Storing a forklift for months is about stopping three slow kinds of damage: batteries losing charge, rust and perished rubber from moisture and sun, and seals and tyres deforming while the truck stands still. Park it under cover on firm, level ground, at least 3 m from power lines and rail lines as WorkSafe Queensland advises. Leave the battery at the charge level its manual sets and protect exposed cylinder rods. Then check the truck on the manual's schedule, and have a technician inspect it before it works again.
Service the forklift and fix faults before you store it
Before a forklift sits for weeks or months, after a harvest, a finished project or the Christmas peak, service it, fix its faults and record what was done. WorkSafe Queensland says to keep records of all forklift maintenance, including servicing and testing, and a service before storage shows the truck was sound when it was parked. Your model's operator's manual says when its storage procedure applies; check every step against it.
Record the hour meter reading and take photos of the truck, the mast and the engine or battery compartment. If a service is close to due, do it now rather than when the truck comes back, because forklift service intervals run on elapsed time as well as hours worked.
Fix small leaks and faults before the truck sits. A weeping seal or a slow coolant leak gets worse standing still, and old engine oil holds acids and moisture that attack internal parts.
Clean the truck before storage, because dirt holds moisture against metal. Keep high-pressure water away from controllers, wiring plugs, charging sockets and lithium battery packs.
Can a forklift be stored outside?
It's best not to. WorkSafe Queensland's forklift safety guide says to park forklifts in a well-lit area under cover and on an even surface, away from ignition sources, doorways and pits, and at least 3 metres from power lines and rail lines. Sun, rain and coastal air also speed up rust and perish rubber when a truck sits outside for months.
If the truck has to stay outdoors, use a breathable cover that keeps water off without trapping condensation, and park on firm ground that won't soften in heat or rain.
Wherever it is stored, park it the same way each time: on level ground, forks lowered to the ground, parking brake on, controls in neutral, engine or power off and the key removed. Under WHS laws, the person who manages a forklift must make sure an unattended truck can't be moved or operated by someone who isn't authorised to use it.
How to store an electric forklift battery
The battery needs the most care during storage, and the right approach depends on its type. A flooded lead-acid battery is normally stored fully charged, topped up with water after charging and in a ventilated area, but follow the manual for your battery. A lead-acid battery left partly discharged can lose capacity it won't get back. Storage needs are one more practical difference between lithium and lead-acid forklift batteries, alongside watering and charging time.
Keep a lithium battery at the storage charge in its manual, and don't let it run flat. The manual also says whether to disconnect it. The battery management system and any tracking device still draw a little power while the truck sits.
If the truck is stored in a cold shed over winter, some lithium packs help: the battery on Hangcha's XC Series 4-wheel electric forklift 1.8-3.1 t has low-temperature electric heating. Check the charge at the interval the manual gives and recharge as directed.
Storing LPG and diesel forklifts
On an LPG forklift, turn off the cylinder valve, remove the cylinder and keep it in the site's LPG storage cage. When it goes back on, SafeWork NSW says the pressure relief valve must sit at the 12 o'clock position and the mounting bracket should be checked regularly. Only a licensed gas fitter should repair or replace parts of the LPG system.
On diesel and petrol forklifts, fuel and engine oil both age in storage. Change the engine oil and filter before storage if a service is near. Follow the manual on whether to fill or drain the fuel tank, and check the coolant mixture suits the temperatures where the truck is stored.
Protecting the forklift mast, hydraulics and tyres in storage
Lower the carriage fully and tilt the mast back so the cylinder rods retract as far as they can. Chrome rods left exposed can pit with rust, and a pitted rod damages its seals the first time it moves again. Coat any exposed rod with the protective oil or grease the manual specifies.
Tyres can develop flat spots when a heavy truck stands in one place for months. Follow the manual on moving the truck from time to time or supporting it to take weight off the tyres, and check pneumatic tyre pressures before it moves again. If a tyre has gone flat or been damaged, WorkSafe Queensland advises having tyre work done by a competent tyre fitter.
Rodents chew wiring in stored machines, so look under covers and inside compartments whenever you check the truck.
Checking a forklift while it is in storage
Give one person the key and a simple log. At each check the manual calls for, record the battery charge, look for leaks under the truck, make sure the cover is intact and look for signs of pests. If the manual asks for the hydraulics to be cycled or the engine to be run, do it and note it in the log.
The table lists what each part of the truck needs before storage, at each check and before it works again.
| System | Before storage | While stored | Before it works again |
|---|---|---|---|
| Lead-acid battery | Charged and topped up with water as the manual says | Recharge at the interval in the manual | Check charge, water level and connectors |
| Lithium battery | At the storage charge level in the manual | Check charge; disconnect if the manual says to | Check charge, warning codes and the charger |
| LPG | Cylinder valve off, cylinder removed to the storage cage | Cylinder stays in the cage until it is refitted | Cylinder refitted with the relief valve at 12 o'clock |
| Diesel engine | Oil and filter changed if a service is near | Look for leaks under the truck | Fluid levels, then idle and watch for warnings |
| Mast and hydraulics | Carriage down, mast tilted back, exposed rods coated | Check for leaks and rust | Wipe the rods, check oil for water, cycle unloaded |
| Tyres | Pressures set, truck on level ground | Move or support the truck as the manual says | Pressures and flat spots, wheel nuts |
| Security | Key removed and held by one person | Log each check | Technician inspection, then pre-start checks |
Most of the work sits in the first and last columns. The checks in between are short, but they catch a flat battery or a leak while it is still cheap to fix.
Bringing a stored forklift back into service
A forklift that has stood for months needs more than a turn of the key. Have a suitably qualified technician check it first, including:
- wiping the protective coating off the cylinder rods before the mast moves
- checking the hydraulic oil for water, and every other fluid for level and condition
- the lift chains, mast rollers and forks
- the brakes, including the parking brake
- wiring, battery connectors and the charger
- tyres and wheel nuts
DJJ Equipment services all forklift brands and repairs Hangcha forklifts; repairs on other brands are assessed case by case, so check your model with the service team. On-site forklift servicing covers 50 km around the Silverwater, Meadowbrook and Bayswater branches, and each branch has a workshop.
Once the technician has finished, start an engine truck and let it idle while you watch for warning lights and leaks, then run the mast through its full range without a load.
The operator then does the usual forklift pre-start checks before the first lift of the day.
Store the forklift, sell it or hire instead?
Storage still costs money: floor space, battery care, regular checks and a return-to-service inspection. If a forklift only works a few months a year, compare that cost with hiring a machine for the busy season.
With forklift hire, the machine goes back to the hire company at the end of the term, so there is nothing to store between seasons. Minimum hire terms depend on the machine and branch.
If the truck isn't likely to be needed again, selling it or trading it in on a machine that suits your work can make more sense than storing it. A complete service history helps its value.
Tell the DJJ team the model, its hours, how long it has been stored and where, and the service team can check it before it goes back to work. Call 1300 646 747 for service, 1800 355 388 for sales and hire, or send an enquiry to your nearest branch.
