Common Forklift Problems and Solutions: A Troubleshooting Guide
When your forklift isn’t working right, it doesn't always mean you need a major repair. Use this troubleshooting guide to review some of the most common forklift problems and solutions, so your machine can get back to work.
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Common Forklift Problems
When operating a forklift every day, normal wear and tear is expected. When something isn’t working the way it should, you need to know how to troubleshoot it. But to troubleshoot, you have to know what problems to look out for. Here are some of the most common forklift problems to watch for in your equipment.
1. Starting Problems
Problems starting your forklift? You could be experiencing one of two issues: a fuel or electrical problem.
Gas Forklifts
If you have a gas forklift, start by checking the fuel supply. It sounds silly, but sometimes the solution is as simple as an empty tank or a cylinder valve that needs adjusting. If your fuel supply isn’t empty, work through these forklift checks in order:
- Check the fuel quality: old fuel or the wrong type can cause starting issues. Flush the system and replace it with new fuel.
- Check the fuel filter: dirty or clogged filters can prevent the engine from turning over. Clean or replace the filter to prevent further damage.
- Check for gas leaks: do you notice a stronger gas smell? That, paired with a faint hissing sound near the tank, hoses, or fittings, could point to a leak. Stop using the forklift and call a qualified technician immediately.
- Check that you’re following all safety precautions: modern forklifts come with certain safety features that keep the system from turning on when operators aren't seated or strapped in. Are you following all safety measures? If not, this could be the culprit, especially if all other checks come back normal.
Electric Forklifts
If you operate an electric forklift, start by checking the battery. Does it have a charge? If yes, here are some other items to inspect:
- Check for visible damage: rust or corrosion to the battery case, damage to connectors, cables, and tips, or lost/damaged water inlet covers can keep electric forklifts from starting.
- Check the battery voltage: working batteries should hold a voltage of between 2.0 V and 2.2 volts when charged and at rest. Anything lower, or that drops quickly under load, can point to battery problems.
- Check the water level: low electrolyte levels expose the battery plates and reduce capacity. Top it off with distilled water after charging, not before.
- Check for fault codes: electric forklifts display error codes on the dash. Look the code up in your operator's manual. It often points directly to the issue.
2. Mast Problems
The mast does the heavy lifting, so problems can hurt both productivity and safety. Keep an eye out for these common forklift mast problems and try these solutions:
- Jerky or sticking movement: this can be caused by dirty or dry mast components. Clean the channels, lubricate the chains, and inspect the rollers for signs of wear.
- Uneven forks or a tilted carriage: tilting usually means the lift chains are uneven. Check both chains and adjust the tension until it’s equal on each side.
- Stretched or damaged chains: lift chains stretch over time. Measure them with a chain wear gauge and replace them once they reach 3% elongation, or right away if you find cracked, rusted, or stiff links.
- Forks drifting down or the mast tilting forward under load: these are common indicators of hydraulic system problems.
Safety tip: If you need to inspect the mast in a raised position, block it securely first. You should never stand, walk, or work under raised forks.
3. Steering Problems
Steering issues can make a forklift harder to control and more dangerous to operate, and should be addressed immediately.
- If steering feels hard or heavy: check the power steering fluid. Top it off with the correct fluid and check for leaks. If you have a pneumatic tire truck, check the tire pressure. Low pressure can make steering harder.
- If steering feels loose: this usually means steering components are worn out. Grease the axle fittings, and replace worn components before they cause bigger problems.
- If steering is pulling to one side: look for uneven tire wear, mismatched tires, or dragging brakes. These can pull steering in one direction.
- If there's whining when turning: Often a sign of low fluid or a steering pump that's starting to fail. Top off the fluid. If the noise continues, the solution may require a formal inspection.
- If power steering is not responding: Check the display for fault codes, then check fuses and motor connections.
4. Hydraulic Problems
Your forklift's hydraulic system powers many systems, including lifting, lowering, tilting, and sometimes even steering. Look out for these common problems:
- Low or contaminated fluid: milky fluid means water contamination. Foamy fluid means air is in the system. Dark fluid with a burnt smell means overheating. Drain, flush, and refill with the fluid your manufacturer suggests, and replace the hydraulic filter.
- Hydraulic leaks: inspect all hoses, fittings, and cylinders for wet spots or drips. Tighten loose fittings and replace cracked hoses and worn seals. Never use your hands to search for a pinhole leak. Pressurized fluid can penetrate the skin. Use a piece of cardboard instead.
- Slow lifting or won't lift a rated load: Start with the simple causes: low fluid or a clogged filter. If those check out, the pump, relief valve, or control valve may be worn, and that's a job for a technician.
- Noisy pump: Whining or knocking often means the pump is pulling in air because of low fluid or a clogged suction strainer. Top off the fluid and clean or replace the strainer.
- Overheating: Low fluid, a clogged hydraulic cooler, or regularly lifting over capacity can all overheat the system. Clean the cooler and stay within your truck's rated capacity.
5. Transmission Problems
Transmission problems can stop a forklift in its tracks, but often, the solutions are simple. Troubleshooting starts by matching the symptom to the most likely cause:
- Slipping or loss of power: Low or burnt transmission fluid is the most common culprit. Check the fluid level according to your manual (some trucks are checked warm, in neutral, with the engine running). If the fluid is dark or smells burnt, change the fluid and filter.
- Delayed or rough movement: When the truck hesitates or lurches after shifting into forward or reverse, check for low fluid, the wrong fluid type, a clogged filter, or an inching pedal that's out of adjustment.
- Won't move in one direction: This often points to the shift linkage, the direction switch, or a solenoid. On electric trucks, check the display for a controller or direction switch fault code.
- Grinding, whining, or clunking: Noises like these can mean low fluid or worn internal gears and bearings. Check the fluid first. If the noise continues, stop using the truck and call a technician before minor wear becomes a major repair.
- Overheating: A clogged transmission cooler, overuse of the inching pedal, or riding the brake can overheat the transmission. Clean the cooler and radiator fins, and train operators to avoid riding the pedals.
6. Tire Problems
Tires carry your forklift and every load it lifts. Problems can impact stability, capacity, and operator comfort. Take note of:
- Underinflated pneumatic tires: low pressure causes faster wear and less stability. Check pressure daily and inflate to the spec on the truck's data plate.
- Uneven wear: mismatched tires, overloading the forks, using the wrong tires for your job, or taking sharp turns at speed can cause tires to wear faster and unevenly. Replace tires in pairs on the same axle. If the uneven wear keeps coming back, your alignment could be off.
- Chunking, cuts, and flat spots: debris, rough surfaces, and hard braking tear up tires. Keep floors and yards clear of debris, and consider solid pneumatic tires for rough outdoor work.
- Tires worn past the wear line: worn tires reduce stability and safe load capacity. Most cushion tires have a wear indicator line, and should be replaced when the tires reach it.
When to Call a Professional
Troubleshooting can solve many common forklift problems, but some troubleshooting solutions are safer for a qualified technician to handle. Keep yourself and your crew safe by seeking professional help for
- Fuel or gas leaks
- Brake problems
- Internal transmission repairs
- Hydraulic pump or control valve failures
- Electrical or controller issues (beyond basic fault codes)
- Cracked forks, a damaged mast, or any structural damage
If you're not sure, take the truck out of service and call a professional. A short delay costs far less than an accident.
Prevent Forklift Problems with Regular Maintenance
Following proper forklift maintenance can help reduce the likelihood of one of these problems occurring. OSHA requires forklifts to be examined before being placed in service, at least once a day.
A quick pre-shift inspection catches low fluids, worn chains, damaged tires, and leaks before they turn into breakdowns. Paired with regular planned maintenance every 200 - 250 hours can help catch forklift problems early, so you’re less likely to need a major repair.
Is It Time to Replace Your Forklift?
Do the same issues keep coming up, or are repair costs starting to add up? Troubleshooting common forklift problems and solutions can only do so much. You might be due for a forklift replacement. Compare quotes on new and used forklifts from multiple dealers near you, all from one simple request.
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