Reduce Manufacturing Costs - 6 Steps
Here are 6 effective steps to reduce manufacturing costs: 1. Reduce Forklift Operating Costs 2. Lower Your Cost for Materials 3. Encourage Higher Efficiency Rates from Your ...
Here are 6 very effective steps that you can take to reduce manufacturing costs:
If you want to lower your forklift operating costs and downtime, contact us.
Follow these steps to reduce manufacturing costs
6 Steps to Reduce Manufacturing Costs
1. Reduce Forklift Operating Costs
Rent Temporary Forklifts:
You can reduce manufacturing costs by lowering your total overhead costs. Find ways that you can reduce big capital purchases, such as purchasing new forklifts.
For example, you may find that you can actually save money by renting additional material handling equipment during your peak seasons instead of purchasing extra equipment that you don't need to use all year long.
Invest in Electric Forklifts:
Whenever possible, choose an electric forklift over one that burns fossil fuels. Even though the initial purchasing cost can be higher with electric forklifts, your total cost of ownership is usually much less.
This total cost of ownership calculator can show you how much you could save by switching to an electric forklift.
PUrchase electric forklifts to save money
Choose a Lithium-Ion Battery:
If you want to save even more on your forklifts costs, choose an electric one that is powered by a lithium battery instead of a lead-acid one. Lithium batteries are virtually maintenance-free so you don't have to pay someone to water and maintain them and they don't require a lengthy cooling down time.
They are also 50% more energy-efficient than lead-acid batteries. Here’s another calculator that you can download to discover how much you could save using a lithium-powered forklift.
Automation:
You can reduce manufacturing costs by finding ways to automate processes and thereby producing products at a faster rate.
Invest in AGV (automated guided vehicle) forklifts that will efficiently operate without a paid operator. Automated forklifts can run as long as they are needed without taking breaks.
Check out this AGV forklift in action
2. Lower Your Cost for Materials
The materials that you use in the manufacturing of your product make up a large portion of your manufacturing costs. Here are a couple of ways to lower your cost for materials.
Use Economic Order Quantity (EOQ):
Economic Order Quantity is a formula that helps you figure out your optimal quantity of materials to order.
EOQ will enable you to only order the amount of materials that you actually need thus lowering the cost of placing and receiving an order. By using an EOQ you won't be tying up too much of your cash flow in inventory that you don't need yet.
Getting the right balance of materials to order is a skill, but the EOQ formula can help. The following video will show you how you can set up this formula in an Excel spreadsheet for easy calculations
Learn how to calculate the right amount of materials to order
Deal with the Best Raw Material Suppliers:
Another way that you can reduce manufacturing costs is by finding suppliers that will give you the best prices for the materials.
This doesn't mean buying inferior materials. Instead, you try to find suppliers of the quality of raw materials and ask them to give you a quote. You can then choose the one with the best material at the best price. You can also look for suppliers who offer a discount on bulk purchases.
In addition to local suppliers, you can also look online to find appropriate suppliers. Websites such as Alibaba, Global Sources, and eWorldTrade help suppliers and customers locate each other.
3. Encourage Higher Efficiency Rates from Your Staff
Encouraging higher efficiency from your workers is another area where you could reduce manufacturing costs. Here are some creative ways to get your staff to work more efficiently:
Give Proper Training: Provide specialized training that will teach your workers to work more efficiently.
Offer Great Incentives: Offer great incentives to your staff such as bonuses or time off to those who produce an average unit faster than the normal rate.
Provide Ergonomic Equipment: Provide ergonomically designed equipment and work areas that will help your workers to work better, longer, and with fewer injuries.
Encourage Innovation: Reward employees who figure out any cost-reducing techniques in production and use their ideas.
Provide your employees with ergonomically designed equipment
4. Reduce Accidents and Loss
Reduce Accidents:
Accidents and injuries can add to your manufacturing costs. Not only do you want your staff to be safe, but you also don't want to have to pay for the downtime and product damage caused by avoidable accidents.
Providing proper safety training for your staff and proper safety equipment around your facility can help to decrease the number and severity of workplace accidents.
Reduce Loss:
You can lose inventory either by misplacing it or by theft. Make sure that you employ a clear labelling and storage procedure to ensure that your materials and products don't get misplaced.
To prevent theft:
Hire security staff to check out employees and visitors entering and leaving your facility,
Keep your doors locked and put in a key card system.
Install a security system
If you are not running around the clock, employ a security guard during off-hours.
The following video explains how a key card system works.
A key card system can help reduce manufacturing costs
5. Cut Down on Waste
As a plant manager, you need to conduct periodic checks to find out what is causing excess waste and develop an effective plan to reduce the waste. Here are some different kinds of waste in a manufacturing setting that you could try and avoid:
Producing Too Soon: Producing products before they are needed means you are tying up your cash flow and your product could get damaged while it is being stored.
Overstocking: Overstocking your inventory with more products than you need also ties up your cash flow.
Production Delays: Production delays that make your staff and machinery wait around during the manufacturing cycle wastes time and money.
Unnecessary Movement: Moving people and products around unnecessarily wastes time and resources.
Defects: Defective products that need to be repaired while still under warranty wastes time and resources as well.
Production delays waste time and money.
6. Reduce Forklift Downtime
Reducing forklift downtime can help you reduce manufacturing costs. Here are some ways to cut down on forklift downtime.
Keep Your Equipment Maintained:
One of the best ways to reduce forklift downtimes is to make sure that your equipment is well maintained. You should follow the manufacturer's guidelines for regular maintenance and get any small issues repaired as soon as they come up.
Keeping your forklifts properly maintained and serviced will go a long way in preventing huge repair bills or having to replace damaged equipment. Regular maintenance can catch a small problem and get it fixed before it becomes a larger, much more costly one.
Rent Temporary Forklifts:
While your forklifts are being serviced or repaired, temporarily rent others so you don't have to stop working. A reputable forklift dealer will provide you with rental units at discounted rates while they are servicing them.
Use Onboard Chargers:
You can also use forklifts with onboard chargers so that they don't need to be out of service for charging times. In addition, purchase forklifts with faster charger times such as lithium-ion forklifts. They can fully charge in as little as 2 hours compared to a lead-acid battery which takes 8-10 hours.
Reduce manufacturing costs by keeping your forklifts well maintained
How Wayco Can Help
You can trust Wayco with all your forklift equipment repairs. Wayco can also help make sure that your forklifts are well maintained.
We can track and pre-schedule all maintenance work for you so that your equipment is properly serviced in a timely manner.
This will help you avoid expensive downtime and you won't have to remember to schedule or book your service work. We'll do it for you!
Wayco also has an incredibly fast response time so you won't have to wait to get your lift trucks back in operation. We can usually have our service tech at your location within 2 to 3 hours and we also guarantee same day service.
Wayco can also help you find the best forklifts that will reduce your manufacturing costs.
We have been in the forklift business in KW for more than 40 years and we have earned a solid reputation for being trustworthy and fair.
Our knowledgeable staff will be able to help you choose the perfect model that best suits your particular applications and we will accept your old forklift as a trade-in towards your purchase.
Contact Wayco today to find out what forklifts they have in stock, both used and new models.
“We purchased a used fork lift from Wayco in January. It was extremely clean and in excellent condition when it was delivered. We have also had incredible ongoing service from the professionals at Wayco. Overall dealing with them has been an excellent experience.”
How To Increase Forklift Efficiency
Learn how to increase forklift efficiency by using telematics, keeping your forklifts tuned up, properly maintaining your tires, turning off engines when not being used, and more!
Welcome to our comprehensive guide on increasing forklift efficiency! With over 40 years of experience in the material handling industry, we're excited to share our expertise and insights with you. Today, we'll explore practical tips and strategies to enhance the efficiency of your forklift operations. But that's not all—improving overall material handling efficiency will also be part of our discussion. Let's dive in and discover how you can optimize your operations for maximum productivity and effectiveness.
Click on the corresponding link to jump ahead:
Learn how to increase your forklift efficiency
How to Increase Forklift Efficiency
Use Telematics
In order to increase your forklift efficiency, you first need to gather information about how your forklifts are being used such as:
If they are being used in the right places
If they are sitting idle
If they are safe enough to operate
How your drivers are treating your equipment, etc.
Basically, telematics is a system where you install devices inside your forklifts that use cellular networks to transmit data back to servers hosted by your telematics provider.
The data is stored remotely in the cloud and can be easily available from any device that is connected to the Internet.
Telematics is a great way for you to manage any type of fleet including forklifts. By using telematics, you can gather useful information about your fleet that will help you to ultimately increase your forklift efficiency.
iWarehouse is one type of telematics system that can help you monitor your forklift efficiency
Ask Your Operators for Forklift Efficiency Suggestions
Your forklift operators can be one of your most valuable resources when it comes to increasing forklift efficiency. You can do the following to help increase forklift efficiency:
Ask about one task: Ask your operators to describe one of the tasks they perform and to outline what steps are involved in that task. Then, get their opinion on how they think that task can be improved.
Watch your top operators: Take some time to observe your top forklift operators. Watch how to they perform their tasks to see if there are any helpful tricks that they are using to make them so efficient and then pass those tricks on to your other operators.
Observe your top operators and learn their forklift efficiency tricks
Pass on training: Have your top drivers take some time to train your other drivers on how to improve their processes to save time and effort.
Keep your forklift operators well-informed: When you decide to implement a new process that is designed to increase forklift efficiency, make sure that all of your operators are properly informed about the new processes and that they clearly understand how to implement them.
Improve Forklift Fuel Efficiency
Another area where you can increase your forklift efficiency is by improving your fuel consumption. Here are some tips for making your forklifts more fuel efficient.
Keep Your Forklifts Tuned Up: If your forklift is regularly maintained it will actually run more efficiently and save you money on fuel costs. Properly tuned engines will have lower CO emissions and are more fuel efficient.
Keep your lift trucks well serviced and tuned up to improve forklift efficiency
Test Your Forklifts Regularly for CO Emissions: Regular carbon monoxide emission testing will let you know when your lift trucks need a tune-up and in turn will help you increase your fuel efficiency and lower harmful emissions.
The CO concentration level of your forklifts should be 1% or less. If the level is greater than 1% your forklift should get a tune-up.
Turn Off Your Forklift When Not in Use: An idling forklift will waste fuel and produce a large amount of harmful CO. If you are waiting for more than 10 seconds, it is better to turn off your engine and re-start it again than to let it idle.
Maintain a consistent speed: It is important to find a good balance between getting your work done quickly and saving on fuel consumption.
Constantly speeding up and slowing down excessively uses more fuel than maintaining a consistent speed while driving. Encourage your drivers to do gradual accelerations and to avoid "gunning the engine."
Ensuring your tires are in good condition can also help to increase forklift efficiency
Keep your tires in good condition: Proper maintenance of parts such as your tires will cut down on your fuel expenses. Normal operation will cause wear and tear on your forklifts' tires.
If your tires are damaged, they can cause harder driving, thus forcing your engine to work harder and consume more fuel.
Following a regular preventative maintenance schedule will not only help you decrease fuel consumption, but will also increase your forklift efficiency, which will save you money.
General Material Handling Efficiency Tips
Coordinate Your Shipping and Receiving
Designate your shifts for shipping or receiving: It is much more efficient to receive goods during one shift and the ship goods during another. That way, you can reduce your staging area requirements by half.
Schedule your trucks carefully: In addition, try to efficiently schedule the arrival of trucks so that they don't arrive all at the same time.
Staggering arrivals also means that you will be able to cut down on the number of dock doors that you use, which can save you money on your utility bills.
Schedule the arrival of your trucks wisely to avoid wait times
Make Improvements to Your Order Packing
Ensure you have sufficient space: Make sure that those who are doing packing have enough room to work so that they aren't knocking into or tripping over each other, thus slowing down the process.
Ensure you have a consistent workflow: Observe your order-picking process to see how effectively it is working, looking for fluctuations in speed. If it isn't as smooth as it could be, make revisions. Your aim is to have a consistent workflow so that you don't have times when everyone is rushing as well as dead periods.
Ensure you have complete orders: Make sure your order pickers are giving your packers complete orders so that they don't need to be looking for missing items, thus slowing down the process.
Make sure orders are complete before they are given to your packers
Want to Increase Your Forklift Efficiency? Get Regular Maintenance and Tune-ups from ForkliftHub
One of the best ways to improve your forklift efficiency is to make sure that your forklifts are regularly maintained and that they have tune-ups when necessary.
ForkliftHub provides the best servicing and maintenance you can find in the Kitchener-Waterloo area. Contact us today to set up a service appointment.
ForkliftHub: For Quality New & Used Forklifts
If you are looking for top-quality new or used forklifts, contact ForkliftHub. We sell the best forklifts you can buy and our knowledgeable staff will be able to help you choose the perfect model that will best suit your particular applications.
ForkliftHub offers the best forklift warranties in the business for both new and used models. We will be happy to answer all of your questions. Contact ForkliftHub today for all of your forklift needs.
Need Safety Training: Contact ForkliftHub
ForkliftHub's intense and comprehensive forklift safety training program will provide you and your employees with the best safety training at the best price.
This thorough program has a 98% pass rate. We can train individuals or groups at our facility or yours - you choose.
Our Safe Operation of a Lift Truck/Forklift Program is an excellent way for you to ensure forklift safety in your workplace. With our training, you will experience:
Innovative training practices
Affordable pricing
Flexible and professional trainers
Comprehensive in-class and practical experience
Contact ForkliftHub today to book your next session.
"I really recommend to get your lift license here. One of the best courses I've taken in my life, they make sure everything's done the safest ways step by step so you can walk out ready for the job. Angela is the best teacher, very funny but makes sure all precautions are taken. Excellent place to get your forklift or scissor license in Kitchener Waterloo."
- Miguel Maza
Read more testimonials here
Forklift Leaking Fluid - How To Find Out What It Is
Is your forklift leaking fluid? Discover what could be causing the leak and what you should do. Don't ignore your leak, get it repaired as soon as possible.
Today we are going to take a look at what you should do if you discover your forklift leaking fluid.
We have over 40 years in the material handling industry and we would love to share our expertise and experience with you.
We'll take a closer look at the types of leaks you could encounter and how to tell what they are. So, let's get started.
Is your forklift leaking fluid? Take steps to address the problem
Forklift Leaking Fluid - What to Do First
If you have a forklift leaking fluid it can be quite difficult to figure out the the cause of the leak.
However, if you notice any damp spots or drips around your forklift equipment, don't ignore it. If left untreated, a small leak could develop into a costly repair down the road.
Before you do any inspections on your forklift hydraulic system, it is a good idea to de-pressurize your hydraulic hoses. Hydraulic fluid is under great pressure and is extremely hot, 300 degrees Fahrenheit or even hotter. This can cause serious burns on your skin.
If it escapes, it can inject fluid through even thick leather gloves and into your skin. When hydraulic fluid is injected into your skin, it will damage the tissue on the way inside.
It can cause pressure to build up inside your body if not treated immediately. You can lose circulation and you are at risk of losing a digit.
Even if the leak is minor, it is important that you de-pressurize before you start looking around it in order to stay safe and avoid injury. The following video will show you how to de-pressurize your hydraulic system.
Depressurize your hydraulic system before you attempt an inspection
Forklift Leaking Fluid: Where Leaks Could Occur
Your forklift could be leaking fluid from different parts. Take a close look at each of the following components to determine where the leak is.
Seals
If your seals are leaking, then you may be able to fix it by simply using a leak stop product. If your seal is torn altogether, it will need to be looked at by a professional.
Control Valve:
Take a look at your control valve. If there is a leak there, it will affect your hydraulic pressure. This in turn can damage your seals and decrease the lift capacity of your forklift.
Inspect various parts of your forklifts, such as the cylinders if your forklift is leaking fluid
Cylinders
Your hydraulic system has several different types of cylinders: lift cylinders and tilt cylinders. You can get a fluid leak both inside and outside of your lift cylinder.
If you notice fluid on parts of your forklift or on the ground, then the lift cylinder may be leaking.
If your tilt cylinder is leaking oil, then the lower fluid level could damage your hydraulics and your mast may begin to move uncontrollably.
The following video will show you the steps to take to fix a leaking hydraulic cylinder. This is the first video of a three-part series.
Click here to view Part 2 and Part 3. This video will show you what is involved in the repair. However, you should get a professional to do it for you.
Hydraulic systems are under great pressure and if you are not sure about the safe procedures to follow when working on them, you could get injured.
They are also quite complex, so if you are not a trained technician, you run the risk of damaging a part or making the problem worse than it was in the first place.
See how a hydraulic cylinder is repaired
Auxiliary Lines and Hydraulic Hoses
Take a look at your auxiliary lines and hydraulic hoses. If any of your lines or hoses are damaged or bent, they may begin to leak.
Also, if they are damaged, then unwanted debris particles could enter your hydraulic system and contaminate the fluid. This could damage your pump.
Hydraulic Filters:
Make sure that your hydraulic filter isn’t blocked. If it is blocked and the flow of oil is restricted, then that could cause extra wear and tear on your system's internal workings.
You should inspect the parts of your forklift’s hydraulic system for leaks - Image Source: Created by Tynt22 using Adobe Photoshop. [CC BY-SA]
Loose Nut
Inspect the nuts in your system to see if they are the cause of your forklift leaking fluid. Tightening the nut may correct the problem. However, you need to be careful not to over-tighten.
Over-tightening may damage the fitting integrity of the part, which can also cause a leak. Be careful to use the right amount of torque on the nut. If you are unsure, then it is best to have a professional tighten it for you.
If you need to replace one of your fittings, be sure to replace it with the exact same type of fitting. Replacing a fitting with one that is even slightly different can be very dangerous.
If you are unsure about what part to use, contact a professional parts department. Don't take chances.
Get regular maintenance to prevent forklift leaking fluid
Forklift Leaking Fluid - Preventative Maintenance
There are a few regular maintenance tasks that you can perform in order to prevent your forklift from leaking fluid in the first place. These include:
Clean out your hydraulic filters once a year
Replace your hydraulic fluid during the annual cleaning
Flush out your lines and pump on a regular basis
ForkliftHub can help you with these regular maintenance tasks. Contact us today to set up an appointment.
Reasons Why You Shouldn't Ignore a Forklift Leaking Fluid
Here are 7 very good reasons why you shouldn't ignore it if you find your forklift leaking fluid:
1. Oil that has leaked out can catch on fire
2. Oil spills can create safety concerns
3. An oil leak can be an indicator of a bigger problem
4. Forklift oil leaks can cause overheating
5. Oil leaks can lead to exposure to other harmful contaminants
6. Forklift oil leaks will cost you money
7. Ignoring oil leaks can cause costly downtime
To learn more about each of these 7 reasons, check out our post "Top 7 Reasons to Repair Your Forklift Oil Leaks."
![Forklift_dealers[1].jpg](https://images.squarespace-cdn.com/content/v1/5bf6c41789c1727b3aa7157a/1566574116225-3U4K7LVN4R8YAATTPLZL/Forklift_dealers%5B1%5D.jpg)
If you notice a fluid leak, get it repaired
ForkliftHub: You Can Trust Us for All Your Forklift Repairs
You can trust ForkliftHub for all of your forklift repairs, including forklift leaks. At ForkliftHub, we will help you with any urgent repairs that you need, and we will make sure that your forklifts are always well-maintained.
We can even track and pre-schedule all maintenance work for you so that your equipment is properly serviced in a timely manner.
This will help you avoid expensive downtime and you won't have to remember to schedule or book your service work. We'll do it for you.
ForkliftHub also has an incredibly fast response time so you won't have to wait to get your lift trucks back in operation. We can usually have our service tech at your location within 2 to 3 hours and we also guarantee same day.
"Our company shopped around for the most competitively priced lift equipment repairs and rental services in the KW region and found Waco Multi Lift Inc. Their repair rates were lower than the other companies out there and the service is prompt and professional for our in house lift trucks…[Read More]”
- CanadianBakeInn
ForkliftHub Offers Quality Service on All Forklift Makes and Models
If you are looking for top-quality forklift maintenance and service, contact ForkliftHub. Our fully equipped service and parts department is open 24 hours a day, 365 days a year.
Our qualified technicians are capable of properly performing maintenance services and inspections of all types.
Our knowledgeable staff can keep your equipment in top working condition, which means lower repair costs and higher machine efficiency. Contact ForkliftHub today for all of your forklift maintenance and repair needs.
Forklift Can't Stop and Has No Brakes
If your forklift can't stop and has no brakes, stop driving it and get it repaired. Learn more about what causes excessive brake wear and how to prevent it.
If your forklift can't stop and has no brakes, take your foot off the accelerator and steer clear of any obstacles until you come to a full stop. Click here to learn more.
If you want to discover more about about forklift brakes, click on the links to the following informative sections:
Having trouble with your forklift brakes? Contact us and we will fix them for you.
Forklift can't stop and has no brakes? Stop using it and get it repaired
Forklift Can't Stop and Has No Brakes - What to Do
If your forklift can't stop and has no brakes, you should:
Take your foot off the accelerator
Steer it clear of any obstacles until you come to a complete stop
Stop using your forklift until you can get it looked at and repaired
Operating your forklift without properly functioning brakes is dangerous and could lead to serious injuries for yourself, pedestrians around you, and cause costly damage to your product and facilities.
If your forklift can’t stop and has no brakes, stop using it and get it fixed
1. Forklift Can’t Stop and Has No Brakes: How to Prevent This
Do Forklift Brake Pre-Shift Inspections
Performing a pre-shift inspection can help you detect any issues with your forklift before they become a more serious problem.
Inspecting to make sure that your brakes are functioning properly should be a part of your pre-shift inspection as required by the Canadian Centre for Occupational Health and Safety (CCOHS) .
During this pre-shift inspection, you need to check the following:
Foot Brake: to make sure that the pedal holds and the unit stops smoothly
Parking Brake: to make sure that it holds against a a slight acceleration
Deadman Seat Brake: to make sure that it holds when the operator gets up from the seat
This inspection can help prevent a dangerous situation, such as when your forklift can’t stop and has no brakes.
Forklift can’t stop and has no brakes: Prevent this by inspecting your brakes before you drive
2. Forklift Brakes vs Car Brakes: How Are They Different?
Feel more aggressive
Forklift brakes often feel more aggressive than car brakes because they are designed to stop a forklift that is carrying a heavy load.
four Brakes vs two Brakes:
Another main difference between car brakes and forklift brakes is that cars have brakes on all four wheels, whereas most forklifts only have brakes on two of their wheels.
Cars have 4 brakes while forklifts usually have 2
Forklifts Have Longer Stopping Distances:
Even though forklifts generally travel at slower speeds than vehicles on the road, stopping a forklift to avoid a collision can be harder than stopping your car. This is because stopping distances are much longer for forklifts than other vehicles.
For example, if your forklift is traveling at 7 mph, it will take you about 16 feet to make a complete stop. If you are traveling at 9 mph, your stopping distance increases to 21 feet. If your forklift is carrying a heavy payload, it will take even longer to come to a complete stop.
The average car, on the other hand, can come to a stop in 20 feet when traveling much faster at 20 mph.
Forklifts have greater stopping distances, especially when they are carrying a heavy load
Loaded forklifts can become unstable when braking:
In addition, forklifts that are carrying a load become unstable when you try to stop them quickly. A sudden stop can cause them to:
Slide
Become unbalanced
Lose their load
Turn over
Stopping with a heavy load can make your forklift unstable
3. Forklift Brake System: A Basic Overview
What type of brakes do most forklifts have?
The most common type is a drum and shoe brake. This is the type of brake that most cars have on their rear wheels.
There are two main parts to this type of braking system: the brake drum and the brake shoes.
How drum and shoe brakes work
When you press your brake pedal on your forklift, the brake shoes are pushed against the brake drum. The friction of the shoes on the drum causes your forklift to slow down.
How drum and shoe brakes are made
Your brake shoes are made of two pieces of steel. The part of your brake shoe that is forced against the brake drum is called the brake lining.
This lining is heat and wear resistant. However, over time, the friction of the lining against the drum will cause your lining to wear down.
Image Source: Pearson Scott Foresman [Public domain]
Over time, the friction of the lining of your brakes against the drum will cause your lining to wear down.
Importance of regular brake maintenance
Your forklift brake shoes will need maintenance and eventually will need to be replaced.
Regular, proper maintenance on your brakes will keep them running longer and will help you avoid more costly repairs due to excessive wear and tear on your forklift brake drums.
The following video will give you a more detailed look at the different parts of a drum brake system and how each part works.
Forklift drum brakes need regular maintenance
Other types of forklift brakes
Disc Brakes: This type of brake is used on the front wheels of most cars. Some forklifts use this type of braking system as well.
Wet Brakes: Wet brakes use hydraulic pressure to squeeze the friction disc packs and slow down your forklift. This type of brakes is a great feature as it rarely needs to be replaced.
Air Brakes: Air brakes are more commonly found on larger heavy-duty forklifts. They use compressed air to apply force on the forklift brake pads or shoes to stop it.
Hydrostatic Drive Brakes: Some forklifts and construction equipment will use hydrostatic drive brakes.
Brakes forklift: Discover how air brakes work
4. Common Causes of Forklift Brake Failure and Excessive Wear and Tear
If you find that your forklift brakes are constantly needed repair or maintenance, it could be due to some common errors including:
Keeping your parking brake on while operating your forklift
Trying to brake too hard without giving your forklift time to decelerate
Driving with your foot constantly on the brake pedal, thus partially engaging your brakes at all times
Driving too fast and having to apply more pressure to the brakes to stop each time
Adding brake fluid to a system that is designed for hydraulic oil
Continuing to operate your forklift even when the brake shoes need replacing or repair
You can cut down on the need for expensive repairs and help prevent costly accidents by making sure that your forklift operators are properly trained on best driving practices and keeping your forklifts well maintained.
Keep your brakes well maintained to avoid the problem of your forklift can’t stop and has no brakes
If Your Forklift Can't Stop and Has No Brakes, Contact ForkliftHub
Wer’re Available 24/7/365
ForkliftHub’s service department is available to you when you need it 24 hours a day, 365 days a year. We understand that a forklift that is broken down costs you money, so we are here to make sure that you are up and running again as soon as possible.
We Have highly trained technicians
Our highly trained technicians are able to repair all popular makes or industrial forklift trucks and we can properly perform any maintenance services and inspections you require.
We can help you set up a Maintenance schedule
We can even help you set up and design a maintenance schedule that suits your particular company's operating requirements and budget.
We'll even keep track of all your scheduled maintenance and let you know when it's time for each service. Contact ForkliftHub to set up your maintenance or service appointment.
Contact ForkliftHub for the Best New and Pre-Owned Warranties in the Industry
Whether you are in the market for a new or used forklift, talk to the professionals at Wayco. Wayco offers the best warranties in the business for both new and used forklifts so you can purchase with confidence!
Forklift Leaking Hydraulic Oil - What to Do?
Is your forklift leaking hydraulic oil? This comprehensive guide will show you what to do if your forklift is leaking oil, what you should check, and some specific do's and don'ts.
Is your forklift leaking hydraulic oil? Here are the steps you should take. Click on each link to read more details about each section.
Step 1: Take Action; Don't Ignore It
Step 2: Depressurize the System
Step 3: Determine Where the Leak Is Coming from
Step 4. Check your Hydraulic Oil
Things to avoid when your forklift is leaking hydraulic oil
Is your forklift leaking hydraulic oil? Don’t ignore it!
Forklift Leaking Hydraulic Oil - What to Do
A forklift leaking hydraulic oil is a warning sign that needs to be addressed. It could lead to a complete hydraulic system failure if not found and fixed in time. If you notice that your forklift is leaking hydraulic oil, then take the following steps.
Step 1: Take Action
It is very important to take the appropriate action as soon as you notice a forklift leaking hydraulic oil. Even a minor leak could be a sign that there is a more severe and expensive problem on the way.
Step 2: Depressurize the System
Before you start an inspection of your hydraulic system to determine where your leak is coming from, depressurize your system. This will reduce the risk of hydraulic fluid bursting from your machine while you are inspecting it.
Hydraulic fluid is under great pressure and is extremely hot. If it escapes, it can inject fluid through even thick leather gloves and into your skin.
Even if the leak is minor, it is important that you depressurize before you start looking around it in order to stay safe and avoid injury. If you are unsure how to safely do this, contact a forklift professional.
The following video will give you a simple overview of how a basic hydraulic system functions.
Hydraulic oil is under a lot of pressure inside the system
Step 3: Determine Where the Leak Is Coming from
There are several different parts of your forklift's hydraulic system where oil can start to leak out. Carefully check each one to determine where the leak is coming from.
Control Valve: If you have a leak in your control valve, it will affect your hydraulic pressure. This in turn can damage your seals and decrease your lift capacity.
Lift Cylinder: You can get an oil leak both inside and outside of your lift cylinder. If you notice fluid on parts of your forklift or on the ground then the lift cylinder may be leaking.
Tilt Cylinder: If your tilt cylinder is leaking oil, then the lower fluid level could damage your hydraulics and your mast may begin to move uncontrollably.
Auxiliary Lines and Hydraulic Hoses: If any of your lines are damaged or bent, they may begin to leak. In addition, debris particles could enter into the system and contaminate the hydraulic oil, thus damaging the pump.
Carefully check the parts of your forklift’s hydraulic system for leaks - Image Source: Created by Tynt22 using Adobe Photoshop. [CC BY-SA]
Hydraulic Filters: If your hydraulic filter is blocked and the flow of oil is restricted, it will result in extra wear and tear on your system's internal workings.
Loose Nut: Your leak may simply be the result of a loose nut. Tightening the nut may correct the problem. However, you need to be careful not to over tighten.
If you over tighten, you may ruin the fitting integrity of the part, which can also cause a leak. Make sure you use the right amount of torque on the nut. If you are unsure, then it is best to have a professional tighten it for you.
If you need to replace one of the fittings, make sure you replace it with the same type of fitting. Even if you have to wait for the correct part, it is worth it.
Replacing a fitting with one that is even slightly different could be very dangerous. If you are not sure what part to use, contact a professional parts department. Don't take chances.
Step 4. Check your Hydraulic Oil
About 80% of forklift hydraulic lift failures are due to the use of hydraulic fluid that has become dirty or contaminated. Water, dirt, and the wear of metals can cause your oil to become contaminated. This can lead to hydraulic leakages and failures.
Forklift leaking hydraulic oil? Check your fluid to make sure it’s not contaminated
Forklift Leaking Hydraulic Oil - Things to Avoid
Never Touch Hydraulic Fluid
Hydraulic fluid can get as hot as 300 degrees Fahrenheit or even hotter. This can cause serious burns on your skin. If you do get burned, you will need immediate medical attention.
Don't Let Your Hydraulic Oil Near Open Flames
Hydraulic oil is highly flammable. You should never have a lit cigarette, lighter, illumination, welding or cutting torches anywhere near your fluid.
Even a pinhole leak can produce a mist-like vapour that is highly flammable and will easily ignite near an open flame.
Never let hydraulic oil come in contact with an open flame
Other Safety Hazards of Your Forklift Leaking Hydraulic Oil
Damage to Other Parts
If your forklift is still able to lift to its full height, it doesn't mean that you have enough oil. Most forklifts carry an additional 3-5 gallons of oil that are used to cool other components in your lift truck.
If your forklift if leaking oil, then there may not be sufficient oil for cooling these components.
Your forklift may seem to be working fine, however the high heats generated may be ruining other expensive parts such as a pump because there isn't enough oil left to keep it properly cooled.
Pedestrian Hazard
Oil that has dipped out onto your warehouse floor could cause another employee or pedestrian to slip and fall and injure themselves. If the injury is serious enough it could result in a costly compensation claim.
Fire Hazard
While moving around the warehouse, forklifts pick up debris such as dust, dirt, paper, and shrink wrap. These objects could get covered with dripping oil and a spark could easily ignite them and set your forklift on fire putting your operator, other employees and your product in danger.
Is Your Forklift Leaking Hydraulic Oil? Wayco Can Fix It
Is your forklift leaking hydraulic oil? Don’t ignore it. Bring it to ForkliftHub: Our professional service technicians can fix or replace any part that is damaged or leaking.
If you want to prevent leaks, we can help you set up a regular maintenance schedule that will ensure that your forklifts are in top working condition at all times. Contact us today to set up an service appointment.
”Wayco takes care of all our forklift repairs and they provide excellent customer service and very competitive pricing. We have used them for over a decade and I would highly recommend them to anyone.”
- OntarioIndustrial
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Whether you are in the market for a new or used forklift, talk to the professionals at ForkliftHub. ForkliftHub offers the best warranties in the business for both new and used forklifts so you can purchase with confidence! Contact us today!
