Common Faults and Solutions of Forklifts

Forklifts are critical tools that keep businesses moving, literally. From warehouses to construction sites, both electric forklifts and diesel forklifts play an essential role in material handling. However, like any machinery, forklifts are prone to wear and tear, which can lead to unexpected breakdowns and inefficiencies.

This guide will walk you through some of the most common forklift issues, their causes, and actionable solutions, empowering operators and business owners to minimize downtime and ensure smooth operations.

Common Faults in Electric Forklifts

Electric forklifts are widely appreciated for their energy efficiency and minimal emissions, making them a popular choice, especially indoors. Nevertheless, they are not flawless and can encounter specific issues over time.

1. Battery-Related Issues

Problem

Electric forklifts rely heavily on batteries for power, and battery problems are among the most common issues. Symptoms include:

● Reduced runtime after a full charge

● Failure to hold a charge

● Acid leakage or corroded terminals

Causes

● Overcharging or undercharging the battery

● Lack of regular maintenance, such as water refilling

● Expired or aging batteries

Solution

● Schedule regular charging: Use a timer or charger with auto-shutoff capabilities to avoid overcharging.

● Monitor water levels: Regularly check and refill distilled water to the correct levels.

● Replace old batteries: On average, forklift batteries last 5-7 years. If your battery is nearing this age and showing frequent problems, consider replacement.

2. Motor Issues

Problem

Faulty electric motors can manifest in decreased speed, overheating, or complete motor failure.

Causes

● Excessive load-bearing

● Improper use of the forklift

● Lack of routine maintenance leading to wear

Solution

● Avoid overloading: Ensure load weights never exceed the forklift’s capacity.

● Schedule inspections: Have the motor inspected by a professional at least once a year.

● Clean components: Keep the motor free from dust or debris that could cause overheating.

3. Steering Malfunctions

Problem

Difficulty steering is a common complaint with electric forklifts, especially as they rack up years of use.

Causes

● Low power steering fluid levels

● Faulty hydraulic systems or worn steering mechanisms

Solution

● Regularly inspect and refill power steering fluid.

● Maintain hydraulic systems by checking for leaks and replacing worn-out components.

Common Faults in Diesel Forklifts

Diesel forklifts are robust workhorses, particularly favored in outdoor environments and for handling heavy loads. Their durability is unmatched, but they come with their own set of challenges.

4. Engine Starting Issues

Problem

Difficulty starting the engine, particularly in cold weather or after prolonged inactivity, is a prevalent problem for diesel forklifts.

Causes

● Dead or weak battery

● Defective glow plugs (often in cold climates)

● Fuel system problems like clogged filters

Solution

● Check the battery: Ensure the battery is fully charged and its terminals are corrosion-free.

● Inspect glow plugs: Replace if damaged.

● Clean or replace fuel filters: Prevent clogs by replacing filters as per the manufacturer’s guidelines.

5. Exhaust Smoke

Problem

Excessive exhaust smoke, whether black, white, or blue, points to engine inefficiencies.

Causes

● Black smoke: Overfueling or poor fuel combustion

● White smoke: Coolant leakage into the combustion chamber

● Blue smoke: Burning oil due to worn engine seals or piston rings

Solution

● Regularly service the engine and emission system.

● Identify and fix leaks immediately to avoid costly repairs.

● Ensure proper fuel quality and use only manufacturer-recommended oil types.

6. Brake Failures

Problem

Brakes are vital for forklift safety, and any inconsistencies, such as longer stopping distances or screeching noises, require immediate attention.

Causes

● Worn-out brake pads

● Hydraulic fluid leaks within the brake system

Solution

● Replace brake pads regularly, especially if the forklift is used in a high-demand environment.

● Check and top up hydraulic fluid to maintain proper braking performance.

General Forklift Faults Applicable to Both Types

Some forklift problems are universal, affecting both electric and diesel forklifts. Below are a few common ones:

7. Mast and Lifting Issues

Problem

Forks may not lift, lower, or tilt smoothly, leading to operational inefficiencies.

Causes

● Hydraulic fluid leaks or contamination

● Malfunctioning mast cylinders or chains

● Overloading the forklift

Solution

● Conduct regular hydraulic system checks and replace fluid when necessary.

● If mast chains show wear or elongation, replace them promptly.

● Always adhere to the lift capacity limits outlined in the forklift manual.

8. Faulty Sensors and Warning Lights

Problem

Forklifts rely on sensors to detect abnormalities. Persistent warning lights can indicate underlying issues, from overheating to low fluid levels.

Causes

● Faulty sensors

● Actual operational failures that sensors are identifying

Solution

● Don’t ignore warning lights. Use diagnostic tools to confirm whether the root issue is a faulty sensor or an actual mechanical problem.

● Maintain a regular schedule for sensor calibration and functionality checks.

Proactive Steps to Prevent Forklift Failures

Reducing the risk of forklift breakdowns requires a proactive maintenance strategy. Here’s how you can prevent most faults:

Conduct Routine Maintenance

Schedule regular preventive maintenance that includes checking battery health, hydraulic systems, tires, fluids, and brakes. A consistent schedule dramatically reduces wear and tear and extends the life of your forklift.

Train Operators

Well-trained operators can significantly mitigate damage caused by improper use. Provide training on how to load forklifts properly, handle turns, and avoid excessive speeds.

Use Genuine Parts

Always use manufacturer-recommended parts for replacements. Substitutes may appear cheaper but could compromise the forklift’s performance and safety.

Track Usage Hours

Keep a comprehensive log of the forklift's runtime. Overused forklifts may require inspections and maintenance more frequently.

Get More from Your Forklift with Expert Assistance

Forklifts—whether electric or diesel—are essential parts of your operation, and keeping them in top shape should be a priority. While minor issues can often be handled in-house with regular maintenance, major repairs require professional attention.

By understanding the common faults and their solutions, you can extend the lifespan of your forklifts, improve safety, and minimize costly downtime.

If you’re looking for expert guidance or parts for your forklifts, consider reaching out to a trusted service provider. With the right support, your forklifts can run efficiently for years to come.

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