Parts of a Forklift and What Every Control Does

A labeled diagram of a sit-down forklift, what each part does, and how the pedals, levers and gauges work. Written for someone who has never sat on a truck.

The short answer

The main parts of a forklift are the mast (the upright that lifts), the carriage that rides up and down it, the forks that carry the load, the load backrest extension behind the forks, the overhead guard over the operator, and the counterweight at the back that keeps the truck from tipping forward. The operator drives with a steering wheel and pedals, and works the forks with the lift and tilt levers, plus a sideshift lever on trucks that have one.

Forklift parts diagram

This is a sit-down counterbalance forklift, shown from the side with the forks on the left. The part names follow the parts diagram in OSHA's forklift eTool. This one runs on propane; an electric truck has no LP tank and carries a battery under a hood instead.

Labeled diagram of a sit-down counterbalance forklift Side view of a sit-down forklift facing left, with labels for the forks, carriage, load backrest extension, mast, lift chain, tilt cylinder, overhead guard, steering wheel, seat, LP tank, counterweight, front wheel and rear steer wheel. Load backrest extension Overhead guard Mast Lift chain Seat Steering wheel LP tank Forks Carriage Front wheel Tilt cylinder Rear steer wheel Counterweight
Sit-down counterbalance forklift (propane). Parts and their positions vary by make and model.

What does each part of a forklift do?

Every part does one of four jobs: lift the load, protect the operator, keep the truck balanced, or power it. Here they are in that order.

The parts that lift

Mast
The vertical assembly that raises, lowers and tilts the load. Masts come in one to four stages (simplex, duplex, triplex and quad). More stages reach higher, and OSHA's eTool notes that lifting capacity drops as the load goes up.
Lift cylinder and lift chains
The hydraulic lift cylinder supplies the power to lift. The carriage moves along the mast on chains, or is attached straight to the cylinder. Never reach into the mast to check a chain; OSHA's eTool says to use a stick or other device.
Carriage
Flat metal plates that ride up and down the mast. The forks and the load backrest hang on it.
Forks
Also called tines or blades, they carry the load. Each has a heel, where it curves upward, and a shank that attaches to the carriage. A fork with cracks, a bend, uneven tips, heavy wear or an unreadable marking must come out of service.
Load backrest extension
The frame above the carriage that keeps a load from falling back toward the operator. OSHA requires one whenever that could happen (1910.178(m)(10)).
Tilt cylinders
Hydraulic cylinders between the frame and the mast that tip the mast forward and back when you move the tilt lever.
Attachments
Sideshifters, clamps, rotators, slip-sheet pushers and similar tools that replace or add to the forks. An attachment adds weight and usually moves the load further out, so it lowers capacity. The data plate must show it.

The parts that protect the operator

Overhead guard
The frame over the operator's seat. It protects against small falling objects like boxes and bags, but OSHA is clear that it is "not to withstand the impact of a falling capacity load" (1910.178(m)(9)).
Seat and seat belt
OSHA's policy is that if a truck has a seat belt or other operator restraint, the employer must require operators to use it. OSHA's tip-over advice for sit-down trucks assumes the belt is already fastened: don't jump, stay in the forklift, hold the wheel, brace your feet and lean away from the impact.
Assist grip
The handle you hold to climb on and off. Use it, not the steering wheel, which can turn under your weight.
Horn, lights and alarms
Every truck needs an operator-controlled horn or other sound device. Many also have headlights, a flashing warning light, a backup alarm and mirrors.

The parts that keep it balanced

Counterweight
The heavy mass built into the back of the truck. OSHA defines it as weight "used to offset the load's weight and to maximize the vehicle's resistance to tipping over." It is why an empty forklift is heavy at the back: Toyota's 8,000 lb, 5,000 lb capacity cushion-tire truck puts 5,180 lb on its rear axle when empty.
Front wheels
With a full load on the forks they carry most of the weight. On Toyota's 5,000 lb cushion-tire truck, the front axle carries 11,310 lb of the 13,000 lb total. They are also the line the truck tips over if the load is too heavy or too far out.
Rear steer wheels
They steer the truck. The steer axle is attached to the frame by a single pivot pin in its center, which is what creates the stability triangle. See our stability triangle explainer.

The parts that power it, and the data plate

Engine and LP tank, or battery
Internal combustion trucks run on propane (LP), gasoline or diesel. Electric trucks run on a large industrial battery. Each has its own fueling or charging rules, which is why OSHA lists refueling and battery charging as a training topic.
Data plate (nameplate)
Shows the truck's fuel type, weight and rated capacity, plus any attachment. OSHA requires it to stay in place and readable (1910.178(a)(6)). Don't run a truck with a missing or unreadable plate. The load capacity calculator shows how to use the numbers on it.

Forklift controls and what each one does

A sit-down forklift has car-like pedals and a steering wheel for driving, and levers for the forks. The levers are where trucks differ most: Toyota sells the same truck with standard levers, mini-levers or a joystick, and Crown offers manual levers, mini-levers or fingertip controls. Before you move anything, OSHA's eTool says to read the operator's manual section on controls and find each one.

Steering wheel

Steers the rear wheels. That is why the back of the truck swings out to the side opposite the turn, so start turns close to the inside corner.

Direction control (forward / reverse)

Picks the direction of travel. It is either a lever on the steering column or built into the accelerator pedal, which you shift side to side. Come to a full stop before changing direction.

Accelerator pedal

Controls travel speed, like the gas pedal in a car.

Brake pedal

Slows and stops the truck, like the brake in a car.

Inching pedal

Gives you finer control of the truck in tight places. Not every truck has one.

Parking brake

Holds the truck when you leave it. Set it every time you get off, and block the wheels if the truck is on an incline.

Lift lever

Raises and lowers the forks.

Tilt lever

Tilts the mast and forks forward or back. Tilt back to cradle a load for travel. Tilt forward with the forks raised only to pick up a load or set it on a rack.

Sideshift or attachment lever

Runs an attachment. A sideshifter moves the forks left and right without moving the truck.

Horn

Warns people. OSHA requires you to slow down and sound it at cross aisles and anywhere your view is blocked.

Two OSHA rules tie straight to these controls. Under 1910.178(o)(6), you may not tilt forward with the forks raised except to pick up a load, and a raised load may only tilt forward when it is over a rack or stack. Under (m)(5)(i), when you leave the truck unattended the forks go fully down, controls go to neutral, power goes off and the brake is set.

How are stand-up forklift and pallet jack controls different?

On the two common types below there is no steering wheel and no gas pedal. Travel and lifting run from hand controls.

Stand-up reach truck

On Crown's RR 5700 reach truck, the operator stands with the right hand on a multi-task controller, the left hand on a steering tiller, the left foot on the brake pedal and the right foot on a presence sensor. That controller lets the operator drive while blending in lift and other load functions. Our reach truck certification guide covers what changes for the operator.

Electric walkie pallet jack

On Crown's WP 3200 walkie, everything is on the control handle. You steer with it, set direction with a forward and reverse thumb wheel, and sound the horn with buttons in the grips. The truck brakes when the thumb wheel returns to neutral or when the handle is moved to its upper or lower braking position. The handle also carries a safety reversing button and a rabbit and turtle switch that sets the top travel speed. Details differ by make, so learn the one you will drive. See pallet jack certification.

What gauges are on a forklift dashboard?

The usual set, per OSHA's eTool: oil pressure, engine temperature, transmission temperature and fuel level on engine trucks, a battery discharge indicator on electric trucks, and an hour meter.

  • Oil pressure and temperature lights: if one comes on, stop operating the truck and tell your supervisor.
  • Fuel gauge: don't run the truck extremely low, and refuel only in designated areas.
  • Hour meter: total hours the truck has run. Maintenance is often scheduled by it, so log it daily.
  • Battery discharge indicator: when it shows low, go back to the charging area.

The rule for all of them is the same: never operate a truck with a warning light or gauge showing an unsafe condition, and don't attempt a repair unless you are authorized.

Which forklift parts do you check before every shift?

Most of them. OSHA requires a forklift to be examined at least daily before it goes into service, and after each shift where trucks run around the clock (1910.178(q)(7)). OSHA's eTool splits it into two checks.

Key off:

  • Fluid levels and leaks, including hydraulic hoses and mast chains
  • Tires for cuts, gouges and pressure
  • Forks, including the top clip retaining pin and the heel
  • Load backrest extension and finger guards
  • Warning decals and the data plate, in place and readable
  • Seat belt and other safety devices

Running:

  • Accelerator, inching control, brakes and steering
  • Forward and reverse, tilt forward and back, lift and lower, attachment controls
  • Horn, lights, backup alarm and hour meter

Our free forklift inspection checklist builds a printable sheet for your truck type and fuel.

Do you need to know the parts and controls to get certified?

Yes. OSHA's training rule lists "truck controls and instrumentation: where they are located, what they do, and how they work" as a required topic (1910.178(l)(3)(i)(C)), along with fork and attachment use, capacity and stability.

Our $59 online course covers that formal instruction in under an hour, in English and Spanish. Your employer then does the practical training and watches you work the controls on the real truck. That hands-on evaluation is required under (l)(2)(ii) and no online course can do it for you. Our free forklift operator evaluation form shows what an evaluator checks.

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Frequently asked questions

What are the forks on a forklift also called?
Tines or blades. Each fork has a heel, where it bends upward, and an upright shank that hooks onto the carriage. A positioning lock holds each fork in place so it cannot slide while the truck is moving.
What is the metal frame behind the forks called?
The load backrest extension. It sits on top of the carriage and stops a load, or part of it, from falling back toward the operator. OSHA requires one whenever the load could fall rearward, under 29 CFR 1910.178(m)(10).
What is free lift on a forklift?
Free lift is how far the forks rise before the mast itself starts to extend. OSHA's eTool gives about 4 to 6 inches for a single-stage (simplex) mast and 50 to 60 inches for two-, three- and four-stage masts.
Why does the back of a forklift swing out when it turns?
A sit-down forklift steers with its rear wheels, so the rear of the truck swings the opposite way from the turn. Watch for people and racking beside the back of the truck, not just in front of it.
Can you add weight to the counterweight to lift more?
No. OSHA's rule says "additional counterweighting of fork trucks shall not be done unless approved by the truck manufacturer" (1910.178(q)(6)). The rated capacity on the data plate is the limit.
What does a forklift data plate show?
The truck's fuel type, its own weight, and its rated capacity at a stated load center and lift height, plus any attachment. OSHA's eTool example shows a propane truck weighing 8,680 lb, rated for 5,000 lb at a 24 inch load center up to 130 inches, and 4,500 lb with its sideshifter. Our load capacity calculator shows how to use those numbers.

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