Whether you’ve only glimpsed forklifts from afar, you’re considering getting one for your business operation, or you’ll be training to operate one soon, there’s merit in knowing how a forklift works.
Today, TAG Forklifts’ team explore the anatomy of a forklift to discover which components make it possible for forklifts to lift and move heavy materials.
What are the Basic Parts of a Forklift?
A typical forklift consists of several main parts:
| Forklift Part | Description |
| Power source | Forklifts derive their power from electric batteries, propane, diesel, or natural gas. Electric forklifts are powered by a large, rechargeable battery, while other types rely on an internal combustion engine. |
| Mast | The mast is the vertical assembly that allows the forklift to lift and lower loads. It consists of interlocking rails that extend and retract, enabling the forks to reach various heights. |
| Forks | The forks are the metal prongs that extend from the carriage to lift and support the load. They slide under pallets or other containers, allowing the forklift to lift and transport them. |
| Carriage | The carriage is the part of the forklift to which the forks are attached. It moves up and down the mast, allowing the forks to be raised and lowered. |
| Hydraulic system | The hydraulic system provides the power to lift and tilt the load. It consists of a hydraulic pump, valve, and cylinders that work together to move the carriage and forks. |
| Counterweight | The counterweight is a heavy mass attached to the forklift’s rear. This mass helps to balance the weight of the load carried at the front. |
| Cab | The cab is where the operator sits and controls the forklift. It includes a steering wheel, control levers, and pedals that allow the operator to drive, lift, and tilt the load. |
Hydraulic System: The Heart of the Forklift
The hydraulic system is what makes a forklift tick because it provides the power needed to lift and move heavy loads. Here’s a closer look at how it functions:
- The forklift’s power source (an electric motor or internal combustion engine) drives the hydraulic pump. The pump pressurises the hydraulic fluid and sends it to the hydraulic valve.
- When the operator moves the control levers to lift the load, the hydraulic valve directs the pressurised fluid to the lift cylinders.
- As the fluid enters the lift cylinders, it pushes against the pistons, causing them to extend and raise the carriage and forks.
- To lower the load, the hydraulic valve releases the fluid from the lift cylinders. This action allows the pistons to retract and the carriage to descend.
This basic hydraulic process is repeated for the mast and the forklift’s lifting capabilities.
How Does the Mast on a Forklift Work?
The mast is a crucial forklift component because it lets the machine lift loads to various heights. Here’s how it works:
- The mast consists of two or more sets of interlocking rails that are fixed on mast rollers.
- When the operator uses the controls to lift the load, the hydraulic system pumps fluid into the lift cylinders, causing them to extend. This action pushes the inner rails of the mast upward, raising the carriage and forks along with the load.
- To lower the load, the hydraulic system releases the fluid from the lift cylinders. This allows the inner rails to retract and the carriage to descend.
Some forklifts also feature a “free lift” cylinder, which allows operators to raise the forks without extending the mast. This is useful in areas with low overhead clearance.
The hydraulic system also controls the mast’s tilt function. There are two pairs of extra hydraulic cylinders at the base of the mast. These cylinders are responsible for tilting the mast forward and backward. This allows the operator to adjust the forks’ angle to keep the load stable.
How Do Forklifts Lift Heavy Loads?
Forklifts lift and transport heavy materials using a combination of their power source, hydraulic system, and mast. Here’s how they accomplish this:
- The power source provides the necessary energy to drive the hydraulic pump.
- The hydraulic pump pressurises and sends the hydraulic fluid to the hydraulic valve.
- When the operator engages the lift control, the hydraulic valve directs the pressurised fluid to the lift cylinders in the mast.
- As the fluid enters the lift cylinders, it pushes against the pistons, causing them to extend. This action forces the inner rails of the mast to move upward, raising the carriage and forks along with the load.
- The counterweight at the rear of the forklift helps to balance the weight of the load, preventing the forklift from tipping forward.
- To lower the load, the operator moves the lift control in the opposite direction, causing the hydraulic valve to release the fluid from the lift cylinders. This allows the pistons to retract and the carriage to descend, lowering the load.
What are the Different Forklift Types?
There are several types of forklifts. They can be divided according to their power source or specific application:
Power Source
- Electric forklifts – Powered by rechargeable batteries, electric forklifts are quiet, emission-free, and ideal for indoor use.
- Internal combustion forklifts – This includes diesel forklifts and gas forklifts. They’re better suited for outdoor use or heavy-duty tasks.
Application
- Reach trucks – Designed for narrow aisles and high racking, reach trucks feature an extending mast that allows the forks to reach into tall racks.
- Rough terrain forklifts – Equipped with large, pneumatic tyres and a reinforced frame, operators use rough terrain forklifts on uneven surfaces and in outdoor environments.
- Pallet jacks – Also known as pallet trucks, these small, pedestrian-operated lifts can move pallets short distances and in tight spaces.
How Do You Operate a Forklift Safely?
Safely operating a forklift requires proper training and sticking to best practices:
- Always wear appropriate personal protective equipment (PPE), such as a hard hat, safety glasses, and steel-toed boots.
- Conduct a pre-shift inspection to ensure the forklift is in good working condition.
- Familiarise yourself with the forklift controls and their functions.
- Ensure the load is stable and secure before lifting.
- Travel with the load tilted back and the forks raised just enough to clear the ground.
- Maintain a safe speed and always look in the direction of travel.
- Be aware of your surroundings and watch for pedestrians, obstacles, and other hazards.
- Never exceed the forklift’s rated capacity or lift a load that’s too heavy or unbalanced.
- When parking the forklift, lower the forks to the ground, set the parking brake, and remove the key.
TAG Us for Your Forklift Truck Solutions
Forklifts are made up of different components, and each part plays a crucial role. Understanding how these components work together is essential if you want to operate a forklift safely and effectively.
At TAG Forklift Truck Services, we offer a wide range of forklift solutions to meet the needs of businesses throughout the UK. Whether you need a reliable electric forklift for your warehouse or a rugged all-terrain model for your construction site, TAG has you covered. Contact our experienced team today to find the right forklift for your operation.
