Maintenance | KION North America

Category Archives: Maintenance

Product Spotlight: The Redesigned Electric Center Rider Pallet Truck Series 1102

We keep the world moving and with that, Linde is continuously looking at new ways to meet the needs of our customers.  Seeking innovative designs to maximize ergonomics, performance, and reliability is paramount in Linde trucks.  The newly redesigned Linde Series 1102 encompasses all those features and more, offering ways to work better, smarter and more efficiently.

Ergonomics

With the operator in mind, the re-designed Series 1102 offers a forward driving position with a unique Linde twin-grip steering control, showcasing an ergonomic tiller head that governs travel direction, speed and automatic return to neutral. This feature offers ease of use of controls by either hand and its power steering reduces steer effort by 70%, decreasing operator fatigue.  Another attribute is the suspended operator platform, that not only provides the operator with an extremely comfortable work environment, but also incorporates an operator-presence sensor, protecting the operator from any unintentional harm.

Performance

The Series 1102 is extremely versatile, enabling low-level order picking and is designed for both long and short travel distances, all backed by the powerful 5.4 hp AC drive motor.  In addition, it allows for operation on or off the truck using the Easy Pick system with electronic coasting feature.  Recognized as being one of the toughest trucks in the market, it delivers high performance acceleration, braking, and travel speeds but also offers a smooth delivery while transporting heavy loads up to 8,000 lbs. 

Reliability

With the job application and operator in mind, the latest features and re-design results in an extremely durable and reliable truck.  Transporting heavy loads are not an issue as the heavy-duty fork stiffeners provide strength along all the way to the tips.  The durable casters and forks provide greater strength, stability, and longer integrity over the life of the truck, making the Series 1102 a dependable asset in your warehouse operations – even in the most demanding applications. 

Efficiency

The AC motor controller provides effective and efficient use of battery voltage and has extremely wide torque and speed range, supporting tailored parameters to meet a wide variety of application requirements.  Zero speed ramp hold applications are also accomplished, as well as full regeneration capability and smooth low speed control.  Maximizing the Series 1102’s capabilities are a reality with the addition of new AC technology, enabling extended maintenance intervals for motors resulting in decreased down time.

Maintaining Your Forklift – Keeping It Clean Will Prolong Its Working Life

When considering ways to extend the life of your forklift, one often gravitates to the more obvious ideas.  Depending on how your truck is powered, you may be thinking regular oil changes, keeping a close eye on the motor/engine, following the manufacturer’s maintenance schedule or regular up-keep of the tires.  One, as important step to maintaining a forklift that often gets overlooked, is cleaning/disinfecting the truck.  Below we will highlight some important steps that will ensure your forklift is functioning at peak performance and will remain running for a long time.

Clean off exterior debris

Just as you would clean your personal car when it becomes visibly dirty, the same applies for the forklift.  Depending on your truck’s source of power will determine what tools you can clean with.  For an electric truck, knocking off accumulated grim with a broom will help dislodge unwanted particles, making it easier to clean.  An air compressor can also assist with the removal along with non-toxic bio-degradable solutions.  Keep in mind that water can affect your trucks electrical components, so use caution to prevent electrical damage.

As noted in the Linde service guide operators manual,hot steam or cleaning materials with a powerful degreasing effect should only be used with great caution as this will affect the grease filling of bearings with lifetime lubrication, causing it to escape. As re-lubrication is not possible, the bearings will be irreparably damaged.“

When cleaning a non-electric truck, it is advised to use a pressure-washer to knock-off hard to remove substances.  In addition, the use of the pressure-washer will prevent the operator from getting too close to the truck, during cleaning, protecting one from potential hazardous run-off or splash-back.

The Linde operator’s manual states, when cleaning with a water jet (high-pressure or steam cleaner etc.), it should not be applied directly to the area of the front axle, electric and electronic components, connector plugs or insulating material. Water should not be used for cleaning in the area of the central electrical system and switch console.“

Don’t forget the underside of the truck

It is often noted that we clean what we see, however, hidden parts of the truck are as important, if not more to maintain.  Depending on where you work, your truck may be used in many different environments.  Dirt and grim can easily build up in those hard to reach areas, causing potential issues to the undercarriage of the truck.  Keeping those areas cleaned, will prevent major issues down the road.

Work from the top of the truck down

For heavier soiled areas, pre-soaking your truck may be necessary.  That will allow build-up to soften, making it easier to clean.  When cleaning your truck, make sure to start at the top and work your way down.  That way, grim and dirt will flow down, and you are not having to re-clean areas.

Allow proper dry time

Once your truck is sufficiently cleaned, park it in an area that will allow appropriate dry time – preferable in the sun.  Allowing your truck to dry will ensure that its components are working efficiently and will prevent damage to the truck.

Protect yourself

No matter how you plan to clean your truck, make sure you are using protective gear.  When using cleaning materials or tools, there is always a chance that substances can splash back on you.  Be sure to wear protective eye-wear, boots and gloves, as well as long sleeves and pants to protect your skin.

Top 6 Forklift Options to Reduce Maintenance Costs

One of the biggest keys to having a profitable business is to find ways to reduce costs without sacrificing quality or customer satisfaction. Buying a forklift, regardless of size, is expensive enough so the maintenance can be even steeper in price. We have compiled a list to help your company save some coins in maintenance costs to make sure you are providing quality as a standard to your company and your customers.

Repair Floors and Eliminate Sources of Tire Damage

Worn out floors can cause serious damage to your forklifts’ tires if the floors have holes or are badly worn down. Debris and waste such as plastic, wooden pieces, and other trash can also cause tire damage, which eventually leads to your machine needing new tires. Making sure that your manufacturing site upholds cleanliness standards and investing in smooth, even floors can eliminate the chances of employee accidents and machine damage.

Introduce Forklift Operating Safety Training

When is the last time your forklift operators participated in a forklift operating safety training? If you could not answer immediately, that means that it is time to plan for a training session. These sessions act as a refresher on safety protocol, while also update operators on any new driving/handling techniques when operating the forklifts. The benefits of these training sessions are that they increase forklift operator awareness and significantly decrease the amount of damage to the machines and any inventory.

Sticking to One Brand of Forklifts 

Various companies make forklifts, and not all of these machines are made the same. Different companies like to add on signature gadgets to build their brand stand out, and these additions can come additional costs. It may be a smart investment to be consistent with the brand of forklifts that your company uses to ensure that you do not have to kick out extra maintenance fees for different brands of forklifts.

Replace Tires and Wheels Frequently

Due to the lack of suspension that forklift machines have, their tires and wheels are prone to become worn down very easily and require frequent maintenance. An excellent investment tool would be to invest in shock absorption pads and replace tires and wheels frequently. Even the most skilled forklift driver is bound to have an incident on while operating the machine. These minor accidents can accumulate damages very quickly, and soon, you will need to replace an expensive machine. Investing in shock alarms to help indicate and absorb some shock will help keep track of how often to replace tires.

Setup a Maintenance Program

Having a contract with a maintenance provider could help companies maintain repair costs. Instead of having unexpected, or large repair bills, Have a monthly fixed price with a service provider to address any problems and eliminate the potential for any significant issues in the future. This is why sticking to one brand of forklifts is essential because this one factor could help to regulate the monthly cost of your maintenance bill. Even if there are no significant repairs one month, the constant upkeep on your machines will save you a ton in the long run.

Investing in Multi-Function Display Screens

Multi-function display screens are vital to any machine. Their primary function is to display the performance of forklift, determine its current condition, and if it’s time for any maintenance checks. It can control and regulate the speed of the forklifts and even measure oil levels. This is a brilliant investment to have seeing as it does most of maintenance monitoring for you.

Steps to an Energy-Efficient Warehouse

Having trouble trying to figure out ways to reduce your overall warehouse costs? We have some easy steps you can take! From recycling, lighting, to different types of forklifts, we have you covered. While lowering costs with these steps, you will also be making a positive impact on the environment.

Motion Activated/Solar Lighting
If you want to decrease your electricity usage, we recommend motion activated and solar-powered lighting. With motion activated lighting, the lights will come on only when the lights sensor motion and will turn off after a few minutes once the employee leaves the area. With solar lighting, you can easily eradicate electric lighting. Both types of lighting are great ways to reduce your costs and help the environment!

Recycle
A full warehouse also means you have tons of boxes! One of the easiest ways to save money, and the planet, is by using cardboard shredders. This a simple way to change your cardboard scrap into recyclable packing which can later be used as packaging material for any shipments you need to send off. Another step you can take when it comes to recycling is reusing your bubble wrap. The bubble wrap you receive from shipments can be saved to act as a cushion in the future for products that you’ll need to ship off to customers.

Air Conditioning
Air conditioning can be very expensive, especially when you need to cool down an entire warehouse, for this reason, many warehouses aren’t cooled. To keep your employees working at a comfortable temperature, we recommend looking into evaporate cooling. Evaporate cooling doesn’t require much power and can reduce the temperature to more than 10 degrees. This is a popular and inexpensive way to keep your warehouse cool.

Electric VS Propane Forklifts
Forklifts are extremely vital and can be found in most warehouses. With electric forklifts, you won’t have any exhaust fumes, which enhances air quality and saves you money. Propane forklifts use about $20 worth of propane. If you cut out propane forklifts and switch to electric forklifts, you will be saving about $4,000 annually. This also helps improve conditions in your warehouse and the environment.

Our hope is to reduce your costs and contribute to saving the environment with these four steps. If you have any questions or concerns, please contact us via our website or by calling us at 843-875-8000.

How Planned Maintenance Saves You Money

To avoid expensive and unexpected repairs, you’ll want to plan maintenance. It will cost you more to service your forklift than to preserve the equipment properly. We want you to take the appropriate steps in caring for your forklifts. Hopefully, these three simple tips can help you schedule your maintenance successfully beforehand to prevent spending more than you need to.

Investment
You will want to protect your investment, which is your forklift. The first step is to make sure that you check your forklift periodically, no matter what type of forklift you own. Regular maintenance checks can increase the lifespan of your forklift. These are expensive pieces of machinery, proper care is crucial.

Never Pay Twice
You should never pay twice for service. Many owners of forklifts who don’t sign up for planned maintenance get charged anyway. Messing up payment is an easy error to avoid, by asking the service you take your forklift to if they could call you ahead of your appointment to double check if you will be using the service.

Planning
When you plan an appointment for maintenance, you won’t have to worry about any breakdowns or remembering to arrange to get service done. This keeps your forklift running and ensures the safety of both the operator and the forklift. Keep reminders on hand of when to create maintenance appointments.

With planned maintenance, this will minimize downtime, enhance productivity, expand the forklift’s lifespan and reduce costs. If you have any questions or want to know more about owning a forklift, contact us via our website or by calling us at 843-875-8000. We hope to hear from you soon!

Importance of Watering a Forklift Battery

When it comes to handling the maintenance of your forklift, you’ll want to be certain that you are taking the proper measures to ensure that your forklift remains in good shape for your use. One of the key components to the forklift is its battery. Maintaining the battery is a responsibility you’ll want to prioritize, more specifically, watering the battery. The following points will help boost the battery’s performance.

Why, When, How
You water a battery because you don’t want your battery to burn out. If batteries aren’t watered down, then this will decrease the lifespan and safety of the battery. You’ll want to water the battery before a work shift. When watering the battery, you’ll want to water each cell within the battery until it is at the maximum height of the lead-acid plates. Try not to over water the battery because it will cause leaks. With that being said, don’t underwater either. If the battery is under watered, it will cause the battery to dry-out, which then requires downtime and extra upkeep.

Clean Distilled Water
We recommend that you use clean distilled water that is between 5-7 on a PH scale. The battery should always be clean and unadulterated. If you use water that is contaminated with other substances, it can cause battery damage, which leads to having to spend a fortune to either repair the battery or purchase an entirely new battery.

Battery Plates
It is suggested that you keep the forklift battery plates below the water-line when you are charging. This is to assure that your battery doesn’t overheat and also doesn’t dry out. If the battery overheats or dries out, this makes it inoperable or unsuitable for your forklift. If the plates go above the water line, then add water to a quarter of an inch aloft the plates, and try not to go over that.

We hope you have rendered this useful to understand the significance of watering your battery and the consequences that will occur if you don’t do it accurately. If you have any questions or regard, please contact us either through our website or by calling us at 843-875-8000.

Product Spotlight: Baoli KBD40/KBD50

The Baoli Series 6012 is the latest addition to KION North America’s Baoli product line. With the introduction of this series, KION North America offers Baoli forklifts with load capacities ranging from 3,500 lbs., all the way up to 10,000 lbs. to provide you with a range of models to get the job done.

Offered in two different models, KBD40 and KBD50, the Baoli Series 6012 is a diesel, four-wheel truck equipped with single or dual SE or pneumatic drive tires, making it suitable for a variety of environments. KBD40 lift capacity is 8,000 lbs. KBD50 lift capacity is 10,000 lbs. Both models have excellent residual capacity at height.

Performance and Value

The Baoli KBD40/KBD50 is an extremely versatile truck that can operate outdoors even in inclement weather with an optional, fully-enclosed and heated cabin. This truck is a perfect match if you need for a sturdy, quality forklift that delivers great value.

Built using proven components, the performance of these trucks is outstanding. The powerful Kohler Tier 4 turbodiesel engine delivers 74 HP and plenty of torque to more easily handle heavy loads. With Kohler’s advanced, common rail direct injection system and Electronic Control Unit (ECU) with fuel mapping, these trucks are very fuel efficient. You can also expect lower maintenance costs and less downtime, with no requirement for a Diesel Particulate (DPF) or Diesel Exhaust Fluid (DEF).

Since no two operations are the same, the Baoli KBD40/KBD50 models offer a multitude of options to meet your operation’s specific needs. Some of these include 4th function hydraulics for special attachments, multiple mast options, and tapered and polished forks.

Reliability

As with any piece of equipment, routine maintenance is crucial to maximizing efficiency and performance. To help you get the most out of your investment, performing operator checks and doing routine maintenance on this truck has never been easier. The hood opens to a nearly 90-degree angle allowing the operator to easily access the engine compartment. Removable floor plates provide access to a majority of truck components. Taking reliability a step further the KBD40 and KBD50 are DEF and DPF free. They do not use diesel exhaust fluid or have a diesel particulate filter that requires downtime for regeneration and periodic service. This saves your business time and money, and helps keep your operation running smoothly.

Even though the KBD40/KBD50 trucks have outstanding quality and reliability, it never hurts to have a good warranty you can rely on. All Baoli forklifts are backed by KION North America’s standard 2-year warranty which covers standard equipment for the first year and unlimited hours, in addition to standard powertrain coverage for two years or 4,000 hours. An optional extended warranty for one additional year or 2,000 hours can also be purchased.

Baoli brand equipment is fully integrated into KION North America’s supply chain and service system. The company’s South Carolina-based warehouse is stocked with a variety of spare parts. Sales and support for the KBD40/50 is provided by a network of authorized dealers throughout the United States.

Comfort

The Baoli KBD40/KBD50 is equipped with a host of standard comfort features at no extra cost including a tilting, adjustable steering column and a comfort suspension seat with a high-visibility orange seat belt. A roomy, cushioned operator compartment makes these trucks comfortable for any size operator.

Confidence

These trucks are not just comfortable. They also offer standard operator assist features like forward-facing twin LED spotlights, dual external mirrors, and separate brake and inching pedals. Treaded entry steps, an overhead guard mounted entry grab bar, and a handgrip built into the seat’s side bolster, give the operator three-point stability when getting on and off the forklift. The seat side bolsters help keep the operator secure when operating the truck.

The standard, amber warning light and backup alarm help create a more confident workplace for everyone.

If you are looking for a quality counterbalanced forklift with the performance, value, reliability and operator confidence your workplace needs, look no further than the Baoli KBD40/KBD 50. For more information or to request a demo contact your authorized local dealer today.

Forklift Battery Do’s & Don’ts

There are simple steps one should take when maintaining proper care of a forklift, one of those steps is making sure you always have a functioning battery. If you keep up with the maintenance that is required for your battery, you can extend the battery life. This helps to avoid investing too much revenue into an unnecessary amount of batteries. Here is what you should and shouldn’t do when it comes to forklift batteries.

Charging The Battery
You always want to ensure that your battery stays above 30% charge. Your forklift battery will hit a ‘red-zone’ once it reaches 20%, you should never fall below that line. If you continue to use the battery consistently after you descend past the 20% mark you will decrease the battery’s overall lifespan.

Keep At Normal Temperature
It’s best to steer clear from exposing forklift batteries to extreme heat. This can destruct the performance of the battery. If you know that you need to use the forklift in exceptionally hot temperatures, you will need to purchase certain batteries created for those specific weather situations.

Regular Cleaning
Batteries should be cleaned every month, this prevents physical damage to the battery. When cleaning, you should use warm water so it can break down chemical build up.

Issues That May Occur
Every once in a while, you might find yourself running into an issue with your battery. For example, if a battery were to overflow, you should rinse the battery with water straight away. Another problem that might arise is battery smoke. When this happens, remain calm and power it off promptly.

Don’t Pick It Up
Forklift batteries are very heavy. We do not recommend anyone pick them up with their hands. Batteries can weigh up to 3,000 lbs and should be transported with a pallet jack.

Protective Gear
When handling a forklift battery, make sure you are wearing appropriate gear. The batteries have sulfuric acid and this specific chemical can and will burn you. You should remove all jewelry before charging or handling any battery.

We hope you have found this useful and if you have any questions regarding your forklift battery, please don’t hesitate to contact us today.

How to Make Battery Charging Rooms Safer

Many warehouses are beginning to switch from combustion engine forklifts to electric forklifts in order to lower operating costs and improve environmental impacts. While electric forklifts have a longer lifespan than gas forklifts, they require proper care and maintenance. Lead-acid batteries can take up to eight hours to charge fully, so it’s important that the warehouse has a safe and efficient battery charging room. Here are four ways to make battery charging rooms safer.

Proper ventilation

Forklift batteries can emit hydrogen gas while they are re-charging, and for a short time afterwards, so it’s vital that the charging rooms are properly ventilated. The hydrogen gas level in the charging room should be below two percent to mitigate possible risks of explosion. Installation of exhaust fans, or providing an opening in the roof of the warehouse, will further reduce this risk.

Acid-resistant flooring

The flooring of the charging rooms must be resistant to acid because battery acid is highly corrosive. Unfortunately, spills do happen, but if floor is acid-resistant the spill will be easier to clean up. Without acid-resistant flooring, the corrosive battery acids could result in structural damage to the warehouse.

Availability to safety equipment

All charging rooms should be fitted with a washing area and a Class E fire extinguisher. Forklift operators may need to be able to quickly extinguish an electrical fire, and/or perform an emergency wash. First-aid kits and personal protective equipment (apron, gloves and eye protection) should also be available in the battery charging rooms.

Correct installation of electrical breakers and charging points

Chargers should be mounted on the wall and fitted with an electrical breaker to stop the flow of electricity in an emergency. When charging multiple forklifts, the distance between each truck should be at least three feet. The distance between forklifts provides safe and easy access for operators.

At KION North America, we care about the safety and efficiency of your warehouse. Follow these four steps to make your battery charging rooms safer. If you’re looking to purchase an electric forklift, our Linde and Baoli brands offer solutions for every application. Have more questions? Contact us at 843-875-8000.

Three Tips to Improve Electric Forklift Battery Life

The majority of warehouses are making the switch from internal combustion forklifts to electric forklifts in order to reduce their carbon footprint. Electric forklifts, such as the Linde 346, produce zero emissions, have a longer economic life and more precise truck control than typical internal combustion forklifts. However, while electric forklifts are more efficient, they require proper maintenance; especially when it comes to the battery. Here are three ways to improve your electric forklift battery life.

Don’t over-charge

Flooded, lead-acid forklift batteries have a limited number of charge cycles. You should charge the battery after an 8-10 hour shift, or when it’s discharged more than 30 percent. Don’t charge the battery during lunch break, or “when it’s convenient” because it will reduce the battery’s lifespan. This kind of opportunity-charging requires a specific battery and charger combination that also needs formal training.

Check the water level

Water plays a pivotal role in the life of the battery, so make sure to check the fluid level of the battery every five charging cycles. The water should only be refilled once the battery is fully charged. Also, keep in mind that you only need enough water to cover the plastic battery element. For additional details, refer to the manual provided by your battery manufacturer.

Keep the batteries cool

Temperature is important in keeping your forklift battery healthy. For optimal operation, keep the temperature in the charging rooms below 113 degrees Fahrenheit (45 degrees Celsius). If the battery is overheated, the lifespan will be decreased, so you need to make sure that the battery is well ventilated when it’s charging and in use.

Follow these three steps to ensure a long battery life for your electric forklift. Check out our Linde and Baoli products if you’re looking to purchase an electric forklift, or contact your local authorized dealer. At KION North America, we understand the importance of an efficient forklift. Please contact us if you have any further questions at 843-875-8000.