Proper Inspection of Your Forklift’s Forks

Your forklift’s forks bear the brunt of your loading and unloading operations. Wear and tear, or damage to either component can create a dangerous situation for your employees and anyone working around your fleet. And a 10% wear on your forks can reduce your safe lifting capacity by 20%, making your 5,000lb. forklift, a 4,000lb. forklift.

Inspecting your forklift forks regularly is essential for safety and efficiency. Here’s a step-by-step guide to inspecting your forks properly:

  1. Visual Inspection
    ✔ Check for Cracks & Damage – Look closely for cracks, bends, or other signs of damage. Pay special attention to welds and stress points.
    ✔ Inspect for Bending or Warping – Lay a straight edge along the fork blade to check for any bending. Even slight bends can reduce lifting capacity.
    ✔ Look for Wear on the Heel – The fork heel (where the blade meets the shank) is a high-stress area. If it’s worn down by 10% or more, replace the fork.
    ✔ Check for Surface Damage – Rust, deep scratches, and chipped paint could indicate hidden damage or weak spots.
  2. Measure Fork Thickness
    Use calipers to measure the thickness of the fork heel.
    Compare it to the original thickness. If it has worn down by 10% or more, replace the fork (this reduces load capacity by about 20%).
  3. Check Fork Hooks & Mounting Points
    ✔ Ensure the hooks are not cracked or excessively worn.
    ✔ Verify that the locking pins are functional and secure.
    ✔ Make sure the forks are properly mounted and not loose.
  4. Confirm Even Fork Height
    Set the forks on a level surface and check if the tips are even.
    A difference of more than 3% of fork length means one fork is more worn than the other and should be replaced.
  5. Inspect Load Markings
    ✔ Make sure the load capacity markings on the forks are visible and legible.
    ✔ If they are missing or unreadable, you may need to replace the forks or have them re-marked.
  6. Test Fork Operation
    ✔ Engage and disengage the forks to ensure smooth movement.
    ✔ Look for signs of unusual resistance, sticking, or instability.
  7. Follow OSHA or Manufacturer Guidelines
    OSHA and forklift manufacturers typically recommend daily pre-shift inspections and full inspections at least once per year (or more in high-use environments).

If any defects or wear exceed safety limits, replace the forks immediately rather than attempting repairs. Forklifts depend on strong, reliable forks to operate safely. Contact us at 800-322-5438 and we will help you select the proper forks for your forklift and operational requirements.

Forklift Safety Inspections

Forklift Safety Day is fast approaching and we want to help raise awareness to help improve safety on, and around the forklifts we operate. Pre-shift inspections have been the law for two decades and besides maintaining compliance, the make great sense in terms of employee safety, productivity and the overall health of your business. Forklift inspections are important for:

  1. Safety: Forklifts are powerful and heavy machinery used to move and lift heavy loads. Regular inspections ensure that forklifts are in safe working condition, minimizing the risk of accidents or injuries to operators and bystanders. Inspections help identify potential hazards, such as faulty brakes, worn-out tires, malfunctioning controls, or hydraulic leaks, which can be addressed before they lead to accidents.
  2. Compliance: Forklift inspections are often required by law and regulatory bodies to ensure compliance with safety standards. In many countries, employers are legally obligated to maintain a safe working environment and regularly inspect their equipment, including forklifts. Adhering to these regulations helps avoid penalties, fines, or legal issues.
  3. Preventive Maintenance: Regular inspections allow for early detection of mechanical issues or wear and tear on various components. Identifying problems in advance enables proactive maintenance and repairs, preventing breakdowns or major failures that could lead to costly repairs, downtime, and interruptions in operations. By addressing minor issues promptly, more significant and costly problems can be avoided.
  4. Equipment Longevity: Forklifts are a significant investment for businesses, and proper maintenance can extend their lifespan. Regular inspections help identify areas that require attention, such as lubrication, filter replacement, or component adjustments. By keeping the forklift in good working condition, its overall longevity is increased, reducing the need for premature replacements and saving costs in the long run.
  5. Operator Confidence: Consistently inspecting and maintaining forklifts boosts operator confidence. When operators know that the equipment they are using is well-maintained and safe, they can perform their tasks more efficiently and with peace of mind. This can lead to improved productivity, reduced operator errors, and increased overall operational effectiveness.

Overall, forklift inspections are vital for ensuring the safety of operators and those around them, maintaining compliance with regulations, preventing accidents and breakdowns, extending equipment life, and optimizing productivity in the workplace. Below is a video that helps walk you through an inspection of your lift trucks.

Our forklift inspection checklists for electric and IC forklifts are also an important tool to help you conduct thorough inspections of your lift trucks. These were developed with inspection suggestions directly from OSHA. Remember to also inspect any additional equipment you’ve added to the forklift, safety lights and other products, attachments etc…

Download our Electric Forklift Inspection Form

Download our IC Forklift Inspection Form

We believe forklift safety starts with operating a safe forklift. For any questions about service or parts as a result of your inspections, please contact us at 800-322-5438.

Taylor Machine Works X280 Forklift Refurb

Instead of buying new equipment, consider letting us take your old, tired forklift, and make it like new again! This Taylor X280 had done it’s job, performed well, but had seen better days. The customer was having a hard time letting it go and purchasing a new one, so we said “hey, let’s take this machine and make it like new again!” Below are the results.

Have a forklift, yard spotter or other piece of material handling equipment, that perhaps you’re just not ready to let go? Give us a call at 800-322-5438 for a quote on letting our team of refurb pros make it like new again!

5 Main Benefits of Planned Maintenance

Like anything else in life, whether it’s your car, your home or even your body, planning and conducting preventive maintenance creates long-term benefits that are well worth the investment. Why would your forklift and other materials handling equipment be any different?

There are many benefits of properly maintaining your forklift fleet and other equipment. However, we have recognized five major benefits that our customers have enjoyed. Planned Maintenance has been proven to:

Lower Your Maintenance Costs
Proactive and preventive maintenance has proven to lower costs by catching small service issues before they blossom into giant repair headaches. Replacing worn or damaged parts early decreases the likelihood of breakdowns.

Improve Useful Equipment Life
Equipment that is serviced regularly does not have to be “turned over” as frequently. This lowers your equipment costs over time.

Increased Productivity
Equipment that is well maintained does not break down. This improves productivity as well as your
bottom line performance. And equipment that is well maintained performs better and more efficiently

Increase Residual Values
When you trade-in your forklifts, or sell it to purchase new equipment, well maintained equipment
has proven to have higher values than equipment serviced on an “as needed” basis.

Enhance Facility Safety
Equipment failures can have catastrophic consequences. Properly maintaining your forklifts will improve operator safety, as well as those that work around your equipment.

Having the right partner in maintaining your equipment is as important as selecting the right doctor for the maintenance of your health. Our trained, experienced technicians perform thousands of Planned Maintenance service calls each year. Whether we’re servicing a giant Taylor Machine Works container handler a forklift or terminal tractor, you can count on our professional staff to minimize your downtime and maximize your productivity.

Learn more about Cal-Lift’s service capabilities, then Contact Us or give us a call at 800-322-5438 for a plan tailored to your equipment and operation.

Minimizing the Costs of Your Forklift Tires

Your forklift tires are the only thing that stands between thousands of pounds of forklift and the Earth beneath. As many can attest, if you ignore the importance of the tires, bad things can happen including more frequent replacement, increased operating costs, accidents and even injuries. Some experts estimate that forklift tires can account for as much as 30% of a forklift’s operating budget.

Following are a few things you can do to ensure that you have optimized the performance of your forklift tires and are getting the best performance and useful life.

Selecting the right tire

We could write an encyclopedia on this topic as there are many factors to consider. Our best suggestion is to meet with a professional who knows forklift tires (like one of our aftermarket customer support representatives).  A trained professional will consider factors like the types of equipment you operate, what type of surface they are operating on and what are the conditions of operation? Do your forklifts operate on a smooth surface in a temperature-controlled environment, or is the surface rough, gravel, blacktop or is the floor subject to debris? Are your forklifts making frequent turns, never getting to full speed, or do your forklifts frequently make long runs which generate much more heat?

After consulting with you and observing your operation, a professional can suggest tires that will last longer, wear better, resist heat, while maximizing operator comfort.

And if you’re purchasing a new forklift, make sure the right forklift tire is part of the quote. Standard issue tires can work for some operations, but be sure you’re getting the right tire for your operation before you put it into service.

Little known fact: If your forklifts frequently carry loads that are half the rated capacity of the forklift, it puts more pressure on your steer tires as the load up front does not balance out the load of the counterweight.

Keep up the Pressure

Keep tires inflated to the recommended pressure. Over-inflation and under-inflation both cause uneven wear.

Purchase a Premium Tire

We’re not suggesting you simply purchase the most expensive tire. However, purchasing a tire simply because it’s on sale or is the lowest cost alternative, will often end up costing you more in the long-run. After consulting with a professional, there are usually options based upon your operation and budgetary constraints. Finding the BEST tire for your operation, usage, wear and tear, will pay off in the long run. The quality of tire should likely increase with the weight of the load, length of the run and condition of the surface on which it operates.

Match Tires to Application

Use tires that are suitable for the specific conditions of your warehouse, such as cushion tires for indoor use or pneumatic tires for outdoor use.

Rotation and Alignment

  • Regular Rotation: Rotate tires regularly to ensure even wear.
  • Alignment: Ensure the forklift’s alignment is correct to prevent uneven tire wear.

Frequent Inspections

Pre-shift inspections are required by OSHA and tire inspections are part of that process.  Look for things like stress cracks, tread wear and chunking. Knowing how to determine wear on your tires depends upon the type of tire and how the manufacturer determines it is time to replace. When you purchase your forklift tires, be sure the representative explains how to inspect them and when it is time for “re-tirement.” And make that inspection part of your forklift operator training. All your operators should know how to inspect all your forklift tires.

Keep it Clean

Keeping the surface a forklift operates on clean will provide additional useful life of your forklift tires. Metal bands, shrapnel, nails, screws and the like are the obvious enemies of a forklift tire and if your operation is manufacturing, you probably have plenty of debris to consider. Often times a floor sweeper (rider or push) will pay for itself over time in reduced damage to your tires.

In addition to the obvious culprits there are other concerns with operating surface. Dirt and debris can build which can reduce traction of the forklift tires creating a dangerous operating environment. A regular review of your floor can also reduce damaging factors. Things like uneven concrete joints, cracks in pavement or concrete surfaces and dock plates that are un-even or damaged can reduce wear and increase damage. Some customers even consider the condition of the tractor trailer floors. Things like nails in the floors or large splinters in trailer floors can wreak havoc on your forklift tires.

Creating a regular process for purchasing and caring for forklift tires can provide many benefits to safety, productivity and your bottom line. Our Planned Maintenance program can take a lot of these considerations off your hands. Learn more and get a quote customized to your operational needs.

To consult with one of our tire professionals, please contact us at 800-322-5438.

Planned Maintenance as Part of Your Safety Program

CLARKMaintenance smallLike anything else in life, whether it’s your car, your home or even your body, planning and conducting preventive maintenance creates long-term benefits that are well worth the investment. Why would your forklift and other materials handling equipment be any different?

Having your forklifts regularly serviced reduces the likelihood of component failure, which improves the safety of not only your forklift fleet, but anyone that works around them.

There are many benefits of properly maintaining your forklift fleet and other equipment. However, we have recognized five major benefits that our customers have enjoyed.

Planned Maintenance has been proven to:

Lower Your Maintenance Costs – Proactive and preventive maintenance has proven to lower costs by catching small service issues before they blossom into giant repair headaches.

Improve Useful Equipment Life – Equipment that is serviced regularly does not have to be “turned over” as frequently. This lowers your equipment costs over time.

Increased Productivity – Equipment that is well maintained does not break down. This improves productivity as well as your bottom line performance.

Increase Residual Values – When you trade-in your equipment, or sell it to purchase new equipment, well maintained equipment has proven to have higher values than equipment serviced on an “as needed” basis.

Enhance Facility Safety – Equipment failures can have catastrophic consequences. Properly maintaining your equipment will improve operator safety, as well as those that work around your equipment.

Having the right partner in maintaining your equipment is as important as selecting the right doctor for the maintenance of your health. Our trained, experienced technicians perform thousands of Planned Maintenance service calls each year.

Get more information or a quote on a Planned Maintenance program for your material handling equipment.

Tips to Lower Your Material Handling Costs

Reducing your costs means increasing your profits and increasing your profits has never been more challenging than in recent years.  Our experience with hundreds of various types of operations, utilizing hundreds of pieces of equipment in more than a thousand ways, has exposed us to thousands of variations in facilities, equipment, and applications. In working with these diverse clients, we have recognized commonalities that, when implemented, resulted in lower total operating costs for materials handling most of the time. Following are five that we highly recommend:

Choose Application-Specific Equipment – In other words, “buy the right equipment for the job at hand.” We often see equipment being used in applications for which they were not designed. That results in accelerated wear, increased damage and ultimately, increased costs. Working with professionals who can survey your applications and recommend the right equipment for each job is one of the most important things you can do to decrease overall costs.  Using the proper equipment with the right specifications means efficient, productive results.

Planned Maintenance – Your fleet equipment works hard. And hard-working equipment needs proper maintenance.  Working with a professional and reputable fleet service provider that serves you at appropriate intervals is the key to catching small maintenance issues, before they become larger and much more expensive. In addition, well-maintained equipment operates more efficiently, experiences more up-time and results in improved operator morale.

Invest in a Robust Training Program – Operator safety training is required by OSHA, and a daily inspection of equipment is one of OSHA’s requirements. Most companies train their operators regarding safe operation, but more often than not, the training stops there. Clients that invest in training employees to perform daily inspections, and to know what to look for, see results. If you install a process for equipment that will eventually need repair, you can ensure that unsafe equipment stays off the operating floor, and small repairs can be handled before they blossom into colossal nightmares.

Work With Single-Source Dealerships When Possible – The more work you can assign to a qualified and reliable supplier, the fewer calls you have to make. In turn, the supplier becomes more familiar with your equipment, facility and applications. This leads to greater efficiencies for you. It also allows your supplier to better understand your operation and thus make logical suggestions that can reduce your costs, increase your efficiency and productivity, and ultimately improve your bottom line.

Fleet Management – Whether you do it yourself or assign responsibility to your materials handling partner, fleet management is a key part of knowing the useful economic lifespan of your equipment. And economic lifespan may vary by application within your operation. If you keep a finger on the pulse of your maintenance expenses and know when it’s time to trade in or re-lease, that process will more than pay for itself in the long run.

There are hundreds of other things you can do to minimize the total operating costs of your facility. We have addressed some of them in previous feature articles. We hope that you have found these Top Five useful.  If we can assist you further, or provide you with more information, please contact us at 888-322-LIFT.

Forklift Cooling System Tips

Forklift engine cooling system tips

Getting hot under the collar is about as good for your forklifts as it is for you.  Heat results in increased engine wear, part failure and lift truck maintenance expenses. Like most other facets of your operation, an ounce of prevention is worth a pound of cure, and keeping your engine operating at recommended manufacturer temperatures will improve your productivity and bottom line.

If your lift trucks are inspected as part of a regular planned maintenance program with inspections being performed by trained lift truck professionals, it is likely that these elements of your cooling system are being inspected and abnormal wear is being brought to your attention. However, one oversight and the end result could be a repair bill mounting into the thousands.

Keeping your cool includes:

Replacing Forklift Engine Coolant with Coolant, Not Water 

Water in your coolant system can be a very short-term patch, but can result in long-term damage to your engine and early failure. Water has a lower boiling temperature than coolant and will cause your engine to run at a higher temperature, resulting in oil viscosity breakdown and undue engine wear.

Replacing Forklift Engine Hoses Before You See Damage

Hoses wear over time, often from the inside out. Inspect for leaks on a regular basis and replace hoses at manufacturers recommended intervals. Leaks can result in loss of coolant over time, increase engine temperature and lower performance. Hose failure and the resulting spill can produce a hazardous situation for everyone in the vicinity.

Keeping the Pressure on

The coolant system is pressurized to raise the boiling point of the coolant. Radiator caps maintain the pressure in the system. When the cap is not functioning properly, coolant can boil out onto the floor at near normal operating temperatures, causing operators or technicians to incorrectly believe that the engine is overheating.  Pressure testing the radiator cap is the only sure way to maintain proper coolant system pressure.

Keeping Your Forklift’s Engine Properly Belted

An engine’s fan belt creates air flow over the engine, removing external surface heat.  It also drives the circulation of the engine’s coolant through the engine, keeping the internal temperature at normal operating limits. Worn belts can reduce the flow of coolant, increasing the temperature and creating a long-term problem for your engine. Belt failure can result in immediate overheating, engine damage and an expensive repair. Have your belts inspected for wear and replace them at factory suggested intervals to ensure proper coolant flow inside and out.

Inspecting Your Engine’s Greatest Fan

Driven by the fan belt to perform, a properly operating engine fan allows for the normal conduction of heat from the inside of the engine to the surface where the fan whisks away the excess heat. A cracked or damaged fan can reduce the effectiveness of the fan and increase engine temperature. Be sure to inspect the fan for wear and damage and replace it with a manufacturer’s suggested replacement. Heavy steel fans can produce undue wear on the engine and reduce the fan’s capacity to remove heat, or even create its own heat by increased demand for energy by a heavier fan.

Regular Coolant Fluid Replacement

Like oil, cooling system fluid has a recommended maximum useful life, and that can vary widely depending upon how your system was serviced and the type of coolant used to replace your current fluid.  Every engine and application is different so don’t solely rely on factory recommended intervals for a flush and refill. Consult with us about an application survey and we can assist you in setting a schedule for regular coolant replacement that makes sense for YOUR operation.

Having your forklift’s cooling system regularly serviced ensures maximum engine performance and useful life. It reduces your maintenance expenses and improves your productivity. Forklifts on the floor, operating are far more essential to your bottom line than they are when they’re sitting in our shop.

If your lift trucks are not on a regularly scheduled Planned Maintenance program, they should be. Let us take the worry out of what and when to inspect, letting you tend to the business of what you do best.

Visit our forklift services page to learn more about how we can help you maximize productivity and minimize costs of your material handling operation. Or contact us at 800-322-5438 to learn more about our Planned Maintenance programs that keep your forklifts, terminal tractors and container handlers cool, under the pressure of Summer.

What’s Reducing the Safe Lifting Capacity of Your Forklifts?

You just purchased a new forklift. Along with your purchase you made sure your forklift operators were trained properly.  Operators’ knowledge of safe lifting capacity equals a lower risk of property damage, injury or death.

Your forklift was shipped from the manufacturer with a data plate indicating lift capacities at various heights based on its equipment options, for example, side shifters, carton clamps or other attachments. Once you put the forklift into service, there are several factors that can, over time, dramatically reduce the safe lifting capacity of that forklift. Below we have highlighted the major factors effecting lift capacity.

Forks – The continual use of forklifts results in normal fork wear. The amount and rate at which they wear depends upon the weight of the loads handled, how they are handled (what type of substrate is coming in contact with the fork) and how often loads are handled (duty cycles). A 10% reduction in fork surface (wear) results in a 20% reduction in the safe lifting capacity of your forklift. A forklift rated to lift 5,000lbs is reduced to 4,000lb once the forks are 10% worn. At this point the forks must be replaced.

Daily Inspections are required by OSHA – While a daily measurement of fork wear is not required, it is good practice to conduct a fork wear inspection on a regular basis, based on previous “FORK” criteria previously mentioned. During daily inspections, forks should be visually inspected for cracks or bends. Both reduce the safe lifting capacity of your forklift and create a dangerous operating condition.

If the load you are carrying changes requiring a need to use longer forks, the load center changes. This results in a reduction of safe lifting capacity. It will be important that you work with the manufacturer to determine the new safe lifting capacity of your forklift with the new fork configuration.

Chains – Chains should be inspected as part of any normal Planned Maintenance Program. Your service technicians should be properly trained to measure chains to determine when they need to be replaced. When a 3% elongation results in a 15% reduction in safe lifting capacity the chains should be replaced. Never attempt repairs on chains that are worn. Replacing them with the proper chains per manufacturer’s specifications is recommended to ensure a safe working environment for your employees.

Load Center – The data plate on your forklift indicates safe load capacities at given fork load centers. Not every pallet received by your facility is loaded according to the forklift manufactures specifications. It is important for safe operation to recognize and adjust your lifting practices to ensure safe handling of materials. As a rule, for every inch beyond the manufacturers recommended fork load center, one hundred pounds of lifting capacity is lost at a lowered height of six to eight inches.

Upon replacing the following, verify:

  • Tires – Verify they meet manufacturer’s specifications. Especially if changing the type (cushion or pneumatic) or the size.
  • Batteries – Verify they meet manufacturer’s specifications. If you have purchased a used forklift this can be an issue. Seek assistance from a professional that you are equipping it with the proper battery.
  • Attachments – Anytime you add an attachment of any kind, regardless of how benign it may seem, work with a professional or the manufacturer to determine if the attachment affects safe lifting capacity – if so, how much.
  • Engines – You might never replace an engine. But if you do, be certain the replacement engine meets or exceeds the weight of the current engine and that the configuration of the replacement engine does not affect the center of gravity of the forklift. This is particularly important if you purchase used forklifts. Ask the seller if the engine has been replaced or altered in any dramatic fashion. If it has, be sure the forklift has been re-rated for safe lifting capacity.

There are sites on the Internet like www.lifttruckcapacitycalculator.com that can assist you in re-rating your forklifts after minor changes such as attachments or other alterations that may affect their safe lifting capacity.

Working with a partner like Cal-Lift to institute and manage a Planned Maintenance Program is the best way to guarantee that your forklift fleet is always operating safely and your employees are not in danger. Planned Maintenance Programs have also been proven to be the best way to maximize the productivity of your forklift fleet by reducing down-time. These programs will pay for themselves over and over again throughout the life of your forklifts.

OSHA Releases Top Ten Cited Categories for FY 2016

Labor’s Occupational Safety and Health Administration releases a preliminary list of the 10 most frequently cited safety and health violations for the fiscal year, compiled from nearly 32,000 inspections of workplaces by federal OSHA staff. One remarkable thing about the list is that it rarely changes.

Year after year, inspectors see thousands of the same on-the-job hazards, any one of which could result in a fatality or severe injury. More than 4,500 workers are killed on the job every year, and approximately 3 million are injured, despite the fact that by law, employers are responsible for providing safe and healthful workplaces for their workers. If all employers simply corrected the top 10 hazards, we are confident the number of deaths, amputations and hospitalizations would drastically decline. Consider this list a starting point for workplace safety:

  1. Fall protection
  2. Hazard communication
  3. Scaffolds
  4. Respiratory protection
  5. Lockout/tagout
  6. Powered industrial trucks
  7. Ladders
  8. Machine guarding
  9. Electrical wiring
  10. Electrical, general requirements

It’s no coincidence that falls are among the leading causes of worker deaths, particularly in construction, and our top 10 list features lack of fall protection as well as ladder and scaffold safety issues. We know how to protect workers from falls, and have an ongoing campaign to inform employers and workers about these measures. Employers must take these issues seriously. We also see far too many workers killed or gruesomely injured when machinery starts up suddenly while being repaired, or hands and fingers are exposed to moving parts. Lockout/tagout and machine guarding violations are often the culprit here.

Proper lockout/tagout procedures ensure that machines are powered off and can’t be turned on while someone is working on them. And installing guards to keep hands, feet and other appendages away from moving machinery prevents amputations and worse. Respiratory protection is essential for preventing long term and sometimes fatal health problems associated with breathing in asbestos, silica or a host of other toxic substances. But we can see from our list of violations that not nearly enough employers are providing this needed protection and training.

The high number of fatalities associated with forklifts, and high number of violations for powered industrial truck safety, tell us that many workers are not being properly trained to safely drive these kinds of potentially hazardous equipment. Rounding out the top 10 list are violations related to electrical safety, an area where the dangers are well-known. Our list of top violations is far from comprehensive.

OSHA regulations cover a wide range of hazards, all of which imperil worker health and safety. And we urge employers to go beyond the minimal requirements to create a culture of safety at work, which has been shown to reduce costs, raise productivity and improve morale.

To help them, we have released new recommendations for creating a safety and health program at their workplaces. We have many additional resources, including a wealth of information on our website and our free and confidential On-site Consultation Program. But tackling the most common hazards is a good place to start saving workers’ lives and limbs..

Well-maintained forklifts are more productive, safer and have a longer useful life. Find out more about how we can help you keep your forklift fleet operating at peak efficiency and safety at our forklift services page.

Contact us to learn more at 800-322-LIFT.