The 5 Most Common Forklift Problems and How To Fix Them

August 30, 2022 - Last modified: September 7, 2022 @ 11:43 am

If your business has a warehouse or construction site, chances are you have at least one forklift on the property. These machines make swift work of heavy lifting, but their frequent use can lead to issues over time. Forklift problems are bound to happen eventually, especially if you have an older machine. However, this doesn't mean your production has to come to a halt. Preparing your team for some of the most common issues and how to repair them can help you get things back on track.

5 Forklift Problems and How To Solve Them

While there are plenty of things that could go wrong with heavy machinery and equipment, these issues are some of the most common that forklift owners face.

1. Hose Damage and Leaks

Forklifts require plenty of energy to operate smoothly, and it's easier than you might think to put excess stress on many of the machine's components. This is especially true of hoses and O-rings, which are numerous in a forklift and highly prone to damage from general wear and tear. The cooling, hydraulic, and steering systems all house fluids in hoses, and if any one of them develops a leak, you're bound to run into trouble. In addition to inhibiting the overall function of the equipment, leaks are a serious safety hazard in any work setting.

Due to the safety and performance risks, you should have any leaks professionally inspected and repaired. While the damage is already done if you have a leak in your forklift, one of the best ways to prevent more forklift problems and minimize costs is to inspect hoses on a routine basis and check to see that all fittings are snug. Replacing a worn-down hose before it leaks can prevent damage to other components.

2. Mast Failure

If your mast fails, it can render your forklift useless. If your hydraulic system is sluggish and leads to erratic mast movements, both your materials and your employees can be in danger. Both scenarios require immediate attention. Mast issues can have a variety of causes. The most common is a damaged wire or a faulty switch. Mast failure can also occur because of a much simpler problem, such as a weak battery, choosing the wrong setting, or dirt and debris in the fuel system.

Basic maintenance can solve these forklift problems in most cases:

• Properly maintaining the battery
• Cleaning and maintaining the fuel system
• Carefully taping any exposed wires

However, in some situations, mast failure could be a result of serious damage, which could be expensive and may even warrant a replacement.

3. Damaged Safety Accessories

OSHA requires that all forklifts have a working horn. Additional safety accessories are also essential, including alarms and lights. If one of these features malfunctions, it must be repaired immediately before your team can continue using the machine.

Much of the time, these issues arise from dirt or general wear and tear on individual components, such as contacts, bulbs, or pins. A blown fuse or broken or exposed wires can also contribute to the issue. In these situations, the forklift problems and solutions are simple; replacement of the damaged components is all that is needed. Keeping these fixtures well cleaned and maintained can improve their longevity in the future.

Sometimes, the damage comes from a sudden impact due to operator misuse. In these cases, it may be time to offer supplementary training on best practices for forklift operation.

4. Startup Issues

Difficulties starting any type of machinery are not uncommon. While there are plenty of troublesome (and expensive) causes, most forklift startup issues arise from the battery, so they are relatively easy to deal with. First, check for proper connections and any signs of potential corrosion. If everything is clear, test the battery itself to see if it's dead and needs recharging or replacing.

To keep the battery in top shape, follow the proper charging schedule (if applicable) and test it often. If you have an electric forklift, add water to the battery on a routine basis according to the operating instructions. A faulty starter and damaged wiring can also cause forklift problems, but these can typically be repaired or replaced.

5. Engine Problems

If you've noticed that your forklift is running rough or stops running altogether, you're likely dealing with engine trouble. There can be dozens of reasons your engine isn't working properly, but most of the time it's due to an accumulation of dirt and debris in the throttle body or radiator ports. A blocked fuel filter could also be to blame. Replacing filters and cleaning out these components may help your engine run more smoothly.

In some situations, the engine problems could be a result of overheating. Check the coolant level to see if more needs to be added. Look for leaky hoses as well. Overall, engine trouble can be tricky to diagnose, so it's a good idea to rely on an expert.

Understanding Forklift Problems and Solutions

The most important factor when it comes to owning, running, and maintaining a forklift is safety. While some damage is minimal and easy to repair, other problems can be serious and lead to machine malfunctions that risk the health and safety of your employees. It's necessary to train all forklift operators on how to identify the warning signs of a potentially serious issue and operate a forklift safely.

When a basic repair won't cut it, it may be time to invest in a new machine. Upgrading to a model that works properly and efficiently could save you time, money, and unnecessary headaches in the long run. Most importantly, it can help to minimize the chances of someone injuring themselves on the job.

Turn to Forklift Inventory for Your Equipment Needs

When it comes to forklift problems, makeshift repairs should never sacrifice the safety and efficiency of the machine. If you have a damaged forklift that needs replacing, Forklift Inventory has a wide variety of brands and models to suit every need. We also offer used options for a budget-friendly alternative to buying new. Contact us today to learn more about our products and find out which ones are the right fit for your business.

Find New & Used Forklifts for Sale Near You.

Sources:

• https://toyotaliftne.com/blog/most-common-forklift-issues/
• https://www.arpac.ca/arpac-blog/common-forklift-problems-and-their-causes
• https://geniegrips.com/common-forklift-problems-you-can-avoid/
• https://www.conger.com/common-forklift-repairs/
• https://www.osha.gov/powered-industrial-trucks