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Average Lifespan of a Forklift

Forklifts, like any heavy machinery, are a pricey investment. You want to make sure you’ve chosen the right one and that you’re maintaining it correctly. Determine the age of your forklift, average lifespan of a forklift, and how to make your forklift last longer by reading this article.

 

How old is my forklift?

A forklift’s lifespan is measured by hours of use, not years, because every business utilizes their machines at different rates.

A five-year-old forklift that was utilized 15 hours a month will usually be in better shape than a one-year-old forklift that was used 8 hours every day.

The stress on a forklift’s mast from raising and lowering of equipment is what causes most machines to break down over time.

Buying a used forklift? Always inspect it for wear, even if it has low hours. Heavy loads can cause damage to a forklift, which won’t be reflected in the running hours.

 

How long should I expect my forklift to last?

The average lifespan of a forklift is 10,000 hours, but it varies based on the manufacturer, type of forklift, and average running conditions. It’s possible to have two forklifts, manufactured the same year, that have different life expectances.

Manufacturer

Brands like Doosan and Toyota typically have longer lifespans up to 15,000–20,000 hours.

Internal Combustion Engines vs Electric Forklifts

On average, you can expect an electric forklift to last longer. Electric forklifts’ batteries typically need to be replaced every five years, or approximately 1,500 charging cycles. However, since they have fewer moving parts, they are less likely to break over time.

Average Running Conditions

Regular heavy loads will shorten your forklift’s total run time, and exposure to extreme temperatures, uneven surfaces, and hazardous substances will cause significant wear. A truck used indoors in clean conditions will last a lot longer than one exposed to extreme conditions. If you have a fleet of forklifts, it’s a good idea to rotate them every few months so they wear at the same rate.

 

How can I extend my forklift’s lifespan?

Regular Maintenance

Preventative and regular maintenance are the key to a forklift’s survival. Always perform daily, routine checks, schedule preventative bi-annual maintenance, and get any issues checked up on immediately.

Most forklifts should be serviced every 200 hours and have extensive maintenance performed every 2,000 hours. Always check the manufacturer’s recommendations to find out exactly when your forklift should be serviced.

Being proactive could help your forklift survive up to five years longer (based on daily use) than expected!

Yard and Warehouse Maintenance

Potholes, sharp turns, and other safety hazards can cause damage and uneven wear to your fleet. A safe environment can lead to less expensive repairs over time.

Staff Training

Several people are standing around a forklift learning how to use it.

Your operators have a huge effect on your forklift’s lifespan. Collisions and tip-overs are obvious causes of damage, but heavy braking, excessive speed, and skipping inspections will also cause your forklift to wear down quicker.

Need staff training? Contact us.

 

 

How do I know when my forklift needs to be replaced?

If a forklift is slowing down productivity by requiring downtime for repairs, it may become too expensive to maintain. Consider the lifespan of the forklift and how much it costs per hour to run.

 

Forklifts are an important part of your warehouse operations. Ensuring your forklifts are running at top efficiency can help them last for years.

Prefer to rent a forklift instead of purchasing? Contact us!

 

Editor’s Note: This post was originally published in October 2021. It was updated for freshness, accuracy, and comprehensiveness in January 2023. 

ANSI A.92 Modifications – The Time Is Now

By now, you may have heard of the upcoming changes to ANSI standards for aerial work platforms, now called MEWPs (Mobile Elevating Work Platforms). While we are still unsure of the effective date, we do know changes are coming very soon. While dealers, owners and operators will all feel the impacts of the new standards, we want to focus on how you, the consumer/operator, will be affected.

The new ANSI A92 standard was developed to improve safety and efficiency for MEWP design and use of MEWPs. Within ANSI A92, there are three standards affecting the MEWP user- the A92.20, covering machine design; the A92.22 covering safe use; and the A92.24 covering training.

Machine Design Standards

Under these new standards, MEWPs are classified differently, divided into the following groups:

  • Group A for those with platforms that move vertically but stay inside the tipping line.
  • Group B for all other MEWPs – typically, boom-type equipment where the platform extends past the tipping line.

Within each of these groups, machines are separated into types:

  • Type 1 for those that travel only in the stowed position.
  • Type 2 for those that can travel while elevated but controlled from the chassis.
  • Type 3 for those that can travel while elevated but controlled from the work platform.

There are also changes to the overall design of the machines.

(Click to Englarge)

Safe Use Program

One new requirement that will promote safety when using MEWPs is creating and implementing a “safe use program.” Users are required to develop and implement a safe use program that includes a risk assessment. This risk assessment needs to include guidelines for MEWP supervisors, operators, and occupants. The risk assessment consists of several stages including; work definition, MEWP selection, risk evaluation, rescue planning, and communication. Before a job starts, and periodically throughout a long-term job, the risk assessment must be reviewed to determine if any pieces of the tasks or the work environment have changed, as well as the effect that it could have on the safety of the job.

(Click to Enlarge)

The user must also develop a written rescue plan that will be carried out in the case of machine breakdown, platform entanglement or fall from the platform. The plan must be put in writing and become part of the company’s training manual. All occupants must receive training that explains the procedures to follow if they fall and await rescue or witness another worker’s fall. This plan must limit the time a properly restrained worker hangs suspended in the air.

Rescue plans can include the following:

  • Self-Rescue- by the person involved (using a self-rescue harness)
  • Assisted Rescue- by others in the work area (using the ground controls or a second MEWP)
  • Technical Rescue- by emergency services (fire department or air rescue)

 

Training

Dealers, owners and users must train and familiarize, or have proof of training and familiarization, for all employees they allow to operate a MEWP. ANSI will allow qualified operators, who have already received proper training and are qualified to operate other MEWP’s, to self-familiarize on machines they have not yet operated. However, all current operators will need to be trained up to the new standards.

Supervisors of those operating MEWPS must also be properly trained. The user must ensure that all personnel that directly supervise MEWP operators are trained in the following areas:

  • Proper MEWP selection- How high?, Outreach or not?, How many people in the platform?, Inside or outside or both?, Doorway access?, Single or double or larger?
  • Rules, regulations and standards that apply to MEWPs, including operation, safe use and training
  • Potential hazards associated with the use of MEWPS and how to protect against them
  • Where manufacturer’s operation manuals should be stored and how they should be used

 

For more information on these new ANSI standards, please visit Hugg & Hall’s additional articles on this subject at www.hugghall.com/news/category/industrystandards/ or contact a Hugg & Hall salesman.

Below are printable forms to better assist you with these modifications.

Printable Risk Assessment Form 

Printable Rescue Plan 

Genie Releases New “High Float” Telescopic Boom Lifts

Genie-S-85-HF-Boom

Genie S-85 HF-Boom

Genie has introduced the release of two “high float,” ANSI-compliant boom lifts. The lifts are engineered to avoid damaging soft ground surfaces while maintaining high lift capacities. Designers created the S-80 HF and S-85 HF machines to “float” on more frangible surfaces like sand and turf. The new boom lifts protect softer surfaces during operation that could be damaged by more aggressive tread on regular rough terrain machines. Hugg & Hall Equipment Company (Hugg & Hall) continually assesses the latest industry trends and advancements. As such, the features of Genie’s new telescopic boom lifts are explored in the below sections.

Float Capabilities

The S-80 HF and S-85 HF lifts were engineered to perform heavy-lifting without creating extensive damage to more delicate surfaces. The lifts protect softer surfaces that could be damaged by the more aggressive tread on regular rough terrain tires, according to Genie. The lifts feature a virtual pivot primary boom which aligns the machine’s center of gravity for lower machine weight.

Lift Capacity

The new high-float machines feature lifting capacities of 600-lbs restricted and 1,000-lbs unrestricted. The capacities will allow lifts to carry up to three people along with any necessary tools and materials, according to an article published by Lift and Access. The capacities are comparable to other models but are notable in congruence with the minimal invasiveness on vulnerable surfaces.

Platforms

Purchasers will have the option between lift baskets featuring 6-foot platforms, with dual-entry, or 8-foot platforms, with tri-entry and side-swing gate, according to Equipment World. The side-swing gate simplifies the process of entering the basket and streamlines the loading of tools and materials.

Tires

The lifts are equipped with air-filled 41/18LL x 22.5 20 ply tires, according to Equipment World. The tires support the machines intended design for productivity on sensitive surfaces, according to Lift and Access.

Engine

Both units are available with a 74-hp diesel engine, according to Lift and Access.

Working Height

The S-80 HF delivers up to 86-feet of working height and 68’6” of outreach, according to Lift and Access. The S-85 HF provides up to 91-feet of working height and 72’6” of outreach.

Features on the new high-float models include automatic envelope control, which retracts the boom when it reaches its operating envelope, and a load-sense cell that automatically limits the operating envelope to match the load chart, according to Equipment World.

Tier 4/ANSI A92 Compliance

The diesel engine offered is Tier 4 compliant, according to Lift and Access.

Corrado Gentile, a Genie product manager, said that the new Genie HF models are based on the design and engineering of the Genie Xtra Capacity (XC) booms, complying with the overload restriction and terrain-sensing guidelines in the new ANSI A92 and CSA B354 industry standards in North America, as well as European EN280 and Australian AS 1418.10 standards, according to Lift and Access.

Smart Link

Genie also added its Smart Link control system to the booms for easier operation, according to Equipment World. Its onboard diagnostics can be displayed on a new LCD screen at the ground controls, allowing machine setup, calibration and troubleshooting on the machine, with no need for a laptop or other accessories.

Other Features

  • 4WD and positive traction drive maintains equal power to all drive wheels
  • 45% gradeability (stowed) for driving on slopes
  • 160˚ platform rotation and 360˚ continuous rotation turntable for quick, precision positioning