BASIC FORKLIFT PRINCIPLES

26/08/2014
Alan Storey / James Newman

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 Basic Principles – Type of Forklifts
Which to use and where?

Warehouse Range
Powered Pallet Truck
Pedestrian Stacker
Reach Truck
Order Pickers L/M/H
VNA

Counter Balance Range

Diesel
Gas
Electric

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 Forks

Latch

Shank

Load roller

Top of fork

Bottom of fork

Heel of fork

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 Basic Principles – Load Centre
• The distance that the centre of the
load is from the load back plate of the
forks (heel) also affects the centre of Example:
gravity. Length:1000mm

• This distance is called the Load

Centre (LC).
WHE LC @ 600mm
• Where the weight of the load is evenly
distributed throughout the load the
centre of weight for a load is in the
middle of the load.
CB LC @ 500mm
• The further away the load centre is Heel
from the back plate of the forks the
closer the centre of gravity will be to
the front of the forklift.
Toe
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 Basic Principles – Stability Triangle
• The stability of a forklift is based on
the stability triangle of the forklift. This
triangle is formed by the front drive
axle and the mid point of the rear F
steering axle.
• When the forklift is not loaded the
centre of gravity for the forklift is at
point D.
A E B
• When a load with a centre of gravity
at F is added to the forks the
combined centre of gravity is located D
at E.
• If the combined centre of gravity
remains within the stability triangle
then the forklift is stable.
• If the combined centre of gravity
moves outside of the stability triangle
the forklift will tip.
C

The stability triangle is the same for 3 or 4 wheel CB 5

 Basic Principles - Load

Applying the same load weight with different dimensions / height alters the stability of the forklift

1000KG 1000KG

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 Basic Principles – Load limits
Load A
Load Centre = 1000mm
Weight = 3000kg

Load B
Load Centre = 600mm
Weight = 3000kg

Load C
Load Centre = 1500mm
Weight = 2000kg

Select a load that will not tip the forklift

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 Basic Principles – Masts
• Lift Height: The height to which the New 2LFL Current 2LFL
top of the fork is raised when the
mast is fully extended.

• Free lift: Height forks can be raised

before the mast extends (i.e. Without
increasing mast height)

• Lowered Height or Collapsed

Height: Height from the fork top to
the top of the mast when it is lowered.

• Extended Height: the height to the

top of the mast or load guard when
mast is fully extended.

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 Basic Principles – Masts
New 2LFL Current 2LFL

3 common mast types:

• Duplex (2 stage) LFL & FFL: Mast

has 2 sections, one outer that does
not move and an inner section that
raises and elevates the carriage and
forks.

• Triplex (3 Stage) FFL: Consists of

three sections (one outer and two
inner rails). The 2 inner sections raise
from outside to in as the mast
elevates higher. The mast type
provides a shorter lowered height for
use through doorways.

• Quad: Consists of four sections

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 Basic Principles – Engines

Diesel engine

LPG engine

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 Basic principles - Drive transmissions

Powershift Transmission (also called

hydrodynamic drive)
The movement (dynamic) of the fluid (hydro)
transmits power to the transmission.

Oil tank

Hydrostatic drive
The pressurized fluid (hydro) transmits power to
the hydraulic motor.

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 Basic principles – Torque Converter

The torque converter

Function:

It declutches the engine from the transmission

It serves as a fluid coupling ensuring a smooth

transmission of power from the engine to
the transmission gear

It is the torque amplifier of the engine

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 Basic principles – Powershift Transmission
Powershift Transmission

Function:
• Transmits rotating forces from engine
to the drive axle.

• Multiplying torque of the engine

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 Basic principles – Transmissions
Differential

Function:
To compensate the rotational differences
while turning of the drive wheels

Transaxle or drive axle

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 Forklift Tyres - Types
Function:
• Have to support the weight of the truck and its load

• To drive the truck

• Provide least roll / drive resistance

• Provide stability and are durable

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 Forklift Tyres - Types
Solid rubber tyres (R)
• Mainly used on trucks for inside use only

• Contribute to a smaller turning radius

Pneumatic tyres (P)

• Conventional tyres with air chambers

• These tyres either:

• diagonal covers or
• radial covers

Super elastic tyres (SE)

• Like a pneumatic tyre only the air
chamber is filled with soft rubber

• For applications with puncture risks

• Contributes to more lateral stability

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 Carriage
Load back rest

Top bar

Side plate

Bottom bar

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 Carriage
Fork carriages
• ISO 2328 has been incorporated into the
German DIN 15173 standard. According to
this standard, lift trucks are divided into four
capacity classes:
• Class 1 up to 999 kg
• Class 2 1000 - 2500 kg
• Class 3 2501 - 4999 kg
• Class 4 5000 - 8000 kg
• Class 5 8000 – 10999 kg

• There is no capacity class standardisation

beyond this.

• Within the groupings mentioned above, a

further division is made between fork groups
A and B (in each case, of course, within a
class):
• A means a fork with a short face
• B means a fork with a long face
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 Data plate / Controls / VDI

• Reach model

• VDI data sheets

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 Questions?

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