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Recent PostsBlog CategoriesMid-Year Maintenance: Why Summer is Critical for Forklift HealthForklift Safety Rules: Best practices for operating forkliftsHandling loadsWorking on slopesKeeping people safeWhen you finish

 

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Most people know regular service is vital for a safe and reliable car. The same goes for forklifts. Setting up a regular forklift maintenance schedule for your forklift fleet can help with things like:

  • Expensive repairs
  • Unexpected downtime
  • Protecting the resale value of your fleet
  • Protecting the safety of your forklift operators and employees

So, how often should you set up a service for your forklift or fleet? Well, it depends on the type of forklifts you use and how often you use them.

Internal Combustion Forklifts

Internal Combustion (IC) forklifts generally need service every 250-300 hours. You may need service more often if you operate forklifts in extreme temperatures or dirty environments or have fork attachments.

Here are the top four things to focus on during a 250–300-hour IC forklift service:

  1. Change filters
  2. Grease parts
  3. Look for minor problems to prevent big problems
  4. Conduct safety inspection

Electric Forklifts

With fewer parts to replace and service, electric forklifts require less maintenance than IC forklifts. In general, you should inspect and service electric forklifts every 500 hours. Again, your service intervals may vary if you work in extreme environments or use fork attachments.

Here are the top six things to focus on during a 500-hour electric forklift service:

  1. Check the motor
  2. Inspect the cables
  3. Lubricate moving parts
  4. Inspect battery
  5. Check lights, accessories, and attachments
  6. Conduct safety inspection

Sample One-Year Maintenance Schedule for IC and Electric Forklifts

For reference, here is a sample one-year maintenance schedule for IC and electric forklifts. It’s a general list of things to focus on; however, you should always follow manufacturer guidelines for your specific forklift.

Every 250 Hours/Two Months

  • Check engine idle speed and ignition timing
  • Lubricate chassis and mast components
  • Change engine fluids and filters
  • Blow out and inspect the brakes
  • Inspect the hydraulic system and mast
  • Check belts, hoses, the drive train, steering, and electrical system
  • Inspect tires for damage and wear
  • Inspect attachments (if applicable)

Every 500-600 Hours/Four Months

  • All items in the 250-hour service above
  • Inspect the chains for damage and proper tension, check the mast operation, inspect carriage rollers, lift and tilt cylinders for proper function
  • Check/adjust the chassis links, clutch release bearing, and mast support bushing
  • Inspect the hydraulic oil pump and check the hydraulic oil level hydraulic filter (replacing if necessary)
  • Clean the radiator
  • Inspect the PCV valve
  • Asses pedal free play
  • Check/adjust hand brake

Every 1,000 Hours/Six Months

  • All items in the 250 and 500-hour service above
  • Change all fluids and filters, including (but not limited to) hydraulic, transmission, and brake fluid.
  • Replace the spark plugs
  • Lube drive hubs

Every 2,000 Hours/One Year

  • All items in the 250 and 500, and 1,000-hour service above
  • Replace the: antifreeze, differential and transmission oil, contact breaker (points), and condenser (on older units)
  • Hydraulic pressure check
  • Cooling system check
  • Inspect steer axle
  • Inspect brake drums (replace if necessary)
  • Compression check
  • Clean and check the fuel system

Service intervals can get confusing if you have a large or mixed fleet. Contact us to set up a service appointment today! Our team of experienced forklift technicians can create a general maintenance plan that considers all the different types of forklifts in your fleet and when to service them.

 

Mid-Year Maintenance: Why Summer is Critical for Forklift Health

As temperatures rise, so does the strain on your forklift fleet. Summer heat can intensify wear on key components—especially your cooling system and engine. If you haven’t scheduled mid-year maintenance, now is the time.

Ignoring signs of heat-related stress can lead to overheating, part failure, and costly downtime. Here’s why coolant flushes and tune-ups are essential in the summer months—and how they protect your equipment when it’s working its hardest.


 

Forklift Safety Rules: Best practices for operating forklifts

The forklift health and safety rules below are drawn from the Health and Safety Executive’s guidance. During the operation of a forklift truck the following checklist of do’s and dont’s from the Health and Safety Executive (PDF available here) guides you through some of the best practices to follow:

Do:

  • Complete a pre shift check.
  • Use the seat belt or other restraint if fitted.
  • Check all around before moving off and look in the direction you are travelling.
  • Drive at a safe speed for the area and the load.
  • Keep forks low but clear of the ground while travelling.
  • Stay alert for pedestrians and obstructions.
  • Avoid harsh braking and sudden stops.
  • Slow down at corners, doorways, and other risk points, using the horn where needed.
  • Apply the parking brake before leaving the truck.
  • Get in and out safely using the steps and handholds, facing the truck. 

Do not:

  • Drive unless you are trained and authorized.
  • Use a truck or equipment you know is faulty.
  • Operate controls from outside the cab unless the truck is designed for it.
  • Stand on or near controls to reach the load or anything outside the cab.
  • Use a truck on uneven ground unless it is suitable.
  • Drive over unprotected cables or flexible pipes.
  • Attempt repairs unless you are a qualified maintenance engineer.
  • Operate under the influence of alcohol or drugs.
  • Use handheld phones or devices while operating or travelling. 

 

Handling loads

Do:

  • Follow floor loading limits and know the weight of the loaded truck.
  • Check there is enough space for the truck and load, including overhead clearance.
  • Lower loads at a controlled, safe speed.
  • Use the right attachments for unusual or wide loads and follow the manufacturer’s instructions.
  • Make sure you are trained and authorized to use the truck with any attachment fitted. 

Do not:

  • Lift loads above the truck’s rated capacity.
  • Move loads that look unstable, unsuitable, or placed on damaged pallets.
  • Travel with loads that block your view.
  • Travel with a raised load unless the truck is designed for it.
  • Use attachments unless the truck’s capacity has been officially reduced and confirmed by a competent person, authorized dealer, or manufacturer. 

Working on slopes

Do:

  • Travel slowly downhill.
  • With a load, keep the forks facing uphill when travelling up or down slopes.
  • Without a load, keep the forks facing downhill when travelling up or down slopes.
  • Adjust tilt to suit the gradient and raise forks enough to clear the ground. 

Do not:

  • Turn on a ramp or slope or travel across it.
  • Leave the truck on a gradient unless it is an emergency and then chock the wheels. 

Keeping people safe

Do:

  • Use a safe system of work for working platforms.

Do not:

  • Lift people on the forks, pallets, or anything balanced on the forks.
  • Carry passengers unless the truck is designed for this.
  • Allow anyone to walk under raised forks or loads.
  • Pick up a load if someone is standing close to it. 

When you finish

  • Park on level ground, not on a slope.
  • Tilt the mast forward and lower the forks fully so the tips rest on the floor.
  • Apply the parking brake, select neutral, switch off, and remove the key.
  • Return keys or activating devices to secure storage. 



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Where innovation meets performance