TLID1307C - Move Materials Mechanically Using Automated Equipment - Learner Guide

TLID1307C

MC

Move materials mechanically using automated equipment

Armstrong’s Driver Education Learner Guide

TLID1307C Move materials mechanically using automated equipment

Page 2 © Australian National Training Authority 2003 ADELG1080 Customised and developed by Armstrong’s Driver Education Pty Ltd July 2009


© Australian National Training Authority 2003 Page 3 Customised and developed by Armstrong’s Driver Education Pty Ltd July 2009 ADELG1080

Contents

What this Learner’s Guide is about ........................................ 5

Planning your learning ........................................................... 6

How you will be assessed ...................................................... 8

Section 1............................................................................................. 9

What is mechanical materials handling equipment? .............. 9

Section 2........................................................................................... 27

Select, maintain and correctly operate a range of MMHE in the road transport industry ......................................................... 27

Additional resources....................................................................... 76

Assessment tasks ................................. Error! Bookmark not defined.

Feedback on activities .................................................................... 78

Training record information ................. Error! Bookmark not defined. Assessment checklist and record sheetsError! Bookmark not defined. Training record sheet ............. Error! Bookmark not defined.





What this Learner’s Guide is about

This Learner’s Guide is about the skills and knowledge required to move materials mechanically using automated equipment such as automatic guided vehicles, tow motors, high level order pickers, conveyor systems, and mechanised pallet movers. This includes selecting appropriate mechanical moving equipment (where relevant), moving materials/goods in accordance with operational requirements, checking condition of materials/goods and completing all required documentation.

The Elements of Competency from the unit TLID1307C Move materials mechanically using automated equipment covered in this Learner’s Guide are listed below.

Select load moving equipment

Move goods

Check goods and complete documentation

This unit of competency is from the Transport and Logistics Training Package (TLI07).



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.



Section 1: What is mechanical materials handling equipment?

Are you able to: Yes No

1. define mechanical materials handling?

2. identify a range of mechanical materials handling equipment used within the road transport industry?

3. outline the use of a range of mechanical materials handling equipment (MMHE) used within the road transport industry?

4. explain what regulations you need to comply with before using the MMHE?

5. explain any workplace policies that apply to the use of MMHE?

6. identify the types of loads that a range of MMHE can safely carry?

Section 2: How to safely operate mechanical materials handling equipment?

Are you able to: Yes No

1. outline the requirements for the maintenance of MMHE?

2. complete a pre-‐use check on a range of MMHE?

3. identify then eliminate any workplace hazards which will affect the safe operation of MMHE?

4. report the results of the inspection according to the workplace requirements?

5. select the appropriate type of MMHE to complete a range of tasks?

6. demonstrate (under supervision) the correct and safe operation of at least three types of MMHE within a workplace situation?



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:

• drive a Forklift truck

• demonstrate basic maintenance skills for MMHE

• undertake inspections of MMHE used in the workplace

• identify licensing requirements for MMHE

• carry out a maintenance check on a conveyor system

• shut down and pack a crane.



Section 1

What is mechanical materials handling equipment?



Section outline

Areas covered in this section

Definition of mechanical materials handling equipment (MMHE)

The types of MMHE and what they are used for

Regulations and workplace policies that you need to know before using MMHE

Identifying what type of loads the MMHE can carry



What is mechanical materials handling?

Materials handling may be defined as moving an object from one place to another. Therefore, mechanical materials handling may be defined as moving an object from one place to another by using mechanised equipment.

Within a road transport organisation, goods or objects are moved many times a day, mostly with mechanical equipment.



Activity 1: Moving goods around your workplace

Take some time to look around your workplace at the tasks involved in moving goods or objects from one place to another. Group each of the tasks into either: • manual materials handling tasks • mechanical materials handling tasks.

List your answers below.

Manual handling tasks Mechanical handling tasks

Why are some of these tasks manual handling and others are mechanical handling tasks?

Write your reasons below.

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What types of mechanical materials handling equipment are there available?

There is a vast range of MMHE that can be used within the workplace. Obviously the type of MMHE used in your workplace depends on the type of load or objects that you need to move.

Most types of MMHE are made in a range of sizes to suit different work requirements.

Some types of this equipment include, but are not restricted to:

• Forklift trucks (including attachments)

• sidelifters

• mobile cranes

• fixed overhead travelling cranes (includes equipment such as slings and shackles)

• conveyors

• carts and trolleys

• hand pallet trucks

• ride on pallet trucks

• tow motors and trolleys

• skates.



Activity 2: Types of MMHE used in your workplace

What type of lifting and mechanical handling equipment do you use in your workplace? List the types of equipment below.

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Using the following resource material: • sales brochures from equipment suppliers • materials handling magazines • road transport magazines • the internet • libraries • books • previous knowledge and experience.

List any other MMHE that could be used in your workplace.

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What conveyor systems are in use in your workplace?

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What are these conveyors used for?

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In much the same way as you need a licence before you can drive a motor car or truck, some mechanical materials handling equipment also requires you to have a licence.

Other mechanical handling equipment may not require a licence but will have other requirements for use of the equipment. These requirements may be placed on you by your workplace or by government authorities.

Each state/territory in Australia has different regulations and requirements for the operation of Forklift trucks and other mechanical materials handling equipment. You will need to find out what, if any, regulations exist in your state/territory. It is also necessary for you to find out if these regulations differ from the National Worksafe Australia guidelines. You can obtain this information from:

• Department of Industrial Relations

• Worksafe Australia, National Occupational Health and Safety Commission

• your workplace trainer

• people you work with, operators of the equipment.



Activity 3: Obtaining a licence to operate MMHE

Using the list of MMHE from Activity 2, list the regulations for obtaining a licence to drive/operate this equipment in your state/territory.

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What is a Forklift truck?

The regulations define the term ‘Forklift truck’ as a powered industrial truck:

• equipped with an elevated load carriage designed to permit tier loading of one load on another

• equipped with forks or other load handling means

• capable of self loading

• on which an operator can sit to operate.

Forklift trucks are available in many different forms with many different specifications. The six main types of Forklifts are:

• straddle trucks

• reach truck

• order picker

• counter balanced stand up

• walkie straddle

• walkie reach.

What is required for Forklift safety?

The most important aspect of Forklift truck driving is safety. As a Forklift truck driver you must be aware that there are always people working around you and if there was an accident they may be injured.

Accident statistics in Australia show that one in ten workplace accidents involves a Forklift truck (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.

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 truck, but also while you are driving the Forklift truck.



Activity 4: Occupational Health and Safety Act as it relates to Forklift trucks

Discuss the legal requirements and the Occupational health, safety and welfare act as it relates to the use of Forklift trucks with your: • trainer • OHS committee • workmates.

What does the term `Duty of Care’ mean to you, as a Forklift truck driver. Write your answer below.

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Think about the type of responsibilities your employer may have towards you, the Forklift truck driver. List these responsibilities in the space provided below.

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Refer to the Occupational health and safety act to check your answers then discuss these with your trainer.



Causes of Forklift truck accidents

There are many types of accidents that can happen to a Forklift truck operator or other workers. The more common accidents are:

• being hit by a moving Forklift, including feet being run over

• operator being hit by falling object

• other employees being hit by a falling object

• accidents occurring while getting on or off the Forklift

• collision with other vehicles or objects.

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 are determined by the work you do. Some types of personal protective equipment include:

• safety helmets

• safety glasses

• safety boots and shoes

• gloves

• aprons

• overalls.

Different organisations have different personal protective clothing requirements for their Forklift truck operators, depending on many factors.



Activity 5: Safety equipment and protective clothing

What protective clothing are you required to wear in your workplace while driving the Forklift truck?

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Are there any items of safety equipment that you use in your workplace that are not listed in this Learner’s Guide? If there are, list these below.

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Types of power used in operating Forklifts

Forklift trucks are powered by an internal combustion engine or battery.

The internal combustion engine in a Forklift works on the same principles as your car. Like your car they burn fuel such as:

• liquid petroleum gas (LPG)

• diesel fuel

• petrol ( not a common source of power).

LPG fuelled Forklift trucks are often used indoors as opposed to petrol or diesel fuelled Forklift trucks which are more often used outdoors. Petrol emits more toxic fumes than either LPG or diesel fuel.

Most Forklift trucks use the internal combustion engine rather than battery power because of its greater versatility as a power source. Since an internal combustion Forklift develops more torque than a battery powered Forklift truck, it yields more power. Internal combustion Forklift trucks will have a higher grade climbing ability than a comparable battery powered Forklift truck.

Battery powered Forklifts are:

• fume free

• quieter

• able to be built to a smaller scale with fewer parts.

The fact it is fume free means that it is ideally suited for use in operations such as food processing or in manufacturing plants where people are working in a confined or poorly ventilated areas.



Activity 6: Safety in Forklift truck use

Why would you use a battery powered Forklift truck in an enclosed area rather than a combustion powered Forklift?

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What is the safe working load (SWL) for your workplace Forklift truck?

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What is the minimum distance you should keep your Forklift truck and load away from power lines?

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Describe the type of surface on which a Forklift truck should operate?

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Can you operate a Forklifts truck on sloping ground?

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When should `personal protective equipment’ be worn in the workplace?

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



Operational work cycle of the Forklift truck

A complete series of movements associated with using an industrial Forklift truck consists of the following:

• move to the load

• pick up the load

• move with the load

• deposit the load

• move away from the load.

Forklift specifications include:

• capacity to lift different weights

• capacity to lift the load to differing heights

• load centres which may be different.

The counterbalance sit down Forklift consists of a number of basic parts. These are:

• headlamps

• counterweight

• operators seat

• drive axle and wheels

• steering axle and wheels

• fuel tank

• tilt cylinder

• lift cylinder

• lift chain

• steering wheel

• overhead guard

• forks or tynes.

Only properly trained and authorised drivers should operate Forklift trucks.

Before operating any type of equipment for the first time you should consult the operator’s handbook.



Activity 7: Identify Forklift truck components

Complete the following activity. Match the components listed in the table to the numbers shown on the Forklift diagram

Component Number

overhead guard

carriage

load backrest

forks

mast

tilt cylinder

counterbalance

lift cylinder

manufacturer’s data plate

steer axle




Section 2

Select, maintain and correctly operate a range of MMHE in the road transport industry



Section outline

Areas covered in this section

Selection of MMHE

Manufacturer’s data plate

Steering

Weight guidelines

Accidents

Hydraulic systems

Loading, carrying and unloading

Refuelling and recharging



Selection of mechanical materials handling equipment

Versatility of the Forklift truck

Forklift trucks can be adapted to carry out a number of specialised functions by replacing the forks with attachments. Some of these include:

• bale clamps -‐ clamps for handling bales or paper rolls

• drum clamps -‐ used in the chemical and petroleum industry

• rotators -‐ revolving carriage for emptying barrels and skips

• paper roll clamps -‐ can rotate and pick up two sizes of rolls at the same time

• personnel lift, or work platform -‐ used where there is a need to elevate personnel to perform special tasks of short duration

• carpet spike -‐ for handling carpets or rolls of wire

• jibs -‐ to lift and suspend loads or work as a small crane

• shovels -‐ for picking up rubble.

Although some types of MMHE are suited to specific loads, generally, loads can be shifted by using more than one type of MMHE.

How do you select which type of MMHE to use?

You need to consider the following:

• the load:

− type

− weight

− shape

• the environment

− available space

− ramps or steps

− rough or smooth ground

• the distance the load is to be shifted

• the availability of different mechanical materials handling equipment



• the most efficient type of MMHE which will enable you to shift the load as quickly as possible with the least amount of effort.



Activity 8: Suitability of MMHE

Walk around the workplace and complete the following chart.

Task Type of MMHE that you would use

Why would you use this equipment?



Make sure the Forklift has been parked correctly before you do any checks. This means:

• park on level ground

• lower forks completely, and tilt them forward slightly, so that the tips are in contact with the ground

• place all controls at neutral

• apply the parking brake

• switch off the engine or power supply and remove the key

• close the fuel-‐isolating valve on LP gas fuelled Forklift truck.

Make sure the Forklift truck is clean and tidy and there is no rubbish lying on the floor. Dirty, greasy machines can be a safety hazard.



Activity 9: Pre-start and post-start safety checks on the MMHE

Before starting work, you should also carry out a pre-start safety check. No vehicle should be operated unless it is in good working condition. Check the following:

Pre-start safety check list

Yes No Comments

1. Is data and load capacity plate attached to vehicle and in good condition?

2. Are tyres in good condition and are tyre pressures correct?

3. Is the engine oil level correct?

4. Are there any oil leaks?

5. Is fuel tank filled? If LPG powered, confirm that LPG compliance plate is current and relief valve is facing up.

6. Is the hydraulic oil level correct?

7. Are the chain mast and hinges in good condition and lubricated?

8. Are there any fuel leaks?

9. Are there any water leaks?

10. Is the electrically operated Forklift truck sufficiently charged?



Pre-start safety check list

Yes No Comments

11. Is the battery fluid level correct? Are the terminals free of corrosion?

12. Are the safety guards in good condition? Check for cracks.

13. Is the radiator coolant level correct?

There are a number of checks that must be carried out after you have started the Forklift truck. Make sure the Forklift truck is in neutral and the handbrake is applied. Start the engine (fuel operated). Turn on the power (electric).

Post-start safety check list

Comments

1. Is there sufficient fuel?

2. Is the oil pressure correct?

3. Are hydraulics are in working order, so that the forks can be: • raised? • lowered? • tilted?

4. Are the hand brake and the foot brake working?

5. Is the hydraulic lifting mechanism in proper working condition?



Post-start safety check list

Comments

6. Are warning devices and lights are working? For example:

• horn • indicators • reversing device • flashing lights.

7. Is the steering OK?

8. Is the transmission oil at the correct level?

Should you find any faults or damage, do not operate the Forklift truck. Park the vehicle in the appropriate manner, switch off and remove key. Tag the Forklift, and report faults or damage to your trainer.



Manufacturer’s data plate

Every Forklift truck shall have attached, in clear view of the operator, a Data plate which will include the following information:

• make

• model number

• serial number

• safe working load at nominated load centre distances (mast vertical)

• alternative rating mast full up with full tilt forward

• mast tilt (degrees forward and rear)

• maximum lift height

• tyre pressure

• gross vehicle weight and steer axle load (unladen, mast vertical), or drive axle and steer axle loads (unladen).

Where attachments are fitted, the plate will show:

• rated capacity of attachment when fitted to that make/model at the nominated load centre distance

• gross weight of the attachment

• test load applied.



Activity 10: Forklift truck safety

Can additional counterweights be added to a Forklift truck?

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Why shouldn’t you operate a Forklift truck with a flat or under-inflated tyre?

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What is the correct tyre pressure for the Forklift truck?

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What are the three mandatory safeguards for the Forklift truck?

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Give three reasons for doing post-operational checks.

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What would you do if you found a structural fault in your Forklift truck?

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Should your Forklift truck be refuelled while the engine is running? Explain your answer.

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For what reason is the fuel isolator valve turned off after parking and leaving a Forklift truck?

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Fork length

You should always use a shorter fork than the load you are handling. For example, if you are handling a 1200mm pallet you should use 1000mm forks. This is to prevent the forks from protruding beyond the load and damaging another load when stacking.

Fork extensions slide over the regular forks to give added length.

Fork spacing

The forks should be evenly spread out towards the sides of the load. The distance between the forks should be adjusted to around 60-‐70% width of the pallet to give the best possible support and to enable greater manoeuvrability, especially when stacking or unstacking in a confined area.



Activity 11: Forklift truck stability

Discuss with your trainer how lengthening the load centre can affect the capacity of a Forklift truck?

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Can a load be carried by only one fork of a Forklift truck?

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Steering

Forklift truck steering features rear end steering, power steering and steering which will not self centre.

Rear end steering:

• allows the Forklift truck to turn much sharper than front wheel steering

• tail end swing is a characteristic of Forklift trucks. This is a result of being steered by rear wheels. An operator needs to become accustomed to this.

The effects of rear wheel steering are somewhat similar to driving a motor vehicle in reverse. It also imposes different steering characteristics. When a motor vehicle is turning, the rear wheels will ‘track’ inside the turning arc of the front wheels. With rear wheel steering, the rear wheels will ‘track’ outside the front wheel radius. This causes rear end swing.

Tail end swing is a major contributor to a number of accidents. You should be aware of this before you attempt to drive a Forklift truck.

The speed of rear end swing will be approximately three times the forward speed of the Forklift truck.

Forklift steering will not self centre:

• before mounting the Forklift truck check the position of the rear wheels

• one hand must be on the steering wheel at all times during operation

• travel at safe speeds to allow steering manoeuvres to be carried out safely.

Power steering:

• turn steering wheel only when moving

• make sure tyres are inflated to recommended pressures

• do not switch engine off while vehicle is moving as loss of engine power will result in a loss of power steering functions.




Discuss with your trainer the differences between operating a Forklift truck and a motor car. Talk about speed, steering and reversing.

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At what speed would you drive your workplace Forklift truck?

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What would you do before reversing your Forklift truck?

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Forklift truck stability

Forward stability is affected by:

• overloading

• rough operation of controls

• exceeding load centres

• negotiating inclines

• overhead obstructions.

Side stability is affected by:

• turning too fast

• turning on an incline

• incorrect tyre pressure

• ground obstructions

• unbalanced loads

• loads carried too high:

− tilting

− side shift.




Name at least three things that may cause a Forklift truck to tip over sideways?

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Name at least three things that may cause a Forklift truck to tip forwards?

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Would you use a damaged pallet in your workplace?

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Operating principles

The pivot point (fulcrum) or point of balance on your Forklift truck is the front axle of the vehicle. Your Forklift truck operates on the same principle as a child’s see-‐saw.

The counterweight of a Forklift truck must always be greater than the load. If the load is greater than the counterweight, the Forklift truck will tip forward.

This can also happen with a load weighing less than the counterweight. If you place the load too far forward on the forks, this is called ‘under cutting the load’.

There are several causes of forward instability. These are:

• overloading

• tilting mast forward

• under cutting the load

• travelling on a ramp with the load facing downhill.

Stability triangle

One of the most important concepts to understand about Forklift trucks is that although they have four wheels, they are suspended at only three points. The rear steering axle is mounted to the Forklift truck by means of a pivot point in the centre of the axle.

The stability triangle is created by an imaginary triangle drawn between the two front wheels and the pivot point on the rear axle.

Whenever operating a Forklift truck, the centre of gravity must remain within the stability triangle or it will tip over.




Show your trainer where the forward tipping axis or fulcrum is located on your Forklift truck.

Show your trainer the stability triangle on your Forklift truck.




Weight guidelines

Do not overload your Forklift truck, check the load weights and handle only within the rated capacity of your Forklift truck. Before picking up a load, be sure of how much it weighs and where its load centre is located. Safe operation requires understanding and observing the Forklift truck’s rated load capacity. Below are some examples of items and their weight:

• oils, all types 200 litre 200 kg

• empty, 200litre drum 13 kg

• grease, 200 litre 200 kg

• cement, 1 bag 40 kg

• cement, 24 bags 1 tonne

• bricks, common 1,000 4 tonnes

• cast steel, cu. m 8 tonnes

• pallet, empty 60 kg

• sleepers 225 mmx114 mm x 2.4 m 80 kg

• 385 super Ft timber hardwood 1 tonne

• 670 super Ft timber softwood 1 tonne



Activity 15: Site inspection prior to operating your Forklift truck

Prior to operating the Forklift truck, walk around your workplace and check out: • walkways • look up for:

− overhead powerlines − gas lines − tops of doorways − lights − sprinkler systems

• pallet and cargo stacks • sheds and buildings • driveways are firm and level • path surface is not rough, wet or slippery • other possible hazards.

Discuss these potential hazards with your trainer.



Activity 16: Forklift safety

Where practicable, what action is required to restrict pedestrian access during Forklift truck operation?

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Is it allowable to lift personnel on a pallet or fork arms?

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Is all the weight behind the tipping axis or fulcrum acting as a counter weight?

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A pallet appears to be unsafely loaded, would you attempt to lift it?

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Some stock is heavy, for example, refrigerators. How do you find out the weight of heavy objects?

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Which vehicles must you give right of way to during emergency situations?

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Name at least three (3) areas where you would not park your Forklift truck.

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What is the reason for removing the ignition key when leaving a Forklift truck unattended?

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The hydraulic system

A Forklift truck uses a hydraulic system to lift loads. Without a hydraulic system the Forklift truck would be almost useless; with it, it becomes a very powerful and useful piece of industrial equipment.

The following information describes in detail a Forklift truck’s hydraulic system so you can recognise:

• how it works

• why it works

• safety procedures.

How does the hydraulic system work?

Forklift trucks are powered by an electric motor or by an internal combustion engine which can be fuelled by either petrol, diesel or liquefied petroleum gas (LPG).

The motor operates a hydraulic pump. This pump takes low pressure hydraulic oil from the tank or reservoir and pushes oil under great pressure to the Forklift truck controls. The driver or operator uses the controls to allow the oil into the hydraulic cylinder. As the cylinder chamber is filled with oil the cylinder extends.

The hydraulic cylinder pushes the mast upwards which raises the forks on the Forklift truck.

To lower the mast, the operator or driver again uses the controls to allow the oil to return to the tank through a filter.

Single acting cylinders

The cylinder that allows the mast to raise and lower on most Forklift trucks is a single acting cylinder. It directs the hydraulic oil under pressure to raise the forks. Gravity lowers the forks. Most modern Forklift trucks have two lift cylinders. Some older machines may only have one cylinder.

Double acting cylinders

Forklift trucks fitted with a tilt mechanism are usually hinged at the base of the mast. Above the hinge are two hydraulic cylinders that work in both directions. These cylinders are called double acting cylinders.



The combined action of the hinge and cylinders allows the mast to move safely backwards and forward while supporting the weight of the load.



Activity 17: Procedure for checking hydraulic oil in your Forklift truck

Check the hydraulic oil in your Forklift truck.



Safety with hydraulics

• Every hydraulic system has a relief valve to set the hydraulic pressure and act as a safety valve. Only qualified people may adjust a relief valve.

• At normal operating temperature the hydraulic oil is hot. Do not let the oil come into contact with your skin. Hot oil can burn.

• Do not check hydraulic hoses with bare hands as reinforcing wire braid covering the hoses may be exposed causing serious personal injuries.

• The lift cylinder on most Forklift trucks has a restricting opening built into the base of the cylinder which would prevent the load from crashing to the ground if a hydraulic hose failed.

Loading, carrying unloading

When loading or unloading with a Forklift truck, the following practices are to be observed.

Pick up a load • Make sure load is within the rated capacity of the Forklift

truck (take into account the load centre as well as the mass).

• Make sure the load is not top heavy, unstable, projecting or unequally distributed.

• Check the condition of load supports, for example, pallet, containers, dunnage. The sudden collapse of block-‐stacking can often be caused by these items being damaged or deteriorated.

• Always consider the journey’s end of a load before picking it up. A convenient position of a load for picking up may not be convenient for stacking.

• It is good practice not to attempt to lift or carry, at one time, more than one loaded pallet of any type, nor more than one unloaded container type pallet.

• Use a load backrest extension when handling loads which are high or segmented.

• Hazardous goods are identified and handled according to procedures for handling hazardous and dangerous goods. Occupational health and safety regulations and company policy must be adhered to at all times.



• Follow the recommended procedure:

− Position the Forklift truck square and central to the load, spread the forks apart sufficiently to make sure of the load stability, make sure there is ample clearance beneath the load to insert the forks.

− Approach the load with the mast vertical. Insert the forks under the load (make sure that the load is squarely positioned over the forks). Then raise the forks carefully, take the strain, elevate slightly and apply sufficient backward tilt to stabilise the load. Raise the forks to a position just clear enough from the ground to avoid level variations.

− When lifting from a stack, withdraw the load a sufficient distance only to clear the stack. Then lower the load to a safe travel height.



Activity 18: Pick up and lower a load safely

Demonstrate the safe picking up and lowering a load for your trainer.

Ask your trainer for feedback on your performance after completion of this task.



Travelling with a load

When travelling with a load all the following points must be observed.

• Never travel with load higher than necessary to give adequate ground clearance (safe travel height approx. 150mm -‐ 200mm).

• Never travel with load at vertical tilt or forward tilt.

• Take particular care when braking, accelerating or turning, as the force applied will alter the balance of your Forklift truck.

• Ascend or descend gradients slowly, and at all times keep the load facing up the grade -‐ drive up reverse down.

Note: The maximum incline on which a Forklift truck may operate is one (1) in ten (10), a 10% slope.

• Take extreme care when carrying double or multi-‐tiered loads. They may be unstable and difficult to control. Remember, when carrying a high load it is your responsibility to make sure that it is stable.

• Do not transport any flammable liquids, acids, corrosives or any other dangerous goods if they are not properly packaged (in sealed containers) and secured within a carriage box or to a pallet.

• All compressed gas cylinders, for example, oxygen, LPG, acetylene, air, etc., must be stowed for transport in a vertical (upright) position. To prevent toppling, cylinders should be carried in a cradle or other safe means of containment.

• When carrying long loads (bar stock, piping, timber or other long items) you should be conscious of load swing or load shift when turning.

• Always cross railway tracks slowly and at a slight angle. This provides better traction and stability for the load.

• Before loading or unloading a rail car, you must carry out the following safety precautions:

− to prevent movement, make sure the railcar’s brakes have been applied

− before driving onto a rail car, inspect the condition of the floor to make sure that it will support the Forklift truck and load



− before attempting to drive on to a rail car, make sure that the means of access has been affectively secured in position, for example, bridge plates, dockboards.

Remember:

• Differences in lighting can be dangerous:

− when driving from bright sunlight into darker areas, enclosed areas, allow time for the eyes to adjust. This also applies when driving from a dimly lit area into bright sunlight.



Activity 19: Shift a load with your Forklift truck

Demonstrate for your trainer travelling with a load (carrying) on the Forklift truck.

Ask your trainer for feedback on your performance after completion of task.



Unloading (placement of load)

When unloading or placing a load, the following must be observed:

• Before attempting to place a load make sure that the location is suitable and that there is sufficient access.

• Approach the unloading point slowly and squarely, raise the load slightly higher than the stacking height when stacking, tilt the mast to the vertical position, position the load over the stack and then lower the load gently on to the stack.

• Make sure the load is secure on the stack, do not attempt to withdraw the forks until they are free of the load; withdraw the forks from the load by reversing from the stack and when the forks are clear of the load, lower them to travel height.

Remember:

• tilt the load forward only when directly over the stack or the unloading place

• always lower heavy loads slowly and stop them gently

• do not leave a load on a stack if it appears unstable

• never butt loads into position with your Forklift truck.



Activity 20: Demonstrate stacking and placement of a load

Demonstrate for your trainer unloading, stacking and placement of a load.

Ask your trainer for feedback on your performance after completion of task.



Refuelling and recharging

Before refuelling or recharging an industrial Forklift truck, you should observe and carry out the following safety precautions:

• lower the forks completely, place the gear lever in neutral, apply the parking brake and then switch off the engine or power source

• open flames and smoking are prohibited within 10 metres of any Forklift truck being refuelled or recharged.

Diesel or petrol refuelling:

• no smoking, naked lights or other sources of ignition are permitted in the designated refuelling area

• care should be exercised to avoid spilling petrol or overflowing the tank during refuelling. Replace the cap securely, flush down any spilled fuel and allow sufficient time for that fuel to completely evaporate, before restarting the Forklift truck.

Liquid petroleum gas (LPG) refuelling:

• smoking, naked lights or other sources of ignition are strictly forbidden in the cylinder refill or replacement area

• cylinders permanently mounted on Forklift trucks shall be fitted or exchanged only at locations designated for that purpose (well ventilated, isolated from all sources of ignition)

• only trained and authorised personnel may recharge or exchange LP gas cylinders

• flexible hoses on LPG Forklift trucks should not protrude beyond the extremities of the truck and are to be protected from abrasion or sharp edges

• if the fuel system has a leak report it immediately. Action should be taken to prevent the use of the Forklift truck being used until the leak has been corrected.

Remember:

• make sure that the engine has stopped and the fuel isolating valve is shut off before attempting to disconnect the cylinder



• handle all cylinders and associated plumbing with extreme care. Damage from dropping or abuse could result in a serious fire

• make sure the cylinder is correctly positioned, so that the safety relief valve is uppermost

• chains must not be used to replace straps in the cylinder clamping device

• LPG Forklift trucks should not be refuelled or parked in close proximity to open pits, as there could be a `build up’ of vapour in these confined areas.

Battery charging and changing

• No smoking, naked lights or other sources of ignition are permitted in the designated charging area.

• Battery charging and changing shall be carried out only at locations designated for that purpose (well ventilated areas).

• Only trained and authorised personnel may recharge or change batteries.

Remember

• Do not attempt to top-‐up, service or charge a battery until the main power supply lead to the Forklift truck has been disconnected.

• Any spillage of acid should be neutralised and washed away immediately.

• You should make sure that any battery fitted corresponds to that type designated on the date plate.

Note:

The gas given off when a battery is being charged is highly flammable. All refuelling operations shall be carried out in a defined isolated area, for example, a clean open area.

Safe practices for Forklift truck operators

The following ‘Safe Practices’ have been compiled to safeguard the operator and fellow workers. They must be strictly observed in all Forklift truck operations.



• Only people who have been issued with a Division of Workplace Health and Safety Certificate of Competency or a Permit to Learn (the learner to be under supervision) are authorised to operate a Forklift truck (check if your state/territory has deregulated the need for a licence).

• In the event of a fault being revealed by the pre-‐operation check, or if at any time the Forklift truck should become unsafe during operations, report the matter immediately and do not use the truck until the fault or unsafe condition has been rectified.

• Do not operate a Forklift truck with a leak in the fuel system.

• Do not make repairs, alterations or adjustments to any Forklift truck, unless authorised to do so.

• Do not use a Forklift truck for any purpose other than that for which it was designed, e.g. towing, pushing, bumping, etc.

• Report the occurrence of any new hazard.

• Report all accidents, including accidents with personnel, buildings, structures, equipment and stock.

• Ensure that all safety equipment, i.e. flashing lights, reversing beepers, turn indicators, etc., are maintained in working condition.

• Safeguard pedestrians at all times. Pedestrians always have the right-‐of-‐way.

• Do not allow passengers to travel on a Forklift truck, unless an approved seat has been installed for that purpose.

• Do not allow any persons to stand or pass under elevated forks or attachments, whether loaded or empty.

• Never reach through or around the uprights of the mast, or place your arms, legs or head outside the confines of the truck.

• Never lift a load that is beyond the rated capacity of the Forklift truck, or the attachment fitted.

• Do not use additional counterweights or personnel to increase the load capacity of any Forklift truck.

• When the Forklift truck is equipped with attachments that are unloaded, operate the truck as though it is partly loaded.



• Inspect forks (tines) at regular intervals, look for bending of forks and cracks at the heel of the fork arm.

• Always raise a load with the mast vertical or tilted slightly backwards.

• Only raise or lower a load whilst the truck is stationary.

• Do not lift a load any higher than necessary.

• When travelling, keep the load or the forks (unladen) as low as possible to the ground.

• When carrying a high load be conscious of, and avoid contact with, overhead electrical systems (minimum distance 2 metres), pipes and sprinkler systems.

• Do not use your truck as a personnel elevator unless it is equipped with a work platform that complies with AS2359.

• When carrying bulky loads which block forward vision, have a competent person direct you, or drive with the load trailing (except up a ramp or in line).

• Ascend and descend ramps slowly, and at all times keep the load of the truck facing uphill. (The forks of an unladen truck must face downhill.) REMEMBER! HEAVY END UPHILL

• Always carry a load with its heavy end against the heel of the fork arms.

• Ensure that the mast is on rear tilt when travelling with a load.

• Always face the direction of travel.

• Do not operate without adequate lighting.

• Observe all plant traffic regulations.

• Slow down and sound the horn, when passing by or through doorways, at crossings and any other location when vision is obstructed.

• Do not turn on or drive across a slope.

• Keep to the left-‐hand side of roadways and wide aisles wherever practicable.

• Do not overtake any vehicle at crossings, blind corners or other dangerous locations.

• When operating a Forklift truck on wet or slippery surfaces, reduce speed and proceed with caution.

• Drive slowly when turning and always be conscious of rear-‐end swing.



• Avoid sudden stopping and starting, as these are the most frequent causes of loads falling.

• Always bring the Forklift truck completely to a stop before changing direction from forward to reverse or vice versa.

• Always check the strength, width and security of a ramp. Never use loose timber or scrap metal as a temporary ramp.

• Never run internal combustion Forklift trucks in cold rooms or other confined spaces. Operation of industrial trucks with internal combustion engines in cold rooms or other confined spaces is dangerous and should be strictly controlled due to the emission of contaminants in the exhaust gases.

Mobile cranes

There are many types of mobile cranes which may be used in your workplace. These include:

• mobile cranes:

− self propelled

− sub-‐base mounted

− tractor connected

− tractor mounted

− trailer mounted

− truck connected

− truck mounted

• fixed cranes

− monorail crane

− overhead travel crane.



Activity 21: Workplace crane and capacity

What type of crane do you use in your workplace?

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What is the lifting capacity of your workplace crane?

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Slings

Slings used to shift loads with the crane may consist of:

• wire:

− straight sling

− reeved sling

• rope:

− straight sling

− reeved sling

• chain and hooks:

− straight sling

− adjustable sling

− reeved sling

• lifting beams

• log hooks.

Slings are weighted for their load capacity, this information is contained on the sling tag which is attached to the particular sling. Your first job when you are using any lifting equipment is to make sure the weight that has to be lifted is no greater than the safe working load of the equipment.

Before using a crane to lift and shift a load, you need to check:

• the weight of the load

• the safe working load of the crane

• the safe working load of any lifting slings or beams.

• the slings for damage such as:

− twisted chain links

− broken or cracked chain links

− cracked or worn sling hooks

− frayed ropes

− broken or parted strands of wire rope.



Activity 22: Inspect crane slings

With your trainer, inspect the crane slings in your workplace.



Activity 21: Crane hand and whistle signals

Demonstrate to your trainer the following hand and whistle signals you would receive from your crane chaser (dogman) and the actions you would follow.

Directions Whistle answers Hand answers Stop

Lower

Hoist

Travel

Traverse in

Traverse out



Procedures for moving the load

Make sure warning signs are in place particularly on regularly used pathways and roads.

Give directions to your crane operator in order to locate crane in a suitable, non-‐hazardous location after checking for overhead power lines.

Prepare for the lift

First make sure:

• the sling you select has the capacity to lift the load according to safety standards

• the sling is placed correctly on the load

• the sling is vertically (above centre of gravity) attached to the crane hook in order to prevent the load dragging or swinging as it is lifted

• the area around lift is clear

• other personnel are advised of what you are doing.

Then:

• commence the lift, making sure people are kept clear

• raise the load, make sure the lift is vertical and the slings and hooks are correctly located

• if the load swings dangerously, lower the load and have the slings repositioned

• move load and carry load at a safe height:

− about waist high

− not over people’s heads

• if you need to lift the load high to clear obstructions or stacks:

− advise people in the area

− lower to safe height as soon as practicable

• travel at a slow walking pace

• slow down before stopping to prevent load swing

• lower load onto bearers

• remove sling from load



• store sling on the crane, or place in storage location.

Inspect unloaded goods for damage

All moved goods are inspected for damage once they have been unloaded and stacked or stored. Any damage must be recorded and reported in accordance with company policy.

Documentation recording the movement of inward/outwards stock is completed in accordance with company requirements. Any shortages or overages must be reported and recorded.



Activity 22: Demonstrate the crane shut down procedure to your trainer

At the end of a shift or after completing a load shift, shut down and park the crane.

Ask your trainer check the procedure.

Task Steps Did the learner:

Yes No

1. Refuel, shut down and check crane and secure the site

• complete any load deliveries?

• locate crane in an area clear of doorways and where it will not be a traffic hazard?

• check instrument panel and make sure equipment is operating correctly?

• switch off crane and crane isolator?

• remove key from crane? • remove any rubbish from

cab of crane? • refuel crane, if necessary? • check:

— oil — hydraulic system — battery — radiator, takes care if

vehicle is hot? • check crane for:

— fuel — oil — water leaks?

• check tyres for: — damage — wear — air pressure?



Task Steps

Did the learner: Yes No

• check cables and grease or oil any that that require servicing?

• fill in daily log book? • lock crane • report any wear or damage

to the crane that requires attention?

• deliver workplace documentation to the responsible office personnel?





Additional resources



Paper based:

The references listed below should not be regarded as a definitive list and should be amended and updated on a regular basis. This list is not intended to be prescriptive as it is realised that many trainers have assembled their own references and resources.

Cranes Regulations, Department of Labour, Victoria, 1989.

Manual Handling Regulations and Code of Practice, Department of Labour, Victoria, 1985.

Manufacturers’ brochures, manuals and videos.

Shop Crane Safety (video).



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.



Activity 6: Safety in Forklift truck use

• Persons in a confined space could be overcome by carbon monoxide gas created by the combustion process.

• As indicated on the data plate secured to the machine. • 2 metres from distribution line or poles, 6 metres from

transmission lines on towers, closer if lines are covered. • Hard, level surfaces. • No, most Forklift trucks are top heavy and would overturn on

slopes. • Where there is an injury or health risk that is not practicable to

control by other means.

Activity 7: Identify Forklift truck components

Component Number overhead guard 3 carriage 6 load backrest 10 forks 9 mast 2 tilt cylinder 8 counterbalance 4 lift cylinder 1 manufacturer’s data plate 7 steer axle 5




• No, the existing counterweights have been designed for the maximum safe working load of the Forklift truck.

• When the load is lifted the machine may tip over. • As indicated on the machine data plate. • Overhead guard, footguard, load guard • Check for damage, systems are closed off, metal fatigue, leaks

in oil or hydraulic systems. • Stop the Forklift truck and immediately report to an authorised

person for repairs to be carried out. • No, the fuel could be ignited by the running engine. • To eliminate the risk of explosive gas mixture prior to start up.


• Lengthening the load centre, that is lifting a long or wide load reduces the fork capacity of the Forklift truck.

• No, not only could the fork carrying the load be overstressed but also the stability of the Forklift truck will be seriously affected.


• The rapid sideways movement at the rear of the Forklift truck creates a hazard particularly for pedestrians close by.

• At a speed you can stop with safety. • Look behind to make sure the way is clear.




• Turning at speed. • Driving over uneven surfaces. • Driving too fast (even unloaded). • Unevenly distributed load. • Travelling with the load raised. • Braking too hard when turning • Overloading. • Severe braking. • Shifting the load forward (which has the same effect as

overloading). • Not in any circumstances.


• At the centre of the front wheels. • The stability triangle is created by an imaginary triangle drawn

between the two front wheels and the pivot point on the rear axle.

Activity 16: Forklift safety

• Compliance with the requirement of the Statutory Authority. Forklift truck working area fenced off from personnel, other than drivers.

• No, this is strictly forbidden. • Yes. • No, have it restacked so it is stable before lifting. • Check weighbridge certificates. These should be kept, so that

the weights can be checked. • Fire, ambulance, police and other emergency vehicles. • First Aid Stations • Fire fighting appliance doorways • Building exits • Fire escapes • Across driveways • Obstructing other traffic



• Less than 2 metres to the nearest rail of a railway track. • To prevent unauthorised movement of the Forklift truck.

Activity 17: Procedure for checking hydraulic oil in your Forklift truck

To check the oil level the Forklift truck must be parked properly. This means: • park on level ground • lower forks flat to the ground • put the parking brake on • switch off the motor • remove the key • locate the hydraulic oil tank or reservoir on the forklift truck.

There is a level marked on a sight glass or a dipstick in the hydraulic oil tank or reservoir. Do not fill the tank above the correct level or it may damage the hydraulic system.

To check the oil level accurately all hydraulics must be lowered otherwise oil will remain in the cylinders and give a false reading.

Do not permit dirt to enter the hydraulic system when the oil level is checked or it will clog the filter and/or damage the system.

Activity 21: Workplace crane and capacity

As indicated on the vehicle’s data plate.



Activity 22: Crane hand and whistle signals

Directions Whistle answers Hand answers

Stop One short blast Hand held high, palm towards the driver

Lower One long blast Hand fully extended, palm down, move in circular downward direction

Hoist Two short blasts Hand fully extended, fist closed, index finger points in direction required - Operators left

Travel One long, two short Hand fully extended, fist closed, index finger points in direction required - Operators right

Traverse in One long, four short Fist in front of chest, thumb pointing away from chest, move fist in direction required

Traverse out One long, three short Fist in front of chest, thumb pointing away from chest, move fist in direction required

Documents

TLID1307C - Move Materials Mechanically Using Automated Equipment - Learner Guide