Forklift won’t start? It could be these causes…
If your forklift won’t start, there could be a number of things at play. The external environment might be affecting your vehicle and causing starting problems, but most likely there will be something going on within the vehicle’s battery or engine. Remember that regular maintenance is one of the most straightforward ways to avoid larger issues with your truck’s operation, so ensure you’re regularly having your trucks serviced.
It could be a simple fix, or a larger issue that requires an engineer’s expertise. Read on to discover the typical causes of a malfunctioning forklift and see if you can locate the problem when your forklift’s not starting.
Forklift starting problems and solutions
Battery issues
If you’re turning the ignition and there’s no engine sound, only a clicking, then the issue is likely with the battery. Firstly, make sure the battery is charged and properly connected.
You can try recharging the battery, but if this doesn’t fix your starting issues, then it might need replacing. Another reason your battery might not be working is if it’s too cold. Just like a car, a forklift battery can struggle to get going in minus temperatures! More on this in our next point….
The impact of cold temperatures
If your forklift won’t start when cold, it’s important to remember that forklifts that have been sat in the cold can experience issues, particularly LPG and electric models. Low temperatures can thicken the battery electrolyte, causing it to fail. LPG fuel can also be affected by a weakened battery, and in freezing temperatures, fuel regulators can freeze too.
Gas and diesel forklifts use more fuel in cold temperatures due to hard starts. And if the vehicle is running low or empty, it’s possible for condensation to build up in the tank, causing the engine to stutter and fault when started.
Prevent this by:
- Storing forklifts indoors or under a shelter
- Warming up the engine before starting it
- Regularly using forklifts so they are not sat out in the cold for long periods
- Keeping vehicles well-fuelled
Forklift overheating
An overheating forklift is a problem, and one that causes starting issues. Forklifts overheating isn’t just a problem in the hot summer months, although it is more likely to occur when the temperatures are high. If your forklift is overheating and won’t start, there are a few things you can try.
- Check the radiator for debris – a radiator blockage can cause overheating
- Check your coolant levels and add more if needed
- Check for damage on your water pump
- Check there are no hose leaks
Remember, just like a person, a forklift should have regular breaks when the temperature is very high to avoid overheating. Regular maintenance is also important in extreme weather.
Emergency power off
Forklifts are fitted with an emergency stop button. If this has been activated the last time the vehicle was in use, it will need to be de-activated before the forklift will start again.
Warnings and alerts
When your vehicle won’t start, it’s a good idea to check the dashboards for any warning lights you might not have spotted. If there’s a light you don’t recognise, refer to your usual manual or the manufacturer’s website to diagnose the issue.
Fuel-powered forklifts
If your vehicle runs on fuel, always check the levels. Find out when the tank was last filled or when the fuel was last changed. It could be that the vehicle has been sat still too long and the fuel needs changing.
Weighted seats
Many forklifts are fitted with a safety feature that means they won’t start unless there’s a weight in the seat. Make sure you’re sat firmly and fully in the driver’s seat before trying to start the vehicle.
Engine sounding, but not starting
“My forklift engine is turning over, but not starting”
If you can get the engine to turn over, but not start, this indicates the issue isn’t with the vehicle battery (but it is worth ruling out as a low battery might not be able to supply the ignition system properly).
Are the lights coming on? Does the dashboard light up as normal with no warning lights? If so, the problem is likely nothing to do with your battery or electrics.
If your vehicles battery is working, the fault could be a number of different things that will need to be checked out by an engineer. These include faults with the:
- Spark plugs
- Fuel and air filters
- Regulator
- Electrics
For LPG forklifts, this could indicate the fuel tank isn’t connected properly. Sometimes the rubber seal can become dislodged when the tank is changed. This will need amending or replacing if it happens.
Spark plugs
A common issue for forklifts that will turn over but won’t start is the spark plugs. If you have a spark tester, you can check the strength of the spark. If the spark is weak and yellow, the plug may need replacing. A good spark is solid blue spark.
Other parts of the ignition system to check are the condenser, rotor, and coil wires. If any of these parts are corroded or damaged, they need replacing. Even if the are not the root cause of the fault, it’s good maintenance to do so.
Fuel system
If your ignition system is performing, this suggest there’s a fuel system problem. Parts at fault could be the fuel filter, lock-off valve, fuel regulator, and tank connector (LPG).
Troubleshooting a forklift that’s turning over but won’t start is a process of elimination. If you have someone on site with mechanical skills, they may be able to locate the part (s) at fault with some visual checks and tests.
However, unless someone knows what they’re doing, you may waste more time. A forklift engineer will be able to diagnose the problem in no time at all.
Diesel forklift cranks but won’t start
If a diesel forklift cranks but won’t start, this could be a sign that fuel isn’t able to get to the engine. Make sure your fuel injectors aren’t dirty or clogged with dirt or rust. You should also check the fuses and battery and ensure that everything is hooked up as it should be.
Toyota forklift won’t start, just clicks
A lot of people have questions surrounding why a specific brand of forklift won’t start, for example, Toyota. Like a car, every model of forklift truck works slightly differently, but they all have the same components and work in essentially the same way. If your Toyota forklift won’t start and instead just clicks, the issue is likely with the ignition or fuel system rather than the battery. There are a few things you can check:
- See if an emergency power button was used by the last user. This will prevent the engine from starting normally.
- Check if there are any error codes showing. If there are, it’s best to call an engineer to find out the next steps.
- If you’ve had recent extreme weather, like very hot or very cold conditions, consider if this could have affected your truck. As stated above, many forklifts will not start when cold and will need to warm up to the right temperature first. In the winter months, make sure you’ve given your truck enough time to get to the correct temperature.
Propane forklift won’t start
If your propane forklift won’t start, please check the rest of the solutions on this page to ensure your problem hasn’t already been covered. Again, troubleshooting can vary depending on the manufacturer, but we’d usually recommend it should start in the tank.
The first questions to ask are:
- Is there enough fuel in the tank?
- Is the tank is positioned correctly and everything connected as it should be?
- Is the fuel filter is blocked or clogged?
- Could cold weather have affected the forklift? (If so, please read above)
We hope these forklift problems and solutions have helped you to get to the bottom of your starting problem and your forklift back up and running. If not, you can get in touch with our Yorkshire-based team to request a callout. To find out if we cover your area, call us on 0113 393 2881 or email enquiries@moorgateltd.co.uk.
