flt itssar handout 09102013 - … itssar handout 09102013.pdf · the theory test can be ... it is...

ITSSAR ACCREDITED

LIFT TRUCK TRAINING COURSES

Operator Handbook

PLEASE DO NOT WRITE IN THIS BOOK AND RETURN WHEN YOU HAVE COMPLETED YOUR COURSE.

“This handbook is designed to help you complete the Theory and Practical elements of this course. You will find lots of useful information in this handbook to help you complete the knowledge criteria of the course. This handbook also contains information about CAB Training Limited, some simple rules to follow while you are on site. Should you need any other help or information please speak to your instructor who will be glad to help”.

Carol Wheatley Managing Director – CAB Training Limited

Index

Site Rules…………………………………………………………….……………..1 Truck Types (to include characteristics)……………………….………………..2 Course Aims and Objectives………………………………….…………………..4 The Need to Train…………………………………………….…………………….6 Types of Training………………………………………….……………………......8 Legislation (Policies & Procedures)……………………………………………….9 Safety Rules………………………………………………………….……………..15 Drivers Guide……………………………………………………….……………….16 Stability………………………………………………………………………………18 Safe Operating Procedures………………………………………………………..27 Pre Use Inspection………………………………………………………………….31 Refuelling to include Battery Maintenance……………………………………….37 Scheme of Work/Session Plans…………………………………………………..43

Site Rules

IMPORTANT PLEASE READ

1. Please ensure you sign the fire register upon entering the building, and sign out when you leave site.

2. When entering the building please use the pedestrian walkway.

3. DO NOT RUN

4. Smoking is permitted in the designated area outside only, please ensure you put only cigarette ends in the disposal unit on the wall, not rubbish.

5. Taking drugs and drinking alcohol is not permitted at CAB Training Limited.

6. Anyone found doing so will be removed from the course with immediate effect and asked

to leave site.

7. Mobile phones must be switched off (or switched to silent), during training. Remember!!!! You are here to learn not chat.

8. When upon hearing the fire alarm, you will evacuate the premises immediately by the nearest fire exit point.

9. Once outside you will make your way to the fire assembly area, to the right of the main gate.

10. Do not attempt to return to the building until you are told it is safe to do so.

11. The first aid stations are situated around the warehouse, your instructor will point out

your nearest station is.

12. Start 0900 – Lunch - Finish 1600.

13. The aim of this course is to demonstrate and instruct you how to operate a forklift truck in a warehouse environment.

14. The objective is for you to demonstrate you have met the learning outcomes at the end

of the course, by means of a Basic Operating Skills Test to include Practical Test, Associated Knowledge and Pre-Use Inspection.

15. Session plans can be found in your handbook.

16. You will be required to sit a theory test (Associated Knowledge).

17. If you feel that you may have problems with this test, please speak to your instructor at the earliest possible opportunity, who will be able to help you.

18. The Theory test can be conducted orally.

Truck Types Types of trucks and their functions and characteristics:

This is a Counterbalance, it is driven forwards to engage forks into a load to manoeuvre. It is found in most industries, as it can be used indoor and outside. Accredited Operator training is required to use this equipment.

This is a Reach Truck and is used indoor only. They are driven forward to engage forks into a pallet. They are very common in warehousing as they require less space to move around in, than a counterbalance. The forks are reached out to deposit loads, from 4 to 6 meters and they are more compact than a counterbalance. Accredited Operator training is required to use this equipment.

This is a Hand Pallet truck, and is used either in or outdoors. It is a manual truck, not self-propelled. This truck can only move loads around at low level. It does not stack at height. No Accredited Operator training is required to use this equipment.

This piece of equipment goes by many names some being PPT, Order Picker, Pallet Truck, Ride-on, to name but a few….. We will call it a PPT (Pedestrian Operated Pallet Truck). This truck, however does have a rider platform fitted, for travelling over long distances. It is mainly used indoor, and can only move pallets at ground level.

Course Aim & Objective Only fully qualified and accredited ITSSAR Forklift training Instructors/Examiners, who after passing rigorous courses laid down by the relevant training board are able to offer training and certification. All lift truck courses are mainly practical in nature but do include an element of theory. Trainees must be minimum school leaving age (16 ), reasonably fit and able to hear all verbal instructions and audible warning signals.

On completion of the course all operators will be able to use the lift truck safely and efficiently in accordance with the manufactures handbook and to the standards laid down by the Health & Safety Executive’s Approved Code of Practice (ACOP L117). Operators will clearly understand the causes of instability of lift trucks and their loads, be able to carry out routine pre-shift inspections and understand the importance of defect reporting. The operator will be able to replenish the machines energy source and operate it in a variety of environments with varied loads. On successful completion of the course and the ITSSAR Skills Test, trainees will receive a certificate, confirming their competence to operate the relevant lift truck for the course that they have attended. It must be stressed however that the operator will need to gain experience whilst under supervision in his given workplace and will be required to undergo a further period of familiarisation training. Please visit ITSSAR website for more info: www.itssar.org.uk

No training can be undertaken by candidates who suffer from vertigo.

The Course will comprise theoretical and practical instruction covering the following:

• Responsibilities under the Health & Safety at Work Act, PUWER 98 & LOLER 98. • Operators Safety Code • Battery maintenance and charging procedures • Pre-use inspection • Stability • Controls Motive/Hydraulic • Stacking – Racking, Bulk, Corner Post Pallets • Lorry Loading and Unloading

The Need to Train

Why do Fork Lift Operators need to be certified?

Special Requirements: Under the Health and Safety at Work Act of 1974, and under The Provision and Use of Work Equipment regulations 1998, no one should be permitted to operate a lift truck until they have been selected, trained, certificated and authorised to do so.

The responsibility for the safe operation of lift trucks in the workplace lies with both the employers and employees. Managers, supervisors and operators alike must play their part to ensure the safety of those working on or in the vicinity of lift trucks. The Law states that the employer has a duty as far as is reasonably practicable to ensure your safety at work. They must give you the information, instruction and training necessary to ensure that you can do your job safely and keep records of your training. An Approved Code of Practice (ACOP L117) is published by the Health and safety Executive to assist employers and trainers to do this. They must also provide you with the necessary protective clothing free of charge. You must take care of yourself and others. You must co-operate with your employer in the interests of safety and not interfere with the equipment provided.

Penalties for breaking the law: 1. Summary conviction at a Magistrates Court.

a. For breaches of sub section 2 to 6 of the Health and Safety at Work Act 1974. Maximum fine £20,000.

b. Failing to comply with an Improvement or Prohibition Notice.

Maximum fine £20,000.

c. For breaches of the remaining sections of the H&S at Work Act and Subordinate regulations. Maximum fine £20,000.

2. Indictment at a Crown Court.

a. Certain offences involving required licences. b. Certain offences involving explosives. c. Contravention of an improvement or prohibition notice.

Maximum penalty 2 years imprisonment and an unlimited fine.

PLEADING IGNORANCE IS NO DEFENCE.

Types of Training.

Once a candidate has been selected, he/she will undergo 3 types of training. These are Basic, Specific Job and Familiarisation Training. Basic Training consists of a comprehensive operator’s course, in this case carried out at CAB Training, Training Centre. The course will include the theory of safe operating, practical driving skills and ends with a practical assessment of the operator’s skills. The course is designed and overseen by ITSSAR Specific Job Training is additional information and practice required to operate safely at a particular site. This may include training on a particular type of machine including the use of its controls, the layout of premises (highlighting danger areas), various attachments in use there and specific site rules. Familiarisation Training is carried out on the job under normal working conditions. Close supervision by a responsible person is essential to ensure that the new operator is fully competent and safe at that site. Always remember that manufacturers are continually updating and designing new equipment and it is the individual’s responsibility as well as their employers to ensure that individuals receive additional specific and or familiarisation training before operating any truck.

More importantly to the individual, ensure that you have your employer’s written consent before operating any truck.

Legislation (Policies and Procedures)

Health and Safety. The Health and Safety at Work Act of 1974 etc. states that both employers and employees are responsible for safety at work. Enforcement of this is carried out by the Health and Safety Executive and the Local Authorities. As part of this act, the employee is responsible for looking after the health and safety of themselves as well as other people in the workplace. This means that lift truck drivers are responsible for looking out for pedestrians. They have to co-operate with the management on all aspects of safety and they must not interfere, misuse, abuse, be reckless or modify anything provided for health, safety and welfare. The lift truck operator’s code of practice is provided to advise duty holders on how to comply with legislation.

The law Employers have a duty under health and safety law to ensure, as far as is Reasonably practicable, the health, safety and welfare of their employees. The main legislation applying to the use of lift trucks is: (a) The Health and Safety at Work etc Act 1974 (HSW Act); (b) The Management of Health and Safety at Work Regulations 1999; (c) The Provision and Use of Work Equipment Regulations 1998; (d) The Lifting Operations and Lifting Equipment Regulations 1998; (e) The Workplace (Health, Safety and Welfare) Regulations 1992; and (f) The Construction (Design and Management) Regulations 2007.

The Management of Health and Safety at Work Regulations 1999

The Management of Health and Safety at Work Regulations 1999 Require a risk assessment to be carried out to identify the nature and level of risks associated With a work activity. Appropriate precautions need to be taken to eliminate or control these risks. A proportionate response according to the risk is required. The higher the level of risk identified through the assessment, the greater the measures that Will be needed to reduce it. Risk assessment provides the basis for safe systems of work to eliminate or reduce risks as far as possible. Safe systems of work are formal procedures which should be followed to ensure that work is carried out safely. They are necessary where risks cannot be controlled adequately by other means. Employers must ensure that the systems of work to be followed are properly Implemented and monitored, and that details have been given to those at risk.

The Provision and Use of Work Equipment Regulations 1998

The Provision and Use of Work Equipment Regulations 1998 apply to all work equipment. Commonly referred to as P.U.W.E.R. PUWER are a set of legal regulations requiring risks to people’s health and safety, from equipment that they use at work, to be prevented or controlled. Regulation 9 (9.1) Every employer shall ensure that all persons who use work equipment have received

training for the purpose of health and safety, including training in the methods, which may be adopted when using work equipment, any risk, which such use may entail, and precautions to be taken.

Regulation 9 (9.2) Every employer shall ensure that any of his employees who supervises or manages the

use of work equipment have received adequate training for purposes of health and safety, including training in the methods which may be adopted when using the work equipment, any risks which such use may entail and precautions to be taken.

Regulation 25 Every employer shall insure that no employee is carried by mobile work equipment unless:

a) It is suitable for carrying persons; and b) It incorporates features for reducing to as low as is reasonably practicable risks to their

safety, including risks from wheels or tracks. c)

Regulation 26 and 27 Where there is an increased risk of anyone being injured by mobile work equipment rolling over, then a suitable restraining system should be fitted. Regulation 28 Requires duty holders to ensure that their equipment is safe to use, which may mean taking measures such as retro-fitting roll over protective structures (ROPS), falling object protective structures (FOPS), seat belts etc, and prevention from unauthorized usage.

The Lifting Operations and Lifting Equipment Regulations 1998

LIFTING OPERATIONS AND LIFTING EQUIPMENT REGULATIONS (1998) Commonly referred to as LOLER LOLER are a set of legal regulations requiring risks to people’s health and safety, from equipment that they use at work, to be prevented or controlled. Regulation 4 Every employer shall ensure that;

a) Lifting equipment is of adequate strength and stability for each load. b) Every part of a load and anything attached to it and used in lifting it is of adequate

strength and stability for each load. Regulation 5 Every employer shall ensure that lifting equipment for lifting persons;

a) Is such as to prevent persons being crushed, trapped or being struck by an object, and can be easily freed if need be.

Regulation 7 Every employer shall ensure that; Lifting equipment is clearly marked to indicate safe working loads. Regulation 8 Every employer shall ensure the equipment is Used safely, i.e. the work is planned, organized and performed by competent people, supervised and carried out in a safe manner. Regulation 9 Every employer shall ensure before lifting equipment is put into service for the first time by him, it has been thoroughly examined. Lifting equipment should have a LOLER inspection at regular intervals for example every 12 months. Where lifting equipment is used for lifting persons it should be inspected every 6 months.

The Workplace (Health, Safety and Welfare) Regulations

The Workplace (Health, Safety and Welfare) Regulations Require that workplaces should be organised to ensure that vehicles and pedestrians can move Around safely. This includes: (a) Sufficient lighting to enable people to work and move around safely (including Not obscuring lights by stacking goods in front of them); (b) Construction of floors and traffic routes to ensure that they are suitable for the Purpose for which they will be used and do not expose users to health and Safety risks; (c) Organisation of traffic routes to enable pedestrians and vehicles to circulate Safely; and (d) The need to ensure that doors or gates which can be pushed open from either Side give a clear view, when shut, of the space close to both sides.

Rider-operated lift trucks

Operator training and safe use. Approved Code of Practice and guidance

This revised edition of L117 is aimed at employers and those responsible for the safe operation of lift trucks, as well as those in control of worksites, the self-employed, managers and supervisors. It includes an outline of the main legal requirements relating to lift trucks; the Approved Code of Practice text (unchanged from the previous edition) and guidance on operator training for stacking rider-operated lift trucks. It also includes the some of the guidance from HSG6 Safety in working with lift trucks (and replaces HSG6), for example, information about lift truck features; guidance on the safe use of lift trucks and how to protect pedestrians; and guidance on the maintenance and thorough examination of lift trucks. More detailed advice on these and other legal requirements is available in the Approved Codes of Practice (ACOPs) and Guidance

CAB Training Limited also operates the following policies:

• Equal Opportunities. • Equality & Diversity. • Health & Safety. • Risk Assessments. • Grievance, Complaints and Appeals. • Safe Operating Procedures.

For more information see Carol Wheatley

Safety & Site Rules

1. Only operate equipment for which you are trained and authorized. 2. Always read the manufacturers handbook before operating the equipment. 3. Always carry out the pre-shift checks. 5. Wear spectacles if you need them to meet the official eyesight test. 6. Do not attempt to repair any equipment yourself, report all defects to a supervisor immediately. 7. Report all accidents immediately they occur. 8. Observe all speed limits, slow down for wet or slippery surfaces. 9. Don’t EVER carry passengers. 10. Comply with the Highway Code or Road Traffic Act where appropriate, give signals to help other road users, and use lights after dark. 11. Diesel and L.P.G. trucks should be re-fuelled outside of buildings, if applicable. 12. Electric equipment should be recharged only in authorized charging bays. 13. Keep a constant look out for danger spots, i.e. pedestrians, inspection covers, platform edges, ramps, protruding obstacles, crane areas etc. 14. Slow down and sound your horn (Several Short Blasts) at intersections and doorways, watch out for roller shutter doors and use extra care when going through plastic curtains. 15. Always face the direction of travel, if your view is obstructed travel in reverse. 16. Never allow anyone to walk under or over the forks, whether or not a load is being lifted. 17. When parking, ensure the machine is not going to cause an obstruction. DO NOT park in front of Fire Equipment, Electrical Boards, Fire Exits, On a slope, On

gangways/pedestrian routes or where the forklift may cause an obstruction. 18. Damaged stock, pallets or loads should be reported to your Instructor Immediately.

Drivers Guide Before starting work. You must have ‘written authorisation’ from your employer to operate a lift truck in the working environment. It is the drivers’ responsibility to ensure that the lift truck is in good working order before using it. This involves carrying out a pre-shift check and an operational check. The pre-shift check involves examining items such as the forks, mast, chains, wheels, tyres, seat, horn etc. the operational check should include the steering, brakes (both foot and parking), and the hydraulics. If there is a serious fault with the truck, stop immediately and report it. Driving the truck. Ground surfaces can affect the truck considerably. Understand what effect they could have and what you can do about it. When preparing to move off, first select the direction you want to go, look around to ensure the area is clear and then release the handbrake. Always travel with the forks as low as is practically possible and tilted back. Ensure that you can see where you’re going. In normal circumstances, if the load obscures your view, drive the truck in reverse. When approaching blind bends, doorways or when exiting narrow aisles, sound several short blasts on the horn to attract attention. Always leave at least three truck lengths clearance when following another truck around the warehouse. If driving across railway lines, drainage gullies etc. always cross slowly and if possible, diagonally, this reduces the chance of tipping or loosing the load. Ensure that rubbish and packaging is cleared away from areas where the truck is to be driven. If a safety cage is to be used, ensure that it is up to the requirements laid down by the HSE. It must be fixed securely to the forks and a safe method of use must be agreed before starting work. Only authorised persons should be lifted in it.

Stability. The load should always be against the heel of the forks to ensure the truck’s stability, the load stability and also to keep the truck and load as short as possible in confined spaces. Leaving a gap between the load and the heel of the forks is called undercutting the load and is sometimes necessary if the forks are longer than the load and there is an obstruction behind it. Undercutting can cause the truck to tip over forwards as will a load that is too heavy or if it’s centre of gravity is too far forward. Harsh braking, rough use of the hydraulics or handling a live load can also cause the truck to tip over forwards. With the load high up, tilting the load forward will increase the load centre. This, as well as harsh acceleration in reverse can also cause the truck to tip over forwards. Trucks can also tip over sideways, usually because of driving round corners too fast, especially when un-laden. Driving across a slope or having the load offset or uneven can cause a truck to topple over sideways as can not having the forks evenly spaced or side shift centralised, turning with the mast in the air or transporting a live load.

Slopes. Slopes will affect the stability of the lift truck. Driving a lift truck across a slope may cause it to tip over sideways. When on a slope, the load must always face up the slope so that it cannot slide forward off the forks. With an un-laden truck, the empty forks should face down the slope as this improves traction, stability and adhesion. Normally, you would never park your truck on a slope. In an emergency, if you have to park on a slope, always chock the wheels.

Calculating weights. Before attempting to lift a load, you should know how much it weighs. It may have the weight printed on it or on the accompanying paperwork. Remember, the net weight is the weight of the product only; the gross weight is the weight of the product, packaging, pallet, etc. on the load. In addition to the weight of the load, the load centre must be known. The load centre is the measurement given forward from the front face of the fork arms to the centre of gravity of the load. When the load centre is increased, the amount of weight the truck can lift is reduced. Remember, the weight of the loads left outside can be affected by rainwater or snow Capacities. Firstly, the truck must have a rated capacity plate attached to it. This will tell you the maximum weight the truck can lift the load centre distance and the maximum stacking height. To calculate if a load can be lifted safely, you will need to find out how much the load weighs and where its centre of gravity is. Take the information on the trucks rated capacity plate and multiply the trucks weight capacity by the trucks load centre capacity. Divide this by the load’s centre of gravity to find out the maximum permitted weight of the load. Handling loads. Before attempting to move a load, find out what it is. Is it dangerous or hazardous? Find out how much it weighs, where the load centre is and whether it is secure and stable. Before operating the hydraulics, make sure that the parking brake is on and the truck is in neutral. This ensures that the truck is stable and allows you to concentrate on operating the controls. You should stop the truck a short distance from the stack (150 – 200mm) so that pedestrians cannot walk between the truck and the stack. It also helps with accuracy and reduces possible damage to stacked loads. To comply with the manufacturers stated lifted capacity and ensures the trucks stability, the mast must be vertical and the truck be on level ground. Before lifting a load, you should adjust the forks to suit. With a pallet, there should be equal weight on each fork. However, with metal stillages or cages, the forks should be set as wide apart as possible to prevent the stillage slipping sideways. When transporting loads, ensure that they are as low as practically possible and that there is sufficient back tilt to cater for the type of load and ground conditions. The term Free lift is the distance that the forks can be raised before the mast begins to extend. Lorry loading. When loading or unloading a lorry, first ensure that the lorry / trailer cannot move. The parking brake should be on, the keys removed and the wheels chocked. The unloading area should be clear, level and free from uneven surfaces. Parking. You should not park your truck blocking fire exits, fire fighting equipment, first aid points, doorways or blind corners. Also, avoid parking on slopes, near electrical boards or switches or on wet, muddy or soft ground. When parking, the forks should be tiled forwards and lowered to the ground to reduce the chance of people tripping over them.

Stability

Lift Truck Stability Overview

• Engineering Principles. • Rated Capacity and capacity plate. • Stability Factors.

The fulcrum or pivot point is located in the middle of the drive wheels

The stability triangle is between the front drive wheels and rear wheel on a three wheel truck or middle of the rear axle on a 4 wheel truck

When is the truck more stable? Loaded or Unloaded

= Loaded = Unloaded

DO NOT tilt the mast forward at height!

Tilting the load forward at height will move the “Combined centre of gravity forward, and could cause the truck to tip”

DO NOT leave a gap between the heel of the forks and the front side of the load, this will increase the load centre, and could cause the truck to tip forward.

A capacity plate will give information on what the truck can lift, to a desired height. It will also tell you your load centre, which is the distance from the heel of the forks, to the centre of gravity of the load. Every truck should have a capacity plate in view of the operator. Always ensure you know the capacity of the truck you are using. Three pieces of information that need to be on the capacity plate are:

1. The Rated Capacity (what the truck can lift). 2. The Lift Height (in mm) 3. The Load Centre (in mm)

The lift trucks “rated capacity” applies with the mast in the vertical position, this also applies with the manufactures stated lifting capacity. When the load centre increases the truck carrying capacity will reduce. The rated capacity of a forklift should not exceed four fifths of the balance weight. The balance weight of a forklift truck is established by a machine test carried out during manufacture. Therefore the rated capacity (or safe working load) of a truck with a balance load of 5000kgs will not exceed 4000kgs.

Every object has a centre of gravity. It is the place where the load is balanced in all direction….. Try it for yourself! Take the TV Remote control, and balance it on two fingers……the point at where it is balanced is where the centre of gravity is.

The “Load Centre” is measured from the heel of the forks to the centre of gravity of the load.

If we collect this pallet width ways, then the load centre is 500mm If we collect the pallet long ways, then the load centre is increased to 600mm

While this may look safe, it is a dangerous manoeuvre; as soon as you raise the load it also raises the combined centre of gravity of the truck and the load and moves it out of the stability triangle

THERE IS TWO BASIC WAYS IN WHICH A TRUCK CAN OVERTURN. LONGITUDINAL (Lengthways). Caused by: 1. Overturning. 2. Undercutting. 3. Tilting a raised load forward. 4. Lifting or raising the load while facing downhill on a slope. 5. Travelling forward down a slope with a load. 6. Excessive braking when loaded. 7. Erratic use of the speed control. 8. Harsh use of the hydraulic controls. 9. High winds (with a raised load). 10. A live Load

LATERAL (Sideways). Caused by: 1. Turning at excessive speed. 2. Turning on a ramp or incline. 3. Lifting or raising a load while sideways on a slope. 4. Driving over obstacles, e.g. pieces of wood. 5. Driving into potholes. 6. Operating the truck with incorrect tyre pressures. 7. Picking up a load off-centre to the forks. 8. Incorrect use of the sideshift. 9. High winds (with a raised load) 10. A live Load

EXTENDED LOAD CENTRE Extended load centre means when the centre of gravity is further away from the heel of the forks. Pallet not heeled up. Pallet larger than 1000mm by 1200mm. (Standard Pallet Size). Attachments i.e. extended forks to pick up large bulk loads. All these will reduce the lifting capacity of the truck.

Safe Operating Procedures

They make fast work out of lifting, loading and unloading, stacking, and transferring crates, drums, pallets, and other materials. But, forklifts can be dangerous if not operated properly. Drivers and colleagues can be hurt (or killed) by forklifts that tip over or fall off loading bays, Or by collisions or falling loads.

In fact, more than 200 serious injuries a year are caused by improper forklift operations. Nearly 1,000 other workers require time off due to injury. 1. Know how your forklift operates. 2. Understand the load characteristics: weight,

Size, shape etc. 3. Drive safely (plan your route). 4. Load and unload safely. 5. Learn and follow the manufacturers and

Company safety rules and procedures.

The HSE requires that only “Trained” and “Authorised” personnel operates forklifts. Do not operate a FLT if you have not been trained or authorised. You and your forklift make a powerful team. Before using any forklift, be sure you: • Have been properly trained. • Read your operator’s manual and follow the

Instructions. • Read the forklift data plate to see how heavy a

Load it can carry – and stay within that range. • Follow all the manufacturers and your company’s

Inspection procedures.

Follow the rules of Safety 1. Never tilt a load while moving. 2. Stay at least three vehicle lengths behind the

Vehicle ahead. 3. Keep out of pedestrian lanes and walk ways. 4. Always give the right-of-way to pedestrians. 5. Slow down, stop, and sound the horn at

Intersections and blind spots. 6. Use the mirrors on your vehicle, plus those on the walls and ceilings to see around Corners. 7. Follow your company policy on the use of a hard hat, protective gear, and seat belt. 8. Do not use unapproved forklifts in areas that have flammable or explosive materials. 9. Keep arms, hands, and legs inside the forklift. 10. Stay away from edges of ramps, platforms, and

Elevated docks. 11. Avoid sharp turns. 12. Keep a clear view of where you’re going; drive in

Reverse (except up slopes) if the load obstructs your View – always look before reversing.

13. Don’t drive up to a person standing in front of a Bench, table, wall, or other fixed object. 14. Don’t let anyone stand or walk under the elevated part

Of the forklift – full or empty. 15. Obey speed limits and other road signs, including floor

Markings. 16. Remember, this is not a car, it’s a specialised machine. 17. Don’t let anyone ride on the forklift or use it to Lift people unless it is specifically designed for that Purpose or has an approved basket or lifting cage. 18. Don’t reach through the mast. 19. Don’t drive the forklift on to public roads unless you

Hold the correct licence and the truck is also licensed. Rules of the road.

1. Make sure you won’t hit overhead lights, wires, pipes, sprinklers, or opening doors. 2. Don’t pass at intersections or blind spots. 3. Drive slowly over dock plates. Make sure them

Are secured with bolts or pins. 4. Watch out for holes, grease, or uneven surfaces

On the floor. 5. Cross railroad tracks diagonally if possible. 6. Try not to run over loose objects. 7. Slow down for turns. 8. Stop before going into reverse. 9. Make wide turns to avoid tipping over.

On slopes. • Go up and down slopes slowly the correct way. • Point the load uphill if the slope grade is more

Than 10%. • Note: As a general rule, it is wise to travel with

The load uphill. • Keep the load only as high as necessary to clear

The road surface so it doesn’t have far to fall.

Parking. • Park away from traffic, preferably on a flat surface, if you have to park on a slope,

chock the wheels. • Don’t block aisles, doors, exits, fire extinguishers, electrical panels, or access to stairs. • Lower the forks to the floor and tilt them flat. • Put controls in neutral, turn off the machine, and set the brake. • Remove the key.

Loading. • Check the load. Make sure it’s - Within the trucks rated capacity. - Stable and centred – stack and / or tie

Loose or uneven loads. • Use the proper lift fixture for specific loads, such as a carpet spike or drum grappler.

To pick up the load. • Set the forks wide and high enough to go under the load. • Drive into the loading position. • Put the load squarely on the forks. • Drive under the load until it touches the carriage slightly. • Lift the load. Tilt it back before travelling.

As you carry. • Keep the forks low – 150 – 200mm (4 – 6 Inc) above the ground. • Carry loads low and tilted back. • Don’t carry anything on the overhead guard. • Do not raise or lower the load while moving.

Unloading. • Turn the forklift slowly into position. • Go straight into trailers or railcars. • If you’re unloading onto a truck:

- Make sure the truck’s rear wheels are Chocked, with brakes on.

- Make sure the dock plate is secure and Won’t move.

- Position the load, tilt it forward, then Release it.

• If you’re unloading onto a rack or stack:

- Tilt the load forward. - Raise and position the load to the correct height. Be sure to check overhead Clearance levels. - Move it slowly into position. - Lower it onto the rack or stack. - Pull the forks back slowly. - When stacking, know how high you can safely stack

Materials.

After unloading, always back out slowly, looking over your shoulder.

DAILY INSPECTION or PRE-USE CHECK.

NOTE: ALL CHECKS SHOULD BE IN ACCORDANCE WITH MANUFACTURES HANDBOOK AND INSTRUCTIONS. FORKS: CHECK FORK ARMS ARE NOT TWISTED AND ARE LEVEL - CHECK FOR CRACKS, CHIPS, SPLINTERING or BITS MISSING. CYLINDERS: CHECK FOR SIGNS OF HYDRAULIC LEAKS. CHAINS: CHECK FOR MISSING LINKS, RUST and ALL SECURING PINS ARE IN PLACE AND THEY ARE ADEQUATELY GREASED. BATTERIES: CHECK THEY ARE SECURELY STOWED AND FILLER CAPS FITTED AND SECURE. HYDRAULICS: LEAVE MAST FULLY EXTENDED FOR 30 SECONDS AND CHECK THAT MAST DOES NOT START TO CREEP DOWNWARDS. NOTE: ALWAYS CHECK HYDRAULIC OIL LEVELS BEFORE USING ANY

CONTROLS, BECAUSE HYDRAULIC OIL WILL THEN BE IN THE HYDRAULIC SYSTEM.

THEREFORE GIVING A FALSE READING IN THE HYDRAULIC FLUIDTANK.

Give your partner a daily check-up. Good maintenance is important!!! • Check your machine daily to make sure it’s in Good operating condition. Follow all manufacturers And company procedures carefully.

• Be sure all dials, gauges, and equipment work properly. • Check tyre condition and air pressure if appropriate. • Check for water and oil leaks, particularly in the hydraulic system. • Test brakes, steering, horn, warning lights, backup alarms, and other controls. • Make sure the fire extinguisher is in place and properly serviced. • Check for cracks at the heel of the forks. • Look for bent or damaged forks – this usually means a serious safety problem. • Never attempt to alter or repair the forks yourself. They either need to be

replaced, or repaired by the manufacturer. • Clean your truck at the start or end of each shift to remove dust, dirt, and

grease. • Use non-combustible cleaning agents on the forklift. • Don’t drive a forklift if anything is sparking, smoking, or if any temperature gauges

register above normal. Report the problem. And while you’re inspecting, always keep your hands away from parts that can move. Maintenance is very important. Keep maintenance records neat and up-to-date. Report any problems to your supervisor and let a trained mechanic fix them. Place a “Do Not Operate” tag or sign on the forklift and remove the keys so that no one else can use it.

Daily Inspection or Pre-Use Checks

Item Mon Tue Wed Thu Fri Sat Sun Shift Fork Arms Carriage

Stop Bolts Load Back Rest Mast and Rollers Chains/Securing Pins Lift Cylinders Wheels (nuts & rims)

Tyres (condition & pressures) Overhead Guard General Bodywork Capacity Plate Check Fuel/Battery/Oil & Water Check Hydraulic Oil Tank (before using hydraulic controls) Check Oil Hoses for Leaks

Check Seat for Security & Condition Check Horn Check Beacon Flashing Check all Warning Lights Start the Truck Check ALL Brakes

Check Hydraulic Controls Checked by - Initials Park Truck and report any faults to supervisor Faults to be logged in fault report book Sign Inspection Log book if truck is serviceable

Lift truck Fault reporting log.

Truck Fleet Number/Serial Number……………………….

Date Fault Found Operator Signature

Supervisor Signature

Date Repaired Engineer Signature

FILLING INSTRUCTIONS AND SAFETY NOTES FOR LIFTING CALOR REFILLABLE CYLINDERS USED ON FORK LIFT TRUCKS.

Electric Dispenser Pump and Hand Operated Pump Sitting, Installation and Maintenance of Fuel Storage Tanks. The above should be carried out in accordance with the following publications: Code of Practice No 1 – Installation and Maintenance of Fixed Bulk LPG Storage at Consumers Premises – Published by LPGITA. Code of Practice No 20 – Automotive LPG Refuelling Facilities Published by LPGITA. HS/G34 – The Storage of LPG at Fixed Installations – Published by HMSO. Guidance Note CS4 – Keeping of LPG in Cylinders and similar Containers – Published by HMSO.

Safety Rules: No smoking, naked lights or other sources of ignition should be permitted in the vicinity of the refuelling site and signs to this effect must be displayed. The area must be kept free from grass, weeds, rubbish and other readily ignitable materials. Suitable Fire extinguishers (Dry Powder) should be sited adjacent to the installation. Protective rubber gloves should be provided and worn at all times when refuelling is taking place.

VEHICLE CYLINDER REFUELLING INSTRUCTIONS.

1. Park truck, set brake and switch off engine. Close Service Valve ‘F’ on

cylinder. 2. Check by Contents Gauge that cylinder is not already full. 3. Remove Filler Valve Dust Cap. 4. Connect the Filling Nozzle to the Filler Valve on the cylinder by means of the

union connection (normal right – hand thread). Ensure that the Vent Valve (if fitted) is closed.

5. Open Valve ‘K’ underneath storage tank (electric pump) or Valve ‘D’ on top of

storage tank (hand pump) as appropriate. 6. Open Valve ‘J’ on end of Filling Hose and note reading of Contents Gauge

on cylinder. If this indicates ¾ (70%) or above, open Fixed Level Gauge Valve ‘E’ on cylinder, switch on electric pump, or operate hand pump, and commence filling. When a visible spray of LPG issues from the Fixed Level Gauge Valve ‘E’ immediately close Filler Valve ‘J’ on end of hose and cease filling.

7. With Valve ‘J’ closed, open Vent Valve (if fitted) and allow the small amount of gas trapped in the Filling Connection to escape. Do not attempt to break this connection until all gas flow has ceased from the vent valve.

8. Disconnect Filler Hose from cylinder and stow correctly. Finally replace dust cap on cylinder.

9. Keep Valve ‘K’ underneath storage tank (or Valve ‘D’ on top of tank) closed at all times when the installation is not in use.

10. If the Fork Lift Truck cylinder is removed for filling, this should be done with the cylinder in the horizontal position, with the locating hole in the shroud positioned at the lowest point.

NOTES: (i) When refuelling, truck must be at least 3m (10ft) from storage tank. (ii) It is important that the filling hose should be inspected prior to use on every

occasion, as damaged hoses can result in serious incidents. If any damage

is detected, do not use the hose, and immediately contact your nearest Service Office for assistance.

(iii) Do not drop the Filling Connection or drag the hose along the ground. This will result in damage to the union and subsequent leakage.

(iv) Never fill beyond the Max Level ‘F’ (or 80 %) on the Contents Gauge, or after liquid spray emerges from the Fixed Level Gauge when the valve is opened.

If, for any reason, the cylinder has been inadvertently overfilled, it is essential that the truck engine should be run to reduce the quantity of gas in the cylinder to the correct amount before the truck is left unattended.

Safety Data Information Sheet PROPANE. Substance Identification Number: 1978 HAZCHEM Code 2WE General: Commercial propane is supplied as a liquid under pressure in various sizes of steel cylinders, or in bulk for storage in steel pressure vessels on site. Containers are equipped with a hand wheel valve and the outlet is fitted with a gas-tight plastic plug for transportation. The gas is stenched to provide a characteristic odour. Physical Data: Boiling Point -40° C (approx). Vapour pressure at 15° C 7.5 bar (g). Vapour Density (air = 1) 1.56 at 0° C. Specific Gravity (water = 1) 0.51 at 15.6° C. Flammable Limits in air 2.2 – 9.5% by volume. Auto-ignition Temperature 460° C (approx). Volume of gas per unit volume of liquid = 274. SAFETY INFORMATION. Warning: Flammable gas – No smoking or naked lights – Keep container in well ventilated place – Liquid may cause frostbite. Health Hazards: Eye: Contact by liquid can cause burns similar to frostbite. If affected, immediately flush eyes with plenty of water for at least 15 minutes. Get immediate medical attention. For protection, wear chemical goggles. Skin: Contact by liquid can cause burns similar to frostbite. If affected, immediately wash area with cold water for at least 15 minutes. Get immediate medical attention. For protection, wear gloves and impervious clothing. Inhalation: Asphyxia in high concentrations. At lower concentrations, lack of oxygen will cause dizziness, nausea, increased depth and frequency of breathing, and ultimately unconsciousness. If affected, immediately remove patient to uncontaminated area. If patient has stopped breathing, commence artificial respiration. Summon immediate medical attention. For protection, if ventilation is inadequate, the use of positive pressure air line respirator is required.

ACTION IN CASE OF FIRE: Vacate the area and call the Fire Brigade. Small fires can be attacked with dry powder fire extinguishers. If it is safe to do so, close the container valve. Cool neighbouring cylinder(s) or tank(s) with water. Do not use water to extinguish LPG fires

BATTERY LOG

TRUCK DETAILS: Toyota 7FBEF-18 DATE:

6 7 18 19

5 8 17 20

4 9 16 21

3 10 15 22

2 11 14 23

1 12 13 24

Use the box beside the number to record the SG readings before charge. Use the box under the numbers to record the SG readings after charge.

Low charge 1140 Typical values: Medium 1225 High 1280

Unusual readings were recorded for the following cells: .....................................................................................................................................

REMOVING FROM CHARGE.

1. SWITCH OFF CIRCUIT BREAKER. 2. SWITCH OFF MAIN ISOLATOR. 3. REMOVE CHARGING LEAD FROM BATTERY CONNECTOR ON

FORKLIFT TRUCK. 4. REPLACE CHARGING LEAD ONTO CHARGER STOWAGE POINT,

ENSURE THAT CABLE IS NOT TRAILING ON THE FLOOR. 5. CARRY OUT HYDROMETER READING AND ENTER INTO BATTERY LOG

BOOK.

6. YOU MAY NEED TO TOP UP INDIVIDUAL CELLS IF SO YOU WILL BE UNABLE TO TAKE ANY READINGS. 7. ALLWAYS USE THE CORRECT PPE & EQUIPMENT PROVIDED FOR

TOPPING UP THE CELLS AND FOLLOW MANUFACTURERS RECOMMENDATIONS.

8. ENSURE ANY SPILLS ARE CLEANED UP. 9. ENSURE ALL BATTERY TOPS ARE SECURE AND ANY FURRING IS REMOVED FROM BATTERY TERMINALS. 10. REPLACE SEAT AND ENSURE IT IS SECURE. 11. REPLACE FORKLIFT POWER PLUG TO BATTERY SOCKET ON THE FORKLIFT TRUCK. 12. CONTINUE PRE-USE CHECKS AS PER INSPECTION SHEET.

PLACING ON CHARGE. 1. PARK TRUCK NEXT TO BATTERY CHARGER. 2. SWITCH OFF AND REMOVE KEY. 3. DISCONNECT PLUG FROM BATTERY CONNECTION ON THE FORK LIFT TRUCK. 4. CHECK THAT MAIN ISOLATOR IS IN THE OFF POSITION. 5. CHECK THE LEADS OF THE CHARGER AND MAKE SURE THERE ARE

NO SPLITS IN THE CABLE BEFORE TURNING ON THE CHARGER! 6. CONNECT BATTERY CHARGER LEAD TO BATTERY CONNECTOR ON

THE FORKLIFT. 7. SWITCH THE MAIN ISOLATOR TO ON. 8. SWITCH CIRCUIT BREAKER TO THE ON POSITION.

9. THE CHARGER WILL START AUTOMATICALLY.

ALWAYS FOLLOW THE MANUFACTURERS INSTRUCTIONS WHICH CAN DIFFER ON DIFFERENT MACHINES.

Notes:

flt itssar handout 09102013 - … itssar handout 09102013.pdf · the theory test can be ... it is...

Documents