Forklift Troubleshooting Checklist

This forklift troubleshooting checklist aims to provide operators with quick, actionable steps if a breakdown occurs.

Initial Safety Measures

Maintaining safety measures in the workplace is crucial, especially when machinery is present. Some safety measures to employ include:

Forklift Certification

Every operator of a forklift should complete an OSHA-approved forklift training course.

Proper Safety Gear

Safety shoes, hard hats, and a high-visibility jacket or vest should always be worn.

Class and Specifications of the Forklift

Keep in mind weight limits, speed capabilities, and maintain operating procedures

Maintain Visibility

360-degree visibility for safety. If a load blocks your view, drive in reverse.

Secure and Stabilize Loads

Ensure the load is balanced on the forks and strapped down if needed.

Electric Forklift Troubleshooting

Electric forklifts can break down for several reasons. Some of the common issues with an electric forklift include:

Check the Battery

Check the battery voltage. Charge or replace the battery if it does not hold a voltage of 12.6.

• Check for any rust, corrosion, or damage to the battery case.
• Check the connectors. Heat can damage the plastic.
• Check the battery cables and tips. 
• Check the plastic water inlet covers. Replace if lost or damaged.

Control Panel and Error Codes

Familiarize yourself with the forklift before starting any forklift troubleshooting measures.

• Check for and write down error codes.
• Delete error codes.

Keep the error code manual for the forklift close.

Test Key Switch and Ignition

Suppose the forklift will not start or starts intermittently. Check the ignition switch.

• Disconnect the wiring harness.
• Use a multimeter on the ignition switch. Turn the key on and off.
• If there is no reaction, a replacement is needed.

Motor and Controller Inspection

If the forklift engine does not turn over, there is a clicking noise, or the start motor doesn’t turn off while the engine is running, the starter motor may be faulty.

• Check the starter motor for damage.
• Attach the positive jumper cable to the battery and solenoid of the starter motor.
• The starter motor must be replaced if the engine doesn’t turn over.

Gas Forklift Troubleshooting

Gas forklifts can break down for some of the same reasons an electric forklift does. However, there are also differences. Here are some common reasons for a breakdown in a gas forklift.

Check the Fuel Supply

Check the fuel supply by checking the fuel gauge.

• If there is little to no gas, refill the tank.
• If this does not fix the problem, check the fuel quality. Old or the wrong type of fuel can cause issues.
• Flush the fuel system and replace the fuel.

Fuel System and Carburetor

The fuel system may be to blame if the fuel supply and quality are good.

• Check the fuel filter. If it is dirty or clogged, clean it or replace it.
• If the problem is not fixed, check the fuel pump to ensure the forklift is getting enough gas.

Engine and Exhaust System

Check the spark plugs. If they are worn out or corroded, replace them. Remove the spark plug wire, remove the spark plug, replace it with a new one, and put the wire back on.

Keep This Checklist Close If You Need Help With Quick Forklift Troubleshooting

This checklist provides the operator with quick and easy steps for electric or gas forklift troubleshooting methods. If you have any questions or need further assistance, Forklift Inventory is there to help.

Sources:

Forklift Preventive Maintenance Checklist (clickmaint.com)

Forklift Will Not Start (Common Reasons & Troubleshooting) (operatorhq.com)

Forklift Battery Maintenance: The Complete Guide - Foxtron Power Solutions

Basic Troubleshooting – Forklift Error Codes (forkliftcodes.com)

Mitsubishi Forklift Error Codes: Troubleshooting Guide & Solutions (mechanicsnews.com)

Welcome To Forklift Inventory