Ongoing maintenance is essential to keep your forklift in the best condition, which is why it’s smart to have a dedicated budget for repairs and maintenance. You want to maintain the productivity of your crew, which is why it might even make sense to have some of the most commonly replaced forklift parts on hand. When you know what to expect with upcoming maintenance, you can avoid surprise breakdowns and manage your budget accordingly.
Tires Wear Out the Fastest
Every forklift part replacement schedule includes regular tire maintenance. In fact, the tires are usually the first thing to wear out, especially if you are running the forklift on concrete or gravel. The rough materials can take a toll on the tires over time.
As a general rule of thumb, most forklift tires need to be replaced every 1,500-2,000 operating hours. But if you are using the forklift on rough surfaces, then the tires will wear out even faster.
Make sure that tire inspection is included on your daily checklist. Operators should be looking for signs of wear and tear, such as chunks of the tires that are missing, flat spots, or visible cords. If you notice any of these issues, then it means that the tires must be replaced immediately.
Brakes Wear Faster Than You Might Expect
The brakes are another common maintenance requirement, especially because of the heavy stop-and-go cycles that wear down the brake components. You might notice that the brakes need attention when they start to make a grinding noise, you can feel that the brake pedal is soft, or more distance is required to come to a full stop. If you notice any of these warning signs, then it’s essential to take the forklift off the floor and handle the brake maintenance right away.
Remember that reliable brakes are a safety-critical part, which is why the brakes should always be included on your inspection schedule. Don’t wait for the warning signs to pop up before you address issues with the brakes.
Batteries on Electric Forklifts
The battery lifespan depends on the type of battery you are using and how hard your crew is pushing the forklift each day. If you have a well-maintained lead-acid battery, then it will usually last around 1,500 charging cycles (which usually works out to be about 5 years). Lithium-ion batteries last longer and can give you a few more years of reliable performance before they need to be replaced.
One of the most obvious signs that you will need to replace the battery soon is that you notice that the run time for each charge is decreasing. How often should forklift batteries be replaced? When you notice that the battery charge limits could potentially impact shift productivity due to downtime for charging, it’s probably time to replace them. Downtime can be quite expensive, which is why it makes sense to replace the forklift battery proactively so that you can keep the equipment running.
Also, keep in mind that charging habits make a big difference in the lifespan of the battery. You can extend the battery’s timeline by following the manufacturer’s recommendations for watering and charging cycles.
Oil and Air Filters to Protect the Engine
Filters are cheap maintenance, especially when you consider the engine damage they are preventing. So, always follow filter replacement recommendations because they are designed to protect your forklift and lengthen the engine’s lifespan.
If you have an internal combustion forklift, then filter service is typically recommended every 200 to 250 operating hours. It might seem like a small maintenance task, but this proactive approach can save you from expensive repairs in the future.
Lift Chain Wear and Tear
As you are moving through load cycles, the mast chain can take a beating, which is why periodic lubrication is essential. Also, make sure that a chain inspection is happening daily to catch any potential signs of wear and tear in the earliest stages.
If the chain is stretched or corroded, it could fail without warning, posing a serious safety threat. Staying ahead of the chain maintenance will reduce the risk of accidents and injuries in the workplace.
Check your OEM manual for the exact chain maintenance timelines. Most manufacturers recommend chain inspection before you reach the 10,000-hour mark (or sooner if the forklift is operating in a wet or dusty environment).
Build a Schedule Instead of Reacting
Instead of waiting to act when the forklift breaks down, it’s better to maintain a proactive schedule to stay ahead of maintenance and repairs. We recommend that you track the actual operating hours for each forklift and know the most commonly replaced forklift parts in advance so that you are ready.
Check your OEM manual to find the exact recommendations for your forklift instead of following a generic industry schedule.
Even though it takes time and money to keep up with your maintenance schedule, it’s worth the investment. Having a preventative schedule can save you as much as 40% in the long run because you are avoiding breakdown repairs.
FAQs
How often should I replace my forklift battery?
Most lead-acid batteries have a lifespan of about five years or 1,500 charge cycles, as long as you are consistent with proper charging habits. Lithium-ion batteries usually last longer.
What is the average lifespan of forklift tires?
You can expect good forklift tires to last between 1,500 and 2,000 operating hours. If you are using the forklift on rough or uneven surfaces, then the tires will wear out more quickly.
What happens if I ignore forklift maintenance?
Skipping forklift maintenance will lead to bigger and more expensive issues in the future, including repairs and downtime. Additionally, you might be facing safety issues with OSHA.
What’s the most expensive part to replace?
Batteries and lift chains are the most expensive forklift replacement parts.
Your Customized Schedule for Forklift Maintenance
Our team at BullDog Forklifts offers personalized support to help you stay ahead of all of your maintenance needs. Not only do we have a full stock of the most commonly replaced forklift parts, but our technicians will come to your site to complete the maintenance and repair work.
For more information about forklift maintenance, repairs, rentals, or sales, contact us today.