Major Parts of a Forklift Truck
This guide provides you with an overview of the major components of a forklift truck.
Click here for the full guide to the parts of a forklift truck.
Power Source
Forklifts come with one of two power sources, either electric or internal combustion (IC):
Electric: Battery operated forklifts utilize one large battery to power the truck. Full guide on the parts of a forklift battery.
Electric forklifts are often used in enclosed spaces, such as warehouses or manufacturing plants.
Internal combustion: Many lifts use internal combustion engines to power the truck. These engines will either be diesel or bottled gas such as propane.
In electric and IC trucks the battery or engine is housed in the compartment under the driver’s seat. For propane trucks a gas bottle is mounted on the outside at the rear of the truck.
Mast
The mast is the vertical against the load end of the chassis that provides a path for the rollers and so the lift can raise and lower the forks as needed. It also contains the pulleys, lift chains, and hydraulic hoses that extend and retract on the pulley system as the load is lifted or lowered.
Lamps
Forklifts have several different types of lamps depending on application. One of the most common is a lamp attached to the overhead guard. This lamp is a directional light source controlled by the operator. Like a spotlight, it is useful in providing spot lighting in truck ends, containers and other spaces where loads are being placed or removed.
Warning Signals and Alarms
Forklift safety is extremely important as there are still tens of thousands of injuries per year using lifts within the workplace. To aid in safe operation, many forklifts have alarms and signals when the truck is in use. Types of alarms include:
Backup Alarm
Max Height Alarm
Low Power
Horn
Lift Cylinder
The lift cylinder powers the vertical movement of the load on the mast. This is usually a single acting cylinder and the sizing is determined by the mast size and number of stages.
Tilt Cylinder
Tilt cylinders control the forward and backward tilt of the load forks.
Swing Cylinders
Some trucks have swing cylinders. These cylinders allow the load to swing left or right up to 90° depending on application.
Forklift Carriage
The Forklift Carriage includes the load backrest and the forks:
The backrest is connected to the mast and keeps the load from shifting off the truck, to the side or toward the operator.
The forks, also called tines, are the carrying apparatus for loads, drums, pallets and other load types. Forks come in a large variety of shapes and sizes. Depending on the model, fork types may be interchangeable. Common fork types include
- Forks
- Clamps
- Rotational Forks
- Scales
- Drum Handling
- Telescopic
- Extended
Read our full guide on forklift forks.
Counterweight
Because of the heavy loads lifted with a forklift, they must be properly counterbalanced. The counterbalance weight is proportional to the max load weight and offsets the load carried by the forks.
Tires
Load and environment will determine the type of tires to use. For indoor, industrial and warehouse environments, cushion tires are most often used. For outdoor use, pneumatic tires are more common. Read our full guide on forklift tires.
Wheels
On a forklift you have drive wheels and steering wheels. Unlike an automobile the steering wheels are at the rear and drive wheels at the front.
Brakes
Forklift brakes are comprised of brake shoes and a brake drum. They are engaged via a foot pedal or a handbrake. Many modern electric forklifts have regenerative braking, this uses the electric motor to slow the forklift, with the energy generated used to put charge back into the battery.
Cab Enclosure
Cabs may be open or enclosed depending on safety concerns or environment:
Seat
Overhead Guard
Lever Controls
- Tilt Lever — Controls the angle of the forks relative to the ground.
- Lift Lever — Engages the lift mechanisms on the mast.
- Side Shift Lever — Allows the load to be moved a few centimeters left or right.
- Swing Lever — For trucks with a swing mechanism such as those used for racking systems, the swing lever allows the load to be turned up to 90° left or right.
Brands of Forklifts
Irrespective of make the major parts of a forklift counterbalance truck can largely be described the same. However, when it comes to replacing these parts it is important to ensure that you replace like for like. Parts manufactured for 1 brand will not necessarily work with another.
Major brands of forklift manufacturers are:
- Toyota (Raymond and BT)
- Jungheinrich
- Crown
- Hyster
- Yale
- Linde
- Atlet
- Clark
- Caterpillar
- Daewoo
- Doosan
- JCB
- Kalmar
- Komatsu
- Mitsubishi
- Nissan
- Komatsu
- Hyundai
Summary
As the workhorses of any operation, forklifts can help to create a safe and efficient environment for moving heavy or bulky loads. Facility type, height, max load sizes, environment and other factors will impact the type and capability of the forklift required.
In heavy use environments, many forklift partss will require replacement while others will last the lifetime of the lift.
