Forklift - Plan

5/2/2020 Forklift - Wikipedia
Forklift
A forklift (also called lift truck, jitney, fork truck, fork Forklift
hoist, and forklift truck) is a powered industrial truck used to
lift and move materials over short distances. The forklift was
developed in the early 20th century by various companies,
including Clark, which made transmissions, and Yale & Towne
Manufacturing, which made hoists.[1][2][3] Since World War II,
the use and development of the forklift truck have greatly
expanded worldwide. Forklifts have become an indispensable
piece of equipment in manufacturing and warehousing.[4] In
Forklift being operated by a US
2013, the top 20 manufacturers worldwide posted sales of $30.4
airman.
billion, with 944,405 machines sold.[5]
Classification Vehicle
Industry Various
Contents Application Multiple
History Fuel source Various including:

Gasoline
General operations
Propane
Forklift control and capabilities
CNG
Design types Diesel
Low lift truck Lead Acid Battery
Towing tractor Fuel cell
Stacker
Powered Yes
Reach truck
Wheels Various wheel
Counterbalanced forklift
configurations
Sideloader
Telescopic handler Axles 2–3
Order picking truck Components Power source,

Articulated very narrow aisle counterbalanced trucks Mast, Frame,
Guided very narrow aisle truck Counterweight,
Guided very narrow aisle order picking truck Cab, Axles,
Truck-mounted forklift/sod loader Wheels, Overhead
Guard, Load
Specialized trucks
Articulated counterbalance trucks Backrest, Hydraulic
Pump, Hydraulic
Guided very narrow aisle trucks
Lines, Hydraulic
Marina forklifts
Controls, Hydraulic
Omnidirectional trucks
Cylinders and
UL 558 safety rated trucks
Attachments
Explosion proof trucks
U.S. Military 10K-AT "Adverse Terrain"
Automated forklift trucks
Methods of propulsion
Internal combustion
https://en.wikipedia.org/wiki/Forklift 1/21
Liquefied petroleum gas (LPG)

Battery electric
Hydrogen fuel cell
Counterbalanced forklift components
Attachments
Replacing or adding attachments
Lift truck associations and organizations
Forklift safety
Standards
Driver safety
Forklift training in the United States
Forklift training in the United Kingdom
Forklift training in Australia
Forklift training in New Zealand
Unit standards
Attachments
Safety Products
Pedestrian Detection Systems
Ultrasound Radars
RF Systems
Manufacturers' worldwide ranking
See also
References
External links
History
The middle nineteenth century through the early 20th century saw
the developments that led to today's modern forklifts. The
forerunners of the modern forklift were manually powered hoists
that were used to lift loads.[4] In 1906, the Pennsylvania Railroad
introduced battery powered platform trucks for moving luggage at
their Altoona, Pennsylvania, train station. World War I saw the
development of different types of material handling equipment in
the United Kingdom by Ransomes, Sims & Jefferies of Ipswich.
This was in part due to the labor shortages caused by the war. In
A forklift truck being used during
1917, Clark in the United States began developing and using World War II
powered tractor and powered lift tractors in their factories. In 1919,
the Towmotor Company, and Yale & Towne Manufacturing in 1920,
entered the lift truck market in the United States.[2] Continuing development and expanded use of
the forklift continued through the 1920s and 1930s. The introduction of hydraulic power and the
development of the first electric power forklifts, along with the use of standardized pallets in the late
1930s, helped to increase the popularity of forklift trucks.[4]
The start of World War II, like World War I before, spurred the use of forklift trucks in the war
effort.[6] Following the war, more efficient methods for storing products in warehouses were being
implemented. Warehouses needed more maneuverable forklift trucks that could reach greater
heights and new forklift models were made that filled this need.[7] For example, in 1954, a British
company named Lansing Bagnall, now part of KION Group, developed what was claimed to be the
first narrow aisle electric reach truck.[6] The development changed the design of warehouses leading
to narrower aisles and higher load stacking that increased storage capability.[6] During the 1950s and
1960s, operator safety became a concern due to the increasing lifting heights and capacities. Safety
features such as load backrests and operator cages, called overhead guards, began to be added to
forklifts produced in this era.[4] In the late 1980s, ergonomic design began to be incorporated in new
forklift designs to improve operator comfort, reduce injuries and increase productivity.[8] During the
1990s, exhaust emissions from forklift operations began to be addressed which led to emission
standards being implemented for forklift manufacturers in various countries.[9] The introduction of
AC power forklifts, along with fuel cell technology, are also refinements in continuing forklift
development.[4][10]
General operations
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- Forklift cab with control layout.
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".
Forklifts are a critical element of warehouses and distribution centers. It’s imperative that these
structures be designed to accommodate their efficient and safe movement. In the case of Drive-
In/Drive-Thru Racking, a forklift needs to travel inside a storage bay that is multiple pallet positions
deep to place or retrieve a pallet. Often, forklift drivers are guided into the bay through guide rails on
the floor and the pallet is placed on cantilevered arms or rails. These maneuvers require well-trained
operators. Since every pallet requires the truck to enter the storage structure, damage is more
common than with other types of storage. In designing a drive-in system, dimensions of the fork
truck, including overall width and mast width, must be carefully considered.[11]
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 ergonomic 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.[12]
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
Dedicated container forklift of
operate on non-level ground. Skilled forklift operators annually
HMNZS Canterbury vessel of the
compete in obstacle and timed challenges at regional forklift
New Zealand Navy
rodeos.
Design types
Low lift truck
Powered pallet truck, usually electrically powered. [13] Low lift

trucks may be operated by a person seated on the machine, or by
a person walking alongside, depending on the design.
Towing tractor
A truck-mounted forklift.
May be internal combustion engine or electrically powered.
Stacker
Usually electrically powered. A stacker may be operated by a person seated on the machine, or by a
person walking alongside, depending on the design.
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 is
common in North America, and moving mast which is common in the rest of the world, and
generally regarded as safer
Counterbalanced forklift
Comes in Stand on End Control, Stand on Center Control, and Sit Down Center Control, which is the
most numerous
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 Electric forklift
Telescopic handlers have Hybrid drivetrains.
Order picking truck
Similar to a reach truck, except the operator either rides in a

cage welded to the fork carriage or walks alongside, dependent
on design. If the operator is riding in the order picking truck,
they wear a specially designed safety harness to prevent falls. A
special toothed grab holds the pallet to the forks. The operator
transfers the load onto the pallet one article at a time by hand.
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 Electric Multidirectional Sideloader
internal combustion engine or an electric motor. Electric motors
are the 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.
A reach truck with a pantograph
allowing the extension of the forks in
Guided very narrow aisle truck tight aisles.
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.[14]
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.
Specialized 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
A straight mast
throughput with guided very narrow aisle trucks, while also being capable
container handler at
of loading trucks, which VNA units are incapable of doing.[15] Haikou Xiuying Port,
Hainan, China
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.
Marina forklifts
These lifts are found in places like marinas and boat storage facilities. Featuring tall masts, heavy
counterweights, and special paint to resist seawater-induced corrosion, they are used lift boats in
and out of storage racks. Once out, the forklift can place the boat into the water, as well as remove it
when the boating activity is finished. Marina forklifts are unique among most other forklifts in that
they feature a "negative lift" cylinder.[16] This type of cylinder allows the forks to actually descend
lower than ground level. Such a functionality is necessary, given that the ground upon which the
forklift operates is higher than the water level below. Additionally, marina forklifts feature some of
the longest forks available, with some up to 24 feet long. The forks are also typically coated in
rubber[17] to prevent damage to the hull of the boats that rest on them. Manufacturers of marina
forklifts include Wiggins, Hoist, and Toyota.
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. An 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'.
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 ask them what the correct safety standard is for your
workplace.
UL 583 is the Electric equivalent of UL 558. As with UL 558 it is a two-stage standard.
Explosion proof trucks
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. [19][20] Automated forklifts are also called forked automated
guided vehicles and are already available from a growing number of suppliers.[21]
Methods of propulsion
Internal combustion
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.
Liquefied petroleum gas (LPG)
These forklifts use an internal combustion engine modified to run on LPG. The fuel is often stored in
a gas cylinder mounted to the rear of the truck. This allows for quick changing of the cylinder once
the LPG runs out. LPG trucks are quieter than their diesel counterparts, while offering similar levels
of performance.[22]
Battery electric
Powered by lead-acid batteries or, increasingly, lithium-ion batteries, include: cushion tire forklifts,
scissor lifts, order pickers, stackers, reach trucks and pallet jacks. Electric forklifts are primarily used
indoors on flat, even surfaces. Batteries prevent the emission of harmful fumes and are
recommended for indoor facilities, such as food-processing and healthcare sectors.
Hydrogen fuel cell
Fuel cell forklifts are powered by a chemical reaction between hydrogen and oxygen.[23] The reaction
is used to generate electricity which can then be stored in a battery and subsequently used to drive
electric motors to power the forklift. This method of propulsion produces no local emissions, can be
refueled in 3 minutes, and are often used in refrigerated warehouses as their performance is not
degraded by lower temperatures.[10]
Counterbalanced forklift components

A typical counterbalanced forklift contains the following components:
Truck frame – 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 – 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 battery
may serve as part of the counterweight.
Cab – the area that contains a seat for the

operator along with the control pedals, steering
wheel, levers, switches and 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.[24]
Overhead guard – 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.[25] Image of an electric forklift with component
descriptions
Power source – may consist of an internal
combustion engine that can be powered by LP
gas[26], Proper cylinder mounting and LPG forklift
cylinder safety., CNG, gasoline or diesel fuel. Electric forklifts are powered by either a battery or
fuel cells that provides power to the electric motors. For warehouses and other indoor
applications, electric forklifts have the advantage of not producing carbon monoxide.[27][28]
Tilt cylinders – hydraulic cylinders that are mounted to the truck frame and the mast. The tilt
cylinders pivot the mast backwards or forwards to assist in engaging a load.
Mast – 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.[29]
Carriage – 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.[27]
Load backrest – 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.[27]
Attachments – may consist of a mechanism which is attached to the carriage, either
permanently or temporarily, to help in the 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.[30]
Attachments
Below is a list of common forklift attachments:[31]
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 – 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.[32]
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 – 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.[33] Hydraulic elevator for
Pole attachments – in some locations, such as carpet warehouses, tractors
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 – 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.[33]
Slip sheet attachment (push-pull) – 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 – 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 – 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 – 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.
Snow plough – a mechanical attachment that allows the forklift operator to easily and quickly
move snow. The snow plough can often also be utilised at other times of the year as an
attachment to clean up workplaces.[34]
Skips – a mechanical attachment that is fitted to the forklift to allow safe and speedy removal of
waste to the appropriate skip or waste compactor. There are two types of skips: the roll-forward
type and the bottom-emptying type.[35]
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 online calculators to a typical load capacity chart
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 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.
Lift truck associations and organizations

There are many national as well as continental associations related to the industrial truck industry.
Some of the major organizations are listed as:
Industrial Truck Association (ITA) (North America)[36]

Material Handling Equipment Distributors Association (MHEDA) (North America)[37]
Fédération Européenne de la Manutention – European Federation of Materials Handling
(FEM)[38]
Fork Lift Truck Association (FLTA) (UK)[39]
British Industrial Truck Association (BITA)[40]
Japan Industrial Vehicles Association (JIVA)[41]
Korean Construction Equipment Manufacturers Association (KOCEMA)[42]
There are many significant contacts among these organizations and they have established joint
statistical and engineering programs. One program is the World Industrial Trucks Statistics (WITS)
which is published every month to the association memberships. The statistics are separated by area
(continent), country and class of machine. While the statistics are generic and do not count
production from most of the smaller manufacturers, the information is significant for its depth.
These contacts have brought to a common definition of a Class System to which all the major
manufacturers adhere.
Forklift safety
Standards
Forklift safety is subject to a variety of standards worldwide. The most important standard is the
ANSI B56—of which stewardship has now been passed from the American National Standards
Institute (ANSI) to the Industrial Truck Standards Development Foundation (ITSDF) after multi-
year negotiations. ITSDF is a non-profit organization whose only purpose is the promulgation and
modernization of the B56 standard.[43]
Other forklift safety standards have been implemented in the United States by the Occupational
Safety and Health Administration (OSHA) and in the United Kingdom by the Health and Safety
Executive.[44]
Driver safety
In many countries, forklift truck operators must be trained and certified to operate forklift trucks.
Certification may be required for each individual class of lift that an operator would use.[45]
Forklift training has many names, such as forklift licensing or forklift certification. Whichever term
is used, training must adhere to federal or national standards.
Health care providers do not recommend that workers who drive or use heavy equipment such as
forklifts treat chronic or acute pain with opioids.[46]
Forklift training in the United States
In the United States, workplace forklift training is governed federally by OSHA the Occupational
Safety and Health Administration. In 1999, OSHA updated its 29 CFR 1910.178 regulations
governing "Powered Industrial Trucks" (the term OSHA uses to include forklifts among other types
of industrial vehicles.) A major component of these regulations deals with forklift operator training.
The standard requires employers to develop and implement a training program based on the general
principles of safe truck operation, the types of vehicle(s) being used in the workplace,[47] the hazards
of the workplace created by the use of the vehicle(s), and the general safety requirements of the
OSHA standard. OSHA believes that trained operators must know how to do the job properly and do
it safely as demonstrated by workplace evaluation. Formal (lecture, video, etc.) and practical
(demonstration and practical exercises) training must be provided. Employers must also certify that
each operator has received the training and evaluate each operator at least once every three years.
Prior to operating the truck in the workplace, the employer must evaluate the operator's
performance and determine the operator to be competent to operate a powered industrial truck
safely. Refresher training is needed whenever an operator demonstrates a deficiency in the safe
operation of the truck.[48]
Forklift training in the United Kingdom
In the UK, the Provision and Use of Work Equipment Regulations state that operators of forklift
trucks must be adequately trained, the general standards of that training and good operating practice
are found in the HSE Code of Practice 117 (Third edition)[49] issued in 2013. Third party
organisations have developed de facto 'best practice' standards for forklift training, commonly
referred to in the UK as a 'forklift licence', these are no longer recognised as proof of training as
defined in the COP 117 (third edition) and as such training is not a legal requirement as is commonly
believed.[50] Organised training however helps to demonstrate that an employer has taken steps to
ensure its 'duty of care' in the unfortunate event of an accident.
In the UK, forklift training is carried out by a number of different voluntary standard training
organisations, They can be directly recognised by the HSE who have formed a new organisation
known as "Accrediting Body Association Work place transport 2012".[51] In all cases qualified forklift
instructors must be registered with at least one of the voluntary training organisations. Although
RTITB operators are registered on a database which has to be a 3 yearly basis, the amount of time
determined between refresher courses is subject to the H&S Executive, Insurance companies or
company policies. The H&S Executive (HSG136 Workplace Transport Safety) does recommend re-
training/testing every 3 to 5 years.[52]
Forklift instructors throughout the UK tend to operate either as small independent training
companies or as a part of a larger training provider. Training is delivered in one of two ways; on-site
(sometimes referred to as in-house training) where training is delivered to a clients' premises
making use of their own equipment, or off-site (public courses) at a training centre. Training centres
offer the opportunity for the unemployed with little or no forklift operating experience to achieve a
certificate of competence and increase their employment opportunities. Training certification
standards at schools tends to follow closely the standard required by their individual Training
Standards Accrediting Body to which they are affiliated. It is not unusual for a Training school to be
registered with one or more body at any one time.
The British Industrial Truck Association (BITA) categorises the different forklift truck types into
groups and assigned a unique identifier to each classification. Known as the ‘BITA List’ it has become
accepted as a standard in the UK. Forklift training certificates display the appropriate BITA
classification to clearly identify the confines of the certification.[53]
Forklift training in Australia
Prior to 2011 all States and Territories of Australia independently regulated occupational health and
safety in that state, including forklift licensing.
Whilst the Occupational Health and Safety laws of the different states were based on similar
underlying principles there were differences between the various jurisdictions in the detail and
application of those Occupational Health and Safety laws.
In 2008 the Inter-Governmental Agreement for Regulatory and Operational Reform in Occupational
Health and Safety was formed between the Commonwealth of Australia and the six states and two
territories of Australia to formalize cooperation between these jurisdictions on the harmonization of
Occupational Health and Safety legislation.[54]
As a result, the national Model Work Health and Safety Act (WHS) was enacted following a review of
work health and safety laws across Australia; said review involved significant public consultations
effort. This act was finalized in June 2011.[55]
This act formed a framework for the individual jurisdictions to enact supporting legislation, as the
individual jurisdictions are tasked with managing State and Territory Occupational Health and
Safety laws, including the issue of licences coming under the legislation.
Each individual state and territory issue licences in their own jurisdiction, including what is known
as "high-risk work licences" for high-risk work. Forklift licences are classed as "high-risk work
licences".[56]
To obtain a forklift licence in any State or Territory an applicant must undertake a training course
with an approved training organisation and then, on completion of the course, apply to the
appropriate State or Territory for a forklift licence. The unit of competence is known as the National
High Risk Licence Unit of Competence TLILIC2001 – Licence to Operate a Forklift Truck, or in the
case of an LO licence Unit of Competence TLILIC2002 – Licence to Operate an Order Picking
Forklift Truck. There is a fee attached which varies from jurisdiction to jurisdiction.
Forklift licences issued in one jurisdiction are recognized in all. Licence cancellation in one
jurisdiction is also recognized in all.
Forklift training in New Zealand
Forklift operator training is divided into two types:[57]
Operator's certificate (previously OSH certificate), to operate a forklift in a private yard or area.
Forklift (F) driver licence endorsement, to drive a forklift on public roads.
The operator's certificate is based on the Approved Code of Practice for Training Operators and
Instructors of Powered Industrial Lift Trucks ('ACOP')[58] published in 1995 by the then Department
of Labour. It gives permission for operators to operate a forklift in an enclosed space (i.e. a space not
considered to be a 'road').
To use a forklift on a public road, the operator must obtain a forklift (F) endorsement on their driver
licence. Operators with a class 1 (car) licence and an F endorsement may only operate forklifts up to
18,000 kg gross laden weight, while those holding a class 2 (medium rigid) licence and an F
endorsement can operate a forklift of any gross laden weight.
The ACOP is a set of best practices, guidelines and recommendations for training a forklift operator.
However, training can be tailored to the operator's specific needs and the attachments they use, as
required under the Health and Safety at Work Act 2015.[59]
Training consists of a theory session delivered in-person or online followed by a brief practical
assessment of 15–20 minutes. If the ACOP guidelines are followed this consists of a stacking and
destacking pallets at low, medium and high levels, as well as driving forwards and in reverse around
a coned figure-of-eight while carrying a load.
Unit standards
Unit standards are available for forklift training but are not required. The primary unit standard is
US10851.[60]
Attachments
The ACOP deals specifically with a forklift operator using only the standard forks. Forklift
attachments, such as barrel clamps, fork extensions, rotators and personnel cages are covered under
a separate unit standard (US10852). It is not mandatory to achieve a unit standard; a company can
simply induct the operator on the attachments used.
Safety Products
A number of solutions can be found on the market today to reduce occupational hazards caused by
forklifts.
Pedestrian Detection Systems
These are proximity sensors that detect objects and pedestrians

from a few centimeters to several meters. The sensor makes the
difference between a person and an object and alerts the driver
without useless alarms. Based on stereovision, an algorithm
analyses on real time if a person is in a blind zone of the forklift.
Ultrasound Radars
A pedestrian detection system.
Ultrasonic sensors are proximity sensors that detect objects at
distances ranging from a few centimeters to several meters. The
sensor beeps and measures the time it takes for the signal to
return. It does not discriminate between people and objects. Any obstacle located behind the truck
will be detected. Normally, this type of sensor is used only for detection in rear areas.
RF Systems
These are solutions that alert forklift drivers of the people found in its vicinity. Pedestrians must
carry a radio frequency device (electronic tags) which, emit a signal when a truck detects them,
alerting the driver of the potential risk of an accident. It detects both in the front and at the back and
it differentiates between people and the usual obstacles found in warehouses. For this reason, the
driver is only alerted when there is a pedestrian near the truck. There are different solutions on the
market:
Pedestrian Alert System PAS [61]
Manufacturers' worldwide ranking

Every year Modern Materials publishes a Top 20 Global Ranking of Forklift Manufacturers by sales
in dollars.[62] A modified copy of the report is below in a sortable table.
North
2013 2014 World
Rank Company Name American Country
Rank Revenue Headquarters
Brands
Toyota, BT,
1 Toyota Industries 1 $7,712,000,000 Aichi Japan
Raymond
VOLTAS, Linde,
2 KION Group 2 $5,314,000,000 Wiesbaden Germany
STILL, OM, Baoli
Jungheinrich Lift
3 3 $3,033,000,000 Jungheinrich Hamburg Germany
Truck Corp.
Hyster-Yale Material Hyster, Yale,
4 4 $2,767,000,000 Cleveland, Ohio USA
Handling UTILEV
Crown Equipment New Bremen,
5 5 $2,500,000,000 Crown, Hamech USA
Corporation Ohio
Mitsubishi Caterpillar
6 6 $2,159,000,000 Mitsubishi, CAT Sagamihara Japan
Forklift America
Nissan, Barrett,
UniCarriers Americas
Atlet, TCM,
Corporation (http://ww
7 7 $1,533,000,000 UniCarriers (http:// Tokyo Japan
w.unicarriersamericas.
www.unicarriers.c
com/)
o.jp/en/)
8 Anhui Forklift Group 8 $1,123,000,000 Heli Hefei, Anhui China
Zhejiang Hangcha
9 Engineering 9 $971,000,000 HC Hangzhou China
Machinery Co.
10 Komatsu Utility Co. 10 $900,000,000 Komatsu, Tusk Tokyo Japan
Clark Material South
11 11 $741,000,000 Clark Seoul
Handling Company Korea
South
12 Doosan Infracore 12 $683,000,000 Doosan Seoul
Korea
Hyundai Heavy South
13 13 $477,000,000 Hyundai Ulsan
Industries Korea
Lonking Forklift
14 14 $190,000,000 Lonking Shanghai China
Company, Ltd
14 Combilift 16 $190,000,000 Combilift Monaghan Ireland
16 Tailift 15 $181,000,000 Tailift, Worldlift Taichung Taiwan
17 Hubtex 17 $108,000,000 Hubtex Fulda Germany
18 Hytsu 18 $82,000,000 Hytsu Shanghai China
Godrej & Boyce Not available in
19 19 $76,000,000 Mumbai India
Manufacturing N.A.
20 Paletrans Equipment 20 $69,000,000 Paletrans Cravinhos Brazil
See also
Electrocar
Forklift Driver Klaus – The First Day on the Job
Hydrogen vehicle
Non-road engine
Pallet
Pallet jack
Slip sheet
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ublications/pages/model-work-health-safety-act-23-june-2011) Archived (https://web.archive.org/
web/20140328060437/http://www.safeworkaustralia.gov.au/sites/swa/about/publications/pages/m
odel-work-health-safety-act-23-june-2011) 28 March 2014 at the Wayback Machine
56. High Risk Work Licences (http://www.safeworkaustralia.gov.au/sites/swa/whs-information/licensi
ng/high-risk-work/pages/high-risk-work-licences-high-risk-work) Archived (https://web.archive.or
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57. "Forklift training in New Zealand" (https://www.drivingtests.co.nz/resources/forklift-driver-

training/). Archived (https://web.archive.org/web/20170327060653/https://www.drivingtests.co.nz/
resources/forklift-driver-training/) from the original on 27 March 2017.
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Trucks" (https://www.competenz.org.nz/assets/Uploads/ACOP-Aug-1995.pdf) (PDF). Archived (h
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P-Aug-1995.pdf) (PDF) from the original on 10 February 2018.
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16 April 2018.
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vt.nz/ncea/assessment/view-detailed.do?standardNumber=10851) from the original on 11 May
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External links
Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts (https://www.cdc.
gov/niosh/docs/2001-109/), an alert from the National Institute for Occupational Safety and
Health (NIOSH)
Safety and Health Topic: Powered Industrial Trucks (http://www.osha.gov/SLTC/poweredindustria
ltrucks/index.html), from the Occupational Safety and Health Administration (OSHA)
Retrieved from "https://en.wikipedia.org/w/index.php?title=Forklift&oldid=951734732"
This page was last edited on 18 April 2020, at 16:14 (UTC).
Text is available under the Creative Commons Attribution-ShareAlike License; additional terms may apply. By using this
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History Fuel source Various including:

Order picking truck Components Power source,

Liqueﬁed petroleum gas (LPG)

Forklift control and capabilities

Forklift trucks are available in many variations and load

In addition to a control to raise and lower the forks (also known

Low lift truck

Powered pallet truck, usually electrically powered. [13] Low lift

Forklifts built in countries such as Iran or Russia will typically

Comes in Stand on Center Control, and Sit Down Center

Order picking truck

Similar to a reach truck, except the operator either rides in a

Articulated very narrow aisle counterbalanced trucks

Sometimes called "Flexi or Bendi Trucks" after two of the largest

Guided very narrow aisle order picking truck

Truck-mounted forklift/sod loader

Articulated counterbalance trucks

UL 558 safety rated trucks

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

U.S. Military 10K-AT "Adverse Terrain"

Automated forklift trucks

Liqueﬁed petroleum gas (LPG)

Hydrogen fuel cell

Counterbalanced forklift components

Cab – the area that contains a seat for the

Below is a list of common forklift attachments:[31]

Rotator – to aid the handling of skids that may have become

Replacing or adding attachments

It is possible to replace an existing attachment or add one to a

Lift truck associations and organizations

Industrial Truck Association (ITA) (North America)[36]

Forklift training in the United States

Forklift training in the United Kingdom

Forklift training in Australia

Forklift training in New Zealand

Forklift operator training is divided into two types:[57]

Pedestrian Detection Systems

These are proximity sensors that detect objects and pedestrians

Pedestrian Alert System PAS [61]

Manufacturers' worldwide ranking

13. "Pallet Racking Systems Ltd" (http://www.palletrackingsystemsltd.co.uk/glossary/forklift-truck/).

30. "Forklift Operator Safety Training" (http://www.masco.net/safety/forklift_safety/forklift_training_we

57. "Forklift training in New Zealand" (https://www.drivingtests.co.nz/resources/forklift-driver-

Retrieved from "https://en.wikipedia.org/w/index.php?title=Forklift&oldid=951734732"

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