The Layman’s Guideto Fork Lift Trucks

The aim of this guide is to provide a brief overview ofthe different types of fork lift truck and other relatedhandling equipment in order to make the readerbetter aware of the enormous variety of equipmentavailable on the market.

The guide is general in nature and cannot cover the widerange of products within each category. For example,one manufacturer alone lists more than 20 differentelectric pedestrian stackers within its current range.

We start off with counterbalance trucks and comment ontheir flexibility. They are indeed wonderful pieces ofequipment. However, in the wrong hands and on thewrong task they can be as unsafe as a loaded gunwithout a safety catch.

As you browse through the guide think of your ownoperation and the equipment you use. Suitability andefficiency are both key considerations: it may be that youreally need a counterbalance, sideloader, telescopichandler or reach stacker for the yard, and a palletstacker or reach truck for inside use.

Modern trucks have many built-in safety features. Thereare other safety devices that can be added to mosttypes of truck as optional extras. Knowledge of what isavailable and keeping up with good design and bestpractice helps to make your lifting operations as safe aspossible.

A number of manufacturers produce heavy lifttrucks, up to a limit of about 60,000 kg. Modelsinclude giant counterbalance fork lifts, reachstackers, full or empty container handlers andspecialist equipment designed for specificapplications. As an example, an empty containerhandler can stack empty containers up to 8 high.

These trucks are also very popular and can be found in manywarehouses. The load is carried partially within the chassis with themast “reaching” out and in to place and recover the load. With acapacity of 2,000 kg or more, they can be configured to lift loads upto about 12 metres.

Reach trucks are usually battery powered. The operator generally sitssideways, although there are also stand-on models. Reach trucks areparticularly useful for flexible narrow aisle storage within rackingsystems. They are designed to operate indoors on smooth floors andhave solid tyre wheels. A few models can be fitted with cabs andtyres suitable for yard use.

This is the most popular type of fork lift truck. Theweight of the load (forward of the chassis at thefront) is counterbalanced by a large weight built intothe rear of the vehicle.

The vehicle is very flexible as it can be used indoorsand outdoors and can be fitted with a wide range of

attachments. There are many variants andmanufacturers, so like buying a car you can

purchase anything from aTrabant to a Rolls Royce, with asimilar variation in safety characteristics.

Popular models have alifting capacity in therange of 1,000 to3,000 kg and lift heightsof 3 to 6 metres or more,

depending on the mast

configuration. Some aredesigned with low masts inorder to operate incontainers orother confinedspaces. Intermediate trucks, with lifting capacities upto say 9,000 kg are also readily available. There arespecialist heavy lift trucks with capacities muchgreater than this – see below. At the other extreme,small, three-wheel machines can deliver high levelsof manoeuvrability and productivity.

An important early decision to be made whenpurchasing a counterbalance truck will be the powersource. This decision brings its own safety issues,not least the issues of fumes and fuel storage. Thissubject is discussed in the Power Sources sectionof this guide.

Counterbalance Trucks

Heavy Lift Trucks

Reach Trucks

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The VNA turret truck or high rack stacker is a highlysophisticated piece of equipment designedto work in exacting conditions. As thename suggests, the truck operates in verynarrow high aisles in order to maximisestorage density. The operator can swivelthe forks and reach the load forward toput it away in the racking. Depending onthe specification, loads of 1,500 kg can bewhisked up to 17 metres.

l Man Down is the name given toequipment where the operatorremains at ground level

l Man Up is the name given toequipment where theoperator’s cab lifts up on thecarriage, level with the forks

Precision is key in allVNA operations. Rail,wire or radio guidancecan assist withpositioning, together with end of aisle control systems.Floor condition is critical for the safe operation of thesetrucks and specialist advice should be sought fromappropriate truck manufacturers.

Rope Evacuation from Mechanical Handling Equipment

Users of VNA equipment and high lift order pickersshould be familiar with guidance on rope evacuation.FLTA guidance is available in Fact Sheet 14 within thepopular Fact Sheet section of the Association’swebsite. You can also read the Health and SafetyExecutive’s (HSE’s) guidance.

As indicated by the name,these trucks feature anarticulated front end, allowingthe front wheels, mast andfork assembly to twist to theside to put away pallets. Thisallows them to operate invery narrow aisles. However,they also have features

associated with a counterbalance truck, such ascushion tyres, and can readily leave an aisle to load or unload a lorry.

A number of different makes and models areavailable with chassis widths of 1 to 1.4 metres.Loads of 2,000 kg or more can be lifted to about 12 metres. They are usually electric powered, but there are some LPG variants and at least onepedestrian-controlled machine.

Order Pickers

Very Narrow Aisle (VNA) Turret Trucks

Articulated Trucks

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As the name suggests, these are trucksdesigned to maximise order picking operations.

Some types are little more than adapted electricpallet trucks, for ground level operations, andmay include long forks for carrying two or threepallets. They may be called horizontal or lowlevel order pickers. Some have an elevatingoperator platform and others have forks that canbe raised to an appropriate picking height forbetter ergonomics.

At the other extremethere are high lift orvertical order pickers,quickly and safelylifting 1,200 kg up to 11metres. Operating in narrow aisles, thisequipment gives operators access to bothsides picking at these high levels. Additionalequipment may include guide rails and radio-based positioning technology. Floor condition iscritical for the safe operation of these trucks.

Man UpTurretTruck

Man DownTurret Truck

These trucks are similar to sideloaders but have theability to drive in any direction giving themenormous flexibility. The capacity range is 2,000 to25,000 kg, with lift heights up to 4 metres.

(The term omni-directional is used in the USA buttends to refer to hybrid designs such as the AirtraxSidewinder. For a modest diversion, look here.)

Rough terrain – sometimes called all-terrain –trucks are designed to operate on unevenground such as construction sites, roadmaintenance areas, agriculture and forestry.They can be useful in unpaved yards and othersuch locations. Stability is an issue for all fork lifttruck operations and this is an increasinglyimportant safety factor when on soft or unevenground. As for other specialist operations, theoperator will need specialist training. Roughterrain trucks may be masted or telescopic andsome lighter models may have skid-steer.

l Masted trucks There are a number ofnimble lightweight machinesavailable, but the generalrange covers trucks lifting upto 5,000 kg to heights of 6metres or more. At theheavier end there aretrucks capable of lifting32,000 kg up to 6 metres.

Sideloaders are like a cross between alorry and a reach truck, with the mastand forks mounted sideways andcentrally. The forks reach out with thecarriage to collect the load which isthen drawn back to rest on the bed ofthe truck to travel around the yard.This concept is ideal for long or

protruding loads such as timber, steel rods,pipes, etc. Trucks can be powered bybattery, LPG or diesel and may have 3 or 4wheels depending on the requirement.Commonly, loads of about 5,000 kg can belifted to heights of 8 metres, but specialisttrucks with a capacity of 50,000 kg areavailable.

Sideloaders

Multi-DirectionalTrucks

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Rough Terrain Trucksl Telescopic

With a telescopichandler the forks areattached to a sectioned boomwhich can be moved forward and up. There are avariety of configurations. There are lightweightmodels that can readily load pallets across thebed of a lorry, lifting 1,500 kg to 4 metres. Otherscan lift loads of 4,000 kg to over 16 metres,perhaps placing pallets of tiles on the roof of abuilding.

l Skid-SteerAlthough typically awheeled vehicle, thistruck operates like atracked vehicle and issteered by changingthe speed of the leftor right side wheels. As such it is highlymanoeuvrable, albeit with limited liftingcharacteristics. It is particularly useful in someconstruction and agricultural applications.Maximum lifting capacity is just over 1,400 kg.

Tow tractors are mentioned here as towing trailers isoften required where fork lift trucks operate. Most lifttrucks are not designed to tow trailers and there are

safety implications if they are. See FLTA Fact Sheet 26.Many fork lift truck manufacturers also producededicated tow tractors.

These hybrid trucks are designed tobe carried by special mountings onthe back of lorries or trailers. They usetheir power and lifting mechanism to“mount” or “dismount” the lorry in lessthan a minute. This means thatpalletised goods can be delivered to

locations that do not have a fork lift truck inplace, making for highly flexible deliveries.Trucks with capacities up to 3,500 kg can liftto heights of about 3 metres. Special safetyconsiderations should include the likelihoodof these trucks being used on public roads –see FLTA Fact Sheet 08.

Lorry Mounted Trucks

Tow Tractors

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There is a wide range of equipment available includingdouble-decker variants. They provide a flexible means ofmoving and stacking within a warehouse or similarenvironment. Common models have a lifting capacity ofabout 2,000 kg and a lift height of 2.5 metres.

This more bulky style of equipment removes theproblem of intrusive straddle legs from traditionalstackers and can deliver a lift of about 1,600 kg toover 5 metres An articulated pedestrian-controlledtruck is also available.

There are many types of electric pallet truck available for movingand picking goods, capable of lifting up to about 3,500 kgdepending on the model. They can be designed for the operator towalk with, stand on or sit on the equipment. Some may have extra-long forks to carry three pallets or have a low level “dead” lift for

order picking work. There are also rough terrainvariants available for construction sites, etc.

Note on Pedestrian TrucksTraining is important for the safe use of all types of pedestrian trucks described below. Take this opportunity to read FLTA Fact Sheet 09 on this subject.

Electric PedestrianPallet Trucks

Electric PedestrianStackers

PedestrianControlled CounterbalanceTrucks

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The cheap and cheerful workhorse of manyoperations, there are many variations of hand pallettruck available. Commonly called a “pump truck”the forks are often raised sufficiently to clear the loadfrom the ground by pumping the control arm. Somemay have battery assistance and, of these, somemay have on board chargers.

Some trucks have especially flat forks, some have ascissor lift action, or perhaps a high lift up to 0.6

metre. Some are designed to lift just a ½ or ¼ pallet load. Some are made fromstainless steel for the food industry

or may be corrosion protected. Some havea ramp lifter, to raise enough to negotiate a ramp, oron board weighing scales. Some models have anespecially quiet operation to aid early morningdeliveries.

Shuttle Pallet Carriers

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Remote control carriers arefor the independentmovement of pallets,usually in a high capacitystorage environment.These are specialist itemsfor particular functions.

Hand Pallet Trucks

Industries that produce, store, or distributeflammable materials need to be aware of the risk ofan explosive atmosphere being generated duringnormal operation. Unprotected fork lift trucksoperating in such an area may cause an explosion.Pyroban Ltd is one of a number of companies thatoffer appropriate protection for diesel and electrictrucks used within such areas, protecting the peopleand the site. Their products remove the sources ofignition whilst retaining the original ergonomics andperformance of each vehicle, and comply with theEuropean Directive ATEX 94/9/EC.

If you think this requirement may apply to youroperation you should seek professional advice.

It is worth noting that a number of manufacturers,including attachment manufacturers, may be ableto adapt or design new equipment to meetspecific operational needs. Depending on therequirement, the FLTA may be able to suggestwhich companies may be able to assist you.Contact the FLTA for more details.

Many manufacturers will supply battery-powered trucks especially adapted for coldstore operations, including special heatedcabs. This can include equipment that willoperate in temperatures down to -35°C.

Cold Stores

ExplosionProofing

Special BuildEquipment

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Specialist Requirements

There are specific rules for the use of working platformsor safety cages. These are covered in an HSE documentcalled PM28: Working platforms (non-Integrated) onforklift trucks.

If you intend to use a working platform we recommendyou first look at the FLTA guidance in Fact Sheet 18,and then read the HSE’s Guidance Note PM28 onworking platforms.

Before reading about attachments it is reallyimportant to understand load rating and the need for de-ration. This is explained in FLTA Fact Sheet 11.

There is a wide range of fork lift truck attachmentsavailable for purchase or hire, for trucks large andsmall. The following list provides a selection ofequipment but is by no means exhaustive:

l Brick/block grabs

l Carpet booms

l Crane jibs

l Double pallet handlers

l Drum handling equipment – lifting, rotating etc.

l Fork clamps

l Fork extensions and sleeves

l Lifting beams

l Load stabilisers

l Pallet rotators/tippers

l Pusher forks

l Roll handling

l Rotating fork clamps

l Scoops and buckets

l Sideshifts

l Snow ploughs and salt spreaders

l Sweeping equipment

l Telescopic forks

l Tipping skips/bins

l Weighing systems

l Wide load stabilisers

l Working platforms/safety cages

Attachments

Working Platforms

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Use of the correct tyres is important for stability, brakingand traction. The correct type of tyre to use will dependon the truck, the application and the operatingconditions. This needs to be discussed with your truckand/or tyre provider. Tyres need to be checked regularlyas part of the pre-shift check regime, and replaced whenworn or damaged. Further guidance on tyre safety isavailable in FLTA Fact Sheet 20.

There is an ever-increasing range of safetyequipment available for fitting to, or using with, forklift trucks. In addition to improving safety, thisequipment will often enhance productivity, makingfor a “win-win” situation. When you are consideringthe purchase or hire of a fork lift truck you shouldaim to discuss which systems would be of benefit toyour operations with your selected dealer – just asyou would for a car or lorry.

The range of such safety equipment includes thefollowing:

l Cabs and canopies for outdoor use –to protect operators from inclementweather

l Enhanced lighting – to see and beseen

l Flashing beacons

l Reversing alarms including low noisedirectional alarms which can be moreenvironmentally friendly than “bleepers”

l A wide range of specialist mirrors toenhance visibility

l Cameras – either as movement orvisibility aids, especially for large trucks,or to help position forks

l Proximity alarms to warn the operatorof the presence of people or otherobstacles, or to warn others of thepresence of fork lift trucks (there are anumber of different systems available)

l Speed inhibitors capable of use withspeed zones

l Speed cameras and other monitoringsystems – some with public displays

l Key control systems

l Operator recognition systems – toblock inappropriate use

l Fork positioning systems

l Data logging systems, includingspeed, operator efficiency, accidentlogging, immobilisation post collision, etc.

l Maintenance reporting, including pre-shift checks (with go or no-go),routine maintenance, ThoroughExamination log, etc.

l Fleet management systems

l Various guidance systems for VNA equipment

l On board weighing systems

l Ergonomic enhancements such asjoystick controls, special seating,stowage, etc.

l Rotating seats to aid reversing andreduce strain

Providers of Safety Equipment

Some providers advertise in the trade magazinessuch as SHD Magazine, Handling & StorageSolutions or Warehouse & Logistics News. Thosethat are Members of the FLTA are listed according to speciality here.

Safety Equipment

Tyres

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DieselAdvantagesFlexibility

Good for outdoor use – can beused indoors (with caution)

Fuel efficient

Good if attachments are to beused

Good on gradients

Cheaper to buy than electric

Relatively easy and cheap tomaintain

Quick and easy to refuel

Long life with a good residualvalue

DisadvantagesExhaust fumes

Not ideal for indoor use

Can be noisy

Tend to be bulkier than other types

Require greater operator skill thanelectric

SafetyFume and particulate hazard. See FLTA Fact Sheet 22. More detailed guidance from the HSE is available here

Fuel storage and security need tobe considered

Fuel spillage – need companyrules for immediate clear up, etc.

Hot exhausts

LPGAdvantagesFlexibility

Suitable for outdoor and someindoor use

Can be more manoeuvrable thandiesel trucks

Good overall performance

Much reduced air particulatescompared to diesel

When fitted with three-waycatalyst contains virtually zerocarbon monoxide andhydrocarbons

Quieter than diesel

Cheapest to buy

DisadvantagesCan be fume issues

Relatively high fuel costs

Relatively high maintenance costs

Can be more difficult to refuel

Lack of fuel gauge can be aproblem

Lowest residual value

Requires greater operator skillthan electric

SafetyThere can be a fume hazard inconfined spaces such ascontainers and underneathmezzanine floors. See FLTA Fact Sheet 22

Fuel storage and security areimportant considerations. See FLTA Fact Sheet 13on LPG storage

Hot exhausts

ElectricAdvantagesEnvironmentally friendly – nofumes when operating

Quiet

Highly manoeuvrable

Relatively cheap to run

Cheapest to service and maintain

Easiest to operate

DisadvantagesHigh purchase and set up cost

Space required for charging area

Possibility of power cuts needs tobe considered

Time and space for batterychanging

Need a good smooth floor surface

Limited outdoor application

Not good for gradients

SafetyFumes during battery chargingcan be a hazard. See HSEpublication: Using electricstorage batteries safely, whichincludes a section on calculatingventilation requirements

Your battery supplier should alsoprovide appropriate safetyinstructions and other material

Staff need additional training andPPE

Quiet operation of trucks could bea hazard in some environments

Power Sources

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The best or more appropriate power source for your fork lift trucks will depend onyour application and perhaps your budget. Importantly, there will be health and safetyimplications for whatever power source you use, and these need to be consideredtoo. The main points are considered below.

Fuel Cells For general information on fuel cell use for fork lift trucks, look on the Wikipedia site here.

WhereCan I GetFurtherAdvice?The largest and most respected organisation inthis sector is the Fork Lift Truck Association(FLTA). Since 1972, FLTA Members have built,supplied, supported or maintained over 1.5million fork lift trucks.

Its Members abide by a strict Code of Practicewhich acts as the industry's benchmark forintegrity, professionalism and high qualitycustomer service.

If you would like a list of FLTA Members in your area, please visit the FLTA website at fork-truck.org.uk where you can conduct anonline search, or contact the FLTA secretariatdirectly using the details listed on the website.