Extention Fork Forklift
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GENERAL OPERATION FORKLIFT TRUCK
Forklifts
are rated for loads at a specified maximum weight and a specified forward center of gravity.
This information is located on a nameplate provided by the manufacturer, and
loads must not exceed these specifications. In many jurisdictions it is illegal
to alter or remove the nameplate without the permission of the forklift
manufacturer.
An
important aspect of forklift operation is that it must have rear-wheel
steering. While this increases maneuverability in tight cornering situations,
it differs from a driver’s traditional experience with other wheeled vehicles.
While steering, as there is no caster action,
it is unnecessary to apply steering force to maintain a constant rate of turn.
Another
critical characteristic of the forklift is its instability. The forklift and
load must be considered a unit with a continually varying center of gravity
with every movement of the load. A forklift must never negotiate a turn at
speed with a raised load, where centrifugal and gravitational forces
may combine to cause a disastrous tip-over accident. The forklift is designed
with a load limit for the forks which is decreased with fork elevation and
undercutting of the load (i.e., when a load does not butt against the fork
"L"). A loading plate for loading reference is usually located on the
forklift. A forklift should not be used as a personnel lift without the fitting
of specific safety equipment, such as a "cherry picker" or
"cage".
Forklift control and capabilities
Forklift hydraulics are controlled either with levers directly
manipulating the hydraulic valves, or by electrically controlled actuators,
using smaller "finger" levers for control. The latter allows forklift
designers more freedom in ergonomical design.
Forklift trucks are available in many variations and load
capacities. In a typical warehouse setting most forklifts have load capacities
between one and five tons. Larger machines, up to 50 tons lift capacity, are
used for lifting heavier loads, including loaded shipping containers.
In addition to a control to raise and lower the forks (also
known as blades or tines), the operator can tilt the mast to compensate for a
load's tendency to angle the blades toward the ground and risk slipping off the
forks. Tilt also provides a limited ability to operate on non-level ground.
Skilled forklift operators annually compete in obstacle and timed challenges at
regional forklift rodeos.
Forklift Design Type
The
following is a list, in no particular order, of the more common lift truck
types:
Hand
pallet truck - no
on-board power system of any kind; the operator's muscle power is used to
jack-up and move loads.
Walkie
low lift truck - powered
pallet truck, usually electrically powered
Rider
low lift truck - usually
electrically powered
Towing
tractor
may
be internal combustion engine or electrically powered
Walkie
stacker - usually electrically powered
Rider
stacker - usually electrically powered
Reach
truck - variant on a Rider Stacker
forklift, designed for small aisles, usually Electrically Powered, named
because the forks can extend to reach the load. There are two variants, moving
carriage, which are common in North America, and moving mast which are common
in the rest of the world, and generally regarded as safer
Electric
counterbalanced truck - comes in Stand on End
Control, Stand on Center Control, and Sit Down Center Control, which is the
most numerous
Internal
Combustion Engine Powered Counterbalanced Forklift - comes in Stand on End
Control, Stand on Center Control, and Sit Down Center Control, which is the
most numerous. Engines may be diesel, kerosene, gasoline, natural gas, butane,
or propane fueled, and may be either two stroke spark ignition, four stroke
spark ignition (common), two stroke compression ignition, and four stroke
compression ignition (common). North American Engines come with advanced
emission control systems. Forklifts built in countries such as Iran or Russia
will typically have no emission control systems.
Electric
forklifts
- powered
by lead-acid batteries or
sometimes lithium-ion batteries,
several types of forklifts are electric: cushion tire forklifts, scissor lifts,
order pickers, stackers, reach trucks and pallet jacks. Electric forklifts are
primarily used indoors on flat, even surfaces. Electric forklift batteries last
6 consecutive hours or throughout an 8-hour shift with 2-3 breaks. Batteries
prevent the emission of harmful fumes and are recommended for facilities in
food-processing and healthcare sectors.
Fuel cell forklifts - produce no local emissions,
can work for a full 8-hour shift on a single tank of hydrogen, can be refueled
in 3 minutes and have a lifetime of 8–10 years. Fuel-cell-powered forklifts are
often used in refrigerated warehouses as their performance is not degraded by
lower temperatures.
Sideloader - comes
in Stand on End Control, and Sit Down End Control, which is the most numerous.
It may be electrically powered, or have an internal combustion engine. Engines
may be diesel, kerosene, gasoline, natural gas, butane, or propane fueled, and
may be either two stroke spark ignition, four stroke spark ignition (common),
two stroke compression ignition, and four stroke compression ignition (common).
North American Engines come with advanced emission control systems. Forklifts
built in countries such as Iran or Russia will typically have no emission
control systems. Some sideloaders have hybrid drivetrains.
Telescopic handler
- comes in Stand on Center
Control, and Sit Down Center Control, which is the most numerous. Usually has
an Internal Combustion Engine. Engines are almost always diesel, but sometimes
operate on kerosene, and sometimes use propane injection as a power boost. Some
old units are two stroke compression ignition, most are four stroke compression
ignition (common). North American Engines come with advanced emission control
systems. Forklifts built in countries like Iran or Russia will typically have
no emission control systems. Some Telescopic handlers have Hybrid drivetrains.
Walkie
order picking truck - usually Electrically Powered
Rider
order picking truck - commonly
called an "Order Picker"; like a small Reach Truck, except the
operator rides in a cage welded to the fork carriage, while wearing a specially
designed safety harness to prevent falls. A special toothed grab holds the
pallet to the forks. The operator hand transfers the load onto the pallet one
article at a time. This is an efficient way of picking less than pallet load
shipments, and is popular for use in large distribution centers.
Articulated
very narrow aisle counterbalanced trucks - sometimes
called "Flexi or Bendi Trucks" after two of the largest
manufacturers. Comes in stand on center control, and sit down center control,
which is the most numerous. May have an internal combustion engine or an
electric motor. Electric motors are most common. Engines may be diesel,
kerosene, gasoline, natural gas, butane, or propane fueled, and may be either
two stroke spark ignition, four stroke spark ignition (common), two stroke
compression ignition, and four stroke compression ignition (common). North
American Engines come with advanced emission control systems. Forklifts built
in countries such as Iran or Russia will typically have no emission control
systems. Some units have hybrid drivetrains. Unlike Standard
Counterbalance and Reach Forklifts, These forklifts are steered via the front
swivel articulation of the forklift and are therefore much different to
manoeuvre than regular forklifts and additionally have no pantograph feature
for retrieving stock in narrow aisles.
Guided
very narrow aisle truck - A counterbalance type Sit
Down Rider Electric Forklift fitted with a specialized mast assembly. The mast
is capable of rotating 90 degrees, and the forks can then advance like on a
reach mechanism, to pick full pallets. Because the forklift does not have to
turn, the aisles can be exceptionally narrow, and if wire guidance is
fitted in the floor of the building the machine can almost work on its own.
Masts on this type of machine tend to be very high. The higher the racking that
can be installed, the higher the density the storage can reach. This sort of
storage system is popular in cities where land prices are really high, as by
building the racking up to three times higher than normal and using these
machines, it is possible to stock an incredible amount of material in what
appears to be a small space.
Guided
very narrow aisle order picking truck - counterbalance type Order
Picking Truck similar to the guided very narrow aisle truck, except that the
operator and the controls which operate the machine are in a cage welded to the
mast. The operator wears a restraint system to protect him against falls.
Otherwise the description is the same as guided very narrow aisle truck.
Truck-mounted
forklift / sod loader - comes in sit down center
control. Usually has an internal combustion engine. Engines are almost always
diesel, but sometimes operate on kerosene, and sometimes use propane injection
as a power boost. Some old units are two-stroke compression ignition, most are
four-stroke compression ignition (common). North American engines come with
advanced emission control systems. Forklifts built in countries such as Iran or
Russia will typically have no emission control systems.
Forklift Cost
The cost of a new forklift can vary between $15,000 to in excess
of $150,000, depending on the model and, in particular, the capacity of the
forklift. The most common forklifts are typically gas powered and have a
capacity of between 2 and 2.5 tonnes. The cost of these varies from around
$18,500 for some of the lesser well known Chinese-manufactured forklifts to
around $20,000 for the German forklifts from well-established manufacturers. It
is important to take fuel and maintenance costs into account when calculating
the total cost of ownership
Specialty trucks
At
the other end of the spectrum from the counterbalanced forklift trucks are more
'high end' specialty trucks:
Articulated
counterbalance trucks - These are, unlike most lift
trucks, front wheel steer, and are a hybrid VNA (very narrow aisle) truck
designed to be both able to offload trailers and place the load in narrow aisle
racking. Increasingly these trucks are able to compete in terms of pallet
storage density, lift heights and pallet throughput with guided very narrow
aisle trucks, while also being capable of loading trucks, which VNA units are
incapable of doing.
Guided
very narrow aisle trucks - These are rail- or
wire-guided and available with lift heights up to 40 feet non-top-tied and 98
feet top-tied. Two forms are available: 'man-down' and 'man-riser', where the
operator elevates with the load for increased visibility or for multilevel
'break bulk' order picking. This type of truck, unlike articulated narrow aisle
trucks, requires a high standard of floor flatness.
Omnidirectional
trucks - Omnidirectional
technology (such as Mecanum wheels)
can allow a forklift truck to move forward, diagonally and laterally, or in any
direction on a surface. Omnidirectional wheel system is able to rotate the
truck 360 degrees in its own footprint or strafe sideways without turning the
truck cabin. One example is the Airtrax Sidewinder. This forklift truck has
also made an appearance in the TV series called 'Mythbusters'.
UL
558 safety rated trucks - In North America, some
internal combustion powered industrial vehicles carry Underwriters
Laboratories ratings that are part of UL 558.
Industrial trucks that are considered "safety" carry the designations
GS (Gasoline Safety) for gasoline powered, DS (Diesel Safety) for diesel
powered, LPS (Liquid Propane Safety) for liquified propane or GS/LPS for a dual
fuel gasoline/liquified propane powered truck.[18]
UL
558 is
a two-stage Safety Standard. The basic standard, which is G, D, LP, and G/LP is
what Underwriter's Laboratories considers the bare minimum required for a lift
truck. This is a voluntary standard, and there is no requirement in North
America at least by any Government Agency for manufacturers to meet this
standard.
The
slightly more stringent GS, DS, LPS, and GP/LPS, or Safety standard
does provide some minimal protection, however it is extremely minimal. In the
past Underwriter's Laboratory offered specialty EX and DX safety
certifications. If you require higher levels of protection
you must contact your local Underwriter's Laboratory Office and check
ask them what the correct safety standard is for your workplace.
UL
583 safety rated trucks - UL
583 is
the Electric equivalent of UL
558.
As with UL 558 it is a two-stage standard.
Explosion
proof trucks "EX RATED" - These are for operation in
potentially explosive atmospheres found in chemical, petrochemical,
pharmaceutical, food and drink, logistics or other industries handling
flammable material. Commonly referred to as Pyroban trucks
in Europe, they must meet the requirements of the ATEX 94/9/EC Directive if
used in Zone 1, 2, 21 or 22 areas and be maintained accordingly.
U.S.
Military 10K-AT "Adverse Terrain"
Automated forklift trucks - In
order to decrease work wages, reduce operational cost and improve productivity, automated
forklifts have also been developed.
Automated
forklifts are also called forked automated guided vehicles and are already
available from a growing number of suppliers.
Counterbalanced forklift components
Truck frame -
is the base of the machine to which the mast, axles, wheels, counterweight,
overhead guard and power source are attached. The frame may have fuel and hydraulic fluid tanks
constructed as part of the frame assembly.
Counterweight -
is a mass attached to the rear of the forklift truck frame. The purpose of the
counterweight is to counterbalance the load being lifted. In an electric
forklift the large lead-acid battery itself may serve as part of the
counterweight.
Cab -
is the area that contains a seat for the operator along with the control pedals, steering wheel, levers, switchesand a
dashboard containing operator readouts. The cab area may be open air or
enclosed but it is covered by the cage-like overhead guard assembly. When enclosed,
the cab may also be equipped with a cab heater for cold climate countries along
with a fan or air conditioning for hot weather.
Overhead guard -
is a metal roof supported
by posts at each corner of the cab that helps protect the operator from any
falling objects. On some forklifts, the overhead guard is an integrated part of
the frame assembly.
Power source -
may consist of an internal combustion engine that can be powered
by LP gas, CNG, gasoline or diesel fuel.
Electric forklifts are powered by either a battery or fuel cells that
provides power to the electric motors. The electric motors used on a forklift
may be either DC or AC types.
Tilt cylinders -
are hydraulic cylinders that are mounted to the truck frame and the mast. The
tilt cylinders pivot the mast backward or forward to assist in engaging a load.
Mast -
is the vertical assembly that does the work of raising and lowering the load.
It is made up of interlocking rails that also provide lateral stability. The
interlocking rails may either have rollers or bushings as guides. The mast is
driven hydraulically, and
operated by one or more hydraulic cylinders directly or using chains from the
cylinder/s. It may be mounted to the front axle or the frame of the forklift. A
'container mast' variation allows the forks to raise a few meters without
increasing the total height of the forklift. This is useful when double-loading
pallets into a container or under a mezzanine floor.
Carriage -
is the component to which the forks or other attachments mount. It is mounted
into and moves up and down the mast rails by means of chains or by being
directly attached to the hydraulic cylinder. Like the mast, the carriage may
have either rollers or bushings to guide it in the interlocking mast rails.
Load back rest -
is a rack-like extension that is either bolted or welded to the carriage in
order to prevent the load from shifting backward when the carriage is lifted to
full height.
Attachments -
may consists of a mechanism which is attached to the carriage, either
permanently or temporarily, to help in proper engagement of the load. A variety
of material handling attachments are available. Some attachments include
sideshifters, slipsheet attachments, carton clamps, multipurpose clamps,
rotators, fork positioners, carpet poles, pole handlers, container handlers and
roll clamps.
Tires -
either solid for indoor use, or pneumatic for
outside use.
Attachments
Below is a list of common forklift attachments
Dimensioning devices-fork truck-mounted dimensioning systems provide dimensions for
the cargo to facilitate truck trailer space utilization and to support
warehouse automation systems. The systems normally communicate the dimensions
via 802.11 radios. NTEP certified dimensioning devices are available to support
commercial activities that bill based on volume.
Sideshifter - is a hydraulic attachment that allows the operator to
move the tines (forks) and backrest laterally. This allows easier placement of
a load without having to reposition the truck.
Rotator - To aid the handling of skids that may have become
excessively tilted and other specialty material handling needs some forklifts
are fitted with an attachment that allows the tines to be rotated. This type of
attachment may also be used for dumping containers for quick unloading.
Fork positioner - is a hydraulic attachment that moves the tines (forks)
together or apart. This removes the need for the operator to manually adjust
the tines for different sized loads.
Roll and barrel clamp
attachment - A mechanical or hydraulic attachment used to squeeze the
item to be moved. It is used for handling barrels, kegs, or paper rolls. This
type of attachment may also have a rotate function. The rotate function would
help an operator to insert a vertically stored paper into the horizontal intake
of a printing press for example.
Pole attachments - In some locations, such as carpet warehouses, a long
metal pole is used instead of forks to lift carpet rolls. Similar devices,
though much larger, are used to pick up metal coils.
Carton and multipurpose
clamp attachments - are hydraulic
attachments that allow the operator to open and close around a load, squeezing
it to pick it up. Products like cartons, boxes and bales can be moved with this
type of attachment. With these attachments in use, the forklift truck is
sometimes referred to as a clamp truck.
Slip sheet attachment
(push - pull) - is a hydraulic attachment that reaches forward, clamps
onto a slip sheet and draws the slip sheet onto wide and thin metal forks for
transport. The attachment will push the slip sheet and load off the forks for
placement.
Drum handler attachment - is a mechanical attachment that slides onto the tines
(forks). It usually has a spring-loaded jaw that grips the top lip edge of a
drum for transport. Another type grabs around the drum in a manner similar to
the roll or barrel attachments.
Man basket - a lift platform that slides onto the tines (forks) and
is meant for hoisting workers. The man basket has railings to keep the person
from falling and brackets for attaching a safety harness. Also, a strap or
chain is used to attach the man basket to the carriage of the forklift.
Telescopic forks - are hydraulic attachments that allow the operator to
operate in warehouse design for "double-deep stacking", which means
that two pallet shelves are placed behind each other without any aisle between
them.
Scales -Fork truck-mounted scales enable operators to efficiently
weigh the pallets they handle without interrupting their workflow by travelling
to a platform scale. Scales are available that provide legal-for-trade weights
for operations that involve billing by weight. They are easily retrofitted to
the truck by hanging on the carriage in the same manner as forks hang on the
truck.
Single-double forks - are forks that in the closed position allow movement of
a single pallet or platform but when separated, turn into a set of double forks
that allow carrying two pallets side by side. The fork control may have to
replace the side-shifter on some lift trucks.
Any attachment on a forklift will reduce its nominal load
rating, which is computed with a stock fork carriage and forks. The actual load
rating may be significantly lower.
Replacing or adding attachments
It is possible to replace an existing attachment or add one to a
lift that doesn't already have one. Considerations include forklift type,
capacity, carriage type, and number of hydraulic functions (that power the
attachment features). As mentioned in the preceding section, replacing or
adding an attachment may reduce (down-rate) the safe lifting capacity of the
forklift truck (See also General operations, below).
Forklift attachment manufacturers offer on-line calculators to
estimate the safe lifting capacity when using a particular attachment. However,
only the forklift truck manufacturer can give accurate lifting capacities.
Before installing any attachment you should contact your local authorized
dealer of your forklift brand and ask them to begin re-rating your lift
according to the attachment you want to install. Once re-rated the forklift
should have a new factory authorized specification plate, to replace the
original plate, installed showing the new rating for the lift.
In the context of attachment, a hydraulic function consists of a
valve on the forklift with a lever near the operator that provides two passages
of pressurized hydraulic oil to power the attachment features. Sometimes an
attachment has more features than your forklift has hydraulic functions and one
or more need to be added. There are many ways of adding hydraulic functions
(also known as adding a valve). The forklift manufacturer makes valves and hose
routing accessories, but the parts and labor to install can be prohibitively
expensive. Other ways include adding a solenoid valve in conjunction with a
hose or cable reel that diverts oil flow from an existing function. However,
hose and cable reels can block the operator's view and are problematic, easily
damaged. The Ditto Valve kit uses a solenoid valve and special HydWire hoses,
in which the wire reinforcing braid doubles as an electrical conduit. These
hoses replace those already on the forklift, nesting in the original reeving,
keeping it safe from damage and out of the operators field of vision.
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Engine Group (Cylinder head, Bushing Valve, Seat valve, Chember, Gasket kit head, Liner Cylinder, Piston assy, Ringset piston, Bearing conecting rod/ metal jalan, Bearing crangshaft/ Metal duduk, Washer thrust/metal bulan, Conecting rod/stang piston, Crankshaft/ As kruk, Vale intake, Valve Exhaust, Oil Filter, Fuel Filter, Aircleaner, Filter Hydraulic, Nozzle, Injection, Spare plug, Glow plug, Oil pump dll).
Clutch group (Master Cylinder assy, Master release assy, Cove clutch/matahari, Disc clutch/pelat coupling, Bearing release.)
Manual Transmission group (Gasket kit transmission, Gear Forward, Gear reverse, shinchonize, Yoke, Spider set, Propeller, Wire.)
Automatic Transmision group (Gasket kit transmission, Disc clutch, Plate, Ring seal, control valve, torque converter.)
Differential group/ Gardan (Pinion Ring gear, planetari gear, shaft, Wheel/pelg, Solid tire/ban mati, Penumatic tire/ban hidup).
Brake group (Wheel cylinder, Shoe lining/kanvas rem, Wire Rh dan Lh, Master brake, Kit wheel cylinder, kit master brake),
Rear axle group (Kit kingpin, kit bellcrank, pin knucle, pin bellcrank, pin tierod, Kit cylinder steering)
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Acceories/ Electrical group (Head lamp, Front lamp, Rear Lamp, Switch lamp, Relay, Cotactor, Motor drive, Motor hydraulic, Sensor steering, Tire angle sensor, CPU board, Mpu Board, Controller, Transistor, Diode, Rotary lamp, Battery forklift, Motor starter, Dinamo Amphere).
Attachment (Paper Roll Clamp, Bale clamp, Side sifter, hanged fork, Puspull, Doubledeep, Bucket, Rotating Fork, Fork Stabilizer, Rum Fork, Fork Shoes).
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