Brake maintenance. Brakes and all related components represent one of the most importantl systems for the safety of any vehicle. What is their function and how to comply with adequate maintenance?
Brake maintenance. How do the brakes work and how is adequate maintenance complied with?
Brakes and attachments are fundamental components for moving vehicles. Their main aim is to convert the physical pressure exerted by the user on the brake pedal.
One of the fundamental components of the brake “system” is the master cylinder. It is easy to understand how much the quality of the brake pump is of primary importance to guarantee the best performance of the vehicle. The material with which a brake master cylinder is produced must be resistant to wear, must be safe and must guarantee very high standard levels.
In this regard, the use of cast iron and steel ensure the seal of the component over time. Aluminium could also be used, which make brake pumps lighter, but still resistant and able to guarantee the same performance.
Brake maintenance. How is security maintained
Tamarri S.r.l has always been involved in forklift safety. More and more frequently there are reports of accidents at work due to poor and “distracted” maintenance. Too often we are informed of accidents because maintenance has not been expected by competent and specialized personnel.
Regarding this, it is essential to do a regular and accurate monitoring the operation of the vehicle. A detailed analysis follows and the subsequent replacement of the worn part with the new one. To ensure that the analysis is always timely, many companies have already specialized in predictive analysis of the medium.
In the field of safety, why are the brake pumps of a forklift truck a fundamental element?
The brake pumps are very important, not only for the performance of the vehicle, but above all to safely manage the various activities.
Anyone who has had anything to do with forklifts will have noticed that. As time passes, there is less and less precise braking of the forklift. This is due to the loss of tightness of the internal rubber pads.
But why do the rubbers tend to decrease their hold? In several years, it is normal for the rubber pads to undergo normal wear. Furthermore, their duration is closely linked to the operator’s driving style.
For example, the habit of abruptly braking or the tendency to keep the foot lightly resting on the brake pedal, are all attitudes that represent a threat to the life of the rubber pads. If the grommets are worn out by some bad practice, the pump itself will also suffer the consequences.
Brake maintenance. What are the alarm bells for noticing brake wear?
It is not difficult to notice that the brakes are starting to wear out. Just keep an eye and monitor the vehicle often in order to check it. The punctuality of the forklift braking takes place in a decidedly less efficient way.
When the problem gets worse, you will notice that the brake pedal goes down empty. At this point the situation is worrying and the forklift is no longer safe: all that can be done is to stop it and ask for help from technical assistance.
How can the problem be solved?
It is essential not to underestimate the signs of malfunction and to know how to promptly remedy this malfunction. To prevent an inconvenience from turning into a serious risk for the operator and pedestrians, it is essential to resort to a specialized technician.
If the technician deems it necessary to replace the brake master cylinder, he will intervene directly at the customer’s site. In fact, the sealing rubbers are not easily replaceable by anyone because they are located within the single central block. Therefore it is an operation that requires about 2 or 3 hours of specialized work of a competent technician.
Forklift maintenance: a commitment to safety
Monitoring the operation of the forklift means making a daily commitment to ensure safety at work.
If you are looking for spare parts for the entire braking system, made to ensure resistance over time, excellent quality and delivered in a very short time (24/48 hours), Tamarri S.r.l is the company for you!
We have the best products on the market: safe, tested and CE marked, to guarantee our customers the highest quality standard in the industry. 🙂
Industrial IoT: five objectives to achieve within 2021 by elaborating datas in a comptetent way
Industrial IoT: Let’s clarify the data reading
Often due to the difficult interpretation, some entrepreneurs do not fully exploit what can be obtained from data and the value they can generate. A value often not clearly identifiable. Let’s try to clarify.
We assume that data is increasingly a strategic asset for any business. So it is clear that knowing how to decode them, understand them is important to be able to activate an entrepreneurial policy that takes into account their forecasts, which will make the difference.
Let’s analyze five aspects that are able to make the company competitive. These are extremely concrete aspects that can be achieved during the year. How? With a correct and competent analysis of the data generated by machinery through Industrial IoT solutions.
Five objectives for a competitive company
1. Ordinary maintenance
OEMs, i.e. Original Equipment Manufacturers (original equipment manufacturers) play a key role right now. To concretely assist their customers by encouraging rigorous and constant maintenance.
How? They Decline their know-how to the analysis of diagnostic data collected over time. This activity, which should become a real program, will produce value over time that will lead to an increasingly predictive, precise and effective analysis.
2. Know your customers
The analysis of data from IoT is a fundamental tool in order to learn about the machine life. Through the data it is possible to understand if the operators are using them correctly and how and when maintenance is done
This is how you can understand if there is room to use them even better to achieve maximum efficiency and therefore full customer satisfaction.
3. Predictive problem analysis
Accessing the data allows greater proactivity towards the customer because it allows you to act before the assistance channels are activated.
How? By equipping the after-sales service with the tool able to monitor the connected machines. By doing so, it is possible to identify in time critical and alarming situations, unsafe working conditions or major failures
4. To Understand concretely how to improve the machines
Thanks to the correct use of analytical data it becomes less complex to understand how to improve the product in terms of mechanics and engineering. The technical and R&D department itself can also benefit from this.
5. Be more proactive towards the final customer
For every company is foundamental the need of manufacturers, which is to capitalize on product know-how effectively, thus improving knowledge of the machinery.
Only by doing so it will be possible to be closer to customers, with the common aim to increase and finalize the productivity and competitiveness levels.
To achieve this virtuous circle, an effective paradigm is to offer training on maintenance and process optimization, offering the possibility of remote diagnostic assistance and new methods of guarantees.
Tamarri S.r.l. is able to provide a complete solution in this area: discover our SMARTPASS 4.0 EVO platform for the complete management of the vehicle in cloud.
The law that regulates forklifts can be a perfect vademecum for the owner of the machine and for a right risks analysis.
The legislation that regulates forklifts: a supervision tool
Whoever owns a forklift must comply with the maintenance activities and the safety checks that must be done on the forklift by law until the end of its working activity.
The need for an efficient and safe fleet for those working in this sector is increasingly strong and shared by the companies that deal with handling.
In Italy the legislation relating to forklifts and equipment in the sector is governed by very strict and precise rules aimed at the builder, the distributor, the user and the assistance service. This is a sector which can lead to serious workplace injuries if not well protected.
That’s why this is a particularly sensible sector for security.
The precautionary and scheduled maintenance is an essential task for a periodic and efficient check of the forklift. It’s important to ensure the optimal operation of all its main components, from the brake assy to the mast, unti the control system
Decrees and circulars governing forklifts
Let’s see together just a bunch of the most important decrees that govern the forklift sector. Among these, the only law that has been revised and now outdated is the 1955 D.P.R 547. These law dealt with the prevention of workplace injuries and represented a fundamental reference both for builders and users
Despite the fact that this law is outdated because the machines have evolved, it’s still an important reference point for builders and all the operators in the sector.
The other decrees and circulars relating to handling equipment provide information both to manufacturers and employers and also to the operator who uses it.
In particular, the D.L. 304 of 10 September 1991 which indicates the technical specifications and tests to be performed on the forklift, in compliance with Community directives 6/663 and 89/240.
Aimed to the manufacturer is also the 24th of July 1996 D.P.R 459 (machines guideline) which, again with reference to EU directives, protects the safety criteria, the health of the operator and the requirements of the environment in which the forklift operates. And again the D.I.R. 73/23 which defines the requirements of the electrical equipment supplied by the manufacturer.
Particularly important is the Circular 8/2001 of the Ministry of Industry – Forklifts in order to reduce the still widespread risk of accidental overturning of the forklift.
Laws that regulate the equipement
As we said the decreed doesn’t regulate only the dispositions related to the forklift but also the equipement. It’s aimed to the employer and also to the worker the 19th September D.L 626/94, the genera law that protect workplace safety.
Not only safety checks to be carried out on the truck with the obligation to provide the instructions for use, but also periodic and constant checks of the safety devices, lifting chains, forks, protective screens of moving parts, plates identification. Therefore, Law 626 in Article 35 paragraph 4 letter c extends the obligation of periodic maintenance to all equipment as well.
So it is for the D.I,R 95/63 that defines the minimal safety and health requirements during the use of the work equipement the the employer mast adopt. Also the safety instructions that the operators must adop.
For a controlled and shared verification with the Supervisory Authorities over a period of 5 years from the date of the last registration or until the decommissioning, the Legislative Decree 359 of 4 August 1999 requires the employer to carry out periodic checks and record the results. The document produced will “follow” the machine wherever it is used.
Naturally, some circulars such as Circular 3/2001 of the Ministry of Labor “remind” the periodic checks to be carried out on forklifts and related accessories.
For further clarity, the D.L. 81/08 (Article 71 paragraph letter a and letter b) quotes:
“A) the equipment is subject to suitable maintenance in order to guarantee the permanence of safety requirements over time”
“B) the maintenance and updating of the work equipment control registers are taken care of”.
Control and verification of lifting machines
The lifting devices represent the crucial part of the entire forlift at a functional level, therefore also with regard to operator safety. In particular, the control of the chains is regulated by the D.P.R. 547 of 1955 (Article 179). This article states that they must be checked every three months.
It is imperative to replace them promptly if there is a condition of wear or an elongation that exceeds the measure indicated by the manufacturer.
For this it will be advisable to check the length of the chains through the appropriate precision instruments such as gauges or millimeter lines.
Finally, the control of the hydraulic pipes must be performed at least once a year and is regulated by the circular of the Ministry of Labor of 1 February 1979 no. 9. The circular provides for a visual analysis of the state of the pipes and their fittings. It also establishes that the pressurized pipes must be replaced at least every 2 years.
Tamarri S.r.l. : a competent partner
Nel prossimo articolo ci occuperemo della manutenzione e smaltimento delle batterie da trazione, e della formazione del personale che opera nel complesso settore dei carrelli elevatori.
In the next article we will deal with the maintenance and disposal of traction batteries, and the training of personnel working in the complex forklift sector.
Tamarri S.r.l. is a competent partner that has always been committed to the protection of safety. We are always available to help you better understand the legislation and to provide you with the tools you need to comply with the regulations in force. Calipers, millimeter lines, and even chain cutters and other precision tools, all at your disposal! 😉