What Are The Parts Of A Forklift And Their Functions?

Forklifts are core tools in warehouses and other industrial scenarios. Understanding their key components can help improve safety, maintenance efficiency and overall performance. This article will analyze the main components of counterbalanced forklifts in detail, explain their functions and highlight important safety features, providing professional reference for industry practitioners.
What Are The Parts Of A Forklift And Their Functions?

The three core components of a forklift include: chassis system, mast system and overhead guard. In addition, the forklift is equipped with a variety of safety devices to ensure safe operation. The following will be a detailed disassembly of each system.

The chassis serves as the structural foundation of a forklift, comprising four key components:

Located at the rear of the forklift, the counterweight balances the load on the forks to ensure stability. Using the front wheels as the fulcrum, it prevents the forklift from tipping forward by offsetting the weight of the load.

Bulk-Type Counterweight: The most common type, typically featuring a hollow body filled with lead, a single metal casting, or a mix of concrete and metal.

Stack-Type Counterweight: Used on high-capacity forklifts, consisting of stackable metal plates or housings (e.g., 2.5-ton plates) to adjust lifting capacity.

Electric Forklifts: Rely partially on heavy batteries (weighing several tons) as counterweights, reducing the need for traditional full-sized counterweights.

This component houses the forklift's power source:

Internal Combustion (IC) Forklifts: The engine compartment beneath the operator's seat contains the engine, transmission, fuel system (gas/diesel/propane), cooling system, hydraulic pump, and electrical components.

Electric Forklifts: The battery compartment (also under the seat) holds industrial batteries that power operations. Electric models use hydraulic systems (pistons, cylinders, fluid) to control mast and fork movements, with no transmission or fuel system.

The operator's workspace includes:

Controls:

Steering Wheel: Directs movement, often with a built-in horn.

Pedals: Accelerator, service brake, parking brake, and inching pedal for precise positioning.

Levers: Hydraulic controls for lifting/lowering forks, tilting the mast, and operating attachments (e.g., side shifters).

Instrumentation: Gauges for monitoring engine temperature, speed, battery level, and an hour meter.

Data Plate: Provides critical specifications (load capacity, tire size, fuel/battery type, mast type) and compliance with safety standards (e.g., ASME ANSI B56.1).

Safety Features: Overhead guard, seatbelts, and seat sensors that restrict operation if the operator is not properly seated and belted.

Drive Wheels: Front-mounted, non-steering wheels that transmit power from the engine/motor and bear most of the load.

Steer Wheels: Rear-mounted, responsible for turning and supporting the counterweight. Forklifts steer from the rear to maintain stability under load.

Tire Types:

Pneumatic: Air-filled, suitable for uneven outdoor terrain but prone to punctures.

Solid Pneumatic: Foam-filled, puncture-resistant, ideal for debris-heavy environments (e.g., scrap yards).

Cushion Tires: Solid rubber, designed for smooth indoor surfaces; non-marking variants prevent floor damage.

Wheels And Tires

The mast, located at the front of the forklift, is responsible for lifting, positioning, and lowering loads.

Single-Stage Mast: Single-channel design with limited lifting height (no free lift), suitable for low-clearance outdoor tasks.

Two-Stage Mast: Double-channel, with or without free lift, ideal for standard warehouse heights (e.g., truck loading).

Three-Stage Mast: Triple-channel (most common), enabling higher lift heights for warehouse racking.

Quad Mast: Four-channel design with full free lift, used for extreme high-stacking in specialized warehousing.

Rails: Structural framework allowing vertical extension/collapse of the mast.

Lift Cylinders: Hydraulic cylinders (free lift or outboard) that power vertical movement of the mast and load.

Tilt Cylinders: Double-acting cylinders controlling forward/backward mast tilt for load stability.

Lift Chains: Connect the carriage to hydraulic cylinders, facilitating vertical movement.

Carriage: Supports forks and attachments, moving along mast rails. Classified by load capacity (Classes I–V, with capacities ranging from <2,200 lbs. to 24,198 lbs.).

Attachments:

Forks: Horizontal prongs for lifting loads, available in various lengths (42"–96").

Sideshifters/Fork Positioners: Enable lateral load adjustment.

Paper Roll Clamps/Multiple Pallet Handlers/Slip Sheeters: Specialized tools for specific load types (e.g., cylindrical items, non-palletized goods).

A mandatory safety feature, the overhead guard is a steel structure designed to protect operators from falling objects (e.g., boxes, debris). Required by OSHA, it meets impact resistance standards but is not rated for heavy load collapses.

Modern forklifts incorporate multiple safety devices:

Seatbelts: Restrain operators during tip-overs.

Lighting: Headlights for visibility in low-light areas, blue/red warning lights to alert pedestrians.

Mirrors: Side-mounted for rear visibility (not universally required).

Signaling: Brake lights, turn signals, strobe lights, and backup alarms (audible warnings during reverse operation).

Horn: Mandatory for alerting pedestrians in shared spaces.

Understanding the chassis, mast, overhead guard, and safety features of a forklift is fundamental to safe and efficient operation. Each component-from the counterweight's stability function to the mast's hydraulic precision-plays a critical role in industrial applications. Regular maintenance and adherence to safety protocols are essential for prolonging equipment life and minimizing risks. Whether operating or maintaining a forklift, this knowledge ensures optimal performance and compliance with industry standards.

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