Forklifts, as indispensable handling equipment in modern warehousing, logistics, and manufacturing industries, play a pivotal role in daily operations. Their efficient handling capabilities greatly enhance productivity. However, forklifts are also high-intensity machines that bear heavy loads. Without proper maintenance and timely repairs, frequent breakdowns, reduced lifespan, and even serious safety accidents can occur—leading to personal injuries and property damage. Therefore, forklift maintenance and repair are not only essential cost-saving measures for businesses but also critical to ensuring safety and continuous operation.

Forklift maintenance generally falls into three levels: daily maintenance, periodic maintenance, and special inspections. Daily maintenance is typically performed by operators before and after each use and includes visual checks, fluid level checks, tire conditions, and the functionality of lights and horns. Daily inspections help identify minor issues early and prevent them from escalating. For example, checking for hydraulic leaks, battery charge levels, or brake pedal responsiveness are simple yet effective preventive actions.

Periodic maintenance is conducted based on the forklift's operating hours or mileage—commonly every 250, 500, or 1,000 hours. For internal combustion forklifts, this includes oil and filter changes (engine oil, fuel filters, air filters), inspection of spark plugs, the cooling system, brakes, and the steering system. Other essential tasks involve lubricating the transmission chain, checking the hydraulic cylinders, and tightening components. Electric forklifts require additional attention to battery maintenance, such as topping up electrolytes, cleaning connections, and avoiding over-discharge. These tasks should be performed by certified technicians to ensure safety and adherence to technical standards.

Special inspections refer to annual technical evaluations or diagnostic checks in response to specific abnormalities, such as sudden power loss, steering issues, or unusual noises. In such cases, forklift operation should be halted immediately, and a qualified repair technician should diagnose and resolve the problem to prevent further damage or safety hazards.

Forklift repairs can be divided into preventive maintenance and corrective repairs. Preventive maintenance is conducted proactively, based on inspection results, to replace components or fine-tune systems before failures occur. For instance, even if the hydraulic system appears functional, seals may be replaced after a set number of operating hours to prevent sudden pressure loss or leaks.

Corrective repairs are performed after a fault has already occurred, restoring the forklift to working condition. This involves diagnosing the root cause of the failure, replacing damaged parts, and adjusting system parameters. Effective repair requires technicians with mechanical, electrical, and hydraulic expertise. For example, if the lifting mechanism fails, the root cause could involve a worn hydraulic pump, a stuck control valve, or contaminated hydraulic oil—each possibility must be ruled out systematically rather than relying on quick, superficial fixes.

It’s important to note that forklifts come in various models—internal combustion, electric counterbalance, reach trucks, stackers, etc.—each with unique mechanical and control systems. This diversity demands a higher level of specialization in maintenance and repair. Companies should therefore establish a comprehensive equipment record-keeping system to track each forklift's model, purchase date, maintenance history, and fault logs. This supports data-driven decision-making for long-term equipment management.

In addition to the mechanical aspects of forklift maintenance, operator behavior plays a crucial role. Improper operation is one of the primary causes of equipment damage. Overloading, aggressive acceleration or braking, frequent heavy lifting, and careless handling all accelerate wear and tear and can even lead to structural damage or rollover accidents. Companies must regularly train forklift operators, ensuring they understand equipment capabilities, operating procedures, and emergency response protocols.

With the rise of digital and smart technologies, many businesses are adopting intelligent maintenance systems, remote monitoring tools, and fleet management software. These systems allow real-time monitoring of equipment status, automatic reminders for maintenance schedules, and remote fault diagnosis—greatly improving the precision and efficiency of forklift management.

From a financial perspective, some companies attempt to cut costs by delaying maintenance, only to face higher repair expenses and productivity losses when equipment fails unexpectedly. Studies and field experience consistently show that scheduled maintenance costs far less than reactive repairs and downtime. Preventive care extends equipment lifespan and improves return on investment.

In conclusion, forklift maintenance and repair are not merely technical routines but strategic elements of business operations. Establishing a structured, standardized, and scientific maintenance system—combined with disciplined operator management—is the best way to shift from passive repairs to proactive care. This ensures extended equipment life, minimizes safety risks, and supports efficient, stable business operations.