“Have you tried restarting your machine?”
It’s such a stereotypical troubleshooting question that it’s almost a joke. Yet it remains a common tech support inquiry because the solution is sometimes that simple. Professionals know it’s predatory to bill you for a service call when the resolution is only a couple of clicks away. That’s why almost every tech support call starts with that classic question.
Some power-related forklift repairs are almost as simple.
Most forklift repairs require professional help, but in a few cases, there’s no need to call in the experts. Knowing the difference can save you time and money. Making the distinction isn’t hard. It all comes down to some basic troubleshooting.
Read on to learn what to do when:
- Your forklift won’t start.
- Your forklift lacks power.
- Your forklift dies mid-shift.
DIY Forklift Repair
If your forklift loses power, stepping aside might be your best answer.
Modern forklifts aren’t hobby cars. They’re sophisticated machines, built to safely transport bone-crushing loads. Even well-meaning tinkering can undermine safety and function. With lives and livelihoods on the line, DIY repairs are usually more trouble than they’re worth. The safest choice is always to have a certified forklift technician handle your troubleshooting and repairs.
That said, there are a few simple fixes to check before sending up a distress signal.
What Causes a Forklift To Lose Power?
Forklift power-related problems generally fall into one of three categories.
Each has several potential sources:
- Won’t start. Fuel supply, fuel system, and ignition issues are the most common causes of a failure to start.
- Studders, stalls, or lacks power. Low fuel pressure, dirty filters, and an imbalanced air-to-fuel ratio can cause a forklift to run rough.
- Dies mid-shift. Overheating, blocked fuel lines, weak batteries, and faulty chargers can kill a forklift mid-shift.
However, most of these causes link to the forklift’s power source.
Consequently, troubleshooting a few specific systems will help you better understand the issue and guide next steps.
When Your IC or Electric Forklift Won’t Start…
If your forklift is struggling, check out these systems first:
For IC Forklifts, Inspect the Fuel System:
- Fuel levels and connections. Double-check that the forklift has enough fuel. For LPG forklifts, ensure the valves are completely open. Inspect lines and hoses for cracks, leaks, and rust. Low fuel, damaged hoses, and partially closed valves restrict fuel to the engine, leading to various types of power failure.
- Blockages. Look for blockages in the fuel injector, carburetor, and regulator. Debris and oil can accumulate in these components, disrupting fuel flow.
- Filters. Check for clogged air and fuel filters. Dirty filters limit air and fuel flow. The engine requires both for efficient combustion. Minor blockages can cause the forklift to run rough, while severe clogs can keep it from starting.
- Worn parts. Examine the spark plugs and fuel pump. As these parts age, they perform inconsistently, causing power loss.
- Frozen regulators. Ensure your regulator isn’t frozen. LPG regulators can freeze in warm environments with enough humidity. Pressurized gas rapidly cools the regulator’s metal components as it flows from the tank into the fuel system. Condensation forms, and if the cooling continues, the water droplets can freeze. This restricts fuel flow.
For Electric Forklifts, Inspect the Battery and Charger:
- Battery charge. Check the battery’s charge. Depth of discharge can affect battery efficiency. Ensure the battery is fully charged before use.
- Connectors. Look for loose connections and corrosion on the charger and the battery. Both cause inconsistent charging and discharging, leading to partially charged batteries and rapid battery depletion.
- Fuses. Inspect the charger and forklift for blown fuses. Damaged fuses can cause intermittent power loss or a complete failure to charge.
Inspect the Cooling System:
- Coolant. Replenish or replace the forklift’s coolant. Forklifts generate lots of heat. Without sufficient coolant, they overheat quickly. Overheating can cause a forklift to lose power mid-shift and prevent it from starting again until it cools down.
- Radiator. Clean the radiator. Debris and buildup can block radiator ports, preventing coolant from circulating. Just like low coolant levels, this causes rapid overheating.
Inspect the Lifting System:
- Mast. Check the mast for damage, misalignment, and inadequate lubrication. These all increase friction, forcing the forklift to work harder. Overworked power systems can overheat, rapidly drain batteries, or force a shutdown.
- Hydraulics. Look for worn-out or leaking hydraulic hoses. These cause pressure drops. They will not cause the forklift to shut off, but they will reduce lifting power. Reduced lifting power is easily confused with reduced motive power.
Not every issue you find will be a candidate for a DIY repair.
When in doubt, contact our service team for guidance.
Forklift Maintenance Is Repair Prevention
All forklift power issues have two things in common.
First, they all kill your productivity. Even quick-fix issues create exponential downtime. During troubleshooting and repair, your forklift is out of commission. An hour of unplanned downtime can cost you thousands in lost productivity and missed deadlines.
Second, forklift power issues are preventable.
Poor maintenance is the root of most power-related problems. Consequently, operations without a service plan encounter these issues more frequently. Even small maintenance oversights compound over time, leading to strings of expensive repairs.
Forklift repair should be a last line of defense.
Planned maintenance prevents these repairs. Our certified technicians look for these common failure points with every inspection, allowing them to fix a breakdown before it ever occurs. That professional care keeps your forklifts running longer, increases productivity, and reduces your total cost of ownership.
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
How Dangerous Are Forklift Hydraulic Leaks?
The Risks of DIY Forklift Repair
How To Calculate the True Cost of Downtime