Forklift Gears

Korea Ever-Power manufactures specialised forklift gears for the complete range of electric and internal combustion forklifts — from compact 5-tonne electric forklifts to heavy 10-tonne electric drive units, and including CT and CY forklift gearbox configurations. Customer drawings and samples are welcome. Korea Ever-Power's forklift gear programme covers gear sets for forklift drive axles, transmission gearboxes, and hydraulic pump drives across the major forklift capacity classes and gearbox types used in warehouse, logistics, port, and heavy industrial applications.

Korea Ever-Power's forklift gears programme includes: 10T electric drive forklift gear sets; 5T electric forklift gear sets; CT forklift gearboxes; CY forklift gearboxes; and forklift parts and components. All produced to OEM specification from customer drawings or samples — providing both original equipment supply to forklift manufacturers and replacement part supply to the forklift maintenance and repair market.

Electric Forklift Drive System (5T and 10T)

Electric forklifts (5T and 10T class) use AC or DC traction motors driving the front axle through a compact fixed-ratio drive axle gear set. Because the electric motor provides high torque from zero RPM and can be reversed electronically (without a mechanical gearbox), the drive axle gear system is simpler than IC forklift transmissions — typically a two-stage spur or helical gear reduction from motor speed to wheel speed, providing the single fixed ratio required between the motor output shaft and the drive wheel.

Key characteristics of electric forklift drive gears: compact (the drive axle housing must fit within the counterweight envelope); high reduction ratio in two stages (motor speed 1,000–3,000 RPM → wheel speed 50–150 RPM → drive ratio 10:1 to 30:1); very high torque at wheel (10T class: drive axle output torque 15,000–25,000 Nm); and sealed-for-life lubrication requiring minimal gear surface wear over 10,000+ operating hours.

IC Forklift Transmission (CT and CY Gearboxes)

Internal combustion forklifts (diesel or LPG engine) use a torque converter or power shift transmission between the engine and the drive axle. CT and CY type forklift gearboxes are the two most common power shift transmission configurations for IC forklifts in the 2–10 tonne capacity range. These gearboxes provide forward and reverse selection through hydraulically-actuated multi-plate clutch packs and a planetary gear system for speed/direction change — all controlled by the operator's direction selector without a clutch pedal.

CT and CY gearbox gear components: planet gears, ring gears, sun gears, output shaft spur gears, and reverse idler gears — all in carburised alloy steel (20CrMnTi or 20CrMnMo) for the high fatigue life required under the continuous forward–reverse cycling of forklift stacking operations. Korea Ever-Power's CT and CY gearbox gear sets are produced to the OEM dimensions of the original gearbox manufacturers for direct replacement fitment.

Extreme Duty Cycle

A warehouse forklift in multi-shift operation completes 200–500 full load stacking cycles per shift — each cycle involving a forward travel load, lift, forward positioning, lower, and reverse travel. Each direction reversal imposes a load reversal shock on the drive gears. Over a 10-year service life, this equates to 50–100 million gear load cycles — requiring a fatigue life far beyond typical industrial drive applications.

Full-Load Starts and Reversals

Unlike most drives that start unloaded and accelerate to speed, forklifts start at full rated load from standstill — the maximum possible torque shock. Direction reversals at slow walking speed subject the drive gear pair to tooth load reversal on each working cycle. The gear tooth root must have sufficient fatigue strength to withstand not just the compressive tooth loading but the reverse bending stress on load reversal — requiring deep case hardening (1.2–1.8 mm) on both tooth flanks.

High Continuous Torque at Low Speed

Forklifts operate at very low travel speeds (3–15 km/h) with high continuous torque — the drive axle gear set must transmit the full drive torque at shaft speeds far lower than most gear applications. This low-speed, high-torque condition is the most demanding for gear tooth contact (Hertzian) stress: low pitch velocity means the lubricant film is thinner and the contact stress duration per tooth is longer. Large module gears with deep case depth and tight pitch accuracy are required.

Compact Envelope Requirement

The forklift drive axle gear system must fit within a very compact envelope — the drive axle housing is constrained by the forklift's overall width, counterweight position, and chassis geometry. Achieving high torque capacity within a small volume requires the highest quality material (carburised 20CrMnTi or 20CrMnMo, HRC 58–62), precise tooth form, and optimised gear geometry — exactly the capability Korea Ever-Power's forklift gear manufacturing programme delivers.

Sealed-for-Life Lubrication

Electric forklift drive axles are typically sealed-for-life — the gear oil is replaced only at major overhaul, not during routine service. The gear tooth surface must have sufficient hardness and surface quality to withstand 10,000+ hours of operation in the sealed oil without pitting progression that would contaminate the oil with wear particles and accelerate failure. Korea Ever-Power's forklift gears are ground to Ra 0.8 µm or better to maximise the initial oil film thickness and minimise the initial surface wear rate.

Warehouse and Logistics

5T electric forklift gear sets in multi-shift warehouse operations — the highest duty cycle application where direction reversal frequency, operating hours per day, and total service life requirements are most demanding. Korea Ever-Power's 5T electric forklift gear sets are designed for 10,000+ hours sealed operation in these applications.

Port and Heavy Industry

10T electric drive forklift gear sets for port container handling, steel mill coil handling, and heavy manufacturing material movement. 10T class forklifts operate at the maximum practical drive axle torque for electric forklifts — requiring the largest module gears, deepest case depth, and highest material grade in Korea Ever-Power's forklift gear range.

IC Forklift Overhaul and Repair

CT and CY forklift gearbox gear sets for power shift transmission overhaul and repair. When a CT or CY gearbox reaches its overhaul interval (typically 5,000–10,000 operating hours), the complete internal gear set — planet gears, ring gears, clutch hub gears, and output gears — is replaced. Korea Ever-Power's CT and CY gearbox gear sets provide the complete replacement part kit for these overhauls.

Manufacturing and Production Facilities

Forklift drive gear sets and individual forklift parts for production facility internal logistics — automotive assembly plants, electronics factories, food processing facilities. Production facility forklifts operate continuously in shift-work patterns with high annual operating hours, making gear quality and reliability directly tied to production line uptime.

What information is needed to quote forklift gears?

Provide the forklift brand, model, capacity class (5T, 10T, etc.), drive type (electric or IC), and gearbox type (CT, CY, or other designation). If you have the OEM part number for the gear or gearbox, include it. If not, send a sample gear or a drawing (DWG, STEP, PDF) with critical dimensions. Korea Ever-Power's engineering team will identify the correct gear specification from this information and prepare a quotation.

Can Korea Ever-Power supply individual gear components as well as complete gear sets?

Yes — Korea Ever-Power supplies both complete forklift gearbox gear sets (for transmission overhaul) and individual forklift gear components (for specific part replacement). Individual component supply is useful when only one gear in a set has failed due to a specific cause (debris ingestion, bearing failure causing shaft misalignment) and the remaining gears are still serviceable. Provide the individual part number or sample for individual component quotation.

Are forklift gears from Korea Ever-Power OEM-equivalent quality?

Yes — Korea Ever-Power's forklift gears are produced to OEM-equivalent specification: same material grade (20CrMnTi or 20CrMnMo), same case depth, same tooth form dimensions (from OEM drawing or measured sample), and same surface hardness (HRC 58–62). The manufacturing process — gear hobbing, heat treatment, and inspection — follows the same process controls as OEM production. For aftermarket replacement supply, Korea Ever-Power can provide material certification and dimensional inspection reports on request. Contact Korea Ever-Power for a quotation.

"We are a forklift maintenance company and source CT gearbox gear sets from Korea Ever-Power for our fleet overhauls. Planet gears: tooth flank hardness 60 HRC, case depth 1.5 mm — matches OEM spec. Bore to OD runout: 0.018 mm for 6 pcs checked. Fitment to CT gearbox housing: correct to existing shim without adjustment. 14 gearbox overhauls completed using Korea Ever-Power gear sets — no re-do required."

Kim Dong-min  |  Forklift Service Manager, Incheon Industrial Equipment Service Co.  ·  Q1 2026

"We operate a fleet of 10T electric forklifts in our container handling yard and source drive axle gear sets from Korea Ever-Power. Sealed drive axle oil analysis at 8,000 hours: iron particle count 42 ppm — within our 100 ppm change threshold, indicating minimal gear wear. Full service life target: 12,000 hours without gearbox overhaul. Drawing-to-sample match confirmed by CMM check at incoming inspection. Sample from Korea Ever-Power delivered in 10 days."

Lee Jae-chan  |  Fleet Maintenance Manager, Busan Container Terminal Co.  ·  Q4 2025