Forklifts are just like any other piece of machinery: They need a little TLC from time to time. And if you’re in charge of forklift maintenance, this task falls on you.
But if you feel a little overwhelmed, don’t worry - you’re in the right place.
Smart buyers know: a forklift with the right options is a machine that lasts longer and has fewer problems. This article includes best forklift options for class 2 and 3 lift trucks to reduce downtime, lower maintenance costs and create a low cost of ownership. For each option, In this blog, we will discuss six ways to reduce forklift maintenance costs in 2021:
1) Focus on security
2) Go electric
3) Use lithium-ion batteries
4) Practice possibility billing
5) Enhance battery temperature
6) Forklift Options That Lower Maintenance Costs
In order to keep worker safety on top of the concern checklist, numerous stockrooms consider their safety checks a part of basic forklift maintenance, as the two are very closely relevant.
OSHA has actually executed safety and security studies and discovered that companies were able to minimize prices by 20-40% after the implementation of safety and security strategies.
Use a daily forklift driver checklist to ensure that the equipment is operating correctly.
Forklift batteries and the battery charging process present a host of potential safety risks as well. Lead acid batteries contain sulfuric acid and when charging they emit flammable hydrogen gas.
Lithium-ion batteries do not have the same risks in the charging process that lead acid batteries do, around the workplace.
Additionally, using forklift batteries that are TUV Listed improves safety for the operator. A TUV Listing means a battery has met stringent safety testing requirements.
One easy way to reduce forklift maintenance is to opt for electric powered lift trucks over internal combustion ones.
The industry is already moving in the direction of electric forklifts. A report done by the Industrial Truck Association (ITA) showed that the ratio of electric forklifts sold compared to internal combustion units was 66:34 in 2019 and that ratio increased to 73:27, for the first eight months of 2020.
Although electric forklifts generally require a higher investment up front, the total cost in ownership for an IC forklift is far greater in the long run.
Additionally, IC forklifts have many more internal parts that are subject to wear and tear compared to electric forklifts. An internal combustion engine has numerous parts requiring adjustments as well as a fluid filled cooling system that must be inspected regularly. Regular servicing costs can add up.
Lithium-ion forklift batteries require less maintenance than lead acid batteries.
● Can’t be accidentally overcharged
● Don’t require transport to a separate ventilated charging room
● Don’t require watering to maintain their performance and lifespan
● Additionally, lithium-ion’s higher energy density and longer lifespan delivers for increased warehouse productivity.
A battery with a high energy density has a longer battery run time; lithium-ion batteries can last throughout multiple shifts in a day. At 2000-3000 cycles, llithium-ion forklift batteries have nearly double the lifespan of a lead acid battery.
Lead acid batteries come with specific manufacturer requirements for charging that makes maintaining the battery more costly.
Lithium-ion batteries do not require an equalization charge. This allows you to avoid the labor costs and the electricity costs associated with equalization.
Lithium-ion batteries do perform better with opportunity charging. Opportunity charging is when a battery is charged for short periods of time throughout the day instead of all at once after the battery is fully discharged.
In general, the depth of discharge along with frequency of forklift use determines the battery’s lifespan, or cycle count. It is better to avoid fully discharging the lithium-ion battery. Instead, make opportunity charging a practice in operations.
Opportunity charging can increase battery cycle life which reduces forklift maintenance costs.
One of the biggest culprits for forklift battery degradation is exposure to extreme temperatures, both cold and hot. This applies to all types of batteries, not just lithium-ion.
For lithium-ion batteries, the recommended operating temperature is around 68° F. The higher that temperature rises, the more its performance might increase, but its lifespan will decrease.
When the temperature is too low, battery performance will be degraded. With the loss of battery performance, the increased internal resistance will have a warming effect caused by the voltage drop. A heater will allow the battery to work in colder temperatures as low as -4°F.
Without heaters, lithium-ion batteries can be safely discharged within the recommended range of 32°F to 131° F. They may experience some degradation to their lifespan if temperatures are higher than the recommended operating temperature.
For lead acid batteries, the general benchmark is that each 15° F rise in temperature cuts the battery lifespan in half, permanently, and 122° F is their highest limit. When the temperature is too low, the electrolyte can freeze and expand, cracking its container and damaging the battery permanently.
Managing battery temperature and keeping it in the range is the number one way to ensure that your batteries do not sustain damage that can shortened lifespans. Maximizing the lifespan of your battery is one way to reduce the maintenance cost of putting a replacement battery in service.
The following factory options are specifically designed to reduce downtime and maintenance costs:
BSLBATT forklift multi-function displayOption: New cloud-based fleet management software, GPRS+GPS
Benefits: BSLBATT’s new through the cloud system on the batteries, GPRS, GPS function, users are able to see key parameters such as battery location, status, BMS information, discharge current, charge current, and charge status in real-time. Simple, traffic-light-style reports enable energy consumption and productivity to be optimized. The software also notifies users immediately of any issues in the fleet using state-of-health information, allowing corrective action to be taken before uptime is affected. Preventative maintenance can also be scheduled automatically. And, as mentioned, more efficient maintenance plans tend to be less costly for your company.
Forklifts are an important investment which require maintenance to maximize it’s working life. If you are looking to reduce maintenance cost this year, there are many ways to do so.
Skipping maintenance is a bad idea and can compromise safety for equipment operators. Neglecting maintenance could also minimize the lifespan of forklifts. Lithium-ion batteries can play a huge role in reducing forklift maintenance expenses 2021.
