To troubleshoot a forklift, you should:
- Take the lift out of service. Do not allow an operator to use a lift that may be malfunctioning. ...
- Find the source of the issue. Assess the lift to determine the root cause of the issue. ...
- Ensure the repairs are performed properly. Verify that any repairs are performed by a qualified technician. Upon completion, evaluate the lift and ensure it works properly. ...
What do forklift operators do when a forklift malfunctioning?
When a forklift is malfunctioning, they investigate the problem and consult operating manuals in order to figure out what work needs to be done. Then, they complete whatever repairs are needed, such as replacing worn-out machine parts.
What to do if your forklift won’t go up or down?
If you spot a problem when performing such an inspection, immediately shift into forklift repair mode. For instance, if you spot an oil leak, or a mast that won’t go up or down, it’s important to fix them as soon as possible. Other issues are less obvious but may still impact the forklift’s performance.
How often should a forklift be serviced?
A regular forklift repair schedule is paramount. Typically, it helps to perform forklift troubleshooting and repairs approximately every 90 days. If you use your lift regularly, you may require more frequent troubleshooting and repairs. How to Repair a Forklift
Is it better to repair or replace a forklift?
No matter the reason, it’s always better to repair forklift problems as soon as possible. Delaying repairs can make the problem worse. This can cause more downtime for the truck and lead to costly repairs. When one part doesn’t function right it can cause problems in other areas of the forklift.
How do you troubleshoot a forklift?
If your forklift is electric, follow these troubleshooting steps: Check the charging level of your battery: When was the battery last charged? Was it charged properly? Test all auxiliary functions: Test your brakes, lights and other functions to find out whether they work.
How do you fix a forklift that won't start?
Firstly, make sure the battery is charged and properly connected. You can try recharging the battery, but if this doesn't work, then it might need replacing. Another reason your battery might not be working is if it's too cold. Just like a car, a forklift battery can struggle to get going in minus temperatures!
Can forklift forks be repaired?
If your forks are damaged, and you're not sure how to repair forklift forks, that's entirely OK! In fact, without manufacturer approval, it's not recommended to repair your forks when they're damaged, as this can compromise safety. Always log any incident involving forklift fork damage.
What are the three major parts of a forklift?
What Are the Three Major Parts of a Forklift? Answer: The chassis, the mast, and the overhead guard. Additionally, forklifts have numerous safety devices distributed throughout the truck.
What would cause a propane forklift not to start?
If your propane powered forklift cranks but will not start, especially after replacing the LP tank, check for a “Double O-ring” in the hose connection that screws into the propane tank. There is a sealing O-ring which belongs in the tank fitting. Oftentimes, the O-ring gets stuck in the forklift hose connection.
What causes a forklift to lose power?
The most common causes of electrical problems are malfunctioning switches, broken wiring, loose hardware, blown fuses, and corrosion.
What type of metal are forklift forks made of?
Forklift forks are made from very tough steel, usually 4140 or 4340. These types of steel are used due to their toughness and they maintain a high tensile strength during forging. The most common mounting found for forks on a forklift is the Hook method.
When should forklift forks be replaced?
Know When to Replace Forklift ForksMore than 10 percent wear - the metal on a fork gradually wears down. ... If the shank or the blade are bent more than 93 degrees, replace the fork(s). ... Surface cracks - they typically appear in the heel area and around welds.More items...•
What steel is used to make forklift forks?
Forklift Fork Materials Answer: Chrome-manganese steel. Other steel alloys include: 1045 to 1060 steel. 4140 or 4340 steel.
What is the most important part of a forklift?
the operatorThe Driver. By far, the most important part of a forklift is the operator.
What are the 8 principles of forklift equipment?
0:111:51Forklift Basic Principles - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe forklift will not tip forward the force of moving turning. And the loads height and balance onMoreThe forklift will not tip forward the force of moving turning. And the loads height and balance on the forks can easily tip the truck from side to side tip overs are the most serious.
What is the top of a forklift called?
MAST. The forklift mast is the raised vertical support that allows loads to be raised and lowered. For most forklifts, the mast is designed toward the front of a forklift and directly in the forklift operator's line of vision.
How do you weld a fork?
0:203:05The Welded Angel - How to weld forks and stuff for the holidays - YouTubeYouTubeStart of suggested clipEnd of suggested clipJust use flux core wire where you solid wire and make gas. I'm burning off the zinc coating from theMoreJust use flux core wire where you solid wire and make gas. I'm burning off the zinc coating from the I'll be sure to do this in a well-ventilated. Area.
How do you level a forklift fork?
0:112:20Leveling Your Forks - YouTubeYouTubeStart of suggested clipEnd of suggested clipOnce the driver has learned the basics of rear-wheel steering. It's time to learn how to pick up andMoreOnce the driver has learned the basics of rear-wheel steering. It's time to learn how to pick up and place loads to do this it's important that the operator learned how to level the forks. This.
Steering
Forklifts aren’t the easiest pieces of machinery to steer, so it’s important that the steering is as smooth as possible at all times. Faulty steering can be caused by low levels of steering fluid transmission, so make sure to check this and top up as necessary.
Forklift Engine
A common cause of forklift failure is the engine overheating. This is a result of the radiator breaking or becoming blocked. Blockage is caused by a buildup of dirt and debris, making it important to ensure that the radiators remain clean.
How often should you repair a forklift?
The general rule of thumb regarding forklift troubleshooting is that you should always repair your forklifts as soon as you notice a problem. While it might be easy to put off fixing minor issues in a busy warehouse environment, it is not a wise decision, as delaying repairs can exacerbate the problem, resulting in more expensive repair costs, extra downtime for your machine, and even hazardous conditions for operators. Even if only one part of your lift truck is not functioning properly, it can quickly lead to issues in other areas of your forklift. Outlined below are three common problems and how to address each one.
What is a forklift mast?
The mast on a forklift is the frame that facilitates the lowering, lifting, and tilting of the machine. The carriage and forks are attached to the mast and are powered by a hydraulic piston when lifting a load. Some common mast problems include the following:
What Are the Most Common Forklift Failures?
If you own a forklift, it’s a good idea to familiarize yourself with the issues you’re most likely to encounter. The most common problems are the following:
How to Diagnose a Forklift Issue
When experiencing any of the above failures, you may need to complete a bit of troubleshooting to pinpoint the source of the problem. For each problem, we’ll share some tips on how to figure out what the issue is and how it can be fixed.
When to Call an Expert
When you’re familiar with the most common forklift problems and solutions, you can be better prepared to deal with an issue. However, keep in mind that most fixes, including technical repairs and part replacements, should still be left to professional technicians.
Work With an Expert Repair Shop
Gregory Poole Lift Systems has a vast network of experienced, highly trained repair professionals throughout the Carolinas and Virginia. Thanks to our in-house training department, our technicians have extensive experience working on all kinds of forklifts and can provide high-quality customer service.
What to do if your forklift doesn't work?
If they don’t work, you may have a dead or corroded battery, or have a bad connection from the battery.
Why is my forklift not starting?
Other possible reasons for a non-starting forklift are overheating (from lack of coolant), or if you have a cold engine . Check coolant levels or move the forklift to a warmer location.
When is the best time to replace a forklift?
Nothing will extend the life of a truck more than regular scheduled maintenance. It would seem the best time to replace a forklift is when it reaches the end of its operational life.
How many hours does a forklift last?
Frequent accidents can also cause excess wear, which can shorten the life of a truck. The average use of a forklift is around 2,000 hours per year. More use than that will require more frequent maintenance and repairs. Forklifts that work longer shifts will wear out sooner.
How long does a forklift last?
The average lifespan of a forklift is around 10,000 to 12,000 hours. This comes to about seven years of daily use. Some high-end forklifts have a lifespan of 20,000 hours or more. Many factors can affect how long a truck lasts before needing forklift replacement. These include: Type of forklift.
How to tell if a forklift tire is worn?
It’s time for forklift wheel replacement when you spot any of these signs: Less than an inch from the lettering on the tires to the top of the tires. When the tire is worn down to the safety line.
What are some examples of forklift parts?
Using forklift replacement parts can also help. Parts most often replaced tend to be engine components. For example, oil and air filters, chains, and spark plugs.
What is the life of a forklift?
Forklifts actually have two types of lifespans – economic and useful. The useful life is the amount of time the forklift can still do the job. It ends when no amount of repairs can keep it going. The economic life is the time for which it makes economic sense to maintain the forklift.
Why is a forklift important?
Forklifts are important machines in many work environments. They perform a variety of jobs that can make a warehouse or other job site more efficient and productive. Yet , they also cost a lot to buy and maintain, and most don’t have a very long service life. That’s why the decision to repair or replace a forklift is so important.
What is a forklift technician?
Forklift technicians are highly-trained professionals with a sixth sense for forklifts. Let them be your eyes and ears - and help save you money on repairs.
Is a forklift invincible?
Forklifts and other material handling equipment are rugged machines, built to work hard, but they’re not invincible. All too often we end up doing expensive repairs on equipment that could have been avoided had the machine been properly maintained.
What is a forklift mechanic?
A forklift mechanic is a mobile heavy equipment technician who specializes in the maintenance and repair of forklifts. They perform regular inspections and scheduled maintenance of these machines. When a forklift is malfunctioning, they investigate the problem and consult operating manuals in order to figure out what work needs to be done.
What equipment do you use to service a forklift?
Your work may involve using diagnostic equipment, power tools, handheld tools, welding equipment and calibration tools. For some tasks, you might use computers or computerized equipment. You are in charge of making sure each forklift you service remains in good working order, has a long operating life and operates safely.
What education do you need to be a forklift mechanic?
Education Required. Postsecondary certificate or associate degree. Education Field of Study.
What training do you need to be a heavy equipment mechanic?
Employers typically prefer you complete a formal training program in heavy equipment mechanics. However, you may be able to gain the knowledge and skills you need through on-the-job training, which some companies may offer. Formal programs in heavy equipment mechanics usually result in an associate degree or certificate.
Forklift Battery/Motor
Lifting/Equipment
- One of most common problems that can occur with a forklift is issues with the mast, which is the lifting mechanism. If the mast becomes faulty it may be a sign that the hydraulic system is malfunctioning in which case you’ll need ro repair the leaking cylinder and replace the defective forklift parts like the oil filter and oil seals. If the oil is...
tyres/suspension
- Even though forklifts don’t travel far, the stress and pressure put on the tires will gradually wear them down. Tyres are key to vehicle performance, and if they become flat or damaged it can affect the safety and stability of the forklift. Worn out tyres will need to be replaced to ensure traction and stability. Similarly, suspensions also react in response to the load. These will need t…
Steering
- Forklifts aren’t the easiest pieces of machinery to steer, so it’s important that the steering is as smooth as possible at all times. Faulty steering can be caused by low levels of steering fluid transmission, so make sure to check this and top up as necessary. Steering issues can also be the results of worn out gears, in which case you would need to call in professionals!
Forklift Engine
- A common cause of forklift failure is the engine overheating. This is a result of the radiator breaking or becoming blocked. Blockage is caused by a buildup of dirt and debris, making it important to ensure that the radiators remain clean. If the issue still persists there may be corrosion in the radiator, in which case it will need to be repaired, or possibly replaced.