Forklift Types, Mast Configurations, and Key Features

Understanding Forklifts: Components and Operation

Forklifts (also known as Elevating Carts or ECs) are self-propelled vehicles, typically constructed with a chassis or frame, featuring a traction motor that can be either internal combustion or electric. Combustion engines operate with a hydraulic drive and electric control.

A forklift is equipped with a telescopic mast or lifting pole that can have 2 or 3 positions. This mast moves via a hydraulic cylinder, driven in turn by its own internal combustion engine or a second electric motor. Forklifts typically have 2 axles and 3, 4, or 6 wheels, which can be solid or cushion tires. They also feature a pair of forged steel forks for lifting loads. These forks are responsible for collecting pallets and stacking loads efficiently.

Key Forklift Mast Types Explained

Forklift masts are primarily categorized into three types:

• Double Telescopic (Duplex) Masts

  These masts allow elevation to reach heights of up to 5.5 meters in 2500kg capacity forklifts, and 6 to 7 meters in forklifts with capacities up to 7 tons. The main drawback of this system is that the fixed mast height can be too high for certain applications, especially in areas with low overhead clearance.

• Double Masts with Total Free Lift

  This design allows the forks to elevate significantly before the mast's inner section begins to rise. Forklifts equipped with such masts are ideal for high-level storage and for efficiently filling and emptying containers, as they can lift loads without increasing the overall mast height initially.

• Triple Masts

  Composed of three telescopic sections, triple masts are designed to achieve great lifting heights. Triple masts can be configured with or without total free lift. Their key advantage is the ability to reach impressive elevation heights while maintaining a relatively low retracted mast height, offering greater flexibility in various operational environments.

Common Forklift Categories

Forklift types include: counterbalance, reach trucks, and trilateral forklifts.

• Counterbalance Forklifts

  These forklifts are named for the heavy counterweight (often made of iron) integrated into their rear. They lift loads from the front, with the counterweight balancing the load to ensure stability. These self-propelled vehicles are commonly used in loading and unloading areas.

  Counterbalance forklifts can be classified in two primary ways:

  • Classification by Wheel Type

    This category includes forklifts operating on pneumatic tires (for outdoor or uneven surfaces) and those on solid tires (for indoor or smooth surfaces).

  • Classification by Traction Type

    This classification distinguishes between forklifts powered by thermal internal combustion engines (gasoline, diesel, LPG) and those driven by electric motors or traction batteries.

• Reach Trucks

  Reach trucks operate with electric motors and are designed primarily for indoor use, particularly in warehouses. They typically have solid, small-diameter tires. They are distinguished by requiring narrower aisles for maneuvering compared to counterbalance forklifts, making them highly efficient in compact storage spaces.

  There are two main types of reach trucks:

  • Reach Trucks with Retractable Mast

    In this design, the mast extends forward, allowing the forks to reach into racking systems, often passing through the outriggers or load legs to pick up or deposit pallets.

• Trilateral Forklifts

  (Information on trilateral forklifts was not detailed in the original document, but they are a distinct type of forklift.)