Forklifts are the backbone of many warehouses, manufacturing plants and logistics centres across Australia. When running smoothly, they increase productivity and help keep operations moving efficiently. But like any piece of heavy equipment, forklifts can experience issues that lead to costly downtime, safety risks and expensive repairs.To keep your fleet in top condition and your team safe, it’s essential to understand the most common forklift issues and, more importantly, how to prevent them.
Tyre Wear and Damage
Forklift tyres take a beating, especially in high-use environments. Over time, tyres can become worn, flat-spotted or damaged, reducing stability and handling. This can lead to uneven loads, decreased fuel efficiency and a higher risk of tipping.Prevention Tips:
- Conduct regular tyre inspections for wear, cracks or punctures.
- Ensure tyres are properly inflated (for pneumatic models).
- Rotate tyres as needed and replace them according to manufacturer guidelines.
Hydraulic Leaks
Hydraulic systems power key functions such as lifting and tilting. Leaks can occur in hoses, seals or fittings, leading to reduced lifting capacity, potential contamination and increased risk of system failure.Prevention Tips:
- Monitor hydraulic fluid levels and check for visible leaks.
- Train operators to report changes in lifting performance.
- Schedule regular servicing to replace worn seals and hoses before failure.
Battery Problems (for Electric Forklifts)
Battery issues are a leading cause of downtime in electric forklifts. Common problems include undercharging, overcharging, and improper watering—all of which can shorten battery life.Prevention Tips:
- Stick to a consistent charging schedule.
- Use only approved chargers and follow manufacturer recommendations.
- Check water levels weekly and top up with distilled water as needed.
Brake Wear and Malfunctions
Given the heavy loads and frequent stopping, forklift brakes are prone to wear and tear. Delayed stopping or squealing noises can indicate brake issues, which pose a significant safety hazard.Prevention Tips:
- Inspect brakes routinely as part of daily checks.
- Replace brake pads and shoes at the first sign of wear.
- Ensure operators are trained to recognise early signs of brake failure.
Steering Issues
If your forklift feels sluggish when turning or exhibits inconsistent steering, the cause could be low steering fluid, worn gears or issues with the steering cylinder.Prevention Tips:
- Check steering fluid levels regularly.
- Include steering checks in your preventative maintenance schedule.
- Lubricate steering components to reduce friction and wear.
Fork Misalignment or Damage
Forks can bend, crack or become misaligned through improper use or overloading. This can affect lifting accuracy and compromise load security.Prevention Tips:
- Train operators to avoid dragging forks or overloading.
- Perform visual inspections to detect damage early.
- Use fork callipers to ensure they remain straight and within spec.
Operator Safety Concerns
Many forklift-related incidents stem from operator error or a lack of awareness. While proper training is essential, technology also plays a key role in modern safety practices.Prevention Tips:
- Provide thorough training and refresher courses for all forklift operators.
- Install a forklift proximity detection system to enhance safety and reduce the risk of pedestrian collisions in high-traffic areas.
- Maintain clear floor markings and signage in shared spaces.
Preventative maintenance and operator vigilance are key to avoiding the most common forklift problems
By establishing a consistent inspection routine and investing in modern safety technologies, you can extend the life of your equipment, improve efficiency and keep your workplace safe.Whether you operate a single forklift or manage a large fleet, proactive care and attention to detail will always pay off in the long run.
