What Should You Expect from Forklift Servicing

[MikePhua]

The Rise of Electric Forklifts and Their Maintenance Needs
Electric forklifts have become a cornerstone of modern warehousing and logistics operations. With zero emissions, quiet operation, and lower maintenance costs compared to internal combustion models, they are especially favored in indoor environments. Brands like Crown and Caterpillar have led the charge in this segment, offering counterbalance and reach truck models tailored for tight aisles and high stacking.
Crown Equipment Corporation, founded in 1945 in Ohio, has grown into one of the top five global forklift manufacturers, with over 500,000 units sold annually. Caterpillar, with its industrial equipment legacy dating back to 1925, entered the forklift market through partnerships and acquisitions, offering robust reach trucks designed for precision and durability.
As these machines age, servicing becomes critical—not just for performance, but for safety and compliance. Yet many operators remain unclear about what a forklift service actually entails.
What Does a Forklift Service Include
A comprehensive forklift service typically goes beyond fluid top-ups. For electric models, especially reach trucks and counterbalance units, a standard service may include:

• Visual inspection of mast, carriage, and forks for cracks or wear
  
• Lubrication of mast channels, chains, and pivot points
  
• Adjustment of chain tension and fork alignment
  
• Inspection of hydraulic hoses and fittings for leaks or abrasion
  
• Testing of lift and tilt functions under load
  
• Battery condition check (if not leased separately)
  
• Brake system inspection, including pedal travel and fluid level
  
• Steering system evaluation for play or binding
  
• Tire condition and inflation check
  
• Safety feature verification (horn, lights, backup alarm)
  
• Diagnostic scan for error codes via onboard controller
  
• Cleaning of contactors and electrical terminals
  
• Inspection of seat, restraints, and operator controls
  

Some service providers advertise a “63-point check,” which may sound generic but often includes the above items. The term “service” can vary by vendor—some treat it as a preventive maintenance visit, others as a full mechanical and electrical overhaul. It’s important to clarify whether adjustments and minor repairs are included or billed separately.
Juddering at Full Reach and What It Might Mean
A common symptom in aging reach trucks is juddering or jumping when the mast nears its maximum extension. This can be caused by:

• Worn mast rollers or guide bearings
  
• Hydraulic cylinder stiction due to contamination
  
• Air in the hydraulic system
  
• Weak lift motor or degraded brushes
  
• Controller miscalibration or sensor drift
  

To address this, technicians may:

• Flush and replace hydraulic fluid
  
• Bleed the lift circuit to remove trapped air
  
• Inspect and replace worn rollers
  
• Calibrate lift height sensors
  
• Test motor output under simulated load
  

In one case, a distribution center in Manchester experienced intermittent juddering on a CAT reach truck. After multiple service visits, the issue was traced to a cracked mast weld that flexed under load. The repair required welding reinforcement and realignment, restoring smooth lift operation.
Contracted Service vs. In-House Maintenance
Large operations often outsource forklift servicing under annual contracts. While cost-effective, these arrangements may prioritize speed over thoroughness. Technicians perform safety checks, scan for faults, and report issues—but repairs may require separate work orders, delaying resolution.
Advantages of contracted service:

• Predictable costs
  
• Access to OEM diagnostic tools
  
• Compliance with safety regulations
  
• Scheduled visits reduce downtime
  

Disadvantages:

• Repairs may be delayed due to parts availability
  
• Technicians may lack familiarity with site-specific usage
  
• Battery systems often excluded from service scope
  

In contrast, in-house maintenance teams can respond faster and tailor inspections to operational needs. However, they require training, tools, and access to technical documentation.
Battery Maintenance and Why It’s Often Overlooked
Electric forklifts rely on traction batteries—either lead-acid or lithium-ion. In leased battery arrangements, servicing may be handled by a separate vendor. This can lead to gaps in maintenance, especially if battery health is not monitored regularly.
Key battery checks include:

• Electrolyte level and specific gravity (for lead-acid)
  
• Terminal corrosion and cable integrity
  
• Equalization charge scheduling
  
• Temperature monitoring during charge cycles
  
• Battery management system (BMS) fault logs
  

Neglecting battery care can result in reduced runtime, voltage drops under load, and premature failure. A 2021 study found that forklifts with proactive battery maintenance had 22% fewer breakdowns and 15% longer service life.
Preventive Maintenance and Long-Term Reliability
To maximize uptime and reduce repair costs, operators should implement a preventive maintenance schedule:

• Daily pre-shift inspections (brakes, steering, lights, forks)
  
• Weekly lubrication of mast and pivot points
  
• Monthly hydraulic fluid checks and top-ups
  
• Quarterly diagnostic scans and brake inspections
  
• Annual full service with load testing and controller updates
  

Documentation is key. Logging service intervals, fault codes, and technician notes helps identify recurring issues and supports warranty claims.
A Story from the Warehouse Floor
In 2018, a logistics hub in Birmingham faced repeated lift failures on their Crown counterbalance fleet. Despite regular servicing, trucks stalled mid-lift, causing delays. After an internal audit, they discovered that the service vendor had skipped controller updates for two years. Once firmware was updated and lift parameters recalibrated, performance stabilized. The incident led to a revised service contract with stricter compliance checks.
Conclusion
Forklift servicing is more than a checklist—it’s a safeguard against downtime, injury, and operational inefficiency. Whether managing a single truck or a fleet, understanding what a service entails empowers operators to demand thorough inspections and timely repairs. From mast juddering to battery neglect, every symptom tells a story—and every service visit is a chance to write a better one.