It’s frustrating to realize your forklift won’t start…you’re ready to start working for the day and suddenly have a schedule delay because troubleshooting and repairs are needed. The good news is that there are a few common root causes, and it might be possible to identify the cause without calling a technician.
In this guide, we are sharing a few things that you can do to identify the problem and get your machine running again, as well as when you know that it’s time to call for help.
Before You Touch Anything: 3 Safety Steps
Safety is always the highest priority, even when the forklift is parked. So, make sure that you always follow these three safety tips before trying to figure out why your forklift won’t start:
- Set the park brake
- Lower the forks to the ground
- Place the directional lever in neutral
Never try to bypass a component or jumpstart the forklift without confirming that the machine is stable and the surrounding area is clear.
If you think that there might be an issue with the electrical or fuel system, then the machine must be tagged out. Professional repairs are essential before the forklift goes back into operation again.
Forklift Not Starting: Troubleshooting Guide
In this section, we’ll walk through some of the symptoms you might be experiencing that could be affecting the function of the forklift.
- Completely Dead (No Lights/Sound): If the forklift won’t start and you can’t even turn on the lights or sound, then it is likely caused by a dead battery, a blown main fuse, or a disconnected battery cable.
- Only Clicking: When the forklift won’t start and just clicks, it typically means that you are dealing with a weak battery or a failed starter solenoid. You might notice a single click or rapid clicking, depending on the situation.
- Cranks But Won’t Fire: If it seems like it’s trying to start and you can crank the starter, but it never actually fires, then check the fuel delivery. Other possible issues might be the ignition components, like spark plugs or glow plugs, depending on the type of fuel that the forklift uses.
- Starts Then Dies Immediately: When you can get it to start but it won’t stay on, it is likely an issue with the seat switch, an engaged emergency stop, or a fuel flow restriction.
The 11 Most Common Forklift Starting Problems
Some of the most common issues that need to be addressed if you are having problems starting the forklift might include:
- Dead or Weak Battery: Forklifts that use a 12V starting battery will have trouble cranking if the battery is 11.9V. Test the battery first and replace it if it is old.
- Corroded or Loose Terminals: Check the battery connections to see if there is any corrosion or loose parts. A wire brush can be used to clean the corrosion, and also try tightening the terminals to see if that helps.
- Blown Fuse, Bad Relay, or Faulty Key Switch: Before you assume that there is a deeper electrical issue, check to make sure that the fuse panel is working properly. Replacing a $3 fuse is a common solution, and it is much cheaper compared to other electrical repairs.
- Failed Starter Motor or Solenoid: If the battery test looks good and you are getting a single click when trying to start the forklift, then you likely need to repair the starter motor or solenoid.
- Empty Tank, Stale Fuel, or Water in the Fuel: It might seem obvious, but make sure that there is fuel in the tank. Also, keep in mind that if the machine hasn’t been used and the fuel has been sitting for more than 30 days, it can degrade enough to prevent ignition. Drain and refill the fuel tank.
- Clogged Fuel Filter or Failed Fuel Pump: If the fuel flow is restricted, then it might seem like ignition failure. Follow regular maintenance to replace the fuel filter on schedule.
- Worn Spark Plugs or Ignition Components: Check to see if you have degraded plugs, a cracked distributor cap, or a failing ignition component that needs to be replaced.
- Emergency Stop Reset: When you have a bumped or partially engaged e-stop, the machine automatically cuts power to the start circuit entirely. It might be as simple as resetting the emergency stop.
- Seat Switch Not Detecting Weight: Most forklifts are designed with a system that only allows the machine to function if there is an operator present. Sit in the seat fully and try again. Also, check the operator presence switch.
- Directional Lever Not in Neutral: Most forklifts require that the directional transmission lever is in neutral before it will crank.
- LPG Valve Closed or O-Ring Damaged: After a tank swap, confirm the service valve is fully open. A worn O-ring at the coupling will starve the engine of fuel immediately.
FAQ
What should I do first when my forklift won’t start?
Follow these immediate steps if your forklift won’t start: set the park brake, make sure the directional lever is in neutral, release the emergency stop (if needed), and test the battery voltage. If you can’t identify the issue at this point, then further troubleshooting is needed.
Why does my forklift just click when I turn the key?
If you have just a single click or rapid clicking, then it’s likely due to a low battery or a failed starter solenoid.
Why won’t my forklift start in cold weather?
Cold weather is a common culprit in forklift starting issues because the temperatures can affect the battery capacity and cause engine oil to thicken. If possible, store the forklift in a heated area. Also, make sure that you are using oil and fuel that are rated for cold weather conditions.
Forklift Starting Problems? Contact BullDog Forklifts for Same-Day DFW Repairs
If you are asking, “Why won’t my forklift start?” then rest assured knowing that our technicians at BullDog Forklifts are always here to help. Our mobile technicians come to your site and offer same-day services throughout the Dallas/Fort Worth area. We’re also here to help with forklift sales and rentals. Contact our experienced team to learn more about available services.