Why Maintenance Matters for Heli Forklifts
A well-maintained Heli electric forklift can operate reliably for 10,000+ hours. Neglected maintenance leads to unexpected breakdowns, costly repairs, and safety hazards. This guide provides a complete maintenance schedule for Heli G-Series and CPD electric forklifts.
Daily Pre-Operation Checks
Before each shift, operators should perform these visual and functional checks:
Visual Inspection
- Check for fluid leaks under the forklift
- Inspect tires for damage or excessive wear
- Verify all safety labels are present and readable
- Check forks for cracks or bending
Functional Checks
- Test horn and backup alarm
- Verify all lights function (head, tail, warning)
- Check steering responsiveness
- Test service brake and parking brake
- Operate lift and tilt through full range
Battery Check
- Verify charge level indicator
- Check for corrosion on terminals
- Ensure vent caps are in place
- Look for electrolyte leaks (lead-acid) or swelling (lithium)
Weekly Maintenance Tasks
Hydraulic System
- Check hydraulic fluid level in sight glass
- Inspect hoses and fittings for leaks
- Listen for unusual pump noises
Electrical System
- Clean battery terminals with approved solution
- Check cable connections for tightness
- Inspect contactors for pitting or wear
Drive System
- Check drive axle boots for damage
- Verify motor cooling fan operates
- Listen for unusual drive motor noise
Monthly Maintenance Tasks
Mast and Lift System
- Lubricate mast rails with approved grease
- Inspect lift chains for stretch (measure against specifications)
- Check chain anchors and sheaves
- Verify lift cylinder rod condition
Steering System
- Check power steering fluid level
- Inspect steering cylinder for leaks
- Verify tie rod end condition
Brake System
- Measure brake pad thickness
- Adjust brake pedal free play
- Inspect brake fluid level (if applicable)
Quarterly Service (250-Hour Interval)
At 250 operating hours:
- Replace hydraulic filter
- Change hydraulic fluid if contaminated
- Calibrate load sensor (if equipped)
- Perform controller diagnostics scan
- Torque all accessible fasteners to spec
Annual Service Requirements
Major Components
- Replace hydraulic fluid completely
- Replace brake fluid (if applicable)
- Service or replace battery pack
- Inspect all hoses, replace if cracked
Safety Systems
- Test overload cutout
- Verify interlock functions
- Calibrate tilt angle sensors
- Update controller firmware if available
Common Wear Parts for Heli Forklifts
Keep these parts in inventory to minimize downtime:
- Brake pads and drums
- Hydraulic seals and O-rings
- Lift chains (matched sets)
- Contact tips for battery connector
- Drive motor brushes
- Steering cylinder seals
Record Keeping
Maintain detailed records including:
- Hour meter readings at each service
- Parts replaced with part numbers
- Technician observations
- Any operational issues reported
Good records help predict failures and prove maintenance history for resale value.
