The efficiency of a forklift mainly lies in the realization of cargo handling, transportation and unloading at the destination. Below, we will introduce the techniques for handling and unloading goods with a forklift, key points for loading/unloading and stacking operations, and matters to be considered before forklift operation and when using attachments.
Forklift Cargo Handling
Steps for handling cargo: The process of forklift cargo handling can be summarized into eight actions.
① Approach the pallet. After starting the forklift, drive it to the front of the pallet according to its position and stop steadily.
② Vertical mast. After stopping, place the gearshift in neutral, push the tilt control lever forward to restore the mast to a vertical position.
③ Adjust fork height. Pull back on the lift control lever to raise the forks so that the tips of the forks align with the gap under the cargo or the fork holes of the pallet.
④ Forking and lifting. Place the gearshift in first gear, move the forklift forward slowly to insert the forks into the gap under the cargo or the fork holes of the pallet. When the arms touch the goods, apply the brakes.
⑤ Slightly lift the forks. Pull back on the lift control lever to raise the forks to a height where the forklift can leave the ground.
⑥ Tilt the mast back. Pull back on the tilt control lever until the mast tilts back to its limit position.
⑦ Withdraw from the position. Place the gearshift in reverse first gear, release the brake gently, and back the forklift out to a position where the cargo can be lowered.
⑧ Adjust the fork height. Push the lift control lever forward to lower the forks to a height of 200-300mm above the ground, then start moving towards the cargo placement location.
Operational Requirements:
a. Whether tilting the mast or adjusting the fork height, continuous actions should be performed to achieve success in one go, avoiding repeated adjustments to improve operational efficiency. The speed of forking can be controlled through the clutch.
b. After the forks are fully inserted under the cargo or pallet fork holes, stop and apply the brakes, place the gearshift in neutral, then complete other actions.
c. While driving with a load, the mast should normally be tilted back. If special cargo prevents the mast from tilting back, ensure the mast is in a vertical position. Otherwise, binding measures must be taken, and it is absolutely not allowed to drive a loaded forklift with the mast tilted forward.
Forklift Cargo Unloading
Unloading procedure: The process of unloading cargo with a forklift can also be summarized into eight actions.
① Approach the cargo position. Drive the forklift to the unloading location, stop steadily, and prepare for unloading.
② Adjust the fork height. Pull back on the lift control lever to raise the forks to the necessary height for placing the cargo.
③ Position the forklift. Place the gearshift in forward gear, move the forklift forward slowly until the forks are directly above the designated placement area for the cargo (pallet), then stop and apply the brakes.
④ Vertical mast. Push the tilt control lever forward to return the mast to a vertical position. On slopes, mast tilting forward is permitted.
⑤ Lower forks and unload. Push the lift control lever forward to lower the forks slowly, place the cargo (pallet) stably on the pile, then slightly withdraw the forks from the bottom of the cargo.
⑥ Reverse and withdraw forks. Place the gearshift in reverse gear, release the brake gently, and back the forklift away to a distance where the forks can be lowered.
⑦ Tilt the mast back. Pull back on the tilt control lever to tilt the mast back to its limit position.
⑧ Adjust the fork height. Push the lift control lever forward to lower the forks to a height of 200-300mm above the ground, then drive away towards the next cargo pick-up location to begin the next cycle of picking up and placing cargo.
Operational Requirements: Control levers should be operated smoothly, with appropriate speed. Sudden lifting or lowering of the forks is strictly prohibited to prevent cargo from falling and causing damage or injury. When aiming for the cargo position, maintain an appropriate distance between the forks and the cargo position for fine adjustment. Do not turn the steering wheel too sharply. Ensure the mast is vertical before positioning to allow for movement while the mast is tilted back. After lowering the forks and unloading, when withdrawing the forks, ensure the fork height is appropriate to avoid dragging or scraping the cargo. When inserting forks into pallets, aim accurately for the insertion holes and insert horizontally to minimize collisions.
Forklift Techniques for Handling and Unloading Goods
Key Points for Forklift Loading/Unloading and Stacking Operations
The maximum lifting capacity of a forklift refers to the greatest weight of cargo that can be lifted when the center of gravity of the cargo is aligned vertically with the center of the load. The load center is the horizontal distance from the center of gravity of the cargo to the front wall of the vertical segment of the forks. In general, the load center of a forklift ranges from 400 to 600mm. When the center of gravity of the cargo is within this range, the forklift can handle the rated load for normal loading/unloading operations. If the center of gravity of the cargo exceeds this range, it may compromise the longitudinal stability of the forklift, preventing it from operating at its rated load and potentially causing accidents. Drivers must adhere to the load center requirements specified in the forklift's user manual. If the center of gravity of the cargo extends beyond the load center range, the load must be reduced accordingly to ensure safe operation.
Forklifts are often used for short-distance back-and-forth transport within workshops, warehouses, or yards. These areas typically have narrow and winding paths, leaving little lateral space for vehicles. Overly wide loads can affect passage capability and increase the likelihood of collisions or scrapes, leading to accidents. To avoid such incidents, a minimum lateral safety clearance must be maintained from obstacles on both sides. Higher speeds decrease vehicle stability, increasing sway amplitude, thus requiring greater minimum safety clearances. The shortest distance from the forklift to obstacles should also increase. When navigating curves, centrifugal force increases proportionally with speed, making it easier for the forklift to overturn laterally. Therefore, turning speeds must be kept low. Additionally, when lifting cargo without securing it, high speeds reduce stability and increase swaying, which can lead to cargo tipping over and causing harm.
Forklift engines are generally longitudinally installed at the rear, and counterbalanced forklifts have balancing weights at the tail. Thus, in an unloaded state, longitudinal stability is good. However, when loaded, the center of gravity shifts beyond the wheel support surface, increasing the risk of longitudinal overturning. Different working attachments and operational methods can also affect longitudinal stability. For instance, when using a hoist on a sloping surface and raising the mast to its maximum height, the forklift's longitudinal stability decreases significantly, making it more prone to longitudinal overturning. Similarly, sharp turns on inclines with cargo lifted too high and excessive speed can result in lateral overturning due to centrifugal forces. Stability during forklift operation is crucial for safe operation. In practice, apart from reducing turning speeds, smoother routes with gentle slopes and larger turning radii should be chosen, and the cargo's center of gravity should be lowered to enhance stability. Operators must strictly follow operational and safety procedures, correctly addressing various situations to ensure safe forklift operation.
Understanding and familiarizing oneself with forklift operation conditions and scope aids in selecting and utilizing forklifts effectively. Compared to other material handling equipment like bridge cranes and gantry cranes, forklifts are smaller in size, capable of self-loading and unloading, carrying loads while running, and operating in narrower channels and tighter turning spaces. During actual operations, forklifts can reduce manpower by 1-2 people, eliminating direct contact with personnel during loading/unloading, enhancing safety. Forklifts offer higher efficiency and capacity in material handling and stacking, occupying less space in warehouses and improving utilization rates. Additionally, forklifts can collaborate with other material handling equipment, surpassing others in cross-departmental operations and stacking tasks, especially in assembly line operations where they perform timed and quantified loading/unloading tasks.
Forklifts can also serve as towing vehicles and transport goods to and from conveyor systems on production lines. With multiple attachments, they can handle various types of cargo. However, forklift operations also have limitations and drawbacks, such as being uneconomical for long-distance cargo handling exceeding 150 meters, producing vibrations during operation, and requiring relatively flat surfaces for optimal performance.
When selecting a forklift, consider channel dimensions and road conditions—solid tires are preferable for flat surfaces or unavoidable debris-laden roads, while pneumatic tires are better suited for uneven terrain. For stacking operations or maximizing warehouse space, choose forklifts with high lift heights and multi-stage masts. Inside low-ceilinged warehouses or for container operations, select low-lift-height forklifts or those with full free-lift forks.
In forklift operations, the maximum allowable load at the specified load center must not exceed the rated capacity. If the cargo's center of gravity changes (e.g., elevated), the load must be correspondingly reduced. Adjust the fork spacing according to the size of the cargo to evenly distribute the weight. Avoid using forks to pry buried objects unless the prying force has been calculated beforehand. When inserting forks under cargo, tilt the mast forward; after the cargo is secured on the forks, tilt the mast back to secure the cargo against the fork carriage before moving. Mast movements should generally occur in a vertical position. During loading/unloading, use the handbrake to stabilize the forklift. Never stand under the forks or ride on them while they are raised. Cargo should be raised and lowered at moderate speeds. At extreme mast tilt positions or maximum height, quickly return the control lever to the neutral position. When raising/lowering cargo, do so with the mast in a vertical position. While transporting cargo, keep the forks approximately 300mm off the ground, avoid sudden braking and sharp turns. Do not park loaded forklifts on steep slopes or descend rapidly; if necessary, reverse downhill. When large cargo obstructs the driver’s view, operate the forklift in reverse at a slow speed. Never leave the engine idling unattended, nor leave cargo suspended while stepping away from the operator's seat. When parking mid-operation with the engine idling, tilt the mast back and retract it. After the engine stops, lower the carriage and tilt the mast forward to rest the forks on the ground. If any unusual noises or irregularities are detected during operation, stop immediately to inspect and resolve the issue before continuing. When parking, engage the handbrake, shift into neutral, idle the engine for 2-3 minutes before shutting it off, drain coolant in cold weather, check all fasteners, clean internal/external dirt, and address leaks.
Preparations Before Forklift Operation and Matters Concerning Attachments
(1) Preparations Before Forklift Operation
Before starting, check that the radiator water is full; the oil level is within the dipstick scale range; the fuel tank has sufficient fuel; there are no leaks at oil or water pipe connections. Check that the clutch pedal and foot brake pedal have normal free travel and that the brakes are flexible and reliable. Inspect all system pipes and joints for damage, looseness, or leaks (especially the lifting system, hydraulic system, and braking system). Check that all electrical connections, wiring, and lighting are intact and secure, that electrical devices and signals function properly, that the battery fluid level and specific gravity meet specifications, that the generator is charging, that the tire pressure meets requirements, and remove stones or foreign objects embedded in the tread grooves. Inspect all bolts and nuts for looseness.
Before driving, let the engine idle for about 5 minutes after starting, ensuring the water temperature rises above 60°C before full-load operation. During idling, check that all instrument readings are within specified limits. Before driving, thoroughly inspect the braking system to ensure it is sensitive and reliable; adjust if necessary.
During operation, start with a slow gear; after starting, test the brakes and steering. Change gears by pressing the clutch pedal first, then shifting the gear lever. When changing direction, stop the forklift completely before doing so. On steep descents, use the "slow" gear and intermittently press the brake pedal. When climbing uphill, switch to "slow" gear promptly. Reduce speed before turning. Do not coast by releasing the clutch, nor keep your foot on the clutch pedal while driving. When pressing the clutch, disengage quickly and re-engage smoothly.
(2) Matters Concerning Attachments
Attachments, also known as multi-tools, are the best tools for achieving multiple uses from a single forklift. They allow convenient replacement of various work attachments on a forklift with forks as the base to adapt to different operational needs. Common in large warehouses, stations, ports, and especially in mechanical industries, forklifts play a critical role in cargo handling and transportation. Most forklifts come equipped with a pair of differently shaped forks, which are the simplest and most commonly used work attachments. They are used to handle various shapes and weights of components. Cargo can also be placed on pallets or specialized containers and handled by the forks. Thus, the forks are the primary load-bearing components of a forklift. During operation, the forks bear impacts from uneven surfaces and inertial loads, creating unfavorable conditions such as eccentric and dynamic loading. Additionally, the upper and lower surfaces of the horizontal segments of the forks endure wear and impact from the ground or objects. Therefore, materials commonly used for manufacturing forks include low-alloy steel, medium carbon steel, alloy steel, and spring steel, along with heat treatment to enhance their wear resistance and overall mechanical properties.
When using attachments, pay attention to the maximum rated load specified on the attachment label and its usage instructions. Avoid using the fork tips to pick or push cargo. In cold conditions, be cautious of ice formation inside the material when using a flip bucket, and avoid directly shoveling into the material pile. When using a crane hook, be mindful of cargo swinging during transit.
For paired forks, the thickness and length should be roughly equal, and the angle between the vertical and horizontal segments should be consistent. After mounting the forks on the carriage, their upper horizontal surfaces should align in the same plane. Strictly adhere to operating procedures, avoid overloading or transporting goods over long distances. When handling oversized or uncertain-center-of-gravity items, have a dedicated person direct the operation and exercise extra caution. Adjust the fork spacing appropriately to match the width of the load, insert the forks as deeply as possible under the load, use minimal mast tilt back to stabilize the load and prevent it from sliding backward. When placing the load down, slightly tilt the mast forward to safely lower the cargo and withdraw the forks. During operations, keep the forks as close to the ground as possible (about 30-40mm), tilt the mast back appropriately, and avoid arbitrarily raising or lowering the forks while driving. Do not make turns or ascend/descend slopes at high speeds, and never use the forks to tip pallets as a method of unloading. Avoid using a single fork for operations or relying on inertia to pick up cargo. Never use the brakes to slide round or easily rolling goods.
With the recent widespread drop in temperatures, it's time to give our vehicles a thorough inspection and maintenance check. As the saying goes, 'three parts repair, seven parts maintenance.' Proper vehicle care is essential to maintaining optimal performance.
Vehicle Exterior Inspection and Maintenance
★ If your vehicle has noticeable scratches or abrasions, timely exterior repainting is recommended. Paint not only enhances aesthetics but primarily serves to prevent rust.
★ Choose a sunny day to give your car a full waxing to protect the paint surface. For already damaged areas, avoid frequent polishing and consider redoing the paint job instead.
★ Winter rubber becomes harder and more brittle, reducing friction coefficients and increasing the likelihood of leaks or punctures. Check for visible external damage, ensure standard tire pressure, regularly clean debris from the tread, and replace heavily worn tires. Using winter-specific tires in snowy regions is advisable.
★ Don't forget to check the headlights; if the bulbs have dimmed, replace them promptly. Pay attention to fog lights as well. Brake lights are prone to damage and should be checked and replaced regularly.
★ Be cautious with windshield washer fluids, opting for winter-specific products in colder climates.
★ Replace wipers if they've been in use for too long. With increased snow and rain in winter, maintaining clear visibility is crucial.
Vehicle Performance Inspection and Maintenance
★ With temperature changes, lubricants generally become less fluid in cold weather, increasing friction and potentially causing difficult cold starts, reduced engine power, and severe cases of bearing seizure. Switch to winter-grade oil for better performance.
★ Cold weather makes vehicle startups more challenging, and batteries are more prone to losing charge. Clean battery terminals of oxidation to ensure good contact and eliminate hard-start issues. For liquid-filled batteries, check electrolyte levels and top up with distilled water if needed. Batteries with insufficient charge should be sent to a repair shop for recharging promptly.
★ Antifreeze should be replaced every two years under normal circumstances. A trip to the repair shop for an antifreeze freeze point test before winter is advisable to determine if replacement is necessary.
★ Inspect the heating system and repair any issues promptly.
★ Braking fluid is critical for safety and should be replaced with quality winter-specific fluid.
Chassis Performance Inspection and Maintenance
★ Carefully inspect suspension and front half-shafts for leaks. On flat ground, press down on each corner of the car to listen for unusual sounds.
★ Check brake pads, discs, and drums, including the handbrake system. If everything checks out, use a repair shop air gun to clean dust from drum brakes and grind uneven brake pads smooth.