Posts tagged ‘Service’
Most people know that regular service is vital for a safe and reliable car. The same goes for forklifts. Setting up a regular service schedule for your forklift fleet can help with things like:
- Expensive repairs
- Unexpected downtime
- Protecting the resale value of your fleet
- Protecting the safety of your forklift operators and employees
So, how often should you set up a service for your forklift or forklift fleet? Well, it depends on the type of forklifts you use and how often you use them.
Internal Combustion Forklifts
In general, Internal Combustion (IC) forklifts need service every 250-300 hours. If you operate forklifts in extreme temperatures or dirty environments or have fork attachments, you may need service more often.
Here are the top four things to focus on during a 250–300-hour IC forklift service:
- Change filters
- Grease parts
- Look for minor problems to prevent big problems
- Conduct safety inspection
With fewer parts to replace and service, electric forklifts require less maintenance than an IC forklift. In general, you should inspect and service electric forklifts every 500 hours. Again, if you work in extreme environments or use fork attachments, your service intervals may vary.
Here are the top six things to focus on during a 500-hour electric forklift service:
- Check the motor
- Inspect the cables
- Lubricate moving parts
- Inspect battery
- Check lights, accessories, and attachments
- Conduct safety inspection
Sample One-Year Maintenance Schedule for IC and Electric Forklifts
For reference, here is a sample one-year maintenance schedule for IC and electric forklifts. It’s a general list of things to focus on; however, you should always follow manufacturer guidelines for your specific forklift.
Every 250 Hours/Two Months
- Check engine idle speed and ignition timing
- Lubricate chassis and mast components
- Change engine fluids and filters
- Blow out and inspect the brakes
- Inspect the hydraulic system and mast
- Check belts, hoses, the drive train, steering, and electrical system
- Inspect tires for damage and wear
- Inspect attachments (if applicable)
Every 500-600 Hours/Four Months
- All items in the 250-hour service above
- Inspect the chains for damage and proper tension, check the mast operation, inspect carriage rollers, lift and tilt cylinders for proper function
- Check/adjust the chassis links, clutch release bearing, and mast support bushing
- Inspect the hydraulic oil pump and check the hydraulic oil level hydraulic filter (replacing if necessary)
- Clean the radiator
- Inspect the PCV valve
- Asses pedal free play
- Check/adjust hand brake
Every 1,000 Hours/Six Months
- All items in the 250 and 500-hour service above
- Change all fluids and filters, including (but not limited to) hydraulic, transmission, and brake fluid
- Replace the spark plugs,
- Lube drive hubs
Every 2,000 Hours/One Year
- All items in the 250 and 500, and 1,000-hour service above
- Replace the: antifreeze, differential and transmission oil, contact breaker (points), and condenser (on older units)
- Hydraulic pressure check
- Cooling system check
- Inspect steer axle
- Inspect brake drums (replace if necessary)
- Compression check
- Clean and check fuel system
If you have a large or mixed fleet, service intervals can get confusing. Contact us to set up a service appointment today! Our team of experienced forklift technicians can create a general maintenance plan that considers all the different types of forklifts in your fleet and when to service them.
Depending on the use and application, metal forks can last years, but they don’t last forever. It’s important to know how to inspect your forklift forks and when to replace them.
Why is it important to inspect your forklift forks daily? Not doing so can lead to snapped forks, dropped loads, and injuries. This can be avoided by daily inspections and proper fork maintenance. As a reminder, OSHA requires daily inspections of all powered industrial trucks, including forks.
How do forks typically get damaged?
- Wear from regular use
- Improper chain adjustments
- Minor accidents
- Fork use beyond its rated capacity
- Driving with forks are touching the floor
- Using a lifting chain on one fork to lift heavy objects
- Picking up loads too far out on the forks
- Attachments that stress the forks
What should you look for?
- Surface cracks. There should be no cracks anywhere on the forks. Check the heel area and welds carefully.
- Blade and shank angle. Check the angle between the upper face of the blade and the front face of the shank. If the angle exceeds 93% the forks must be replaced.
- Straightness. If the forks are bent in excess of 0.5% of the corresponding blade length or shank height, they must be replaced.
- Fork tip height. Forklift blades should be the same height. If there is a noticeable difference between the tips, they should be checked. If excessive, the forks should be replaced.
- Positioning lock. If the positioning lock or other fork retention device malfunctions, it should be checked carefully before continuing use. These types of pins lock the fork to the carriage to prevent the forks from sliding off.
- Fork thickness. Metal on forks wears down over time. A 10% decrease in fork thickness reduces load capacity by 20%. Use forklift calipers to measure the thickness of the fork blade, heel, and hook.
- Capacity stamp. The capacity stamps should be always visible.
Forklift forks should be inspected at least once a year by a qualified service technician. Our experienced forklift technicians are available to inspect your forklifts and forks to ensure efficient and safe work conditions. Contact us to set up a service appointment today!
Chains are a necessary and important feature of a forklift. They lift thousands of pounds of material and failure in any part of the chain can cause a safety issue for the forklift operator and anyone standing nearby. Inspecting forklift chains should be part of your forklift operator’s daily inspection. Here are ten common forklift chain problems and solutions to be aware of:
- Problem: A worn contour, typically caused by normal wear on the sheave or from abnormal wear from rubbing on the guides. Solution: To fix a worn contour caused by normal wear, replace the leaf chain when it is worn down 5 percent. If it is caused by abnormal wear, check the leaf chain alignment, or increase the clearance.
- Problem: Worn surfaces on outer plates or pinheads, caused by misalignment and rubbing on the side flanges. Solution: Check the leaf chain alignment and correct the clearance, as necessary.
- Problem: Tight joints, caused by dirt or foreign substance packed in joints, or corrosion, rust, or bent pins. Solution: Clean and re-lubricate the leaf chain or replace it entirely.
- Problem: Missing parts. If you find your leaf chain is missing parts, it is usually because it was omitted in the original assembly. Solution: In this case, you need to completely replace the leaf chain.
- Problem: Abnormal protrusion or turned pins, usually caused by excessive internal friction caused by high loading and inadequate lubrication. Solution: Replace the leaf chain, improve lubrication, and eliminate overload conditions.
- Problem: Cracked plates from fatigue, caused by loading beyond the chain’s capacity and endurance limit. Solution: Replace chain with leaf chain of larger dynamic capacity or eliminate high load conditions.
- Problem: Fractured plates in tension mode caused by high overload. Solution: Replace the leaf chain and correct the cause of the overload.
- Problem: Enlarged holes caused by high overload. Solution: Replace the leaf chain and correct the cause of the overload.
- Problem: Corrosion due to environment. Solution: Replace the leaf chain and protect it from a hostile environment.
- Problem: Worn leaf chain anchor bolt connecting pin caused by normal wear. Solution: Replace worn leaf chain components as necessary and always replace the components when fitting new leaf chains.
In a single shift operation working on flat, even surfaces, chains can last 3 – 5 years. In more harsh environments, chains may need to be replaced much sooner. Even though inspecting forklift chains should be part of your forklift operator’s daily inspection, for safety reasons, it is necessary to schedule a professional assessment at least once a year.
Our service associates are experts at finding and fixing forklift chain issues. Contact us to schedule a service appointment today!
It’s probably an understatement to say the COVID-19 pandemic has thrown us all for a loop. One of the main discussion points here at Toyota Material Handling Solutions is how we can continue to provide excellent service while keeping everyone safe.
To carry on with our company’s well-known commitment to safety, we’re taking every measure to protect your employees’ health and ours during this pandemic. Besides donning gloves and masks, practicing social distancing, and disinfecting equipment, we train our technicians to take specific steps to perform service during the pandemic safely.
To help alleviate any fears you might have about servicing your equipment during this time, we want to share the steps we take to keep you safe. Here are six areas our service technicians focus on to safely service your forklift fleet.
- Prevention: We instruct our associates to maintain excellent personal hygiene measures and stay home if they have any symptoms of COVID-19 or any other virus.
- Social distancing: We tell our associates to keep a six-feet distance from others and avoid group meetings or other gatherings.
- Disinfecting: Our technicians sanitize the equipment before and directly after performing service work, including spraying disinfectant and letting it sit for one minute and wiping down all controls, covers, and doors.
- Communication: Our service department contacts you to determine a safe work area before your service appointment. When they arrive, our technicians comply with any screening you require and section off the desired work area with safety cones to ensure proper social distancing.
- Proper safety protocol: Our technicians perform personal hygiene measures before entering your facility and wear masks and gloves the entire time.
- Work order procedures: To complete necessary work orders and approvals while observing social distancing, our technicians print your name on the signature line and take a picture of you for identification purposes. If you prefer to sign the bill, we wipe down the phone before and after your signature while maintaining social distancing.
Your safety is our top priority. Call 800-794-5438 if you have questions regarding our COVID-19 safety procedures or contact us to schedule a service appointment today.