When it comes to your forklift fleet, the right servicing interval matters for safety, productivity and cost-control. In this guide, we’ll look at what determines the service frequency, what the standards say in Australia and how you should build a schedule.
What Australian Safety & Maintenance Standards Say
In Australia, forklift servicing is a legal and safety requirement under national workplace regulations. Safe Work Australia and state-based regulators such as WorkSafe Queensland and WorkSafe Victoria all emphasise that a forklift must be maintained in a condition that is safe to use at all times. This starts with pre-start inspections, which operators are required to carry out before every shift or when a new operator takes over.
These quick checks cover essentials like tyres, fluids, brakes, and lifting equipment, helping to identify small faults before they become serious hazards.
Beyond daily inspections, manufacturers set recommended service intervals, which typically fall every 250 operating hours or six months, whichever comes first. These guidelines are designed to ensure that vital components such as hydraulics, brakes, and mast assemblies are inspected and maintained before wear or fatigue sets in.
For forklifts that operate in harsher environments — such as outdoor yards, cold rooms, or dusty warehouses — the intervals should be shortened to reflect the additional strain.
Australian Standard AS 2359 provides the benchmark for forklift operation, safety, and maintenance across the country. It specifies how often inspections should occur, what records must be kept, and the qualifications required of service personnel. Following this standard not only ensures compliance with workplace safety laws but also reduces liability for business owners in the event of an incident. In short, keeping up with these service requirements protects operators, extends equipment life, and maintains your forklift’s compliance with Australian safety regulations.
Key Factors That Determine How Often to Service Your Forklift
The “one size fits all” schedule does not apply. Consider these variables when building your servicing plan:
1. Usage/operating hours
- A forklift running 8 – 12 hrs per day or with multiple shifts will accumulate wear faster.
- A forklift used only for light intermittent tasks may require less frequent deep servicing.
2. Working environment
- Forklifts operating outdoors, in dusty or wet yards, in cold-storage, or near corrosive materials require more frequent attention.
- Indoor light-duty forklifts in clean conditions may have longer intervals.
3. Load types and attachments
- Heavy loads, frequent lifts, and harsh attachments (rotators, side-shifters) increase stress on hydraulics, mast, and tyres.
- Also, attachments change the dynamics of the machine—check compatibility with the maintenance schedule.
4. Manufacturer’s recommendations & age of equipment
- Always refer to the forklift’s service manual for recommended intervals.
- Older forklifts (> 8-10 years) may benefit from more frequent inspections as parts wear and fatigue accumulate.
5. Regulatory and safety obligations
- Under Australian safety law, if a forklift is found to be unsafe, it must be removed from service until repaired. Regular servicing helps catch issues early.
What’s Included in a Full Forklift Service
A full forklift service is a comprehensive inspection that ensures every part of your machine operates safely, efficiently, and in line with manufacturer and safety standards. For example, when you book a full service with Freedom Forklifts, our qualified technicians perform a detailed, multi-point assessment tailored to your forklift’s type, age, and workload.
The process begins with engine or motor diagnostics, depending on whether your forklift is diesel, LPG, or electric. This involves checking fluid levels, spark plugs or ignition systems, and running performance tests to identify any irregularities in power delivery. From there, we move into the hydraulic system, replacing filters, topping up fluids, and inspecting hoses, seals, and cylinders for leaks or pressure loss. These systems are critical to safe lifting performance, and early maintenance prevents costly breakdowns.
Next, the mast assembly, chains, tyres, and forks are inspected for visible wear, cracks, or deformation. Even minor imperfections in these components can affect load balance and introduce safety risks. The service also includes a full review of brakes, steering, and the drive train, ensuring smooth handling and controlled stopping power under load.
Safety is a major focus throughout the service. All lights, alarms, horns, and warning indicators are tested to verify they’re working correctly. Our team checks that the load plate, compliance markings, and serial tags are clear and legible — essential for meeting Australian Standard AS 2359.
Once all inspections are complete, we provide a detailed service report and maintenance log outlining what’s been done, what’s due next, and any components that may require replacement soon.
Risks of Infrequent Servicing
Skipping or delaying forklift servicing might seem harmless in the short term, but the consequences can build quickly. Forklifts operate under constant strain, and even small issues can escalate into safety hazards or costly downtime if left unchecked.
Here are some of the most common risks associated with irregular or overdue servicing:
- Unexpected breakdowns – Minor faults in hydraulics, brakes, or steering can go unnoticed until they cause complete system failure, halting operations.
- Reduced safety compliance – Outdated or missing inspections can lead to non-compliance with Australian Standard AS 2359 and workplace safety obligations.
- Accelerated component wear – Dirty filters, worn seals, and neglected fluids increase friction and heat, shortening the lifespan of key parts like engines, masts, and transmissions.
- Increased operating costs – Repairing or replacing major components after failure is far more expensive than preventative maintenance.
- Higher risk of accidents – Malfunctioning brakes, steering, or lift systems directly endanger operators and anyone nearby.
- Decreased fuel and power efficiency – Poorly maintained forklifts require more energy to perform the same tasks, raising running costs and emissions.
In Need Of A Forklift Service?
Regular forklift servicing is a key part of running a safe, efficient, and compliant operation. Sticking to a consistent service schedule helps prevent breakdowns, reduces long-term costs, and ensures every lift your team performs is safe and controlled.
At Freedom Forklifts, we provide full servicing, safety inspections, and replacement parts for all major forklift brands. Our technicians are experienced, reliable, and committed to helping your business stay compliant with Australian safety standards.
Keep your operations moving with confidence. Contact Freedom Forklifts today to schedule your next service or discuss a tailored maintenance plan for your fleet.
