Keeping your forklift running smoothly isn’t just about avoiding downtime — it’s about protecting your team, your investment, and your workflow. If you’ve ever wondered how to maintain a forklift or why it matters, this guide will walk you through everything you need to know, from daily inspections to battery care, OSHA compliance, and smart cost-saving strategies.
Let’s get into the real-life tips and strategies that keep your lift trucks in top shape.
Forklifts are workhorses, but without proper care, even the toughest lift can break down.
Here’s why regular forklift maintenance is critical:
Well-maintained forklifts save you time, money, and headaches — period.
Understanding your service schedule is step one. While specifics vary by model, usage, and environment, here are general forklift maintenance intervals:
Daily (Pre-Shift Inspections)
Every 250 Hours (6 Weeks)
Every 2,000 Hours (Annually)
Tip: More hours, older forklifts, or harsh environments may require shorter maintenance intervals.
The best maintenance starts with a habit. Train operators to complete a daily pre-use checklist before every shift.
Engine-Off Checks
Engine-On Checks
Electric forklifts are quiet, efficient, and low-maintenance — if you care for the battery properly.
Key Battery Care Tips:
Neglecting your forklift battery can shorten its life by years — and cost thousands to replace.
Keeping your forklift in good condition isn’t just smart — it’s required.
According to OSHA Standard 1910.178:
Maintenance Recordkeeping
While OSHA doesn’t require written inspection logs, keeping daily checklists and maintenance records is strongly recommended — especially during audits or accident investigations.
❌ Skipping Daily Inspections
Leads to undetected damage, unsafe conditions, and OSHA violations.
❌ Overcharging or Undercharging the Battery
Causes heat damage or incomplete cycles, shortening battery life.
❌ Ignoring Small Fluid Leaks
A small drip today could mean a major repair next week.
❌ Delaying Routine Service
Postponing scheduled maintenance often leads to higher long-term costs.
❌ Failing to Wash the Forklift
Dirt buildup damages components and may violate OSHA's cleanliness standards.
Sometimes, even with maintenance, your forklift may refuse to cooperate. Here’s how to safely move one that won’t start:
1) Turn off the key switch and set the parking brake.
2) Check the transmission and move it to neutral.
3) Use a tow tractor or another forklift to move the non-starting unit.
4) Never push with the forks — it can damage hydraulics.
5) Place warning signs to keep others away during the move.
If the battery or engine is completely dead, it’s best to call a certified technician rather than force a move.
Forklift maintenance costs vary by type, usage, and age — but here’s a general idea:
Cost-Saving Tips:
You can’t do it alone. Your operators, supervisors, and service techs all play a role in safe and efficient forklift upkeep.
Training Tips:
Make maintenance part of your culture — not just a task.
Daily inspections are the most critical step. They help catch safety issues early, keep your equipment OSHA-compliant, and prevent costly breakdowns.
Check electrolyte levels weekly, clean terminals, only charge when below 30%, and avoid using the battery right after charging to prevent overheating.
Set the parking brake, place the transmission in neutral, and move it using a tow tractor or another forklift. Never push it using the forks.
Most forklifts require full service every 250 hours (roughly 6 weeks) and deep service every 2,000 hours (annually), depending on use and environment.
No, but it’s highly recommended to keep inspection and maintenance logs for internal tracking and to protect yourself during audits.
Whether you run one forklift or a full fleet, preventive care is the key to reliability. A well-maintained forklift lasts longer, costs less, and keeps your warehouse running at full speed.
By building habits around daily inspections, battery care, and scheduled service, you’ll avoid surprises — and stay OSHA compliant.
If you’re looking for quality forklifts or parts that are built to last, Build-A-Ware has you covered.
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