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Load Composition
Figure 1. As the center of gravity for the load moves forward, the lifting capacity for the forklift decreases.
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Figure 3. The heaviest weight should be loaded as close to the masts as possible. |
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Field Calculation of Safe Load Capacity Assume a situation where a forklift truck that has a 5,000 pound capacity at a 24 inch load center needs to handle a load whose center is 28 inches from the front face of the forks in the horizontal direction. The first thing to recognize is that the actual load center distance of 28 inches exceeds the standard load center distance of 24 inches on which the 5000 pound capacity is based, so the safe load capacity is actually less than 5000 pounds. To estimate the truck's safe load capacity at a 28-inch load center, take the rated load center and divide it by the actual load center. Then multiply this number by the stated capacity to get the new approximate safe load capacity: 24 in/28 in x 5,000 lb = 4,285 lb (approximate safe load capacity) Using the example in Figure 4, take the stated standard load center of 24 inches and divide it by the actual load center of 36 inches. Multiply this number by the stated capacity of 4,000 lb to get the new approximate safe load capacity: 24 in/36 in x 4,000 lb = 2,666 (approximate safe load capacity) |
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Lift a 5 pound box. As you extend your arms, the center of the box’s weight moves a greater distance from your body, so the box feels heavier and you will tend to fall forward. The same idea of increasing the load center distance applies to a playground see-saw: the farther you sit from the middle, the more you increase the load center distance and the more force you put on that end. The same principle—increasing the load center distance—can cause a forklift to tipover. When the load center distance increases, it is actually increasing something called the 'Load Moment': Load Moment is the product of the object's weight multiplied by the object’s distance from the fulcrum, which is a fixed point that acts as the pivot point. On a sit-down counterbalanced forklift, the fulcrum or pivot point is the axle of the front wheels. It is this product, or Load Moment, which determines how much overturning force is being applied to the forklift. Load Moment = Weight X Distance Because the overturning force depends on both the weight of the load and the load’s distance from the pivot point, a forklift’s capacity is always stated in terms of both: the load’s weight and its load center distance. For example, if a forklift’s capacity as stated on its data plate is “3,000 pounds at a 24 inch load center,” this means that the Load Moment cannot safely exceed 72,000 inch-pounds (24-in. x 3,000 lb = 72,000 inch-pounds.) If the load center distance for the actual load is greater than the standard 24 inches, the only way to keep the Load Moment from exceeding 72,000 inch-pounds is to reduce the load. The easiest way to determine the maximum load when the load center distance is greater than the distance stated on the data plate is to divide the maximum Load Moment by the actual load center distance. For example: If a load is 60 inches long (30-inch load center) then the maximum that this load can weigh is: 72,000 inch-pounds / 30 in-load center = 2,400 pounds |
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Center of Gravity Potential Hazards: While operating a forklift, be aware of the following:
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Shifting Center of Gravity
When a load is placed on a forklift, the key concept is the combined center of gravity of the forklift and the load. For example, a typical unloaded forklift weighing 4000 pounds may have its center of gravity about 10 inches (25.4 cm) above and two feet (0.6 m) behind the front axle, about half way up the truck body. The heavy counterweight located toward the rear of the forklift places the center of gravity toward the rear, which keeps the forklift from tipping forward. In the meantime, a 4,000 pound load consisting of a cube with even weight distribution has a CG in its center. When the load is placed on the forklift, the combined center of gravity of the forklift and the load will move forward, but the forklift will not tipover so long as the weight of the load is centered and does not exceed the capacity stated on the data plate. But if the load is too heavy, or if it is placed at the end of the forks so that the load center distance is increased, the excessive load moment will cause the forklift to tip forward. Remember, when the forklift engages a load, the combined center of gravity of both the load and the truck system shift forward from the center of gravity of the unloaded forklift. (Figure 11 and 12) Potential Hazards: Be aware of tipover or falling loads while:
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The Stability Triangle |
- Maintain stability. Keep the combined center of gravity within the stability triangle.
- Do not accelerate rapidly or brake suddenly. Sudden changes in direction may also shift the combined center of gravity outside the vehicle's stability triangle and destabilize it.
- Do not turn rapidly. The combined center of gravity may shift outside the stability triangle and may cause the vehicle to tipover to the left or right.
- Never turn on a grade or ramp. Even a 10 percent grade may shift the combined center of gravity outside the stability triangle and cause the vehicle to roll over laterally.
- Cross an obstacle (railroad tracks, beam, pot hole) at a 45 degree angle, so both wheels do not elevate simultaneously.
- Maintain control of your vehicle at all times. Adjust your speed to match the conditions. Be aware and anticipate dangerous motions and avoid them.
- Consider the dynamic forces that result when the vehicle and load are put into motion.The weight's transfer and the resultant shift in the center of gravity due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations. [A-7.1.29 CFR 1910.178 Appendix A]
- When determining whether a load can be safely handled, the operator should exercise extra caution when handling loads that are close to the truck's stated capacity.
If an operator must handle a maximum load:- The load should be carried at the lowest position possible,
- The truck should be accelerated slowly and evenly, and
- The forks should be tilted forward cautiously.
- However, no one rule can cover all eventualities.[A-7.2.29 CFR 1910.178 Appendix A]
Types & Fundamentals | Operating the Forklift | Understanding the Workplace | Training Assistance |