Forklifts are the backbone of warehouses, distribution centers, and construction sites. They’re essential for productivity, but they also come with a hefty price tag. The last thing any business wants is to deal with unexpected breakdowns, costly repairs, or premature replacements.

That’s where preventive care comes in. With the right maintenance habits, you can extend the lifespan of your forklift, reduce downtime, and save money. Let’s break down the key steps to keeping your forklift running smoothly for years to come.

Regular Inspections: Catch Small Issues Before They Become Big Problems

Would you drive a car for months without checking the oil? Probably not. The same logic applies to forklifts. A quick daily or weekly inspection can prevent small issues from turning into major mechanical failures.

Key areas to check:

• Tires – Look for wear, punctures, or low pressure.

• Hydraulics – Inspect for leaks or sluggish lifting.

• Battery – Ensure proper charge levels and clean terminals.

• Brakes – Test responsiveness and listen for unusual noises.

Routine inspections don’t just protect your equipment; they keep operators safe, too. Make it a habit.

Proper Battery Care: Avoiding Costly Replacements

If your forklift runs on batteries, how you charge and maintain them matters. Improper battery care can cut its lifespan in half, leading to unnecessary expenses.

Best practices:

• Charge only when the battery level drops to 20-30%—don’t top off unnecessarily.

• Avoid “opportunity charging” (charging multiple times per shift) unless using lithium-ion batteries designed for it.

• Keep battery terminals clean and corrosion-free.

• Store batteries in a temperature-controlled environment.

Taking care of your battery means getting the most out of every charge and reducing the need for frequent replacements.

Keep Your Forklift Clean: Why Dirt is the Enemy

Forklifts operate in tough environments, picking up dust, debris, and grime daily. While it might not seem like a big deal, accumulated dirt can clog filters, interfere with moving parts, and even cause overheating.

Cleaning tips:

• Wipe down the forklift at the end of each shift.

• Keep air filters free of dust.

• Remove debris from under the chassis and around the wheels.

• Use compressed air to clear out hard-to-reach areas.

A clean forklift runs more efficiently and lasts longer—simple as that.

Tire Maintenance: A Small Fix That Saves Big Bucks

Tires don’t just affect ride quality; they impact safety and fuel efficiency. Worn-out tires can lead to poor traction, increased strain on the engine, and even accidents.

Signs you need to replace your forklift tires:

• Bald spots or uneven wear.

• Visible damage, such as cracks or chunking.

• Decreased shock absorption, making rides rougher.

Pro tip: Keep tires inflated to the correct pressure and rotate them regularly to extend their lifespan.

Proper Operator Training: The Key to Longer Equipment Life

Even the best-maintained forklift won’t last if it’s handled poorly. Operator habits play a huge role in wear and tear.

Common mistakes that shorten forklift lifespan:

• Excessive speeding and sudden stops.

• Overloading beyond weight limits.

• Incorrect lifting techniques that stress the hydraulics.

• Ignoring warning signals on the dashboard.

Regular training and refresher courses can ensure operators handle forklifts responsibly, reducing unnecessary damage and repair costs.

Scheduled Professional Maintenance: When to Call in the Experts

No matter how diligent you are with daily maintenance, forklifts still need professional servicing. Trained technicians can identify hidden issues, replace worn-out parts, and ensure everything is running at peak efficiency.

Recommended service intervals:

• Every 250 hours – Basic maintenance check.

• Every 500 hours – Fluid replacements and brake inspections.

• Every 1,000+ hours – Deep inspections and potential part replacements.

Investing in professional servicing may seem like an added expense, but it pays off in the long run by extending the forklift’s lifespan and preventing major breakdowns.

Invest in Preventive Care for Long-Term Savings

Taking care of your forklift isn’t just about maintenance—it’s about maximizing your investment. By performing regular inspections, keeping the forklift clean, maintaining the battery and tires, training operators properly, and scheduling professional servicing, you can ensure your forklift stays in top shape for years to come.

Need help finding the perfect forklift or expert advice on maintenance? Forklift Select has a wide inventory of new and used forklifts from all major brands. Contact us today to keep your operations running smoothly.