Comprehensive forklift inspections: A closer look at a 42-Ton Konecranes SMV Forklift
Welcome to Heavy Cargo Lifters! In this post, we’re taking you behind the scenes to showcase how we inspect equipment before offering it to the market. In this instance, we’ll walk you through our process with a remarkable 42-ton Konecranes forklift from 2010 with +/- 11.000 running hours. Proper inspections ensure the equipment we sell meets high safety and performance standards. Let’s dive into the details of how we evaluate heavy duty forklifts.
Step 1: Conducting a full audit
The first step in our inspection process is to assess the overall condition of the forklift. Special attention is given to components that are costly to repair or replace. For example, the forks, lifting chains, mast, front axle and the complete drivetrain will undergo a detailed evaluation.
But also just listen to your gut feeling when inspecting! If something feels off ask questions to the seller and see what they know or can tell you!
Step 2: Fork condition analysis
One critical aspect of the inspection is checking for wear and tear on the forks. While forks are designed to stay off the ground during driving, minor wear can occur over time. Here’s how we approach this:
- Measuring Thickness: The upright sections of the forks are measured against the lower sections to detect any reduction in thickness. Whilst forks shouldn’t wear out, since the drive should lift the forks before driving the truck, in practice the forks are always wearing!
- Results: In this case, the total width was 135mm, with a slight reduction to 130mm at the lower part. This 5mm difference is within the allowable tolerance of 10%.
- Checking for Bends: Forks are also inspected for bending. These particular forks passed with flying colors as they remained upright and in good shape.
Step 3: Lifting Chains Inspection
Lifting chains are vital for a forklift’s operation, so we ensure they meet stringent standards:
- Wear and Tear: The chains are inspected for widening of the pins and openings, which typically occurs at the point of maximum lifting stress at the carriage.
- Recent Replacement: In this case, the customer replaced the chains just a year ago, so they remain in excellent condition. But just measure the pin distance from several parts of the chain in order to evaluate the wear!
Step 4: Mast Examination
The mast plays a crucial role in the forklift’s lifting capabilities. Here’s what we check:
- Smooth Operation: The mast is lifted and lowered to detect any unusual sounds or resistance, which could signal damage.
- Measuring Play: The gap between mast sections is measured to ensure minimal play. For this forklift, the difference was negligible, indicating the mast is in top condition.
Step 5: Front Axle and Hub Inspection
The front axle and hubs are inspected for oil leaks, as this can lead to costly repairs:
- Visual Inspection: The hubs are checked for signs of oil leakage, and in this case, everything is in perfect working order, considering the forklift’s age and usage hours. If the axle is showing signs of wear it can usually be sensed from leakages on the internal side of the hubs, between the tires, or on the outside, rim side, of the tires. Also pay attention to the axle on the rear side (crawl under the truck and you can easily sense what is going on there!).
Step 6: Complete drivetrain analysis
- Check for any leakages at the engine: leakages can be from small issues but can easily also mean big overhauling costs. So check closely for leakages and, to do an even better job, make sure the engine and gearbox are clean so that you can easily trace a leakage!
- Listen closely to the sound of the engine
This is important to do while running and also when it is in idling modus. If you have some experience with engine sounds in a port environment you might be able to sense if the engine is in order or not.
- Check for any leakages at the gearbox: for the gearbox the same applies as for the engine. Make sure you have a close look for leakages.
Have a good sense of the gearbox’ behavior while driving: Check, while driving, how the gearbox goes through the gears. If there’s an abrupt moment of going into the next gear there might be something going on. Could be simple: the gearbox has to undergo a calibration process, but can also be expensive: the gears have internal leakages! If any doubt have a specialist coming over to test because the costs for replacement can be quite heavy!
Key Takeaways
At Heavy Cargo Lifters, we emphasize the importance of regular inspections to keep heavy equipment running smoothly. Here’s our advice for port equipment operators:
- Daily Inspections: Ensure drivers conduct daily checks to spot minor issues before they escalate. We have inspection forms to assist you with this, just follow this link and we can send it to you on request!
- Preventive Maintenance: Routine maintenance is essential to prolong the lifespan of your equipment. Don’t be greedy and make sure you have your supplier taking care of the maintenance!
- Professional Inspections: For in-depth evaluations, our team is always ready to assist. We also provide inspection forms to help streamline your daily checks.
Thank you for joining us on this inspection walkthrough. If you have any questions or need help with your equipment inspections, feel free to contact us. Stay tuned for more insights and tips in our upcoming posts. Until next time, happy lifting!