What are the dimensions of forklift forks?
Forklift fork dimensions are generally 1070, 1220, and 1550 mm. The first two are more common.
Forklift Loading Techniques
1. Forklift Loading
Loading Procedure: The process of a forklift loading goods can be summarized into eight actions.
(1) Approaching the Stack: After starting the forklift, drive it to the front of the stack and stop it, depending on its position.
(2) Verticalizing the Mast: After the forklift stops, put the gear lever in neutral and push the tilt lever forward to return the mast to a vertical position.
(3) Adjusting the Fork Height: Pull the lifting lever back to raise the forks so that the fork tips are aligned with the undercarriage clearance or pallet fork holes.
(4) Loading the Goods: Shift the gear lever into forward first gear and slowly move the forklift forward until the forks are engaged in the undercarriage clearance or pallet fork holes. When the forks contact the goods, brake the forklift.
(5) Slightly lift the forks. Pull the lifting lever back to raise the forks to a height where the forklift can leave the operating position.
(6) Tilt the mast back. Pull the tilt lever back to tilt the mast to its maximum position.
(7) Exit the loading position. Shift the gear lever to reverse, release the brake, and reverse the forklift to a position where the goods can be lowered.
(8) Adjust fork height. Push the lifting lever forward to lower the forks to a height of 200-300mm from the ground. Reverse the forklift and drive towards the loading location.
Operating Requirements:
A. Whether tilting the mast or adjusting the fork height, the actions must be continuous and successful in one go. Avoid repeated adjustments to improve work efficiency. When the forks are engaged to retrieve goods, the fork engagement speed can be controlled using the clutch.
B. Once the forks are fully engaged in the undercarriage clearance or pallet fork holes, stop the forklift, put the gear lever in neutral, and then complete other actions.
C. When a forklift is carrying goods, the mast should generally be in a tilted-back position. When picking up special goods that prevent the mast from tilting backward, the mast should at least be in a vertical position. Otherwise, measures such as securing the mast should be taken; heavy-duty forklifts are never allowed to travel with the mast tilted forward.
2. Unloading Goods with a Forklift
Unloading Procedure: The process of unloading goods with a forklift can be summarized into eight actions.
(1) Approaching the Loading Location. The forklift drives to the unloading location and stops, preparing for unloading.
(2) Adjusting the Fork Height. Pull the lifting lever backward, raising the forks to the required height for loading.
(3) Positioning the Forklift. Place the gear lever in forward gear, and the forklift slowly moves forward until the forks are above the load (pallet). Stop and brake.
(4) Verticalizing the Mast. Push the tilt lever forward, tilting the mast forward and returning it to a vertical position. When there is a slope, the mast may tilt forward.
(5) Lowering the Forks to Unload. (5) Push the lifting lever forward. Slowly lower the forks, placing the goods (pallet) smoothly on the stack, then slightly lift the forks off the bottom of the goods.
(6) Reverse and release the forks. Put the gear lever in reverse, release the brake, and reverse the forklift to a distance where the forks can be lowered.
(7) Tilt the mast back. Pull the tilt lever back, tilting the mast to its maximum position.
(8) Adjust the fork height. Push the lifting lever forward, lowering the forks to 200-300mm above the ground. Move the forklift away to the pickup location to begin the next round of pickup and pickup operations.
Operating requirements: When operating the lever, the movements should be gentle and the speed appropriate. Sudden raising or lowering of the forks is strictly prohibited to avoid scattering and damaging goods or injuring people. When aligning with the pickup location, leave an appropriate distance between the forks and the location to fine-tune the forklift to ensure it is aligned with the location. Do not turn the steering wheel to its maximum position. Vertical mast loading and unloading operations must be performed only after aligning the forklift with the cargo position, ensuring the forklift moves with the mast tilted back. After unloading, when removing the forks, the fork height must be appropriate; dragging or scraping the cargo is prohibited. When picking up pallets, the forks should be aligned with the pallet's insertion holes and inserted horizontally, minimizing collisions.
3. Key Techniques for Forklift Loading, Unloading, and Stacking Operations
The maximum lifting capacity of a forklift refers to the maximum weight of goods that the forklift can load or unload when the center of gravity of the goods and the load center are on the same vertical line. The load center is the horizontal distance from the center of gravity of the goods to the front wall of the vertical section of the forks. Generally, the load center of a forklift is 400–600 mm. When the center of gravity of the goods is within the load center range, the forklift can perform normal loading and unloading operations according to its rated lifting capacity. When the center of gravity of the goods exceeds the load center range, it may compromise the longitudinal stability of the forklift, preventing it from performing loading and unloading operations according to its rated lifting capacity and potentially causing an accident. Therefore, the driver must load according to the load center specified in the forklift's instruction manual. If the center of gravity of the cargo exceeds the load center of gravity range, the load capacity will be reduced accordingly to ensure safe operation.
Forklifts often perform short-distance reciprocating transport operations within workshops, yards, or warehouses. These locations typically have narrow and winding roads, resulting in limited lateral space for vehicles. Oversized cargo can impede passage and increase the risk of collisions with other objects. Maintaining a minimum lateral safety distance from obstacles on both sides is crucial to prevent collisions. Higher speeds lead to lower stability and greater swaying, necessitating a greater minimum safety distance and increasing the minimum distance between the forklift and obstacles. When traveling on curves, the vehicle generates centrifugal force, which is proportional to speed. When this force reaches a certain limit, the forklift is prone to tipping over. Therefore, slow speeds are essential when turning. Furthermore, forklifts rely on their attachments for support or gripping, rather than being secured, and are often positioned by their own weight. At high speeds, the forklift's stability is poor, with large swing amplitudes, leading to instability of the cargo and a high risk of tipping over.
Forklift engines are generally mounted longitudinally at the rear, and counterbalance forklifts are equipped with counterweights at the rear. Therefore, under no-load conditions, longitudinal stability is good. However, when loaded, because the load's center of gravity is outside the wheel support profile, the possibility of longitudinal tipping increases. In actual operation, the longitudinal stability of a forklift varies depending on the attachments and operating methods used. For example, when using a hook on a longitudinal slope, if the lifting mast tilts forward and the cargo reaches the forklift's maximum lifting height, the forklift's longitudinal stability decreases significantly, making longitudinal tipping most likely. When making sharp turns on a slope, if the cargo is lifted too high and the speed is too high, lateral tipping is very likely to occur due to centrifugal force. Forklift stability is a crucial factor in safe operation. Therefore, in practice, besides minimizing turning speed, it's essential to choose routes with gentle slopes and large turning radii, and appropriately lower the center of gravity of the load to improve forklift stability. During operation, strictly adhere to operating and safety procedures, and correctly handle various situations to ensure safe forklift operation.
Familiarity with forklift operation and its scope is helpful for the correct selection and use. Compared to other loading and unloading equipment, such as overhead cranes and gantry cranes, forklifts are characterized by their small size, self-loading and unloading capabilities, ability to operate with loads, limited aisle space, and small turning radius. In actual operation, forklifts can reduce the number of loading and unloading personnel by 1-2. Since there is no contact with personnel during loading and unloading, their safety is high compared to direct handling. Because forklifts can independently load, unload, run, and stack, their loading and unloading efficiency is high, and their handling capacity is large. Furthermore, they require little floor space during operation, maximizing warehouse space utilization. The biggest advantage of forklifts is their ability to work in conjunction with other loading and unloading machinery. Therefore, using forklifts across workshops and factories for loading, unloading, and stacking, especially for quantitative and timed loading and unloading on assembly lines, is unmatched by other loading and unloading machinery.
Forklifts can also be used as towing vehicles and flatbed trailers to transport goods onto and off assembly lines. If equipped with various attachments, forklifts can also handle various specially shaped goods.
Using forklifts for loading and unloading operations also has some limitations and disadvantages: for example, it is obviously uneconomical when the distance for loading and unloading goods is too long or exceeds 150m; the mast of the forklift will vibrate during loading and unloading operations; and the road surface along the forklift's operating route has certain requirements for flatness.
When selecting a forklift, the operating aisle and road surface requirements should be considered. For flat roads or unavoidable surfaces containing slag or scrap metal, solid-tire forklifts are preferable; for uneven roads, pneumatic-tire forklifts should be used. In stacking operations or situations requiring efficient use of yard and warehouse space, forklifts with high lifting heights or multi-stage masts are recommended. When operating in warehouses with low masts or low ceilings, or when entering containers, low-mast (low lifting height) forklifts or forklifts with fully free-lift forks can be used.
During forklift operation, at the specified load center of gravity, the maximum load on the forks must not exceed the rated lifting capacity. If the center of gravity of the goods changes (e.g., the center of gravity rises), the load capacity should be reduced accordingly. Adjust the fork spacing according to the size of the goods to ensure even weight distribution between the forks. Do not use the forks to pry up buried items; calculate the prying force beforehand if necessary. When inserting the forks into a stack of goods, the fork carriage should tilt forward; after loading the goods onto the forks, the fork carriage should tilt backward to ensure the goods are close to the fork sides before proceeding. Raising and lowering the fork carriage should generally be done from a vertical position. Use the handbrake during loading and unloading to stabilize the fork lugs. Standing under the fork carriage is strictly prohibited, and riding on the forks during lifting is strictly forbidden. The speed of lifting and lowering goods should not be excessive. When the forks are tilted to their extreme positions or raised to their maximum height, the control lever must be quickly placed in the neutral position. When operating one lever, ensure the other lever does not move. Lifting and lowering goods should generally be done when the mast is vertical. When carrying goods, the forks should be approximately 300mm off the ground; emergency braking and sharp turns are prohibited. Forklifts carrying goods should not be parked for extended periods on steep inclines, nor should they descend rapidly; if necessary, reverse downhill. When handling large loads, if the load obstructs the driver's view, the forklift should be reversed at low speed. It is strictly forbidden to leave the engine idling unattended after stopping, and it is even more forbidden to leave the driver's seat with loads suspended in the air. When the forklift stops mid-operation and the engine is idling, the mast should be tilted back and retracted. After the engine stops, the carriage should be lowered and the forks tilted forward to touch the ground. During operation, if any suspicious noise or abnormal phenomena are observed, the forklift must be stopped immediately for inspection and immediate action taken to eliminate the problem; it must not be operated while malfunctioning. After the forklift stops, the handbrake should be engaged, the gear lever should be in neutral, and the engine should be allowed to idle for 2-3 minutes before being turned off. If the temperature is low, drain the coolant, check all tightness, clean the inside and outside of the forklift, and eliminate any oil or water leaks.
4. Preparations and Attachment Use Before Forklift Operation
(1) Preparations Before Forklift Operation
Before starting the forklift, check that the radiator is full of water; the engine oil level is within the dipstick range; the fuel tank has sufficient fuel; and all oil and water pipe joints are free of leaks. Check the clutch pedal and foot brake pedal for normal free travel and ensure the brakes are flexible and reliable. Check all pipes and joints for damage, looseness, and leaks of oil, water, or air (especially the lifting system, hydraulic system, and braking system). Check all electrical connections, wiring, and lighting for integrity and security; ensure electrical equipment and signals are functioning correctly; check the battery fluid level and specific gravity for compliance with regulations; check if the generator is charging; check the tire pressure of the front and rear tires for compliance with requirements; and remove any stones or debris embedded in the tire treads. Check all bolts and nuts for looseness.
Before driving, start the engine and let it idle for about 5 minutes until the water temperature reaches above 60℃ before full-load operation. During idle operation, check that all instrument readings meet the specified requirements; otherwise, repair the system. Before driving, carefully check the braking system; it must be sensitive and reliable, otherwise adjust it.
When operating the forklift, start in a low gear. After starting, test the brakes and steering to ensure they are working properly. When shifting gears, first depress the clutch, then change gear positions. When changing direction, ensure the forklift has come to a complete stop. When descending steep slopes, use a low gear and intermittently depress the brake pedal. When ascending slopes, also shift to a low gear promptly. Reduce speed in advance when turning. Do not coast with the clutch disengaged, and do not place your foot on the clutch pedal while driving. When depressing the clutch, disengage quickly and engage smoothly.
(2) Precautions for using attachments
Attachments, also known as multi-tools, are the best tools for maximizing the versatility of a forklift. They require easy replacement of various working attachments on a forklift based on its forks, allowing the forklift to adapt to different working conditions. Large warehouses, railway stations, ports, and especially machinery companies all rely heavily on forklifts for loading, unloading, and handling goods. Most forklifts are equipped with a pair of forks of different shapes. These are the simplest and most commonly used forklift attachments, used to handle parts of various shapes and weights. Goods can also be placed on pallets or in special containers and then lifted by the forks for loading, unloading, or handling. Therefore, forklifts are crucial load-bearing components. During operation, forklifts experience impacts from uneven surfaces and fully loaded forks, as well as inertial loads, leading to unfavorable conditions such as uneven loading and dynamic loading of the forks. Furthermore, during forklift operation, the upper and lower surfaces of the horizontal section of the forks, in addition to bearing the load, must also withstand frequent wear and impacts from the ground or objects. Therefore, commonly used materials for manufacturing forks include low-alloy steel, medium-carbon steel, alloy steel, and spring steel. Heat treatment is essential to improve the forks' wear resistance and overall mechanical properties.
When using attachments, pay attention to the maximum lifting capacity and usage instructions specified on the attachment's nameplate to prevent using the fork tips to lift or push goods. In extremely cold conditions, when using a tipper bucket, be aware of ice buildup inside the material pile and never scoop directly into it. When using a crane boom hook, be mindful of the swaying of goods while driving.
During forklift operation, the thickness and length of the two paired forks should be approximately equal, and the angles between the vertical and horizontal sections of the two forks should also be consistent. After the fork carriage is attached, the upper horizontal planes of the two forks should remain on the same plane. Operating procedures must be strictly followed; overloading or long-distance transport of goods is prohibited. When handling excessively long objects or objects whose center of gravity is uncertain, a designated person must be in charge, and extra caution must be exercised. When using forks to lift goods, the fork spacing should be suitable for the width of the load. The forks should be inserted as deeply as possible under the load, and the mast should be tilted back with minimal back tilt to stabilize the load and prevent it from slipping backward. When lowering the load, the mast can be tilted forward slightly to safely lower the goods and remove the forks. During operation, the forks should be moved at a low speed, ideally 30-40mm from the ground, and the mast should be tilted back appropriately. The forks should not be raised or lowered arbitrarily while moving, and turning on slopes or crossing slopes is prohibited. It is not allowed to use the forks to lift and overturn pallets for unloading. It is not allowed to use the forks to directly scoop and transport dangerous goods and flammable materials. It is not allowed to use a single fork or rely on inertia to lift goods. Furthermore, it is not allowed to use braking inertia to slide round or easily rolling goods.
