Heavy-duty vehicles, such as forklift trucks, get a lot of abuse. Drivers may take excessive loads, speed over bumps, and even crash. Manufacturers compensate for heavy abuse, and over-engineer parts to handle over-stressing. Yet, a forklift is not immune to damage, and parts will fail. So, before having to take the forklift for repair in Melbourne, look for the following issues.

Issues related to:

  • Hydraulics
  • Masts
  • Steering
  • Electrics
  • Wheels

Hydraulics

The hydraulic pumps of a forklift are under constant use, and these machines need regular maintenance. The flow of hydraulic fluid, to the mast and other actuators, is at high pressure, and it needs to stay high to supply a fast response. The lift will either rise, pushed by an actuator, or with a pump driven gear and chain system. The fluid levels and the integrity of the fluid return lines, need regular inspections to ensure safe usage. Control values protect the hydraulic lines that regulate the pressure. Relief valves protect over-pressurization; the washers and seals need regular servicing.

Masts

The frame of a lift is under a lot of strain, at the top of the run, and on the forks that keep the loads straight. This is a common area for issues, and a lack of lubrication will damage the lifting mechanism. Excessive loads put an extra strain on hydraulic pumps, shortening their lifespan. Over lifting, can also result in a bent mast, that will need straightening before trying to use it again. A bent mast will, in a weakened state, continue to bend and eventually break under heavy loads.

Steering

What starts out as a small shake in the steering can evolve into more damaging issues further down the line. Low levels of steering fluid can put extra demands on the lines and reduce their lifespans. Shakes can also be the faulty bearings connecting the axle to the wheels. All bearings degrade over time as they become smaller from wear, and gaps will appear as a shake in the steering. Even a simple loose steering wheel can impact on the steering system each time a turn is made. These issues are common, and if caught early, they are quick and cheap to fix.

Electrics

Batteries and wiring do not last forever; a typical battery will last around 2 years at the most. The signs start when it takes longer than normal to start the vehicle. This is often because the battery is no longer keeping the same amp hours, as when it was new. A battery will suffer more in the winter months, as the engine will take more turns to get started. It is possible to prolong the life span of a battery with drip charging in the hours the forklift is not in use.
Wires of forklifts are under a lot of vibration stress on the connectors, solders, and screws will shake loose over time. It is vital that the system information on coolant temperature and hydraulic pressures are true and exact. Regular testing on sensors and the control panel should be done to make sure the gauges are correct.

Wheels

Tires of a forklift take a lot of punishment, from heavy loads to driving over plank with nails sticking out. An air-filled tire would not last in these conditions, so most forklifts use solid tires. These tires have a variety of treads, and like normal tires, they have best before dates, 5 years after the production date is typical. After this period, the rubber in the tire will begin to degrade and crack. Under heavy loads and being solid, the tires are more prone to splitting.

Check for:

  • Cracks
  • Expiry Dates
  • Wear Markers
  • Rounding

Like normal road tires, they will last a certain distance before getting through all the treads and down to the softer part of the tire. Manufacturers make tires with markers that show through the tire when it has worn down. Going beyond this point is dangerous for the driver and will start to show as a loss of grip.

All these issues have a warning with them, and it is important for the driver to keep their eye on any signs of machine fatigue. Use a little diligence and ask an expert, to avoid a long forklift repair in Melbourne.