Comprehensive SWMS for Pedestrian-Operated Forklift and Walkie-Stacker Operations

Forklift - Pedestrian Operated Safe Work Method Statement

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Pedestrian-operated forklifts, including walkie-stackers, walkie-reach trucks, and powered pallet jacks, provide material handling capacity for construction and warehousing operations where operators walk alongside or behind equipment during operation. These machines combine manual handling assistance with powered lifting capability whilst requiring operators to navigate equipment through confined spaces, coordinate equipment movement with pedestrian activity, and manage unique hazards from working directly alongside powered equipment. This SWMS addresses the critical safety requirements for pedestrian-operated forklift operations including foot and leg crushing hazards, load stability management, confined space operation, and coordination with other warehouse activities in compliance with Australian WHS legislation and high-risk work licensing requirements.

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Overview

What this SWMS covers

Pedestrian-operated forklifts represent an essential category of material handling equipment providing powered lifting and transport capability whilst operators walk alongside or behind equipment during operation. These machines serve warehousing and construction logistics requirements where full-sized ride-on forklifts would be excessive capacity, too large for confined spaces, or where operational flexibility benefits from operators directly controlling equipment whilst maintaining ability to quickly dismount for other tasks. The pedestrian-operated category encompasses several distinct equipment types each suited to specific operational requirements and presenting unique hazard profiles requiring specific controls. Powered pallet jacks (also called electric pallet trucks or walkies) represent the most basic pedestrian-operated equipment, providing motorised travel capability for moving palletised loads horizontally whilst forks remain at ground level. Operators walk behind equipment using tiller handle for steering and speed control, with equipment lifting loads only sufficient height to clear ground for transport. These units typically have capacity 2000-3000kg and are battery-powered electric machines operating in warehouse aisles, loading docks, and material storage areas. Walkie-stackers (pedestrian-operated stackers) add vertical lifting capability to powered pallet jack chassis, allowing loads to be lifted to heights typically 3-5 metres for placing on racking or stacking operations. Counter-balanced walkie-stackers use rear weight to stabilise loads similar to standard forklifts, whilst straddle walkie-stackers use outrigger legs extending either side of pallets to provide stability. Walkie-reach trucks incorporate extending forks allowing loads to be placed deep into racking whilst machine remains in aisle, maximising warehouse space utilisation in narrow-aisle configurations. The fundamental operational characteristic distinguishing pedestrian-operated equipment from ride-on forklifts is the operator position alongside or behind equipment throughout operation. This positioning creates unique hazard exposures including foot and leg crushing risks from equipment running over operators' feet if operators lose control or are struck by reversing equipment, operators being crushed between equipment and structures in confined aisles, and operators being struck by raised loads if load stability is lost. However, operator positioning also provides operational advantages including superior visibility compared to ride-on equipment as operators can see directly around equipment without visual obstructions from cabs or overhead guards, ability to quickly step away from equipment if unsafe conditions develop, and enhanced manoeuvrability in tight spaces where ride-on equipment cannot operate effectively. Pedestrian-operated forklifts commonly operate in warehouse environments including narrow storage aisles with minimal clearances either side requiring precise positioning and awareness of surroundings, loading dock areas where coordination with delivery vehicles and manual handling operations occurs simultaneously, cold storage facilities where reduced temperatures affect battery performance and create additional environmental hazards for operators, and construction site material storage areas often with uneven surfaces and outdoor weather exposure. The confined nature of many operational environments means pedestrian-operated equipment frequently works in close proximity to other workers conducting manual handling, order picking, or maintenance tasks, requiring continuous awareness and communication to prevent incidents. Operational requirements include loading and unloading delivery vehicles coordinating with delivery drivers and traffic management, placing materials on storage racking at various heights requiring precision positioning in confined spaces, retrieving materials from storage for despatch or construction use, and transporting materials across warehouses or between storage and work areas. Battery-powered operation provides environmental advantages including zero exhaust emissions allowing operation in enclosed spaces, reduced noise compared to combustion engines, and lower operating costs, whilst creating specific considerations including battery management, charging infrastructure requirements, and performance variation as battery charge depletes throughout shifts. Licensing requirements under Australian WHS regulations classify some pedestrian-operated equipment as requiring High Risk Work Licences (HRW Licence class LO - Order Picking Forklift for equipment with lifting capability), whilst simple powered pallet jacks without lifting beyond load clearance may not require licensing depending on jurisdictional interpretations and specific equipment capabilities.

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Why this SWMS matters

Pedestrian-operated forklift operations present serious injury risks that have resulted in fatalities and life-changing injuries across Australian warehousing and construction sectors. The most common serious incident type involves operators' feet or legs being crushed when run over by equipment, typically occurring when operators lose control of equipment on slopes or ramps, when equipment rolls unexpectedly due to brake failure or operator error, or when operators attempt to step aside from moving equipment but misjudge equipment path. Safe Work Australia data shows foot and leg crushing injuries are overrepresented in pedestrian-operated forklift incidents compared to ride-on forklift incidents, reflecting the close proximity between operators and moving equipment throughout operation. The weight of pedestrian-operated equipment (typically 500-2000kg unladen) means even slow-speed contact can cause severe crushing injuries including fractured bones, crushed feet requiring amputation, and soft tissue damage requiring extensive medical treatment and rehabilitation. Crushing incidents between equipment and structures occur when operators work in confined aisles or loading areas with minimal clearance, becoming trapped between moving equipment and fixed structures, racking, vehicles, or walls. These incidents often occur during reversing operations when operators walking backwards whilst controlling equipment cannot see obstacles behind them, or when operators attempt to guide equipment through tight clearances misjudging available space. The consequences of being crushed between multi-tonne equipment and solid structures include severe internal injuries, spinal damage, and potential fatalities depending on crushing forces and body areas affected. Unlike ride-on forklift operators who are protected by operator restraints and overhead guards, pedestrian-operated forklift operators have no protective structures and rely entirely on maintaining safe positioning relative to equipment. Load stability incidents including loads tipping from forks or equipment tipping over cause serious injuries when operators are struck by falling loads or trapped under tipped equipment. Contributing factors include exceeding equipment capacity limits, operating on slopes or uneven surfaces affecting stability, raising loads too high for equipment stability particularly on walkie-stackers with high lift capacity, and sudden stops or sharp turns causing load shift. The elevated working positions required for some operations including accessing elevated storage racks mean loads falling from height gain significant impact energy capable of causing fatal injuries to operators positioned below. Equipment tip-over incidents can trap operators beneath equipment causing crushing injuries and preventing escape requiring emergency services assistance for equipment removal. Under the Work Health and Safety Act 2011 and associated regulations, persons conducting a business or undertaking have duties ensuring powered mobile plant including pedestrian-operated forklifts are designed, maintained, and operated safely. This includes requirements for operator training and licensing where applicable, systematic maintenance programmes ensuring equipment operates safely throughout its service life, implementation of traffic management separating powered equipment from pedestrian workers where possible, and adequate supervision particularly for new or inexperienced operators. Failure to meet these duties can result in prohibition notices halting operations, substantial financial penalties for safety breaches, and prosecution following serious incidents particularly those resulting in fatalities or permanent injuries. The growing use of pedestrian-operated forklifts in construction logistics driven by increasing prefabrication, just-in-time delivery systems, and warehouse-style material storage at construction sites means more workers are exposed to these hazards across diverse environments often with less structured safety management than permanent warehouse facilities. Construction site operation introduces additional hazards including uneven ground surfaces, outdoor weather exposure affecting equipment traction and operator comfort, temporary storage configurations with varying aisle widths and racking stability, and interaction with construction activities creating dynamic hazard profiles. Comprehensive SWMS documentation ensures systematic identification and control of hazards specific to pedestrian-operated forklift operations, supports competency-based training addressing unique operational requirements, provides reference materials for operators working independently, and demonstrates due diligence in managing complex hazards spanning manual handling, powered equipment operation, load management, and workplace traffic control. Given the severity of potential outcomes and high frequency of incidents in this equipment category, proper SWMS implementation is essential for protecting operators and other workers in warehousing and construction logistics operations.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Foot and Leg Crushing from Equipment Running Over Operator

High

The most serious and common hazard in pedestrian-operated forklift operation is operators' feet or legs being crushed under equipment wheels or load wheels. This occurs when operators lose control of equipment on slopes or ramps where gravity accelerates equipment faster than operators can safely walk, when equipment unexpectedly rolls due to brake system failures or failure to engage park brakes during stationary operations, when operators attempt to step aside from moving equipment paths but misjudge equipment movement or stumble whilst moving, or when operators position feet too close to equipment whilst manoeuvring in confined spaces and equipment wheels contact feet. The weight of pedestrian-operated equipment typically ranges from 500kg to 2000kg depending on model and battery weight, concentrating crushing force through small equipment wheel contact areas creating tremendous pressure on feet or legs contacted. Battery weight positioned low in equipment provides stability but significantly increases total equipment mass. Slopes and ramps present particular risk as equipment can gain momentum if operators lose grip on tiller handles or attempt to control descents without proper braking, with loaded equipment having significantly greater momentum than unladen machines. Wet or contaminated floor surfaces reduce equipment traction and increase likelihood of equipment sliding or skidding beyond operator control. Operator fatigue from extended shifts walking behind equipment reduces reaction times and stability, increasing stumble and contact risks.

Consequence: Severe crushing injuries to feet including fractured bones, crushed metatarsals requiring surgical reconstruction, soft tissue damage, and potential requirement for toe or foot amputation if crushing damage is extensive. Extended time off work for treatment and rehabilitation, permanent disability affecting mobility and capacity for manual handling work, chronic pain, and psychological trauma from injury experience.

Crushing Between Equipment and Structures in Confined Spaces

High

Operating pedestrian-operated forklifts in warehouse aisles, loading areas, and confined spaces creates crushing risks when operators become trapped between moving equipment and fixed structures including racking, walls, columns, or parked vehicles. This hazard is acute during reversing operations when operators walk backwards whilst controlling equipment, unable to see obstacles behind them and relying on awareness of aisle layouts and mirror checks. Confined aisle operations with minimal clearances either side of equipment mean operators working alongside equipment have limited space to position themselves safely, particularly when loads extend beyond equipment width requiring operators to stand very close to racking or structures whilst manoeuvring. Misjudgement of available clearances when navigating tight spaces can result in operators realising too late that insufficient space exists between equipment and structures to accommodate both equipment and operator, becoming trapped as equipment continues moving. Equipment unexpected movement due to unintended tiller control activation or equipment rolling on slopes can push operators against structures before they can escape. Working in congested areas with multiple pedestrians, other equipment, or temporary obstacles reduces available maneuvering space and creates distraction preventing operators maintaining full awareness of positioning relative to surrounding structures. High-visibility clothing worn by operators provides limited protection if operators are squeezed between equipment and structures as crushing forces are independent of visibility.

Consequence: Severe crushing injuries to torso, pelvis, or legs causing internal injuries, fractured pelvis or ribs, spinal damage, and potential fatalities depending on crushing forces applied and duration of entrapment. Medical shock and organ damage requiring emergency treatment. Permanent disability from spinal injuries affecting quality of life long-term. Psychological trauma requiring counseling and potential inability to return to warehouse or materials handling work.

Load Tip-Over and Falling Loads from Height

High

Walkie-stackers operating with extended masts to place loads at height present falling load hazards if load stability is compromised during lifting, lowering, or transport operations. Loads can tip from forks if loads are not properly centred on forks before lifting, if loads shift during transport due to inadequate stability or sudden equipment stops, if operators raise loads whilst equipment is on slopes creating tilted mast conditions, or if load capacity limits are exceeded causing loss of stability. Palletised loads may appear stable but can have shifted contents, damaged pallets, or asymmetric weight distribution not apparent until loads are elevated. Operating on uneven surfaces causes mast tilt affecting load security particularly when loads are raised to substantial heights. Sudden acceleration or braking whilst transporting raised loads generates dynamic forces that can overcome fork retention causing loads to slide from forks. Operators positioned near equipment to control operations are in direct fall path if loads detach from forks or tip over equipment. Load weights in construction materials handling operations can range from light packaged goods to heavy masonry materials, steel products, or dense aggregates, with heavier loads generating greater impact forces if falling. Working under or adjacent to raised loads whilst attempting to guide placement in racking positions operators directly beneath loads where fall consequences are most severe.

Consequence: Severe injuries from impact with falling loads including fractures, head trauma, spinal injuries, and potential fatalities particularly for heavy loads falling from elevated positions. Crush injuries if operators are knocked down and landed upon by fallen loads. Damage to delivered materials requiring replacement and customer disputes. Near-miss events creating anxiety about equipment safety affecting operator performance and willingness to conduct required work.

Equipment Tip-Over on Slopes or Uneven Surfaces

High

Pedestrian-operated forklifts can tip forward, backward, or sideways when operating on slopes, uneven ground surfaces, or when stability limits are exceeded through improper loading or operation. Tip-over risks are highest when travelling across slopes (perpendicular to slope direction) where equipment lateral stability is compromised, when loads are raised whilst on slopes changing centre of gravity, when operating at excessive speeds on uneven surfaces causing dynamic loading, or when equipment wheels drop into holes, depressions, or onto soft surfaces creating sudden stability changes. Straddle walkie-stackers with outrigger legs have different stability characteristics than counter-balanced designs, requiring operators to understand specific stability limitations. Construction site operation on temporary surfaces, unsealed ground, or areas with service trenches and uneven compaction presents greater tip-over risks than smooth warehouse floors. Loads positioned with centres of gravity forward of equipment centreline reduce rearward stability making forward tip-over more likely during braking or descending ramps. Battery weight provides beneficial stability in normal operation but can contribute to tip-over momentum once tipping is initiated. Operators positioned alongside equipment during tip-over can be trapped beneath equipment if unable to clear tip-over path, with equipment weight causing severe crushing.

Consequence: Operators crushed or trapped under tipped equipment requiring emergency services extrication, causing severe crushing injuries, fractures, internal injuries, and potential fatalities. Equipment damage requiring repairs before return to service. Load spillage damaging materials and creating additional hazards. Project delays whilst incident investigation occurs and alternative material handling arrangements are made. Prosecution risk if investigation identifies inadequate supervision, training, or equipment maintenance contributing to tip-over.

Collision with Pedestrians and Other Equipment in Shared Spaces

Medium

Operating pedestrian-operated forklifts in warehouses and construction sites where other workers conduct manual handling, order picking, or other tasks creates collision risks between equipment and pedestrians. Unlike ride-on forklifts where operators are elevated with broader fields of view, pedestrian-operated forklift operators have limited visibility when loads are raised, when walking backwards during reversing operations, or when navigating around loads positioned on equipment. Other workers focused on their own tasks may not monitor for approaching powered equipment, particularly in high-noise environments where equipment approach may not be audible. Warehouse aisles often have multiple workers conducting picking or stacking operations whilst equipment operators attempt to navigate same aisles for load placement or retrieval. Equipment speeds whilst unladen can be relatively high compared to loaded operation, with operators sometimes moving quickly between tasks without adequate awareness of other workers. Congested loading areas where delivery vehicles, forklift operations, and manual handling occur simultaneously create complex traffic situations with numerous potential conflict points. Pedestrians may assume equipment operators have seen them and will yield, whilst equipment operators may be focused on load stability or navigation challenges not recognising pedestrian presence. High-visibility clothing worn by workers provides some collision protection but is ineffective if equipment operators are not looking in directions where pedestrians are positioned.

Consequence: Pedestrians struck by equipment causing impact injuries including fractures, soft tissue injuries, and potential crush injuries if pedestrians are knocked down and equipment travels over them. Head injuries from impacts with raised equipment components including masts or overhead guards. Psychological impacts affecting both injured pedestrians and equipment operators involved in collisions. Project disruptions whilst investigations occur and modified traffic management is implemented.

Operator Fatigue and Musculoskeletal Strain from Extended Walking

Medium

Operating pedestrian-operated forklifts requires operators to walk behind or alongside equipment throughout entire shifts, typically covering substantial distances in warehouse or construction site environments. This sustained walking, combined with manual effort to control equipment tiller handles, creates cumulative fatigue and musculoskeletal strain affecting operator alertness and capacity to respond to hazards. Operators may walk 10-20 kilometres or more during extended shifts, with additional physical effort from operating equipment controls, manually positioning loads when required, and maintaining posture necessary for equipment operation. Tiller handle operation requires sustained grip strength and arm positioning that can cause hand, wrist, and shoulder strain particularly when operating continuously without adequate breaks. Cold storage operations compound fatigue through additional thermal stress requiring extra physical effort to maintain body temperature. Concrete warehouse floors provide hard walking surfaces increasing impact forces on feet, ankles, and knees compared to softer surfaces. Equipment vibration transmitted through tiller handles can cause hand-arm vibration syndrome with prolonged exposure. Fatigue reduces operator alertness increasing likelihood of control errors, misjudgement of clearances or stability limits, and delayed reactions to developing hazards. End-of-shift fatigue is highest when incidents are statistically more likely to occur, compounding risks from reduced vigilance.

Consequence: Musculoskeletal disorders including back pain, knee injuries, foot pain, and hand-arm vibration syndrome requiring medical treatment and potential time off work. Cumulative fatigue increasing incident risk through reduced alertness and delayed reactions. Long-term chronic pain affecting quality of life and capacity to continue manual handling and materials handling work. Fatigue-related errors causing load spills, collisions, or equipment damage requiring investigation and corrective actions.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Equipment Design Features and Operator Protection Systems

Engineering

Engineering controls addressing crushing hazards include equipment design features providing operator protection and reducing hazard exposure. Modern pedestrian-operated forklifts should incorporate dead-man controls on tiller handles that automatically stop equipment movement if operator releases handle, preventing equipment continuing uncontrolled if operator loses grip. Tiller handle positioning systems should include horizontal and vertical adjustment allowing operators to position handles at comfortable heights and distances reducing awkward postures. Equipment braking systems must provide adequate braking performance including service brakes activated by tiller controls, park brakes engaging automatically when operators dismount or release controls, and emergency braking systems operating if normal brake systems fail. Anti-crush zones built into equipment design including sensors that detect operator presence in unsafe positions relative to equipment and automatically limit equipment movement prevent crushing between equipment and structures. Foot guards or footrests on some equipment designs provide designated positions for operators' feet reducing risk of feet positioning under equipment wheels. Visibility enhancement features including mirrors, lights, and warning devices improve operator awareness and alert other workers to equipment presence.

Implementation

1. Specify pedestrian-operated forklifts with dead-man control systems requiring continuous operator contact with tiller handle to maintain equipment movement, with equipment stopping within 1 second of handle release. 2. Ensure equipment has adjustable tiller handle positions allowing operators of different heights to operate comfortably without excessive reaching, bending, or awkward arm positions. 3. Verify equipment braking systems provide adequate performance through testing, with brakes capable of stopping fully-loaded equipment on maximum slopes where equipment will operate. 4. Prioritise equipment with anti-crush sensing systems detecting operator presence too close to structures and automatically limiting equipment speed or stopping movement. 5. Provide equipment with enhanced visibility features including rear-view mirrors positioned for operator sightlines, LED lighting improving operator visibility in dim areas, and audible reversing alarms. 6. Install load backrest extensions on walkie-stackers preventing loads from sliding rearward off forks towards operators during transport or load handling. 7. Fit equipment with emergency stop buttons or tiller release mechanisms allowing operators or bystanders to immediately stop equipment in emergency situations. 8. Maintain equipment in optimal condition through preventive maintenance ensuring all safety features including brakes, dead-man controls, and anti-crush systems function correctly throughout equipment life.

Competency-Based Training and Licensing Compliance

Administrative

Ensuring operators possess adequate competency for safe pedestrian-operated forklift operation requires systematic training addressing equipment operation, hazard recognition, load management, and emergency procedures. Training must cover both theoretical knowledge including load capacity calculations, stability principles, and legislative requirements, and practical skills including equipment control, load handling techniques, and safe work positioning. For pedestrian-operated stackers with lifting capability exceeding simple load clearance, operators require High Risk Work Licence class LO (Order Picking Forklift) issued by state or territory work health and safety regulators following successful competency assessment by registered training organisations. However, licensing alone does not ensure safe operation - site-specific induction covering traffic management, aisle layouts, load types, emergency procedures, and communication protocols supplements formal licensing. Competency assessment should verify operators can demonstrate safe equipment operation under supervision before authorisation for independent work, with particular emphasis on slope operation, confined space manoeuvring, and maintaining safe positioning relative to equipment throughout operation.

Implementation

1. Verify all operators of pedestrian-operated stackers with lifting capability hold current High Risk Work Licence class LO, with licence verification conducted before operators commence work. 2. Provide comprehensive training covering equipment operation, pre-use inspection procedures, load capacity assessment, stability principles, safe positioning during operation, and emergency response. 3. Deliver practical training allowing operators to practice equipment operation, load handling, slope negotiation, and confined space manoeuvring under supervision of experienced operators. 4. Conduct competency assessments requiring operators to demonstrate safe equipment operation including pre-start inspections, load pickup and placement, travel loaded and unladen, and emergency stop procedures. 5. Implement site-specific induction for operators working at new locations, covering aisle layouts, traffic management, load types and securing requirements, exclusion zones, and communication protocols. 6. Establish refresher training schedules providing annual retraining to reinforce critical safety messages, address skill degradation, and update operators on procedural changes or new equipment. 7. Provide additional training when new equipment models are introduced with different control systems, stability characteristics, or operational requirements than existing equipment. 8. Maintain training records documenting operator licensing, training completion dates, competency assessment results, and authorisation for independent equipment operation.

Traffic Management and Pedestrian Separation Systems

Engineering

Preventing collisions between pedestrian-operated forklifts and other workers requires traffic management systems separating powered equipment movements from pedestrian work areas where possible, and controlling interactions where separation cannot be achieved. Engineering controls include physical barriers delineating equipment-only travel routes from pedestrian walkways, floor markings showing designated equipment paths and pedestrian areas using highly-visible line marking and colour coding, and one-way traffic systems in aisles reducing conflict points where equipment may meet. Pedestrian crossing points equipped with appropriate controls including stop signs, mirrors showing approaching equipment, or signalling systems alerting equipment operators to pedestrian presence provide controlled interaction points. Exclusion zones preventing pedestrians entering areas where equipment is actively operating, enforced through physical barriers, signage, or personnel assigned to maintain zone integrity, eliminate exposure during high-risk operations including load placement at height or equipment operation in confined areas. For operations where complete separation is impractical, convex mirrors at aisle intersections, elevated crossings allowing pedestrian traffic over equipment routes, and designated safe waiting areas where pedestrians can stand clear during equipment movements provide defence-in-depth traffic management.

Implementation

1. Designate specific traffic routes for pedestrian-operated forklifts using floor marking, signage, and barriers creating clear separation between equipment routes and pedestrian work areas. 2. Install physical barriers including guardrails, bollards, or safety gates separating pedestrian walkways from equipment operating areas where space permits dedicated separated routes. 3. Mark pedestrian crossing points across equipment routes using high-visibility floor markings, signage warning both equipment operators and pedestrians, and mirrors showing approaching equipment. 4. Implement one-way traffic systems in narrow aisles preventing equipment meeting head-on or requiring reversing in confined spaces, with clear directional signage and entry/exit points. 5. Establish exclusion zones around active equipment operations using barriers, tape, or assigned personnel preventing other workers entering areas where equipment is placing loads at height or operating in confined spaces. 6. Install convex mirrors at blind aisle intersections allowing equipment operators and pedestrians approaching from different directions to see each other before entering intersection. 7. Provide elevated pedestrian crossings (overhead walkways) where high-volume equipment and pedestrian traffic cannot be effectively managed through surface-level controls. 8. Designate safe waiting areas at loading docks and high-traffic locations where pedestrians can stand clear during equipment movements, marked with floor paint and signage identifying safe zones.

Load Stability Assessment and Capacity Management Procedures

Administrative

Preventing load tip-over and falling load incidents requires systematic assessment of load characteristics and verification that equipment capacity limits are not exceeded. Administrative controls establish procedures for operators to assess loads before lifting including visual inspection of load condition, pallet integrity, load symmetry and balance, and estimation or verification of load weight. Load capacity charts displayed on equipment show maximum safe loads at various lift heights, with loads reduced as lift height increases due to stability limitations. Operators must verify load weights do not exceed capacity for intended lift heights, with weighing systems or load weight data from suppliers providing verification. Load positioning procedures require loads to be centred on forks before lifting, with heavier portions of loads positioned against mast to optimise stability. Restrictions on operating with raised loads on slopes or uneven surfaces prevent stability compromise from mast tilt. Procedures specifying maximum travel speeds, particularly whilst loaded, reduce dynamic forces that can cause load shift. Documentation requirements including load tracking systems recording load weights, equipment used, and lift heights provide evidence of systematic capacity management and support incident investigation if problems occur.

Implementation

1. Display load capacity charts on all equipment showing maximum safe loads at various lift heights, with capacity reducing as lift height increases, clearly visible to operators. 2. Establish load assessment procedures requiring operators to visually inspect loads before lifting, checking pallet condition, load symmetry, securing of load items, and apparent weight. 3. Provide load weight verification systems including weighing equipment, load weight documentation from suppliers, or reference tables showing typical weights for common materials. 4. Require operators to verify load weights do not exceed equipment capacity for intended lift height before commencing lifting operations, with supervisor consultation if uncertainty exists. 5. Establish load positioning procedures requiring operators to centre loads on forks with load centres aligned with fork centres, and heavier portions against mast maximising stability. 6. Prohibit operating with loads raised above minimum transport height whilst travelling on slopes, uneven surfaces, or in congested areas where sudden stops may be required. 7. Implement maximum speed limits for equipment operation, typically 8-10 km/h unladen and 5 km/h when loaded, with slower speeds in congested areas or on uneven surfaces. 8. Maintain load handling logs for high-value or unusual loads documenting load weights, lift heights, equipment used, and operator verification of capacity compliance.

Pre-Use Inspection and Equipment Maintenance Programmes

Engineering

Maintaining pedestrian-operated forklifts in safe operating condition throughout equipment life requires comprehensive pre-use inspection programmes detecting defects before equipment is operated, combined with scheduled preventive maintenance addressing wear before failures occur. Daily pre-use inspections conducted by operators verify critical safety systems including brakes (service, park, and emergency systems), tiller controls (dead-man functions, steering response, speed control), hydraulics (mast operation, fork positioning, absence of leaks), wheels and tyres (condition, inflation, secure mounting), battery (charge level, secure mounting, condition), and safety features (lights, alarms, mirrors, guards). Any defects identified during inspection must result in equipment quarantine preventing use until repairs are completed and verified. Scheduled preventive maintenance based on manufacturer recommendations and operating hours includes detailed inspections, adjustments, parts replacement, and load testing verifying equipment operates within design specifications. Maintenance work on powered mobile plant should be conducted by qualified technicians with specialist knowledge of forklift systems, with critical safety system work including brakes and hydraulics documented and verified through testing before return to service.

Implementation

1. Develop equipment-specific pre-use inspection checklists covering all critical safety systems and components, appropriate for equipment model and operational environment. 2. Train operators to conduct daily pre-use inspections before first use each shift, recognising defects requiring immediate attention versus items that can be scheduled for repair. 3. Require documented pre-use inspections with checklists signed by operator and retained for verification by supervisors and evidence of systematic inspection programme. 4. Provide equipment defect reporting systems allowing operators to easily report problems including defect tags, logbooks, or electronic reporting, with defects tracked to resolution. 5. Implement equipment quarantine procedures for defective equipment including removal from service, physical quarantine tags preventing unauthorised use, and priority repair scheduling. 6. Establish preventive maintenance schedules based on manufacturer recommendations and operating hours, typically including monthly detailed inspections and annual comprehensive servicing. 7. Engage qualified service technicians to conduct scheduled maintenance including brake testing and adjustment, hydraulic system inspection and servicing, wheel and tyre replacement, and load testing. 8. Maintain equipment maintenance logs documenting inspection history, defects found, maintenance work completed, parts replaced, and load test results demonstrating ongoing compliance with safety standards.

Operator Positioning and Safe Work Procedures During Operation

Administrative

Reducing crushing and collision risks requires establishing safe work procedures specifying how operators should position themselves relative to equipment during different operational phases. Procedures should require operators to maintain designated positions alongside or behind equipment throughout operation, never stepping in front of loaded equipment or positioning between equipment and structures in confined aisles. Walking speed requirements ensure operators do not attempt to operate equipment faster than comfortable walking pace, preventing situations where operators cannot keep pace with equipment. Reversing procedures require operators to check behind equipment before commencing reversing operations, use mirrors during reversing to monitor path, and reverse slowly whilst maintaining awareness of obstacles and other workers. Three-point contact principles when dismounting equipment or accessing elevated positions maintain stability preventing falls. Procedures prohibit riding on equipment except on designated operator platforms if provided, preventing injuries from falling off equipment during movement. Emergency stop procedures training ensures operators understand how to immediately stop equipment if hazards develop, using dead-man handle release, emergency stop buttons, or key removal.

Implementation

1. Establish operator positioning requirements specifying operators must remain alongside or behind equipment during operation, never in front of equipment or between equipment and structures. 2. Require walking-pace equipment operation with operators maintaining comfortable walking speed throughout operation, prohibiting attempting to walk faster than sustainable pace to keep up with equipment. 3. Develop reversing procedures requiring operators to check areas behind equipment before reversing, use mirrors during reversing operations, and reverse at reduced speeds whilst monitoring path. 4. Train operators in three-point contact principles maintaining two hands and one foot, or two feet and one hand, in contact with equipment when mounting or dismounting. 5. Prohibit riding on equipment except on designated operator platforms, with disciplinary procedures for violations treating as serious safety breaches. 6. Provide emergency stop procedure training covering dead-man handle release, emergency stop button activation, and key removal for different emergency scenarios. 7. Implement work rotation schedules for operators conducting extended equipment operation, with periodic breaks allowing rest and reducing cumulative fatigue. 8. Establish procedures for operating on slopes including maintaining loads low during slope travel, facing uphill when ascending slopes, and controlled descent speeds on downward slopes using equipment braking.

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Personal protective equipment

Safety Boots with Steel Toe Caps

Requirement: Certified to AS/NZS 2210.3 with steel toe protection and metatarsal guards where available

When: Mandatory at all times when operating pedestrian-operated forklifts to protect feet from crushing injuries if equipment runs over feet, or if loads or equipment components fall onto feet during operations.

High-Visibility Clothing

Requirement: Class D Day/Night compliant with AS/NZS 4602.1

When: Required when operating in areas with other powered equipment, delivery vehicles, or multiple workers to ensure operator visibility to other equipment operators, drivers, and pedestrians particularly in dimly-lit warehouse areas or outdoor construction sites.

Work Gloves

Requirement: Rated for mechanical risks per AS/NZS 2161.2 with adequate grip and protection

When: Required when handling loads, operating equipment tiller controls for extended periods, or conducting equipment inspections to protect hands from abrasion injuries, splinters from timber pallets, and sharp edges on loads or equipment.

Hard Hat

Requirement: Type 1 helmet compliant with AS/NZS 1801

When: Required when operating in areas with overhead work, when placing or retrieving loads on elevated racking where loads positioned above operator, or when operating on construction sites with overhead hazards.

Hearing Protection

Requirement: Class 4 or 5 earplugs or earmuffs per AS/NZS 1270

When: Required when operating in high-noise warehouse environments with multiple equipment operating simultaneously, or when operating near construction site activities generating significant noise exposure.

Cold Weather Clothing

Requirement: Insulated jacket, thermal gloves, and thermal base layers for cold storage operation

When: Required when operating in cold storage facilities or refrigerated warehouses to prevent hypothermia and maintain manual dexterity necessary for safe equipment operation. Not required for ambient temperature warehouse operations.

Safety Glasses

Requirement: Impact-rated to AS/NZS 1337 with side shields

When: Required when operating in dusty environments, when handling loads that may produce flying particles, or when site-specific risk assessments identify eye hazards from construction activities occurring in vicinity of material handling operations.

Inspections & checks

Before work starts

  • ✓Inspect tiller handle controls for damage, verify dead-man control releases immediately when handle is released, and confirm steering and speed controls respond correctly
  • ✓Test brake systems including service brakes, park brake engagement and holding capacity on slopes, and emergency brake operation if fitted
  • ✓Check hydraulic systems for leaks from hoses or cylinders, verify mast raises and lowers smoothly without jerking, and confirm forks tilt correctly
  • ✓Inspect wheels and tyres for damage, adequate inflation, secure mounting, and absence of foreign objects lodged in wheels
  • ✓Verify battery charge level is adequate for planned operations, battery is securely mounted, and battery connector is undamaged
  • ✓Test safety features including lights, reversing alarms, mirrors, load backrest, and overhead guard where fitted
  • ✓Check forks for damage including cracks, bending, or wear, and verify forks are securely locked in mounting and properly positioned for loads
  • ✓Inspect general equipment condition for damage, loose components, fluid leaks, or unusual sounds during operation that may indicate problems

During work

  • ✓Monitor equipment performance throughout operation noting any unusual sounds, vibrations, or changed handling characteristics indicating developing problems
  • ✓Check load stability before and during transport observing for load shifting, pallet damage becoming apparent, or tilting suggesting asymmetric loading
  • ✓Verify equipment maintains adequate braking performance during loaded and unladen operation, particularly on slopes or wet surfaces
  • ✓Observe battery charge indicators if equipped, planning charging or battery change operations before charge depletes to levels affecting safe operation
  • ✓Maintain awareness of surrounding environment including other workers, equipment, obstacles, and changing site conditions requiring operational adaptations
  • ✓Monitor floor surfaces for contamination including oil spills, water, debris, or uneven surfaces affecting equipment traction or stability
  • ✓Check loads periodically during extended transport operations to verify loads remain properly positioned and secured on forks

After work

  • ✓Lower forks to ground level or safe storage position preventing trip hazards and reducing battery drain from maintaining raised fork positions
  • ✓Park equipment in designated storage areas clear of traffic routes, loading areas, and fire exits where equipment will not create hazards
  • ✓Engage park brake, switch off equipment power, and remove key if provided preventing unauthorised use or unintended equipment movement
  • ✓Connect equipment to battery charger if required, following proper charging procedures including verification of ventilation and charger selection
  • ✓Report any equipment defects, operational issues, or near-miss incidents in equipment logbook or electronic reporting system for supervisor review
  • ✓Clean equipment removing debris, spills, or materials accumulated during operations maintaining equipment in good condition and allowing defect identification during next pre-use inspection
  • ✓Document hours operated if equipment has hour meters, supporting scheduled maintenance intervals based on actual operating hours rather than calendar time

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

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1

Conduct Pre-Use Equipment Inspection and Battery Verification

Before commencing pedestrian-operated forklift operations, conduct comprehensive pre-use inspection following documented checklist procedures specific to equipment model being used. Begin inspection by verifying battery charge level is adequate for planned work duration, checking battery charge indicator shows acceptable charge level (typically minimum 20% remaining charge for extended operations). Inspect battery mounting ensuring battery is securely positioned in compartment without excessive movement. Check battery connector for damage, corrosion, or loose connection affecting power delivery. Inspect tiller handle controls by operating controls through full range of movement, verifying smooth operation without sticking or excessive free play. Test dead-man control by releasing tiller handle whilst equipment power is on, confirming equipment power immediately cuts off when handle is released. Test service brakes by engaging brakes and attempting to push equipment forward, verifying brakes hold equipment stationary. Test park brake engagement and release mechanisms, confirming positive engagement preventing equipment rolling. Operate hydraulic controls raising and lowering mast through full range, listening for unusual sounds and observing for smooth operation without jerking. Inspect hydraulic hoses and cylinders for visible leaks, damage, or deterioration. Check forks for cracks, bending, or excessive wear, and verify forks are securely locked in mounting. Inspect wheels and tyres for damage, adequate inflation, and foreign objects. Test lights, reversing alarm, and mirrors for correct operation. Document inspection completion and resolve any deficiencies before operation.

Safety considerations

Never operate equipment with defective brakes as loss of braking control can result in equipment running over operators' feet or crushing operators against structures. Dead-man control failure allows equipment to continue operating if operator loses grip, creating severe crushing risks. Hydraulic system leaks can cause loss of load control potentially dropping loads or failing to lower loads safely. Damaged forks can fail under load causing catastrophic load dropping. Low battery charge can result in equipment stopping mid-operation potentially in unsafe positions blocking traffic routes or with loads raised.

2

Assess Load Characteristics and Verify Equipment Capacity

Before attempting to lift any load, conduct assessment of load characteristics ensuring equipment capacity is adequate and load is suitable for safe handling. Visually inspect load checking pallet condition for cracks, broken boards, or deterioration that could cause pallet collapse during handling. Observe load positioning on pallet verifying load is centred and stable, not overhanging pallet edges excessively or showing signs of shifting. Look for asymmetric loading where one side of pallet appears heavier than other, indicating potential stability challenges. Verify load securing observing whether items on pallet are banded, shrink-wrapped, or otherwise secured preventing movement during transport. Determine load weight either through reference to documentation, markings on loads, or estimation based on material types and dimensions. Compare load weight to equipment load capacity chart considering lift height required, verifying load weight does not exceed capacity for intended operation. Account for load centre distance - loads with centres of gravity further from mast face require capacity derating. If load weight is uncertain or appears to approach equipment limits, obtain verification through weighing or consult supervisor before attempting lift. For unusually configured loads including long items, asymmetric loads, or loads without pallets, assess whether load can be safely handled using available equipment or whether alternative handling methods are required.

Safety considerations

Exceeding equipment capacity creates tip-over risk potentially crushing operators or other workers in equipment fall path. Damaged pallets can collapse during lifting or transport causing loads to fall and strike operators. Poorly secured loads can shift during transport or fall from forks creating impact hazards. Underestimating load weight is common error - when in doubt, verify actual weight rather than guessing. Different equipment configurations have significantly different capacity limits - never assume equipment capacity without consulting capacity chart for specific equipment and lift height.

3

Position Equipment and Pick Up Load Using Correct Fork Placement

Approach load squarely ensuring equipment is aligned perpendicular to pallet allowing forks to slide fully under pallet without contact with pallet sides or load items. Adjust fork spacing if adjustable fork equipment is used, positioning forks to distribute load weight evenly across both forks whilst allowing adequate clearance between forks for pallet boards. Lower forks to ground level before attempting to insert under pallet, preventing forks striking pallet or load during approach. Slowly advance equipment inserting forks fully under pallet until fork tips approach rear pallet edge, ensuring forks support entire pallet depth and load weight is distributed along fork length rather than concentrated near fork tips. Verify forks are inserted straight without angling into pallet, and that load centre aligns with equipment centreline. Tilt mast rearward slightly if equipment has tilt function, nestling load against mast for stability during transport. Raise load only sufficient height to clear ground for travel, typically 100-150mm clearance, maintaining low centre of gravity for maximum stability. Before travelling, conduct final visual check confirming load is stable, properly positioned, not tilting, and forks fully support load. Sound horn or provide verbal warning to alert other workers that loaded travel is about to commence.

Safety considerations

Partial fork insertion under pallets concentrates load weight near fork tips creating instability and potential for pallet or load tipping forward off forks. Asymmetric fork positioning where one fork is inserted further than other creates unbalanced loading causing load or equipment tip-over. Raising loads higher than minimum clearance required increases tip-over risk particularly during travel over uneven surfaces or on slopes. Approaching loads at angles can cause forks to contact load items or pallet sides potentially damaging loads or destabilising pallet stacking. Alert other workers before travelling with loads as loaded equipment has reduced manoeuvrability and longer stopping distances compared to unladen operation.

4

Transport Load Maintaining Safe Speed and Operator Positioning

Transport load to destination maintaining walking pace appropriate for conditions and surroundings, typically maximum 5 km/h when loaded. Position yourself alongside or behind equipment maintaining comfortable walking speed without excessive effort, never attempting to walk faster than sustainable pace to keep pace with equipment. Maintain continuous observation of travel path ahead, load stability on forks, and surrounding workers or obstacles. Navigate corners and turns slowly, allowing adequate radius preventing load from shifting due to centrifugal forces. Avoid sudden stops or starts that create dynamic loading potentially causing load movement. When approaching intersections, ramps, or congested areas, reduce speed further and increase vigilance for pedestrians or other equipment. Maintain loads at minimum transport height throughout travel, only raising loads when reaching destination for placement. If travelling across slopes cannot be avoided, minimise time on slopes, maintain slow speed, and monitor load stability continuously for signs of shifting. Sound horn at intersections or when approaching blind corners alerting other workers to equipment approach. If visibility ahead is obstructed by loads or equipment configuration, use mirrors or request spotter assistance rather than continuing with impaired visibility. Maintain adequate spacing from other equipment allowing stopping distance if equipment ahead stops unexpectedly.

Safety considerations

Excessive speed reduces reaction time and increases stopping distance, whilst also creating dynamic forces that can cause load shift or tip-over if sudden stops are required. Operating faster than comfortable walking speed creates risk of operator losing grip on tiller handle allowing equipment to continue uncontrolled potentially running over operator's feet. Travelling with loads raised high creates top-heavy configuration significantly increasing tip-over risk particularly during cornering or on uneven surfaces. Travelling across slopes (perpendicular to slope direction) creates lateral instability risk - if slope crossing is unavoidable, do so slowly whilst continuously monitoring for equipment or load tipping. Sudden stops or starts can cause loads to slide forward off forks or backward against mast potentially dislodging loads onto operator.

5

Position Load at Destination and Lower Safely

When reaching load destination, slow equipment to minimum speed and approach placement position carefully assessing available clearances and identifying where load should be positioned. For ground-level placement, position equipment with forks directly over placement location ensuring adequate clearance to obstacles either side. Lower load slowly using hydraulic controls, maintaining control throughout lowering process and observing load contacts ground level evenly without tipping. Once load is firmly supported on ground, tilt mast forward slightly to disengage forks from pallet if tilt function is available. Slowly reverse equipment withdrawing forks from under pallet straight back without angling, preventing forks from contacting pallet sides or dragging pallet. For elevated placement on racking, approach rack position slowly verifying adequate clearance to rack uprights and adjacent loads. Raise load to required height using hydraulic controls, monitoring load stability throughout raising process and ceasing raising if load appears unstable. Position equipment precisely aligning load with rack placement location. Extend forks into rack if reach equipment is used, or advance equipment forward for standard walkie-stackers until load is positioned over placement supports. Lower load carefully onto rack supports, verifying load is properly seated before withdrawing forks. Extract forks slowly whilst observing load remains stable on supports and does not tip or shift as forks are withdrawn.

Safety considerations

Positioning loads on elevated racking requires precision - contact with rack uprights during load placement can damage racking potentially causing rack collapse. Raising loads whilst equipment is not level due to uneven floors creates tilted mast increasing load instability and tip-over risk. Operators working beneath or adjacent to raised loads during placement are in direct fall path if loads tip or fall - maintain safe positioning and never stand directly beneath raised loads during placement operations. Withdrawing forks at angles from pallets after placement can drag pallets from intended positions potentially causing loads to fall. Verify rack supports are adequately rated for load weights and are in good condition before placing loads - overloaded or damaged racks can collapse.

6

Operate on Slopes and Ramps Using Appropriate Procedures

When operating on slopes or ramps, implement specific procedures addressing stability and control challenges presented by inclined surfaces. Before approaching slopes, lower loads to minimum height above ground reducing centre of gravity and tip-over risk. Assess slope gradient and surface conditions including traction and evenness before committing to slope operation. When ascending slopes with loads, travel forward with load positioned on uphill side of equipment ensuring weight distribution aids uphill traction and maintains visibility ahead. Control ascent speed maintaining slow steady pace without excessive speed that could cause loss of control or momentum challenges if obstacles are encountered. When descending slopes loaded, reverse down slope with load on uphill side, allowing operator to walk forward down slope maintaining better balance and load visibility whilst controlling equipment from behind. Use equipment braking to control descent speed preventing gravity from accelerating equipment beyond safe speed. Never attempt to turn on slopes as lateral forces significantly increase tip-over risk - drive straight up or down slopes, turning only on level areas. Avoid crossing slopes (travelling perpendicular to slope direction) whenever possible due to lateral tip-over risk, particularly when loaded or with raised loads. If slope crossing is unavoidable, maintain very slow speed, keep loads low, and monitor continuously for signs of equipment or load instability. Park brake should never be relied upon to hold equipment on slopes - only park equipment on level ground with park brake engaged.

Safety considerations

Operating on slopes presents highest tip-over risk in pedestrian forklift operation particularly when loads are raised or loads exceed moderate weight. Descending slopes facing forward when loaded results in load potentially sliding forward off forks if sudden braking occurs, whilst also placing operator below equipment on slope where equipment could roll over operator if control is lost. Travelling too fast on slopes can result in brakes being insufficient to control descent speed particularly on wet or contaminated surfaces. Turning on slopes creates combination of lateral forces from turning and gravitational forces from slope creating severe tip-over risk. Equipment parked on slopes can roll unexpectedly if park brakes fail or ground gives way - never park on slopes even briefly.

7

Respond to Equipment Control Loss and Emergency Situations

If equipment begins operating unexpectedly or control is lost during operation, immediately release tiller handle activating dead-man control that should stop equipment within one second. If equipment does not stop when handle is released indicating dead-man control failure, activate emergency stop button if fitted, or turn key switch to off position stopping equipment power. Move clear of equipment path preventing being struck or crushed if equipment continues moving. Alert other workers to uncontrolled equipment using verbal warnings allowing them to clear area. Do not attempt to physically stop uncontrolled equipment which could result in being crushed - allow equipment to come to rest naturally and establish exclusion zone preventing others approaching until equipment can be safely secured. For equipment that has tipped over or dropped loads, establish exclusion zone preventing workers approaching until conditions are assessed and recovery procedures are implemented. If loads are jammed in raised position due to hydraulic failures and cannot be safely lowered, establish exclusion zone beneath and around equipment preventing workers being beneath unsupported raised loads. Engage maintenance or technical support to address equipment failures rather than attempting repairs without proper training. For incidents involving injuries, provide first aid as appropriate for injuries present, call emergency services if injuries are serious, and secure incident scene for investigation. Document all incidents and near-misses including equipment involved, conditions present, sequence of events, and any injuries or damage, supporting investigation and preventing recurrence.

Safety considerations

Attempting to physically stop uncontrolled equipment creates severe crushing risk - operator safety is more important than preventing equipment damage or load spilling. Dead-man control failures allowing equipment to continue operating when tiller handle is released represent serious safety system failures requiring immediate equipment quarantine. Tipped equipment or fallen loads create ongoing hazards from unstable equipment potentially shifting further, electrical hazards from damaged batteries, and chemical hazards from battery acid spills if batteries are damaged. Never walk under raised loads that cannot be lowered due to hydraulic failures - equipment or hydraulic failures can occur suddenly causing loads to fall onto workers beneath. Equipment incidents require investigation to identify root causes - secure incident scenes preserving evidence and preventing recurrence through systematic investigation.

8

Complete Operations and Conduct Post-Use Equipment Securing

At completion of equipment operations, return equipment to designated storage area clear of traffic routes, doorways, fire exits, or locations where equipment would create obstacles to other work. Lower forks completely to ground level removing trip hazards and reducing battery power consumption from maintaining hydraulics. Position equipment on level ground in designated parking area. Engage park brake firmly ensuring equipment cannot roll. Switch off equipment power using key switch or power control. Remove key if provided, preventing unauthorised equipment use particularly in areas accessible to untrained personnel. Connect equipment to battery charger if next use will not occur soon, following proper battery charging procedures including verification charger is appropriate for battery type and charging area has adequate ventilation. Ensure charging cable routing does not create trip hazards and charger displays confirm charging is progressing correctly. If battery charge is very low, notify supervisor or next shift operator that immediate charging is required before next use. Clean equipment removing debris, spills, or accumulated dirt that could obscure defects during next pre-use inspection or create housekeeping hazards. Document any equipment defects, operational concerns, or incidents that occurred during shift in equipment logbook or electronic reporting system. Report unusual equipment behaviours including changed sounds, vibrations, or handling characteristics even if equipment appeared to operate safely, as these may indicate developing problems requiring maintenance attention. Complete operator hour records if maintained, supporting scheduled maintenance intervals based on actual operating hours.

Safety considerations

Equipment left in traffic routes creates collision hazards and obstructs emergency egress routes potentially delaying emergency evacuations. Forks left raised create trip hazards causing injuries to workers walking through areas, whilst also consuming battery charge maintaining hydraulics reducing charge available for next use. Equipment left on slopes can roll unexpectedly if park brakes fail or are not engaged, potentially crushing workers or causing equipment damage. Battery charging without adequate ventilation creates explosion risk from hydrogen gas accumulation. Failure to report developing equipment problems allows defects to worsen potentially causing failures during subsequent operations. Documenting equipment condition at shift end protects operators from being held responsible for pre-existing damage or defects that occurred during previous shifts.

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Frequently asked questions

Do I need a High Risk Work Licence to operate pedestrian-operated forklifts?

Licensing requirements for pedestrian-operated forklifts depend on specific equipment capabilities and how equipment is classified. Under Australian WHS regulations, pedestrian-operated forklifts that lift loads to heights greater than 1 metre typically require High Risk Work Licence class LO (Order Picking Forklift). This includes walkie-stackers with mast lift capability for placing loads on racking. However, simple powered pallet jacks that only raise forks sufficient height to clear ground for travel (typically under 200mm lift height) may not require HRW licensing depending on jurisdictional interpretations. Despite licensing not being legally required for basic pallet jacks, employers should still provide comprehensive training covering safe operation, hazard recognition, and emergency procedures. The distinction can be unclear for borderline equipment - consult your state or territory work health and safety regulator for definitive guidance on specific equipment models. High Risk Work Licences are obtained through registered training organisations (RTOs) that deliver structured training covering theoretical knowledge and practical skills, followed by competency assessment. Licence applications are submitted to state/territory regulators who issue licences valid across Australia. Maintain current licence and carry when operating equipment as inspectors may request licence verification. Beyond formal licensing, site-specific induction covering traffic management, load types, aisle layouts, and emergency procedures is essential before operators commence work at new locations even if they hold appropriate licences.

What should I do if I lose control of equipment on a ramp or slope?

If equipment begins moving faster than you can safely control on slope or ramp, immediately release tiller handle activating dead-man control that should stop equipment within one second. If equipment does not stop indicating dead-man failure, activate emergency stop button, turn off key switch, or remove key stopping equipment power. Simultaneously move laterally away from equipment path - step to the side rather than continuing to walk behind or in front of equipment path where you could be crushed if equipment continues rolling. Do not attempt to physically push, grab, or stop equipment using body weight as equipment mass far exceeds your capacity and you will be crushed. Alert other workers to uncontrolled equipment allowing them to move clear. Once equipment stops rolling or reaches level ground, establish exclusion zone preventing workers approaching until equipment can be safely assessed. Check yourself for injuries - adrenaline during incidents can mask injury symptoms, particularly foot injuries if equipment ran over your feet. Report incident immediately to supervisor providing details about where control was lost, slope conditions, load weight and height, and equipment behaviour. Equipment that does not stop when tiller handle is released has serious dead-man control failure requiring immediate quarantine and repair before any further use. Incident investigation should examine multiple factors including slope gradient (slopes may exceed equipment design limits), surface conditions affecting traction, brake system condition, load weight potentially exceeding capacity for slope operation, and operator training adequacy for slope operation. Prevent recurrence through slope operation risk assessment potentially including gradient measurement, installing warning signs identifying slopes requiring special procedures, or prohibiting equipment operation on slopes exceeding design specifications.

How do I operate safely in narrow warehouse aisles with limited clearances?

Operating pedestrian-operated forklifts in narrow aisles requires heightened awareness and specific techniques addressing crushing risks from limited clearances. Before entering narrow aisles, reduce speed allowing more reaction time for tight maneuvering. Verify aisle is clear of other equipment or workers before entering - two-way traffic in narrow aisles creates severe collision and crushing risks. Position yourself alongside equipment rather than directly behind where possible, maximising distance from aisle walls or racking. Continuously monitor clearances either side noting distance between equipment and structures. When loads overhang equipment width, account for total width including load overhang when assessing clearances. Use mirrors if fitted or periodic visual checks behind you during reversing to identify obstacles or workers entering aisle behind you. Maintain slow controlled speed allowing immediate stop if clearances become inadequate or unexpected obstacles appear. If clearances become so tight you cannot safely position yourself alongside equipment without being crushed against racking, stop operation and reassess. Options include using smaller equipment better suited to aisle width, modifying loads to reduce width, requesting aisle be widened, or implementing one-way traffic systems preventing equipment meeting in aisles. Never continue operations where you must squeeze between moving equipment and structures - crushing injuries occur within seconds if equipment contacts you. Sound horn before entering aisles alerting any workers in aisles to equipment approach. Establish protocols with other workers about right-of-way in narrow aisles and safe procedures if equipment meets. Consider installing mirrors at aisle entrances allowing operators to see down aisles before entering. For very narrow aisles approaching equipment width, consider whether ride-on equipment with operators protected by operator cages is safer than pedestrian operation exposing operators to crushing risks.

What factors affect load capacity and stability of pedestrian-operated stackers?

Load capacity of pedestrian-operated stackers varies based on multiple factors that must be understood to prevent overloading and tip-over incidents. Rated capacity shown on equipment data plates represents maximum safe load at specified load centre distance (typically 600mm for industrial pallets) at minimum lift height. As lift height increases, capacity reduces due to changed centre of gravity creating tip-over risk - equipment capacity charts show reduced capacities at elevated lift heights. Load centre distance significantly affects capacity - loads with centres of gravity further from mast face than standard load centre require capacity derating according to load centre derating charts. Equipment configuration affects capacity with straddle stackers having different capacity characteristics than counter-balanced models due to different stabilising mechanisms. Battery weight provides beneficial stability when battery is full but as battery depletes and weight reduces, equipment stability can reduce slightly. Operating surfaces affect practical capacity - uneven floors, slopes, or soft surfaces reduce stability compared to smooth level warehouse floors, requiring additional capacity margin. Load characteristics beyond simple weight affect stability including load height (tall loads with high centres of gravity are less stable), load symmetry (asymmetric loads shift centre of gravity), and load rigidity (flexible loads can shift during handling). Dynamic forces during acceleration, braking, or cornering create momentary loading exceeding static load weight, requiring capacity margin. Conservative approach is to operate well below maximum rated capacity (safety factor of at least 1.5) particularly when conditions vary from ideal test conditions where capacity ratings were established. When in doubt about whether load is within capacity, weigh load before attempting lift, consult supervisor, or use larger capacity equipment. Never gamble on capacity - consequences of overloading including tip-over or load drop can be catastrophic.

How do I prevent foot and leg injuries when operating pedestrian-operated forklifts?

Preventing foot and leg crushing injuries, the most common serious injury in pedestrian forklift operation, requires multiple defensive practices maintaining safe distance between your feet and equipment wheels. Primary control is maintaining proper operator positioning alongside or behind equipment throughout operation, never positioning feet or legs in front of equipment where wheels could run over them if equipment accelerates unexpectedly. Maintain comfortable walking speed sustainable throughout shift without rushing - attempting to walk faster than sustainable to keep pace with equipment increases stumble risk and likelihood of losing control. Use equipment speed controls setting maximum travel speed appropriate for conditions and your walking capability. On slopes and ramps, extreme caution is required as gravity can accelerate equipment beyond your safe walking speed - maintain very slow controlled descent speed using equipment braking. Wear appropriate safety footwear with steel toe caps providing some protection, although steel caps cannot prevent all injuries from multi-tonne equipment. Maintain excellent housekeeping on walking surfaces removing trip hazards including debris, cables, or spills that could cause stumbles. If you stumble or feel unstable, immediately release tiller handle activating dead-man control stopping equipment rather than attempting to regain control whilst unstable. Never step aside from moving equipment by stepping in front of equipment path - if you need to step away, step laterally to the side clear of equipment travel path. Maintain awareness of workers behind you particularly in narrow aisles - if worker approaches from behind, you may instinctively step forward potentially into equipment path. If equipment begins running away or accelerating beyond your control, release handle and step aside immediately rather than attempting to maintain control whilst at risk. Report any dead-man control malfunctions immediately - equipment that does not stop when handle is released creates extreme crushing risk. Consider whether ride-on equipment would be safer for operations involving extensive slope work, long-distance travel, or high-volume operation causing operator fatigue.

What maintenance and servicing is required for pedestrian-operated forklifts?

Pedestrian-operated forklifts require systematic maintenance addressing wear from daily use and ensuring safety-critical systems remain reliable throughout equipment life. Daily pre-use inspections by operators check critical safety systems including brakes, dead-man controls, steering response, hydraulic operation, wheels and tyres, battery condition, and safety features such as lights and alarms. Any defects identified during pre-use inspection must result in equipment quarantine until repairs are completed - never operate defective equipment due to time pressure or equipment shortages. Weekly detailed inspections by supervisors or maintenance personnel should examine equipment more thoroughly including hydraulic system pressure testing, brake adjustment verification, wheel bearing condition, electrical system integrity, and structural components for cracks or damage. Monthly maintenance typically includes complete hydraulic system inspection with fluid level and condition checks, filter replacement if required, hose inspection and replacement of damaged hoses, brake system detailed inspection and adjustment, wheel and tyre replacement if required, and battery system inspection including terminals, cables, and mounting. Annual comprehensive servicing by qualified service technicians should include complete equipment strip-down examining all wearing components, load testing to verify capacity ratings remain valid, safety system function testing, and compliance verification with Australian Standards. Maintain detailed maintenance logs documenting all inspections, servicing work, parts replaced, and load testing results. Logs demonstrate systematic maintenance approach providing evidence of due diligence if incidents occur. Battery maintenance is critical component including regular water level checking and topping for lead-acid batteries, cleaning terminals to prevent corrosion, and ensuring charging systems operate correctly. Consider maintenance agreements with equipment suppliers providing scheduled servicing, genuine replacement parts, and technical support for troubleshooting. Equipment operating in harsh environments including dusty conditions, wet areas, or cold storage may require more frequent servicing than manufacturers' standard recommendations. Budget adequately for maintenance recognising that preventive maintenance costs are insignificant compared to costs of equipment failures, incidents, or prosecution for operating unsafe equipment.

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