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Risk - Assessment - Telehandler
Risk - Assessment - Telehandler
NOTE: This assessment is bsed on the design of the unit prior to additional hazard control measures incorporated
into the Australian build design.
Table 1: Risk & Hazard Likelihood
HAZARD (A) Likelyhood of Occurring (B) Consequence of Occurring RISK SCORE*
As listed in Table 2 (1) Rare (1) First Aid Risk Scores* are found
(2) Very Low (2) Casualty by adding likelihood (A)
(3) Low (3) Hospitalisation & consequence (B) of
(4) Moderate (4) Disabled occurrence together.
(5) High (5) Fatality Risk Scores range from
(6) Very High (6) Numerous Fatalities 2-12
*The higher the risk score the larger the requirement for the hazard to be addressed and guarded against. Please see Table 2
for identification of hazard types checklist.
1
A hazard is anything with potential to cause injury, illness or harm when the plant is operated, maintained, serviced, repaired, inspected,
transported and stored.
2
Plant in this case is defined as a one of the JLG telescopic material handler models referenced in the table at the top of the page.
3
JLG considers that “reducing the risk as far as practicable” to be an undertaking of out duty of care in that we have addressed the potential
to exposure to a risk during design and manufacture and have adhered to the required standards during this time. Any identified additional
risks raised during this assessment have been addressed and eliminated for normal machine operation by trained personnel.
4
Systems of work describe all operating/maintenance procedures and in general systems used by workers in servicing, inspecting,
transportation and storage
1 Revised 13/08/10 DMM
TABLE 2
HAZARD TYPE CHECKLIST
A. CRUSHING. -can anyone’s hair, clothing, gloves, cleaning apparatus or any other materials become entangled in
ENTANGLEMENT. moving parts, or objects in motion.
CUTTING. -crushing due to material falling from plant.
STABBING. -uncontrolled motion or unexpected movement of plant.
PUNCTURING. -inadequate stopping devices of plant to control movement.
SHEARING. -support structure collapse.
FRICTION. -being thrown from or within plant.
STRIKING. -cutting, stabbing & puncturing due to contact with sharp or flying objects.
-parts of plant or worksite material disintegrating or falling.
-movement of plant.
-can anyone’s body parts be sheared between moving parts or surfaces of the plant.
-can anyone be burnt due to contact with moving parts or surfaces of the plant.
-can anyone be struck by moving objects due to uncontrolled or unexpected movement of plant.
B. ERGONOMIC. -can anyone be injured due to poorly designed seating or repetitive body movements.
SLIPPING. -constrained body posture or the need for excessive effort.
TRIPPING. -design inefficiency causing mental or psychological stress.
FALLING . -inadequate or poorly placed lighting of plant or workers.
-lack of failsafe measures against human error.
-mismatch of plant with natural human limitations.
C. HIGH PRESSURE -can anyone come into contact with fluids under high pressure, due to plant failure or misuse.
FLUIDS. -can anyone come into contact with objects at high temperatures, or objects which can cause fire or burns.
HIGH -can anyone suffer illness due to exposure to high or low temperatures.
TEMPERATURES. -can anyone be injured by explosion of gases, vapours, liquids, dusts or other substances triggered
FIRE/EXPLOSION. by the operation of the plant or workpieces.
D. SUFFOCATION. -can anyone be suffocated or drowned due to lack of oxygen, or atmospheric contamination.
DROWNING.
E. ELECTRICAL. -can anyone be injured by electric shock due to the plant coming into contact with live conductors.
-plant being too close to high tension power lines.
-overload of electrical circuits.
-electrical wiring or switch shorting.
-lack of insulation against water contact shorting.
-magnetic interference from workplace corrupting electrical components.
F. STABILITY. -can machine tip or roll over due to outriggers not extending.
-outriggers failing mechanically, or retract unintentionally.
-control valve or interlock failure.
-set up on soft ground, unlevel or uneven ground, excessive slope.
-driving on rough surfaces, over potholes, hitting fixed objects, excessive side loads e.g wind.
G. HYDRAULIC -hydraulic system failure.
FAILURE. -check valve or relief valve failure.
-hose or cylinder failure - mechanical or fatigue.
H. STRUCTURAL -boom failure due to fatigue, corrosion, or overloading.
FAILURE. -pin, cable or linkage failure.
-general overload - lifting excessive load, loading attachment in an unintended way.
I.. MAINTENANCE. -can anyone be injured while carrying out routine, preventative or corrective maintenance.
-explosion due to welding spark etc. near charging battery
-adjusting equipment for essential components faulty or seized.
-guard removal.
J. TRANSPORT. -can anyone be injured due to machine instability while transporting.
-plant or objects falling from transport truck.
K. OCCUPATIONAL -plant obstructing other plants at site.
HAZARDS -unauthorised use by untrained personnel.
-unintended use of duplicate controls while working.
-hearing loss or communication interference due to excessive noise.
-safety signs or decals removed.
-energy supply failure (chemical, electrical or mechanical).
*
Table 2 is based upon N.Z Chamber of Manufacture hazard identification guide, & specifications from the Elevating Work Platform
purchasing Specification and Operating Guide by the Electricity Association NSW - 1996, and pr EN280.
HAZARD HAZARD TYPE LOCATION/SCENARIO RISK CONTROL MEASURES TO REDUCE RISK NEW
NUMBER SCORE RISK
SCORE
1 Crushing, Operating unit in an area 2+6 Crushing hazard decals are clearly displayed on the machine. A backup alarm and a horn are fitted 1+6
collision/striking where obstacles, other to warn of movement. A revolving beacon option is fitted to Australian units. Safe operating
people and plant may be procedures are placed in the operator’s manual.
present
2 Crushing Between boom and frame 2+4 A back-up alarm and a horn are fitted to warn of movement. A revolving beacon option is fitted to 1+4
Australian units. Safe operating procedures are placed in the operator’s manual.
3 Crushing. Lifting machine incorrectly 3+6 Designated lifting points are indicated by decals. Correct lifting procedures in manual. 1+6
4 Crushing, Moving parts 3+5 Crushing and shearing hazards have been marked with warning decals. Correct maintenance and 1+5
shearing operating procedures and safety instructions are placed in the operation and safety manual.
5 Crushing, Underneath attachment when 2+5 A horn is fitted to warn of movement. A revolving beacon option is fitted to Australian units. 1+5
collision/striking. boom is being lowered Section 1.3 of operator’s manual says to warn personnel to keep others away while operating.
6 Crushing, striking. Objects falling from plant 2+5 Cab is FOPS compliant. Components designed to withstand vibration, and are tested in harsh 1+5
conditions in excess of normal use. Locking type hardware is used to reduce the risk of components
working loose. Section 1.3 of operator’s manual says to warn personnel to keep others away while
operating.
7 Entanglement, Maintenance 2+4 Guarding provided is a fixed permanent nature and can only be removed with tools. Correct 1+4
friction, cutting maintenance procedures placed in the service manual.
8 Entanglement, High-speed components 2+4 All high-speed components are enclosed. Engine is enclosed under covers. Maintenance to be 1+4
friction, cutting carried out by qualified personnel.
9 Crushing, striking Sudden or unintended boom 3+5 Decals inside cab show correct operating instructions. Holding valves on cylinders to prevent 1+5
movement movement in the event of power failure or hose failure. Correct inspection and maintenance
procedures are placed in the service manual. Section 1.3 of operator’s manual says to keep clear
from under boom.
10 Crushing, striking Sudden or unintended 2+6 Back alarm, horn and beacon are fitted to warn of monement. Striking due to sudden machine 1+6
movements while driving movements when driving is restricted with smooth and accurate control of steering and braking
systems. Braking is achieved through the use of closed loop hydraulics and a manual park brake
lever. Operator location provides good visual access to extremities of plant. Headlights are provided
to illuminate the work area. Tail light assembly provides a visual indication of stopping and turning.
Turn indicators are also provided at the front of the machine. All cabin controls are illuminated. A
seat belt is provided to protect the operator. Inspection and maintenance procedures are placed in
the manual. Warning decals are placed on the plant, and safe operating procedures are placed in the
manual. Section 1.3 of operator’s manual says to keep others away while operating.
11 Collision Driving 2+6 Headlights are provided to illuminate the work area. Tail light assembly provides a visual indication 1+6
of stopping and turning. Turn indicators are also provided at the front of the machine. All cabin
controls are illuminated.
HAZARD HAZARD TYPE LOCATION/SCENARIO RISK CONTROL MEASURES TO REDUCE RISK NEW
NUMBER SCORE RISK
SCORE
1 Stability General operation with jib 3+6 Load Management Indicator System (LMIS) is supplied or maybe retrofitted for machines which 1+6
use Jib as one of the attachements. The LMIS provides visual indication and cut function when
loads programmed into LMIS are exceeded. Correct operating procedures are placed in the manual.
Level gauges inside cabin to show machine’s tilt angle. Pendulum is installed on boom to show
boom angle. Load charts inside cabin show maximum ground slope, boom angle and boom length.
Stability testing is done to EN1459 and/or AS1418.19 as applicable. JLG conducts operator and
service training courses to all customers.
2 Stability Ueven, soft or sloping round 2+6 LMIS provides an audible and visual alarm as well as function cutout as the limit of longitudinal 1+6
stability is approached. Level gauges inside cabin to show machine’s tilt angle. A permanent type
specification plate is permanently attached to the machine which shows the machine ratings.
Warning decals are placed on machine, and safe operating procedures are placed in the manual.
Load charts provided state allowable ground conditions. Outriggers fitted to 13m and 17m models
with more forward reach.
3 Structural failure General overload with jib 2+6 LMIS is used to prevent excessive loads being lifted by the machine with jib. Special access to 1+6
system is required to alter settings. Load charts provided and LMIS control panel indicate the
allowable capacities, boom angle and length. Plate on jib indicate the maximum capacities. Relief
valve are used to prevent excessive loads being lifted by the machine. Safe operating procedures are
placed in manual. Correct pressure settings are placed in the manual.
HAZARD HAZARD TYPE LOCATION/SCENARIO RISK CONTROL MEASURES TO REDUCE RISK NEW
NUMBER SCORE RISK
SCORE
1 Crushing, Operating unit in an area 3+6 Reflective warning stripes fitted to platform. Section 1.3 of operator’s manual contains instructions and 1+5
collision/striking. where obstacles, other guidelines for operating in these circumstances. Machine can only be driven in 1st gear with boom
people and plant may be under 10 degrees if platform is fitted to the hitch.
present.
2 Crushing, Underneath basket when 1+6 Section 1.3 of operator’s manual (under the heading “Pinch Points and Crush Hazards”) says to keep 1+6
collision/striking. basket is being lowered. clear from under boom and keep others away while operating.
3 Crushing, striking. Objects falling from 3+6 Kickboard around bottom of platform. Section 1.3 of operator’s manual (under the heading “Load 1+6
platform. Falling Hazard”) says not to suspend load from platform or supports, do not carry materials directly on
platform railing unless approved by JLG, and ensure the power tools are properly stowed and never left
hanging by their cord from the platform work area. Manual also says to keep others away while
operating and head gear is to be worn by ground personnel.
4 Crushing, striking. Sudden or unintended 2+6 Park brake has to be engaged and outriggers have to be deployed to enable platform. Operator is unable 1+6
movements. to drive machine from platform. Machine can only be driven in 1st gear with boom under 10 degrees if
platform is fitted to the hitch. Emergency stop switches are in place to halt movement in the case of an
emergency. Controls return to neutral when released. Enable (trigger) switch must be held down for
boom functions to be controlled from platform. Section 1.3 of operator’s manual says do not allow
personnel to operate the machine from the cab when personnel are in the platform except in an
emergency. Platform recognition sensor automatically enforce the interlocks in case the electric harness
to the platform is unplugged.
5 Cutting, stabbing, General operation. 1+2 Controls and other contact surfaces have no sharp edges. 1+1
puncturing.
6 Falling. General operation. 2+5 Lanyard attachment points provided for personnels in the platform. These are marked by decals. Solid 1+5
peripheral rail around entire platform. Gate as designed is self closing. Correct operating instructions
are in the manual.
7 Slipping, tripping. Slipping or tripping from 4+1 Platform floor is made from mesh steel, aiding grip and preventing water from building up on the floor. 1+1
within platform Section 1.3 of Operator’s manual says to keep platform floor free of debris, mud, oil, grease and other
slippery substances. Solid handrail to hold on to while operating the platform controls.
8 Excessive effort. General operation from 2+1 Controls are designed to operate with one hand and are either of joystick, toggle or button type. Non- 1+1
platform. assisted controls are minimized using electrical actuation. Where controls are mechanical in nature
operating effort is reduced as far as practicable.
9 Operating stress. General operation. 2+1 Control panels use pictures for functions, and switches, which control direction operate in that 1+1
direction. Plants are field tested for controllability and ease of use. Handrails are provided around
control station for support during motion. Warning decals are used to warn of incorrect operating
procedures.
Please Note: That the risk assessment compiled and attached is prepared in ADDITION
to many other activities which have been undertaken by JLG to ensure the safety of the
product.
These include:
• European CE design reviews are completed and independently verified for this model
machine.
• Extensive field testing of prototype units to ensure faults and hazards are identified
before manufacture is completed.
• JLG conduct an intensive Product Development Process to fully specify, design, risk
assessment and safety test and field prove the design. This process is outlined in our
proprietary IPD process - which can be viewed on request.
• JLG Industries (Australia) offer training and maintenance courses to any interested
companies. World class Operation, Safety, Illustrated Parts, Service and Maintenance
manuals are available from JLG Industries (Australia) for each model.
• JLG Industries (Australia) support industry safety for operations and maintenance
(being an EWPA member and an AS1418 & AS2550 Standards Association of
Australia committee member).