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Forklift Life Expectancy


How Long Will a Lift Truck Last?

old yale forklift

Many people suggest that a lift truck can last up to 10,000 pedal hours, while some brands may last as long as 13,000 hours or more, especially in freezer and cooler environments.

A forklift may continue to operate long after it’s been replaced, but the key question is: how reliable and costly will it be to maintain?

Related: How to Reduce Lift Truck Fleet Costs

As a lift truck ages, maintenance costs inevitably rise, though several factors contribute to this.

Does the Fork Truck Work on the Dock?

When a lift truck crosses a dock plate, the vibrations can significantly affect its lifespan. Key areas impacted include:

  • Pallet jack
    • Undercarriage, pins, and bushings begin to wear out.
  • Forklift
    • Motors may vibrate and loosen over time.
  • Reach truck
    • Not recommended for dock work, as the base legs can twist and become uneven.

Does the Lift Truck Work in a Cooler or Freezer?

Expect a shorter lifespan for forklifts in cold environments. Just as cars wear out faster in cold climates compared to dry, arid ones, forklifts will also age more quickly when exposed to low temperatures.

Does the Forklift Operate Around Brine or Poultry?

This environment can cut the lift truck’s lifespan in half. Exposure to fish scales or chicken by-products accelerates corrosion and weakens the metal, making it one of the harshest environments for a forklift.

Can an Electric Lift Truck Work Outside?

Unless the electric forklift is adequately protected from water entering the motor compartment, the electrical components can become damaged, leading to costly repairs.

Cost of Ownership for a Forklift

As a lift truck ages, the cost of keeping it operational increases. Components have a limited lifespan and will require replacement over time. Factoring in the cost of repairs, downtime, and lost labor creates a compelling case for replacement. Fleet managers often measure the rising cost of ownership by dividing maintenance and repair costs by the number of pedal hours the lift truck operates over a given period (e.g., quarterly, bi-annually, or annually). This calculation yields a cost per pedal hour. Benchmark this figure against 8% of the truck’s original purchase price annually. If the lift truck costs more than 8% of its purchase price per year to maintain, it may be time to consider replacing it.

Forklift Maintenance Extends the Life

Maintenance is critical for materials handling equipment. While it may seem like an unnecessary expense, especially during the warranty period, regular maintenance extends the life of a lift truck. Here are some ways maintenance reduces overall ownership costs and extends a forklift’s lifespan:

  • Factory warranties typically require regular maintenance to remain valid.
  • Bushings and grease zerks need regular greasing. Without it, metal-on-metal wear can occur, causing fittings to loosen and create further damage as the lift shifts.
  • A trained technician can identify debris or trash caught in the gears or bearings during routine inspections, preventing them from binding and causing failure.
  • Replacing an aging hydraulic line before it fails is less expensive than replacing electronics damaged by a hydraulic leak.

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