Closely linked to the forklift 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 together.

Replacement forklift engines are available as OEM, aftermarket, reconditioned or used parts. Age, type and power are the factors to consider when choosing a forklift engine. The age of a reconditioned or used engine is important because a forklift must lift heavy loads while moving.

The motor control units start or stop the motor, select the direction of rotation of the motor, regulate the speed through motor speed controllers, limit the torque and protect it against overloads. Switches are an essential part of an engine control unit and can be connected directly to the battery or via relays and contactors connected to sensors that automatically start and stop the engine.

Contactors and relays are electrical switches that are part of a forklift’s electrical system. The contactor is a type of relay used to handle the high power required 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 a truck’s starter solenoid. A contactor is an essential part of a magnetic starter that 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 RPMs, the diodes and rectifiers convert the alternating current to direct current. The solenoid is a specific type of relay that operates an electrical switch in the system.

The forklift’s electrical system is also connected to other electrically operated parts, such as the front and rear flood lights, taillights, instrument panel, and gauge lighting. The lights are turned on and off by individual switches connected to the electrical system. The brake light switch is often mounted above the brake pedal linkage and comes on when the driver steps on the brake pedal.

The forklift’s electrical system provides power 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 gauge.

Another set of parts connected to the truck’s electrical system are warning lights, buzzers, indicator lights, and the horn. These include 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 or other brand forklift. Familiarizing yourself with where these are located on the truck will save downtime when performing maintenance work on the truck’s electrical system.

Forklift electrical parts affect many truck components and must be kept in good condition at all times for safe and efficient performance.