{"id":14359,"date":"2023-09-15T11:43:54","date_gmt":"2023-09-15T17:43:54","guid":{"rendered":"https:\/\/limblecmms.com\/?p=14359"},"modified":"2025-05-30T13:03:28","modified_gmt":"2025-05-30T19:03:28","slug":"forklift-checklist","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/forklift-checklist\/","title":{"rendered":"Forklift preventive maintenance checklist"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><div class=\"vc_row wpb_row vc_row-fluid limble-page-blog-width vc_custom_1684450192166 vc_row-bg-position-top\">\n<div class=\"wpb_column vc_column_container vc_col-sm-12\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"wpb_text_column wpb_content_element \">\n<div class=\"wpb_wrapper\">\n<div class=\"vc_row wpb_row vc_row-fluid limble-page-blog-width vc_custom_1684450083195 vc_row-bg-position-top\">\n<div class=\"wpb_column vc_column_container vc_col-sm-12\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"wpb_text_column wpb_content_element \">\n<div class=\"wpb_wrapper\">\n<div class=\"vc_row wpb_row vc_row-fluid vc_row-bg-position-top\">\n<div class=\"wpb_column vc_column_container vc_col-sm-12\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"wpb_text_column wpb_content_element vc_custom_1684440885221\">\n<div class=\"wpb_wrapper\">\n<div class=\"vc_row wpb_row vc_row-fluid vc_row-bg-position-top\">\n<div class=\"wpb_column vc_column_container vc_col-sm-12\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"wpb_text_column wpb_content_element vc_custom_1686694634753\">\n<div class=\"wpb_wrapper\">\n<p>Whether you operate a warehouse, supermarket, manufacturing facility, or airfield, you can\u2019t get work done without forklifts (also known as lift trucks). But to prevent unexpected breakdowns and lower downtime, knowing effective forklift <a href=\"https:\/\/limblecmms.com\/strategies\/preventive-maintenance\/\">preventive maintenance<\/a> is a must.<\/p>\n<p>Forklifts are vital for material handling. If they stop working out of the blue, they can threaten the operational efficiency of a facility, skyrocket maintenance costs, and even result in accidents. We\u2019ll break down the forklift preventive maintenance process into multiple checklists, which you can use as templates for your organization.<\/p>\n<p><em><a href=\"https:\/\/limblecmms.com\/resources\/\">Explore our free maintenance templates &amp; checklists<\/a><\/em><\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"vc_row wpb_row vc_row-fluid vc_row-bg-position-top\">\n<div class=\"wpb_column vc_column_container vc_col-sm-12\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"wpb_text_column wpb_content_element \">\n<div class=\"wpb_wrapper\">\n<h2>Forklift Preventive Maintenance Checklist at-a-glance<\/h2>\n<p>At first, a forklift may seem like a complex machine. However, it only consists of the following main components:<\/p>\n<ul>\n<li>The engine (the main power source)<\/li>\n<li>Counterweight (prevents the forklift from flipping\/lifting when weight is added)<\/li>\n<li>The carriage (the base of the lift)<\/li>\n<li>The mast (this is the \u201clift\u201d part of the vehicle that includes interlocking rails, forks, and rollers)<\/li>\n<\/ul>\n<p>By knowing these different components, you can move on to perform maintenance checks on your forklift.<\/p>\n<p>Keep in mind that the exact set of maintenance checklists will vary from manufacturer to manufacturer.\u00a0But at the end of the day, all forklifts require the same level of care (not considering the source of power) \u2013 keeping the OSHA requirements as a universal yardstick.<\/p>\n<p>Before we jump into the main checklists, let\u2019s look at the basics:<\/p>\n<ul>\n<li><strong>Check Fluids<\/strong>\u00a0\u2013 regardless of what type of forklift you\u2019re using, always check fluid levels before operating the machine.<\/li>\n<li><strong>Look for Visible Damage<\/strong>\u00a0\u2013 instruct operators to ensure that their forklifts are in good condition before they start using them. They should check all the components for any visible damage and don\u2019t hesitate to report this to their supervisors.<\/li>\n<li><strong>Inspect Tires Regularly<\/strong>\u00a0\u2013 this also includes breaks. A forklift crashing into a stack of pallets can cause injuries, result in monetary damages, and just royally ruin your day.<\/li>\n<li><strong>Keep the Vehicle Spotless<\/strong>\u00a0\u2013 remove debris from the compartment and make sure that it\u2019s comfortable and safe for the operator.<\/li>\n<li><strong>Check the inspection Decals\/Stickers<\/strong>\u00a0\u2013 one of OSHA\u2019s requirements for forklift safety is to make sure that the inspection stickers and decals are placed on the right spots (and that they are easily readable).<\/li>\n<\/ul>\n<p>The aforementioned points broadly cover almost everything.\u00a0However, we need to get a little more specific. To help out, we\u2019ve broken down the checklist into two phases.<\/p>\n<p>Let\u2019s jump right in.<\/p>\n<p>[vc_row content_placement=&#8221;middle&#8221; css_animation=&#8221;fadeInDown&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1699310630716{margin-top: 30px !important;margin-bottom: 50px !important;padding-top: 50px !important;padding-bottom: 50px !important;background-color: #dde4e8 !important;border-radius: 20px !important;}&#8221;][vc_column width=&#8221;2\/3&#8243; css=&#8221;.vc_custom_1699310302582{padding-left: 25px !important;}&#8221;]<header class=\"kd-section-title col-lg-12 text-left  subtitle-below-title    vc_custom_1699310643691\" ><h3 class=\"separator_off\" >Download our Free Preventive Maintenance Plan Template!<\/h3><p class=\"subtitle\" >Following a consistent Preventive Maintenance Plan can make life easier. Use this template to create your own.<\/p><\/header><a  href=\"https:\/\/limblecmms.com\/resources\/free-preventive-maintenance-checklist\/\"  target=\"_self\"  title=\"Download Now\"  class=\"tt_button tt_primary_button btn_primary_color  button-center button-action-link icon_right\" ><span class=\"prim_text\">Get the Template<\/span><span class=\"fas fa-angle-right iconita\" ><\/span><\/a>[\/vc_column][vc_column width=&#8221;1\/3&#8243;][vc_single_image source=&#8221;external_link&#8221; custom_src=&#8221;https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/PM%20Checklist%20mockup.png&#8221; css=&#8221;.vc_custom_1699310204115{padding-bottom: 10px !important;}&#8221;][\/vc_column][\/vc_row]<\/p>\n<h3>Phase-1: The Stationary Checklist<\/h3>\n<p>In the first phase of forklift preventive maintenance service, you\u2019ll kick things off by inspecting and servicing the vehicles when they\u2019re not moving.<\/p>\n<p>To be more specific, this involves looking under the hood (at the engine and other critical components of the forklift) and ensuring that everything is in optimal condition.<\/p>\n<p>However, there\u2019s no one-size-fits-all checklist for every forklift, as they can be of the following three types:<\/p>\n<ul>\n<li>Internal combusting engine forklifts<\/li>\n<li>Battery-powered\/Electric Forklifts<\/li>\n<li>Propane Forklifts<\/li>\n<\/ul>\n<p>Each type entails a different set of tasks. Let\u2019s take a look at them \u2013 one at a time:<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"img-fluid wp-image-193 aligncenter\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance.jpg\" sizes=\"auto, (max-width: 640px) 100vw, 640px\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance.jpg 640w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-116x300.jpg 116w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-395x1024.jpg 395w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-592x1536.jpg 592w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-92x238.jpg 92w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-113x292.jpg 113w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-23x60.jpg 23w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-156x405.jpg 156w, https:\/\/limblecmms.com\/wp-content\/uploads\/2017\/08\/Forklift-Maintenance-39x100.jpg 39w\" alt=\"Forklift Maintenance\" width=\"500\" height=\"1296\" \/><\/p>\n<h4>For Internal Combustion Engine Forklifts<\/h4>\n<p>These forklifts are powered by conventional internal combustion engines. Typically, they require gasoline or diesel as the fuel.<\/p>\n<p>Internal combustion engine forklifts generate more power than electric ones and are therefore suitable for outdoor use.<\/p>\n<p>To prevent yours from breaking down, follow these forklift preventive maintenance tasks:<\/p>\n<ul>\n<li><strong>Check Engine Oil Levels<\/strong>\u00a0\u2013 before anything else, make sure that your engine oil levels aren\u2019t below acceptable levels. If the engine is deprived of oil, friction between the intricate parts will eventually result in a seizure.<\/li>\n<li><strong>Inspect Fluid and Coolant Levels<\/strong>\u00a0\u2013 in addition to the engine oil, also check the hydraulic brake fluids to prevent breaks from failing (and clutches from breaking down). Furthermore, check the levels of engine coolant\/anti-freeze.<\/li>\n<li><strong>Check Radiator and Air-Filter<\/strong>\u00a0\u2013 make sure that the radiator is clean. And make sure that the air filter doesn\u2019t need changing (a rule of thumb is to change them after every 500 hours).<\/li>\n<li><strong>Inspect Hoses and Belts<\/strong>\u00a0\u2013 finally, make sure that there aren\u2019t any cracks in the hoses and that the belts haven\u2019t worn out.<\/li>\n<\/ul>\n<p>In addition to the above, make sure that the hood latch is properly secured (this applies to all forklifts).<\/p>\n<p>If you regularly check all of the above, your internal combustion engine forklifts will stay up and running.<\/p>\n<h4>For Battery Powered Forklifts<\/h4>\n<p>Like electric cars\/trucks, forklifts can also be powered with batteries (both lead-acid and lithium).<\/p>\n<p>Compared to internal combustion engine forklifts, electric forklifts can\u2019t lift a lot of weight. For that reason, they are most suitable for indoors.<\/p>\n<p>To increase the lifespan of your battery-powered forklift, do the following:<\/p>\n<ul>\n<li><strong>Check Water Levels<\/strong>\u00a0\u2013 if your forklifts are powered by lead-acid batteries, make sure that they are adequately watered on a daily basis.<\/li>\n<li><strong>Check for Sulfur Deposits<\/strong>\u00a0\u2013 again, this applies to only lead-acid batteries. Over time, needle-like deposits can form on the lead plates, which can hinder the performance of the battery. It can even cause a short-circuit in the battery.<\/li>\n<li><strong>Inspect Wiring<\/strong>\u00a0\u2013 finally, ensure that the cables aren\u2019t loose and\/or frayed. Exposed wires are a recipe for disaster.<\/li>\n<\/ul>\n<p>Lithium batteries usually don\u2019t require much maintenance. Just make sure that you don\u2019t operate your forklift in unusually hot environments.<\/p>\n<h4>For Liquid Propane Forklifts<\/h4>\n<p>As the name suggests, these forklifts are powered by liquid propane \u2013 a type of liquid petroleum gas (LPG).<\/p>\n<p>They use propane tanks that are usually mounted at the back. Extreme care is warranted since liquid propane is highly flammable.<\/p>\n<p>To create a safe environment for your staff and ensure the longevity of your forklifts, take the following steps:<\/p>\n<ul>\n<li><strong>Inspect the Tank<\/strong>\u00a0\u2013 first and foremost, ensure that the propane tank is mounted properly. Furthermore, keep an eye out for any visible damage (usually, you\u2019ll hear a hissing sound which can indicate gas leakage.<\/li>\n<li><strong>Check the Position of the Relief Valve<\/strong>\u00a0\u2013 the relief valve of the propane tank should always point upwards.<\/li>\n<\/ul>\n<p>Finally, check the belts and hoses for any visible damage, and replace them from time to time. And as mentioned above, make sure that the hood latch is working properly.<\/p>\n<h3>Phase-2: The Mobile Checklist (For Every Type of Forklift)<\/h3>\n<p>After catering to the critical components, it\u2019s time to move on to phase-2 of forklift preventive maintenance.<\/p>\n<p>For this purpose, you may need to operate the different forklift parts in question to ensure they are in optimal conditions.<\/p>\n<p>Keep in mind that this checklist applies to every type of forklift.<\/p>\n<h4>Check the Basic Components of the Vehicle<\/h4>\n<p>Start off by checking the basic components found in almost every vehicle.<\/p>\n<p>This includes:<\/p>\n<ul>\n<li><strong>Tires<\/strong>\u00a0\u2013 as mentioned earlier, worn-out tires (and brakes) can result in serious accidents. Checking the tire condition should be your first priority (after the main engine\/power source).<\/li>\n<li><strong>Steering<\/strong>\u00a0\u2013 if the operators feel that the steering isn\u2019t working smoothly, they should immediately report to their supervisors.<\/li>\n<li><strong>Accelerator<\/strong>\u00a0\u2013 make sure that the forklift is moving at a normal speed.<\/li>\n<li><strong>Clutch<\/strong>\u00a0\u2013 if your forklift has the option to shift to a higher gear for increased speed, check the clutch to see if it\u2019s working properly. Furthermore, check that all gears work properly.<\/li>\n<li><strong>Lights<\/strong>\u00a0\u2013 like other vehicles, forklifts have headlights and brake lights. Additionally, they can also have strobe lights (however, they aren\u2019t required by OSHA).<\/li>\n<li><strong>Safety Devices<\/strong>\u00a0\u2013 this includes the seatbelt, horn, and the backup alarm. All of these things are important for the safety of the operators and other personnel in the facility.<\/li>\n<\/ul>\n<p>After checking and tending to the main vehicle, the only thing left to do is to look at the actual forklift part of your forklift.<\/p>\n<p>If the lift unexpectedly breaks down, the entire forklift will become pretty much useless.<\/p>\n<p>To make sure that doesn\u2019t happen, you should:<\/p>\n<ul>\n<li><strong>Check the Carriage<\/strong>\u00a0\u2013 make sure that no nuts\/bolts are loose.<\/li>\n<li><strong>Check the Mast<\/strong>\u00a0\u2013 this is the main part of the lift. Check if it\u2019s working properly, and if not, take appropriate measures to fix the problem.<\/li>\n<\/ul>\n<p>The key to keeping the lift in an optimal condition is to always keep it well-lubed.<\/p>\n<h3>Increase the Lifespan of Your Forklifts<\/h3>\n<p>Forklifts are expensive. And if they break down frequently, their unplanned maintenance costs can substantially add up.<\/p>\n<p>For that reason, you should have a separate preventative maintenance program for your forklifts.<\/p>\n<p>Here\u2019s what it entails:<\/p>\n<h4>Create a Forklift Maintenance Schedule<\/h4>\n<p>Start off by marking a calendar with maintenance tasks for your forklift.<\/p>\n<p>If the manufacturer has provided any recommendations for how often you should perform maintenance, stick with those.<\/p>\n<p>In case there aren\u2019t any clear recommendations, follow OSHA\u2019s requirements:<\/p>\n<ul>\n<li>Perform a short-term inspection every 200 hours.<\/li>\n<li>Perform an in-depth inspection once every year or after every 2000 hours (whichever comes first).<\/li>\n<li>Conduct a special lifting inspection when the forklift is used for the first time or handed over to a new owner. In any case, the lifting mechanism should be inspected once every year.<\/li>\n<\/ul>\n<p>Automate the work orders and share the schedule with everyone.<\/p>\n<h4>Create an Effective Training Program<\/h4>\n<p>In addition to having experienced forklift operators, you also need licensed technicians who know what they\u2019re doing.<\/p>\n<p>For that reason, you need to create and implement a comprehensive training program \u2013 just for forklift preventive maintenance.<\/p>\n<h4>Leverage a CMMS<\/h4>\n<p>Last but not least, it\u2019s highly recommended that you install and use a trustworthy <a href=\"\/cmms\/\">computerized maintenance management system (CMMS).<\/a><\/p>\n<p>Manually managing a forklift maintenance plan can take its toll on your administrative capacity.<\/p>\n<p>Some automation will leave you with enough time to focus on other important things.<\/p>\n<h2>Final Thoughts<\/h2>\n<p>With effective planned maintenance, you can substantially slash the downtime, boost efficiency, and extend the lifespans of your forklifts.<\/p>\n<p>The same applies to almost every machine.<\/p>\n<p>Performing annual and daily checks on a consistent basis will help you stay on top of things and ensure the optimal performance of your assets.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>Whether you operate a warehouse, supermarket, manufacturing facility, or airfield, [&hellip;]<\/p>\n","protected":false},"author":77,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[398],"tags":[],"class_list":["post-14359","post","type-post","status-publish","format-standard","hentry","category-preventive-maintenance"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Forklift Preventive Maintenance Checklist | Limble CMMS<\/title>\n<meta name=\"description\" content=\"Develop combustion engine, battery powered, or liquid propane forklift preventive maintenance checklists with this helpful guide.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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