Forklift High Risk Work (HRW) Vocabulary and Safety Principles

Forklift Pre-Operational and Start-Up Procedures

• Timeline for Damage Inspection   - A forklift must be checked for damage at three distinct stages: Before, During, and After operation.

• Pre-Operational Checklist (6 Essential Items)   - Log book: Must be present and up to date.   - Data plate: Must be legible and attached to provide capacity information.   - Seat: Condition of the operator's seat.   - Seat belt: Functionality and condition of the restraint system.   - Lights: Functional check of all operational lighting.   - Mirrors: Cleanliness and proper adjustment for visibility.

• Start-Up Checks (6 Essential Items)   - Lights: Re-confirming functionality under power.   - Horn: Ensuring the audible warning device works.   - Chains: Inspecting for wear, tension, and lubrication.   - Pulleys: Checking for proper rotation and alignment.   - Hand Brake: Ensuring the parking brake holds the vehicle.   - Hoses: Checking for leaks, cracks, or hydraulic fluid seepage.

• Data Plate Regulations   - It is strictly forbidden to use a forklift that has a missing data plate.   - Action for Missing Data Plate: The operator must isolate the machine, tag it out of service, and report the issue immediately.

Workplace Communication and Safety Consulting

• Importance of Communication   - Communication with workplace personnel is vital before commencing work to identify potential hazards and ensure that all necessary control measures are in place.

• Personnel to Consult   - Before starting work, operators should consult with their Supervisor, Coworkers, and the Manager.

• Communication Methods (6 Examples)   - Face to face interaction.   - Telephone or radio communication.   - Signage posted throughout the worksite.   - Manuals and written procedures.   - Hand signals (standardized gestures).   - Eye contact (to confirm awareness between operators and pedestrians).

• Handling Unclear Information   - If given unclear instructions regarding work tasks, the operator must stop the forklift and ask for clarification immediately.

Hazard and Risk Management

• Key Definitions   - Hazard: Something that may cause harm.   - Risk: The possibility of a hazard actually causing harm.

• Site vs. Non-Site Hazards   - Site Hazards (6 Examples):     - Power Lines     - People (pedestrians and other workers)     - Forklifts (other mobile equipment)     - Rain (environmental conditions)     - Wind (stability impact)     - Ramps (inclines and declines)   - Non-Site Hazards (6 Examples):     - Permits (legal/procedural requirements)     - Load Characteristics (instability, weight distribution)     - Attachment Required (changes in forklift dynamics)     - Communications (failures in messaging)     - Egress (exit routes)     - Safe Work Limit (exceeding equipment capacity)

• Refueling Risks   - Refueling while the engine is running is extremely dangerous because fuel or vapors could explode.

• Hazard Control Application   - Hazard controls must be applied whenever hazards are identified in the work area.

Operational Safety on Ramps and Slopes

• Ramp Travel Procedures   - A loaded forklift must always travel uphill when on a ramp (load facing the incline).   - Turning on Ramps: Attempting to turn a forklift on a ramp or sloping surface may result in the loss of the load or the forklift tipping over.

• Travel Height   - When traveling, the load should be raised to axle height or below to maintain a low center of gravity.

• Raised Load Hazards   - Operating a forklift with a load raised is unsafe because it can lead to the loss of the load or causes the forklift to tip.

Loading Docks and Load Handling

• Bridge and Dock Plates   - A bridge plate or dock plate must be provided to bridge the gap between a truck and the loading dock before shifting any load.

• Unbalanced Loads   - If a pallet contains an unbalanced load where one end is heavier, the heaviest end should always be placed against the heel of the fork arms.

• Unsafe Pallet Stacking   - If a pallet appears unsafely stacked, corrective actions include:     - Do not stack the load too high.     - Ensure the stack is even.     - Ensure the load is on a firm, level surface.     - Place the heaviest items at the bottom of the stack.

• Load Monitoring   - Operators must constantly monitor load movement to ensure that both the forklift and the load remain stable.

• Heel Position   - If a load is not hard up against the heel of the fork arms, the forklift may tip or the load may be lost.

Power Line Safety

• Working Near Power Lines   - If work must occur closer than minimum required distances, the Operator must involve the Power Authority and utilize a Spotter.

• Visibility Aids for Power Lines   - Tiger Tails: Used to make lines visible.   - Marker Balls: Used for high-elevation visibility.

• Voltage Identification   - Voltage of overhead lines can be verified by contacting the relevant Power Authority.

• Contact with Power Lines   - If the forklift contacts a power line, the operator must:     1. Warn others to stay away.     2. Try to detach or disconnect from the line if possible.     3. Stay inside the forklift until told otherwise.     4. Report the incident to the Supervisor.     5. Thoroughly check the forklift for damage before any further use.

Confined Spaces and Engine Safety

• Internal Combustion Engines   - These are dangerous in restricted or confined spaces due to the emission of toxic fumes.

• Battery Charging   - Batteries must be charged in well-ventilated areas to prevent the buildup of toxic or flammable gases.

• Preferred Equipment   - The best forklift to use for work in confined spaces is an electric-powered model.

Pedestrian and Environmental Safety

• Control Measures (3 Categories)   - Signs: Visual warnings.   - Gates: Physical barriers.   - Exclusion Zones: Designated areas where pedestrians are prohibited.

• Low Visibility Conditions   - Adequate lighting must be provided when working at night or in dark areas.

• Wet and Slippery Surfaces   - Operators should turn slow, drive slow, use a "slow and steady" approach, and brake slowly.

• Personnel Safety   - Loads must never be raised or lowered near or over people due to the risk of serious injury or death.

Forklift Capacity and Attachments

• Single Fork Use   - It is not permissible to carry a load using only one fork arm because it can cause the forklift to tip and the load to fall.

• Passengers   - Passengers are only permitted on a forklift if the vehicle was specifically designed to carry them.

• Impact of Attachments   - Adding an attachment decreases the overall capacity of the forklift and decreases the Safe Working Load ($SWL$).   - Centering Side Shifts: Side shift attachments should be centralized before traveling to keep the load and the forklift stable.

• Determining Load Weight   - Methods include: weighing the load, calculating the weight manually, and checking labels or dockets.

Tipping and Stability

• Tipping Procedure   - If a forklift begins to tip while the operator is inside, they must brace for impact and stay fully inside the forklift cabin.

• Fulcrum Point   - The fulcrum or point of balance on a forklift is located at the front wheels.

• Reasons for Forward Tipping   - Driving off a dock.   - Driving with an uneven load.   - Driving on an uneven surface.   - Driving too fast.   - Driving forward down a ramp with a loaded basket.

• Reasons for Sideways Tipping   - Turning with an uneven load.   - Turning on an uneven surface.   - Turning too fast.   - Turning on a ramp.   - Turning with the load raised.

Parking and Post-Operational Care

• Restricted Parking Locations   - First aid stations.   - Fire extinguishers.   - Doorways.

• Parking Requirements (3 Considerations)   - Forks must be tilted down (flush to the ground).   - The vehicle must be in neutral gear.   - The handbrake must be engaged.

• Key Removal   - Keys must be removed after use to prevent unauthorized use of the equipment.

• Defect Reporting   - If a defect or damage is noticed, the operator must stop, isolate the machine, tag it, and report it.

Legal Duties and Compliance

• Duty of Care (HRW Operator)   - The primary duty is to keep yourself and your co-workers safe.

• Employer Health and Safety Duties   - Provide a safe workplace.   - Provide necessary facilities.   - Provide safe plant and equipment.

• Information Sources for Health and Safety   - Codes of Practice.   - Acts and Regulations.   - Standards.

• Penalties for Unsafe Operation   - Operators may face fines, suspension of their license, or permanent loss of their license.

Equipment Specifics and Maintenance

• Wheels and Tyres Verification   - Check for tread depth, missing chunks of rubber, loose or missing nuts, damage to rims, and general tyre wear.

• Obstructed Views   - When driving with a large load that obstructs the forward view, the operator should use a spotter and/or drive the forklift in reverse.

• Common Attachments   - Bale clamp, Carpet spike, Jib, Paper roll clamps, Rotators, Slippers, Drum carrier, and Work platform.

Mathematical Weight Calculations

• Example 1: Steel Drums   - Data: 4 steel drums of water at $212\,kg$ each + 1 pallet at $45\,kg$.   - Calculation: $4 \times 212 = 848\,kg$.   - Total: $848 + 45 = 893\,kg$.

• Example 2: Cartons on a Pallet   - Data: 6 cartons per layer, 6 layers, each carton at $36\,kg$ + 1 pallet at $40\,kg$.   - Calculation: $6 \times 6 = 36$ total cartons. $36 \times 36 = 1296\,kg$.   - Total: $1296 + 40 = 1336\,kg$.

• Example 3: Boxed Load   - Data: 56 boxes at $33\,kg$ each + 1 pallet at $42\,kg$.   - Calculation: $56 \times 33 = 1848\,kg$.   - Total: $1848 + 42 = 1890\,kg$.

Load Chart and Data Plate Analysis (Model ACLF-011)

• Technical Specifications   - Max Height: $3700\,mm$.   - Max Back Tilt: $10\,Degrees$.   - Mast Forward Tilt: $6\,Degrees$.

• Capacities based on Mast Position   - Forward Tilt ($6\,Degrees$): Safe Working Load is $1480\,kg$ at a load centre of $600\,mm$.   - Vertical Position: Safe Working Load is $1890\,kg$ at a load centre of $600\,mm$.

• Feasibility Questions   - Can a load of $1890\,kg$ at a $700\,mm$ load centre be raised vertically? No (exceeds the $600\,mm$ load centre rating).   - Can a load weighting more than $1890\,kg$ be raised vertically? No.   - Maximum height for vertical lift: $3700\,mm$.

Model GDLRAIS155KXH123 Data Plate Details

• Physical Specs   - Truck Weight: $9750\,kg$.   - Tread Width: $1844\,mm$.   - Tyre Pressure (Front and Rear): $800\,kPA$ ($116\,PSI$).   - Tyre Size: $8.25-15/14-PLY\,Dual\,Pneu$.

• Capacity with Vertical Mast   - Maximum Capacity: $6130\,kg$.   - Load Height (Dim A): $4400\,mm$.   - Load Centre (Dim B): $915\,mm$.   - Load Centre (Dim C): $915\,mm$.

• Verification Scenarios   - Scenario 1: Pallet length $1175\,mm$, height $1600\,mm$, weight $1700\,kg$.     - Load centre calculation: $1175 \div 2 = 587.5\,mm$ (Less than $915\,mm$).     - Result: YES, this can be lifted.   - Scenario 2: Container with $6000\,kg$ load and tare weight of $2500\,kg$.     - Calculation: $6000 + 2500 = 8500\,kg$.     - Comparison: $8500\,kg$ is more than the maximum capacity of $6130\,kg$.     - Result: NO, this cannot be lifted.