EP.1 Extend the Lifespan of Your Forklift: 9 Essential Practices to Keep Your Equipment Running Longer

Forklifts are complex and high-value industrial machines that represent a significant investment for many businesses. Proper usage and maintenance are critical to ensuring long-term performance and minimizing issues before the next equipment replacement cycle. Here are 9 key practices to help extend the lifespan of your forklift:

1. Provide Proper Operator Training

Forklift operators play a crucial role in preserving equipment life. Comprehensive training not only enables correct operation and maintenance, but also helps reduce the risk of accidents and damage from improper use. Common causes of damage include:

• Incorrect operation, such as overloading or excessive use of the inching pedal (third pedal in engine forklifts) which can lead to clutch and transmission wear.
• Operator negligence, including collisions, excessive speed, and unsafe handling—resulting in structural damage and costly repairs.
• Lack of routine checks, such as ignoring low engine oil levels, which can lead to severe engine failure.

Daily pre-operation inspections can reduce accident risks by up to 70%. Additional measures include:

• Promoting a safety-first culture among employees.
• Installing speed limiters.
• Using collision detection and alert systems.

Warehouse managers should require all operators to attend certified forklift training courses provided by licensed training centers accredited by the Department of Skill Development.

2. Adapt Maintenance to the Work Environment

Forklifts are used across a wide range of industries, each with unique working conditions—rough terrains, potholes, dust, moisture, chemicals, or extreme temperatures—all of which can negatively impact forklift lifespan. Common issues include:

• Malfunctioning motors or drivetrains.
• Clogged cooling systems.
• Faulty switches or control units.

Simple actions can help protect your forklift:

• Regular cleaning to prevent rust.
• Dust removal with compressed air, especially in the engine bay.
• Selecting forklift models designed for specific environments.
• Inspecting and clearing work areas of obstructions and repairing damaged floors.

3. Maintain the Battery Properly

For electric forklifts, battery care is essential. Using undercharged batteries or neglecting distilled water levels accelerates battery degradation. Best practices include:

• Charging the battery fully before use.
• Avoiding use when charge drops below 30%.
• Refilling distilled water after full charge.

Read more about battery care →

4. Change Engine Oil on Schedule

For internal combustion forklifts, timely oil changes ensure performance, reduce fuel consumption, and prevent soot-related damage. Delaying oil changes may lead to severe engine damage.

• Change oil every 3 months or as recommended by the manufacturer.
• For forklifts used 8 hours daily, quarterly oil changes are ideal. For heavier use (over 12 hours/day), increase frequency to every 2 months.
• Check and top up other fluids like transmission oil, brake fluid, and radiator coolant.

5. Inspect Transmission and Drive Systems

Modern forklifts use automatic transmissions for better performance. Despite their durability, misuse and poor maintenance can cause damage.

• Replace transmission oil every quarter.
• Schedule comprehensive inspections every 10,000 hours.
• Train operators on proper driving techniques.
• Report abnormal noises, poor acceleration, or decreased performance immediately.

6. Prioritize Brake System Maintenance

Accidents caused by brake failure can result in massive costs and safety risks. Key maintenance steps include:

• Regularly check brake fluid levels and brake pad condition.
• If braking requires deep pedal pressure, consider replacing the pads.
• Don't forget to check the handbrake to prevent rollaways on inclines.

7. Inspect Fork Condition

Forks are vital load-bearing components and must be checked regularly. Ensure forks are straight and free of bending or deformation. Damaged forks can lead to:

• Load instability or accidents.
• In severe cases, tip-overs.

Replace forks that show signs of bending, cracking, or excessive rust.

8. Ensure Tires Are in Good Condition

Forklifts are heavy machines, especially under full load. Tires bear this weight and must be in optimal condition. Most operators prefer solid tires for their durability and low maintenance.

• If using pneumatic tires, check air pressure regularly.
  • Low pressure affects handling and causes rapid wear.
  • Overinflation increases the risk of blowouts, especially under heavy loads and high temperatures.
• Replace worn or peeling tires to ensure driving safety.

Learn more about tires →

9. Implement Preventive Maintenance (PM)

Adhering to the manufacturer’s recommended maintenance schedule ensures optimal performance and safety. Preventive maintenance reduces breakdown risks and extends equipment lifespan.

Ignoring regular maintenance may:

• Lead to equipment deterioration.
• Violate labor safety regulations.
• Result in high repair costs or revenue loss from operational downtime.

While scheduled PM may temporarily pause operations, it is far more cost-effective than emergency repairs. Whether you operate forklifts daily or occasionally, maintenance should never be overlooked.

A Final Note on Forklift Lifecycle Value

These practices are not only applicable to forklifts, but also to pallet trucks and hand lifts. If in-house maintenance isn't feasible, consider service contracts with authorized dealers for professional inspection and upkeep. Typically, a new forklift offers a minimum working lifespan of 10,000 hours. Even well-maintained older units may become economically inefficient. Rather than continuing repairs, it may be more cost-effective to invest in a new unit. For example, an engine-powered forklift used 8 hours per day, 5 days a week for 5 years will approach 10,000 operating hours. If the cumulative repair costs approach the price of a new forklift, it’s time to consider a replacement.

Need Assistance?

Jenbunjerd offers forklift sales and rental services, with service centers located in Nakhon Ratchasima, Ayutthaya, Rayong, Chonburi, and Lopburi. Feel free to contact us for more information.