Fundamentals of Counterbalanced Vehicles Section #1

FUNDAMENTALS OF COUNTERBALANCED VEHICLES SECTION #1

THE THREE (3) PRIMARY OBJECTIVES OF THIS COURSE ARE:

1 – To learn how forklift trucks operate. 2 – To become familiar with the rules of the road. 3 – To understand what can cause a forklift accident or to flip over.

OPERATING A FORKLIFT IS SERIOUS BUSINESS:

Innocent carelessness can cause accidents. Reckless operation will create dangerous situations. Operating a forklift is a big responsibility:

• To you • To your employer • To your fellow workers • To your family and the families of fellow workers

Accidents and injuries CAN BE AVOIDED!!

PROFESSIONAL FORKLIFT OPERATORS ARE:

Responsible On Time Rested and Alert Knowledgeable of company rules, operations and vehicles Wear required protective clothing and equipment Use safety equipment (i.e. seat restraint systems) Keeps vehicle under control at all times

Forklifts are much heavier than cars; a car can weight about 3000 pounds while a small forklift can weight approximately 5000 pounds. Remember the 2 to 1 rule: A forklift will weight approximately two times its lifting capacity.

2 Component Terminology

TIRE TYPES

Cushion / Solid Tires

Operate effectively on smooth, dry surfaces which do not distort under heavy loads. The solid compound design minimizes damage caused by debris. Cushion tired vehicles should NOT be used on non-improved surfaces

Pneumatic / Air Filled Tires

Operate best on uneven or broken surfaces, or where additional traction is required. The air filled design provides for a smooth resilient ride. Pneumatic tired vehicles are considered more versatile because of their ability to work on a wide range of surface types.

SECTION #1 COURSE REVIEW

1. Which is NOT one of the three primary objectives of this course?

a. To learn how forklift trucks operate b. To learn the forklift “Rules of the Road’. c. To learn how to change the engine oil and filter. d. To learn how to perform the pre-shift inspection process.

2. OSHA requires forklift operators to be licensed.

a. True b. False

3. OSHA requires forklift operators to be trained.

a. True b. False

4. OSHA requires certification every:

a. 4 years b. 2 years c. 3 years d. Every year

5. What are the two types of tires used on forklifts?

a. Cushion and Foam filled b. Solid and Vinyl c. Air Filled Profile and Pneumatic d. Cushion and Pneumatic

6. Cushion or Solid tires operate best under what conditions?

a. wet, broken pavement b. uneven, soft under footing c. dry, smooth surfaces d. railroad crossings

7. Where is the steer axle located?

a. at the top of the carriage b. at the rear of the vehicle c. at the center of gravity d. at the front of the vehicle

8. What do you receive after the completion of this course?

a. a drivers license b. an operators permit / safety certification c. a forklift license d. a drivers permit

9. Where is the drive wheel located on a SIT DOWN forklift?

a. at the top of the bottom b. at the front of the vehicle c. at the rear of the vehicle d. at the front of the forks

10. How much more does a forklift weigh than its load?

a. 10 Times b. 6 Times c. 2 Times d. 5 Times

11. Which is NOT a characteristic of a professional operator?

a. Responsible b. Wears required protective clothing c. Capable of unloading a trailer or railcar in 15 minutes d. Wears the seat belt at all times

12. All forklifts are required to carry labels warning that improper operation can result in injury or DEATH .

a. True b. False

FUNDAMENTALS OF COUNTERBALANCED VEHICLES SECTION #2

The term “Counterbalanced ” refers to the fact that the load is carried at the front of the vehicle and is offset or “counterbalanced ” by the weight of the vehicle located at the Pivot Point or the drive tires .

Because of counterbalancing which must take place, the gross vehicle weight without a load will always exceed the vehicle’s rated lifting capacity and will normally approach twice the vehicle’s rated capacity. Example: a 5,000 pound capacity unit will weigh around 10,000 pounds.

The stability of a sit-down rider type forklift is based on the “Principle of Balance ”. The balance or pivot points of the truck are the Drive Wheels.

The Pivot Point on a Stand Up, Order Picker and Pallet Jack are the Load Wheels

Balancing In All Directions

The Center of Gravity of any object is the single point about which the object is balanced in all directions. Every object has a Center of Gravity When the lift truck picks up a load, the truck and the load has a new combined center of gravity. The stability of the lift truck is determined by the location of its center of gravity. Think of riding a tricycle around a corner. If you lean forward you will overturn as you moved you CG to the narrowest portion of the tricycle. If you lean back applying your CG over the two rear wheels, you are less likely to tip as you moved your CG to the widest portion of the tricycle.

The lift truck has moving parts and therefore has a CG that moves. The CG moves forward and back as the upright is tilted Forward and Back .

The CG moves up and down as the upright moves Up and Down.

The weight distribution on the steer and drive axles will vary depending on the load weight and position.

The “CENTER OF GRAVITY ”” is the location within and object around which all weight is evenly distributed.

The “Vehicular Center of Gravity” is located within the “ STABILITY TRIANGLE” which is an area contained inside a set of straight lines drawn between the two drive tires and the center point of the steer axle .

The “ CENTER of GRAVITY ” will move as a result of two factors:

STATIC FORCES

Load Characteristics Lift Height Amount of Tilt Tire Condition

DYNAMIC FORCES

Acceleration Braking Travel Speeds Surface condition

As long as the “Center of Gravity” remains within the confines of the Stability Triangle, the vehicle will remain counterbalanced.

When the Center of Gravity extends beyond the Stability Triangle, a condition of “Imbalance ” occurs. This condition will result in one or more of the following situations:

Loss of Steering Unstable loads Potential tip over Loss of Traction

All forklifts regardless of make, model or year of manufacture are required to display certain performance data in a recognizable form somewhere on the vehicle. This information is typically summarized on the “ Data Plate ”.

The information required to be displayed include such things as:

Machine Working Capacity Gross Vehicle Weight Load Center Maximum Lift Height Attachment Identification and Serial Number Capacity Rating with Attachment

The operating capabilities of forklift will change if an attachment is added to the vehicle. Different attachments will have a greater of lesser impact on capacity and only the manufacturer of the individual attachment can give the exact operating characteristics and the effects which it will have on vehicle performance. Attachments will affect lifting capacity, load center and in general how the forklift will operate, you MUST make yourself familiar with the attachment and how it operates. You must practice how the unit handles in a safe area.

If the forklift which you are operating has an attachment make sure that the DATA PLATE has the proper updated information.

Attachments must only be used for the intended purpose, DEATH or injury can result from inappropriate use.

SECTION #2 COURSE REVIEW

1. On what principle is the stability of a forklift based on? a. Gravity Principle b. Stability Principle c. Principle of Balance d. Principle of rear end Swing

2. Where are the Balance / Pivot Points on a sit down forklift? a. Forks b. Steer Tires c. Drive Tires d. Counterweight

3. Where are the Balance / Pivot Points on a Stand Up forklift? a. Forks b. Steer Tires c. Load Wheels d. Overhead Guard

4. When unloaded, about 60% of forklifts weight is on which axle? a. Steer Axle b. Drive Axle

5. When loaded to capacity and the load raised to maximum lift height, what percentage of the weight remains on the steer axle? a. 60% b. 50% c. 10% d. 25%

6. What is the imaginary point in the load around which all the weight is evenly distributed. a. Stability Triangle b. Center of Gravity c. Principle of Balance d. Pivot Point

7. The Center of Gravity always stays in the same place. a. True b. False

8. What two factors will cause a forklift to tip over? a. Static and Lateral c. Static and Dynamic b. Dynamic and Acceleration d. Dynamic and Vertical

9. The vehicles center of gravity moves forward as the mast is tilted forward, and moves back as the mast is tilted back. a. True b. False

10. The vehicles center of gravity moves up as the mast is raised, and moves down as the mast is lowered. a. True b. False

11. The vehicles center of gravity must remain inside the Stability Triangle to prevent the forklift from tipping over. a. True b. False

12. Which is NOT one of the three supporting points of the Stability Triangle? a. Center point of the steer axle. b. Left drive tire. c. Center point of the drive axle. d. Right drive axle.

13. What happens when the vehicles center of gravity moves outside the Stability Triangle?

a. A condition of imbalance occurs b. The steer wheels can be lifted off the ground. c. Steering control is lost. d. All of the above.

14. Fill in the blanks. a. What is the forklift weight? ______b. What is the load center? ______c. What is the forklift capacity? ______d. What is the maximum lift height? ______

15. The addition of an attachment does NOT affect the vehicles lifting capacity.

a. True b. False

FUNDAMENTALS OF COUNTERBALANCED VEHICLES SECTION #3

CAL / OSHA 3650 (t) (7) Drivers shall check the vehicle at the beginning of each shift, and if it is found to be unsafe, the matter shall be reported immediately to a foreman or mechanic, and the vehicle shall not be put in service again until it has been made safe. Attention shall be given to the proper functioning tires, horn, lights, battery, controller, brakes, steering mechanism, cooling system, and the lift system for forklifts (forks, chains, cable, and limit switches).

FED / OSHA 1910.178 (q) (7) Industrial trucks shall be examined before being in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used around the clock, they shall be examined after each shift. Defects when found shall be reported and corrected.

Walk Around Inspection Operational Inspection

1. Forks / Locking Pins 1. Engine 2. Chains / Hoses 2. Mast, Lift & Tilt Cylinder, Side Shifter 3. Leaks 3. Levers 4. Head / Tail lights 4. Horn 5. Seat Belts 5. Steering 6. Load Back Rest 6. Forward / Reverse (Transmission) 7. Tires 7. Service / Parking Brake 8. Battery 8. Pedals 9. Fluid Levels 9. Back up alarm (if installed)

THE DO’S AND THE DON’TS OF FORKLIFT OPERATION

Intended Purposes Only Designated Areas Clear View of Travel Approved Aisles Watch out for others

No Riders Maintain Distance Obey Signs Use Horn Check Mirrors Lookout for Hazards Eliminate the Condition Call Attention to hazards

Use the HORN around PEDESTRIANS , other VEHICLES , DOORWAYS and at INTERSECTIONS.

Always travel in reverse if the load obstructs your view. Riders are NEVER allowed.

TRAVELING ON GRADES

Without a load:

Back up the grade Forward up the grade

With a load :

Forward up the grade Reverse down the grade

NEVER TURN WHILE YOU ARE TRAVELING ON A RAMP OR ANY SLOPED SURFACE.

INCHING INTO LOADS

Move slowly into position

Engage the load squarely DO NOT slam the carriage into the load NO LIFTING while traveling Raise load 6 – 8 inches Assess load stability

LIFTING LOADS

Carefully tilt the mast back

Reassess load stability Check for rear obstacles, you must always look back FIRST before backing up.

TRAVELING WITH A LOAD

Maintain Control Center the load on the forks Look in the travel direction!

Slow down as required Watch for obstacles and OTHERS! Utilize controlled stops 17

WHEN MAKING TURNS

APPROACH THE TURN SLOWLY !! Sound your horn Stay close to the inside corner

REAR WHEEL STEER

Advantage : Improved Maneuverability

Disadvantage: Rear end swing Loss load Tip over

Working in Trailers and Railcars Always chock the wheels or anchor to the dock!!

Unattached trailers may require a support jack. Inspect dock plate position and condition. Inspect flooring before entering.

Pedestrians and Forklifts

Pedestrians MUST ALWAYS be given the RIGHT of WAY . You must evaluate where your pedestrians and forklifts meet, and understand the danger at these locations. Everyone must do their part in avoiding accidents, not just the forklift operator.

When forklifts and pedestrians meet, the pedestrian ALWAYS loses.

NEVER back up without looking FIRST!!!!!

Companies should also make ALL employees aware of the danger of a moving forklift. Injuries and accidents can be reduced if everyone does their part.

ALWAYS stop and sound your horn at blind corners.

LIFTING PERSONNEL

Never use a pallet or the bare forks to lift personnel, OSHA regulations prohibit this act but most of all, IT’S STUPID . If you survive the fall, how much damage can you do to yourself should you fall from such heights?

Always use an approved Safety platform The operator must be in the drivers’ seat while workers are on the platform. The operator must be in the drivers’ seat while raising and lowering the platform. The forklift must not travel from point to point with the platform greater that 4 feet while the platform is occupied. When necessary, an occupied platform can be moved as long as the forklift is traveling at a very low speed .

Seat Restraints / Seat Belts

Forklift manufactures recommend that the seat belt must be worn whenever you operate the forklift.

National Institute for Occupational Safety and Health (NIOSH) June 2001, forklifts strike pedestrians everyday, resulting in 100 deaths and over 20,000 injuries annually in the United States. Approximately every 3 days, someone in the US is killed in a forklift related accident. Each year, an additional 10 – 20,000 injury related to forklift accidents are reported. The costs incurred due to forklift accidents are estimated to be over a hundred million dollars.

The Bureau of Labor Statistics reports that in 2006, 81 people were killed by a forklift accident.

If your forklift fell off a loading dock and you did not have a seat belt on, would you survive this fall? A forklift weighing approximately 10,000 pounds would crush you and you would have little chance of survival.

Seat belt usage becomes a burden when you are constantly getting on and off as some jobs require. This feeling of burden can cost you your life.

PARKING PROCEDURES

ATTENDED

When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement. It is NOT required that the power be shut off.

UNATTENDED

When the operator is 25 ft . or more away from the vehicle even if it remains in his view, or whenever the operator leaves the vehicle and it is not in his view. When a powered industrial truck is left unattended:

Do not park on a grade, unless wheels are blocked.

Park in authorized areas only. Park a safe distance from fire aisles, stairways or fire equipment. Do not block traffic.

Fully engage the parking brake.

Lower the load engaging means (lifting mechanism) fully.

Neutralize the controls.

Set the direction lever in neutral, and lock the mechanism (if available).

Tilt the mast forward slightly and lower the forks to the floor until the fork tips touch the floor.

If the lift mechanism is disabled, and the forks cannot be lowered to the floor, attach a warning tag to the tip of the fork and position the forks away from pedestrians. Do not allow anyone to stand or pass under the forks.

Turn the key to OFF, and stop the engine. Remove the key.

Get off the forklift without jumping.

SECTION #3 COURSE REVIEW

1. OSHA requires a detailed walk around inspection prior to the beginning of each work shift.

a. True b. False

2. When should you use the horn?

a. Approaching intersections b. Approaching pedestrians c. Approaching other vehicles d. Approaching doorways e. All of the above

3. What should you do if a load restricts your forward view?

a. Slow down and proceed carefully b. Get someone else to move the load c. Operate the vehicle in reverse with the load trailing d. Sound the horn continuously

4. What are the proper techniques to use during a tip over?

a. Hold tight, lift feet, lean toward the fall, don’t jump b. Release steer wheel, brace feet, jump from the vehicle c. Hold tight, brace feet, lean away, don’t jump d. Release steer wheel, lift feet, jump from vehicle

5. The driver should never make a turn when the load is raised MORE than 6-8 inches above the ground.

a. True b. False

6. Changing the load height affects the vehicles stability.

a. True b. False

7. When are riders allowed?

a. When you are training b. When the supervisor allows it c. When no one is watching d. Never

8. The seatbelt should be used when:

a. Your supervisor is watching b. When you drive fast c. Whenever you drive d. When the floor is wet

9. When traveling on grades turning is allowed:

a. When you are driving very slowly b. You have someone helping you c. Your load is very low to the ground d. Never

10. Never operate a forklift in and out of a trailer unless the wheels are chocked or anchored to the dock.

a. True b. False

11. Whose responsibility is it that the truck is anchored or chocked?

a. The truck driver b. The supervisor c. The forklift operator d. The dispatcher

12. Who is responsible for checking the floor of the trailer?

a. The truck driver b. The forklift operator c. The supervisor d. The owner of the trailer

13. When do pedestrians have the right of way?

a. At intersections b. Near doorways c. Always d. At break or lunch time

14. What are the two types of parking described in this course?

a. Safe and Unsafe b. Attended and Unattended c. Attended Unsafe d. Unattended Safe

15. This type of parking requires the power to be shut off .

a. Unsafe b. Unattended c. Safe Attended d. Attended

16. When must you shut off the forklift?

a. When you go to lunch b. When you go to the bathroom c. You are more then 25 feet away d. All of the above

24 PRINCIPLES OF INTERNAL COMBUSTION SECTION #4

The most widely used forklifts have an internal combustion engine powered by fuels that include gas, liquid petroleum, diesel fuel, and compressed natural gas. Forklifts with internal combustion engines can be quickly refueled but require regular maintenance checks for leaks of fuel or oil, worn parts requiring replacement, and to keep systems working properly.

Potential Hazards:

Exposures to engine exhaust containing carbon monoxide. If the engine is not properly combusting fuel, the exhaust may contain high levels of carbon monoxide.

Exposure to spills and leaks of fuel and oil.

Requirements and Recommended Practices:

Do not operate in a poorly ventilated area where fumes can concentrate.

Carefully wash away or completely evaporate spillage of oil or fuel.

As part of the pre-operation inspection, check all fluid levels, including oil, water, and hydraulic.

Check for leaks from the hydraulic cylinder, the battery, and the fuel system.

Check the exhaust color for incomplete combustion. For example, black smoke may be an indication of incomplete combustion.

Check and report unusual noises or excessive vibration.

You must use Personal Protective Equipment (PPE) when changing out a tank.

Liquid Petroleum Gas (LPG) is a commonly used fuel for forklifts. It is a safe fuel when handled properly. When handled improperly, it can cause serious injury or death.

Potential Hazards

LPG vapor is heavier than air and will seek the lowest lying area. If not adequately dissipated, it will collect in pockets and possibly ignite when exposed to a heat source.

LPG is extremely flammable.

LPG is extremely cold when exposed to the atmosphere. If your skin is exposed to LPG, you can get frostbite.

Requirements and Recommended Practices:

Do not refuel LPG-powered trucks in confined areas where LPG vapors could collect if a leak occurs.

Do not leave LPG-powered trucks near heat sources, stairways, exits, or other egress areas.

When parking LPG-powered trucks for a long period of time, turn the service valve off .

Only trained and authorized personnel should replace LPG containers .

Follow proper procedures for storing and handling liquid petroleum gas.

All propane tanks must be shut off overnight. Always follow company policy. Always shut off the engine. Do not smoke will fueling and while driving the forklift.

26 SECTION #4 COURSE REVIEW

1. Liquid petroleum gas (LPG) is heavier than air.

a. True b. False

2. When refueling you should ______.

a. follow company policy b. never smoke c. shut off the engine d. all of the above

3. Smoking is allowed on a forklift when ______.

a. you are outside b. there are no leaks c. Never d. the company allows it

4. When changing a propane tank, protective equipment should be worn.

a. True b. False

5. Never attempt to refill a propane tank unless you have been specifically trained.

a. True b. False

6. Why should you never place your hand on a frosted LP tank nozzle?

a. The feeling is so good you won’t let go. b. The nozzle will crack c. Your skin could be severely burned d. The tank may explode

7. Propane tanks should be shut off overnight?

a. True b. False c. Not important

PRINCIPLES OF ELECTRIC POWER SECTION #5

Electric powered forklifts utilize three voltage types:

24 Volts 36 Volts 48 Volts

The battery size will affect:

Vehicle lifting capacity Vehicle stability Charge life Work cycle duration

1100 lbs 1600 lbs

The battery is part of the counterbalance system . Check your data plate for the proper size required, there is also a minimum and a maximum battery weight that will be listed.

An electric forklift is designed to operate for one shift and then be charged on the next shift or overnight. Some employers routinely change batteries instead of charging them in the vehicle. The discharged battery is removed from the forklift and a charged battery is installed in its place.

Only trained personnel should charge and change batteries in electric forklifts . In addition to training in battery changing and charging procedures, employees should be trained on emergency procedures in the event of an acid splash, including how to use eyewash and shower facilities. Personal Protective Equipment MUST be worn when servicing any battery.

Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries.

29 SECTION #5 COURSE REVIEW

1. The primary voltage used are:

a. 12, 24 and 36 volt b. 24, 48 and 72 volt c. 24, 36 and 48 volt d. 36, 48 and 72 volt

2. Personal protective equipment should be worn at all times when servicing a battery.

a. True b. False

3. Before charging a battery you must be trained.

a. True b. False

4. The battery is NOT part of the counterbalance system.

a. True b. False

5. The data plate on an electric unit has information about the allowed battery size.

a. True b. False

6. When is smoking allowed on electric forklifts?

a. When you are outside. b. When there is good air circulation inside. c. Never d. If the company allows it.

30 NARROW AISLE EQUIPMENT SECTION #6

THE THREE TYPES OF NARROW AISLE TRUCKS ARE:

• Stand-up Reach Truck, Single and Double reach • Orderpicker • Walkie and Walkie Rider Pallet Jack

Become familiar with the data plate for your vehicle, they have different information from the propane type forklift.

As with all units, all safety warning stickers must be on the unit.

Stand-up Unit

Stand-up units turn very sharp, they can OVERTURN very easily. Since manufactures differ in operation, ALWAYS check the operators’ manual for proper operation. NEVER TRAVEL OR TURN with the blades extended as your center of gravity is now out further, OVERTURN risk is now very high.

31 Order Picker

These units must NEVER BE USED AS AN ELEVATOR or for pulling pallets from the rack. You place yourself in danger as you face the rack while moving forward. They are only to work parallel with the rack.

This unit has an Emergency Lowering Control Valve , it is located in the chassis / tractor portion of the vehicle. To lower the platform in a emergency situation, push the knob down and turn 180 degrees counter clockwise. The knob will pop out and the platform will lower to the ground at a controlled speed.

You MUST wear a safety harness or belt before raising the platform and it must be secured to the vehicle. Never exceed the vehicles rated capacity. Make sure the load is centered and secured, always use the pallet clamp. Do not climb into the rack. Slowly approach pick location. Raise or lower the platform to where you are safe, comfortable and close enough to the rack beam so there is no danger of falling through any opening between the rack and the platform. Stay with the compartment when picking material. HOLD ON when rising or lowering platform.

32 WALKIE / WALKIE RIDER

PLUGGING

Plugging is an effective way of slowing travel speed and changing direction during operational maneuvering. It may also be used to stop the vehicle. It will NOT stop as quickly as braking; it is an alternative which will not harm the vehicle. Read and understand the operators’ manual before operating equipment. IN AN EMERGENCY, always use the brake.

Allow ample distance to stop. Make sure you are familiar and practice this technique. Practice in an open area. All equipment may be different from others, make sure you read the operators manual.

SECTION #6 COURSE REVIEW

1. On a Stand-up Reach unit, it is okay to drive with the blades extended______

a. When you do not have a heavy load. b. When the load is not very high off the ground. c. When your supervisor lets you d. It is never allowed

2. On an Order Picker , it is okay to have a passenger as long as they are also harnessed to the unit.

a. True b. False

3. It is okay to pull a pallet off the rack with an Order Picker unit?

a. True b. False

4. On an electric pallet jack it is okay to operate without a working horn.

a. True b. False

5. Plugging is an easy and safe way to stop in an emergency situation.

a. True b. False

6. When is it okay to operate a Narrow Aisle unit without a horn?

a. When everyone is very quite b. When you are not going very far c. It is never allowed d. When your supervisor allows it

7. Operators manuals are not necessary to have on each unit because all Reach trucks operate the same.

a. True b. False