Key Signs Your Forklift Needs Maintenance-RUNTX Machinery Group

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Key Signs Your Forklift Needs Maintenance

Sep 26,2025

Typically, a forklift should undergo a thorough inspection every 3 to 6 months to identify potential issues. Even if your forklift appears to be in good condition, it's prudent to check carefully for any signs of damage.

To prevent further damage, operators need to know what warning signs to look for. Our forklift maintenance checklist will help address this.

1. Damaged Forklift Chains

Damaged chains are a primary cause of forklift breakdowns. A failure during operation can lead to costly downtime and project delays.

Forklift chains generally don't require frequent replacement if properly lubricated with oil. However, signs of corrosion, rust, kinks, or excessive stretching indicate a need for repair or replacement. As a critical functional component, worn-out chains can also damage the loads being carried.

2. Fluid Leaks

This is one of the most critical aspects on the maintenance checklist. Be alert for leaks under or on the forklift; often, traces will be visible around the worksite.

Leaks mean less oil is available to lubricate moving parts, leading to increased friction, gear wear, and disrupted smooth operation. While adding oil is a common temporary response, it doesn't fix the root cause. Addressing leaks promptly is essential to prevent potential hydraulic system failure.

3. Battery Drain Issues

Choosing an electric forklift is an excellent decision for indoor operations. However, paying attention to battery maintenance is crucial, especially if it fails to hold a charge as it used to.

Start by assessing its condition: note how long the battery lasts compared to its previous performance. Typically, recharging when the battery reaches 20-30% of its capacity is recommended. Using the correct charger and ensuring adequate water levels are also important. If you notice rapid drainage, it's time to call for professional electric forklift repair services.

4. Worn or Damaged Forks

The forks are essential for forklift operation, and neglecting their condition poses both financial and safety risks. Damaged forks may fail to support loads properly, leading to dropped goods and product damage. Mishandling loads also creates safety hazards for onsite personnel.

Natural wear and tear occur over time based on load weight and usage frequency. However, visible surface cracks, bends, or misalignment demand immediate attention. Significant wear can also reduce the forks' load capacity, indicating that replacement is necessary.

Other Warning Signs Requiring Maintenance

In addition to the issues above, include the following points in your maintenance checklist to keep equipment running smoothly:

Excessive white or black exhaust smoke with a strong odor.
Rough operation indicating tire damage or need for replacement.
Engine temperature rising above the normal operating range.
Slow mechanical response when lifting or using attachments.
Mast wear or damage that hinders lifting functionality.
Timely detection through early maintenance can help avoid heavy repair costs. By adhering to these essential guidelines, your organization can prevent long-term and expensive consequences in forklift operations.

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