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Forklift brakes can feel aggressive to an operator, especially when the forklift isn’t carrying a load. This is because they’re designed to stop the unit with a full load. Also, the brakes rarely heat up so condensation can form. If rust or brake dust causes a build-up, the forklift brakes may be more intense after the unit sits overnight.
Brake squeal or other noises are often questioned by forklift operators, but these sounds do not always signify a problem with the forklift. Different brake designs and materials complicate our ability to troubleshoot, plus cars are our main point of reference for brakes. Cars have (4) wheel brakes and most forklifts have only (2) wheel brakes. The power brakes, semi-metallic / ceramic pads and anti-lock systems for cars are also different and cannot be compared to forklifts.
Several braking or speed reduction systems are available on forklifts. Below is an overview:
Drum & Shoe Brakes
This brake includes a drum, shoes and hydraulic wheel cylinders. It’s common to the rear brakes of most cars and is the most common brake design used on forklifts.
Disc Brakes
Disc brakes consist of a rotor, a mechanical, hydraulic or air-operated caliper and friction pads. This type of brake is common on the front axle of most automobiles and used in some forklift applications.
Wet Brakes
Discs similar to transmission clutches are located inside the drive axle and are lubricated and cooled by the transmission fluid or axle oil. Hydraulic pressure is used to squeeze the friction disc packs and slow the drive axles. The advantage of wet brakes is they seldom require replacement.
Air Brakes
Air brakes use compressed air pressing on an actuator to apply the mechanical force to the brake shoe or pad. Air brakes are used in larger heavy vehicles. These systems require an engine-driven air compressor and air pressure is tightly governed.
Hydrostatic Drive Brakes
The forklift is driven by hydraulic oil from a pump driven by the engine to hydraulic motors at the wheels. When drive is not requested, oil stops flowing and a natural braking effect is the result as oil can’t exhaust out of the wheel motors. This type of brake is used in some forklifts, many aerial lifts and primarily for construction equipment.
Dynamic, Plugging or Regenerative Braking
Drive systems on electric forklifts and other electric drive systems have the capability of using magnetism in the drive motors to magnetically slow the drive motor armature by changing direction (i.e. forward to reverse).
No one is safe on or around a forklift with faulty brakes. All braking systems require adjustments, making maintenance and repair vital. Contact ProLift to schedule a technician at your site!