PM planOfficial FreeMaint

Forklift preventive maintenance plan, every 250 hours

Service plan for a counterbalance forklift every 250 hours or 3 months: forks, mast and chain elongation, hydraulics, brakes, steering, tyres and safety devices, battery care on electric trucks, engine fluids and oil change on engine trucks.

12 tasksForklifts and material handlingVersion 1Updated

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Schedule

Every 3 months or every 250 h, whichever comes first

  • The next date is counted from the last completion.
  • Work order window: 7 days
Estimated duration: 2 h 30 minPriority: High

Imported inactive and without equipment: assign it to your assets, set its start date (the first due date), check the intervals against the manufacturer’s manual, then switch it on.

Tasks at each service

  1. Review the daily checks and the reported defects

    Read the pre-use checks since the last service and the defects reported by the drivers, and treat each of them during this service.

    Inspection10 min

  2. Inspect the forks and the carriage

    Look for cracks at the heel and the shank, bending, and a difference in height between the fork tips. Measure the blade thickness at the heel: withdraw the fork when it has dropped to about 90 % of the original thickness (about 10 % wear), or at the manufacturer’s limit. Check the positioning locks and the load backrest.

    Inspection15 min

    Tools: Fork wear caliper

  3. Inspect the mast and measure the lift chain elongation

    Check the mast channels, rollers and stops, and the chain anchors and pins. Measure the chain elongation with a chain gauge over the most used section and replace the chains at the limit given by the manufacturer (often 3 %); chains are always replaced in pairs.

    Measurement20 min

    Tools: Chain wear gauge

    Risks: Never work under raised forks or a raised carriage that is not mechanically blocked.

  4. Lubricate the chains, the mast and the grease points

    Lubricate the lift chains with chain lubricant and grease the mast, tilt cylinder pins, steering axle and other grease points listed by the manufacturer.

    Action15 min

    Tools: Grease gun

  5. Check the hydraulic system

    Check the oil level, look for leaks at the cylinders, hoses and fittings, and check that a rated load held at mid height does not drift down or tilt forward.

    Inspection15 min

    Risks: Release the hydraulic pressure before loosening any fitting.

  6. Test the service and parking brakes and the steering

    Check the service brake stopping distance and the parking brake on a slope, the brake fluid level where fitted, and the steering play and steer axle pivots.

    Verification15 min

  7. Inspect the tyres and the wheels

    Check the tyre wear against the wear line, cuts and chunking, the pressure of pneumatic tyres, and the tightness of the wheel nuts.

    Inspection10 min

    Tools: Torque wrench

  8. Test the safety devices

    Check the horn, lights and beacon, the reversing alarm, the seat belt and seat switch, the overhead guard, and that the capacity plate is fitted and legible.

    Verification10 min

  9. Electric trucks: check the battery and the charger connection

    After a full charge, top up the electrolyte with demineralised water where the battery requires it, check that the terminals and cables are clean and tight, and the charger plug is undamaged.

    Action20 minoptional

    Risks: Wear eye protection and gloves; charge only in a ventilated area, away from flames and sparks.

  10. Engine trucks: check the engine, its fluids and the fuel system

    Check the engine oil and coolant levels, the air filter, the belts and the exhaust. On an LPG truck, check the cylinder bracket, the hose and the connections for leaks with a leak detection product.

    Inspection20 minoptional

  11. Engine trucks: change the engine oil and filter

    Change the engine oil and the oil filter with the grade and quantity given by the manufacturer, and dispose of the used oil as hazardous waste.

    Action30 minoptionalonce every 2 services

  12. Test the truck with a load and record the hour meter

    Lift, lower, tilt and travel with a load to check every function, then record the hour meter reading and the findings in the work order.

    Verification15 min

Parts (indicative)

  • Lift chain lubricant × 1
  • Grease cartridge × 1
  • Engine oil filter (engine trucks) × 1

Tools (indicative)

  • Fork wear caliper
  • Chain wear gauge
  • Grease gun
  • Torque wrench
  • Tyre pressure gauge — Pneumatic tyres

Indicative list: on import it is written into the plan’s description, to link to your own inventory.

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Licence

Official FreeMaint template, free to use and adapt inside your FreeMaint workspace. An adaptation may be shared in the library under CC BY 4.0; its page then credits this template.

Templates are general guidance. They do not replace the manufacturer’s instructions, your site procedures or applicable regulations.

Equipment: Forklifts and material handling

Industries: Manufacturing, Retail, Food and beverage, Construction

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