachments to a forklift

Withfittingattachmentstoaforklift,itisimportantforyoutomakesurethattheattachmentsarefittedaccordingtomanufacturersguidelines.

Theseguidelinesareusuallyfoundintheoperating/manufacturersmanual.Manualstellyouwhattheattachmentisdesignedtodoandhowyouaremeanttoattachittotheforklift.

Manualswillalsoincludeschematicdrawingswiththeirinstructions.Manualsarespecificallydesignedforeachattachmentsoitisimportantforyourtomakesurethatyouarereferringtothecorrectmanual.


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Activity 7: Fitting attachments

Identify two types of forklift attachments.

Write a step by step list of instructions on how to fit the attachmentsto the forklift.

The worksheet on the following page is designed to help youthrough this process.

Sources of information include:

your trainer

forklift attachment manuals/brochures

companies specialising in forklift attachments

schematic drawings.


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Type of forklift:

Type of attachments:

Steps: Description:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.


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Lifting, carrying and setting down loads

Asaforkliftdriveryoucanalreadylift,stack,de-stackandmove

differentloads.Whenusingattachmentsthetheorybehindtheprocessesyouarecurrentlyusingisverysimilar.


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Activity 8: Lifting, carrying and setting-down loads

The following exercise lists the correct procedures that you already

use for lifting and carrying a load. Fill in the missing words.

1. Approach the load ____________ making sure that theforklift 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 theload and the load is ____________ against the forkbackrest. Ensure that the load is ____________.

3. Raise the load until all ____________ are cleared.

____________ load backwards to ensure safe handling ofthe load.

4. To transport the load, the mast needs to be tilted slightly____________ to ensure that the load is stable. Do nottravel with the load raised higher than ____________ foradequate clearance. This is generally no higher than____________ .

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 ensurethat the forks are smoothly withdrawn from the load.

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



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Why are pre-operation safety checkscompleted?

Before using any attachment with a forklift it is essential that you conduct

a pre-operation safety check on both the forklift, the attachment and the

worksite.

Thischeckistoensurethattheequipmentissafetouseandtheactualworksiteissafetoworkin.

Thesafetycheckontheforkliftisto:

ensurethattherearenofaultsordamagetotheforkliftwhichmakeitunsafetooperate

completeachecklisttofulfilworkplacepoliciesandregulationsbeforeusingtheequipment.

Thesafetycheckonattachmentsisto:

ensureattachmentsadheretoOHSregulations

ensureattachmentisfittedcorrectly,accordingtomanufacturersmanualandsecure

ensurethatattachmentmovementsandcontrolfunctions

aresmoothandcomplywithoperatingrequirements.

Thesafetycheckontheworksiteisto:

ensurethattheworksite(thepaththatyouwillactuallybetakingwhenmovingtheload)isfreefromobstaclesorsafetyhazards

informpeopleandappropriatestaffwhomaybeworkinginornearyourpath

erectbarriersandsignstoinformotherpeopleofany

possibledanger(wherenecessary).


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Activity 9: Pre-operational safety check equipment

Watch your trainer or an experienced person demonstrate a pre-

operational safety check on the forklift.

The pre-operational check will include a pre-start check and anoperational check.

The pre-start check is to check for safety features that can bechecked before using the equipment; for example, flat tyres, wornslings, etc.

The operational check is to determine if all forklift parts are workingproperly 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 itdown to form a list. An activity worksheet is provided to help youand is located on the following pages. Decide if it is a pre-startcheck or an operational check and mark accordingly.


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Example: forklift with a jib attachment (this example is notcomplete).

Name of equipment Forklift with jib attachment

Parts Checked Pre-start Pre-start Operational

Forklift

Tyres for damage, pressure

Wheel nut not missing, tight

Safety cage damage, not loose

Park brake

Horn

Attachment

Slings good condition, not worn, brokenfibres/wires, rust, cuts, stretching/bending of

links

Hooks good condition, not worn, approvedtype

Fitted correctly bolted

Ease of movement


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Activity 10: Check of work area

Ask your trainer to give you an imaginary forklift task using an

attachment. Check out the work area where you would be using theforklift and identify any potential hazards or risk areas that mightaffect the safety of the operation.

Write down areas that have potential hazards and any hazards orrisks that you actually found. Then identify the actions that youwould take (or actually took) to eliminate the hazard.

Hazard or risk Action taken

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



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Reporting of pre-operation check results

Onceaninspectioniscomplete,theresultsofthatinspectionneedto

bereported.Manyworkplaceshaveastandardchecklistandprocedureforthereportingofforkliftpre-operationalchecks.Thisstandardprocedureisusedbyallemployeeswhousetheforklift.

However,someworkplacesexpectyou,theemployee,toberesponsibleforthisprocess.

OccupationalHealthandSafetyregulationsinsomestates/territoriesrequirethatapre-operationalcheckisdonebyyoubeforeyouusetheforkliftandequipment.Theresultsthenneedtoberecordedand

reported.Therefore,itmaybeyourresponsibilitytodothis.


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Activity 11: Pre-operational checklist

First, find out if your workplace has a standard procedure for

conducting the pre-operational check and for recording andreporting the results.

If so, obtain a copy of the relevant documentation for yourreference and use.

If not, study the pre-operational checklist on the next page.

Once completed, show the checklist to your trainer and discusswhat items need to be checked and if your organisation has anyother requirements that you need to complete.


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Pre-operational checklist for counterbalanced forklift withattachments

Pre-start check - outsidevisual

Pre-start check - insideengine 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, wheelnuts not loose, tyre pressure

Fan belt - correct tension

Mast assembly - damage,obstructions, lubrication, chain tension

Battery - water level, connections andsecurity

Forks/attachments - condition, secure,

locking pins secure

Battery (electric forklifts) - sufficient

charge, water levels

Load backrest -secure, not damaged Condition - any leaks, damage orobstructions

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 fromobstacles, 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 _____________


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Refuelling/recharging the forklift

Aspartofyourdrivingskillsyouwillobviouslyneedtoknowhowto

refueltheforklift.

Itisimportanttofollowspecificinstructionswhenrefuellingtheforklift.Althoughtherearedifferentfuelsforforkliftsandthereforedifferentrefuellingmethodsthefollowingrulesapplytoallforkliftswhenrefuelling.

Rules

1. Beforerefuellingshutofftheengineandthelightsanddonotrestartengineuntilrefuellinghasfinished.

2. Smokingisprohibitedinanyareawherethetruckisbeingrefuelled.

3. Refuellingshouldbedonewellawayfromwelding,openflamesandsparks.

4. Ifyoudetectafuelleak,dontstarttheforklift,pullitoutsideandaskforhelp(supervisorormaintenance).

WithLPG,therefuellingprocessinvolveschangingoveragasbottle,notsimplyfillingupthetankaswedowithmotorvehicles.

ThefollowingprocedureshouldbefollowedwhenreplacingtheLPGgascylinderontheforklift.

Beforechangeover

nosmoking

havetheenginerunning

closethecylindershutoffvalve

lettheenginerununtilitstops

wearglovesandeyeprotection.

Conductingchangeover

unscrewthebottlefitting-usegloves

removethecylinder

storeemptycylinderuprightinthedesignatedarea(mustbeundercover)

connectupnewcylinder.


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Afterchangeover

startforkliftandcontinuework

ifaleakisdetectedinthefuelsystem,stopimmediately,

turnoffisolatorvalve,putanappropriatesignonforkliftandreportleaktosupervisor.

Batterycharging

Ifyouhaveanelectricforkliftyouwillobviouslyhavetorechargethebatteryratherthanrefueltheforklift.

Whentheforkliftneedsitsbatterychanged,theforkliftmustbestationaryandintheproperparkedposition.Batteriesshouldbechangedinadesignatedareawhichisfreefromobstacles,welding

equipment,sparksandopenflames.Itshouldalsohaveproperventilationasbatteries,duringcharging,giveoffhydrogengaswhichisextremelyflammable.Theareashouldalsobeanon-smoking-acigarettecouldcauseanexplosion.

Tipsonbatterycharging

parkforkliftinthedesignatedarea-ensurethehandbrakeison

nosmoking

openbatterycompartmentandleaveopen ensureventcapsarefunctioningproperly

leaveventcapsinplacetoavoidelectrolytespray

donotwearrings,wristwatches,jewellery,orothermetalobjects.Theymaycontactelectricalpartswhichwillcausearcingandelectrocution.

keepallmetallicobjectsawayfromthetopofthebatteryasthesemayalsocausearcing

ifanyleakageofthebatteryelectrolyteoccursthenflushit

away.Reportanymajorspillage.


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Activity 12: Battery charging

Thefollowingdiagramshowsaforkliftdriverinvolvedinmanyunsafe

practices.Listtheunsafepracticesthatyoucanidentify.

_______________________________________________

_______________________________________________

_______________________________________________

_______________________________________________

_______________________________________________

_______________________________________________

_______________________________________________


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Lifting, carrying and setting down loads withattachments

Whenusingattachmentsthisliftingandcarryingprocedureneedstobemodifiedaccordingtotheattachmentchosen.Forexample,whenusinganauto-liftdrumattachmentyouneedtotakeintoconsiderationtheoperatingarmswhichareusedtopickupthebarrels.

Procedureswithoutattachment Attachmentproceduresauto-liftdrum

Approachtheloadslowlymakingsurethattheforkliftissquaretotheload.

Approachtheloadslowlymakingsurethattheforkliftissquaretotheload.

Theforksarelevelandatthecorrectheightforslidingundertheload.

Thearmsarelevelandcomeincontactwiththedrumsjustbelowthefirstrib.

Moveforwardslowlyuntiltheforksareentirelyundertheloadandtheloadisrestingagainsttheforkbackrest.

Lowertheforkswhileslowlymovingforward.Thiswillcausethearmstoopenandthenclosearoundthedrum.

Raisetheloaduntilallobstaclesarecleared.Tilttheloadbackwardstoensuresafehandlingoftheload.Totransport

theload,themastneedstobetiltedslightlybackwardstoensurethattheloadisstable.

Donottravelwiththeloadraisedhigherthannecessaryforadequateclearance.Thisisgenerallynohigherthan150mm(axleheight.)

Whenarmsarecompletelyengaged,raiseforksuntilarmscontactupperribsandliftdrumstodesiredheight.

Donottravelwiththeloadraisedhigherthannecessaryforadequateclearance.Thisisgenerallynohigherthan150mm(axleheight.)

Tounload,firsttheloadneedstobetiltedslightlyforwardthenloweredtothe

ground.Itmaythenbenecessarytotiltthemastfurtherforwardtoensuretheforksaresmoothlywithdrawnfromtheload.

Toreleasedrums,lowerforksuntiltheycontactlowerribsandstarttoopenthen

backaway.


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Activity 13: Lifting, carrying and setting-down loads withattachments

Identify two types of forklift attachments.

Write down the procedure for lifting, carrying and setting down aload. Use the example of the auto-lift drum attachment as aguideline.

The worksheet on this page is designed to help you through thisprocess.

Type of forklift:

Type of attachments:

Steps: Description:

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Sources of information include:

your trainer

forklift attachment manuals/brochures

companies specialising in forklift attachments

schematic drawings.


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Activity 14: Driving the forklift with attachments

During this activity you will be required to practise using the forklift

within a variety of workplace situations, using a number ofattachments.

This activity must be done under supervision and according to anyregulations or workplace and equipment policies.

This activity only allows you to practise using the equipment. Therewill be separate assessment exercises that you need to complete.

Your trainer will give you different workplace tasks to do. Theymust include:

using the forklift with attachments with a variety of loads

lifting, carrying and setting-down loads with attachments.

Each time you use the equipment, fill in the log book contained inthe Assessment Tasks section of this Learners Guide.

Once you feel that you are competent in the use of this equipmentin all of the above tasks, approach your trainer and request anassessment.


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Additionalresources


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State/territorylicensingauthorities:

WorkcoverAuthorityofNSW http://www.workcover.nsw.gov.au/

WorkSafeVictor http://www.workcover.vic.gov.au/wps/wcm/connect/WorkSafe

WorkCoverQueenslandhttp://www.workcover.qld.gov.au/

WorkCoverWA http://www.workcover.wa.gov.au/

WorkCoverSA http://www.workcover.com/home.aspx

ACTWorkCover http://www.workcover.act.gov.au/

WorkplaceStandardsTasmaniahttp://www.wst.tas.gov.au/node/WST.htm

NTWorkSafehttp://www.worksafe.nt.gov.au/


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Work area:____________________________________________________

Assessed by: _________________________________________________

Date: ________________________________________________________

Feedback on

activities

The responses provided in this section are suggested responses.Because every workplace is different, your responses may varyaccording to your specific workplace procedures, the equipment

available and the nature of the business.


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Activity 1: 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 acounterbalance forklift looklike? (draw or find a picture andplace in the space opposite)

Why is it called a counterbalance forklift?

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

Where is the balance pointor fulcrum of acounterbalance forkliftfound?

A point on the ground vertically below the front axle

List the two main powersource options that you findon counterbalance forklifts?

internal combustion engine

electric powered - battery


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Straddle forklift or reach truck

What does a straddle forkliftlook like? (draw or find a pictureand place in the space opposite)

How is the weight of theload distributed on astraddle forklift?

The weight of the load is distributed between the four wheelsof the forklift while moving. This dismisses the need for theforklift to counter-balance any load

What is a straddle forkliftprimarily designed for?

The straddle forklift is primarily designed for use in thewarehouse. They are designed to be manoeuvrable and to liftpallet loads to great heights

What is the primary powersource for straddle forklifts?

Most straddle forklifts are electric powered


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Order pickers

What does an order pickingforklift look like? (draw or finda picture and place in the spaceopposite)

What is an order pickingforklift primarily designedfor?

An order picking forklift allows you to pick out specific goodsfrom higher storage areas.

These forklifts allow you to choose a portion of the goodsstored, eg. You can choose one unit from a pallet. This means

you do not have to unload a pallet and take out what you needand then store it again.

Why is it called an orderpicker?

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

What is the differencebetween an order pickerand a straddle forklift?

The order picker and the straddle are quite similar in theirlooks but with an order picker the operator and the forkliftcontrols are actually lifted to the desired height.

With a straddle forklift. it is only the load which is lifted to thedesired height.


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Side loading forklift

What does a side loadingforklift look like? (draw or finda picture and place in the spaceopposite)

What is a side loadingforklift primarily designedfor?

A side loading forklift allows you to lift goods which are longand need to be manoeuvred into small short area. The typesof long loads, you can use this forklift for include, timber, metalpiping and prefabricated large posts.

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 forkliftto be manoeuvrable with long awkward loads

What types of loads arehandled by the side loadingforklift?

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

Give two examples of

workplaces that might usethe side loading forklift?

Timber yards, timber merchants

Steel and pipe retailers

Anyone who moves long loads of timber, steel, plastic

Container storage areas


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Activity 2: Advantages and disadvantages of electric poweredforklifts

Advantages of electric powered forklifts Disadvantages of electric poweredforklifts

No exhaust fumes emitted

Therefore suitable for enclosed spaces, coolrooms, warehouses, etc

Very little engine noise

Virtually no vibration

Ongoing maintenance costs seem to be lessthan internal combustion

Cost saving on fuel

Batteries are bulky, very heavy and veryexpensive.

The actual forklift is usually more expensivethan an internal combustion forklift.

Battery takes quite a few hours to recharge

therefore there is either the need for an extrabattery or a long wait between forklift use.

Extra cost of battery recharging equipment.

Less power than internal combustion.

Relatively short operating time betweenrecharges.


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Activity 3: Data plate information for attachments

Complete the chart by completing the definition and then selecting

one of your workplace forklifts and give actual data plate readings.

Information Definition Data plateinformation

Load Centredistance

The distance between the centre ofgravity of the load and the vertical face ofthe forks on the forklift. This is usually600mm but may be 500mm on someforklifts

Maximum safeworking load

The maximum weight the forklift cansafely carry

Maximum liftheight

The maximum height that the forklift canlift the maximum safe working load

Mast tilt - degrees The amount of forward and reverse tilt inthe mast. The figure is in degrees; forexample: 6 degrees.


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Activity 5: Jib equipment safety

Equipment type Safety considerations

Slings There are many different types of slings - wire rope, chain,webbing, natural fibre & synthetic.

Check slings prior to using them every time -you use it - checkfor excessive wear, broken fibres or wires, weathering, mould,rot or sun damage, rust or cracks, cuts or gouges and stretchingor bending of links.

Ensure that the SWL (Safe working load) of the sling is neverexceeded.

All slings must have a label indicating either the SWL or theWLL (working load limit) - if the label is missing do not use thesling.

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 thesling.

Hooks used with jib attachments must always be the swivellingtype - never the fixed type.

Ensure hook is centred directly over the load before lifting toensure forklift stability is unaffected.

Discard if more than 10% wear is evident.

Rings Many different types.

Ensure that it is an approved type of shackle - neverhomemade.



Shackles Many different types.

Ensure that it is an approved type of ring - never homemade.




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Activity 8: Lifting and carrying

Approach the load slowly making sure that the forklift is

square to the load and the forks are level and at thecorrect height for sliding under the load.

Move forward slowly until the forks are entirely under theload and the load is resting against the fork backrest.Ensure that the load is centered.

Raise the load until all obstacles are cleared. Tilt the loadbackwards to ensure safe handling of the load.

To transport the load, the mast needs to be tilted slightlybackwards to ensure that the load is stable. Do not travel with theload raised higher than necessary for adequate clearance. This isgenerally no higher than 150mm.

(axle height).

To unload, first the load needs to be tilted slightly forward then

lowered to the ground. It may then be necessary to tilt the mastfurtherforward to ensure that the forks are smoothly withdrawnfrom the load.

Slowly back away from the load ensuring that the forks do notcatch on the load.

Documents

TLID1107C - Conduct Special is Ed Forklift Operations - Learner Guide