How do forklifts work? It’s a question that many people have, including those who have used these machines in the past and people who are simply curious.
In short, a forklift uses a combination of components to lift heavy objects and carry them across distances. For example, they’re commonly used on construction sites and in warehouses and distribution centers.
There are nine main parts of a forklift, each of which is critical to its safe and efficient operation.
Every part of a forklift is important, as it helps the operator safely lift, transport, and lower loads of varying weights1.
Knowledge of the parts of a forklift allows you to understand how it works. The machine’s forks are attached to the frame with two roller chain pulleys. It’s this forklift mechanism that allows the machine to do its job.
Here’s how it works:
The hydraulic system powers the forklift, with these three parts doing the work:
All of these forklift parts must work in unison for the machine to function properly2.
There are two main controls of a forklift: one for steering and one for lifting. While it sounds simple enough to use these controls, it takes quite a bit of knowledge and training to do so safely and effectively.
Forklift steering controls are similar to what you would find in a conventional motor vehicle. There is a brake, gas pedal, steering wheel, forward gear, and reverse gear.
Forklifts use rear-wheel steering, which allows the operator to control the rear wheels. This is preferred over front-wheel control since it provides the operator with better rotational control and precision.
Forklifts have one lever for moving their forks up and down, and another for tiling the load forward and backward.
Pushing the lifting lever forward moves the forks up while moving it backward brings it down.
Tilting is more complex, as there are more parts involved in the process. Here’s what happens when using the tilt lever:
Most new forklift operators find it easier to use steering controls than they do lifting controls. Fortunately, with the right training and proper practice, it soon becomes second nature3.
With so many types of forklifts to choose from, there’s a greater chance of finding one that suits the specific requirement of your job. Choose a forklift based on factors such as:
Here are some of the most common uses of forklifts:
The more you learn about how forklifts work, the easier it is to assume that you know how to safely use one of these machines. But even if you have the proper training and years of experience, there’s always a chance of an accident that can cause serious injury or even death4.
Here are five forklift safety tips to keep in mind at all times:
This is everything you need to know about how forklifts work, along with an overview of their many parts, controls, and uses.
Every forklift runs on the same basic principles to allow lifting and transporting at such high weight capacities. The hydraulic system is the centerpiece of this technology, and it functions similarly across all forklifts. The main components of each forklift’s hydraulic system are the pump, the hydraulic cylinders, and the lift handle. There are also release valves in the system that help mitigate pressure if it starts building dangerously5.
The pump moves hydraulic fluid throughout the system. It sends fluid to the cylinder, where pressure begins to build, allowing the cylinder to rise and lift the forks. The lift handle is in the cab and is the tool that allows the operator to control the flow of hydraulic fluid and, therefore, the movement of the lift’s arms.
A forklift’s counterweight plays a crucial role in forklift safety. It is typically installed at the rear of the vehicle, as far from the load as possible, where it serves to balance out and counteract the weight of the cargo being hauled at the front of the vehicle.
Because a forklift’s load moves around, the vehicle’s center of gravity is constantly shifting, and the counterweight helps keep it lower to the ground during operation. A low center of gravity means a lower risk of tipping and a lower risk of injury to the operator6.
The counterweight also helps keep the lift’s weight evenly distributed over the vehicle, reducing wear and tear on a forklift’s axles and frame.
A forklift mast is the vertical assembly found at the front of the lift that enables the vehicle to raise and lower cargo. Mast types are typically differentiated by how many times they articulate and, correspondingly, how high they can lift. Simplex masts have only a single stage and can only lift material as high as the top of the mast. Duplex and even quad masts exist, allowing for significantly more reach.
The mast is also responsible for directing the weight of the cargo down the rails and handling the brunt of that weight during the lifting process. It also features the load backrest, which supports the cargo and keeps it from shifting and falling off the back during loading7.
Forklifts typically have one of two power sources: electricity or combustion. Electric forklifts are powered by large rechargeable batteries that can run a lift for a few hours or up to a day, depending on how the lift is being used. Combustion forklifts may be powered by gasoline, diesel, LP gas, or other fuels. These lifts require only minimal downtime when refueling, but they’re not suitable for all environments.
Electric lifts tend to be quieter and have relatively low emissions. They’re perfectly suited to indoor use, such as in a warehouse. Internal combustion lifts are louder and emit fuel byproducts that shouldn’t be breathed, making them best suited for outdoor projects. However, electric lifts are also perfectly suited to outdoor work, and combustion lifts can be used indoors if one is mindful of their uptime.
Forklifts come with numerous safety features to minimize the risk of injury during operation, both to the operator and to bystanders. Operators are protected by the load backrest and overhead guard, which are designed to stop cargo from falling off the forks and onto the operator. Most lifts also come with safety belts to keep drivers safe in the event of a crash.
Many lifts also come with a dead-man pedal, which will cut power to all systems when not depressed. This protects pedestrians from runaway lifts if the driver becomes incapacitated. Lifts are also equipped with horns to announce their presence on a job site and mirrors to make it easier to have a good sense of your surroundings while driving8.
Forklifts are impressive machines that leverage physics to help make work easier. Understanding the basic principles of physics that underlie forklift operation can make it easier to recognize when something isn’t right and can help operators use their machines more safely.
If a driver knows how to roughly calculate the load center, they can judge if their cargo is safely arranged. If they know about the forklift stability triangle, they’ll be able to use their judgement about whether a job is safe9. Arming your drivers with knowledge allows them to be more effective and improves safety at the job site.
