Travel & Lift Problems

When the forklift mast won’t go up or the lift won’t stay running, it poses problems to the management and operators alike. It costs money in terms of lost productivity and high repair costs. The average cost of travel and lift repairs is $428.

The most common causes of travel & lift problems are:

• Broken wires
• Malfunctioning contactors or switches
• Weak or dead battery
• Speed set too low
• Fuel system problems

In rare cases, the problem can be caused by:

• Debris in the hydraulic pump
• Locked up brake
• Valve blockage
• Bad motor

Broken wires are the main cause of travel and lift problems. Wires break due to heat, age and movement. The hotter the wires get the more brittle they become. When paired with aging and movement, the brittle wires snap easily and lead to myriad problems.

How To Prevent Travel & Lift Problems

The first thing you need to do is tape the exposed wires. Adding an electrical tape or good insulating material to exposed wires and keeping the movement of the components to the minimal will help.

Taking care of your batteries will also help. Keep them watered and charged. Doing so will prevent battery issues that can lead to travel and lift problems.

Last but not least, you have to adjust the fuel system and remove gunk. Draining the regulator periodically will help clear the build-up of gunk.

Accessories: Horns, Lights And Travel Alarms

For safety and operational purposes, forklifts come with a combination of horns, travel alarms as well as lights. However, like all ‘things’, these essential accessories can stop working suddenly. On average you can expect to spend $207 on all accessory repairs.

The most common causes of accessory problems include:

• Worn or dirty components: light bulbs, horn contacts or pins
• Damaged or malfunctioning headlight, travel alarm assemblies or taillights
• Broken wires

In rare cases, the problems can be caused by:

• A blown fuse
• Missing mounting hardware
• Misaligned or malfunctioning switch

OSHA requires that forklifts have a working horn. A problem with the horn must be fixed immediately. As for the lights and travel alarms, it all depends on where the forklift will be used. For example, if the forklift is used in areas with low light, the headlights must be functioning properly.

How To Prevent Accessory Problems

The horn contacts and pins can be cleaned during regular maintenance intervals. You should also grease using di-electric grease to reduce metal-on-metal wear. However, over time these parts will degrade until the horn becomes inoperable. You should change the horn before it wears out completely. This is because if the horn is the warning device, OSHA considers a truck with no horn unsafe.

Proper operator training can help reduce issues. This is because a major cause of light and travel alarm problems is operator-inflicted damage.

Error Codes & Check Engine Lights

Just like with a car, forklifts also have the check engine light. At times, the presence of this light is followed by the engine failing to work. Other times it is followed by nagging problems that never go away. The most common causes of the error codes and check engine lights are:

• Bad electrical component: contact, switch or sensor
• Broken wires
• Weak or dead battery
• Fuel mixture

The less common causes are:

• Faulty control handle
• Bad motor
• Dirty motor brushes

How To Prevent Error Codes

The error codes and check engine lights are very hard to predict. This is because problems with broken wires, contactors, sensors, and switches tend to happen when we least expect. Limiting heat, debris and movement can, however, help reduce the chances of these components from acting up.

A problem with your batteries may cause error codes. That is why you need to keep the batteries properly watered and charged. Refrain from using the batteries until they are fully charged.

Last but not least, you need to keep the fuel system clean. The fuel system is the main cause of problems. Keeping it clean will help prevent error codes from displaying. Whenever you get an error code, always keep a record. That way you will be able to tell when one code popups in a row.

Forklift Won’t Start

There are times when the forklift will just not start. The problem is mostly caused by a dead battery. There are also other issues that can cause a forklift not to start. The most common issues are:

• Weak or dead battery
• Fuel system problems. This can include dirty components or leaking regulator
• Bad starter
• Broken wires

In rare cases, the start problems can also be caused by:

• A bad gear selector
• No fuel
• Blown fuse
• Bad seat belt/seat belt switch
• Tracker system fault

The regulator is the part where liquid fuel is turned into gas. Regulators fail when they are filled with gunk. They can be filled with dust and debris from the fuel tank. Over time the debris clogs the regulator. When it is clogged, less fuel gets to the engine. This leads to engine start and run problems.

How To Prevent Battery Problems

The key to preventing battery problems is proper maintenance. With batteries used in internal combustion forklifts, there is not much you can do to prevent problems.

With electric forklifts, the batteries are designed to be recharged when they are 80% discharged. You also need to keep the batteries watered and wait until they are fully charged before you start using them.

Battery Problems

Electric lifts use batteries as the main source of power. The internal combustion trucks use the battery to power the starter motor. Batteries play a huge role in the operation of a forklift. The main causes of battery problems include:

• Weak or dead battery
• Melted or damaged connector
• Bad ALT

Less common causes of battery issues include:

• Bad water filling system
• Battery leak
• Lifting eyes bent on the battery case

While all the problems listed above do not impact safety, you have to handle batteries with care. Since they are filled with acid, leaks from batteries need to be cleaned immediately. Coating the spills with baking soda can neutralize the acid and help prevent injuries. It is also good to wear the right protective clothing to prevent electrocution and injuries from the acid. You should also not attempt to lift the batteries without the proper equipment. The batteries of an electric forklift weigh a few hundred pounds.

How To Prevent No Start Problems

Installing a battery disconnect switch can help prevent dead batteries. Considering the battery powers multiple accessories including safety lights, headlights, coolers, and computers, installing a disconnect switch will help prevent these accessories from draining the battery.

Cleaning the fuel system can prevent start issues too. You need to make time for regular cleaning and maintenance.

Broken wires and bad starters are much harder to prevent. They don’t give warnings. When they are damaged, you need to replace them.

Running Rough

Running rough can be caused by backfiring, losing power, and spitting and sputtering. The majority of problems relating to running rough are common with internal combustion trucks. With electric trucks, the issue was mainly caused by ‘losing power’. The main causes of rough running are:

• Problem with the fuel system. This includes regulator leaking, VF voltage adjustment, throttle body, and a dirty fuel filter. The VF voltage is what governs the forklift’s air-to-fuel mixture. If the VF voltage is off there will be too much air or fuel getting to the engine thus causing rough running.
• Dry or weak battery
• Damaged wires

The issue can also be caused by:

• Regulator vacuum hoses leaking or coming off
• Bad alternator belt
• Improperly installed fuel line
• Bad wiring harness and engine control unit

A leaking regulator and loose vacuum hoses are a safety concern because of emissions.

How To Prevent Rough Running

One of the best things you can do to prevent rough running is to clean the fuel system. This should be done to get rid of grit and grime which accumulates during normal operation. Replacing fuel filters will also help prevent the rough running problem.

Battery issues cause rough running in electric forklifts. Ensuring the battery is watered regularly and charged fully will help.

Electrical Problems: Buttons, Switches And Controls

There are many issues that fall in the broad category of electrical. They include switches, wiring, buttons, and anything that is not a specific problem or did not affect operations. These issues are mainly caused by:

• Malfunctioning switches
• Missing or loose hardware
• Bad wiring

They can also be caused by:

• Debris
• Bad spring
• Blown fuses

Heat, dirt, and excessive dryness are the main factors that cause switches to go wrong. Some operating environments such as extreme heat, moisture, or debris are also harder on a forklift. Forklifts operating in these conditions experience more problems.

Electrical problems are a safety issue when they affect the operation of the equipment. For example, when a faulty belly button turns on an electric pallet jack. Such a switch has to be replaced immediately.

How To Prevent Electrical Issues

The most important thing you have to do to prevent electrical problems is to limit exposure to excess heat, moisture, and debris. Debris can compromise sensitive equipment, so you need to blow out your unit regularly to reduce problems. Keeping the various components dry, clean, and stationary will go a long way in preventing electrical problems. Don’t forget to cover exposed wires with tape or insulation.

Seat & Seat Belts

Not all forklifts have seats. Those that do must have the seats and seat belts working properly. This is because seats and seat belts are the last line of defense against operator injury in the event of a tip-over or collision. The seats have to be bolted down and the seat belts should be free of tears, rips, or fraying. In addition to that, if the truck has a seat switch or an interlocking seat belt, they have to be operable. If they are not working, they should be removed from service until the issues are fixed. On average it costs about $304 to have the seat and seat belt repaired.

The most common causes of seat and seat belt problems are:

• Damaged or worn-out seat cushion or seat belt
• Loose or damaged hardware
• Damaged wires

How To Prevent Seat And Seat Belt Problems

Seats and seat belts are wearable parts. Getting on and off of them and buckling and unbuckling the seat belt causes them to wear. This is what causes them to degrade. Even so, you can extend the life of the forklift’s seats and seatbelts by ensuring operators don’t have sharp objects on them that can tear the seats. Not placing objects with sharp edges/protrusions on the seat while working can also help prolong the life of the seats and seat belts.

Cooling System Problems

The general rule about forklifts is the cooler you keep them the longer they will last. Heat is the main cause of problems for the forklift parts. This is more so when it comes to the transmission and engine. This is why you must address cooling system problems as soon as they arise. On average it costs about $635 to get all cooling system repairs.

The main causes of cooling system problems include:

• Worn or clogged radiator
• Bad water pump
• Bad thermostat

Although not common, the issues can also be caused by:

• Bad regulator hose
• Fuel mixture out of adjustment
• Cracked engine block
• Loose hose clamps

How To Prevent Cooling System Problems

If the forklift is used in operations that involve the production of debris such as in paper mills and insulation manufacturing plants, the radiators are prone to get clogged quickly. To prevent cooling system problems, you need to blow out the radiator with air at least once every shift. This will keep them from getting clogged and improve cooling.

The other parts such as the water pumps and the thermostats are prone to degrading over time. They are harder to predict when they will fail. You should, however, have them replaced as soon as they start malfunctioning.