2025.12.10
Many enterprises have the misunderstanding of "over-maintenance and neglect of maintenance" in forklift maintenance, which not only increases the operation and maintenance costs but may also shorten the service life of the equipment. Bojun Forklifts offer the following 3 money-saving tips to help enterprises optimize their operation and maintenance plans:
Some enterprises, in pursuit of peace of mind, have shortened the replacement cycle of hydraulic oil for diesel forklifts from half a year to three months. In fact, this is not necessary - as long as the cleanliness of the hydraulic oil meets the standards, it can be replaced according to the forklift manufacturer's specified cycle. Excessive replacement will cause unnecessary waste.
When replacing spare parts or lubricating oil, choosing non-original or uncertified inferior products seems to reduce procurement costs in the short term. However, low-quality accessories have insufficient precision and are not wear-resistant in material, which can easily lead to abnormal wear and performance degradation of related components, and even cause safety accidents. Similarly, using substandard hydraulic oil and gear oil will accelerate internal corrosion and carbon deposits in the system, seriously affecting transmission efficiency and component lifespan. "Original factory parts" or "OEM equivalent quality" certified parts, although the unit price may be slightly higher, the equipment reliability, fuel economy and longer
Through the ledger, managers can clearly see how many hours on average the hydraulic system of a certain vehicle leaks after running, or the life cycle of a certain brand of motor under specific working conditions. This enables the maintenance team to upgrade from "on-time maintenance" to "condition-based maintenance", precisely intervening before potential faults occur, and completely avoiding production disruptions and high costs caused by unplanned downtime.
The proportion of electric forklifts has risen to over 60%, but misunderstandings about battery maintenance are particularly prominent. Overcharging, deep discharging, and failure to replenish fluid in a timely manner can all significantly shorten the battery's lifespan. Proper battery maintenance can extend the service life oflead-acid forklifts by more than 25%. It is recommended to be equipped with an intelligent charger, implement opportunistic charging, and perform equalization charging regularly.
Many minor issues, such as early tire wear, micro-cracks in the forks, and abnormal noises, can be detected in advance through standardized "daily inspections". In addition, it is necessary to cultivate employees' awareness of taking care of equipment, which can reduce abnormal wear and tear from the source and is an extremely efficient "money-saving" investment.
The drawbacks of untimely maintenance：
Costs：Maintenance costs have increased geometrically, and energy consumption has risen significantly，A fuel filter that is not replaced in time may cause fuel line blockage and engine damage. Slightly contaminated untreated hydraulic oil may eventually require the replacement of the entire hydraulic pump assembly
Safety：The braking system failed, the steering system malfunctioned, the lifting system had hidden dangers, and components fell off，If brake fluid is not replaced regularly, it will absorb water and deteriorate. If brake pads are worn out excessively and not replaced, it may lead to an increase in braking distance or even complete failure, which can easily cause serious accidents when moving heavy objects or in crowded areas..If the load-bearing components such as the mast chain, rollers and bearings lack lubrication and inspection for a long time, they may suddenly wear out or break, causing the load to fall.Deterioration of the steering system oil and aging and oil leakage of the hydraulic pipelines can cause heavy steering or sudden loss of control.
Production：Sudden malfunctions and shutdowns lead to reduced operational efficiency and attendance rates,A sudden malfunction caused the equipment to break down, directly interrupting the logistics operation line. The cost is not only maintenance hours, but also delayed production orders, stalled production lines and defaulted customer deliveries. The loss caused by the shutdown is often several times or even dozens of times the maintenance cost.
In equipment maintenance, "less" is sometimes "more". Refusing "excessive maintenance" is a rational management attitude based on science and respecting data. It requires managers to shift resources from "unnecessary replacement" to "more meticulous monitoring and protection". By strengthening condition monitoring and focusing on pollution control, enterprises can ensure the reliability of equipment while effectively reducing costs and achieving true cost reduction and efficiency improvement. Remember, "True saving money is not about spending less, but spending money correctly." Under the background of cost reduction and efficiency improvement, the professionalization and refinement of forklift maintenance have become a key link in the competitiveness of enterprises. By avoiding these common misunderstandings, enterprises can not only ensure operational safety but also achieve true cost optimization in the long term.
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