Forklift maintenance on a preventive schedule is the simplest way to keep trucks available, safe and long-lasting. Well-maintained trucks break down less often, need fewer major replacement parts and hold their value better at resale. This article summarises the items to check on electric and diesel forklifts, in qualitative terms, so you can build a plan that fits your operation.
Three levels of forklift maintenance
An effective maintenance programme usually combines three complementary levels:
- Pre-shift checks: carried out by the driver before taking the truck, focusing on safety items that can be checked quickly.
- Scheduled servicing: carried out by technicians at the intervals in the manufacturer’s manual, usually based on operating hours or time, whichever comes first.
- Safety inspection: carried out by an authorised body according to current regulations.
Specific service intervals vary by model, drive type and working conditions. Trucks running multiple shifts, in dusty, hot and humid environments or on poor floors need more frequent care. Always follow the manufacturer’s instructions and your technician’s advice.
Common items for all forklifts
| Component | Inspection and servicing | Signs that action is needed |
|---|---|---|
| Mast and lift chains | Check chain elongation and lubricate; rollers and channels | Noisy chains, jerky lifting, mast play |
| Forks | Check heel wear, cracks, straightness; locking pins | Worn or bent forks, forks at different heights |
| Hydraulic system | Oil level and condition, hydraulic filter, hoses, cylinders | Oil leaks, mast creeping down, slow lifting |
| Brakes | Brake linings, brake fluid (if applicable), parking brake | Long stopping distance, noisy brakes |
| Steering | Play, joints, power steering | Heavy or loose steering, truck pulling to one side |
| Wheels | Wear, cracks, tread separation; wheel bearings | Vibration, uneven tyre wear |
| Safety equipment | Horn, lights, warning lights, mirrors, seat belt, overhead guard | Equipment not working or damaged |
| Chassis and counterweight | Cracks, loose bolts | Unusual noises while driving |
Maintaining electric forklifts
Electric forklifts have fewer moving parts than diesel trucks, so maintenance needs are generally lower. Many STILL trucks use AC motors that the manufacturer describes as low-maintenance. The following items still need attention:
Lead-acid batteries
- Check and top up with distilled water to the correct level at the right time as instructed (usually after charging).
- Clean the battery top and terminals; check for corrosion.
- Charge correctly, avoiding deep discharge and constant partial charging.
- Keep the charging area well ventilated, with safety measures for gases released during charging.
Lithium-ion batteries
- No watering required, but cables, connectors, battery casing and charger still need checking.
- Watch for battery management system warnings on the truck display.
- Use only a compatible charger.
For a detailed comparison of the two technologies, see lithium-ion vs lead-acid forklift batteries.
Electrical system
- Power cables, plugs, emergency stop switch.
- Clean dust from the controller and motors using a suitable method.
- Read stored fault codes in the controller to detect hidden issues.
Maintaining diesel and LPG forklifts
Internal combustion trucks have an entire engine system that needs regular care:
- Engine oil and oil filter: change at the manufacturer’s intervals using the correct oil grade.
- Air filter: clean or replace; especially important in dusty environments.
- Fuel filter and water separator: contaminated fuel can easily damage the injection system.
- Cooling system: coolant level, clean radiator, fan and belts.
- Exhaust system: check for leaks and exhaust condition; abnormal smoke indicates an engine problem.
- Starter battery, alternator, starter motor.
- Transmission and drivetrain: oil level, leaks.
- LPG trucks: check for leaks at the cylinder, valves and lines; vaporiser.
If you are deciding between the two, electric vs diesel forklift covers operating and maintenance costs in more detail. See the STILL diesel and LPG forklifts range.
Tracking maintenance with data
Paper records are easily lost, especially for large fleets. Connected solutions such as STILL FleetManager and Smart Portal handle driver management, shock detection and service interval tracking via a web interface. The display on many STILL trucks shows operating hours and battery status, making maintenance scheduling more accurate. See fleet management.
In-house maintenance or a service contract?
Businesses can handle pre-shift checks and simple tasks such as cleaning and battery watering themselves. Specialist work on hydraulics, control electronics, engines and brakes should be left to technicians trained to manufacturer standards using genuine parts. Non-standard parts can compromise safety and durability.
T&C provides forklift maintenance and repair services, scheduled or on demand.
Frequently asked questions
How often should a forklift be serviced?
Follow the intervals in each model’s operating manual, adjusted for the number of shifts and working environment. A technician will recommend a suitable schedule after an assessment.
Do electric forklifts need maintenance?
Yes. Although they have fewer wear parts than diesel trucks, electric trucks still need care for the battery, brakes, wheels, mast, hydraulics and electrical system.
Which signs require a technician immediately?
Weak brakes, loose steering, the mast creeping down, oil or fuel leaks, unusual noises or repeated error messages. Stop the truck and report it to maintenance.
Does T&C maintain used forklifts?
Yes. Contact us for an assessment of the truck’s condition and a proposed maintenance plan.
Need a maintenance plan for your fleet? Request a quote or call our hotline 0902 63 79 70.