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Forklift Education

Fallsway Equipment’s experts are leaders in their field. Find more about Forklifts, forklift accessories, and trends in the industry from our experts on our blog.

When to Replace Your Forklift Forks

Seemingly indestructible, forklift forks are often forgotten about when considering equipment maintenance and workplace safety. However, considering how much weight they lift, normal wear, and damage they endure every day, it is important to know how to inspect and when to replace your forklift forks.

If a damaged or worn-down fork is not noticed and replaced, it is in jeopardy of snapping and dropping the load, which would result in:

  • Damaged goods
  • Injure operator
  • Forklift downtime

Fork Inspection

Not only are regular inspections the best way to proactively avoid costly factors associated with work failure, but they are also required by OSHA and the Industrial Truck Standards Foundation (ITSDF).

Firstly, OSHA requires daily inspection of the condition of the forks as part of their Forklift Pre-Operational Inspection Checklist. ITSDF requires a yearly inspection, repair, and testing of forks done by a knowledgeable and trained individual (ANSI/ITSDF B-56.1).

When to Replace Forks

forklift fork breakdown

Damaged

Replace forklift forks when there is damage, including:

  • Surface cracks
  • Bent shank, blade, or hooks
  • Uneven blade height
  • Non-operational position lock

Wear

The constant loading/unloading of cargo and repositioning of forks will cause the metal on the blade, shank, and hooks to wear down over time. Harder to identify than damage, fork wear requires use of a caliper to determine if replacement is necessary.

How to Find the Wear of the Fork Blade:
Step 1: Set caliper by measuring thickness of fork shank
Step 2: Without adjusting caliper, position caliper over forklift arm blade (2” from inside of heel)

when to replace forklift forks worn down forks

If back teeth of caliper pass freely over blade of fork, replace the fork.
If back teeth of caliper hit the blade, the fork does not need replaced.

How to Find the Wear of the Fork Hooks:

when to replace forklift fork worn out hooks

With nearly 30% of forks failing to meet safety standards, inspecting and knowing when to replace forklift forks can save your operation significant time and money.

Schedule a FREE inspection or order forklift forks today!

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Turret Trucks

Turret Trucks what are

Before diving into why your operation should consider adding a turret truck to your fleet, the first order of business is answering the question, “What is a turret truck?”. Turret trucks are very specialized machines for very-narrow-aisle (VNA) applications. Immediately drawing attention due to its unique design, there are traditionally two options available, man-up, the more common option where the carriage and operator are lifted to retrieve and store pallets, and man-down, where the operator stays down while picking orders.

Increase Warehouse Capacity

Jungheinrich Turret Truck EKX5156k
Jungheinrich EKX516k

Is your operation limited because you don’t have enough room to store inventory? Turret trucks are designed to increase warehouse capacity by reducing aisle widths, thus making room for more aisles.  Since the forks are mounted on a smaller front mast that can rotate 180 degrees, the operator has access to both sides of the racking aisle without rotating the unit. VNA turret trucks can reduce aisle width by 50%. Save space and increase warehouse capacity with turret trucks!

Increase Productivity

With a pallet throughput 3x as high as the standard counterbalance forklift, no equipment can handle more pallets and loads than turret trucks. However, not only are turret trucks implemented in operations that are looking to increase volume and productivity, but also for those looking to cut costs. When turret trucks are added to a fleet, fewer operators are needed to produce the same output. Whether looking to increase productivity or cut costs, turret trucks are designed to optimize your operation.

Turret Trucks from Jungheinrich

Selling more turret trucks worldwide than Crown, Raymond, or Yale, Jungheinrich is your industry leader for quality and cost-savings. German designed, you will find unmatched energy efficiency, productivity, ergonomics, and intelligence in each Jungheinrich turret truck.

Energy Efficiency

Jungheinrich EKX man-up Turret Truck
Jungheinrich EKX Turret Truck

A pioneer in AC forklift motors, Jungheinrich has unmatched technology and the most experience relating to energy efficiency. For example, they are the only turret truck manufacturer on the planet that can guarantee two shifts (16 run hours) on one battery charge. Regardless if your operation is one or two shifts, you will need to charge your battery less frequently, resulting in a significant increase in battery life and cost savings. In addition, exclusively Jungheinrich offers reluctance AC motors, reducing energy losses by up to 50% when driving, steering, and using hydraulics. Energy efficiency saves you money, and none do it better than Jungheinrich.

Productivity

For Jungheinrich, performance is just as important as energy efficiency. Not only do they manufacture turret trucks with the highest reach on the planet at an impressive 708”, but put head-to-head against competitors, Jungheinrich is also more productive and has a higher lift speed. They work smarter so you can work harder. Enjoy unmatched productivity and performance with turret trucks from Jungheinrich.

Ergonomics

Jungheinrich EKX 516k turret truck controls
Jungheinrich EKX 516k

Turret trucks from Jungheinrich increase efficiency and performance through operator comfort and optimized design. Your operators are guaranteed to love the spacious operator compartment with extensive legroom and a full suspension seat with adjustable armrests. In addition to a flexible concept for comfortable sitting or standing, Jungheinrich also implements intuitive and comfortable operator controls.

Intelligence

Jungheinrich Warehouse Navigation is a form of semi-automation that uses RF transponders to pinpoint and navigate to the next order in the quickest time and using the least amount of energy. Implementing this technology could increase productivity by up to 25%. Warehouse Navigation can be to be integrated with your warehouse management system, eliminating operator errors and make every operator a top performer!

When choosing a turret truck, Jungheinrich is a clear choice. Experience the difference for yourself and demo against the competition. Not only will your operators love it, but the increase in productivity and cost savings will take your operation to the next level. Contact Fallsway today to find the perfect fit for your operation!

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Forklift Load Capacity

Safe forklift operation is essential for any business. An important detail to know when operating a forklift is the capacity of your forklift limit. Below we will explain what forklift load capacity is, as well as what you need to know to safely operate your forklifts. 

Safety is a top priority for any business owner and operators should:

Forklift operator training
  • be trained
  • know safety devices and functions of the lift truck.
  • use the forklift as intended to be used.
  • not drive recklessly.
  • space out forks properly.
  • never exceed the rated capacity of the forklift.

What is Capacity and How to Determine the Weight You Can Carry?

OSHA requires that ALL forklifts have an updated data plate that indicates information like capacity, load center, and maximum lift height. Loads can come in various shapes and sizes, not just symmetrical boxes. Forklift max capacity is determined by the load center of the product you’re picking up. 

Figuring out the maximum weight your forklift can carry, you must consider several factors.  The load size, position, weight distribution, and the stability of the truck all affect lifting capacity. As an example, if you have a 4,000-pound rectangular box standing up vertically, the forklifts load capacity will be higher than if it was positioned horizontally with the long end of the box overhanging the forks. That is why the center of your loads plays a critical part in determining the maximum capacity.

Risks to Exceeding Forklift Capacities:

Several life-threating hazards can occur if you go over the maximum capacity. Some included are:

  • Dropping the load.
  • Collision.
  • Loss of steering control.
  • Tipping over.

To avoid these hazards, operators should:

  • know where the forklift’s load capacity plate located.
  • understand a load’s weight, shape, size, and position.
  • have the heaviest part of the load closer to the mast.
  • keep the distance from the front wheels to the load’s center of gravity minimum.

Note that having different forklift attachments will change the characteristics of how each forklift will operate, including the load capacity. It is crucial to keep each data tag updated with each attachment and have operators understand the de-rated capacity of the forklift so they can know their limitations.

How to Locate Load Capacity Data

All forklifts have a load capacity data plate. They are usually within viewing distance when the operator enters the forklift, but this varies depending on the make and model of the forklift. The plate differs and may display some or all of the following information:

forklift data plate
  • General information like brand, model, serial number, and forklift type.
  • Information on components and parts: Tire type and sizes, mast type, and tire tread.
  • Forklift and battery weight.
  • Attachments in weight calculation.
  • Tilt degree.
  • Load capacity.
  • Load center distances.
  • Max lifting height.

Lift trucks with high masts will have a different capacity rating for the various heights; as an operator, you should refer to the manufacturer’s capacity plate for the mast height ratings.

Avoiding Load Capacity Issues

These are some of the basic rules you can follow to avoid running into forklift load capacity issues and creating a safer work environment.

  • Train operators to check load capacity plates and never make assumptions.
  • Never go over the forklifts stated load capacity.
  • Purchase equipment with load capacities slightly greater than you need for the job.
  • Instruct operators to read and follow instructions in the operator’s manual.
  • Make sure each forklift has the correct information and is legible to read.
  • Travel at a safe speed that will maintain control of the forklift with and without a load.
  • Keep the load at a safe traveling height of 2-4 inches from the ground. 

Increasing operator awareness and proper training will prevent accidents in the workplace. 

If you still have questions regarding your forklifts load capacity, contact one of our Forklift Specialists for assistance! 

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Snorkel Aerial Equipment

Snorkel aerial lift scissor lift boom lift

Who is Snorkel?

Founded in 1959, Snorkel started out as a firefighting equipment company that developed an aerial work platform specifically designed for aerial firefighting and rescue work. They quickly made a name for themselves in the industry, setting the standard for aerial firefighting equipment. About 20 years later, Snorkel entered the construction and industrial markets with its first telescopic boom lifts. Premiering the first aluminum upper booms and platforms in the industry, this new product line utilized technology from their firefighting equipment, including state-of-the-art hydraulic and electrical systems, to become an industry leader. Since then, Snorkel has continued to grow and currently manufactures aerial lifts of all types and sizes. Whether you are looking for a scissor lift or boom lift, Snorkel has you covered. Also, if you have a unique need, they work with you to provide a custom solution.

Snorkel Equipment

Snorkel has a wide range of equipment based on your specific needs and application.

Snorkel scissor lift aerial lift

Scissor Lifts

Choose from a full line of scissor lifts suitable for indoor and outdoor applications. Ranging from low-level, rough terrain, or electric, the Snorkel line of scissor lifts spans maximum working heights from 12 ft. 6 in. to 45 ft. and maximum platform capacities from 500 lbs. to 1,500 lbs.

Snorkel Boom Lifts Aerial Equipment

Boom Lifts

Whether you are looking for articulated, electric, telescopic, or towable, the Snorkel family of boom lifts combines power and precision for efficient working at height. Ranging from 41 ft. 9 in. to 132 ft. in maximum working height, and maximum platform capacities ranging from 425 lbs. to 600 lbs., there is a Snorkel boom lift for almost any application.

Snorkel and Fallsway: A Perfect Pair

Snorkel and Fallsway are the perfect pair. For starters, we were both established in 1959, currently celebrating our 60th year in business! This is not simply a neat coincidence, but it also shows both Fallsway and Snorkel have the knowledge and experience to provide solutions to even the most difficult problems. If you have ever done business with Fallsway in the past, you know firsthand the pride and trust we have in the products we offer. Not only does Snorkel offer a product that is unmatched when it comes to quality and value, but they also provide first-class support for service and parts.

Contact Fallsway today to learn how your operation can benefit from the high-quality materials and ergonomic designs only offered by Snorkel.

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Jungheinrich EZS 7280NA

Jungheinrich Tow Tractor | Tugger

Jungheinrich EZS 7280NA: Electric Tow Tractor (Tugger)

With a compact durable design, the all-new 64,700 lb. capacity electric tow tractor from Jungheinrich is designed for towing heavy-duty loads in any industry. Enjoy a small turning radius, high performance when moving on ramps, an ergonomic workstation, corrosion protection, and energy efficiency while transporting heavy loads across the airport tarmac or industrial facility. Learn more about the Jungheinrich EZS 7280NA tugger and why it might be a great fit for your operation.

Productivity

Tugger Towing Tractor | Jungheinrich

The EZS 7280NA reaches speeds of 15.5 mph (unloaded) and 7.5 mph (loaded). This allows your operators to quickly and effectively get where they need to go.

Designed to make life easy on your operators and save time, the touch mode feature makes it easy to attach and detach trailers.

Have ramps or inclines? No worry, the EZS 7280NA tows up to 9.5 tons, 21,000 lbs., on 10% grade ramps.

All parts and components are easily accessible; therefore, it is easier and faster to service.

Safety

The Jungheinrich EZS 7280NA provides maximum productivity without sacrificing safety.  

Jungheinrich Tow Tractor Tugger

Driver Visibility – Enjoy a clear driving view with minimal blind spots. Also, cutouts on the rear panel provide an excellent view of the coupling.

Automatic Parking Brake – The tow tractor and trailer are secured automatically when it stops. 

Hill-Start Assist – While on a ramp or incline, start without any roll-back. Paired with anti-skid control (ASC), you are ensured smooth, reliable acceleration in the toughest situations.

curveControl – This option automatically reduces speed while turning corners avoids tipping and ensures control over the load.

Energy Efficiency

The EZS 7280NA comes with proprietary 3-phase AC technology from Jungheinrich, thus consumes less energy, extends the battery life, and increases run times.

For 24/7 operations and high usage applications, the Jungheinrich EZS 7280NA has an XL option, which enables a larger battery size. As a result, there will be an increase in performance and energy efficiency.

Ergonomics

Ergonomic workstation features several designs implemented with the operator in mind, such as:

  • Automotive-style interior and operation with foot-pedal and adjustable steering column
  • Spacious cabin with an optimum all-round view, including great visibility of the coupling from the operator’s seat
  • Low entry step with level foot-well
  • Outlet vents that prevent fogging            

Total Cost of Ownership

Across its product line, Jungheinrich implements productivity features, energy and awareness designs, ergonomics, and uptime to minimize the total cost of ownership. The Jungheinrich EZS 7280NA is no different. Save time and money with 1,000-hour service intervals.

If you are looking to take the total cost of ownership even lower, consider getting it with the lithium-Ion package.

  • Fast charging with no need for battery exchanges
  • Maintenance-free and no odors from gases or acidification
  • Longer service life
  • Charging can be interrupted at any time without damage to the battery
  • 5-year battery warranty

Specs:

Model Basic Capacity (lbs) Voltage Length To Fork Face Chassis Width (in) Chassis Height (in) ¹ Gross Weight (lbs) ¹
EZS 7280NA 61,700 80 118.2 51.2 77.6 9,000
EZS 7280 NA XL 61,700 80 130 51.2 77.6 10,500

Contact us or learn more about the Jungheinrich EZS 7280NA tugger and why it might be a great fit for your operation.

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What to Know When Buying Forklift Tires

Today, fleet owners are offered a large variety of types, sizes, and application-specific lift trucks that serve a specific purpose. Equipment choice ultimately factors into the overall throughput, efficiency, and safety of the operation. When it comes down to it, the choice of tires for the forklift can be one of the most influential factors in efficiency and operating costs for that machine at the application. Here are some of the key points when picking the right forklift tires:

Cushion or Pneumatic Forklift Tires?

The type of tires your forklift has been specifically designed for the surface that the machine will be operating most efficiently on, so choosing the right tire will impact your machine’s maximum performance.

  • Cushion Forklift Tires
    These forklift tires should only be operated on smooth concrete surfaces, most commonly at indoor working facilities, and are typically smaller than comparable capacity pneumatic models.
  • Pneumatic Forklift Tires
    Forklift with pneumatic tires can work indoors and on outdoor surfaces like blacktop, stone, or dirt, but not on rough terrains like fields or severely unsurfaced lots. These tires have a wider versatility of where they can be operated on, thus giving them higher resale value.

Tire Tread & Profile Style

Not only are there different types of forklift tires, but there are also different treads and profile styles you can get with your forklift. Depending on the application it is driven on, the terrain will affect the tread or profile style you may need. Available options include:

  • Smooth Tires – Typically for dry indoor applications and all steer axles.
  • Traction Tires – A general-purpose use in a wide variety of forklift applications.
  • Grooved Tires – Designed for larger-capacity trucks where loads and operating conditions are extreme.
  • Wide-Track Traction Tires – All-season indoor or outdoor use forklift tire.

The quality and consistency of material are also major factors when determining tire performance. If you want your tires to last longer and perform better, determine the correct tread and profile style for maximum efficiency.

For help with selecting the right forklift tires for your application, contact us at 330-633-6000.

Originally published 7/20/2018
Updated 5/21/2019

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When to Replace Forklift Tires

It is important for every operation to know when to replace their forklift tires and what signs indicate the need for new tires. If they are replaced too soon, you are not getting your money’s worth and decreasing operational profitability. However, replacing forklift tires after the wear limit will result in any of the following:

  • Operators noticing lower speeds and reduced ride comfort
  • Increase in maintenance costs
  • A lower ground clearance and reduced lifting height on the forklift
  • Loss of load capacity, causing accelerated wear and overheating

Variety of Forklift Tires

The first reference to look at when looking to replace lift truck tires is the forklift tire operator’s manual, provided by your forklift tire manufacturer. This is a helpful tool that covers wear limits and the proper time to change your tires. Along with following the manual, there are additional signs that show when it is time to replace old forklift tires.

Wear Indicator Bar

There is a significant amount of forklift tires that come with a wear bar molded into the tire’s sidewall. This indicator becomes visible as the rubber tread wears out – a clear sign that your forklift tires need to be replaced.

Manufacturer Name

Looking for a quick eyeball test to determine if tire replacement is needed? Most tires have the name of the manufacturer molded into the sidewall. Generally speaking, when the tire wears to the top of the nameplate, it should be replaced.

Tire Deformities

A forklift tire needs to be replaced when there are unusual appearances on your tire. These appearances include:

  • Chunking & Tearing – When pieces of the forklift tire are falling off or there are parts tearing.
  • Splits or Cracks – When radial splits or cracks appear on the sidewall of the tire.
  • Non-Round Spots – When flat spots appear on the forklift tire.

Not 100% sure that your tires need replaced? Contact Fallsway today for a free forklift tire inspection by a forklift expert.

So your forklift tires do need replaced…

Next, you need to choose the right type of forklift tire for your machine. Learn what you need to consider when deciding what type of forklift tire suits your application and needs.

Originally published 10/1/2018
Updated 5/16/2019

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Jungheinrich EKM: Small Parts Order Picker

Fallsway Mirrored Warehouse Banner

Designed to be an alternative to a traditional ladder, the new Jungheinrich EKM 202 small parts order picker is a must-have. This forklift is typically used in applications that require order picking without a pallet, light maintenance, or retail outlets. But what makes the EKM unique to other Jungheinrich order pickers?

Ergonomics:

Jungheinrich EKM 202 Small Parts Order Picker

This Jungheinrich EKM 202 is equipped with many features that benefit the operator’s comfort and safety. The EKM comes with a generous workstation that provides the operator comfort while driving and standing sideways to remove goods. The stand-on platform can be freely selected with the equipped sensor mat on the floor, providing maximum mobility in the workstation area. There is also an easy-to-use travel switch located on the right handles thumb position. While operating the EKM small order picker, the operator will feel safe and comfortable.

Productivity:

Jungheinrich EKM 202 Small Parts Order Picker at Ground Level

To make your job easier while operating, the EKM comes with a variety of options. The AC drive has a max speed of 5 mph to get you between jobs faster. It comes with two sorts of trays, a lower and upper tray for added storage and working space. Additionally, with the maintenance-free, 192-amp-hour battery, you’ll experience less downtime and more usage out of your machine. And when you run out of battery, connect the onboard charger to the closest wall outlet for an easy charge.

Awareness:

Elevated Jungheinrich EKM 202 Small Parts Order Picker

The Jungheinrich EKM has many factors that increase the operator’s awareness while on the job. The sturdy mast gives the order picker added stability even at max heights. The operator can feel safe in the compartment with automatic closing doors so the operator can only lift the platform when closed. Another great feature with this forklift is the adjustable storage tray that can add extra visibility and additional comfort while at elevated heights.


Want to learn more about the Jungheinrich EKM 202 small order picker? Contact us at 855-662-4379 for a quote!

Updated 5/23/2019

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Forklift Classes: What You Need To Know

Multiple Forklift Drawings on Blue Strip Background

Forklift classes can get complicated, whether you have been working in the material handling industry your entire life or as a novice forklift operator. We created this guide to help you decide which forklift class is most important for your business or application.


Electric Motor Rider Trucks Class 1 Banner

Class I forklifts have electric motors and allow operators to operate them while standing or sitting. They use a heavy battery as their primary power source, which also serves as the counterbalance for the lift truck.

With options for either cushion or pneumatic tires, these trucks are highly versatile for any application. Pneumatic-tire models are intended for applications with uneven surfaces, like gravel, while cushion-tired trucks are best suited for flat, indoor surfaces like warehouses or large retail stores. Some benefits include being quieter, reduced fuel costs, usage in strict air quality applications, and lower maintenance costs.

Class I forklifts include CAT counterbalanced forklifts, Mitsubishi counterbalanced forklifts, and Junheinrich counterbalanced forklifts.

Electric Motor Narrow Aisle Trucks Class 2 Banner

Class II forklifts have solid, cushion tires and are engineered specifically for smaller, indoor work environments. Several of these forklifts perform a specific job, designed with specific attachments.

The concept behind Class II forklifts is to increase the efficiency of space and speed of operation. Such forklifts include side loaders, order pickers, turret trucks, and reach trucks.

Electric Motor Hand or Hand & Rider Trucks Class 3 Banner

Class III forklifts, such as Mitsubishi walkies and Jungheinrich stackers, effectively transport products in the warehouse or retail stores at low lifting heights, either out of trailers to low-level racking or out to the retail floor.

These electric hand trucks are commonly used in applications that don’t require long distances or high lifting heights such as stores, small warehouses, or loading/unloading small trailers. Class III forklifts are controlled by a handle located in the back of the truck, hence being called an electric motor hand truck. The handle controls the speed, steering, and lifting.

Internal Combustion Engine Trucks & Cushion Tires Class 4 Banner

Class IV forklifts are commonly used to move goods from loading docks to elevated storage areas. They can be used outdoors but are favored in indoor warehouses due to their adverse traction on wet or uneven surfaces. Also, they are lower to the ground than most forklifts, providing a lower clearance.

Class IV forklifts operate on diesel, gasoline, LP gas or compressed natural gas. This class of forklifts is specific for equipment with cushion tires, which are designed to be driven on dry, smooth surfaces. Class IV forklifts include internal combustion, cushion tire CAT forklifts and Mitsubishi forklifts.

Internal Combustion Engine Trucks & Pneumatic Tires Class 5 Banner

Just like the forklifts in Class IV, these lift trucks use the same type of fuel but they utilize pneumatic tires and have a wider range usage. Class V forklifts include internal combustion, pneumatic tire CAT forklifts and Mitsubishi forklifts.

Pneumatic tires are designed for rugged applications, thus allowing it to be used on uneven surfaces like gravel, but they can also be used in indoor applications as well. They can be outfitted with special solid tires that reduce the chance of punctures. Class V forklifts are commonly used in outdoor applications like lumber yards, metal fabrication, stone yards, and industrial machinery.

Electric & Internal Combustion Engine Tractors Class 6 Banner

Particularly designed for pulling rather than lifting, Class VI forklifts are normally called “Tuggers.” Commonly used at airports, lugging baggage carts between terminals and planes, these lift trucks come in both internal combustion and electric choices.

An example of the Class VI forklift is the Jungheinrich EZS 720NA tow tractor.

Rough Terrain Forklift Trucks Class 7 Banner

Class VII forklift trucks are heavy-duty and typically have large tractor-like tires. These trucks are commonly used on applications that require additional power on rough terrains, like lumber yards or construction sites. This class of forklifts exclusively run on diesel and come in two and four-wheel drive options.

Also, they can have different types of masts, including a telescoping mast to give more reach. Other options for this class can be mounted on the back of large trucks and hauled between job sites.

Class VII rough-terrain forklifts examples include:


Do you have questions about what class of forklift would best fit your application? Give us a call at (855)-662-4379.

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OSHA Forklift Pre-Operational Inspection Checklist

From a single forklift to a whole fleet, a pre-operational inspection of your equipment is necessary on a daily basis. This OSHA Forklift Pre-Operational Inspection Checklist will help keep your equipment, workers, and company safe from any potential harms. Continue reading »

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