All About Forklifts

All About Forklifts
Training Document by : Prathap Chandran
Date : 07.10.2022
Version 1.0

Types of Forklifts – As Per Drive Type
• Diesel Engine
• Petrol / LPG or both of it
• Electric
• Hybrid – combination Diesel & Electric
• Hand Pallet Trucks

Type of Forklifts – By Application
• Outdoor Application
• Diesel Forklifts
• Outdoor & Indoor application
• LPG/ Petrol Forklifts
• Indoor Application
• Electric Forklifts

Diesel Forklifts -Types
• Light Duty Forklifts 1-3 ton
• Industrial Duty Forklifts 4- 10 ton
• Heavy Duty : 12-45 tons
• Container Handlers
• Side Loaders [ 1 to 5 tons]
• Multi Direction
• Single direction
• Muti Terrain Duty Forklifts
• 2 wheel drive
• 4 wheel drive
• Telescopic Forklifts

Electric Forklifts -Types
• Electric Forklifts – 3 wheel [ 1, 1.5, 1.6 & 2 tons]
• Electric Forklifts – 4 wheel [2, 2.5, 3, 3.5, 4, 4.5, 5 tons]
• Multi Direction Side Loaders [ 1 to 5 tons]
• Reach Trucks [ 1.4, 1.6, 2 ton]
• VNA Articulated Trucks [ 1.4, 1.6, 2 ton]
• Order Pickers [1, 1.2 tons]
• VNA Turret Trucks
• Pallet Stackers [ 1.2, 1.4, 1.6, 2 ton]
• Power Pallet Tucks [2 ton]
• Scissor Lifts
• BoomLifts

Various Types of Forklifts

Load Centre

Forklift Components

Counterbalanced Forklift
The most common type of lift truck, also known as a forklift, is
the counterbalanced, sit-down truck. A weight located in the rear
of one of these trucks counterbalances the weight of the load,
ensuring the truck doesn’t tip forward.
A typical counterbalanced lift truck has:
• a capacity of 1800 to 3000 kgs
• a lifting height of about 4.5 to 4.8 meter
• and comes outfitted with lights, backup alarms and other
safety features.
Counterbalanced trucks are powered either by internal
combustion (IC) engines or electric motors.

Electric/LPG/Diesel - Which is Right?
The decision to use an
electric, LP or diesel
forklift is determined by
the application, run-time
requirements, number of
shifts, and environment of
your company. For
assistance in making that
decision, here are some
advantages and
disadvantages of each:

Electric Forklift- Pros & Cons
PROS
▪Zero tailpipe emissions = safer work environment
▪Less noise during operation
▪No outside storage of tanks is necessary
▪No engine, transmission, or radiator = cheaper
maintenance
▪Low center of gravity = better capacity and stability
ratings
▪Turning radius specs are better which increases
storage capacity and reduces potential for damage
▪Rearward visibility increased with no propane
cylinder in the way
▪Long major component life
▪Fewer waste fluids
▪Lowest total cost of ownership
CONS
▪May not perform well when required in high/constant
duty or cold/wet applications
▪Cleaning, watering, and charging requirements of the
battery may not be efficient in a multi-shift operation
▪Forgetting to charge the battery overnight can result
in significant productivity losses the next day
▪Initial investment is higher
▪Adequate ventilation around the lift is required when
charging the battery
▪Battery chargers have certain voltage requirements
and the existing electrical service must meet those
▪Proper safety equipment like eyewash stations and
proper flooring are additional costs to consider

LPG Forklift- Pros & Cons
PROS
▪Little risk associated with running out of fuel
other than the inconvenience of having to change
propane cylinders
▪Initial investment is lower
▪Better than most electric forklifts in high/constant
duty applications
▪Suitable for indoor applications except if there
are food or beverage requirements
CONS
▪Rearward visibility is restricted due to the location
of the propane tank
▪Liability exposure in the form of possible leakage
of the fuel system. Operators need to be trained in
safe handling of propane fuel.
▪Higher fuel costs
▪Higher chance of injuries due to the weight of the
tanks and frequency that they need to be changed
▪Freezing temperatures may cause starting or
reliability issues
▪Fossil fuel prices are predicted to increase over the
years and not readily available in remote locations

Diesel Forklift- Pros & Cons
PROS
▪Lower fuel costs
▪Diesel lifts product more drive line
torque at low RPM when compared to
LPG and electric
▪Rearward visibility is better since
there is no propane tank mounted on
the back
▪Lower total cost of ownership when
compared to LPG
▪Longer engine life than the LPG
CONS
▪Not suitable for indoor use without
expensive emissions accessories and
proper ventilation
▪Initial cost of investment is high
▪Bulk tank for fuel storage is
sometimes required and municipal
regulations may apply to the tank
installation
▪Fossil fuel prices are predicted to
increase over the years and not readily
available in remote locations

Rough Terrain Forklifts
Rough Terrain forklifts are used for outdoor construction and in areas
with difficult terrain. They have inflatable tires with thicker threads that
allow for increase stability on uneven ground. Rough terrain forklifts also
have engines that are more powerful so it can reach higher speeds, which
are perfect for transporting heavy loads across rugged terrain. These
forklifts have calibrated counterbalance at the back of the trucks to
prevent overbalancing.

Side Loaders
Side Loader forklifts are ideal for narrow working environments. The forks
are mounted to the side of the truck. Industrial side loader forklifts are
best for picking up wide or long loads such as timber, piping, and sheets.
There are typically 3 types:
• Enclosed cab – most commonly used outdoors
• Stand up – suited for indoor tasks
• Multi-way – wheels all rotate by 90 degrees, allowing for all-
direction transportation

Side Loaders - On Duty

Heavy Diesel Forklifts Ratings available :
12, 15, 16, 18, 20, 25, 30, 32, 45 tons etc…

Reach Stacker - 25 & 45 tons

Container Handler

Hand Pallet Truck & Manual Stacker

Electric Stacker - Types
Stackers are like Power Pallet Trucks but with a mast allowing the ability to lift pallets to a maximum
height of 5.4m They are also known for their ease of use and are cheaper than conventional forklifts.
This product is great to use in smaller warehouses.
There are two types of Stackers offered depending on the pallet type used being, ‘Fork Over’ and
‘Straddle Stackers’. Training Document by : Prathap Chandran

Power Pallet Trucks -Types

Reach Truck
Built to lift loads up to heights of 13m, these machines allow
warehouses to use very high aisle setups and ultimately save
space with narrow spacing between aisles (roughly 2.6m-3.1m).
There area Stand-On and Sit-On Reach Truck.
The Reach Truck capacities vary from 0.9 Tons - 3.0 Tons with the
1.4 Ton and 2 Ton being the most common option. Like all
warehousing equipment, Reach Trucks can only be used indoors
and must work on clean flat surfaces.

Reach Truck types • Single Reach Truck
• Double Reach Truck
• Mast Moving Reach Trucks
• Multi direction Reach Trucks

VNA Articulated Truck

Why VNA Trucks
1. Indoor and Outdoor Operations: The Very Narrow Aisle UAE is custom-built to stand heavy-duty use inside and out with superior ergonomics &
visibility. It can operate on any floor surface, eliminating the need for multiple pieces of equipment to load and unload your product. As a result,
many operators like the ability to easily drive this forklift into various nooks and corners of the warehouse or yard, handling multiple jobs without
any hassles.
2. Manages Loads in Smaller Spaces : Another significant advantage of VNA systems is that it is perfect for high-density warehouses where
efficiency is key. It is smaller, more maneuverable, and optimized for smaller warehouses spaces where heavy stock must be moved from every
available space in your warehouse. Moreover, it also facilitates and enhances a more clutter-free and generally spacious warehouse environment.
3. Higher Reach and Load Capacity : The VNA system can reach heights of up to 15 meters and can lift heavy loads with no hassles. Thus, its sleek
structure and build do not impede its weight-lifting capacity; instead, its ability to easily load and unload heavyweight goods makes it a popular
choice for warehouses looking for long-term storage solutions.
4. Wise Long-Term Investment for Warehouses; The VNA system is made specifically to help create a safer, faster-operating warehouse. Very
Narrow Aisle UAE is well-constructed with a body and chassis that is durable and strong, which provides a warehouse with the same quality of
service for a long period.
5. Increased Warehouse Capacity: A VNA system combined with expert warehouse planning means more space for goods, thanks to narrower, taller
aisles. One system can increase your warehouse capacity by more than 50% compared to the standard ones, allowing you to overcome the issue of
the cost involved in expanding or moving to a new warehouse when space becomes tight and can hit a company’s bottom line.

Order pickers
While reach trucks and turret trucks are used for storing and retrieving pallet
loads, order pickers are used for handling individual items or cases. An order
picker, also known as a stock picker or order selector, lifts the operator on a
platform along with the forks. The operator picks items from bulk storage
locations and places them directly onto a pallet on the forks of the truck.
Order pickers can safely move forward while in an elevated position. They can
be completely operator-guided or can run on wire guidance systems.

Turret Truck
The lift truck often chosen for work in very narrow aisles is the turret truck.
These trucks have pivoting forks that turn 90 degrees on either side and
traverse from side to side.
To put away a load, an operator drives down the aisle with the load facing
forward and then stops at the designated storage location. The forks pivot
to the appropriate side and lift the load to the desired height. Then the
forks traverse to their full extension, depositing the load. The forks return to
their original position before forward travel resumes.
Turret trucks can be completely operator guided or can run on a wire
guidance system—an attractive option in very narrow aisles. In man-up
trucks, the operator compartment rises with the load. In man-down trucks,
operators remain at floor level.
A good rule of thumb when choosing a turret truck is to measure speeds at
different elevations and compare mast sway. Training Document by : Prathap Chandran

Scissor Lift
Electric Diesel

Man Lift
Articulated Boom Telescopic

Spider Lift

Aisle Width

Pallet Storage - Racking

Right Truck As per Height

Single & Double Deep Racking

Pallet Types

Forklift Fee Lift
Free lift refers to how high a load can be lifted before the
mast starts to extend. The ability to free lift is important if
your lift truck will be lifting and maneuvering in areas where
overhead clearance is restricted, such as double-stacking in a
trailer.
- A mast with no free lift will extend upwards as soon as the
forks begin to lift.
- A full free lift mast allows the forks to raise to the top of the
mast’s inner section before the mast extends upward.

Forklift Mast Types
Single-Stage (aka Simplex) Mast : The single-stage mast, also known as a simplex mast, does not have free lift and only has one channel. The mast
must extend higher to stack loads, which is why this is seen outdoors where overhead clearance isn’t a concern (i.e., no limited lifting height).
Two-Stage (aka Duplex) Mast : The two-stage mast, also known as a duplex mast, has free lift available and is often used for stacking and double
stacking for indoor applications with limited overhead.
Two-stage mast forklifts have good visibility since there aren’t as many mast sections impeding the driver’s view. There’s a hydraulic cylinder in
the center of the mast to push loads upward. Loads can rise (to an extent) while the mast is stationary.
Three-Stage (aka Triplex) Mast : The most common and versatile forklift mast is the three-stage mast, or triplex mast. The outer stage on this
mast doesn’t move. It has two sliding rails and an angled stationary rail. The triple-stage mast has free lift and can reach greater heights, making it
good for warehouse applications.
Four Stage (aka Quad) Mast : The four-stage mast, or quad mast, has the highest reach of all. This mast has four sets of moving rails and chains
and is much more complex than other masts. It’s also important to note that the four-stage mast may have restricted visibility and require special
training to drive.
Conclusion: A forklift is an important tool when you’re moving and racking heavy loads. However, it’s vital to make sure you select the right
forklift with the right mast and know how to prevent forklift accidents.
To choose the forklift truck you need, you must know the vertical space of your facility (or if you’ll be outdoors), the height of the racks where
you’ll be placing or removing loads, and the sizes and shapes of the loads to be handled.

Forklift Heights
Maximum fork height (MFH) -Lift Height:
(also known as maximum fork height or MFH) tells you how high the forks will be with the mast fully extended. When choosing a
forklift mast, add at least six inches to the height of your topmost racking shelf. This will allow your operators to safely adjust loads
when the mast is fully extended.
Free fork height (FFH) --Free lift:
refers to how high a load can be lifted before the mast starts to extend. The ability to freelift is important if your lift truck will be lifting
and maneuvering in areas where overhead clearance is restricted, such as double-stacking in a trailer.
- A mast with no freelift will extend upwards as soon as the forks begin to lift.
- A full freelift mast allows the forks to raise to the top of the mast’s inner section before the mast extends upward.
Overall lowered height (OALH) - Lowered Height or Collapsed Height:
This is the distance from from the floor to the top of the mast when the mast is lowered. If your forklift needs to travel beneath a
garage or container door, the lowered height may be important.
Overall raised height (OARH) -Extended Height:
This measures the height from the top of the mast (or load backrest) with the mast fully extended.

Forks & Classifications

Tyre Types
A forklift’s tires are the only points of contact it has with the ground, and they can significantly affect its handling, safety, and maintenance
needs. Whether it be resilient, solid pneumatic or cushion tires, choosing the right tire for your application will maximize traction and prolong the
service life of your tires. Here are some key attributes pertaining to the more common forklift tire compounds:
Pneumatic -Pneumatic forklift tires are filled with compressed air, similar to the average tire you’d find in your car. These versatile forklift tires
can either be used for heavy-duty outdoor use or indoor use. They have a wider profile for optimal stability and grip as well as it provides a more
cushioned ride.
Solid - Solid pneumatic forklift tires are made entirely out of solid rubber. These forklift tires are ideal for outdoor locations and recycling centers
where there may be stray nails or glass on the ground. Solid tires are puncture resistant but provide a harsher ride for the operator.
Cushion/Press On - Cushion forklift tires are similar to solid rubber tires in that they do not require compressed air to function. These forklift
tires are made with a thin natural rubber compound which reduces chunking and cutting. These inexpensive forklift tires are used on both
electric and internal combustion forklifts but are not suited for heavy-duty outdoor applications.
Polyurethane -Polyurethane forklift tires have a longer lifespan than a conventional pneumatic or cushion forklift tires, but they are only
intended for indoor warehouses where there is little debris. These industrial tires provide better traction on a clean surface, but a stray rock or
improper usage could cause cracks or premature wear. Their solid design allows for a higher carrying capacity than pneumatic forklift tires, but
they can also provide a rough ride.
Polyurethane

Traction Battery Types
Forklift batteries are typically available in two different types:
Lead-acid batteries:
These liquid-filled batteries create electricity through a chemical reaction of sulfuric acid and lead plates.
Most lead-acid batteries need to be “watered” to keep them working, meaning you will have to regularly refill
the water in the battery unit to avoid burnout. It has a life of 1000-1500 battery cycles
Lithium-ion batteries:
These batteries are made up of a cathode, electrolyte, separator, anode and two current collectors, one
positive and one negative. The cathode and anode store the lithium, and the electrolyte carries lithium ions
with a positive charge through the separator. This movement creates the charge, and the electric current
flows through the device to the negative collector. These batteries are more compact than lead-acid
batteries, and they do not require any water maintenance. It has a life of 2500-3000 battery cycles
Lithium-ion batteries typically do not need to be replaced as often as lead-acid batteries, but they do have a
higher purchase cost. They also charge faster and more efficiently, with an average charging time of 1-2 hours
with no cooling period, while lead-acid batteries take 8 hours to charge and another 8 hours to cool down.

Battery capacity
VOLTAGE
The first thing you’ll want to determine is what voltage you need. The best forklift battery voltage depends on
the size of your machine. Typical voltage options include:
24 volt: Ideal for smaller electric lifts such as walkie stackers, pallet jacks and end riders.
36 volt: Designed for mid-size lifts such as narrow aisle forklifts.
48 volt: Used for machines like counterbalanced forklifts & reach trucks
80 Volt : Used for larger machines like 2.5/3 ton above counterbalanced forklifts & reach trucks from 2 ton
Make sure to confirm what voltage your forklift can handle, as the wrong voltage can cause significant damage.
AMP HOURS
Forklift battery amp hour is the rating of how much power the battery can provide within an hour. The higher
the amp hour, the more power generated by the battery. For the maximum power and run time, you’ll want to
choose the highest-rated amp hour battery that will fit in the battery compartment.

Battery Charges & Charging Requirements
• Singe Phase
Transformer Type
Transistor Type
• 3 Phase
Transformer Type
Transistor Type

Battery Maintenance – Lead Acid
There are many things that can shorten battery life, but by far the two major culprits are:
1.Opportunity charging, or “short cycling” a battery using a standard charger. This short cycling creates heat, which is the
main cause of premature battery failure.
2.Lack of water. This lack of water generates more heat, which shortens battery life dramatically.
▪ Do Check the Battery’s Water Level periodically
▪ Add water FREQUENTLY to maintain CORRECT level.
▪ Allow battery to charge fully before using.
▪ Avoid opportunity charging
▪ Keep FLAME, SPARKS, METALLIC OBJECTS away from
top of battery.
▪ Read instructions on Proper charger setting.
▪ Use Hydrometer to check state of charge.
▪ Keep battery top area clean and dry.
▪ Allow battery to COOL down before using after
charging.
▪ Keep charging equipment in good condition; clean
occasionally by blowing out with compressed air.
▪ Give COLD batteries EXTRA time to charge.
▪ Wash and neutralize batteries when required.
▪ Don’t discharge batteries below 20% charge.
▪ Don’t add TOO MUCH water.
▪ Don’t change batteries UNNECESSARILY.
▪ Don’t disconnect battery before turning charger off.
▪ Don’t damage connectors by dropping on floor.
▪ Don’t MEDDLE with charger adjustments.
▪ Don’t add anything other than water to batteries.
▪ Don’t ignore problems. Eliminate them with proper action.
▪ Don’t Use a Battery That Emits Smoke
▪ Don't Keep a discharged battery idle for long time.
▪ Don’t Swap Batteries Mid-Shift
▪ Don’t use Battery in Extreme Temperatures

Popular Forklift Brands
Diesel Units
TOYOTA
CAT
KOMATSU
NISSAN-UNICARRIERS
TCM
YALE
HYSTER
HELI
HANGCHA
Electric Units
LINDE
STILL
BT-TOYOTA
CROWN
HYSTER
YALE
JUNGHEINRICH
Heavy Forklifts
KALMAR
KONE CRANES
HYSTER
CVS Ferrari
Special Units
COMBILIFT
BULMOR
FLEXI
BENDI
Scissor Lifts
JLG
Genie
Haulotte
Aerial Platforms
JLG
Genie
Haulotte
Teupen

For any further details please contact me
Prathap Chandran
General manager
Emirates Forklifts Rental LLC
Al Quoz Indust. Area 4, Dubai, U.A.E
Email : prathap@emiratesforklifts.com
M: +971-55 9545303 / +971-50 5589322

All About Forklifts

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