Section 1 Forklift Training Manual

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

LESSON 1 of 4 Introduction & Overview to Forklifts

Lesson 1 • Page 3

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Welcome to SummerWinds Forklift Certification Training Program, Safety Training Manual The manual contains 4 lessons that are part of our Safety Series. Completion of the 4 lessons, acknowledgment of all forklift safety rules of operation, completion of a practical exam, and successful completion of the written final exam, are required before you are certified by SummerWinds to operate a forklift without a qualified operator in supervision. Review the material in this program carefully , as you will be required to demonstrate competency both in the practical and written exam , as well as in observation at any time operating a forklift. Forklift training and forklift safety rules are designed for the purpose of maintaining safe practices when operating this complicated and dangerous machinery. Understanding and following safety rules with awareness and acknowledgement of the importance of operating the vehicles safely will ensure safe operation. Lesson 1 is designed to help the operator gain an understanding of forklift engineering principles enabling operators to make good judgements, based upon this information.Without this in-depth knowledge of the machinery you are operating, you cannot fully understand why certain safety rules apply, and you may be more likely to violate safety rules.

Lesson 1 • Page 4

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

OVERHEAD GUARD (CHG)

COUNTER WEIGHT

MAST ASSV.

Lift Truck Components The components of a lift truck are typically similar across various types of trucks, here is a diagram of typical lift truck components.

LOAD BACKREST (LBR)

You will need to learn and be able to identify lift truck

CARRIAGE

components to safely operate a lift truck and successfully pass this program.

STEER TIRE

STEER AXLE

DRIVE TIRE

TILT CYL.

DRIVE AXLE

FORKS

Lesson 1 • Page 5

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Principles of a Forklift Equipment

A professional forklift operator knows the equipment , follows the safety rules , and prevents property damage by operating a forklift safely and efficiently . Safe operation requires more than just being a driver. Knowledge of the following essential engineering fundamentals of forklift equipment is needed to make correct decisions while operating the equipment. Odd size loads, heavy materials and unusual situation can then be handled safety as your decision-making ability is enhanced with knowledge .

Principles utilized by forklifts , such as levers, fulcrum principles, load centers, stability triangle etc. are reviewed in detail in the following sections.

As a forklift equipment operator, it is important to understand forklift safety rules, and recognize their adherence to these rules as well as enforcement, is vital to safe operation. You will as they face a wide variety of situations requiring immediate decisions on a daily basis , understanding these rules will aid in your decision making.

Video Here

Lesson 1 • Page 6

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Lever Principles Levers are used as it applies to forklifts with the following illustration.

Levers are used every day: The principle of levers enables a balance of load and effort across a fulcrum point.

A simple way to see this principle is when changing a flat tire, the car is jacked up and a small amount of force is exerted over a long distance to make this possible.The jack handle moves a large distance, but the car moves upward only a short distance. A small amount of force is used to push the jack handle down, but a large amount of force raises the car.

Every time the jack handle is moved down 25 inches, the car raises only one hundredth as far, but with 100 times as much force.

Lesson 1 • Page 7

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

A 20-pound force moves 25 inches and this moves 2,000-pound car a quarter of an inch.That's one application of the lever principle.

heavy for the counter weight, then it will pivot at the fulcrum (the forklift will tip over forwards). Careful consideration must be taken to get the load as near to the fulcrum as possible as any gap here will be exaggerated and the forklift will not be able to pick up as much.

A forklift raises heavy loads using this principle. However, it is the hydraulic system that applies the force to lift the loads. It is important to understand the lever principle before beginning to discuss load centers, gravity and the other fundamentals of the forklift. Note: The forklift can raise the heavy loads using levers, provided the load is offset by the counterweight of the forklift. The forklift is basically like a child's see-saw , the load that is picked up is counterbalanced by a counter weight at the other side. If the load is too

To learn more about levers, click here to visit this website: https://letstalkscience.ca/educational-resources/backgrounders/simple machines-levers

The fulcrum principle is principle two detailed following.

Lesson 1 • Page 8

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Fulcrum Principles

The forklift operates according to the fulcrum principle - weight is balanced by a fulcrum as seen in the lever principle. The forklift has a counterweight which is composed of the engine and heavy metal parts on the rear of the vehicle. The counter weight is the load which is picked up by the forks and this load is balanced by the counterweight on the rear of the forklift.

Where is the fulcrum?

The fulcrum becomes the front tires which is the point where the load is balanced by the counterweight of the vehicle.

Lesson 1 • Page 9

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Data Plate A data plate is installed on the forklift equipment by the manufacturer. This data plate gives the serial and model numbers which are very helpful when ordering parts or servicing the forklift.The data plate also provides information as to the amount of weight that can be safely lifted with the weight of the forklift.This data plate usually shows three different weights that can be safely lifted as it relates to the load centers. Below is a sample data plate and typical information that may be provided. Each manufacturer data plate may differ.

2. Serial Number: The serial number is most important for technician communication.The model serial number combination will allow techs to match parts and understand your particular machine before they arrive. 3. Mast Type :There are various types of masts including 2-stage, 3-stage, and 4-stage that vary depending on your specific forklift model and selected specifications to meet your needs. 4. Fuel Type: Shows whether the machine is powered by electricity (E), liquid propane (LP), diesel (DS), gasoline (G), or compressed natural gas (CNG). 5. Back Tilt: This number represents the degrees back the mast can tilt to help keep loads on the forks securely (6° in this example). 6. Attachments: This lets you know what have been added to the forklift to give you a clear indication of its capabilities. In the pictured data plate, we see the side-shifter is in place, meaning the carriage can be shifted left or right. 7. Front Tread: The front tread of a forklift is equivalent to its overall width. It’s like a forklift’s footprint and helps operators understand the space a forklift will take up. 8. Tire Size: Size and tire type truck was built to use.“Solid” indicates a solid pneumatic tire, Cushion type will state “Smooth” or “Treaded”. Always replace with the same size and type of tire. 9. Truck Weight: The overall weight of the truck. 10.Forklift Diagram: Offers several data points that are important for understanding the forklift function.This helps you understand what the forklift can lift and how it maneuvers in your workspace. a. The horizontal load center b. The vertical load center c. The maximum fork height - The maximum distance the forks can be offset from the forklift’s centerline 11.Only trained operators who have read and understood the operator’s manual should operate forklifts.

1. Model number: The model number of your forklift is extremely important for relaying information to your dealers about repair or technical assistance, understanding your lift capacity, and looking up useful information on the forklift website and shopping for parts. The forklift model number contains a lot of useful information.

Lesson 1 • Page 10

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Load Centers The data plate may read: MAXIMUM LIFTING CAPACITY: 500 lb. at a 24 inch LC at 104 inches.What does it mean - LC, 104 inches? LC means load center and 104 inches indicates how high a load can be safely raised. Most data plates provide more than one safe lifting weight.The reason for this is that the operator will probably be lifting many odd sized and shaped loads. Therefore, understanding how these odd size loads can affect the safe lifting capacity of the forklift is an important part of safe operating practices. The data plate information example below shows how the operator can safely lift a 5,000 lb. load utilizing a 24-inch load center which can be raised to the maximum height of the forklift. In this case it is 10 inches. The data plate also shows how to safely at 4,000 lb. at a 36-inch LC at 104 inches and 3,000 lb. at a 42-inch LC at 104 inches.

SERIAL# 12345678 MODEL#XYZ MAXIMUM LIFT1NG CAPACITIES: 1. 5,000 LB at 24" LC - 104" 2. 4,000 LB at 36” LC – 104” 3. 3,000 LB at 42” LC – 104”

The load center of a fork lift is the distance from the face of the forks to the load’s center of gravity.

24”

The load center is the distance measured from the center of the load to the vertical face of the forks. A standard size pallet size is 48 x 48 inches. Measure from the center of the load to the vertical face of the forks and obtain a 24” measurement. Therefore, an evenly distributed load on a 48”x48” pallet would be considered 24”.

As the load center increases, the lifting capacity of the vehicle decreases.

If the data plate indicates the maximum safe lifting capacity of 5,000 lbs. at 24” load center (LC) then the operator can safely lift 5,000 lbs. of an evenly distributed load measuring 24 inches.This 5,000lb load can safely be lifted to the maximum height of the forklift. Ensure the cargo is using load center as despite the weight an unevenly distributed cargo load can cause instability.

Lesson 1 • Page 11

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Center of Gravity Another core principle that affects safe lifting capacity is the center of gravity. As a load is raised, the center of gravity shifts away from the truck and towards the forks. The forklift has been engineered for this.Therefore, the maximum safe lifting capacity has been calculated using this shifted center of gravity. However, when equipment operators exceed the maximum safe lifting capacity and try to lift excessive loads, the forklift's engineered safety limit can be exceeded, resulting in an accident, injury or equipment damage.

Overloading a forklift puts stress and strain on other parts of the equipment such as the hydraulic system, steering system, and other metal parts. It is very possible that the truck would overturn. Tilting a load or loading improperly can also adversely affect the center of gravity.

Tilt load only when necessary for positioning loads onto racks or other material-handling equipment.

Lesson 1 • Page 12

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Stability Triangle Ensure the cargo is using load center as despite the weight an unevenly distributed cargo load can cause instability. The truck's center of gravity will continue to shift toward the direction of travel until the brakes stop the momentum of the truck. Hopefully, they both stop at the same time. When the forklift is at maximum capacity and as the center of gravity shifts even further toward the fulcrum, it is easy to see how a forklift can be overturned. A narrow wheel base and a high center of gravity tells the operator immediately that the forklift can be easily overturned. A forklift is NOT engineered to make fast, sharp turns. Several things happen to a forklift turning a corner.The momentum of the truck is trying to keep it moving in a straight line and the steering wheel has to counteract the force of momentum exerted on it by the floor or road surface. The lesson to be learned is very simple; slow down and turn slowly! Another reason for making slow turns has to do with the steering and the core stability points of a forklift. These points are part of what is called the “stability triangle.” Since forklifts do not have shock absorbers , engineers have made a three-point suspension system.The rear end is supported by a pivot pin in the center of the axle which allows for the up and down movement of the rear tires when going over bumps and uneven surfaces.This, combined with the two front wheels, makes up the three point system known as the stability triangle .

Understanding the stability triangle and maintaining stability prevents tip-over accidents.

Most counterbalanced forklifts have a three-point suspension system, meaning that the truck is supported at the two front wheels and the center of the steer axle. If you imagine all three points connected into a triangle, this is the forklift’s stability triangle. When the lift truck’s center of gravity falls within the perimeter of this triangle, a load is safe to carry. The Stability Triangle forms by connecting three points: the two front wheels and the center point of the rear axle. For the forklift to remain balanced, the forklift’s center of gravity must stay within the triangle.

If there is no load present, the lift truck’s center of gravity is firmly inside the triangle. Because there is no load, the center of gravity is nearly in the center of the forklift’s counterbalance. As you add weight to the forks, the center of gravity shifts closer to the front axle. Once the center of gravity reaches the front axle, it is at the edge of the stability triangle, and the load becomes unsafe to carry.

Lesson 1 • Page 13

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Control Valve - Starts and stops the direction of fluid and controls where the fluid moves using spools. Without a control valve, forklift hydraulic pressure would be useless. Relief Valve - Protects the hydraulic system from too much pressure.This part is considered a critical safety component of hydraulic forklift hydraulic pressure. Return Line - Returns the fluid to the tank.The return line completes the forklift hydraulics cycle. The types of fluids used in hydraulic forklifts include water-based fluids, petroleum-based fluids, and synthetic fluids. Note: An important thing to remember is that forklift hydraulic systems use small forces on pistons, which exert larger forces to produce a very effective method of

VIDEO HERE

Hydraulics Hydraulic presses put pressure on a small amount of liquid to create a large amount of power. With a forklift, this is lifting power.

The forklift hydraulic system pistons raise the forks and keep them lifted until the hydraulic pressure is released by the operator. In most forklifts, the tank is integrated into the frame of the vehicle.That’s what holds the forklift hydraulic fluid. In addition the hydraulic system includes: The Pump - Produces a constant flow of hydraulic fluid to supply the control valve. Most forklifts use a gear-type pump.The pump consists of a pair of rotating gears that push the fluid in the opposite direction of the rotation.

lifting, moving and shifting heavy loads. Remember that hydraulic systems are under pressure.Worn or cracked hoses can rupture, causing a hydraulic failure. Hydraulic leaks must be corrected as they indicate worn seals, pistons, or other mechanical failures. Report hydraulic deficiencies before they cause accidents. If you wish to learn more about how hydraulics work visit website: www.certifyme.net/osha-blog/forklift hydraulic-system-works/

Lesson 1 • Page 14

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Review of Truck Types The following gallery is a representative sample of the types of trucks utilizing the principles of operation reviewed in this training. Each truck type is use with various functions and tasks fitting the best truck type to the job requirements.

STAND UP RIDER

SIT DOWN RIDER - THREE WHEEL

HIGH LIFT TRUCK / HIGH LIFT PLATFORM TRUCK

SIT DOWN RIDER - FOUR WHEEL

Lesson 1 • Page 15

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

NARROW AISLE RIDER TRUCK, STRADDLE TRUCK

LOW LIFT TRUCK / HIGH LIFT PLATFORM TRUCK RT

MOTORIZED HAND TRUCK, PALLET TRUCK

MOTORIZED HAND / RIDER TRUCK

Lesson 1 • Page 16

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

COUNTERBALANCED FRONT/SIDE LOADER LIFT TRUCK

FORKLIFT WORK PLATFORMS

OPERATOR-UP COUNTERBALANCED FRONT-SIDE LOADER TRUCK

Lesson 1 • Page 17

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Going Forward – Introduction Summary & Review Forklift Principles The principles discussed in this lesson are core to working safely with forklift style trucks, load distribution, and cargo movement. Here is a review of key principles you will be required to demonstrate your competency of: 2. The truck's center of gravity shifts toward the fulcrum as a load is raised.The forklift is engineered for lifting a certain capacity load to the maximum height of forklift. 3. A critical factor affecting the safe lifting capacity is the load center. A load carried close to the forklift is much safer than one with the load center extended away from the forklift. 4. A forklift attachment affects the load center and safe lifting capacity of a 5,000 lb. capacity forklift.The load center would be extended, greatly reducing the maximum safe lifting capacity. 1. The fulcrum principle: A load balancing a counterweight on a forklift with the front tires as the fulcrum of the load.

5. Tilting a load or driving with a load raised can be dangerous . A tilted load extends the load center plus the extra weight of the mass increases the weight of the load being lifted. 6. Driving with a raised load increases the mass of the truck. If the forklift stops quickly, the momentum of the truck and load could cause the truck to overturn. 7. The center of gravity is very high on forklifts because the wheels are close together and the weight of the engine sits several inches off the ground. A forklift can easily be overturned, particularly if the operator is driving too fast or the load is raised. This is the principle of the stability triangle. 8. The hydraulic system is under tremendous pressure. If hose bursts, the entire system could fail.This could result in a serious accident or personal injury. Replace worn, cracked or damaged pans or hoses.

Lesson 1 • Page 18

FORKLIFT SAFETY TRAINING MANUAL • LESSON 1 • INTRODUCTION & OVERVIEW TO FORKLIFTS

Lesson 1 • Page 19

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