Forklift Brake Parts
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When you step on the forklift brakes of your Toyota or Hyster truck, you expect it to stop, on a dime. Otherwise, you could smash a load onto a wall or, worse, drive into a co-worker. Like those on any other motorized vehicle, forklift brakes are what stop the truck when it is in motion. There are two types of systems used in most forklifts today: the drum brake and the wet disc brake. Many of the major brands like Nissan, Yale, Mitsubishi and Komatsu offer models with drums and discs.
With the drum system, you step on the brake pedal and the force is transferred through the brake fluid to brake cylinders which push the brake shoes outwards. The shoes, in turn, press against the drums attached to the wheels causing the wheels to stop rotating. Drum brakes are simple, reliable and easy to maintain. They are less expensive to produce than disc brakes and are still preferred for smaller vehicles like motorbikes. They are also standard equipment in most forklifts with lower load-bearing capacities.
In the disc brake system, discs made of cast iron are connected to the axles or the wheels. In a Hyundai forklift, they are attached to the output shaft of the drive motor. Brake pads mounted on brake calipers are hydraulically forced against both sides of the discs. Friction causes the discs and the wheels, to which they are attached, to stop rotating. Forklift manufacturers usually install disc brakes on their heavy-duty models, often as standard equipment on trucks rated over 10,000 lbs. Trucks with disc brakes can stop in a shorter distance than those with drum brakes. They take longer to suffer brake fade and stay dry longer in wet weather.
Because friction is part of the process, forklift brakes are subjected to constant stress. It is, therefore, important to inspect them often and subject them to a regular maintenance program. When the drum brake does not offer any resistance or makes squeaking noises, it's time to take a closer look at it. For drum systems, good maintenance means making sure that the fluid is topped up at all times and that there are no leaks in the lines. Worn out shoes and pads should be replaced. Drum brakes usually require servicing after every 1,500 hours of use.
With disc brakes, maintenance requirements are significantly less resulting in lower downtime. Disc brakes are sealed to protect them from rust and contamination, and are immersed in oil so that the parts last longer. However, brake pads and discs will wear out and have to be replaced. Brake discs should last twice as long as the brake pads. Brake discs should always be replaced in pairs for balanced braking action.
So, whether your truck uses drum brakes or disc brakes, regular check ups and periodic maintenance of forklift brakes will make sure that the truck stops and your business keeps on going.
Jack Ranger is a Community Manager at LiftX Parts International. Jack regularly writes articles, blogs, and other informational content related to the forklift and material handling industry. Jack's goal is to improve the current material handling online community by promoting education, sharing of information, and engagement.
Closely linked to the lift truck's ignition system, forklift electrical parts control the operation of a forklift's motors. These parts consist of motor control units, diodes and rectifiers, resistors and relays, sensors, solenoids, switches and the wiring that connects the various components to each other.
Forklift replacement motors are available either as OEM, aftermarket, reconditioned or used parts. The age, type and power are the factors to consider in choosing a forklift motor. The age of a reconditioned or used motor is important because a lift truck must lift heavy loads while moving around.
Motor control units start or stop the motor, select the direction of its rotation, regulate the speed through motor speed controllers, limit the torque and protect it against overloads. Switches are an essential part of a motor control unit and may be directly connected to the battery or through relays and contactors connected to sensors which automatically start and stop the motor.
Contactors and relays are electrically-operated switches that are parts of a forklift's electrical system. The contactor is a type of relay that is used to handle the high power needed to directly control the electric motor. Relays, on the other hand, are used to control a high-current circuit with a low-current signal such as the truck's starter solenoid. A contactor is an essential part of a magnetic starter which starts the motor.
The starter motor is also connected to an alternator, an electromechanical device that converts mechanical energy into electrical energy. The alternator recharges the battery and powers the truck's electrical system while the engine is running. Although the alternator runs at various RPM, the alternating current is converted by diodes and rectifiers into direct current. The solenoid is a specific type of relay that operate's an electrical switch in the system.
The forklift electrical system is also connected to other electrically-operated parts like front and rear flood lights, taillights, the instrument panel and gauge lighting. Lights are turned on and off by individual switches wired into the electrical system. The brake light switch is often mounted above the brake pedal linkage and turns on when the driver steps on the brake pedal.
The lift truck's electrical system provides electricity to the various instruments and gauges. These may include an ammeter, hour meter, fuel level gauge, engine oil pressure gauge, engine temperature gauge, transmission oil temperature gauge and air restriction indicator gauge.
Another set of parts connected to the truck's electrical system are warning lights, buzzers, indicator lights and the horn. Among these are a warning light to indicate a broken belt, a broken belt warning buzzer and a transmission high range indicator light.
Lights, instrument panels, buzzers and switches are not always in the same location for a Toyota or Clark lift truck or other brands. Familiarity with the places in the truck where these are found will save on downtime when doing maintenance work on the truck's electrical system.
The forklift electrical parts affect many components of the truck and need to be kept in good condition at all times for safe and efficient performance.
Jack Ranger is a Community Manager at LiftX Parts International. Jack regularly writes articles, blogs, and other informational content related to the forklift and material handling industry. Jack's goal is to improve the current material handling online community by promoting education, sharing of information, and engagement.
Driving a lift truck safely, whether it's a Toyota, Hyster or Clark, consists of having properly-maintained forklift steering parts, knowing the right driving techniques and being aware of driving hazards. Not everyone is authorized to drive a forklift and governments have strict regulations for the accreditation of forklift operators. Whether a forklift is used in a flat-surfaced warehouse or on uneven terrain, the forklift driver must be alert at all times to the environment in which the truck is used. There are not many forklift steering parts but each component must always be well-maintained to avoid accidents.
The Occupational Safety and Health Administration in the United States (OSHA) and the Health and Safety Executive (HSE) in the United Kingdom are among the government agencies that have strict requirements for forklift operations. The first requirement is that forklift drivers must be properly trained, both in theory and in practice on how to drive a forklift correctly. The training may be conducted in-house or with an accredited training institute. Once the operator has passed the training program, he or she must be certified in order to legally drive a lift truck. It's like getting a license to drive a car. The certification has limitations as to which type of forklift the driver can operate. The certification must be renewed every three years or so. Refresher training is mandatory if the driver gets into an accident, or drives a truck for which he or she has no certification.
Proper driving techniques are also a must for a forklift driver. The driver must remain seated under the protective shield of the cab. He or she must never allow anyone to ride on the forks or pass under them. The driver must always be aware of other people in the work area as well as any obstacles that may endanger himself or others. Knowledge of practices like proper load balancing or improper braking are things that the forklift operator must be familiar with. Other precautions the driver must observe are: trucks should not be used on ice or slippery surfaces, forks must be lowered when not in use and wheels should be blocked when the truck is parked are still.
A forklift steers with the rear wheels and front wheels are used for pulling. Forklift steering parts consist of a steering wheel, the steering box, front wheel assemblies, the front wheels and the rear wheels. The different components are connected to each other through links such as cables and a system of gears and tie rods. Pumps which supply power steering fluid to power steering cylinders are used for trucks with heavy load capacities. Each of these parts must be properly maintained for safe forklift operation.
Toyota recommends that, for electric forklifts, excess play, links binding and anchor pin integrity must be inspected. Chains and the steer spindle gear must be properly lubricated and hoses checked for leaks. Nissan, Mitsubishi, Hyster and all other forklift manufacturers also recommend regular and thorough maintenance programs to ensure that forklift steering parts keep on functioning properly for both safety and efficiency reasons.
Jack Ranger is a Community Manager at LiftX Parts International. Jack regularly writes articles, blogs, and other informational content related to the forklift and material handling industry. Jack's goal is to improve the current material handling online community by promoting education, sharing of information, and engagement.
Lifting and moving are the two basic functions of a lift truck and it is forklift drivetrain parts that keep the vehicle on the move. Drivetrains essentially consist of engines and transmissions; the former generates the power and the latter transfers it to the wheels so the truck can move. To do so, a system of gear parts and axle parts are employed.
For a lift truck, a motor or internal combustion engine is used. With an I-C lift truck, gasoline, diesel or propane are used as fuel. The fuel and air combine in a combustion chamber where they are ignited to produce a high-pressure gas. This powers pistons that produce mechanical energy to move the wheels. An electric motor is used to start the internal combustion engine.
The forklift's transmission which can sometimes refer to the whole drivetrain, includes the gear box and gear parts, the clutch, propeller shaft, differentials and drive shafts. The transmission regulates the power of the engine and adapts it to the drive wheels to start, stop or slow down the rotation, changing gear ratios to adjust the speed as necessary. The clutch acts like a switch that engages and disengages power from the engine. A pressure plate is attached to the engine's flywheel and another pressure plate to the transmission.
The transmission is usually connected to the engine's crankshaft and transmits its output through the driveshaft to the differentials which turn the wheels. The driveshaft connects parts of the drivetrain that cannot be directly connected to each other and transmits torque and rotation. A differential is a mechanism using gear parts to transmit torque and rotation to the wheels. Axles are the central shafts for wheels or gears and axle parts and include bearings and bushings around which the wheels rotate.
Proper and regular maintenance is required for forklift transmissions. Toyota recommends a transmission fluid change every 1,000 - 1,200 hours in order to keep the transmission in good condition. The fluid should be clear and not murky and should not smell burned. Keep a record of when the transmission filter is changed so it's easy to note when it's time for another change. Check transmission hoses and replace those that are hard or brittle and tighten loose hose clamps.
Yale and Nissan specify that the engine should be stopped while the transmission fluid is checked. Other brands also recommend the same procedure although older models allow for transmission fluid checking while the engine is running. Mitsubishi cautions against riding the inching pedal because it can damage the forklift's transmission and only use it when approaching a rack preparatory to braking. Hyster touts its electronically-controlled transmission system that helps reduce the stress caused by forward-backward movements of the truck while loading and unloading. All forklift manufacturers emphasize the need for proper lubrication of the drivetrain at all times because of its many moving parts. Aside from OEM parts, there are many aftermarket and re-manufactured parts. This makes it convenient to replace worn-out or damaged forklift drivetrain parts even under tight budgetary constraints.
Jack Ranger is a Community Manager at LiftX Parts International. Jack regularly writes articles, blogs, and other informational content related to the forklift and material handling industry. Jack's goal is to improve the current material handling online community by promoting education, sharing of information, and engagement.
Forklift trucks need to be examined and repaired after regular intervals to ensure the safety and security of the workers working with these trucks. The fork truck add-ons also need to be checked biannually or annually in order to avert malfunction and accidents of fork trucks. Whether you own a truck or operate a forklift while working in a warehouse, you must meet the existing safety guidelines. According to the UK laws, if an owner or operator cannot show the report of Thorough Examination for his truck or the forklift truck attachments, he can be litigated for that.
If you cannot furnish the Thorough Examination certificate before concerned authority when asked for, your license can become invalidated. You might be summoned to the court in case of non-availability of the certificate. The worst happens when a serious accident happens because of faulty equipments or accessories. You might be put behind the bars if it is found that the fork truck accessories you use in your truck are not examined regularly. Fork truck owners are deemed negligent if they do not take proper steps to examine their truck parts and accessories.
Thorough Examination of fork trucks is essentially similar to MOT (Ministry of Transport) Test of cars. It is a detailed assessment of all the fork truck parts and add-ons. However, the Thorough Examination is much more complex than MOT. Brakes, wheels, steering and other embedded components are examined under PUWER 98 (Provision and Use of Work Equipment Regulations 1998) and all the forklift accessories such as hydraulics, chains, forks and other components are checked under LOLER 98 (Lifting Operations and Lifting Equipment Regulations 1998). Thorough Examination is conducted after one year intervals. However, your forklift truck components and accessories might be needed to be checked more frequently. You must keep in mind that Thorough Examination is mandatory and a routine maintenance job. It excludes your general responsibility of maintaining the truck elements and attachments in a proper manner.
According to PUWER 98 and LOLER 98 regulations, Thorough Examination must be conducted by well-knowledgeable persons or entities. Generally speaking, an experienced and proficient fork truck engineer who works on behalf of an inspection agency or insurance company can check the forklift truck attachments and equipments to conclude whether the same is compliant with the safety standards or not. On the other hand, you should be aware that not every 'insurance inspection' is a Thorough Examination. You must obtain the 'Report of Thorough Examination' after the test is conducted. Always ask a manufacturer or supplier of fork truck attachments whether they adhere to the safety standards.
Many forklift accessories manufacturers in the UK religiously adhere to the existing safety standards of the country. These manufacturers and their suppliers inform their buyers about Thorough Examination and other mandatory quality tests for fork truck parts and accessories.
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