The Basics - Forklift 101

In Its Simplest Form, a Forklift

Drives / Travels
Lifts / Other Hydraulic Functions
Utilizes Basic Hydraulics to Accomplish
Work

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

Multiplied Forces Do More Work

Principles of basic hydraulics allow
forklifts to lift heavy loads

Pressure / Flow Must Be Created

Hydraulic pump Usually gear type are
utilized to create flow

Basic Hydraulic Diagram

Various Components Work Together to
Accomplish the Work

Forklift Hydraulic Components

Hydraulic Reservoir (Tank)

Gear Pump ( Creates Flow / Pressure)
Control Valves (To Direst Flow)
Control Valve Levers (Direct Manual)
Electronically Controlled (Joystick, Fingertip controls)

Connectors Steel tubing / hosing / fittings

Cylinders (To Do the Work!!) Single Acting / Double Acting

Lift cylinders
Tilt cylinders
Steer cylinders
Sideshift cylinders

Various Power Sources

Engine Powered Forklifts

Fuel

Advantages

Disadvantages

Gasoline

Readily available, good power & performance,

can run continuously, small & medium
forklifts, high power to weight ratio, starts well
in cold

Emissions, should not be used

indoors, volatile costs, storage and
refueling regulations

LPG

Readily available, easy refueling & tank

storage, small & medium forklifts, cleaner
burning, good power & performance, can be
used indoors, can run continuously, usually
costs less than gas

Tank change-outs might be difficult

for some, volatile costs

Diesel

More durable engine designs, medium, large

and extra large forklifts, sometimes better
performance & power than gas and LPG, can
run continuously

More pollutants, cannot be used

indoors, volatile costs, storage and
refueling regulations, might not start
well in cold environment

Dual Fuel

An engine that runs on either gas or LPG,

better flexibility and good for rental fleet
trucks, can run continuously

Possibly more maintenance, volatile

costs, possible refueling issues

Various Power Sources

Battery Powered Forklifts

Fuel

Advantages

Disadvantages

Lead Acid
Battery

Readily available, various sizes and

capacities, utilized as part of the
counterweight, zero emissions & no
noise, lower maintenance costs

Purchasing fuel upfront, higher initial

cost, replacement usually necessary,
disposal complications

Fuel Cell

Old technology just making its way to

forklifts, water is by-product of process,
quick refueling for long running times,
zero emissions

Durability concerns, very high

acquisition costs & refueling station
costs, not yet mainstream, not as
efficient as hybrid noted below

Hybrid

Emerging technology, Komatsu the

worlds first electric hybrid utilizing
battery & capacitor for power, extended
run times, zero emissions & noise, no
hefty investments needed

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

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

Lift Truck Main Components

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

Engine Powered Forklift

Hydraulic pump

Battery Powered Forklift

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

MFH Maximum Fork Height

Distance measured from the floor to the top of the forks in the full
raised position
Critical to achieve the desired height to put-away a load

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

Ratio of OALH to MFH

Usually the same, but may vary based upon mast overlap / retention

Mast Types

OAHL - overall height lowered

FL - free lift
MFH - maximum fork height

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

optional

BX

standard

CX

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

Higher Moment
Force

Forks
Hook type forks
Most common style
3 typical sizes
Dimensions
Class II 16
Class III 20
Class IV 25

Forks

Pin or Shaft Type Carriage

Generally used on larger applications and
larger capacity trucks such as EX models

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

Other Fork Types

Block fork
Generally a narrow, almost square stock that will easily fit
most concrete block.
Lumber fork
Typically thin, wide fork fully tapered and polished with a chisel
tip IE: 1.5 x 10. The increased width is necessary to maintain
fork capacity.
Gypsum or Sheetrock forks
Generally common to the lumber fork with a rounded or bevel
side edge and/or a padded vertical back to prevent product
damage.

Fork Extensions

Forks

What is the rule of thumb on fork extensions vs standard fork

length?
150% of the standard fork length. IE: 48 fork can support up to a 72 fork extension.

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

Stability of a
Counterbalanced
Forklift
The

fulcrum point of a
counterbalanced forklift is
the center of the drive
axle

Fulcrum is drive tire

Load

Counterweight

Teeter Totter
Principle
Forklifts work on the principle of a
teeter totter. You have a pivot point
(drive axle center) and
counterweight (CW) at one end to
offset the load weight (W).
Too much weight will cause it to tip
over. (or) if you move the weight
further out from the pivot or fulcrum
point it will also cause tip over.

CW

Counterweight Makes
All The Difference

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

Example of Wheel Loading of 400PG

Front
3,740 lbs

Rear
3,300 lbs.

Total weight = 7,040 lbs.

3,740

3,300

Unloaded (Empty)

Front

Rear

10,340 lbs.

1,100 lbs.

Total weight = 11,440 lbs.

10,340

1,100

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

Be Cautious of Long Load Centers!

Long load centers have a very detrimental
effect on the forklift
It transfers more weight off of the rear axle causing
truck instability and possibly tipover!!

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!!

Long Load Centers

Truck Center of Gravity

HCG = Horizontal Center of Gravity
The Center of Gravity of
a forklift changes as the
mast is tilted or raised.
This is important since
all forklift capacities are
based upon the location
of the C of G. This also
changes the wheel
loading on drive and
steer tires.
The illustration show the
effect on the C of G as
the mast is tilted forward
or backward.

Truck Vertical Center of Gravity

The illustration shows
the effect on the C of G
as the mast is raised or
lowered.
As you can see as the
load weight moves up
or down the VCG
(vertical center of
gravity) also changes.

Combined Center of Gravity

An empty forklift has a center of gravity and the load
has a weight and its own center of gravity
When the truck picks up the load, the center of
gravity of the truck shifts forward
As longs as the combined center of gravity of the
truck and the load is located between the front and
rear axles, the truck will remain stable
If the combined center of gravity of the truck and
load is beyond the centerline of the front axle, the
truck will tip over

Combined Center of Gravity

Dynamic vs Static Stability

Static stability is measured when the
forklift is standing still
Dynamic stability is the transfer and
shifting of the CG due to dynamic forces
such as:
Traveling / braking / turning / lifting / lowering

The Stability Triangle

The Stability Triangle

Stability is the result of many
factors
Wheelbase / overall width at
the front axle / weight
distribution / lifting height

Stability refers to longitudinal

and lateral stability, the
stability triangle, and
dynamic vs. static stability

The Stability Triangle

Point A = Center pivot
point of the rear steer axle
Point B and C = Straight
line between centerline of
each drive axle

The Stability Triangle

When a load is
placed on the
forks, the
center of
gravity of the
forklift moves
forward
Ideally the CG
must always
stay within the
stability triangle

The Stability Triangle

This diagram shows the effect
of having the mast vertical and
using a sideshifter
The load causes the CG to shift
forward and sideshifting from
side to sideshifts the CG to the
right or left

The Stability Triangle

DANGER!!
Load is too heavy and too
far out on the forks and the
CG has shifted outside of
the stability triangle!!

The Stability Triangle

Danger!!
The load is not stable and
the heaviest part is out in
front of the CG creating
an unstable situation!!

The Stability Triangle

Danger!!
The load is not stable and the
heaviest part to one side! When
turning the momentum will shift
further to the side creating a
dangerous situation!! The truck
could tip over laterally!!

Stability of Elevated Loads

Tilt table
tests
determine at
what point
the truck
becomes
unstable and
downrates
the truck
accordingly
to maintain
stability with
elevated
loads

To Maintain Truck Stability

Always use caution when

Lifting
Tilting
Turning
Braking
Traveling with an elevated load
Traveling over uneven floor conditions

Always keep the CG within the stability

triangle!!

Tilt Table Testing

The rated capacity and stability
factors of a forklift are
determined by tilt table tests
with criteria established by the
ISO (International Organization
for Standardization) and
ANSI/ITSDF B56.1
The static center of gravity is
definitely not the final
determinant of forklift stability

Capacity Ratings
and the Data Plate

Truck Model

Data Plate
Service Weight IC
Attachment
Attachment 2
Attachment 3
Service Weight
Electric
Battery Weight max.
Battery Weight min.
Battery capacity

Attachment
Tire size

Lift Height

Vertical CG
Capacity

Load center

Tilt Angles
UL Type
Serial Number

Importance of the Data Plate

Every truck must have an accurate, legible data plate

Any approved modifications to the truck must be reflected on the
data plate
Data plates show both English measurements and metric
No changes or modifications can be made to the truck without
written approval from the manufacturer
Any change that effects truck stability i.e.an attachment, longer forks,
etc.
Critical to meet OSHA regulations
A truck without an accurate data plate can be removed from service

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.

US Standard
3,000 lb @ 24 in L.C. = 1,360 kg @ 610 mm 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

5000
4400
3900
2800
2400
24

30

36

40

48

Lift Truck
Performance &
Specifications

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

Length to Face of Forks

This dimension is important when figuring right angle stacking
and dimensions for a working stacking aisle

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 Clearance

The operator must know the trucks

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

Grades and Gradeability

How do we calculate grades and gradeability??

Note: Always drive backwards up a ramp

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

Calculating
a Grade and
Gradeability

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

Your Customers Must Properly

Train Their Operators
Required by OSHA
Promotes safe working environment
A well trained operator
Is far more efficient and productive
Puts safety first!!

Operator Training
OSHA Regulation:29 CFR 1910.178
Regulation essentials
Training (Classroom & Hand-On)
Evaluation
Certification

Regulation topics
Fundamentals
Forklift specific
Workplace specific

Operator Training Is the Law!

The employer must:

Train
Evaluate
Certify
Must re-train when:
There is an accident
Near miss
Observed unsafe behavior

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.

Classifications of Forklift
Trucks in the U.S. Market

Class I

3-Wheel, 4-Wheel Sitdown Riders, Stand-Up

Counterbalance Riders

Class II
Narrow Aisle Reach
Trucks, Order Selectors,
Turret Trucks

Class III

Walkie &
Walkie/Rider & Center
Control Pallet Trucks,Tow
Tractors, Walkie Stackers

Used for trailer

loading/unloading, indoors
in plants & warehouses
where good
maneueverability is needed
Used in warehousing &
distribution for high level
storage and high level
orderpicking in narrow
aisles
Walkie trucks are utilized in
a wide variety of
manufacturing &
warehousing applications

Classifications of Forklift Trucks

in the U.S. Market (cont.)
Class IV

Engine Powered,
Cushion Tire, Sit-down
Rider Forklifts

Class V
Engine Powered,
Pneumatic Tire, Sit-down
Rider Forklifts

Indoor use on loading docks

in plants & warehouses
where power & continuous
usage are expected & good
maneuverability is important
Outdoor use for load
handling in retail, lumber,
shipping & stevedoring
where power and
continuous usage is
expected

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

Engine Forklift Classifications:

Type G / Type GS / Type LP / Type LPS / Type D / Type DS /
Type G/LP / Type GS/LPS / Type DX Diesel explosion proof

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.