What are the most frequent
causes of downtime?
The two most frequent causes are operator abuse of the
equipment and lack of regularly scheduled preventive maintenance.
How do operators abuse the
equipment?
The list is endless but here are a few of
the most common occurrences:
- Failure to check fluids on equipment on a regular basis.
- Failure to use the inching pedal when shifting from forward to
reverse
- Gunning the engine
- Using the forklift to "push" pallets, trailers, or equipment.
Forklifts are designed for lifting not pushing or towing.
- Loading Over the rated capacity of the unit.
- Continuing to use the equipment even though there is a known problem
with it, this often leads to a major problem developing.
What can we do to reduce abuse?
- The first step is to make the operator part of the preventive
maintenance process. Many companies have a checklist that the
operators are expected to fill out on a weekly basis. This
checklist includes checking oil levels and safety devices. It
also includes space for the operator to make the supervisor aware of any
known problems with the unit.
- A second step, in cases were you have a large fleet and frequent
abuse of the equipment is suspected, would be to have us install
devices on the units which are designed to detect abuse such as
operators crashing the units into each other or into other objects.
Devices to limit who can drive which unit, etc.,
- Installation of high visibility strobe lights and OSHA approved
backup alarms can also increase visibility and decrease the chances of a
collision. These items not only help but are required by OSHA on all
forklifts.
Why are repairs performed in-shop so
expensive?
- When a forklift is sent to the shop for service, it is usually
because the job is labor intensive and possibly parts intensive as
well. In many cases the unit may require more than one mechanic to
be involved on the job simultaneously.
- Many customers are under the impression that they will save money if
they have the forklift company perform these jobs on site. This is
a fallacy, since due to the complexity of most of these jobs, a fully
equipped repair shop is required. An in many cases the bill would
increase since mechanics would be required to run back and forth from
the customer site to the shop, getting necessary tools and
supplies.
What benefits will be derived from
regular PM
By performing preventive maintenance at the
recommended scheduled intervals you can expect to see (among many other
things):
- By replacing engine oil at regular intervals you reduce unnecessary
heat and wear to the engine.
- Maintaining proper transmission oil and drive axle levels, is
crucial to the grueling operations that a forklift is asked to perform.
- Lubricating parts that slide against each other, such as mast
components, steer axle components, steer tires, sideshifter attachments
etc., GREATLY reduces wear and tear on the equipment.
- Maintaining the correct battery water level, and proper charging of
an industrial battery (for electric forklifts), can mean the difference
between having and not having the motors work in the unit a couple of
years down the road. Electric forklifts are very sensitive to low
battery voltage, and all components will run hotter and fail more
frequently if you are using an old or poorly maintained
battery.
FORKLIFT OPERATION AND
SERVICE.
BE SURE TO VISIT THE HOME PAGE FOR INFORMATION ON LIFT TRUCKS
REPAIR, SERVICE, TROUBLESHOOTING, AND EVERYTHING YOU NEED TO KNOW ABOUT
FORKLIFTS AND THEIR USE.
MY FATHER'S BIBLE STUDIES
AND YE SHALL KNOW THE TRUTH.
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