Locate us
Contact us
Search 
Technical Articles
- Blog
- Technical
How to Troubleshoot a Forklift When It Doesn't Start
SHARE
Products
Services
Solutions
About Linde
When your forklift won't start, it can bring your warehouse operations to a grinding halt. Understanding why start-up failures happen is important for keeping productivity and safety high. This is key for material handling equipment. This guide will walk you through the essential checks to diagnose and potentially troubleshoot forklift starting issues.
The emergency stop (E-stop) button can be a simple yet overlooked reason for a forklift's failure to start. First, locate the red emergency stop button. Make sure you fully release it by pulling it out or twisting it.
Sometimes, someone may accidentally activate the E-stop during previous operations, so a careful check is essential. Take a moment to inspect the E-stop mechanism for any physical damage that might prevent proper disengagement.
A systematic start-up approach can prevent unnecessary complications. Begin with a visual inspection of the forklift, checking all fluid levels including oil, coolant, and hydraulic fluid.
Verify tire condition and pressure, and ensure all safety guards and covers are in place. Once seated, fasten the seatbelt, and turn the key to the 'on' position. Wait for dashboard lights to stabilise before attempting to start the engine.
Forklifts incorporate multiple safety mechanisms related to gear positioning that can prevent starting. Check that the forklift is in neutral gear and that you have correctly positioned the transmission selector. Confirm that you fully engage the parking brake and that the operator sits in the driver's position. A close look at the gear selector may show any problems that may stop the forklift from starting.
Modern forklifts come equipped with sophisticated diagnostic systems that communicate potential issues through warning lights and error codes. Watch the instrument panel carefully. Check for signs about the battery, charging system, engine temperature, oil pressure, or electrical problems. If possible, note down any specific error codes displayed – these can provide valuable insights into the underlying problem.
Before diving into complex diagnostics, start with the most fundamental power sources. Begin with a complete check of the fuel system.
Inspect the fuel gauge to make sure there is enough diesel or LPG in the tank. Check for any visible fuel line damage, loose connections, or potential leakage. A clogged or dirty fuel filter can stop your forklift from starting; so, check its condition carefully. The battery requires equally meticulous examination. Inspect the terminals for corrosion, and ensure all connections are tight and clean. Using a multimeter, check the battery voltage. A fully charged battery should read around 12.6V.
Check the battery's age. Most batteries last about 3 to 5 years. Also, look for any signs of wear or damage to the cables.
Regular maintenance is the key to preventing start-up issues. Most manufacturers recommend daily pre-operational checks, weekly basic inspections, monthly comprehensive service, and an annual detailed maintenance routine. If these checks don't fix the starting problem, it's important to contact a certified Linde service technician. Avoid attempting complex repairs without professional help.
Troubleshooting a non-starting forklift requires a methodical approach. While these steps can help diagnose common issues, always consider safety and consult professional technicians when in doubt.
Need expert assistance? Contact Linde Material Handling Australia for professional forklift support and maintenance services.
ENQUIRE NOW