Rick Gilleland
The McGill Pain Questionnaire is a medical diagnostic tool that uses 78 adjectives to describe pain.
That’s because each adjective helps a physician pinpoint the underlying cause. The human body is a complex system, and the trouble with complexity is that issues can arise from many different places. Yet, symptoms like pain quality narrow down the possibilities.
Electric forklifts are also complicated systems with diagnostic pain points.
Unsurprisingly, electrical problems are the root of most electric forklift issues. However, “electrical problems” is too broad a term to diagnose the underlying issue.
The first step to fixing those problems is determining whether it's a battery issue or an electrical system issue. Fundamentally, you’re deciding where to focus your repairs: the forklift itself or the battery and charger. Without that insight, you’re just spinning your wheels.
Read on to learn:
- How to distinguish between forklift battery issues and electrical system problems
- What repairs are okay to do in-house, and what should be left to the pros
Electric Forklift Problems
Most of the time, an electrical problem is a battery problem.
Still, jumping to that conclusion only wastes time and money if the electrical system is the real culprit. Fortunately, the pain points themselves will tell you where to focus your time.
Here are common electric forklift problems and their origins.
Forklift Battery Problems
If your forklift feels weak and slow, it’s probably a battery issue.
Other than dead batteries, battery failures generally supply insufficient power rather than no power at all. Consequently, forklift functions won’t abruptly shut down. They’ll build to the eventual failure point.
If your forklift has any of these symptoms, it might be a battery issue:
- Decreased run time between charges
- The forklift battery won’t charge.
- Slower acceleration
- Delayed response to lifting controls
- Dimmed lights
- Reduced travel speed under load
- Excessive heat
All of these suggest an impending battery failure.
Forklift Electrical System Problems
Erratic or intermittent electrical problems usually point to an electrical system issue.
The problem isn’t that the forklift isn’t getting enough power; it’s that the system isn’t distributing that power. Whether it’s controller failures or faulty wiring, part of the electrical system is working inconsistently. For example, forklift lift movement might jostle a frayed wire in and out of position. Sometimes, everything works fine. Other times, the system malfunctions.
If your forklift has any of these symptoms, look for electrical system issues:
- Sudden loss of power
- Jerky movements
- Unresponsive controls
- Erratic system behavior
- Safety system malfunctions
These indicate issues with the forklift’s electrical system.
In-House Electric Forklift Quick Fixes
Electric forklift repairs can get complicated.
However, some are simple issues that are easily fixed in-house. Knowing the difference can save you money and prevent extended downtime.
Here’s what to look for and what to do.
Forklift Batteries
If your battery is the problem, inspect it and the charger.
Look for loose connections, corrosion, damage, and leaks. Check the voltage and monitor the charging time. You can tighten loose connections, top off the water, perform an equalizing charge, and remove surface corrosion. Only a qualified technician should handle other issues.
A professional assessment will tell you if repair or replacement is your best option.
Forklift Electrical System
For the electrical system, look for loose or damaged components.
In particular, inspect the wiring for corrosion, damage, and wear. Error codes may provide additional insight. You can tighten loose components and replace some wires in-house. Consult a technician for more advanced diagnostics and advice before any further DIY repairs.
What appears to be a simple in-house repair could cause downstream issues.
Avoid Most DIY Forklift Repairs
DIY repairs may seem less expensive, but they come with hidden costs.
Fixing a loose wire in-house is no big deal, but as repairs get more complicated, the risk of costly errors increases. Electric forklifts are sophisticated machines with many cooperating parts. A mistake while repairing one can damage another, compounding the first issue and leading to more repairs.
Additionally, DIY repairs may void your warranty and/or UL Ratings.
Many warranties contain repair stipulations to ensure only qualified technicians repair electric forklifts. This is a risk management practice to avoid unnecessary warranty claims and to prevent dangerous failures. Always check your warranty before starting any DIY repairs.
In-house repairs can be a pain, but our technicians are the remedy.
DIY repairs are a gamble, and they take time away from associates who could be adding more value elsewhere. They burden you with additional downtime, parts orders, and schedule adjustments. Often, they cause more trouble than they solve, but our expert technicians prevent all of that.
Our professional staff comes to your site, handles all the repair logistics, and conducts repairs on your schedule. Even better, they are available seven days a week, ensuring you get repairs when you need them.
Don’t let one repair pain point become a dozen. Let our technicians make electric forklift repair pain-free.
To learn more about our maintenance plans or to request a quote, contact us online or visit one of our locations:
Arkansas - Jonesboro
Alabama - Birmingham, Dothan, Irondale, Madison, Mobile, and Montgomery
Georgia - Atlanta
Mississippi - Belden, Tupelo, and Richland
Tennessee - Jackson, Memphis, Knoxville, and Kingsport
Further Reading
The Risks of DIY Forklift Repair
Convert Your Forklift Fleet to Lithium-Ion Batteries: What You Need to Know
How to Move a Forklift With a Dead Battery – 3 Options
Get The Right Forklift
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