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How do I troubleshoot common issues with my electric forklift?

Troubleshooting the common issues of electric forklifts can be both time consuming and costly. Fortunately, TAG Forklifts has created this troubleshooting guide to help you quickly identify and resolve any issues you may encounter while operating your electric forklift.

From identifying a faulty battery to analysing the power supply, this guide will cover the most commonly experienced issues with electric forklifts and provide tips on how to solve them.

Understanding Electric Forklift Safety Features

Electric forklifts are equipped with various safety features to ensure that operators can perform their duties safely and efficiently. These features range from visual indicators to advanced warning systems. Below are some of the most common electric forklift safety features:

Safety Feature


Seat Belt

Most electric forklifts come equipped with a seat belt to keep the operator securely in their seat in case the forklift tips over. It’s important for operators to wear their seat belt while operating the forklift.


The forklift horn is used to alert other workers about the forklift’s presence. Operators should use the horn when approaching blind corners, intersections, or any other areas with limited visibility to prevent collisions.


Electric forklifts have a range of lights fitted to improve visibility and safety. Headlights, rear lights, and emergency lights are some of the most common. They help operators see in poorly lit areas and enable other workers to see the forklift from a distance.

Backup Alarm

This alarm is activated when the forklift is reversing, alerting workers to the forklift’s movement and potential danger. It’s important to ensure that the backup alarm is audible enough so that other workers can hear it.

While these safety features are crucial for protecting operators and other workers in the vicinity, it’s essential to follow other forklift safety guidelines and regulations. Abiding by these regulations can ensure a safe, productive, and efficient work environment. Below are some of the recommended forklift safety procedures:

  • Perform a thorough safety check before operating an electric forklift
  • Keep the forklift’s load within its rated capacity
  • Stay clear of any overhead obstacles when operating the forklift
  • Always use the forklift’s brakes, even on a slight incline
  • Only drive the forklift on designated routes and areas
  • Never permit unauthorised personnel to operate the forklift
  • Always wear the appropriate personal protective equipment (PPE) while operating the forklift

What are some common electric forklift safety guidelines and regulations?

There are several safety guidelines and regulations that operators must follow when operating electric forklifts. These regulations vary depending on the region, but most are similar in content. Below are some of the standard forklift safety regulations:

  1. Operators must be adequately trained and certified to operate the forklift
  2. The forklift must undergo regular maintenance and inspections to ensure it’s safe to use
  3. Operators must adhere to the maximum load capacity of the forklift
  4. Operators must always wear their seat belts while driving the forklift
  5. The forklift must not be operated in areas with insufficient ventilation

By following these guidelines and regulations, operators can significantly reduce the risk of accidents and injuries while operating electric forklifts. When it comes to electric forklift safety, prevention is always better than cure.

Electric Forklift Maintenance for Smooth Operation

Regular maintenance is crucial to keep electric forklifts running smoothly and minimise the risk of accidents. Here are some essential maintenance tasks that should be performed:



Check the battery and charging system

Every shift or at least once per week

Inspect tires and wheels for wear and damage

Every 500 hours of operation or at least once per month

Change oil and filters

Every 250 hours of operation or at least once every 3 months, depending on usage

Inspect brakes and replace components as needed

Every 1,000 hours of operation or at least once per year

It’s also important to use the proper forklift safety equipment, such as seat belts and safety guards, and follow a comprehensive forklift safety checklist. This helps ensure that all safety features are in place and functioning correctly.

In addition to these tasks, operators should also be trained to perform routine inspections of their forklifts before each shift. This includes checking controls, lights, and brakes, as well as examining the forklift for any signs of damage or wear.

Troubleshooting Common Electric Forklift Issues

If you are experiencing issues with your electric forklift, it’s important to troubleshoot the problem as soon as possible. Here are some common issues and steps you can take to resolve them:

Problem: Battery Issues




The forklift won’t start or hold a charge

Dead battery or loose connections

Check the battery connections, replace the battery if needed

The battery takes too long to charge

Faulty charger or battery

Test the charger and battery, replace if needed

Note: Always follow proper safety protocols when handling batteries.

Problem: Electrical Malfunctions




Lights or gauges don’t work

Blown fuse or loose connections

Replace the fuse, check connections

The forklift moves erratically or doesn’t respond

Faulty controller or damaged wiring

Test the controller and wiring, replace if needed

Problem: Motor Issues




The forklift doesn’t accelerate or moves slowly

Faulty motor or damaged brushes

Check the motor and brushes, replace if needed

The forklift overheats or shuts down unexpectedly

Overworked motor or damaged cooling system

Reduce the load, check the cooling system

Remember, if you are unsure how to troubleshoot a problem, always consult the manufacturer’s manual or a qualified technician.

Ensuring Forklift Safety Procedures

Electric forklifts can be dangerous if operated improperly, and it is essential to follow proper forklift safety procedures. By adhering to safety guidelines, operators can minimise the risks associated with forklift operation and create a safe working environment for themselves and others.

It is important to be aware of the potential hazards associated with electric forklift operation. These include tipping, collisions with objects or pedestrians, and the potential for hazardous material spills. To minimise these risks, operators should adhere to best practices, such as ensuring the forklift is in good working condition, maintaining a safe distance from other objects and pedestrians, and operating the forklift at a safe speed.

Another essential aspect of ensuring forklift safety is creating a safe working environment. This involves keeping aisles and walkways clear, marking off hazardous areas, and making sure that all safety equipment is in place and functioning properly. It is also important to have a comprehensive forklift safety plan in place, which outlines the necessary procedures for forklift operation and the steps to take in the event of an emergency.

Operator awareness is also crucial for ensuring forklift safety procedures. Operators should receive proper training and be familiar with all applicable regulations and safety guidelines. They should also be encouraged to report any safety concerns or hazards they encounter during operation.

By following proper forklift safety procedures, operators can ensure that electric forklift operation remains safe for everyone involved. Employers should make forklift safety a top priority and provide operators with the necessary training, equipment, and support to promote a safe working environment. Remember, safety is everyone’s responsibility.

Electric Forklift Safety Training

When it comes to operating electric forklifts, safety should always be the top priority. To ensure operators are equipped with the knowledge and skills necessary to operate these machines safely and effectively, electric forklift safety training is essential.

Training programs should cover a range of topics, including:

  • Forklift safety guidelines and regulations
  • The importance of pre-operation inspections and maintenance checks
  • Proper loading and unloading techniques
  • Safe driving practices, including awareness of surroundings and load stability
  • Emergency procedures and protocols

Additionally, it’s important to provide ongoing training and refresher courses to ensure operators remain up-to-date with the latest safety procedures and best practices.

By investing in comprehensive electric forklift safety training, operators can feel confident and equipped to operate these machines safely, ultimately improving workplace safety outcomes.

For Trusted Electric Forklift Maintenance, Hire & More, Call TAG Forklifts Today

TAG Forklifts understands the importance of proper electric forklift safety training. That’s why we offer comprehensive and up-to-date courses to ensure operators can use their machines safely. Investing in our services provides peace of mind that operations will run smoothly, ultimately leading to improved workplace safety outcomes. Contact us today to learn more about our electric forklift maintenance, hire and more services.

FAQ – Frequently Asked Questions about Electric Forklift Troubleshooting

If you still have questions about electric forklift troubleshooting, you’re not alone. Here are some answers to common queries:

Q: What should I do if my electric forklift won’t start?

A: The most common reason for an electric forklift not starting is a dead battery. Check the battery connection, ensure it is fully charged, and try again. If this doesn’t work, it could be a blown fuse or a controller malfunction. Contact a professional for help.

Q: How often should I perform maintenance on my electric forklift?

A: Regular maintenance is crucial for electric forklifts. It is recommended to carry out maintenance tasks on a daily, weekly, monthly, and yearly basis. Refer to the manufacturer’s manual for a comprehensive maintenance checklist.

Q: Can I replace the battery on my electric forklift myself?

A: It is not recommended to replace the battery on your own, as this can be dangerous and may result in personal injury. Contact a professional to replace the battery and ensure that all safety procedures are followed.

Q: What safety equipment should I use when operating an electric forklift?

A: It is important to wear personal protective equipment, such as a hard hat, safety shoes, and high-visibility clothing when operating an electric forklift. Additionally, ensure that the forklift is equipped with safety features such as seat belts, horns, and brake lights.

Q: How can I avoid tip-over accidents when using an electric forklift?

A: One of the most common hazards associated with electric forklift operation is tip-over accidents. To avoid this, ensure that the forklift is operated on level ground, and that loads are carried low and evenly. Always follow the manufacturer’s guidelines and receive proper training.

Q: Do I need to be certified to operate an electric forklift?

A: Yes. OSHA requires all forklift operators to be certified and trained on how to safely operate an electric forklift. Ensure that you receive proper training before operating the forklift, and keep your certification up to date.

By following proper troubleshooting techniques and safety procedures, you can ensure that your electric forklift operates smoothly and safely. If you have any further questions, contact a professional for assistance.