How is a forklift maintained?
Forklifts are the ideal tool for transporting heavy loads in industry, commerce and trade. As with any machine, the various mechanical parts of a forklift tend to wear out with constant use. This wear is particularly critical in the moving parts, so a continuous forklift maintenance program is necessary.
Recurring maintenance work includes a daily visual and functional inspection of the forklift before work begins. If defects are identified or after a set period of time has elapsed, you can carry out minor maintenance on the forklift yourself. Below you will find an overview of maintenance work that can help you carry it out.
Forklift maintenance: Carry out independent maintenance work
1
Lubricate moving parts. Most of the moving joints or parts of the forklift are lubricated. This is done to prevent the damaging effects of friction. Make sure all of these fittings are lubricated regularly and be sure to replace any worn ball bearings.
2
Top up the oil. To ensure that the forklift's hydraulics function smoothly, it is important to check the oil level regularly. If the level falls below the minimum level, you can top up the oil yourself. Just make sure you use the right oil. This applies to all other fluids that ensure that the vehicle works efficiently, such as coolant and engine oil (for fuel-powered forklifts). The frequency of the check depends on how often the vehicle is used.
3
Charge the battery / fill the tank. Make sure that the battery of the electric forklift is always fully charged. While lithium-ion batteries are maintenance-free, lead-acid batteries need to be regularly topped up with distilled water. If, however, your forklift is powered by gas, diesel or petrol, make sure that the tank is always full to avoid unnecessary downtime and the associated waiting times.
4
Change the bulb. Check the brake, reversing and optical safety lights on the forklift truck, as they are essential for safe use during operation. If the lights no longer work, it is usually sufficient to replace the bulb (LED lamp) to rule out a technical defect in the electronics.
5
Keep tires in good condition. If the tires are air-filled, make sure that the correct air pressure is maintained. If the tires are solid, make sure that they are free from cracks and have sufficient tread. A defect in the forklift tires or insufficient air will lead to increased fuel consumption and can also affect handling and safety.
6
Replacing forks. To operate a forklift safely, intact forks without wear must be used. Damaged forks pose a safety risk as their load capacity is reduced. It is advisable to replace the forks if the minimum thickness of the forks has been exceeded due to wear or if the material has cracks.
Daily maintenance: visual and functional inspection
Companies should do everything they can to ensure regular forklift maintenance. This includes daily visual and functional inspections before work begins. This is not only essential to ensure the safety of employees, but also to check the functionality of the forklift, to identify and avoid damage, and to maintain the operational condition of the industrial truck.
Check the following areas for functionality and damage:
- Vehicle & chassis: Check tires and rims (profile and air pressure), drive and steering, brakes as well as seat and belt
- Battery & engine: Check the battery charge level and connections (for electric forklifts). Check the fuel/LPG, engine oil and coolant levels and check for leaks (for fuel-powered forklifts)
- Hydraulics: Check the hydraulic oil level and test the lifting function and check for leaks
- Electrics: Test lights, indicators, warning devices and windshield wipers
- Load handling: Check fork tines for correct assembly and securing
The forklift truck may only be put into operation and loaded with loads if the inspection shows that the device is in perfect working order and without any defects .
Have your forklift serviced regularly by a specialist
If the company does not have a qualified employee or an internal department that is authorized to carry out maintenance, a specialist is commissioned. In most cases, these are authorized workshops of the forklift manufacturer, which carry out maintenance work and inspections in accordance with the manufacturer's specifications and using original parts.
It is highly recommended to conclude a maintenance contract with the external partner. This includes regular and thorough checking and adjustment of the individual forklift components. More complex tasks such as oil changes, replacing filters and seals and topping up the hydraulic fluid are carried out by the specialist.
In addition, a full-service contract can also be concluded. In addition to inspections and maintenance work, this also includes all repairs, such as replacing batteries or regularly changing tires.
Annual Forklift Inspection
In addition to the daily inspection, the annual inspection is essential when using a forklift in the company, as it is regulated by law. There are requirements from the DGUV (Regulation 68 FEM 4.004 §10 BetrSichV) that require forklifts to undergo recurring checks at least once a year to ensure safety and functionality. The forklift is certified as part of the annual FEM 4.004 inspection and is documented in the inspection log.
Questions & Answers
How often do forklifts need maintenance?
While the visual and functional inspection is carried out daily, regular maintenance depends on the frequency of use and therefore on the operating hours of the forklift in the company. In addition, the DGUV prescribes an annual FEM inspection.
Who is allowed to carry out maintenance and repair work on the forklift?
The daily inspection of the forklift is carried out by the drivers themselves, as it must be done before work begins. Maintenance and repairs, however, may only be carried out by a qualified employee or the internal workshop. If this is not available, an external service provider is commissioned.
Why do forklifts need maintenance?
Although recurring inspections are often viewed as a necessary evil, they are the best choice to keep forklifts operational at all times, reduce the amount of repairs and extend the life of the equipment.
How much does forklift maintenance cost?
In principle, it is difficult to state the exact amount of the costs for maintenance and repairs. Prices vary depending on the offer, provider and the scope of the agreed contract.
