🕒 Updated November 5, 2025
Downtime is expensive.
Not just in repair cost — in stalled production, labour inefficiencies, missed loading windows, and the ripple effect on customer promises. In most operations, a single forklift out of service can disrupt an entire workflow.
The good news?
The majority of forklift breakdowns are predictable. Even preventable.
Here are the five components that most frequently fail — and exactly how to reduce downtime, cost, and frustration.
1. Forklift Tires
Why they fail:
Tires wear down faster on uneven floors, heavy load handling, or aggressive turning.
Symptoms you’ll see first:
- Reduced traction
- Excessive vibration
- Cracking or chunking
Why it matters:
Worn tires increase operator fatigue, reduce control, and place unnecessary strain on mast components and bearings.
✅ Prevention:
- Measure tire wear monthly
- Replace cushion tires at 3× wear line
- Rotate front tires more often — they bear the load and steering stress
2. Batteries (Electric Trucks)
Why they fail:
Improper charging practices. Partial charges, opportunity charges, and plugging in “just to top up” shorten battery lifespan dramatically.
Symptoms you’ll see first:
- Shorter runtime
- Acid residue on top of battery
- Sulfation (white powdery build-up)
✅ Prevention:
- Charge only when battery is at 20–30%
- Complete full charge cycles
- Schedule quarterly battery watering & equalization
A correctly maintained battery lasts 5–7 years. A poorly maintained one? Sometimes less than two.
👉 Don’t let a weak battery slow you down — request a quote today.
3. Lift Chains
Why they fail:
Friction + corrosion + lack of lubrication.
Symptoms you’ll see first:
- Stiff mast movement
- Rust on links
- Kinking or elongation
Why it matters:
Chains carry 90% of the lifting force. Chain failure is a safety-critical issue.
✅ Prevention:
- Inspect every 250 hours
- Replace chains once wear reaches 2%
- Lubricate properly — never with WD-40
4. Forks
Why they fail:
Impact damage, overloading, and improper handling.
Symptoms you’ll see first:
- Uneven fork heights
- Visible bending
- Cracks along the heel or shank
Why it matters:
Bent forks can shift the load centre, causing tip-overs or dropped loads.
✅ Prevention:
- Measure fork thickness — if there’s 10% wear, replace
- Never use forks to pry, push, or break pallets apart
- Add fork protectors if handling skids with metal corners
Fork failure is rarely sudden. It’s gradual — and visible.
5. Cooling System (Internal Combustion Trucks)
Why they fail:
Dust + debris + low coolant + ignored leaks.
Symptoms you’ll see first:
- Overheating after long runs
- Frequent coolant top-ups
- Visible residue around hoses
Why it matters:
Overheating leads to blown head gaskets — one of the costliest engine repairs.
✅ Prevention:
- Inspect coolant and hose condition every 250 hours
- Blow out radiator fins weekly in dusty environments
- Replace coolant every 12–24 months depending on usage
The Common Thread: Downtime Is Preventable
Breakdowns don’t just happen to you.
They happen when components are ignored.
That’s why every Premier Lift Planned Maintenance and Safety Certification service includes:
- Tire condition check
- Battery & charging inspection
- Lift chain wear measurement
- Fork thickness & alignment inspection
- Cooling system evaluation
…and documentation that keeps you compliant.
Because in material handling, accuracy is protection.
🚧 Want fewer breakdowns and more uptime?
For fleets of 1 or 100+, our planned maintenance program keeps you operational, compliant, and predictable.
👉 Book a Planned Maintenance Service on our PM contract and get one free PM, PLUS get a chance to win a 2007 Raymond 8400 for free! Contact us for more details.
👉 Need parts? Our team will source and ship immediately.
👉 Browse our CSA certified inventory here!
