Forklift Maintenance: A Comprehensive Checklist

Whether forklifts operate in the recycling industry, food processing plants, steel and metal processors or any other environment, ongoing maintenance is vital. 

Routine services can extend the service life of a forklift and improve productivity by preventing unplanned downtime. These services also make it possible to identify small issues before they escalate into costly repairs, which can save your organization from high repair costs down the line. 

While maintenance is vital to keep forklifts in good condition, you must conform to the Canadian Center for Occupational Health and Safety (CCOHS) vehicle maintenance requirements. These requirements set standards to protect employees while on the job. 

In this forklift maintenance guide, we’ll cover everything from operator checks to monthly and annual services. 

Forklift Operator’s Daily Checklist

Forklift operators are not just tasked with operating the vehicle safely and efficiently — they must also conduct thorough vehicle and operator checks at the start of each shift. According to CCOHS standards, operators must receive training to perform these maintenance checks and tasks correctly.

These checks are essential to confirm that the vehicle is in suitable working condition. Shift checks also make it possible to identify minor damage and faults. By identifying small issues early on, users can significantly reduce the likelihood of major repair requirements or unexpected breakdowns that can disrupt workflow.

Vehicle Checks

At the start of each shift, forklift operators must conduct the following vehicle checks to ensure a safer working environment and to prevent potentially costly repairs. This portion of the forklift maintenance checklist occurs while the engine is off. 

• Inspect for dents, broken parts and other forms of damage.
• Check for fuel, oil, radiator and hydraulic leaks.
• Inspect the tires and wheels.
• Make sure the forks are not bent or cracked.
• Check the battery cable and connector condition.
• Inspect the condition of the overhead, load backrest and other guards.
• Examine the mechanical safety devices, including operator harnesses and seat belts. 
• Check the operator compartment controls, including pedals, steer tiller and seat locks. 

Operator Checks

These forklift function tests require the engine to be on. They can help diagnose issues with the brakes, battery and other components.

Monthly Lift Truck Maintenance Checklist 

Lubrication

Regularly lubricating essential forklift parts ensures smooth operation. Lubrication prevents friction and grinding between moving parts, which can reduce wear and tear and help prevent premature part replacement. 

The key parts to lubricate include:

• Chassis-mast attachment
• Lift chains and pulleys
• Bearings
• Tilt pins
• Front and rear U-joints
• Tilt cylinder pins and bushings
• Tilt pins and bushings
• Steer-axle mount pivot pins
• Lower carriage bearings
• Slip yoke
• Upper and lower fork bar

Electrical

After lubricating the working parts, technicians need to check that all electrical components are in good working order. Testing these components once a month can help prevent mechanical issues from causing downtime:

• Switches and contact tips
• Drive control system
• Battery connectors
• Communicator and all motors

Hydraulic

The hydraulic system uses high-pressure fluid to move the forks and lift them up and down smoothly. The fluid is stored in a reserve tank that feeds a pump, which pushes the fluid through a control valve and then through various hoses to move the forks. To make sure this system is working properly, technicians check and service these components:

• Cylinders
• Pumps
• Valves
• Hoses

Power Source

Forklifts may run on electricity, diesel, gasoline or liquefied propane gas. With fuel-powered lift trucks, technicians need to maintain the components related to the internal combustion system:

• Inspect and service the radiator
• Check and replace the belts and spark plugs
• Test and service the ignition switch
• Clean or replace the fuel filter and any engine accessories
• Check and correct the fluid levels 
• Change the engine oil and replace the filter
• Replace the engine air filter

For an electric forklift, maintenance tasks may include inspecting the battery’s charge and electrolyte level, case condition, and connectors, as well as confirming that there are no leaks or damage present in the motor. 

General 

Other general areas of a forklift that require routine maintenance include:

• Test and service the steering components
• Test and service the parking brakes, or replace parts as needed
• Replace or service tires 

Inspecting, cleaning and replacing these parts when necessary will help keep your lift truck in top condition. 

Annual Forklift Maintenance Guide

Annual forklift maintenance services must follow the maintenance schedule and standards provided by the manufacturer. These guidelines usually recommend a service once a year or every 2,000 hours of use. 

The operating environment may also impact annual maintenance frequency. If the lift truck is used on rugged terrain, the maintenance needs will increase as the vehicle endures more wear and tear.  

Keep Detailed Maintenance Records

Contact Alta for Reliable Forklift Maintenance Services

Forklift maintenance is key to keeping your plant running smoothly. Alta Material Handling is your one-stop destination for all your forklift needs. Our team of highly trained, certified technicians provides reliable forklift maintenance services. We have structured, comprehensive maintenance programs that are designed to help technicians identify minor issues early and minimize the chances of unplanned downtime. 

We also offer lift truck rentals and customization — if you perform specialized tasks, we can modify your forklift to better suit its intended purpose. Contact us online to schedule an appointment, or reach out to one of our locations by phone to learn more about our comprehensive range of forklift products and services.