Are you thinking of purchasing a forklift that's probably the reason why you need to know what is considered high hours on a forklift?
Or you are planning to rent this equipment that's why you want to know the ideal number.
Whatever your reason might be, knowing the hours is important.
Forklifts, in general, are expected to last somewhere between 10,000 to 20,000 total work hours. When you ask about its “high hours”, you are actually talking about the peak number of hours a forklift can be operated safely and productively.
Referring to its work hours is believed to be more accurate for measuring the productive lifespan of a forklift, compared to noting down its age.
The reason behind this is that forklifts differ from each other based on how often each has been used in the factory or warehouse.
This measurement of work hours usually refers to how many hours the engine of the forklift has been running.
What Is Considered High Hours
A. Average Lifespan of a Forklift in Hours
The average lifespan of a forklift varies depending on several factors, including its type, maintenance history, and intensity of use. However, a general estimate for the lifespan of a forklift falls within the range of 10,000 to 20,000 operating hours. It's important to note that this is just an average, and some forklifts may have shorter or longer lifespans based on the factors mentioned earlier.
B. When Hours are Considered 'High' for Different Types of Forklifts
The threshold for what is considered "high" hours can vary depending on the type of forklift. Generally, for electric forklifts, reaching 10,000 operating hours can be considered high, as they tend to have a longer lifespan compared to internal combustion engine forklifts. In contrast, for internal combustion engine forklifts, particularly those powered by diesel or gasoline, reaching 15,000 to 20,000 operating hours can be considered high.
C. Variances in High Hours Based on Usage and Maintenance
The concept of high hours can be influenced by the intensity of usage and the quality of maintenance. Forklifts that undergo heavy-duty operations, such as continuous use or demanding lifting tasks, may accumulate hours more quickly compared to those used in lighter applications. Similarly, forklifts that have been well-maintained throughout their lifespan may have the potential to achieve higher hours before reaching the point of considering them high.
It's crucial to emphasize that the determination of high hours should not be based solely on the number of operating hours. Other factors, such as the forklift's overall condition, maintenance history, and performance, should also be taken into account when assessing whether the hours are considered high and if any actions, such as repair or replacement, need to be taken.
Read this article: Can Electric Forklifts Be Used in the Rain? (Check the IP)
Understanding Forklift Hours
A. Explanation of What Forklift Hours Are
Forklift hours, also known as operating hours or running hours, refer to the total time that a forklift has been in operation since its manufacturing date. It includes the time the forklift has been actively used for lifting, transporting, and placing loads, as well as periods when the forklift was powered on but not actively used, such as during breaks or shift changes.
B. How Forklift Hours are Measured
Forklift hours are usually measured by an hour meter installed on the forklift, similar to the odometer on a car. The meter starts recording when the forklift is turned on and stops when it is switched off. Some newer forklift models may have advanced metering systems that can differentiate between active operating hours and idle time, providing more precise usage data.
C. Importance of Tracking Forklift Hours
Tracking forklift hours is crucial for several reasons. Firstly, it's an essential factor in planning and scheduling routine maintenance, which is often recommended after a specific number of operating hours. Secondly, tracking hours can help gauge a forklift's lifespan and indicate when it might need significant repairs or replacement.
Forklift hours are also an important consideration when buying used forklifts, as they provide an indication of the machine's usage history and potential remaining lifespan. Lastly, tracking forklift hours can help with operational efficiency, allowing management to assess whether forklifts are being used effectively or whether changes need to be made to deployment or operational procedures.
Read this article: Hazards of Operating Electric Forklifts in Narrow Aisles
How Many Hours Can You Operate a Forklift?
Since the high hours of a forklift tends to hover somewhere between 10,000 hours to 20,000 hours, you can expect your forklift to last for seven years maximum. Much depends on how extensively the machine was used.
Another factor is the number of times the machine needed to be recharged per usage. One claim about electric forklifts is that your forklift will need 1,200 – 1,500 charges maximum which means each charge can power up to eight hours of work. Naturally, this varies from unit to unit and from brand to brand.
Impact of High Hours on Forklift Performance
A. Effect on Engine Performance
High hours on a forklift can have a notable impact on engine performance. As a forklift accumulates operating hours, the engine may experience decreased power and reduced efficiency. This can result in slower acceleration, reduced lifting capacity, and compromised overall performance. The engine may also become more prone to issues such as increased fuel consumption, decreased responsiveness, and difficulty starting, leading to operational inefficiencies.
B. Wear and Tear on Major Components
High hours of operation contribute to increased wear and tear on major components of the forklift. Components such as the engine, transmission, hydraulic system, and brakes are subjected to constant stress during operation. Over time, this can lead to the deterioration of these critical parts, resulting in decreased reliability and potential breakdowns. The likelihood of failures and the need for repairs or component replacements increase as the forklift accumulates high hours.
C. Potential Safety Risks
The safety risks associated with high hours on a forklift should not be overlooked. As the forklift ages and accumulates operating hours, the potential for mechanical failures or malfunctions rises. This can increase the risk of accidents, putting operators, pedestrians, and the surrounding environment in danger. Brake failures, hydraulic system malfunctions, or sudden engine issues can compromise the safe operation of the forklift.
D. Cost Implications
High hours on a forklift can have significant cost implications. As the forklift reaches its later stages of life, the frequency and cost of repairs tend to increase. Maintenance expenses rise due to the need for more frequent servicing, replacement parts, and addressing potential breakdowns. Furthermore, the downtime required for repairs and the resulting loss of productivity can have a financial impact on operations. Ultimately, the cost of maintaining and repairing a high-hour forklift can outweigh the benefits, making replacement or upgrading a more viable option.
It is important to note that regular maintenance, including timely inspections and servicing, can help mitigate some of the negative impacts of high hours. However, as a forklift accumulates high operating hours, it becomes increasingly crucial to carefully assess its performance, safety, and cost-effectiveness to determine whether replacement or extensive refurbishment is necessary.
Factors Influencing Forklift Lifespan
A. Type of Forklift
The type of forklift can significantly influence its lifespan. For instance, electric forklifts tend to have a longer lifespan than internal combustion engine forklifts because they have fewer moving parts, which reduces the potential for mechanical wear and tear. The intended use of the forklift, such as rough terrain forklifts versus warehouse forklifts, also plays a role in its lifespan due to the varying demands and potential wear and tear on the equipment.
B. Quality of Maintenance and Service
Regular and proper maintenance is vital to extend a forklift's lifespan. Regularly scheduled services, proactive replacement of parts nearing the end of their service life, and quick responses to any mechanical issues can all contribute to a longer-lasting forklift. Conversely, infrequent maintenance or neglect can lead to accelerated wear and tear, decreasing the forklift's lifespan.
C. Work Environment and Usage Intensity
The environment in which a forklift operates can have a significant effect on its lifespan. For example, forklifts used in harsh conditions, such as outdoors in the elements, corrosive environments, or rough terrains, may experience more wear and tear, reducing their lifespan. Additionally, the intensity and nature of use, such as heavy lifting or constant operation, can also impact how long a forklift lasts.
D. Manufacturer Quality and Reliability
The manufacturer's quality and reliability are also significant factors in a forklift's lifespan. High-quality forklifts built with robust materials and advanced technology are likely to last longer than cheaper, lower quality models. Furthermore, manufacturers with a reputation for reliability often offer better support and parts availability, which can contribute to a longer operational lifespan for their forklifts.
The Value of a Forklift Hour Meter Reading
The hourly meter readings can be very useful in determining how long your forklift will last. First of all, you need to check if your forklift is electrical or gas-fueled because electrical forklifts are charged, not re-fueled.
The operator of the forklift for each shift is expected to login the meter reading prior to use and after use. This will give you a clear idea about the fuel consumption per operator, per shift and per work day.
You will notice that there are some days when the fuel consumed will be less and other days when it seems more. Logging these details makes the management process more accurate and scientific, compared to just checking the age of the machine.
To make it even more accurate, require the operator of the machine to record up to the tenths digit. This helps make fuel computations more accurate, especially over time.
The Lack of a Forklift Odometer
There is no such thing as a forklift odometer because odometers are commonly used to measure the mileage in mobile vehicles, such as automobiles and trucks. Forklifts do travel on wheels but they are not fitted with an odometer because a forklift usually travels a short distance within the work area of a warehouse or factory.
Yes, the cumulative distance travelled by a forklift may eventually be estimated to reach quite a long distance. But an odometer would be less useful than the usual forklift hour meter that measures the number of hours used in operating a forklift.
How to Make Your Forklift Last Longer
Your first concern while buying a forklift is to make sure that you bought an excellent brand. Generally, some brands are more expensive than others so some company managers may think they get a good deal by buying the more expensive brands. This isn’t always the case.
You may get a great forklift even from a lower-priced brand. If you aren’t sure how to buy a new forklift, you may need another pair of eyes more experience to gauge the value of the forklift you have in mind.
Ask your more experienced maintenance managers to help you out with this. They may be able to spot a better machine than you could, since they’ve already encountered machines from different brands before.
There are two factors that may affect the aging of your forklift. First, the maintenance done on the machine should be regular. This allows your maintenance crew to determine if the unit seems to have some problems already.
After all, the forklift is a big investment on its own. Second, the work environment where you use the forklift should be conducive to letting the forklift do its job without breaking down. Some work environments exert more wear and tear on the unit than others, such as if the warehouse is too cold or too hot. Generally, it is best if the forklift is used under clean and dry work conditions to allow it to function at optimal levels.
What to Look for When Buying a Used Forklift
Company managers may opt to buy a used forklift rather than spend on a brand-new unit. If you intend to acquire a used forklift, you should always check the number of hours it has been used by the original owner. On the outside, the forklift may look as if it had just been bought from a showroom. But if the engine has been operating regularly for the original owner, the machine may eventually just give up the ghost on its own.
Another way to determine if a used forklift makes for a good investment is to check if it runs on electricity or internal combustion. This is because electrics are often used for more hours than the internal combustion forklifts.
You should pay a visit to the workplace where the forklift was used regularly by the original owner. This will help you determine if the forklift was being used in a safe environment or if the forklift may have undergone rough usage. Even the prevailing temperature within the work area can lead the forklift to malfunction more often than a forklift which was operating under cooler temperatures.
Some forklift brands are more durable than others so you may also want to check the brand the used forklift was manufactured under. Some forklift owners may also have conducted regular maintenance checks of their unit, which is great for the next owner.
When to Retire a Forklift
A good rule of thumb when choosing a forklift from your fleet to retire is to examine the point at which the productivity curve intersects with the maintenance curve. In simple terms, you generally want to retain a forklift that is still very productive and not yet requiring constant maintenance checks. The point of intersection varies from forklift to forklift, because the work conditions for a forklift does differ from unit to unit.
If you are the company manager or owner of the forklift, you will need to consult your records about the forklift you are considering to retire. You may notice that the machine tends to require more maintenance as the forklift takes on more and more work hours. If the forklift tends to be used continuously (such as for three consecutive manpower shifts) then you can expect that the maintenance for that unit will go up as well over time.
Ideally, your company will be able to wring out more work from all its forklifts to justify the initial investment in each. If you find that the forklift seems to require more maintenance dollars compared to its initial purchase price, then you may consult your forklift maintenance team to determine what went wrong. This means considering factors like:
- The brand of the forklift and its engine
- The work conditions you subjected your company’s forklift to throughout its years of operation
- The number of times the unit malfunctioned and required a maintenance check
- The ways company employees tend to use the same forklift over time
- The number of work hours the unit has been working under per shift
- The age of the unit itself
Once you know all these, you may perhaps realize that the forklift has been under quite a lot of stress and may need to be sidelined. This doesn’t mean selling the unit right away though. Some maintenance team may recommend that the unit can be put in storage to serve as the source of spare parts in the future.
They may also suggest that the old unit can work under less stressful conditions such as being run for only one shift per work day. If accidents involving the forklift seem to occur when a particular employee is using it, you may want to check the way the employee is actually using the unit. That may show you the nitty-gritty answer to the problem.
Conclusion
If you are looking for a forklift to purchase, it is generally a good idea to buy a forklift that is brand new and in pristine condition. This counters the common practice of doing minor repairs on the aging forklift believing that this helps save money.
he truth is, it is often much more cost-effective to buy a brand new forklift, based on the cumulative costs of doing minor repairs from time to time.
If, on the other hand, you own a used forklift that is already aging, you may opt to keep that unit in storage.
It can still be used for less stressful work meaning it can be employed for one shift only per work day. Its parts can also be cannibalized and used to replace worn-out parts of other forklifts of the same brand and model number.
If you’re the type of machine owner who has been religiously conducting maintenance checks on the unit, you might be able to sell your unit to another company for a fair price. Generally though, a used forklift that has reached the optimum age and has been quite useful over its lifespan may be good for the scrap yard only, in the final analysis.
