Why is Forklift Maintenance Important?

Regular forklift maintenance is important if you want your forklift to operate at its best. Regardless of the model—be it high-reach, all-terrain, or anything else—staying on top of all the moving parts will ensure your team can work safely and efficiently. Want to find out more? Keep reading this blog from the team at Triwest. 

Why Bother with a Forklift Maintenance Plan

Think of a forklift maintenance plan as a roadmap for your forklift’s health, guiding you through the essential checks and maintenance tasks. It’s your secret weapon for maximising your investment and minimising downtime. A well-thought-out plan ensures your forklift stays in tip-top condition, boosting efficiency, safety, and longevity. Here are the forklift maintenance benefits: 

• Pick up on issues early: Having your forklift checked by an experienced technician is key because it will help you catch any potential issues before they get out of hand. This can relate to the motor, the battery, the forks, and all other machine components. Finding problems early can save you a lot of money in the long run, as you can avoid replacing expensive parts altogether. Instead, you may get away with a simple oil change or re-tuning. 
• Prevent accidents: Preventing accidents should be at the top of everyone’s priority list. The good news is that you can limit risk by having your forklift serviced regularly. This is crucial because forklifts are heavy, powerful, and fast, making them potentially lethal. Regular inspections and a thorough forklift maintenance checklist help ensure that all safety features are in working order, protecting your operators and your business.

• Boost productivity: It’s no secret that you need your machinery to work well to run a successful business. With this in mind, it makes sense to prioritise forklift maintenance. The reason is that forklifts that are properly looked after will be able to produce better results. Your team will be more efficient, and you won’t have to worry about breakdowns or costly delays getting in the way of your daily operations. After all, how would your business manage if all your forklifts suddenly stopped working? 

• Reduce wear and tear: Forklifts are made to lift heavy loads, which is taxing work (even for a machine). As a result, your forklifts will experience wear and tear, impacting productivity and compromising safety. For instance, brake pads can become less responsive, acceleration can suffer, and hydraulic strength can diminish with time. A professional service will consider all of these issues, and the work performed will help prolong your machine’s life. 

Creating Your Forklift Maintenance Plan

Don’t stress; creating a forklift maintenance schedule is easier than you think. . Follow these simple steps, and you’ll be well on your way to a well-maintained forklift:

1. Risk Assessment: Identify potential hazards and risks associated with your forklift operations. Consider the environment, the types of loads your forklift handles, and any previous maintenance issues you’ve encountered.
2. Manufacturer’s Recommendations: Check your forklift’s manual for recommended maintenance intervals and tasks. This will give you a good starting point for your schedule.
3. Your Unique Needs: Consider your forklift’s usage, operating environment, and age. These factors will influence how often your forklift needs maintenance. A forklift working long hours in a dusty environment will likely need more attention than one used less often in a clean warehouse.
4. Schedule It In: Create a calendar or spreadsheet to make forklift maintenance schedule tasks, inspections, and servicing. Be sure to include daily, weekly, monthly, and annual checks.
5. Check It Off: Use a forklift truck maintenance checklist to ensure all tasks are completed thoroughly and consistently. This will help you stay on top of your maintenance schedule and identify any potential issues early on.

A good maintenance plan is a living document. Review and update it regularly to stay relevant to your changing needs.

The Importance of Preventative Forklift Maintenance

Preventative forklift maintenance involves addressing potential issues before they become major problems. This proactive approach can save you a lot of money on forklift maintenance costs in the long run.

Here’s what preventative maintenance typically includes for both electric forklift maintenance and diesel forklift maintenance:

• Inspections: Regular inspections by a qualified technician are key to catching potential problems early on. They’ll check everything from the engine and brakes to the hydraulics and electrical systems.
• Fluid Changes: Oil changes, coolant flushes, and hydraulic fluid replacements are all part of the regular maintenance routine. These simple tasks help to keep your forklift’s internal systems running smoothly and efficiently.
• Filter Replacements: Clean filters are essential for optimal performance. Your forklift maintenance schedule should include regular replacement of air, fuel, and hydraulic filters.
• Lubrication: Lubrication keeps your forklift’s moving parts happy. Regular greasing and oiling can prevent wear and tear, reducing the risk of breakdowns and costly repairs.
• Forklift Battery Maintenance (Electric Forklifts): Battery maintenance is crucial if you’re running an electric forklift. This includes checking electrolyte levels, cleaning terminals, and following proper charging procedures to ensure your battery stays in tip-top shape.
• Diesel Forklift Maintenance: Additional maintenance tasks for diesel forklifts might include checking and adjusting the fuel injection system, inspecting the exhaust system, and cleaning the cooling system.

Forklift Maintenance Service Frequency

Forklifts need regular check-ups to stay in tip-top shape. The frequency of your forklift maintenance schedule depends on a few factors. The golden rule is to follow the manufacturer’s recommendations. They’ll have specific recommendations for service intervals based on the model, type, age, and frequency of use. Following these guidelines is important to keep your warranty valid and ensure your forklift gets the right care at the right time.

• Daily: Use your trusty forklift maintenance checklist to give your forklift a quick once-over before each shift. Check for any obvious damage, leaks, or warning lights.
• Every 50-200 Hours: Schedule a basic service for oil changes, filter replacements, and a general inspection. Your forklift truck maintenance checklist will ensure you don’t miss a thing.
• Every 500-1000 Hours: Time for a more in-depth service. This includes thoroughly inspecting all major components, like the engine, transmission, and hydraulic system. For electric forklifts, this is also a good time to check the forklift battery maintenance and make sure it’s in good condition.
• Annually: A yearly service is like a full body check-up for your forklift. A qualified technician will perform a comprehensive inspection and any necessary repairs to ensure your forklift is compliant with safety regulations and ready for another year of hard work.

Keeping it Legal with Forklift Maintenance Requirements

Worksafe Victoria has rules and regulations regarding forklift maintenance in Melbourne, and it’s important to follow them to avoid any unwanted surprises. Think of them as the road rules for your forklift, keeping everyone safe and your business in good standing. Here are the forklift maintenance requirements:

• Regular Inspections: Worksafe Victoria requires all forklifts to be inspected regularly by a competent person. This includes daily pre-operational checks using a forklift maintenance checklist and more in-depth inspections at specific intervals, depending on the type of forklift and its usage.
• Maintenance Records: You need to keep detailed records of all forklift maintenance activities, including the date, the tasks performed, and any worn-out parts replaced, adjusting the brakes, or even taking the forklift out of service until it’s safe. This helps track your forklift’s maintenance history and ensures you’re meeting the forklift maintenance requirements set out by Worksafe Victoria.
• Qualified Technicians: A qualified technician should perform repairs or major maintenance tasks. This includes knowing how to operate the forklift and identify potential problems safely. This ensures your forklift is serviced correctly and safely, minimising the risk of accidents and breakdowns.

What to Expect During Forklift Tune-Up Time

Every forklift, whether a nimble electric model or a powerful diesel forklift, needs some TLC to keep it in top shape. Here are some of the most common forklift maintenance tasks that our expert technicians tackle:

• Fluid Checks & Changes: Your forklift needs regular fluid checks and top-ups like your car. This includes engine oil (for diesel and LPG forklifts), coolant, hydraulic fluid, and transmission fluid. Keeping these fluids fresh and at the right levels ensures smooth operation and prevents costly damage.
• Filter Replacement: Your forklift needs clean filters to perform at its best. Regularly replacing air, fuel (for internal combustion forklifts), and hydraulic filters is a must on your forklift maintenance checklist.
• Brake TLC: Regular brake inspections, adjustments, and replacement of worn-out pads or shoes ensure your forklift stops safely and smoothly every time.
• Tyre Check: Tyres wear down over time, especially with heavy loads and frequent use. We’ll check for wear and tear, ensure they’re inflated to the right pressure, and recommend replacements when necessary.
• Mast & Chain Check-Up: The mast and chains are the backbones of your forklift. We’ll make sure they’re properly lubricated, aligned, and free from damage to ensure safe and efficient lifting operations.
• Electric Forklift Maintenance: If you’re using an electric forklift, we’ll give your battery the attention it deserves. This includes checking water levels, cleaning terminals, and making sure it’s charging properly to ensure optimal performance and lifespan.

Monthly Forklift Maintenance 

Think of monthly maintenance as a regular doctor’s visit for your forklift. It’s a chance to catch any minor issues before they become major headaches, ensuring your forklift stays in peak condition and avoiding unexpected downtimes. Here’s what you should include in your monthly forklift maintenance checklist:

• Visual Inspection: Give your forklift a thorough once-over, checking for visible damage, leaks, or loose parts. Look for cracks in the chassis, worn hoses, or anything that looks out of place.
• Fluid Check and Top-Up: Your forklift needs its fluids topped up regularly. Check the engine oil, coolant, hydraulic fluid, and transmission fluid levels and top them up to the manufacturer’s recommended levels if they’re low.
• Tyre Pressure and Condition: Tyres are essential for safety and performance. Check the tyre pressure and look for signs of wear and tear, such as cuts, punctures, or uneven wear. If necessary, inflate or replace tyres to ensure optimal traction and stability.
• Battery Inspection (Electric Forklifts): If you’re running an electric forklift, checking the battery regularly is crucial. This includes checking the electrolyte levels, cleaning the terminals, and charging the battery properly. Proper forklift battery maintenance can extend the life of your battery and prevent costly replacements.
• Operational Check: Take your forklift for a spin and test the brakes, steering, lights, and horn to make sure everything is working properly.

Annual Forklift Maintenance

While monthly checks are essential, a more comprehensive annual service is also crucial to keep your forklift in peak condition and comply with forklift maintenance requirements. Here’s what’s included in a yearly forklift maintenance service:

• Detailed Inspection: This involves a more thorough inspection of all major components, including the engine, transmission, hydraulic system, brakes, and electrical system. This helps identify potential problems that may not be obvious during a routine check.
• Lubricate Moving Parts: Lubricate all moving parts, including the mast, chains, and axles, to reduce friction and wear. This can significantly extend the lifespan of your forklift and prevent costly repairs.
• Make Necessary Adjustments: Your technician will make necessary adjustments to ensure your forklift operates at peak performance and efficiency. This might include adjusting the brakes, steering, or engine timing.
• Replace Worn Parts: Any worn or damaged parts will be replaced to keep your forklift running smoothly and safely. This could include replacing filters, belts, hoses, or brake pads.

Following a regular maintenance schedule and conducting monthly and annual checks, you can maximise the lifespan of your forklift, prevent forklift maintenance cost breakdowns, and ensure the safety of your operators. 

Forklift Maintenance Checklist

A well-structured forklift maintenance checklist is your trusty companion for keeping your forklifts in peak condition. Think of it as your forklift’s personal health tracker, a roadmap to a long and productive life. It’s a simple, step-by-step guide that outlines all the essential checks and maintenance tasks you need to perform to keep your forklifts running smoothly and safely. This checklist is your first line of defense against costly breakdowns and unexpected repairs. By following it diligently, you can identify potential issues early on, saving you money in the long run. Whether it’s checking the fluid levels of your diesel forklift or ensuring the battery of your electric forklift is in good condition, this checklist covers all the bases. Check out our blog post about the forklift maintenance checklist for a comprehensive guide.

Worried about the lifespan of your forklifts? Triwest offers a reliable forklift maintenance service to customers across metropolitan Melbourne and regional Victoria. With over 40 years of experience, we deliver standout results so you can operate with confidence at all times. Speak to us about our forklift support services by calling 1800 874 937 or complete a contact form and we’ll get back to you as soon as possible.