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A forklift that is not properly maintained is not just an unreliable machine: it is a potential safety hazard. The heavy loads, repeated cycles, and demanding environments that forklifts operate in create wear on critical safety systems that must be regularly inspected and addressed. Understanding what a forklift service schedule looks like, what is checked at each interval, and why it matters is important for any business that owns or operates forklifts.
Mars Forklifts provides forklift repairs and servicing for businesses across Sydney and the east coast. Our technical team services a range of makes and models to keep equipment operating safely and reliably.
Mars Forklifts Repairs and Servicing
Expert technicians. Sydney and east coast. All makes and models. Call 1300 736 231.
Pre-Operation Checks: Every Shift, Every Operator
The pre-operation check is not a maintenance task carried out by a technician: it is a safety check completed by the operator before every shift. Under Australian WHS legislation and forklift operator licence requirements, operators are expected to complete a pre-operation check before operating a forklift each day.
A standard pre-operation check includes:
- Tyres: check condition, inflation (where applicable), and tread. Deflated or damaged tyres affect stability and load handling
- Forks: inspect for bending, cracking, or excessive wear at the heel. Damaged forks must not be used
- Mast and chains: check chain lubrication, inspect for stretched or damaged links, confirm mast moves freely and smoothly
- Hydraulic fluid: check level, look for evidence of leaks under the machine
- Overhead guard: confirm no damage or deformation that compromises protection from falling objects
- Lights and horn: confirm operational
- Seatbelt and operator restraint: confirm functional and intact
- Battery or fuel: check charge level or fuel level as applicable
Periodic Service Intervals: By Hours or Calendar
Formal servicing by a qualified technician is typically scheduled by operating hours rather than calendar time, because a forklift doing eight hours per day accumulates wear much faster than one doing two hours per day. Standard intervals include:
| Service interval | What is typically covered |
| 250-hour (or 3-monthly) service | Oil and filter changes, hydraulic system inspection, brake inspection and adjustment, load backrest inspection, mast chain lubrication, fork inspection, battery water check (lead-acid) |
| 500-hour (or 6-monthly) service | All 250-hour items, plus tyre condition and wear assessment, more detailed hydraulic cylinder inspection, steering system check, all safety systems check |
| 1,000-hour (or annual) service | Comprehensive inspection of all major components: engine or motor condition, mast wear and clearances, hydraulic cylinder seals, brake system, electrical system including all connections, full safety check and certification |
These intervals are indicative. Always follow the manufacturer’s specific service schedule for your forklift model.
What a Service Includes Beyond the Checklist
Beyond the specific checks at each interval, a qualified forklift technician also looks for:
- Emerging wear patterns: uneven tyre wear indicating a steering or alignment issue; mast chain wear that is progressing faster than expected; hydraulic leaks that have developed since the last service
- Operator-reported issues: any issues noted by operators during pre-operation checks should be reviewed and investigated by the service technician. Operators often notice early signs of developing faults that may not be obvious on a scheduled service checklist
- Documentation: a professional service should always produce documented records of what was checked, any findings, any repairs carried out, and the next service due date or hours. This documentation supports compliance records, resale value, and warranty claims
WHS Compliance and Forklift Servicing Records
Under Australian WHS legislation, the person conducting a business or undertaking (PCBU) is responsible for ensuring that plant (including forklifts) is maintained in a safe and serviceable condition. This includes ensuring that prescribed service intervals are met and that records are maintained. Forklifts with overdue service intervals or gaps in service records may be required to be removed from service under a WHS inspection or audit.
Service records are also required evidence in the event of a workplace incident involving a forklift. An incident investigation will examine whether the equipment was properly maintained and whether any known defects existed at the time of the incident.
✦ Hired forklifts and servicing responsibility: If your business hires a forklift, the maintenance and scheduled servicing responsibility typically rests with the hire company, not the hirer. However, the hirer is still responsible for the daily pre-operation check and for reporting any defects identified during operation. Confirm servicing responsibilities with your hire agreement.
Keep Your Forklifts Safe with Mars Forklifts Servicing
Expert technicians. Sydney and east coast. Repairs and scheduled servicing. Call 1300 736 231.
Frequently Asked Questions
What happens if I operate a forklift with a known defect?
Operating a forklift with a known safety defect is a breach of WHS obligations and can result in enforcement action under the WHS Act, as well as significantly increased liability in the event of an incident. Any forklift with a safety defect identified during a pre-operation check or a service inspection should be tagged out of service until the defect is repaired.
How long does a forklift service take?
A standard 250 or 500-hour periodic service on a forklift typically takes two to four hours. An annual 1,000-hour service is more comprehensive and may take four to eight hours or longer depending on the machine’s condition and any additional work identified. Contact Mars Forklifts to arrange a service and discuss timeline.
