In the logistics and warehousing industries, equipment failure can lead to costly downtime and safety risks. This makes maintaining forklifts not just a best practice but a business necessity for enterprises that make use of them. Well-maintained forklifts operate more efficiently, reduce the likelihood of accidents, and minimise repair costs. Ultimately, diligent maintenance extends the life of the equipment, a benefit that translates to long-term savings and a safer work environment for operators.
Performing regular checks and simple maintenance tasks can contribute substantially to the longevity and reliability of forklifts. Routine inspections—whether daily or weekly—can help you and your staff identify minor issues before they escalate into major problems. On-premises maintenance by your staff, such as topping up fluids and cleaning critical components, complements the work of professional service teams and ensures that forklifts are always ready for use. While professional servicing is an irreplaceable aspect of forklift upkeep, basic maintenance performed by in-house teams plays a vital supporting role in keeping operations running smoothly.
Let’s go through some practical advice on how to maintain and replace essential forklift parts:
Forks
Forklift forks are among the most heavily used parts of the machine, often subject to wear and tear due to frequent lifting and transportation of heavy loads. Regular inspections are necessary to maintain them properly. Check for any visible cracks, bends, or signs of wear that could affect their ability to handle loads safely. Additionally, remove all debris or dirt after each use, especially when handling abrasive materials that can degrade the forks faster.
Forks should be replaced when their thickness is reduced by more than 10% from the original measurement, as this indicates significant wear that compromises their load-bearing capacity. Similarly, any visible cracks or bending in the forks will require you to replace them immediately to avoid the risk of accidents. Even minor misalignments in the forks can lead to uneven load distribution, which poses a safety hazard to users and other workplace staff, and can even damage the forklift itself.
Tyres
Forklift tyres take the brunt of the machine’s movement, so they’re critical to both performance and safety. As such, make sure to maintain proper tyre pressure and regularly check for wear and tear to preserve their functionality for longer. Pneumatic tyres should be kept inflated to the correct pressure, while solid tyres should be regularly inspected for embedded debris, such as nails or sharp objects. Checking for sidewall damage or uneven tread wear can also help prevent unexpected tyre failures during operation.
It’s about time to replace your tires when the tread depth becomes dangerously low or when visible flat spots develop, as these can severely impact traction and manoeuvrability. Additionally, sidewall damage—such as large cuts or bulges—indicates that the tyres are no longer safe for use and need replacing. Regular tyre checks can help catch these issues early, prevent accidents, and reduce the risk of downtime caused by a blowout.
Hydraulic System
The hydraulic system is the backbone of a forklift’s lifting mechanism and enables smooth and precise operation. As such, make sure to regularly check hydraulic fluid levels and ensure that the fluid remains free from contamination. Inspect the hoses for any signs of leaks, cracks, or wear, as these can lead to decreased lifting performance. Keep the hydraulic components clean and free of dirt and you’ll be able to avoid damage and preserve their consistent performance.
Replace hydraulic hoses and fittings at the first signs of wear or leakage. A sudden loss of hydraulic fluid can lead to catastrophic failures in lifting operations that endanger both the operator and the load. Seals and gaskets within the system should also be replaced if there’s any indication of pressure loss or fluid leakage, as these issues can affect the overall performance of the forklift.
Brakes
Brakes are a safety feature for any forklift, as they allow the operator to control the machine's speed and stop precisely when needed. Proper maintenance involves regularly checking the brake fluid levels and verifying that the brake pads are not excessively worn. Listen for unusual noises, such as squeaking or grinding, which can indicate that the brake pads or shoes need attention. Regularly clean off any dust and debris from the brake system to maintain its effectiveness.
You’ll need your brakes to be in good shape if you want to prevent accidents, especially when your forklifts operate in busy environments. You should replace your brake pads when they wear down to approximately 25% of their original thickness or when the brakes start to exhibit a noticeable decrease in performance. A squeaking or grinding sound during operation often signals that the brake pads are worn and no longer fit to use.
Cooling System
Forklifts rely on a functioning cooling system to prevent overheating. This system includes the radiator, fans, and coolant, all of which need frequent maintenance to avoid engine damage. Keep the radiator free from dust, dirt, and other blockages, as clogged radiators can significantly reduce cooling efficiency. Regularly check and top off coolant levels to keep the engine at optimal temperature.
If the cooling system shows signs of overheating, such as frequent high engine temperatures or coolant leaks, it’s time to replace faulty components. A damaged radiator or cooling fan will lead to engine overheating, which can cause long-term damage. Replace these parts before they fail completely; this will save you a lot on repair costs and minimise downtime.
There’s no denying that a well-maintained forklift is an asset to your business, but beyond that, it’s also a reflection of your commitment to workplace safety and productivity. When you take a proactive approach to maintaining and replacing your forklift parts, you can avoid any setbacks that might compromise your operations.
