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. 3 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 4 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 5 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 6 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. 7 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 . 8 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 9 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 10 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. 11 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 12 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.