Essential Forklift Parts and Maintenance Guide

Introduction to Forklift Parts

Forklifts, also known as lift trucks, are powered industrial trucks used to lift and transport materials in warehouses, distribution centers, manufacturing facilities, and more. They come in different types like counterbalance forklifts, reach trucks, pallet jacks, and order pickers. Key components of any forklift include:

Mast

The mast is the vertical part of the forklift that raises the forks up and down. Forklift masts are usually made of high strength steel and may have a tilt mechanism. The mast capacity determines how high and how much weight the forklift can safely lift. Common mast types are two-stage, three-stage, triplex, and free lift masts.

Fork Carriage and Forks

The fork carriage moves up and down the mast to raise or lower the forks. The forks slide inside the carriage and can also tilt forward and backwards. Standard forklift forks are made of heavy duty steel for durability. Fork dimensions like thickness, length, width between forks can vary based on capacity needs.

Drive Unit

The drive unit refers to components that enable the forklift to move. This includes wheels, axles, drive motor, steering system, operator compartment, control levers, and more. These units are designed for optimum visibility and maneuverability in tight warehouse spaces.

Common Forklift Parts and Repairs

Like any complex machine, forklifts require periodic maintenance and repairs to remain in safe, working condition. Some key forklift parts that typically wear out include:

Tires

Forklift tires support heavy loads across various terrain and are prone to wear and damage. Routine inspection for cuts, cracks, uneven tread wear is essential. Forklift tire repair or replacement may be needed to boost productivity.

Forks

Bent, cracked, or damaged forks can lead to load instability and accidents. Forks should be checked routinely for signs of wear based on factors like operating hours, application, capacity usage. Forks may need straightening or full replacement if severely damaged.

Hydraulics

Hydraulics power key forklift functions using pressurized fluid. Components like hoses, seals, cylinders, pumps may leak fluid or lose pressure over time. Identifying and fixing minor leaks quickly can prevent bigger issues with hydraulic pressure.

Brakes

Worn brake pads lead to loss of braking power. Slow brake response time reduces productivity and safety. Brake fluid levels and overall brake performance should be monitored to determine if pads, rotors, or calipers need replacement.

Purchasing Forklift Parts

When buying forklift replacement parts, working with an authorized dealer is highly recommended. Dealers have extensive knowledge of model specifications and access to genuine OEM parts made to exact specifications for proper fit and functionality.

Forklift Model

Having forklift nameplate details like brand, model number, serial number, and year manufactured makes finding the right parts easier. This info confirms compatibility with parts or accessories you may want to buy or replace.

Part Number

Referencing specific part numbers when available removes guesswork when ordering parts. The correct part number ensures you receive the accurate component for your forklift model.

Part Condition

Parts can be purchased new, remanufactured, or used. New parts are costliest but optimal for reliability. Remanufactured parts are reused components restored to like-new quality at lower costs. Used parts carry no guarantee but are cheapest.

Warranties

See if any warranty or money-back guarantee applies to the parts you plan to buy. Warranties protect against premature failures - good assurance that critical components like masts or drive units won’t quickly break down.

Maintaining Your Forklift

Along with proper forklift parts replacement, following scheduled preventive maintenance improves safety, maximizes operational efficiency, and extends equipment lifespan. Key maintenance best practices include:

Inspections

Daily and weekly walk-around inspections to check tire pressures, fluid leaks, mast/fork damage. Identify minor issues before they become major repairs.

Fluid Checks

Check and replenish fluids like fuel, motor oil, coolant, brake fluid as scheduled. This maintains optimal levels for hydraulic health, engine performance.

Lubrication

Grease fittings regularly to prevent excessive wear of moving parts like wheel bearings, articulation joints, bushings, pins.

Cleaning

Remove accumulated dirt, debris near radiators, intakes to maximize cooling airflow. Power wash rough uneven floor areas that affect tire life and steering control.

Performing scheduled maintenance not only helps maximize uptime, but may also increase resale value should you decide to upgrade your lift truck down the road.

FAQs

How often should forklift tires be replaced?

On average, forklift tires last 2-4 years with proper maintenance. Tires with excess wear, cracks, or damage should be replaced immediately for safe operation.

When do I need to replace forklift forks?

Bent forks exceeding 3 degrees, cracks deeper than 3mm, or excessive notching over 10% of thickness requires fork replacement. Also replace if fork width tolerance exceeds 5mm.

What is the lifespan of a forklift mast?

A forklift mast has a typical life expectancy of 10,000 - 15,000 hours with occasional repairs. Signs like excessive side play, cracked welds, or leaning backwards/forwards indicate a need for replacement.

Why check hydraulic fluid levels often?

Forklift hydraulics have many moving seals, valves and hoses needing fluid lubrication. Low fluid causes premature wear, leakage, and complete hydraulic failure - so maintaining proper levels prevents repairs.

Should I buy used or new forklift parts?

Genuine new parts provide optimal reliability and warranty protection. But remanufactured or used parts can provide huge cost savings with minor tradeoffs. Evaluate age, hours, application demands before deciding.