Forklift Service

Selecting The Right Tires for Your Forklifts

Barry Uncategorized , , , , , , , ,

It is easy to overlook the humble tire when it comes to maintaining a forklift. Choose the wrong tire, however, and you could end up with a dramatic increase in fleet operating costs or, worse yet, increased safety risks. Choose the right one, and you can realize significant cost-savings, improved safety, and a more efficient operation. For example, a properly chosen tire can last 40 percent longer. Read “Minimizing the Cost of Your Forklift Tires.”

Tires are a safety item that is often over looked, but a good set of tires provide the traction, stability and ground clearance essential for safe lift truck operation. Excessively worn tires reduce ground clearance; bring the bottom of the mast and the engine oil pan dangerously close to the ground.

Making those right decisions can be difficult, because contrary to conventional wisdom, tires are very complex components. There are many brands, types, compounds and treads, which means you must be fully armed with data before making a purchase. Here are some questions we typically ask our customers:

  1. What type of fuel (IC or electric) does your forklift use?
  2. How heavy is your typical load?
  3. How long is your typical run?
  4. What kind of problems are you experiencing with your tires now?
  5. Does your forklift operate over dock plates?
  6. On what types of surfaces do you operate your forklift?
  7. Is your forklift used for multiple shifts?
  8. What percent of time is your forklift loaded?
  9. What is your average and top speed of your forklift?
  10. If you are evaluating tires for more than one forklift be prepared to answer the previous questions for each unit.

In addition to knowing the specifics about your tire needs, it will be helpful for you to understand the unique wording used for forklift tires. Durometer is used to describe the hardness of forklift tires. The higher the durometer number, the harder the tire. Most load tires range in durometer from 83 to 95. Our industry uses a couple of standard classifications that cover 80 percent of the tires purchased today.

Softer tires, like rubber, provide better traction for facilities where frequent maneuvering is required. They also are more forgiving of floor debris and offer the operator a more comfortable ride. Be aware, however, tires made of softer compounds create heat and wear faster, making them a less desirable choice for applications where maximum speed and long runs are the norm.

Harder tires are excellent for maximum loads, multiple shifts, long runs and high speed applications. They will wear better and last longer than tires made of softer compounds. But the ride will be harder and the tire more vulnerable to floor debris. They offer less resistance and are well suited to operators especially concerned with energy efficiency. Universal Compound tires are good all-around tires for the average user, but not always the best choice for durability and traction depending upon your application.

The actual tread of the tire is important to consider, too. Pay special attention to whether you want a smooth tire, such as for indoor applications, or a treaded one, for forklifts operated outdoors or over uneven terrain.

We recommend operators track by application how well their tires perform. Create a spreadsheet with rows for each of your forklifts. Track the date tires were purchased, the type of tire, the reason for the replacement and the hour meter reading. Over time, you will see trends emerge that will help you adjust purchasing decisions for the type of performance you need, such as correlations between harder tires and damage, or softer tires and premature wearing. Inspecting tires is always part of our Planned Maintenance Program. 

In the end, there is no one tire that can optimize tread life, traction, durability and fuel efficiency. The key is finding the best fit for each of your forklift material-handling applications. Working with a company that is knowledgeable about forklift tires can assist you in selecting the right application and optimize your fleets for performance.

Cal-Lift Inc. has been helping companies select the right tires for forklifts, terminal tractors and container handlers for decades. Give us a call today at 800-322-5438 to discuss your tire performance and let us help you improve your bottom line!

5 Main Benefits of Planned Maintenance

Barry Forklift Service, Uncategorized , , , ,

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

Barry Forklift Service, Material Handling Equipment, Uncategorized , , , , ,

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

Barry Forklift Service, Safety, Uncategorized , , ,

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.

Forklift Cooling System Tips

Barry Forklift Service, Safety, Uncategorized , , , , ,
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?

Barry Forklift Service, Uncategorized , , , ,

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.

Daily Forklift Inspection Forms

Barry Forklift Service, Safety, Uncategorized , , , , ,

Forklifts must be inspected daily, or prior to each shift if used in a multi-shift operation. This may seem like a burden and for some large companies, indeed it is. We believe though, that the inspections are a good routine to fall into. Forklifts can be very dangerous machines if something isn’t working right or is damaged. Cracked forks, chains, leaky hydraulics, damaged tires and many other items that are easy to miss, can present a very dangerous, even deadly situation.

We used OSHA guidelines to develop the following forms. One for electric forklifts, the other for internal combustion forklifts. Please feel free to copy and distribute as needed. Remember to keep copies of each inspection, either in a file, or scanned and store digitally.

If you find that your forklift needs to be repaired or service, be sure to use a lockout tag and contact our forklift service department as soon as possible to schedule repairs. Should you need a replacement, we have a large forklift rental fleet to fill your short-term forklift needs.

Any questions about forklift repairs or service, please contact us at 800-322-5438.

Forklift Safety Day 2017

Barry Material Handling News, Safety, Uncategorized , , , , , ,

The Industrial Truck Association has announced it’s second annual Forklift Safety Day, to be held Tuesday, June 13.

While most of you won’t be able to attend, there are things you can do to take advantage of this day to help create awareness about the dangers that forklifts present and how to minimize the potential for accidents that can result in injury or death, damage to your facility, equipment and financial losses.

We’ve compiled a short list of things you can do on June 13th to improve safety on and around your forklifts.

  1. Make sure all your forklift operators have been trained and that their refresher training is up to date, if applicable or necessary.
  2. Take time to teach your forklift operators the importance of daily inspections of their forklifts. Daily inspections reduce the risk of equipment failure and catch small problems before they blossom into giant ones.
  3. Take some time to gather any staff that operates around forklifts, but not on them, to refresh them about the dangers of this equipment and how to be sure to use safe procedures when they are in an area of your facility where forklifts are being operated.
  4. Make sure all your forklift’s maintenance is up to date. If you have a Planned Maintenance Agreement, this would be a good time to review it with your service provider to ensure all standard checkpoints as well as unique equipment attachments are being inspected and maintained properly.
  5. Review any unique “site specific” features your facility may have and be sure your operators are aware of proper handling of equipment while on or around these features (ramps, areas where floors can be slick, floor substrates that vary etc…)
  6. Make sure that training is part of your company’s orientation for anyone that will or MIGHT operate a forklift. Remember, employees that have not been properly trained aren’t even allowed to sit on and start a forklift, much less move it out of the way of anything.
  7. Make sure you forklifts have proper safety equipment and that it’s operating properly. Lights, horns, back-up alarms, seat belts, fire extinguishers etc…
  8. Make sure you have lock-out kits to ensure that forklifts that do not pass an inspection are locked out immediately until repairs are made.
  9. Review all your forklifts for possible replacement. Old forklifts, or those that are getting “up there” in hours, might be potential threats. Review safety records and maintenance logs for your equipment. You might find this could be a good time to replace some or even all of your forklifts.-

Our goal is to help you operate safe, efficient and productive forklift equipment. Any questions about operating a safe forklift fleet, or to get a quote on new equipment, please Contact Us or give us a call at 800-322-5438.

Factors Reducing Safe Lifting Capacity of Your New Forklift

Barry Safety , , , , , ,

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 5,000 lbs is reduced to 4,000 lbs 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.

Environment Conditions – If your forklifts are working outside, winds, soft or uneven ground can effect the safe lifting capacity of your forklift. Be aware of your weather and terrain and make adjustments to your load.

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 Matthai Material Handling 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.