Value of Regular Forklift Maintenance (Checklist Inside)

Regular maintenance of forklifts is paramount for several reasons. Firstly, it ensures the safety of operators and others in the vicinity. Regular checks mitigate the risk of accidents caused by equipment failures, such as brake malfunction or hydraulic leaks.

Secondly, consistent maintenance enhances the longevity and reliability of the forklift, ensuring it operates efficiently for a longer period. This reliability is crucial in maintaining productivity and avoiding costly downtimes. 

Additionally, well-maintained forklifts are more fuel-efficient and environmentally friendly, reducing operational costs and environmental impact. Lastly, adhering to a maintenance schedule ensures compliance with legal and safety standards, avoiding potential legal issues and fines. Thus, regular forklift maintenance is an important aspect of responsible and cost-effective equipment management.

How To Perform Regular Inspections of Your Forklift

Performing regular inspections of your forklift is essential for ensuring safety, efficiency, and longevity of the equipment. Here's a step-by-step guide on how to conduct these inspections:

Pre-Operational Inspection

1. Visual Check

• Forks: Look for bends, cracks, or distortions.

• Mast: Inspect for damage or excessive wear.

• Chains: Check for broken links or rust.

• Tires: Ensure they are in good condition, properly inflated (if pneumatic), and have no significant cuts or wear.

• Body and Overhead Guard: Check for any damage or loose parts.

2. Fluid Levels

• Check levels of engine oil, coolant, hydraulic fluid, and transmission fluid.

3. Leaks

• Look underneath for signs of leaks from the transmission, hydraulics, or engine.

4. Battery (Electric Forklifts)

• Inspect the battery for charge level, clean terminals, and proper water level.

5. Safety Features

• Ensure seat belts, lights, horns, and backup alarms are functioning correctly.

Operational Inspection

1. Engine Start-Up

• Start the engine and listen for any unusual noises.

2. Brake Performance

• Test the foot brake and parking brake to ensure they're functioning properly.

3. Steering

• Check for smooth and responsive steering.

4. Control Operation

• Test lift and tilt controls for smooth operation.

• Check lowering speed and any unusual noise.

5. Warning Lights and Gauges

• Ensure that all gauges function properly and that no warning lights illuminate.

Post-Operational Inspection

1. Clean the Forklift

• Remove debris and clean the forklift to prevent buildup and overheating.

2. Final Check

• Look over the forklift one more time for any new signs of damage or issues.

3. Record Keeping

• Document the inspection and report any problems or repairs needed.

What Does a Typical Maintenance Schedule Look Like For a Forklift?

​Maintenance schedule for a forklift varies depending on the type of forklift, its usage, and the manufacturer's recommendations. However, you can follow general guidelines to ensure proper maintenance. Here’s an outline of what a typical maintenance schedule might look like:

Daily or Pre-Shift Checks

• Visual Inspection: Check for any visible damage or leaks.

• Operational Inspection: Test controls, brakes, lights, horns, and safety devices.

• Tire Inspection: Check for wear and proper pressure (if pneumatic tires).

• Fluid Levels: Check oil, coolant, hydraulic fluid, and fuel levels.

• Battery Check (for electric forklifts): Inspect for charge level and clean terminals.

Weekly or Every 50 Hours

• Lubrication: Grease all necessary components.

• Fork Inspection: Check for wear, damage, or distortion.

• Battery Maintenance (for electric forklifts): Check water levels and clean battery terminals.

Monthly or Every 200 Hours

• Brake Inspection: Check and adjust brakes if necessary.

• Steering System: Inspect and adjust as needed.

• Lift and Tilt Mechanism: Check for smooth operation and adjust if required.

• Filters: Inspect and replace air and fuel filters if necessary.

Quarterly or Every 600 Hours

• Change Oil and Filter: For internal combustion forklifts.

• Transmission Fluid: Check and replace if needed.

• Hydraulic System: Check hoses, valves, and cylinders for leaks or wear.

• Cooling System: Inspect and clean the radiator; check coolant levels.

Semi-Annually or Every 1,000 Hours

• Thorough Cleaning: Deep clean the forklift to remove dirt and debris.

• Tire Inspection and Replacement: Replace worn or damaged tires.

• Fork Inspection: Thoroughly inspect forks and replace if necessary.

Annually or Every 2,000 Hours

• Complete Forklift Overhaul: This includes checking all major components like the engine, transmission, brakes, steering, and hydraulic systems.

• Load Test: Perform a load test to ensure the forklift can handle its rated capacity.

How To Inspect The Battery of Your Forklift

Inspecting the battery of a forklift, especially if it's an electric model, is a crucial part of routine maintenance. Here's a step-by-step guide on how to properly inspect a forklift battery:

1. Safety First

• Wear Protective Gear: Use gloves and safety glasses to protect against acid splashes.

• Ensure Proper Ventilation: Batteries can emit hazardous gases, so ensure the area is well-ventilated.

2. Visual Inspection

• Check for Physical Damage: Look for cracks, bulges, or other signs of damage on the battery case.

• Inspect Terminals and Connectors: They should be clean, tight, and free of corrosion.

• Check for Leaks: You must address any signs of acid leaks around the battery immediately.

3. Electrolyte Levels

• Check Water Levels: Make sure you adequately submerge the plates. If the water is low, add distilled or deionized water after charging, not before.

• Avoid Overfilling: Overfilling can cause acid to overflow during charging.

4. State of Charge

• Check battery charge with a hydrometer or voltmeter by measuring electrolyte gravity or voltage.

• Consistent Readings: Ensure that all cells have consistent readings. A significant variance could indicate a problem.

5. Cleanliness

• Remove Dirt and Debris: Clean the top of the battery to prevent dirt from entering the cells.

• Neutralize Acid Spills: Use a baking soda solution to neutralize any acid spills and then rinse with water.

6. Cable and Connector Inspection

• Check for Frayed Cables: Ensure that all cables are intact and not frayed or damaged.

• Tighten Loose Connections: Tighten any loose connections to ensure efficient energy flow.

7. Charge Level and Charging

• Proper Charging Practices: Charge the battery according to the manufacturer’s instructions. Avoid overcharging or undercharging.

• Equalize Charge at intervals: Perform an equalizing charge if recommended by the manufacturer to balance cell voltages.

Inspecting The Tires of Your Forklift For Wear

Checking tire wear is crucial for maintaining forklift safety and efficiency during routine maintenance. Here’s how you can inspect the tires for wear:

1. Safety First

• Park the Forklift: Make sure you park the forklift on a level surface and engage the parking brake.

• Turn Off the Engine: To prevent accidental movement during inspection.

2. Visual Inspection

• Overall Condition: Check for obvious signs of damage like cuts, gouges, or tears on the tire surface.

• Uneven Wear: Look for uneven wear patterns, which can indicate issues with alignment or suspension.

3. Tread Depth

• Measure Tread Depth: Use a tread depth gauge to measure the remaining tread. Compare this to the manufacturer's minimum tread depth specifications.

• Bald Tires: If the tread is worn down to the wear indicators or is flat and smooth, it’s time for a replacement.

4. Flat Spots and Chunking

• Flat Spots: Check for areas where the tire is noticeably flatter, which can occur from heavy braking.

• Chunking: Look for pieces of rubber that may have come off the tire, often a sign of overloading or rough driving.

5. Check for Cracks and Bulges

• Cracks: Inspect for cracks in the rubber, particularly in older tires, as this can lead to tire failure.

• Bulges: Bulges on the tire surface can indicate internal damage, possibly from hitting obstacles.

6. Tire Pressure (If Pneumatic Tires)

• Check tire pressure with a gauge to make sure it's at the right level recommended by the manufacturer.

• Leaks: Listen and feel for air leaks, which could suggest punctures or valve issues.

7. Inspect Wheels and Rims

• Wheel Damage: Check the wheels and rims for any signs of damage or bending, which can affect tire wear.

8. Alignment

• Observe Alignment: Misaligned tires will show uneven wear. To prevent tire wear, you need to address alignment issues in a timely fashion.

Examining The Lubrication Systems of Your Forklift

1. Safety First

• Park the Forklift: Ensure the forklift is on a level surface and the engine is off. Engage the parking brake.

• Wear Appropriate Safety Gear: Use gloves and safety glasses to protect against grease and other contaminants.

2. Refer to the Manufacturer’s Manual

• Lubrication Points: Identify all the lubrication points as specified in the forklift’s service manual. Different forklift models may have varying lubrication requirements.

3. Visual Inspection

• Check for Leaks: Inspect around seals, hoses, and fittings for any signs of oil or grease leaks.

• Examine Hoses and Lines: Look for cracks, wear, or damage on hydraulic lines and hoses.

4. Check Lubricant Levels

• Engine Oil: Check the engine oil level using the dipstick. The oil should be at the correct level and clean.

• Transmission Fluid: Ensure the transmission fluid is at the proper level and appears in good condition.

• Hydraulic Fluid: Check the hydraulic fluid level. Low levels may indicate a leak or system issue.

5. Assess Grease Points

• Grease Fittings: Identify grease fittings (zerks) on moving parts like bearings, chains, and pivots.

• Apply Grease: Using a grease gun, apply grease to these points until fresh grease squeezes out.

6. Inspect for Contamination

• Check for Dirt and Debris: Ensure that grease points are clean and free from dirt before applying new grease.

Inspecting The Forks On Your Forklift

1. Safety First

• Park the forklift on a level surface, with the engine off and parking brake engaged.

• Lower the Forks: Position the forks flat on the ground.

2. Visual Inspection

• Look for Cracks: Inspect each fork for any visible cracks, particularly in high-stress areas such as the heel and welds.

• Check for Bends: Forks should be straight. Any bending or twisting indicates damage.

• Surface Damage: Look for signs of cuts, gouges, or excessive wear, especially on the fork tips.

3. Measure Thickness and Width

• Thickness: Use a caliper to measure the thickness of the fork, especially at the heel. Compare this to the original specifications.

• Measure the width of each fork to ensure they haven't worn down excessively.

4. Inspect Fork Tips

• Align the tips of the forks. If one fork is higher than the other, it could indicate bending or wear.

• Tip Height Difference: Measure the height of each tip. A significant difference between the two indicates a problem.

5. Check Fork Angle

• Straightness: Verify that the angle of the forks relative to the mast is appropriate. Forks that are not straight can lead to unsafe lifting conditions.

6. Inspect Fork Hooks

• Wear and Damage: Check the hooks for wear, cracks, or deformation. Make sure you securely attach them to the carriage.

7. Examine Positioning Lock

• Ensure that the positioning lock or pin is in good working condition and not damaged.

8. Load Test

• Capacity: Perform a load test to ensure the forks can handle the rated capacity safely.

Checking The Safety Systems of Your Forklift

1. Safety First

• Park the forklift on a level surface, with the engine off and the parking brake engaged.

2. Seatbelt and Restraints

• Inspect the Seatbelt: Check for any signs of wear, fraying, or damage. Ensure it latches securely.

• Restraints: If equipped with additional restraints, check their condition and functionality.

3. Overhead Guard

• Structural Integrity: Examine the overhead guard for any damage, dents, or bends that could compromise its strength.

• Securely fasten any attachments.

4. Brakes

• Foot Brake: Test the foot brake for responsiveness and lack of excessive play.

• Parking Brake: Ensure the parking brake holds the forklift securely in place when engaged.

5. Steering

• Responsive Steering: Check for smooth and responsive steering operation.

6. Lights and Indicators

• Headlights and Taillights: Ensure they are operational.

• Brake Lights and Turn Signals: Test for proper functioning.

• Check the dashboard for any warning lights.

7. Horn and Alarms

• Horn: Test the horn to ensure it’s loud and clear.

• Backup Alarm: Check that the backup alarm sounds when the forklift is in reverse.

• Other Alarms: If equipped with additional alarms (like a seatbelt alarm), test them for functionality.

8. Load Backrest

• Make sure the load backrest extension is firmly attached and undamaged to keep it safe and whole.

9. Tires

• Condition: Check for proper inflation (if pneumatic) and overall condition.

10. Forks and Mast

• Fork Inspection: Look for damage, bending, or cracks.

• Mast Operation: Ensure smooth operation of the mast and lifting mechanism.

11. Fire Extinguisher

• Presence and Inspection: If equipped, ensure there is a fire extinguisher and it's within the validity period.

12. Emergency Shut-Off

• Functionality: Test any emergency shut-off mechanisms to ensure proper operation.

13. Operator Controls

• Label all controls clearly and make sure they are legible.

• Control Responsiveness: Test all controls for responsiveness and ease of operation.

Environmental Considerations When Maintaining Your Forklift

When maintaining a forklift, it's important to consider the environmental impact and implement practices that are environmentally responsible. Here are key environmental considerations to keep in mind:

1. Proper Disposal of Fluids and Batteries

• You must dispose of fluids such as used oils, coolants, and hydraulic fluids properly. Never dump them on the ground or down drains. Use designated recycling or disposal facilities.

• Batteries: Forklift batteries, especially lead-acid types, contain harmful materials. They should recycle them at appropriate facilities.

2. Preventing Leaks and Spills

• Regularly inspect forklifts for leaks of oil, fuel, or hydraulic fluid. Leaks not only pose environmental hazards but also workplace safety risks.

• Have a spill response plan in place. Use absorbent materials and containment strategies to manage spills immediately.

3. Emission Control

• For internal combustion forklifts, regular maintenance of the engine is crucial to keep emissions at a minimum. This includes timely servicing of filters, oil, and exhaust systems.

• Consider using forklifts with cleaner fuel technology, such as electric or hydrogen fuel cells, especially in indoor environments.

4. Energy Efficiency

• For electric forklifts, use energy-efficient chargers and practices. Implement opportunity charging where appropriate to reduce energy consumption.

• Consider solar-powered charging stations if feasible.

5. Sustainable Parts and Lubricants

• Use environmental lubricants where possible.

• Choose parts made from recycled materials and make sure to recycle replaced parts properly.

6. Noise Pollution

• Regular maintenance can reduce noise levels. This includes lubricating moving parts and ensuring that the engine and exhaust systems are in good condition.

• Consider electric forklifts which generally operate more quietly than those with internal combustion engines.

7. Dust and Particulate Matter

• In areas with high dust levels, regular cleaning of the forklift is necessary to prevent dust build up.

• Regularly clean and replace air filters to minimize dust emissions.

8. Operational Practices

• Train operators in eco-friendly practices such as efficient driving techniques to save fuel and reduce emissions.

• Implement no-idle policies to minimize unnecessary emissions and fuel consumption.

9. Workplace Environment

• Ensure good airflow in areas with forklifts, especially indoors, to avoid harmful emissions.

• Use forklifts appropriate for the specific environment — for example, electric forklifts are preferable indoors to reduce air pollution.

10. Regulatory Compliance

• Stay informed about and comply with local environmental regulations regarding forklift operation and maintenance.

• You may need to undergo regular emissions testing and certification, especially for diesel-powered units.

Being eco-friendly helps the environment, saves money, improves efficiency, and creates a healthier work environment. Additionally, it demonstrates a commitment to corporate social responsibility.

How To Find a Forklift Repair Specialist Near You

In need of expert forklift repair? Look no further. Our skilled technicians provide reliable and efficient maintenance to extend the life of your equipment, with exceptional service.

Choose BMH expertise for your forklift care, ensuring smooth and prolonged operation. Reach out to us today by clicking on this link for more information about maintaining your forklifts or to schedule an appointment.