Damaged Forklift Paint – A Sign of Something More

April 26, 2013

What message does this picture convey? Is it “normal” or a sign of a larger problem? If your teenager’s car looked like the forklift in the picture, would you be concerned about his or her safety?

Decimated paint tells a truth we cannot ignore. Paint is an indicator of operator priorities and performance. Every inch of damaged paint indicates something was hit … first a busted pallet, then a steel post and later a rack leg.

What – or who – is next?

ProLift’s trainer, Tony Jones, shares his customer experience.
“A former train-the-trainer student contacted me a year after his class with information relevant to damaged forklift paint. After the trainer class he requested his maintenance department touch up the paint on the forklift fleet. He then told the operators they would be accountable for damaged forklifts – even the paint! A year later, only 50% of the budgeted funds for damaged product had been used. My student attributed the savings to the change in attitude toward more cautious operation.”

Real money – and lives – can be saved.

When we observe beaten up forklifts, it’s time to react and never accept it as “normal”. Poor paint conditions may reflect an operator’s relaxed attitude toward safety, which can lead to an accident or fatality. Implement safety training and reinforce the messages. The changes in operator attitude lead to cost savings and a safer work environment.

Interested to learn more about forklift operator training? Contact our Safety Specialist for class dates and pricing at 800-583-4023.

8 Tips For Installing a Forklift LP Tank

April 12, 2013

Because liquid propane (LP) is a flammable and explosive gas, changing an LP tank on a forklift offers risks. To keep ourselves – and co-workers – safe, we must act responsibly.

8 tips for responsibly installing an LP tank

Wear Personal Protective Equipment (PPE)
The fuel inside the LP tank is contained at a high pressure and has a temperature of 44 degrees below Fahrenheit. Contact with the fuel can damage your eyes and skin, causing frostbite. Avoid contact with wrap-around safety glasses and thick, rubber gloves.

Check for remaining fuel
Never assume that because the forklift engine died that fuel isn’t present. Ensure the line and fitting have no remaining fuel that can spray on your hands or face when you disconnect the coupler.

Disconnect
Unscrew the fitting off the tank. Remove the empty tank and store it properly.

Inspect
A leaking tank can result in an explosion. Inspect your fuel tank for frost build-up, dents, gouges, heavy rust and o-ring condition. Also check the lift truck hose and fitting for any visible damage.

Tank position
Put the tank on the locating pin. The locating pin on the forklift’s tank bracket serves four purposes: it positions the tank properly for the hose and fitting alignment to connect without twisting or stretching the hose; ensures the pressure relief valve won’t spray LP fuel; aligns the main valve pick-up tube inside the tank to get almost all the fuel out of the bottom; and allows the fuel gauge to read correctly.

Check the valve and o-ring
Confirm the new tank valve is off. If the hose coupler is screwed on an opened tank valve, it could upset the check valve in the tank fitting and spray LP. Also, ensure the o-ring from the empty tank did not pull out, jamming the check valve. If no fuel can pass through the check valve, the forklift will not start up.

Connection and the valve
Screw the forklift fitting all the way and hand tighten it on the tank fitting. Slowly open the valve, being careful not to over tighten it – in cases of leaks, fire or explosions, you need to be able to shut off the valve quickly. With the valve opened fully, the 10% surge valve inside the tank will shut the tank off in case an LP hose or fitting fails.

Look, listen and smell
If you see visible white frost, hear rushing noises or smell a bad odor … You have a leak! Because it is heavier than air, LP vapor pools on the ground and will look for a source of ignition. Shut off the tank valve and ventilate the area.

If you have additional questions about installing an LP tank on your forklift, contact ProLift to speak with one of our safety consultants. Or, learn more about overall forklift safety by attending a Forklift Operator Safety Training class.

Buyer Beware: Used Forklift Reconditioning

February 22, 2013

Purchasing a used forklift can be intimidating. Ordering new equipment offers security in the condition of the forklift; however, a used unit doesn’t often come with a detailed history of usage and repairs. How can you ensure your budget dollars go toward a reliable investment?

Request a condition report
Knowing the current status and past history of a used forklift is vital. This report is proof of what items were in need of attention and should or should not be in working condition. If the used forklift received doesn’t match the current condition report, you have a stronger backing for resolution with the seller.

Insist on reconditioning details
A reputable seller will record important reconditioning details for a used forklift such as what items were safety checked and which parts have been repaired or replaced. In some cases, the seller may share the unit’s past application and average daily usage. Inquire how many hours are dedicated on average to reconditioning.

Research more, assume less
Information about a used forklift helps you select the right unit for your application. For example, if your unit will be used outside, every forklift will not accommodate this need. If an advertisement is vague, contact the seller and ask more questions regarding a unit’s hours, tires, fuel, capacity, etc. Many buyers also reach out to peers in their industry for referrals of reputable sellers.

Know the seller’s guarantee
If the used forklift purchase doesn’t work upon delivery or after only a few hours of usage, does the seller offer a guarantee? Most sales over the internet or through an auction are “as is” and do not allow buyers an opportunity to test the equipment. While you might save money on the purchase cost, you may later face a large repair bill.

Used forklifts that have been regularly maintained are good investments and make financial sense for companies using the unit 4 hours or less daily. Cut out the unknowns of purchasing used equipment with questions and research.

Ready to shop for used forklifts? Click here to review ProLift’s inventory and warranty levels. We guarantee your used forklift purchase – if you are not satisfied with the performance of your used forklift, you may exchange it at any time within 30 days of purchase.

Forklift Rental: What To Expect When You Rent

November 30, 2012

A need for a forklift can be immediate or planned.  Immediate needs can occur due to broken equipment, seasonal needs, or unexpected demand while planned needs are usually a result of bidding, contractual projects. For immediate needs, short-term projects and specialty lifts, the solution is renting. Forklifts can be rented daily, weekly, or monthly to meet your specific circumstance. So, what should you expect when planning to rent?

Maintenance Responsibility
The requirements to rent from a forklift dealership, who typically rents for the purposes of industrial or commercial use, include having a one million dollar liability insurance policy and completing the credit application process.  Once approved, the rate of the rental will depend upon the rented timeframe of the lift. General maintenance is included in this rate; however, you may incur variable maintenance and damage costs while the rental is in your possession. Variable maintenance costs are expected costs including: fuel or the need of a specialized attachment.

If operator abuse or unexpected incidents happen to the forklift while in your possession, you may be held liable and obligated to cover the cost of the damages to the forklift. Scratches on forklifts, torn seats, knocked off lights and cut tires are the most common damage cost incurred but can be avoided with cautious and trained operators and pedestrians.

Availability
Availability is being able to get what you need when you need it.  Availability of forklifts will differ from dealership to dealership, but typically the machinery can be received within an hour to a week of the request.  Many will carry brand specific forklifts and much of a company’s rent fleet will be shared among various branch locations.  A significant portion of availability will depend largely on utilization – the percentage of available lifts versus what is currently being rented. It is not uncommon for a dealership to have 80% of its rental fleet rented at any given time. If the piece of equipment you need is in the 80% that is currently on rental, it can take up to a week to locate that piece of equipment from another branch location and deliver it to you.

Considerations
When considering renting from a dealership or a rental company, know that all forklift equipment is not maintained the same.  The age of the equipment, the maintenance of the fleet, and whether the rental forklift is “rent ready” will contribute to the overall rental experience.  As a forklift ages, it becomes less ergonomic for the operator, reducing productivity.  A well maintained forklift will be “rent ready”, ensuring an unlikely probability that issues will occur and the forklift will be in optimal operating condition for the entire stint of your rental agreement.

Considering a forklift rental? Contact us today – if we don’t have what you need, we’ll give you a $50 discount toward your next rental.

Forklift Service: In-House Technician versus Outsourcing Forklift Service

October 21, 2012

One of the biggest decisions your company must make is whether or not to outsource your technician services. Both in-house technicians as well as outsourcing services have proven beneficial, in different ways, depending on the company’s environment. It goes without saying: technicians are assets and hold a vital position within the company. Without the presence of a technician, problems would persist, work could not be conducted, and business would come to a halt. Therefore, your decision on this matter should be based on a number of important weighted factors.

Hiring an in-house technician lends itself to:

  • Flexibility: Unexpected breakdowns and maintenance issues can be handled right then and there. No appointment necessary. The in-house technician is always around. His or her job is to be available whenever needed.
  • Specialized knowledge: For certain industries, specialized training or experience is necessary to be capable in providing maintenance and recommendations as needed. An in-house technician will be trained to provide service on all variety of machines that exist within your company.
  • Competitive advantages: As the number of machines increase within your company and variety of those machines become more specific to your industry, your in-house technician will be trained to adapt. Along the way if you develop certain methods or process, both methods and processes would be held secret within the company.
  • Company focus: The company’s need will always be a priority. The in-house technician would have a personal investment within the company due to employer-employee relationship. He or she will have a greater understanding of the culture, values and goals held by the company.

On the other hand, outsourcing the duties of a technician will ensure:

  • Decrease expense: Have a non-employee as a technician means elimination of human resource duties. Payroll, benefits and liability expenses are not incurred. No hiring hassle process. Expenses paid to the technician are only for the maintenance time required to tend to the machinery. There is no idle time expense.
  • Maintenance efficiency: If equipment is small in number and stays consistent in the type of equipment, outsourcing will benefit the company due to the outsourced technician’s ability to provide detailed recorded maintenance history reports along with regular inspection of safety for all of the fleet.
  • Maintenance experts: Time and money spent to train are non-existent. A certified technician will have expert knowledge, be current on industry processes and bring a new perspective on improvements for the company including fleet management recommendations.
  • Worry-free maintenance: A scheduled maintenance plan that fits your specific needs will aid in catching potential problems early, guaranteeing uptime, providing fast repairs and overseeing maintenance or stock parts.

 

ProLift guarantees we will respond to your breakdown call within 4 hours. Click here to read more about our service capabilities or submit a request to discuss a planned maintenance schedule for your fleet with our consultant.

Forklift Ergonomics: Operator Seat

September 25, 2012

One of the most important assets to your company is your group of dedicated employees and as the employer your goal is to reduce the risk of injury of your employees. Therefore, the comfort and safety of those employees should be a priority.  For forklift operators, the majority of their work day requires sitting for extended periods of time. There are great benefits, for you as the employer as well as the operator, to ensure that this time is as comfortable and safe as possible. Replacing forklift seating with an ergonomic seat is just one of the many ways to accomplish this while also saving you money and time.

Cost to having a poor Operator Seat
If you notice in your place of business that a forklift has a worn or cheaply-made seating, consider this a sign of danger.  Forklift seating that does not provide proper support for the operator can have serious consequences. The nature of the job for a forklift operator is repetitive. When driving a forklift, operators find themselves in awkward posture positions for long periods of time. In addition, constant vibrations and shock experienced result in uncomfortable work conditions. Functioning under these circumstances over time, an operator can produce varying levels of physical damage from strain, severe pain, to even an inability to work, which is a serious liability for employers to consider.

Benefits to having an Ergonomic Operator Seat
There have been an increasing number of back injuries claims among forklift drivers. Why? Older forklift seats were built with durability as its key design advantage.  New ergonomic seating for a forklift takes into consideration the natural sitting position of the body and develops a design that complements that posture.  With currently advanced technology options (such as lumbar support, back adjustments, and shock damper), the body is kept in its most efficient position.  Other functions of ergonomic seating include:

•           Leg, head, shoulder, and neck protection in case of tip-over

•           Swiveling base for increased visibility and needless twisting

•           Armrests to prevent fatigue

•           Weighted suspension that guarantees comfort for all operators

There are many options of seating to choose from.  The frequency of use, the length of time in use, and whether the majority of use is indoors or outdoors is information to keep in mind when replacing the seat of your lift.

Depending on your selection, a new seat can be a large expense; however, the return on investment is far greater than the initial investment. Maintaining forklift parts save you time and money that would otherwise be put towards potential worker’s compensation claims. Also, finding the right seat for your operator’s work conditions is the key to increasing operator satisfaction, delivering optimum body support, and reducing the risk of injury. 

Click here to learn more about ProLift and our parts capabilities, including forklift operator seats. Our Lift Truck Stuff catalog also features and ergonomic back rest and neck support system.

Forklift Leasing – How Long Should You Lease?

August 24, 2012

You’ve weighed the pros and cons of leasing your forklift versus a purchase and have decided to lease. Historically your company has selected a 5-year term; however, a shorter term lease could benefit your production and budget. Consider these factors when determining the length of your lease term:


Utilization

The typical lease includes 2,000 hours of utilization annually, which is approximately 40 hours weekly. While this amount of hours may not seem sufficient for the year’s production, conducting an application survey may show the forklift is not in use as often as predicted.

In the event you find utilization to be more than 2,000 hours you can request a higher number of hours be included in your lease. While this will raise the cost of your monthly lease payments it will almost always be less than the overtime charges which can range from $.45/hour to over $5.00/hour.

If the overtime expense remains a concern, refer to your leasing company’s published overtime rate. You may want to assume the risk of paying the overtime rate versus paying for hours that you may not use. The key to this philosophy is to understand the hourly rate and confirm when the overtime will be measured. The best option is to have overtime calculated at the end of the lease term versus annually. If you have periods with low utilization you might avoid overtime expenses due to short-term peaks in business activity.

Payment Amount
Usually the payment amount is reduced as you lengthen the term of the lease. If the priority is to keep the payment as low as possible you might consider a 5- or 6-year lease. However, you must be careful not to extend the term to the point where the benefits of the payment reduction are offset by an increase in maintenance. For clarification, ask your forklift dealer to quote a Full Maintenance program with 2 or more lease term options. Those combined payments will help you determine when the maintenance expense exceeds the benefit of the longer term.

Contract Length with your Customer
If you have a customer who represents a significant percentage of your business, contemplate matching the term of the forklift lease with the term of the contract. This practice significantly reduces your risk should that business be lost.

Uptime Requirements
If you require a very high percentage of uptime (~97% or higher) for your forklift you should consider a lease that is shorter. A shorter lease decreases the hours on the unit and increases the forklift’s reliability.

Fuel Type
Typically an electric forklift will last longer and have less downtime than an internal combustion (IC) forklift. You can easily add a year to the lease term if you are using electric forklifts. The primary caution is the battery’s limited number of charge/discharge cycles. If you push the lease beyond the life of the battery you may find yourself purchasing a new battery near the end of the lease term which can cost thousands of dollars.

Technology Advances
Technology advancement is more difficult to assign value, but there is no doubt that new technologies continue to improve the safety, fuel efficiency and operator comfort of forklifts.
It is best to explain your situation to your forklift dealer so they can provide the options that might best fit your unique circumstances. There are situations where a shorter term lease can actually provide the same, or lower, monthly payments thereby reducing your exposure to increasing maintenance expenses. The most common mistake customers make is predetermining their lease term based on historical preference. By doing this they may be missing potential changes to the factors above.

Adding or replacing units in your forklift fleet? ProLift’s sales consultants are available to conduct an application survey and review lease term options. Call ProLift today or visit our website to review available new and pre-owned equipment.

Inspecting Fork Hooks, Heels & Tips

August 13, 2012

A forklift’s pair of forks has a limited life span and must be inspected daily to ensure safe operation. The inspection should concentrate on three areas – hooks, heels and tips.

Hooks
Hooks are vital welds on a forklift because they are the main source for lifting and carrying product. If a hook on a fork fails, an elevated load can fall and the forklift may tip-over. Before the start of each shift, operators and technicians should inspect each fork on both sides of the hook for cracked welds and separation from the fork upright shank.

Heels
Fork heels should be visually inspected each day for cracks. When a load is applied, the forks flex and microscopic cracks are produced in the metal. Over time the metal fatigues and the cracks become larger.

Heel thickness is decreased when the heel of a fork is dragged on the floor, especially on rough surfaces such as concrete or blacktop. The heel thickness can be measured with a fork caliper and compared to the fork upright shank thickness. The mast chains and tire wear should also be inspected. If either of these components is worn beyond their useful life, forks might drag.

Tips
Damaged fork tips can cause operator frustration due to loads not properly engaging and disengaging. Fork tips are subject to damage if they are abused to nudge loads into position or hit walls and posts. Fork tips should also be measured with a fork caliper. Per ANSI the tip height of deflection in a set of forks cannot exceed 3% of the length of the blade. A 42” fork set has approximately 1” tip height difference allowed before repair or replacement is required.
The described inspections are daily visual inspections and are applicable to most fork designs; however, forks can be application specific and require different inspection points and standards. More detailed inspections are required by ANSI standards on an annual basis.

Time to replace your forks? Call ProLift today to speak to a consultant or click here to learn more about our Parts capabilities.

Defining Forklift Load Center

August 10, 2012

Understanding the load center of a forklift and its load is vital to an operator keeping the unit stable. To protect operators and product, a manufacturer states load center ratings on the forklift data tag.

To understand the concept of load center, visualize two children – one bigger, one smaller – on a playground see saw. Because of his weight, the bigger child will control the see saw; however, if the smaller child moves farther back on the seat and leans back, she will gain leverage and have more control. A counterbalance lift truck is basically an industrial see saw that can be driven. The lift truck is the “bigger child” and the load is the “smaller child.”

Two dimensions have an effect on leverage. Dimension A is determined by the manufacturer based on engineering standards and does not affect load center. The front axle is the pivot point for the forklift. The farther away the upright face of the fork or attachment from the centerline of the axle, the less lifting capacity the forklift will have. When an attachment is added, the weight and increased distance from the centerline of the front axle to the new load is considered. If Dimension A is changed the manufacturer must be involved with the revision of the forklift’s capacity rating for its data tag.

Dimension B is the load center rating of the truck and is based on the standardized U.S. load size of a 48x48” cube. The center of the cube would be 24” out from the upright face of the forks and 24” up from the horizontal face of the forks.

When training operators on a forklift’s load center and stability, he or she must understand:

  • When a load is larger than the standard, lifting it can have an adverse affect on stability
  • Every inch of extended load center may cause the load to feel 100 lbs heavier

Because every load is unique, each one must be evaluated individually by the operator; however, if loads outside of the standard are transported on a regular basis, a manufacturer can assist with providing an alternate load center rating for your application.

ProLift’s safety training courses review the concept of load center and a forklift’s stability triangle. Call our Safety Specialist at 800-583-4023 to schedule training or click here to review available courses.

Large Capacity Forklifts – How Are They Different?

July 31, 2012

Depending on the industry and application, your facility may use a large capacity forklift. A unit with a capacity of 15,500 lb or more is considered large capacity. Although these forklifts are operated inside the facility to move machinery, machinery dies and specialty manufactured product (low or high volume), oftentimes they are used outside, working on uneven and rough terrain.

While features of a large capacity forklift are similar to its smaller counterparts, they have subtle differences in maintenance and safety.

Tire quality.
To keep your forklift and its load stable, the right tires must be in place. Units with mismatched tires (i.e. new tires matched with worn tires, different ply ratings, Bias versus radial) on the front drive axle will compromise balance. If truck tires have been substituted as replacements, the sidewall will flex and give under the heavy weight. This uneven load can cause an expensive repair such as a broken drive axle. It is also important to ensure your forklift maintains the correct tire pressure to avoid cracked rims.

Load center.
Because of the forklift’s large size, an operator may assume it can carry any load. It is important the operator understands the true load center of the unit – both with and without a load. This information can be found on the forklift’s data tag(s).

Right tools for maintenance.
Large capacity forklifts require unique tools and resources. For example, a technician servicing a radiator will find it to be more compact or working on a mast may require two technicians. Also, inspecting the forklift takes longer and may require a manlift to look at the forklift’s feature. Although some have in-house technicians, many companies find it beneficial to outsource maintenance of their large capacity forklift to eliminate the investment in tools, resources and training.

If you have only one large capacity forklift, your production schedule will be vulnerable to a breakdown. Its rough application exposes your forklift to dust, dirt, sand, etc. placing your unit on a planned maintenance schedule will catch mechanical issues early. Calculate the number of hours the forklift is in use each day to determine an inspection schedule.  

Whether you have a need to purchase or service a large capacity forklift, ProLift can help. We guarantee to respond to your breakdown call within 4 hours or your first hour of labor is free. Click here to contact your local ProLift.

Older Posts »