5 Crucial Signs Your Forklift Needs Preventive Maintenance

Is your forklift showing signs of trouble? Catching issues early with forklift preventive maintenance (PM) can save thousands in unexpected breakdowns, OSHA violations, or lost productivity.

Whether you're a warehouse manager or an operator, learning to recognize the warning signs can keep your equipment safe, efficient, and compliant.

1. Fluid Leaks: A Top Cause of Forklift Downtime

Hydraulic and transmission fluid leaks are a red flag. Leaks hurt performance, safety, and OSHA compliance. They also speed up wear and tear on seals, hoses, and cylinders.

How PM Fixes Hydraulic Leaks

• Inspect hoses and fittings for cracks or looseness
• Check fluid levels and look for contamination
• Replace worn seals and torque fittings

Learn more about our hydraulic repair services

2. Jerky or Sluggish Hydraulics

Does your forklift stutter when lifting or tilting? That’s a sign of air in the lines, old fluid, or a failing hydraulic pump. These issues compromise lifting precision and safety.

PM Solutions for Smooth Lift Operation

• Hydraulic fluid flush and filter replacement
• Cylinder performance testing
• Chain and carriage lubrication

3. Worn Tires or Uneven Tread

Tires are your forklift’s foundation. If you spot balding, cracking, or uneven wear, that’s a major safety risk. Tire damage affects stability, braking, and can even lead to tip-overs.

How PM Prevents Tire-Related Failures

• Visual inspection for tread depth, wear, and bulging
• Pressure checks and rotation schedule
• Load evaluation to correct overuse

Watch this quick tip on diagnosing forklift tire problems from our team at AAA Forklifts.

4. Battery and Electrical System Failures

Corroded terminals, weak charge cycles, and dim lights are early signs of electrical system failure. These issues drain productivity and can trigger total system shutdowns.

PM Battery Checks Include:

• Voltage testing and recharge capacity review
• Terminal cleaning and water level checks
• Wiring inspection on electric and IC forklifts

5. Unusual Noises, Smoke, or Vibration

Grinding, squealing, or clunking sounds should never be ignored. These typically signal belt, engine, or gearbox problems. Smoke from the exhaust can mean faulty injectors or valve wear.

Preventive Maintenance Includes:

• Sound and vibration diagnostics
• Engine and exhaust inspection
• Exhaust emission analysis (for propane/diesel models)

How Often Should Forklifts Be Serviced?

According to OSHA forklift compliance guidelines, forklifts must be inspected daily and serviced at regular intervals based on use:

• Light use (1–2 hours/day): Every 3 months
• Moderate use (3–5 hours/day): Every 2 months
• Heavy use (6+ hours/day): Monthly PM service

Need a reliable partner for scheduled forklift maintenance? AAA Forklifts provides both on-site service and in-shop repairs customized to your operation.

Download Your Forklift Inspection Checklist

Start a simple daily or weekly forklift PM program using our free form:

Click here to download our printable Forklift Inspection Checklist