Supply Chain Issues Have Wreaked Havoc with Equipment Delivery Schedules. Forklifts Are No Exception
All of your forklifts will reach the end of their useful lives at some point. If you’re planning on replacing a forklift in your fleet with a new forklift and are assuming that delivery times will be similar to those of a few years back, you may be in for a rude awakening. You might consider a used forklift, but like the used-car market, the supply of used forklifts is very tight and prices have increased.
That new forklift that you ordered may not arrive for 16+ weeks, and you may need to eke out a few more months out of your existing forklifts. Luckily, a forklift’s useful life can be extended by applying the principles of predictive maintenance rather than waiting for a component to fail. And, to aid in your forklift repair, you should maintain a good inventory of commonly-replaced forklift parts. Those are very wise moves in the current situation.
Here’s a guide to assessing the condition of your existing forklift fleet and squeezing out additional months or years:
With lead-acid battery lift trucks, the battery is the key element, and the life of the forklift’s lifespan can be lengthened simply by making sure the battery is operating properly. Even if the battery has been properly watered and charged, over time, batteries can experience diminished power output because of a buildup of sulfates on the plates.
Use a hydrometer to determine the condition of the electrolyte and add Epsom salts or other proprietary additives to dissolve the buildup on the plates. Always use distilled water to top up the battery. Clean spilled electrolyte off the top of the battery. If cables or wires are frayed or corroded, either clean or replace them.
Avoid opportunity charging, if possible. A lead-acid battery whose cycle is 8 hours in use, 8 hours charging, and 8 hours cooling down will give you the longest in-service time. Charge your forklift’s battery fully (over 80%) and don’t let it get too far discharged (below 20%)
Eventually, however, the battery’s output will diminish beyond the point of usability. Although a new battery is expensive, it may pay to just replace the battery if the rest of the forklift is mechanically sound.
For internal combustion (IC) powered forklifts, the engine is the critical component and often the one that wears out first and requires the most maintenance. Extend the life of your IC-powered forklift by proactively replacing or cleaning engine parts and making sure all of the maintenance protocols are strictly followed:
- Flush and replace all fluids–oil, transmission, hydraulic, and coolant. Replacing the engine oil every 3 months is a good way to extend forklift lifespan
- Replace air, coolant and fuel filters
- Replace plugs or other ignition parts
- Clean all valves, including PCV valve
- Inspect and replace all belts
- Inspect and replace all vacuum and coolant hoses
- Inspect and lubricate clutch and pedal linkages and replace worn parts
Besides the engine and the battery, there are other critical power and structural parts that should be inspected and replaced to get an additional number of months of efficient operation from your forklifts.
- Masts and chains – Check these for damage and replace chains if they appear to be worn out. Check the hydraulic system for leaks and proactively replace components like hoses or valves that appear worn or damaged. Check hydraulic fluid and top up or replace if the fluid is old.
- Forks – Replace damaged, bent or worn-out forks.
- Tires – If tires are worn or damaged, replace them now. Make sure pneumatic tires have the proper air level.
- Steering system – A forklift’s steering system gets a real workout in day-to-day operation. Make sure the steering system’s fluid level is topped up. Replace it if it’s gunky and thick. If the steering system is making strange noises or if steering is difficult or jumpy, have a qualified technician look it over.
- Brakes – A faulty braking system can lead to a costly accident. Replace brake pads and hoses. Inspect master cylinder for leaks.
If you don’t already have one in place, a planned maintenance program is one of the best investments you can make in lengthening the useful life of your forklift fleet. If you don’t have the in-house staff to accomplish that, Apex’s Full Fleet Maintenance Program offers knowledgeable, top-notch inspection and maintenance services to keep your fleet running at peak performance.
One of the best ways to get more mileage from your forklifts is to avoid accidents. A forklift accident can take a truck out of service and severely impact your warehouse’s productivity. If you’re already constrained with having to “make do” with your older forklifts until the new ones arrive, this is an especially important point.
Avoiding accidents begins with operator training. Be certain that everyone who gets on a forklift is properly trained on how to use that specific model. Older forklifts may not have all the safety bells and whistles that new forklifts have, and thus may require a little more care in their operation. Keep a neat facility without objects lying around that a forklift may run over and damage its tires, or worse, tip over.
Finally, make sure your forklifts are stored in a dry place when not in use. Moisture can accelerate the aging of your forklift’s mechanical and electrical components. Before retiring your forklift for the night make sure it’s cleaned to remove dirt, mud or spilled product.
If you need to extend the life of your forklifts until the new ones arrive, Apex can be a valuable partner. We provide complete forklift refurbishing services to make your old forklifts work like new ones. If you don’t have the proper maintenance staff in-house, you can have our team of experienced technicians keep your forklifts in top shape. We have an extensive supply of forklift parts for sale, if you need spare forklift parts for your own overhaul of your fleet. We are your go-to supplier. Apex can provide all of your material handling needs in the Chicagoland area.