Solutions: The Three Most Common Forklift Issues

1 The Charger is Connected to The Forklift, Not the Battery

The forklift and the battery have the same 350 connector. It is a male and female connector.  The battery charger must be plugged into the battery and not the truck, this is the plug that is on top, the one that the operator removes from the bottom plug.

2 Charger is Not Wired Correctly

Many chargers have 3 settings: 208V, 240V, 480V. Jumper wires are to be configured according to match the building’s voltage. Measure the building’s voltage at an outlet with a volt meter. Look on the inside the charger door to locate the schematic. This will show how to configure the jumpers on the transformers as well as the control transformer and then proper fuses are to be installed.  The fuse rating is labeled on the main data tag on the front of the charger door.  Most common amp ratings are as follows:  208/35, 240/25, 480/20

1 Steep angles

Forklifts can get tipped at steep angles during loading & unloading. This can sometimes cause fluids to leak or drip. Leaks and drips caused by steep angles will often stop after a week of operation

2 Residual Dripping From Service

Fluids dripping from a machine don’t necessarily indicate an active leak. All machines have just been through service, and some fluids may have been recently drained & refilled. Often there will be some residual drips following service, these drips usually go away after a week or operation.

1 Double O-Ring on LP Tank Connection

Sometimes the O-ring on the depleted LP tank will fall out and stick in the forklift’s fitting. When the new tank is installed the tank won’t tighten properly with two O-rings and fuel can’t flow properly.

2 Out of Fuel

Sometimes people underestimate how long a tank will last. In large machines especially, fuel will be used up faster than in standard units.

LP tank gauges are often inaccurate. Try removing the tank and shake to detect remaining fluid.

3 Tank coupler not screwed on tight enough

When the tank isn’t screwed on tightly enough, fuel is unable to enter the system. The gap between the coupler & tank collar should be about 1/8^th of an inch. Make sure the coupler is on tightly, sometimes shaking the coupler while tightening helps to ensure the connection is completed.

4 Frost on Fuel Regulators

When the engine compartment is lifted, you may notice frost on the regulator. Defrost with hot water, a blow dryer, or heat gun to defrost the frozen fuel system.

5 Weak Battery

Often freight carriers will leave the key on after securing the load. A jump start may be necessary. If battery replacement is needed, we will cover the costs.

6 Emergency Break Must Be On

Some lifts require the emergency break to be engaged before starting. Many forklifts have a pressure switch built into the seat. Make sure the operator is seated to the rear of the seat, and is heavy enough. Bounce on the seat to activate if necessary.

7 Wiring Connections

Freight can cause vibrations from roadways that loosen wiring and plug connections. Check battery connections & wiring after the long haul.