Mục lục
- Overview of forklift structure
- Detailed analysis of the main forklift parts
- How the lift system works
- Differences in structure between forklift types
- Reading the codes on a forklift in 30 seconds
- The 13 detailed parts of a hand pallet truck
- Frequently asked questions about forklift components
- Contact and forklift quote from ICD
A forklift is built from a few core systems working together: an engine or motor for power, a hydraulic system that does the lifting, a mast that raises the load, forks and carriage that carry the pallet, and a counterweight that keeps the truck stable. Understand how each part contributes and you can choose, operate and maintain a forklift far more safely. This guide breaks down every major component, the lift principle, and a detailed 13-part list of a hand pallet truck.
Overview of forklift structure
Whatever its size or fuel type, a forklift combines several main systems in a coordinated way. It is not just a moving vehicle but an assembly of mechanical, hydraulic and electrical systems.
The main systems are: the power unit (engine or motor), the drive and travel system, the hydraulic system that lifts and lowers, and the chassis that provides stability.
| System | Function |
|---|---|
| Power unit | Supplies energy to the whole truck (engine or electric motor) |
| Hydraulic system | Generates pressure to lift, lower and tilt the load |
| Mast | Raises and lowers the load to working height |
| Chassis and counterweight | Keeps the truck balanced and stable under load |
Detailed analysis of the main forklift parts
Engine or motor
This is the power source for the entire truck.
| Power type | Used on | Characteristics |
|---|---|---|
| Internal combustion engine | Diesel and LPG/petrol forklifts | Powerful, suited to outdoor work, but noisy with exhaust emissions |
| Electric motor | Electric forklifts | Quiet and clean, ideal for indoor and food storage; powered by a large battery |
Hydraulic system
This is the muscle of the forklift, responsible for all lifting, lowering and tilting.
| Component | Role |
|---|---|
| Hydraulic pump | Creates very high oil pressure |
| Lift cylinder | The piston inside pushes the mast upward |
| Tilt cylinder | Tilts the mast forward or backward |
| Valves and hoses | Control the flow of hydraulic oil |
Mast
The most visible component, the mast does the actual raising and lowering. It is usually built in nested stages (two or three) that telescope, letting the truck reach different heights.
Forks and carriage
The forks are two high-strength steel blades that lift the pallet directly; their spacing can be adjusted for different pallet sizes. The carriage is the sturdy metal plate the forks attach to, sliding up and down along the mast.
Counterweight
This is a very heavy cast-iron block at the rear of the truck. It balances the weight of the load at the front so the truck does not tip. This is exactly why you must never lift more than the rated capacity.
Steering system and wheels
Most forklifts steer with the rear wheels, giving a very small turning radius and excellent maneuverability in tight spaces. Wheels come in two main types: cushion (solid) tyres for flat floors and pneumatic tyres for rough terrain.
How the lift system works
Forklift lifting is based on Pascal’s law of fluid pressure. The sequence is simple:
- The engine or motor drives the hydraulic pump.
- The pump draws oil from the reservoir and compresses it to high pressure.
- High-pressure oil is routed through the valves to the base of the lift cylinder.
- The oil pressure pushes the piston and the whole mast upward, raising the load with it.
- To lower, the operator opens a release valve so oil returns slowly to the reservoir, and the forks descend under gravity.
Differences in structure between forklift types
| Comparison | Main structural difference |
|---|---|
| Diesel vs electric forklift | The power source (combustion engine vs battery), which drives differences in noise, emissions and suitable working environment |
| Powered forklift vs hand pallet truck | A powered forklift has an engine and complex hydraulics; a hand pallet truck is far simpler, using a hand-pumped hydraulic jack with no travel motor |
Reading the codes on a forklift in 30 seconds
A forklift body carries three sets of markings that most buyers do not understand. Here is how to read them.
| Marking | How to read it |
|---|---|
| Model code (e.g. BF-III, DF-III, CBD20R) | First two letters = series (BF/DF = low-lift hand truck, CBD = electric stand-on, CDD = electric stacker, OPD = order picker). Number = capacity x 100 kg (CBD20 = 2,000 kg). Suffix (-III, R, E) = generation/variant (-III = improved gen 3, R = rider, E = economy). |
| Capacity plate (metal tag on the mast) | Rated capacity x load center x max lift height (e.g. 2,500 kg x 500 mm x 1,600 mm). Exceeding any figure voids the warranty and risks a tip-over. |
| Serial number | 13-15 characters stamped 0.3 mm deep. First 4 = factory code (NRY = Ningbo Ruyi); next 4 = year-month of manufacture (2406 = June 2024); last 4-7 = sequential production number. A shallow laser-etched serial is a sign of a refurbished unit. |
The 13 detailed parts of a hand pallet truck
Most guides list around nine parts. A hand pallet truck actually breaks down into 13 components worth knowing for maintenance.
| No. | Part | Specification |
|---|---|---|
| 1 | Fork frame | C45 steel, 8 mm thick |
| 2 | Hydraulic pump assembly | Around 9 internal parts |
| 3 | Handle and return spring | High-strength steel |
| 4 | Pump piston (small) | Diameter 11-16 mm by capacity |
| 5 | Lift piston / ram (large) | Diameter 32-50 mm |
| 6 | Seal kit | 5-7 NBR/Viton rubber rings |
| 7 | Check valve | Steel ball and spring |
| 8 | Release valve | Hand or foot operated |
| 9 | Overload bypass valve | Protects the pump beyond rated load (gen 4+ only) |
| 10 | Oil reservoir | Holds 0.8-1.5 L of oil |
| 11 | Steer wheels (front) | Diameter 180-200 mm, PU 80 shore-A |
| 12 | Load wheels (under forks) | Diameter 80 mm, PU 95 shore-A (harder) |
| 13 | Parking brake | Clamps the rear wheel, 1,500 N holding force |
ICD distributes Xilin forklifts and hand pallet trucks across more than 500 models, with rated capacities from 500 kg to 10 tonnes and a 2-year genuine warranty.
Frequently asked questions about forklift components
1. Why do most forklifts steer with the rear wheels?
Rear-wheel steering gives the truck a very small turning radius, letting it maneuver in tight aisles far better than front-wheel steering like a car.
2. What is load center and why does it matter?
Load center is the distance from the front face of the carriage to the center of gravity of the load. The rated capacity (for example 2.5 tonnes) only holds at the standard load center. A longer load shifts the center of gravity outward and reduces the real lifting capacity, which can be dangerous.
3. Does forklift hydraulic oil need periodic changing?
Yes. Like engine oil, hydraulic oil becomes contaminated and loses its properties over time. Changing the oil and hydraulic filter on schedule is a key part of forklift maintenance.
4. What is the counterweight for?
The counterweight is a heavy cast-iron block at the rear that balances the load at the front so the truck stays stable. It is the reason you must never exceed the rated capacity.
5. How many stages does a forklift mast have?
A mast is usually built in two or three nested stages that telescope, allowing the forks to reach different heights while keeping the lowered height compact.
6. How can I tell a genuine serial number from a refurbished unit?
A genuine serial is stamped about 0.3 mm deep, starts with the factory code (NRY for Ningbo Ruyi), and its year-month must match the warranty year. A shallow, laser-etched serial is a warning sign of a refurbished truck.
Contact and forklift quote from ICD
ICD Viet Nam Industrial Production Company Limited
North: Floor 3, Thang Long A1 Building, Bau Hamlet, Thien Loc Commune, Hanoi - 0983 797 186 / 090 345 9186 / 090 5859 186
Email: sales@icdvietnam.com.vn · Zalo: Chat on Zalo now
Tell us your load weight and working environment, and ICD will recommend the right Xilin forklift or hand pallet truck, backed by a 2-year genuine warranty, and quote right away.
