When Should a Forklift have Preventative Maintenance Done?

By Dave Martinez • May 26, 2012 • Posted in Forklift Maintenance, Forklift Operator Training, Preventative Maintenance

How Often Should a Forklift be Serviced?

You just bought a lift truck, and now the sales rep is presenting you with a maintenance contract to sign. The question arises: when should a forklift undergo preventative maintenance? The PM (Preventative Maintenance) contract suggests every 90 days. But how much maintenance is necessary, and how much is too much?

OSHA Rules Around Lift Truck Maintenance

OSHA has specific rules concerning the maintenance of industrial trucks, outlined in section 1910.178(q) of the compliance standards. According to OSHA, a lift truck must be removed from service if it is not “in safe operating condition.” Additionally, “all repairs shall be made by authorized personnel.” When creating a maintenance program, it is important to consult the “manufacturer’s instructions on vehicle maintenance.”

A Lift Truck Must be Safe to Operate

During regular maintenance visits, employers can ensure that a powered industrial truck is safe for use. A lift truck would be considered unsafe if, for example:

A gauge is malfunctioning
Welds are broken
Bolts are missing
The overhead guard is damaged
Tires are missing large pieces of rubber

What Do Manufacturers and Authorized Personnel Recommend?

Following OSHA's requirements for lift truck maintenance, let’s look at recommendations from manufacturers and lift truck maintenance companies.

Hours or Time – Whichever Comes First

Lift truck maintenance companies often recommend servicing forklifts based on usage intervals – measured in pedal or key hours, and time intervals – measured in days or months.

Key Hours vs. Pedal Hours

LP forklifts track hours by key hours, indicating how long the key switch is in the “on” position. Electric lift trucks often have multiple hour meters measuring motor and travel hours. Maintenance intervals typically depend on “Pedal Hours,” which measure when the lift truck’s deadman pedal is depressed.

Internal Combustion Lift Trucks Maintenance Schedule

A field service tech from Sunstate Equipment recommends service intervals based on hours. Here are the recommendations from a forklift mechanic:

Every 50 hours:

Grease zerks

Every 200 hours:

Replace the fuel filter
Perform an oil and filter change
Replace the air filter
Grease all lube points

Every 500 hours:

Service the hydraulic system with new filters
Change the hydraulic oil

Northern ToyotaLift of Vermont suggests servicing forklifts every 30 to 90 days or 100 hours, depending on usage. They inspect the following:

Mast and attachments
Drive train
Engine compartment (fluids and filters)
Electrical system
Brakes
Hydraulics
Steering system
Safety and cosmetic appearance

How Frequently Should I Change the Oil on a Mazda F2 Engine?

The frequency of oil changes for a Mazda F2 engine depends on factors such as the engine’s age, driving conditions, and maintenance history. Mazda generally recommends oil changes every 5,000 to 7,500 miles or every six months, whichever comes first.

What Is the Recommended Oil Change Interval for a GM 4.3 Engine?

For the GM 4.3 engine, the recommended oil change interval is typically every 5,000 to 7,500 miles or six months, depending on the vehicle’s usage and driving conditions. Severe conditions may warrant more frequent changes.

Oil Change Interval for a Toyota 4Y Engine

For the Toyota 4Y engine, oil changes are generally recommended every 3,000 to 5,000 miles, though driving conditions may require adjustments to this schedule.

Oil Change Interval for Nissan K21 and K25 Engines

The Nissan K21 and K25 engines typically require oil changes every 150 to 250 operating hours or three to six months, depending on operational conditions.

Recommended Oil Change Interval for a Mitsubishi S4S Engine

The Mitsubishi S4S engine generally needs oil changes every 250 to 500 hours or six to twelve months, based on usage.

Oil Change Interval for a Yanmar 4TNE Engine

The Yanmar 4TNE engine typically requires oil changes every 250 to 500 hours or six to twelve months, depending on operational conditions.

Kubota V2403 Engine Oil Change Interval

Oil changes for the Kubota V2403 engine are typically recommended every 250 to 500 hours or six to twelve months.

Electric Forklift Maintenance

Electric lift trucks have different maintenance intervals. Raymond Corporation has designed pallet trucks with self-lubricating bushings and AC motors to extend maintenance intervals and reduce maintenance costs.

Conclusion

If you regularly use a forklift, it’s advisable to have a trained technician inspect it every 90 days. Make sure they provide a list of items inspected, and ensure that the lift appears clean and well-maintained after each visit. Keep records of inspections to present to OSHA if needed. When selecting a company for forklift repair and service, check their offerings, inquire about first-call completion rates, and ask for references. Did we miss anything? Leave your comments below.