Forklifts are essential in warehouses, construction sites, and logistics operations. Despite their robust design, regular use causes wear and tear that can reduce performance and increase safety risks. Proactive, routine servicing is crucial to keep forklifts operating efficiently and safely — especially for businesses in busy areas like Perth.
Battery and power issues
Electric forklifts depend on healthy batteries. Common problems include poor charging practices, corroded terminals, and degraded cells, any of which can cause unexpected downtime. Regular inspections should include checking charge cycles, cleaning terminals, tightening connections, and testing individual cells for capacity. In Perth’s warm climate, batteries are also more vulnerable to heat-related degradation, so monitor temperature and charging behaviour closely. For general battery maintenance guidance, see this battery charging resource (Battery University).
Hydraulic system failures
The hydraulic system controls lifting and manoeuvring and is essential to safe operation. Leaks, contaminated hydraulic fluid, worn or damaged seals, and blocked hoses will reduce performance and can lead to dangerous failures. Routine service should include fluid-level checks, fluid condition analysis, seal and hose inspections, and leak detection. Replacing contaminated fluid and worn seals promptly prevents more extensive damage and maintains lifting reliability.
Overheating engines
Internal combustion forklifts (diesel, petrol, or LPG) can overheat if air filters are clogged, coolant levels are low, or thermostats and radiators are faulty. Preventive steps include cleaning or replacing air filters, checking and topping up coolant, inspecting belts and hoses, and verifying thermostats and fans operate correctly. These routine checks are particularly important during Perth’s hotter months.
Tyre wear and damage
Tyres take significant stress in heavy-duty operations and can develop uneven wear, punctures, or blowouts. Regular tyre inspections should include visual checks for cuts and embedded objects, measuring tread wear, and verifying correct tyre pressure. Timely rotation or replacement maintains machine stability, improves traction, and reduces the risk of accidents.
Brake and steering problems
Brakes and steering are critical for safe handling. Brake pads, drums, discs, and hydraulic or mechanical linkages wear with use; steering components can also loosen or misalign. Scheduled maintenance should include checking brake pad thickness, testing braking performance, inspecting steering linkages and bushings, and making necessary adjustments or replacements to ensure responsive, reliable control.
Fork and mast wear
Forks and masts endure constant loading and movement, which can lead to bending, cracks, or misalignment. Routine visual and dimensional inspections detect early signs of fatigue. Addressing wear promptly — repairing cracks, replacing damaged forks, and correcting mast alignment — reduces the risk of failures and extends equipment life.
Sensor and electrical failures
Modern forklifts often incorporate sensors and electronic controls for safety and efficiency. Faulty sensors, corroded connectors, or damaged wiring can produce inaccurate readings or disable safety interlocks. Regular diagnostic checks and electrical inspections help identify faults early so they can be repaired before they cause downtime or unsafe conditions.
Benefits of routine forklift service in Perth
Prioritising routine forklift maintenance delivers clear operational and financial benefits:
- Fewer unexpected breakdowns and less unplanned downtime.
- Longer equipment life and lower long-term replacement costs.
- Improved fuel or energy efficiency.
- Enhanced workplace safety and reduced liability risk.
- Better compliance with local safety guidance and regulations.
For organisations, partnering with a local specialist ensures service schedules, spare parts and maintenance practices are tailored to the regional climate and operational demands. For industry safety standards and guidance, consult your local regulator such as Safe Work Australia or local WorkSafe authorities. For local, tailored support in Perth see forklift service in Perth.
Recommended routine checks
As part of routine servicing, consider a regular checklist that includes:
- Daily: visual safety checks, fluid levels, tyre pressure, battery terminals, and basic controls test.
- Weekly: deeper inspections of brakes, mast and fork condition, and hydraulic lines.
- Monthly or quarterly: electrical diagnostics, battery capacity tests, full fluid changes, and engine tune-ups for combustion models.
Conclusion
Forklifts are indispensable workplace assets, and consistent maintenance is non-negotiable for efficient, safe operations. Addressing common issues through routine servicing reduces downtime, cuts costs, and protects workers. For businesses in Perth, investing in professional, locally informed forklift service is a smart step toward reliable and sustainable operations.
