Forklift Troubleshooting Made Easy: Steps to Take When Your Forklift is Down

Forklifts are critical for smooth operations in warehouses, construction sites, and other places. If your forklift fails, operations could come to a standstill. Regular maintenance is critical to prevent problems.

Forklift troubleshooting measures will help you get your forklift up and running quickly. It will depend on the type of forklift you have. This guide provides easy troubleshooting steps for electric and gas forklifts.

Initial Safety Measures

Proper maintenance helps prevent equipment breakdown and potential injury to operators and others in the surrounding area. It is important to follow all safety measures in the operating manual.

Businesses should create a pre-operation checklist for operators to review before using a forklift. This checklist should be used every time the forklift is operated for safety.

Forklift Certification

All forklift operators should attend an OSHA-approved training course to learn how to use a forklift, safety protocols, load handling, and more.

Proper Safety Gear

Safety shoes, hard hats, and high-visibility jackets or vests are essential for safety.

Class and Specifications of the Forklift

Every forklift is different, so it is important to know the weight limits, speed capabilities, and operating procedures for the equipment you are using.

Maintain Visibility

360-degree visibility is essential for safely operating a forklift. Do not be afraid to drive in reverse if a load blocks your view.

Secure and Stabilize Loads

Before moving the forklift, it is important to ensure the load is balanced on the forks and strapped down if needed.

Electric Forklift Troubleshooting

If your electric forklift breaks down, operations may halt, costing time and money. Forklift troubleshooting takes time, so paying attention at all times can help alleviate future problems. You can check the following to see if you can fix the problem.

Check the Battery

First, check the battery voltage using a multimeter. If it is less than 12, you can charge it. If it does not maintain voltage, a new battery is needed. 

Check the battery case for rust, corrosion, or damage. If any damage is found, replace it.

Next, you need to check the connectors. Since these are plastic, heat can damage them.

The battery cables and tips should be checked. If they are damaged or worn, replace them. A professional should replace them due to the risk of injury.

There are water inlet covers by plastic vent caps that need to be checked. If a vent cap is lost or damaged, it can be replaced easily.

Control Panel and Errors Codes

Checking for error codes when something seems wrong can help determine the cause. Many error codes point to wiring issues. 

After you familiarize yourself with the forklift, check the fault log to determine if a prior fault could be causing other issues. Make sure to write down the codes that pop up. Then, you can delete them and operate the forklift to see if they return.
You should refer to the error code manual for your type of forklift to understand what error codes mean so replacing parts will take less time.

Test the Key Switch and Ignition

The ignition switch starts the electrical process that starts the forklift. The ignition switch may be to blame if the forklift won’t start or starts intermittently.

A multimeter can be used to test the forklift's ignition switch. Start by disconnecting the wiring harness from the ignition switch. Touch the terminals with the multimeter probe while turning the key on and off. If no reaction occurs, a replacement is needed.

Motor and Controller Issues

If you go to start the forklift and the starter motor is just clicking, the engine does not turn over, or after the engine starts and the starter motor does not turn off, the starter motor may be at fault.

First, check the starter motor for damage. To test it, bypass the ignition system by connecting the positive jumper cable to the battery and the solenoid on the starter motor. The starter motor must be replaced if the engine does not turn over.

Due to possible safety hazards, a professional should replace the starter motor.

Gas Forklift Troubleshooting

Forklift troubleshooting is important in the workplace. Several things can go wrong with a gas forklift to cause it to stop running. The quicker you can get the forklift up and running, the quicker operations can continue.

Check the Fuel Supply

When it comes to gas forklift troubleshooting, the first thing you want to do is check the fuel supply. You want to make sure the fuel tank is not empty by checking the gauge in the cab. If there is little to no fuel in the tank, refill it to see if this fixes the problem.

If this does not work, you should check the fuel quality next. If the fuel is old from sitting for an extended period or the wrong fuel is used, the forklift may not start. You can drain the fuel from the system and replace it.

Fuel System and Carburetor

If the fuel supply and quality have been checked and any issues fixed, but the forklift still won’t start, it may be a problem with the fuel system. The fuel system has many components that should be checked. 

For example, the fuel filter may be clogged, or the fuel pump could be malfunctioning. You can clean or replace the fuel filter. If this does not fix the problem, the forklift may not get enough gas from the fuel pump.

Engine and Exhaust System

One thing you should check here is the spark plugs. If they are corroded or worn out, they will not spark properly, causing possible engine issues. If you notice the forklift misfiring or it is hard to start, the spark plugs may be the cause.

To change damaged or worn-out spark plugs, you will need to disconnect the spark plug wire, remove the spark plug, replace it with a new one, and attach the spark plug wire to the new plug.

Find The Help You Need With Forklift Troubleshooting Today

Some issues regarding forklift troubleshooting are easily fixed, while others require a professional. If you follow these steps, the broken-down forklift can be up and running quickly. 

Creating a simple daily checklist can also help prevent future issues.
If you need help troubleshooting a gas or electric forklift, contact us at Forklift Inventory.

Sources:

Forklift Preventive Maintenance Checklist (clickmaint.com)

15 Forklift Safety Rules And 10 Hazards To Prevent Them (hseblog.com)

Forklift Battery Maintenance: The Complete Guide - Foxtron Power Solutions

Basic Troubleshooting – Forklift Error Codes (forkliftcodes.com)

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

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

Find Warehouse Forklifts for Sale Near You (forkliftinventory.com)