Forklifts and all their attachments must be regularly inspected and maintained to minimize risks during use. A maintenance checklist is essential for both employers and forklift operators.
When to Check:
- At the start of each shift
- Before daily use
- When operators change
If any defects are noticed, they should be reported immediately. Qualified forklift technicians should maintain records of inspections and maintenance.
The maintenance and inspection records should include:
- What needs to be checked within the prescribed maintenance cycle
- Items checked during the inspection
- Any maintenance performed
- Defects and corrective actions taken
- Any follow-up maintenance tasks that need signatures or further action
DJJ Equipment provides a straightforward and clear maintenance manual for forklift buyers and renters. If you have any questions, feel free to reach out to us!
Forklift Pre-Operation Checks
According to Safe Work Australia’s Forklift Guide, “Each time a different operator uses an industrial forklift or when a shift change occurs, a pre-start safety check should be completed.”
Suggested Pre-Operation Checks
Warehouse Area and Forklift Exterior
Before hopping on the forklift, check the work area and the forklift exterior. Be sure to pay attention to the following:
- Check the forklift structure for dents, broken parts, or cracks.
- Check the warehouse floor for obstructions that may hinder movement.
- Also, check above to ensure there are no obstacles that could cause an accident.
Tires
Before starting, always check the tires. Low tire pressure or leaks can affect brake performance and lead to accidents.
- Check for tire wear.
- Make sure there are no cuts or scratches.
- Check tire pressure to ensure proper inflation.
Forks
- Check for any bending or cracking in the forks.
- Ensure the lock pins are securely installed.
Fluids
- Before checking the fluids, make sure the forklift is parked on flat ground.
- Check the engine oil, hydraulic fluid, water, and coolant levels.
- Check the underside of the forklift for leaks.
Battery
- Ensure the battery is fully charged.
- Make sure there are no damages, exposed wires, or loose connections.
Forklift Start-Up Checks
Controls
- Once the forklift is started, check the dashboard to ensure all lights and gauges are working properly.
- Ensure there is no unusual noise.
Brakes
- Check the foot brake to ensure it stays stable and the forklift can stop smoothly.
- Check the parking brake.
- When standing up, check the safety seat’s brake system for proper functioning.
Tilt and Lift Mechanism
- Check the tilt mechanism by moving the mast.
- Check if the lift mechanism works properly by raising the forks to their highest point.
- Inspect chains, cables, and other attachments.
Other Controls to Check
- Make sure the seatbelt is functioning properly.
- Check the brake pedal and parking brake.
- Check the backup alarm and horn.
- Ensure headlights and warning lights are working.
- Check that the steering operates smoothly.
- For gas forklifts, check fuel levels and gas cylinder condition.
- Ensure the load backrest is properly mounted and clearly visible.
- Ensure operator manuals and logs are available and up-to-date.
Common Maintenance Categories
Internal Combustion Forklifts
Engine & Fuel
- Check for any fluid leaks
- Change engine oil and oil filter
- Check engine start-up and listen for unusual noises
- Check the fuel system for leaks
- Check the fuel filter for clogs
Air & Cooling
- Clean the air filter
- Check radiator coolant level and any leaks
- Check coolant hoses for damage
- Check fan belt tension
Exhaust
- Check the exhaust system for damage or leaks
- Measure exhaust CO levels
Transmission
- Inspect differential, torque converter, and transmission: oil level, leaks, looseness, and function
- Check clutch and inching pedal function
Electric Forklifts
Motor & Drive
- Check the drive unit for oil levels and leaks
- Listen for abnormal motor sounds
Tires, Axles, Steering & Brakes
- Check tire pressure, wear, damage, and debris.
- Tighten the wheel nuts.
- Inspect rims and side rings for damage.
- Check wheel bearings for noise and looseness.
- Inspect steering for functionality and play.
- Check the parking brake function.
- Inspect brake fluid levels.
Forks, Attachments, Mast & Chains
- Inspect forks and stopper pins for wear or damage.
- Lubricate lifting chains and check tension for wear.
- Inspect mast rollers and other lifting components for damage.
Hydraulic System
- Test overall hydraulic system operation.
- Replace hydraulic oil return filter.
- Inspect the oil pump for leaks and abnormal noise.
- Check hydraulic oil levels for contamination.
- Inspect hydraulic cylinders and hoses for leaks.
Electrical System
- Inspect the battery and wiring.
- Check spark plug gaps (for internal combustion forklifts).
- Inspect electrical components for damage or wear.
Safety Features
- Inspect the overhead guard for damage.
- Ensure all lights, alarms, and instruments are functioning.
- Check seatbelt and safety sensors.
- Ensure the operator presence sensing system works.
This guide covers regular maintenance and special checks for your forklift. If you encounter any issues, feel free to contact us. DJJ Equipment offers quick-response forklift repair services across Australia. Our professional technicians will swiftly resolve your forklift problems, with fast access to local spare parts. Contact us today for a hassle-free service!
FAQ’s
How to do maintenance on a forklift?
Do basic daily checks (battery, tyres, forks, brakes), keep it clean, charge or fuel it properly, and follow the regular service schedule. Major maintenance should always be done by a qualified technician.
How often do forklifts need to be serviced?
Most forklifts need servicing every 250 hours or every 3 months, whichever comes first. High-use forklifts may need more frequent checks.
How much does forklift maintenance cost?
It depends on the model and fuel type. Basic services usually start from a few hundred dollars, while bigger repairs or parts replacement can cost more. Electric forklifts are usually cheaper to maintain than diesel ones.
What is the maintenance checklist?
A checklist usually includes:
- Tyres, forks, mast, and chains
- Brakes, steering, and hydraulics
- Battery or engine system
- Fluids, filters, hoses, and belts
- Safety devices and warning lights
What is the 10 rule of preventive maintenance?
It means checking the 10 key areas regularly:
- Engine or battery
- Hydraulics
- Brakes
- Steering
- Tyres
- Mast & chains
- Forks
- Fluids & filters
- Electrical system
- Safety devices
