Reach Forklift Training Certification

For forklift operators of Far West Construction and SiteServ Panel & Design

Introduction

• To provide a training program based on trainee’s prior knowledge
• Train operators on types of vehicles used in our workplace
• Train operators on hazards associated with Forklift operation
• Course will utilize power point, discussion, and hands-on evaluation,
• Each operator will gain the knowledge and skills needed to do their job correctly and safely.

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To be covered in this course

• Safety concerns
• Certification requirements
• Operator commitment to Safety
• Types, features and physics

• Forklift operations
• Load handling
• Inspecting the vehicle
• Test your knowledge

First off; What is a Powered Industrial Truck?/Forklift

(PIF)

A mobile, power-driven vehicle used to carry, push, pull, lift or stack material.

Why is Certification so important and how often do you need to be certified

Having a certificate that says you have been trained means that you are compliant with OSHA regulations and are up to date on the latest safety issues. Don’t worry you only need to have a renewal every 3 years, and you will be issued with a wallet size card showing you have been trained

Why Train?

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• Keep in mind that improper operation is the most common cause of reach truck injuries and property damage. As operators, we must stay vigilant and avoid committing unsafe actions such as horseplay and stunt driving that can quickly lead to an incident.

• Just as dangerous is falling victim to complacency and letting your guard down after endless hours of incident-free operation.

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• Remember, all it takes is one moment of carelessness to cause a serious incident.

Safety Training Reduces:

• ACCIDENTS by teaching correct methods of avoiding accidents

• PRODUCT DAMAGE by teaching best load handling techniques

• EQUIPMENT DAMAGE by giving instruction in correct

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• operation and handling

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• LOST TIME by reducing accidents, and unplanned work stoppages

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Safety Training increases:

OPERATOR CONFIDENCE

• by showing correct methods of operation

PRODUCTIVITY

• by increasing operator skills

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EMPLOYEE MORALE

• by showing management’s concern for employee health

EQUIPMENT LIFE

• by indicating safety check lists that help spot problems early

Forklift fatalities, �1992-1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

Forklift fatalities by age group

Why?

Since a large percentage of accidents and fatalities were due to operator inexperience, OSHA mandated that operators must be trained and competent.

Certification Requirements

• Every forklift operator needs initial certification good for 3 years
• Refresher training is required every 3 years or sooner if the operator has been involved in an accident or near miss.
• The operator has been observed to be unsafe
• Evaluation indicated need for additional training
• Changes in the workplace affect safe forklift operation
• Or the operator is assigned to a different type of truck
• Being well trained can save your life or the life of a co-worker!

Training requirements

consists of a combination of:

• Formal instruction (power point presentation)
• Written exam (80% pass) (send copy to David at dasay@farwestconstruct.com)
• Practical Hands on training – schedule with mike or hyrum
• Evaluation – (certification card to be presented upon successful completion of performance evaluation)

Don’t worry

This Course only

Covers the Reach style

Forklift

Types, Features, and physics

In this section you will:

• Create familiarity with the basic types and functions of powered industrial trucks
• Develop and understanding of the information shown on a data plate
• Understand the critical truck logistics that affect safety
• Understand the forces that cause tip-overs, and the truck design considerations and safety ratings that help prevent them, including the “stability triangle.”

Basic Types and functions

Far West Construction and SiteServ both use a Reach Style forklift

Forklift functions however are very basic in nature, below is shown a typical forklift and all it’s various standard parts

To the left is a reach forklift – take a few minutes to take note of the various parts and the differences between the two.

Data plate

The load capacity data plate specifies the load each forklift can safely lift at different mast angles or when it is fitted with an attachment. The plate should display; the load capacity, lift height, load centre distance, brand and model number. The plate should also display:

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• Down rating of lifting capacity if a mast is fitted�• Down rating for specific attachments that are identified on the capacity plate

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Truck Logistics safety

• While reach trucks perform the same work and function of a traditional forklift, they are a completely different machine. One of the most important differences between a reach truck and a forklift is its stability characteristics.

• Reach trucks are designed with a narrow wheel base and have front wheels that extend forward of the mast. This allows the load’s “center of gravity,” commonly called the load center, to remain within the wheel base in most cases.

• A traditional forklift has front wheels behind the mast, requiring a large counterweight to balance the load.

• The center of gravity for a properly loaded reach truck falls between the front wheels and the center of the rear axle of the truck. This area is known as the “stability triangle.”

• Lifting a load or reaching out with a load will cause the center of gravity to shift forward; traveling sideways on an incline or turning can cause the center of gravity to turn sideways.

• When reaching with a load, the load center is extended beyond the front wheels. In this instance, the reach truck becomes a counterbalanced truck, but without the benefit of a large counterweight.

• When reaching, the truck depends solely on the weight of the vehicle to counterbalance the weight of the load. This is why a reach truck’s rated capacity is significantly reduced when the load is extended away from the truck.

• Should the center of gravity of the combined truck and load shift outside the stability triangle, the truck will turn over. This is why understanding your truck’s capacity and knowing how to read the data plate information is so important

A

B

C

Vehicle Center of

Gravity (Unloaded)

Center of Gravity

of Vehicle and

Maximum Load

(Theoretical)

Stability Triangle - Figure 1

Notes:

1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C. Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.

2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.

Load CG

Vertical

Stability

Line

(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical

Stability

Line

(Line of Action)

Truck CG

The vehicle is stable

This vehicle is unstable and

will continue to tip over

Stability Triangle - Figure 2

Driving the Truck safely

• The tight turning radius, combined with a narrow wheel base, can easily tip even an unloaded truck when traveling too fast.
• Operators should handle their vehicles at a safe rate of speed at all times. Operators should be able to stop or turn safely at any time the need should arise.
• Remember that your vehicle is not the only thing moving about your facility. Always follow your company’s specific traffic regulations to avoid pedestrians, other vehicles and equipment.
• Intersections and blind corners should always be treated with caution. Come to a complete stop and sound your horn before proceeding cautiously into the intersection; this will alert pedestrians and other vehicle operators of your presence.
• If your facility has mirrors mounted at intersections, be sure to use them before proceeding.
• When traveling behind other vehicles, maintain a safe following distance. A good rule of thumb is to maintain three truck-lengths distance between your truck and another.
• Use extra care when overtaking other vehicles and do not pass at intersections, blind spots or heavy traffic areas.

Navigating a slope

• When navigating an incline, travel at a slow, safe speed, making sure the truck is traveling straight up or down. Never travel at an angle on an incline.
• Avoid turning while on the incline. Make sure your vehicle has reached a flat surface before turning.
• When carrying a load up or down a slope, you should always face the load uphill. This improves the stability and helps the load from falling.
• When your truck is empty, however, most manufacturers recommend traveling with the forks facing downhill.
• Check your truck’s operator manual for the maximum grade on which your truck is designed to travel.

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It’s the little things that count

Truck/forklift operations

• Trucks shall not be driven up to anyone standing in front of a bench or other fixed object.
• Unauthorized personnel shall not be permitted to ride on powered industrial trucks.
• A safe place to ride shall be provided where riding of trucks is authorized.

Watch your head

• No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty.
• The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.

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Immobilize the forklift

• When a powered industrial truck is left unattended, load engaging means shall be fully lowered,
• controls shall be neutralized,
• power shall be shut off, and brakes set.
• Wheels shall be blocked if the truck is parked on an incline
• Never leave the Forklift unattended.

A powered industrial truck is unattended when the operator is 25 ft. or more away from the vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his view.

Overhead Guard

• An overhead guard shall be used as protection against falling objects. It should be noted that an overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc..., representative of the job application, but not to withstand the impact of a falling capacity load.

Load Backrest extension

• A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it falling rearward.

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• Only approved industrial trucks shall be used in hazardous locations.

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Pedestrian safety

• Reach trucks pose obvious hazards to pedestrians. Your co-workers may not be familiar with the tight turning radius or the wide-swinging rear end of your vehicle.
• Pedestrians may stand too close or approach the truck while in operation. As a reach truck operator, it is your responsibility to keep the safety of pedestrians in mind at all times.
• Always allow pedestrians the right away and make sure all personnel are a safe distance away from your truck before moving.
• Never drive your truck directly towards personnel, especially if they are standing next to solid objects such as machines, racks or walls. Pedestrians can be easily crushed when operators ignore this important rule.
• The pinch points created by the moving parts of the mast are also hazardous to pedestrians. Make sure the mast area stays clear of personnel.

Lifting personnel

• Besides material handling, reach trucks may also be used to lift personnel, but only when proper procedures are followed.
• To lift personnel, an approved lifting device with proper guardrails must be used. This platform must be secured to the truck with chains or pins to ensure it does not slide off the forks.
• The personnel on the platform must wear proper fall restraint devices and be sure to keep their hands away from the moving parts of the mast.
• Do not move the reach truck while the platform is raised. The platform must be lowered and the personnel must exit the platform before positioning the lift.
• Never use pallets, boards or bare forks as a lifting platform. This is extremely dangerous and has been the cause of needless injuries and fatalities.

Avoiding Tip-overs

• Never travel with a raised load. A raised load brings the center of gravity toward the front of the stability triangle and the added forces of turning and braking may lead to a tip-over.
• Also do not travel while lifting, lowering, reaching or retracting a load. Stop the truck before operating these controls and always ensure the reach mechanism is fully retracted before moving.
• Always remember that extending a load away from the truck moves the load center outside the wheel base, turning your reach truck into a counterbalanced truck and reducing it’s stability. Make sure you understand your truck’s reduced capacity before reaching.

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Lifting and moving loads safely

• Before lifting a load, make sure the forks are spread as wide as possible for the load being lifted. Lifting a wide pallet with the forks narrowly spaced can create an unstable load.
• Before lifting or moving a load, make sure the forks are completely under the load and that the load is seated against the back of the mast. Placing the load against the back of the mast helps keep the center of gravity inside the stability triangle.
• Be aware that loosely stacked or unstable loads can shift and fall, causing injury and property damage.
• Before moving a load make sure it is stable and centered on the pallet; some loads may need to be secured before moving.

Loading safety

• Collisions with fixed objects occur all too often. Inspect your path of travel before proceeding to ensure it is free of obstructions, holes, drop-offs or other hazards.
• Make sure you are familiar with all racks, walls, machinery or other objects which must be avoided.
• Don’t limit your inspection to eye level. Many reach truck collisions occur overhead when the mast or the load comes in contact with overhead obstructions such as pipes, sprinkler systems, overhead beams, lights or similar items.
• Stay alert for these items, especially when placing the load on a top rack. Maintain adequate clearance to avoid extensive property damage or injury.

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Pre-operation

Checklist

Pre-operational Inspection

• As with all powered industrial trucks, the reach truck operator must perform a pre-operational inspection before use. This will alert you to potential problems before you begin operation.
• While performing your inspection, verify that all covers, guards and safety devices are installed and functioning properly. Check around the vehicle for fluid leaks.
• Inspect the vehicle for signs of structural damage, such as bent or cracked forks.
• Check for any damage or excessive wear on the drive and load wheels.

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• The lights should be in good working order and all safety decals and warning labels in place and legible.
• Inspect the battery area for signs of leaks and be sure the gate is fastened securely in position.
• Test each control mechanism to ensure proper operation, including the lift, reach and lower functions, the directional controls for both forward and reverse, the steering controls, horn, and dead man pedal.
• The dead man pedal must remain pressed for the truck to operate and will stop when released.
• Should you find any problems during your inspection, remove the vehicle from service and report the situation to your supervisor.

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Congratulations on completion of this course

Click Here to take the Exam