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Basic Hydraulics
Liquids cannot be compressed Liquids can assume any shape and be bi-directional in free flow movement Pascals Law states that when a confined liquid is placed under pressure, that pressure is transmitted, without change in intensity equally in all directions
Basic Diagrams
Connectors Steel tubing / hosing / fittings Cylinders (To Do the Work!!) Single Acting / Double Acting
Lift cylinders Tilt cylinders Steer cylinders Sideshift cylinders
Fuel
Gasoline
Disadvantages
Emissions, should not be used indoors, volatile costs, storage and refueling regulations Tank change-outs might be difficult for some, volatile costs
LPG
Diesel
More pollutants, cannot be used indoors, volatile costs, storage and refueling regulations, might not start well in cold environment Possibly more maintenance, volatile costs, possible refueling issues
Dual Fuel
Fuel
Lead Acid Battery
Advantages
Readily available, various sizes and capacities, utilized as part of the counterweight, zero emissions & no noise, lower maintenance costs Old technology just making its way to forklifts, water is by-product of process, quick refueling for long running times, zero emissions Emerging technology, Komatsu the worlds first electric hybrid utilizing battery & capacitor for power, extended run times, zero emissions & noise, no hefty investments needed
Disadvantages
Purchasing fuel upfront, higher initial cost, replacement usually necessary, disposal complications Durability concerns, very high acquisition costs & refueling station costs, not yet mainstream, not as efficient as hybrid noted below Higher costs than normal lead acid battery, must recharge overnight at least weekly, battery replacement necessary after 4 yrs., paying for fuel upfront, possible disposal complications
Fuel Cell
Hybrid
Forklift Terminology
Mast Upright MFH OAHL FL LBR OHG QD Acronyms Etc. IHR OSHA MPH CARB FPM EPA PSI FPM Ah TOPS HP kW ITA kN ANSI dB Nm WB RPM U.L. NFPA Towmotor
Chassis
Counterweight Mast
Counterbalanced Forklifts
99.9% are front wheel drive and rear wheel steering Why?
In a loaded condition all of the weight is over the drive axle for maximum traction and braking power!!
In a turning situation, the rear end of the truck swings while the front end stays stationary
PS motor
Mast Specifications
OALH Overall Lowered Height
The distance measured from the floor to the top of the mast when it is fully lowered and vertical Critical for entering low clearance areas & doorways
FL Free Lift
Distance the forks can be raised without the overall lowered height of the mast increasing Critical when working inside of a trailer or other low clearance areas
OAHL - overall height lowered FL - free lift MFH - maximum fork height
Mast Types
OAHL FL
Mast Types
2 Stage Free View Mast Large open visibility window 2 Main Cylinder design typically mounted behind rails. Limited free-lift. 0 ~ 6
Mast Types
2 Stage Full Free View 3 cylinder design 2 Main rear cylinders 1 Center cylinder is for freelift Full free-lift capability
Mast Types
3-Stage Full Free View New UltraVizion Mast System (BX50) 3 cylinder design 2 main cylinders 1 center cylinder for free-lift Full free-lift capability 4-Stage Full Free View
Available on some models
Carriage Types
4 Roller Carriage AX50 standard Ok with forks or SS. & normal load widths Option of 6 roller for all other attachments, long load centers or wide loads
Carriage Types
6 Roller Carriage AX BX CX optional standard standard
Carriage Types
How do we classify carriages?
Class II 16 Up to 5,500 lbs. Class III 20 6,000 to 10,000 lbs. Class IV 25 11,000 lbs. Plus
Carriage Types
Increased roller span. Reduced roller load & roller surface pressure
Carriages
What are the advantages of 6 roller? Lower surface pressure on load roller face and mast channel
Lower Moment
Forks
Hook type forks Most common style 3 typical sizes Dimensions Class II 16 Class III 20 Class IV 25
Pin or Shaft Type Carriage Generally used on larger applications and larger capacity trucks such as EX models
Forks
Forks
Forks
Standard taper pallet fork Typically a fork that has other than a full taper; commonly this is one-third of the fork blade length. Fork length should typically cover a minimum of 75% of the load length
Forks
Fully polished & tapered Fully tapered bottom (from heel to tip) with a polished top surface
Fork Extensions
Forks
Stability
Stability of Forklifts
Forklifts can and will tip over if overloaded, or if they raise a full load higher than permitted As a Sales Professional you should fully understand the static and dynamic principals of forklift trucks in order to recognize and assure safe operation
Load
Counterweight
CW
Load Capacity
The load capacity of the forklift truck is a measure to indicate the maximum weight load that can be handled as a load on the forks at a given load center with the mast held in a vertical position The load capacity rating is expressed in pounds (or kilograms) at the load center in inches (or millimeters) The chart of the load capacity is referenced from the operators seat on the trucks data plate
500PG
5000 4400 3900 2800 2400
24 30
36
40
48
Load Center
The load center is specified as the distance between the center of gravity of the load on the forks and the vertical front face of the forks.
Weight Distribution
Wheel loadings / weight distribution can be very important in applications where there are floor loading limitations
Elevators / multiple floor buildings / trailers
Empty forklifts have most of their weight in the rear of the truck when unloaded A forklift undergoes the greatest change in weight distribution when a load is placed on the forks
As much as 90% of the weight is shifted to the drive axle when the truck is fully loaded
3,740
3,300
10,340
1,100
Unloaded (Empty)
Loaded
Load Center
The horizontal distance between the face of the forks and the center of gravity of the load it is carrying is called the load center
It is like placing an overload at the normal load center of the forks!! Consult the factory for capacity ratings at extended load centers Anything greater than a 24 load center will reduce truck capacity and have an effect on truck stability!!
Stability refers to longitudinal and lateral stability, the stability triangle, and dynamic vs. static stability
Truck Model
Lift Height
Vertical CG Capacity
Data Plate
Service Weight IC Attachment Attachment 2 Attachment 3 Service Weight Electric Battery Weight max. Battery Weight min. Battery capacity
Load center
Capacity of a Forklift
Is determined by two factors
Weight of the load Distance of the loads center of gravity from the face of the forks
Almost all manufacturers of forklift trucks have standardized on rated capacities at 24 (600 mm) load centers for models up to about 30,000 lb capacity The load center is the horizontal distance between the vertical front face of the forks and the center of gravity of the load Therefore a 5,000 lb. capacity truck rated at a 24 load center can lift a load that weighs 5,000 lbs. that is 48 long provided the load weight is evenly distributed
Understanding Metrics
Metric Standard 1500 kg @ 500 mm L.C. = 3,300 lbs @ 19.7 in L.C.
Inch-pound Ratings
A typical load capacity chart shows a forklift trucks capacities at many load centers. These ratings take into account all dynamic and static stability factors.
500PG
Key Measurements
Discriminating buyers look closely at truck specs to compare competitors How do we measure-up vs. the competition? Key specifications:
Overall width / Overall length / Overall height / Head length / Under clearance / Wheelbase / Outside turning radius / Right angle stacking width / Travel speed / Lift speed / Lower speed
Key individual specifications represent the forklifts work capability and suitability for your customers application
Truck Dimensions
Truck Width
Truck width is a critical measurement because it effects the trucks ability to work in specific areas such as: Go through doorways / Work in drive-thru / drive-in racking / bulk stack If the truck is wider than the load, bulk stacking more than one pallet deep could be a problem The wider the truck, the greater the turning radius will be
Overall Height
Overall height is critical for working inside of trailers, box cars, and containers Overall height is also critical for getting through facility doorways Highest point could be OHG or mast OHG height is usually fixed, mast could be variable
Wheelbase
The wheelbase does not relate directly to maneuvering dimensions (except grade under clearance), but it does affect truck behavior A long wheelbase requires a greater angle of wheel steering and results in less efficient steering operation The shorter the wheelbase the easier to steer
Turning Radius
The turning radius is the radius of the smallest possible circle in which the forklift truck can turn Turning radius is effected by overall truck width and steer angle
Under Clearances
The under clearances of the truck frame, mast, drive, and steering axles can be significant if there are surface irregularities or obstacles. Not all under clearances are indicated on specification sheets. The mast clearance is generally the lowest point and, therefore, most often listed. In backing up over bumps or obstacles, the rear (steer) axle clearance is important. Pneumatictire trucks have higher under clearances because they are intended for poor surface conditions
grade angle capability for operating on ramps or over dock boards and dock plates The incline (in terms of percent) on which the center of the frame under clearance will just touch when the truck is going down from the level to the ramp or when the truck is going down from the level to the ramp or when the truck is going up from the ramp to the level is important And the so called departure angle (from the wheel arc to the truck edge) of the counterweight is also essential. But, in most sales literature, gradeability is substituted for the grade angle
Gradeability How to Calculate A Grade Percent of Grade = vertical ramp rise / horizontal ramp length 0.20 = 20% Ramp Grade 20 4.0
4 ft
20 ft
Conversion Percent to Degrees Percent of Grade 25% 20% 15% 14% 13% 12% 11% 10% 9% 8% 7% 6% 5% 4% 3% 2% 1% Degree of Ramp Angle 14.03 11.31 8.53 7.96 7.40 6.85 6.28 5.71 5.15 4.58 4.00 3.43 2.86 2.30 1.71 1.15 0.56
Operator Restraints
Operator restraint systems are designed to keep an operator within the confines of the operator compartment in the event of a truck tip-over Systems include:
Seat belts / Seats with hip or shoulder restraints / Hood latches / Battery restraints / Decals / Operator manual instructions
Industry Organizations
Industry Organizations
ANSI B56.1 > American National Standards Institute ASME B56.1 2000 > The American Society of Mechanical Engineers ANSI/ITSDF B56.1 > Industrial Truck Standards Development Foundation B56.1 is specifically for Powered and Non Powered Industrial Trucks Develops Safety codes related to Powered Industrial Trucks
For Manufacturers For End Users
Industry Organizations
OSHA > Occupational Safety & Health Administration Governmental Based OSHA's mission is to prevent work-related injuries, illnesses and deaths. Since the agency was created in 1971, occupational deaths have been cut in half and injuries have declined by 40 percent.
Your Responsibilities
As a material handling professional you are obligated to point out any usage of our equipment that does not comply with OSHA to the companys contact person..safety is everyones responsibility Offer your dealerships services to provide required operator training
Operator Training
OSHA Regulation:29 CFR 1910.178 Regulation essentials
Training (Classroom & Hand-On) Evaluation Certification
Regulation topics
Fundamentals Forklift specific Workplace specific
Operators must be re-certified every three years No exemption for temporary workers
Industry Organizations
ITA > Industrial Truck Association
Comprised of Manufacturers & Associate Manufactures Board, Statistical, Engineering & Product Liability groups Develops common standards as guidelines Reviews legislation that impacts group members Gathers Statistical Data.
Class I
Class II
Narrow Aisle Reach Trucks, Order Selectors, Turret Trucks
Class III
Walkie & Walkie/Rider & Center Control Pallet Trucks,Tow Tractors, Walkie Stackers
Class V
Engine Powered, Pneumatic Tire, Sit-down Rider Forklifts
Industry Organizations
UL > Underwriters Laboratory
Underwriters Laboratories Inc. (UL) is an independent, notfor-profit product safety testing and certification organization. Each year, more than 17 billion UL Marks are applied to products worldwide. Generally electrical and fuel related validation.. Trucks must be manufactured in compliance with U.L. U.L. 558 applies to internal combustion engine forklifts U.L. 583 applies to battery powered electric forklifts
Industry Organizations
NFPA > National Fire Prevention Agency
NFPA 505 2006 NFPA distinguishes forklift types in accordance with their suitability for use in special environments which present the risk of fire or explosions NFPA regulations cover designations, areas of use, maintenance and operation Electric Forklift Classifications:
Type E / Type ES / Type EE / Type EX
Industry Organizations
NFPA > National Fire Prevention Agency
NFPA 505 2006 NFPA states that hazardous work areas must be properly marked showing the type of truck classification that must be used in that special area It is the customers responsibility to communicate these special application needs and need to operate the forklift within a hazardous area
Industry Organizations
MHEDA >Material Handling Equipment Distributors Assoc. Dealer based Organization The Material Handling Equipment Distributors Association is the only trade association dedicated solely to improving the proficiency of the independent material handling equipment distributor. MHEDA is your direct connection to the Material Handling Industry's hottest trends, newest products and best management training workshops. MHEDA represents a wealth of resources for all material handling businesses.