When your forklift, cart or other material handling equipment isn’t performing as it should, it’s vital to identify the issue so you can minimize downtime. Read on as we cover some common issues and detailed equipment troubleshooting steps to help solve them.
The Cost of Equipment Downtime
Whether your equipment is running slower than usual or it’s broken down, this downtime is more than just an inconvenience. Equipment downtime directly impacts your productivity, as a slow or malfunctioning machine means you complete less work. Effective troubleshooting means you can quickly isolate the issue and take preliminary steps to resolve it. Sometimes, a simple fix can get your equipment working again, such as replacing a dead battery.
Even if you can’t fix it yourself, knowing when to call in an expert saves you the time of trying to figure out a more complex problem. It also prevents any damage caused by makeshift solutions.
The faster you can diagnose an equipment issue, the quicker you can get back to productive work, keeping up with deadlines and protecting your revenue.
Preventive Steps
Before starting a shift, daily inspections can identify and prevent many common equipment issues.
Whether you’ve got an electric aerial lift or a diesel-powered forklift, there will be varying components and systems that need slightly different daily checks. The Occupational Safety and Health Administration (OSHA) recommends following the manufacturer’s instructions for each piece of equipment. Put together a standardized checklist that all operators must follow for a specific machine. Provide logs to document the checks and show that the necessary maintenance steps have been taken over time.
It can help to divide your inspection into key-off, key-on and engine-running procedures. Some of the key-off checks you should make include:
- Taking a walk-around to check for visible damage
- Inspecting tires
- Checking fluid levels
- Noting any warning lights
- Reporting any odors of propane
- Looking for any oil or fluid leaks
Key-on and engine-running checks include:
- Testing lights
- Checking steering and brakes
- Testing attachments
- Ensuring the horn and any safety features are working
ANSI B56.1 also details the items that should be inspected regularly on a powered industrial truck, as well as the need for more formal periodic inspections.
Common Material Handling Equipment Issues and Fixes
Troubleshooting material handling equipment helps you get your aerial lift, forklift or industrial truck moving again. We’ve compiled a list of common equipment issues and their fixes.
Forklift Troubleshooting
If your forklift won’t start, it could be a battery issue or an empty LPG tank, depending on whether you have an electric forklift or an internal combustion (IC) forklift. Check your battery terminals to ensure all connections are tight and free from corrosion. Recharge your battery and replace it if it no longer holds a charge effectively. Ensure you have enough fuel to start the forklift.
When you have a slow or jerky lifting mechanism, it’s likely an issue with your forklift’s hydraulics. Another issue is the mast drifting down, which can occur when your forklift is loaded or unloaded. Check the hydraulic fluid level and inspect the hoses for any leaks.
Steering difficulties could be caused by low power steering fluid or tire pressure issues. Power steering issues only affect IC forklifts, and low levels of power steering fluids are usually due to tiny leaks in the system. You can check tire pressures and reinflate to the correct levels to see if your steering improves.
Aerial Lift Troubleshooting
Should your aerial lift platform fail to raise or lower, it could be due to overloaded platforms, engaged tilt sensors or hydraulic fluid issues. Ensure the load you’re lifting is within the lift’s capacity and check that your machine is on level ground. Inspect your hydraulic system for any leaks.
If you find that your aerial lift controls are unresponsive, it likely indicates an electrical issue. Check the emergency stop button. Also, inspect the power switches to see if they are correctly engaged.
Industrial Cart Troubleshooting
In busy warehouse environments, a worker may leave an industrial cart unplugged at the end of a shift, which can flatten the battery. If you find that the battery dies too quickly, ensure it receives a full charging cycle. If the issues persist, check the battery water level or recharge as per your model. Refer to your manufacturer’s manual for the best charging practices.
If your cart won’t move, ensure you check the simple things first. It is surprisingly common to overlook the parking brake or that the key isn’t fully engaged. Also, check that you have the forward or reverse selector in the correct position.
When to Call a Professional for Equipment Service
The troubleshooting tips we outlined in this guide are the first steps to help you fix simple issues or narrow down the reasons why your equipment is not working as expected. But sometimes, servicing and fixing material handling equipment is best left to the professionals.
More complex problems need a professional technician so you can get the peace of mind that your issue has been fixed safely and effectively. A professional service can help you avoid the potential costs of a poor DIY repair, such as damage to sensitive components or even risking your workers’ safety.
If you encounter any of the following signs, you should reach out to an expert:
- Hydraulic fluid or oil leaks
- Cracks or damage to the chassis or frame
- Strange engine noises or grinding sounds
- Persistent electrical issues
- Warning lights that you can’t address after checking your manual
- Any issue that may require you to attempt a makeshift repair, which would void your product warranty
By partnering with a reliable company to service and maintain your material handling equipment, you can get your machines back up and running quickly to maximize your productivity. Consider businesses that offer scheduled maintenance and 24/7 emergency repairs, should you need them.
Keep Your Material Handling Fleet Moving With Fitzgerald Equipment Company
Handling material equipment issues quickly and effectively can save your company time and money while protecting your workforce. There are many simple troubleshooting tips you can use to get your forklift, aerial lift or industrial truck moving again. If your machine has a more complicated problem, reaching out to an expert can be more cost-effective in providing a proper first-time fix.
You can rely on our 60+ years of experience in material handling solutions at Fitzgerald Equipment Company to resolve your equipment issues. We have a fleet of mobile service vans and highly trained technicians ready for your next call-out. Protect your fleet with our service coverage across Illinois and southern Wisconsin today by calling 815-397-7050.
