5 Costly Forklift Repair Mistakes and How to Avoid Them

The Importance of Proper Forklift Maintenance

Forklifts are the backbone of warehouse and industrial operations, ensuring the efficient movement of heavy loads. However, poor maintenance practices can lead to costly repairs, unexpected downtime, and even workplace accidents. Many businesses unknowingly make critical forklift repair mistakes, leading to higher operating costs and shorter equipment lifespan.

To keep your forklifts running smoothly and avoid expensive repairs, here are the five most common forklift maintenance mistakes and how to prevent them.

1. Ignoring Minor Issues Until They Become Major Repairs

One of the biggest forklift maintenance mistakes is neglecting small problems, hoping they will resolve themselves. What starts as a minor leak, squeak, or warning light can quickly escalate into a major breakdown.

• Address fluid leaks, engine noises, or electrical faults as soon as they arise.
• Train operators to report issues immediately rather than waiting for scheduled maintenance.
• Implement a preventive maintenance program to catch problems before they lead to costly repairs.

2. Using the Wrong Replacement Parts

Cutting costs by using cheap, aftermarket parts may seem like a good idea at first, but low-quality components can lead to premature failure and safety risks.

• Always use OEM (Original Equipment Manufacturer) or high-quality aftermarket parts that meet manufacturer specifications.
• Consult a qualified forklift technician before replacing critical components.
• Avoid mismatched tires, filters, or hydraulic components that can cause operational inefficiencies.

3. Skipping Regular Battery Maintenance for Electric Forklifts

For electric forklifts, the battery is the heart of the machine. Improper battery care leads to shortened battery life, power loss, and expensive replacements.

• Keep batteries properly charged, avoiding both overcharging and deep discharges.
• Regularly check water levels in lead-acid batteries and use distilled water only.
• Clean battery terminals to prevent corrosion and poor connectivity.

4. Overlooking Fluid and Filter Changes

Just like any internal combustion engine, forklifts require regular oil, coolant, and hydraulic fluid changes. Failing to replace filters and fluids on schedule leads to engine wear, overheating, and hydraulic system failures.

• Change engine oil, hydraulic fluid, and transmission fluid as per manufacturer recommendations.
• Replace fuel, air, and oil filters to prevent contaminants from damaging critical components.
• Inspect hoses and seals for signs of leaks or deterioration.

5. Neglecting Fork and Mast Inspections

The forks and mast assembly endure constant stress and must be inspected regularly for wear and damage. Cracks or bent forks can lead to load instability and serious accidents.

• Check fork thickness—if it's worn more than 10%, it needs to be replaced.
• Look for cracks, bends, or misalignment in the forks and mast components.
• Lubricate chains, rollers, and bearings to ensure smooth lifting operation.

Conclusion

Avoiding these costly forklift repair mistakes can save your business thousands of dollars in unnecessary repairs, downtime, and lost productivity. By addressing minor issues early, using quality parts, maintaining batteries, replacing fluids on time, and inspecting forks and masts regularly, you can extend your forklift’s lifespan and reliability.

For professional forklift maintenance and repairs in Chicago, IL, contact ProLift Inc today. Our experienced technicians ensure your equipment operates safely and efficiently, reducing your repair costs and downtime.