Top 5 Forklift Maintenance Tips to Save Money in 2025

Why Forklift Maintenance Is Your Money-Saver in 2025

Maintenance isn’t just about keeping your forklift alive—it’s about keeping your bottom line healthy. With inflation still pinching and supply chain hiccups pushing part prices up, smart upkeep is a game-changer. The Canadian Centre for Occupational Health and Safety (CCOHS) reports that equipment neglect is behind 15% of workplace incidents—think fines, delays, and repairs. Get ahead of it with these tips, and you’ll see real savings.

Tip 1: Prioritize Battery Care for Electric Forklifts

Electric forklifts are everywhere in 2025, especially with Canada’s push for greener ops. But a dying battery? That’s a $2,000–$5,000 hit. Regular care can double its lifespan, saving you big.

How to Nail Battery Maintenance

• Check water levels monthly—distilled only, no overfilling.
• Clean terminals with a baking soda mix to stop corrosion.
• Charge smart: aim for 20–80% to avoid strain.

Why It Works: A 2023 Material Handling Institute study found that 70% of battery failures tie back to poor maintenance. Keep it simple, and skip the replacement bill.

Tip 2: Stay On Top of Tire Checks

Forklift tires take a beating—cracked concrete, gravel yards, you name it. A blowout isn’t just a hassle; it’s a downtime disaster. In 2025, tire costs are up 10% from last year, per Supply Chain Canada. Stretch their life with these moves.

Tire Care Made Easy

• Inspect daily for cuts or wear.
• Rotate tires every six months on heavy-use units.
• Match tires to your site—solid for indoors, pneumatic for outdoors.

Pro Move: Companies like Forklift Toronto, who handle service and maintenance for all forklift types, swear by proactive tire swaps to cut long-term costs.

Tip 3: Lean Into Preventative Maintenance

An ounce of prevention beats a pound of repair bills. Scheduling regular check-ups catches small issues—like a worn brake pad—before they balloon into a $1,500 fix. In 2025, this is non-negotiable with labour rates climbing.

Your Preventative Checklist

• Monthly inspections: brakes, forks, fluids.
• Log every service for OHSA compliance.
• Partner with a local crew—Forklift Toronto offers fast, GTA-based maintenance to keep costs low.

Data Point: Modern Materials Handling says preventative upkeep slashes repair costs by 25%. That’s cash back in your pocket.

Tip 4: Keep Hydraulics Leak-Free

Hydraulics are the muscle of your forklift, but a leak can sideline it fast. A full system repair can hit $2,000+, and that’s before lost productivity. Stay ahead with routine checks.

Hydraulic Must-Dos

• Top up fluid monthly—check your manual for the right type.
• Scan hoses weekly for drips or cracks.
• Swap filters every six months to keep oil clean.

Why It Pays Off: A clean system boosts lift speed and cuts wear—key for busy Canadian warehouses.

Tip 5: Train Your Operators Right

Your operators can make or break your forklift’s lifespan. Overloading or rough turns wear out parts fast, spiking costs. In 2025, with OHSA training rules tightening, a skilled team is a money-saver.

Training Basics

• Annual refreshers on load limits and handling.
• Pre-shift checks—teach them to spot tire or fluid issues.
• Set clear rules: no overloading, no exceptions.

Real Talk: I once worked with a Mississauga warehouse where untrained operators trashed a forklift’s transmission in six months—$3,000 down the drain. A $200 training session could’ve saved it. Trust me, this one’s personal.

Comparing Maintenance Styles

Preventative wins for busy sites—reactive’s too risky when margins are tight.