Maintaining an electric forklift properly is essential for ensuring operational safety, extending equipment lifespan, and optimizing performance. Below is a structured, actionable guide to help you manage maintenance and upkeep effectively:

1. Daily Pre-Shift Checks (Operator Responsibilities)

Perform these quick inspections before each use to catch issues early:

Battery Health:

Check electrolyte levels (for lead-acid batteries) and top up with distilled water if low.

Inspect terminals for corrosion and clean with a wire brush if needed.

Ensure cables are secure and undamaged.

Tires:

Look for cuts, punctures, or uneven wear.

Verify tire pressure (for pneumatic tires) or tread depth (for cushion tires).

Brakes:

Test brake responsiveness and listen for grinding or squealing noises.

Check brake fluid levels (if hydraulic brakes are used).

Hydraulic System:

Inspect for leaks around hoses, cylinders, and seals.

Test lift/lower and tilt functions for smooth operation.

Safety Features:

Ensure lights, horns, and alarms are working.

Verify the seatbelt and operator presence sensors function correctly.

Cleanliness:

Remove debris from the mast, forks, and operator compartment.

2. Weekly/Monthly Maintenance (Technician Tasks)

Schedule deeper checks to prevent major failures:

Lubrication:

Grease moving parts (e.g., mast chains, steering linkages, tilt mechanisms) using manufacturer-recommended grease.

Avoid over-lubricating to prevent dust accumulation.

Battery Care:

Clean terminals with baking soda and water (for lead-acid) and apply anti-corrosion grease.

For lithium-ion batteries, follow manufacturer guidelines for storage and charging.

Electrical System:

Inspect wiring for fraying, loose connections, or insulation damage.

Test the controller and motor for abnormal vibrations or noises.

Cooling System:

Clean the radiator (if applicable) to prevent overheating.

Check coolant levels in liquid-cooled motors.

Fork Inspection:

Measure fork thickness and check for bending or cracks.

Ensure the load backrest is secure and undamaged.

3. Quarterly/Annual Maintenance (Certified Technician Required)

Conduct thorough inspections and repairs:

Comprehensive System Check:

Test motor, controller, and hydraulic pump efficiency.

Inspect the chassis for cracks or structural damage.

Brake Overhaul:

Replace brake pads/shoes if worn beyond limits.

Check brake discs/drums for scoring or uneven wear.

Wheel Alignment:

Adjust alignment to prevent uneven tire wear and improve handling.

Load Capacity Verification:

Recalibrate sensors (if equipped) to ensure accurate load measurements.

Software Updates:

Update firmware (if applicable) to fix bugs or improve performance.

4. Battery-Specific Best Practices

Batteries are critical to electric forklift performance—handle them with care:

Charging:

Use the manufacturer-recommended charger and avoid opportunistic charging (charge only when battery is at 20–30% capacity).

Never interrupt a charge cycle once started (except in emergencies).

Storage:

Store batteries in a cool, dry place (15–25°C / 59–77°F).

For long-term storage, charge to 50–70% capacity.

Equalization Charging (Lead-Acid Only):

Perform every 30 cycles to balance cell voltage and prevent sulfation.

Replacement:

Replace batteries when capacity drops below 80% of the original rating or if cells fail.

5. Operator Training and Safe Usage

Proper Operation:

Train operators to avoid sudden starts/stops, which strain the motor and battery.

Encourage smooth acceleration and deceleration.

Weight Management:

Never exceed the forklift’s rated load capacity to prevent component stress.

Driving Habits:

Avoid driving over potholes, speed bumps, or debris at high speeds.

Minimize idle time to conserve battery life.

6. Record-Keeping and Documentation

Maintenance Log:

Track all inspections, repairs, and part replacements in a digital or physical log.

Include dates, technician notes, and parts used.

Warranty Compliance:

Follow the manufacturer’s maintenance schedule to avoid voiding the warranty.

7. Safety Precautions

PPE (Personal Protective Equipment):

Wear gloves, safety glasses, and steel-toe boots during maintenance.

Lockout/Tagout (LOTO):

Disconnect the battery and isolate energy sources before working on electrical or hydraulic systems.

Fire Safety:

Keep a fire extinguisher nearby when working on batteries or electrical components.

8. Common Issues and Troubleshooting

Issue Possible Cause Solution

Battery not charging Corroded terminals Clean terminals and check connections

Reduced lifting capacity Low hydraulic fluid Top up fluid and check for leaks

Motor overheating Blocked cooling system Clean radiator and check fan operation

Erratic controls Faulty wiring or controller Inspect wiring and test controller

Example Maintenance Schedule

Task Frequency Responsible Party

Daily inspection Before each shift Operator

Lubrication Weekly Technician

Battery equalization Every 30 cycles Technician

Comprehensive check Annually Certified service provider

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment