Kia ora! With over 30 years of experience working with forklifts in New Zealand, I’ve seen it all. From diesel workhorses on construction sites to electric marvels gliding through warehouses, these machines are the backbone of many Kiwi industries. But even the most reliable equipment can encounter problems.

Here, I’ll share insights into common forklift faults and how to address them promptly to minimise downtime.

New Zealand’s Forklift Landscape

In New Zealand, we primarily rely on two types of forklifts:

• Internal Combustion (IC) Forklifts: These dependable machines utilise diesel, LPG, or petrol for power. Their robust build and engine power make them ideal for heavy lifting outdoors – think construction sites, lumber yards, and ports.
• Electric Forklifts: These clean and quiet machines excel in indoor environments like warehouses and supermarkets. Their efficient electric motors and zero emissions make them perfect for controlled environments.

Identifying and Addressing Common Forklift Faults

While forklifts are designed for durability, certain issues can arise. Here’s a breakdown of the most problems that bring everything to a standstill:

• Battery Concerns (Electric Forklifts): A flat battery is the most common electric forklift issue. Rigorous adherence to charging schedules and utilising high-quality batteries are crucial. A noticeable decline in battery life might indicate the need for a replacement.
• Fuel System Issues (IC Forklifts): Running out of fuel is a preventable mishap. However, more concerning problems include clogged fuel filters or dirty injectors hindering fuel flow. Consistent maintenance and using clean fuel sources are essential.
• Hydraulic System Malfunctions: The hydraulic system is the workhorse of your forklift, responsible for lifting and tilting functions. Sluggish lifting, jerky movements, or fluid leaks signal potential hydraulic issues. Prompt attention from a qualified technician is recommended.
• Steering System Faults: A loose steering wheel, difficulty turning, or vibrations can significantly impact safety. Worn tyres, loose steering components, or even power steering pump malfunctions (on applicable models) could be the culprits. Regular inspections and professional repairs are paramount.
• Electrical System Problems (Both Types): Flickering lights, malfunctioning gauges, or unexplained electrical issues can be challenging to diagnose. Faulty wiring, blown fuses, or alternator problems (on some models) might be at play. Consulting a qualified auto electrician is advisable to avoid electrical hazards.

The Importance of Early Intervention

Here’s why early intervention is your secret weapon when it comes to keeping your forklift fleet running smoothly:

• Minimised Downtime: Imagine a crucial delivery deadline looming, and your forklift sputters to a halt. Early detection of a minor issue, like a sluggish starter motor, allows for a quick fix, preventing a major breakdown that throws your entire schedule into disarray.
• Reduced Repair Costs: Small problems, if left unattended, can snowball into bigger, more expensive ones. A worn bearing, for instance, might initially just cause a slight vibration. But neglecting it can lead to a complete bearing failure, requiring a more extensive and costlier repair.
• Enhanced Safety: Ignoring warning signs like a loose chain or a faulty brake light can have serious safety consequences. Early intervention ensures your forklift operates within safe parameters, protecting both your operators and those around them.
• Extended Forklift Lifespan: Just like any machine, a forklift thrives on preventative care. By addressing minor issues promptly, you’re essentially preventing premature wear and tear on your equipment. This translates to a longer lifespan for your forklift, saving you money in the long run.

Proactive Maintenance Strategies:

The key to minimising downtime is early detection of issues. Be observant! Unusual sounds, vibrations, or performance changes warrant investigation. Addressing minor problems promptly prevents them from escalating into significant breakdowns.

Here are some ways to cultivate a culture of early intervention within your forklift operation:

• Implement a Regular Maintenance Schedule: Develop a comprehensive maintenance plan specific to your forklift models and usage patterns. This might include daily operator checks, monthly inspections, and biannual servicing by qualified technicians.
• Train Operators to be Observant: Empower your forklift operators to be the first line of defense against potential problems. Train them to identify unusual sounds, vibrations, or performance changes and to report these promptly.
• Invest in Preventative Maintenance Tools: Consider using basic diagnostic tools like voltage meters or battery testers to identify electrical issues early on. These relatively inexpensive tools can save you significant time and money in the long run.

Seeking Professional Assistance

While a proactive approach to maintenance is key, there are times when seeking professional assistance is the wisest course of action. Here’s when to call in the forklift cavalry:

Beyond Your Expertise: Complex repairs involving engine overhauls, hydraulic system adjustments, or major electrical work should be left to qualified mechanics. These professionals possess the specialized knowledge, tools, and diagnostic equipment required to address these intricate issues efficiently and safely.

Safety-Critical Issues: Don’t gamble with safety. If you encounter a problem that compromises the safe operation of your forklift – like a cracked mast, malfunctioning brakes, or a suspected steering issue – immediately halt operations and seek professional assistance. A qualified technician can assess the situation, undertake the necessary repairs, and ensure your forklift is back in safe working order.

Warranty Considerations: Many forklift manufacturers offer warranties on their equipment. However, these warranties typically become void if repairs are attempted by unauthorized personnel. Consulting a qualified mechanic who is authorized to work on your specific forklift model ensures your warranty remains valid and protects your investment.

Time Constraints: Sometimes, deadlines loom large, and in-house repairs simply aren’t an option. Partnering with a reputable forklift service provider with a proven track record of swift and efficient repairs can minimize downtime and get your forklift back in operation quickly.

Finding the Right Forklift Mechanic:

Choosing the right mechanic can make all the difference. Here are some tips to help you find a reliable partner:

• Seek Recommendations: Talk to colleagues or industry contacts for recommendations on reputable forklift service providers in your area.
• Check for Qualifications: Ensure the mechanic is certified to work on your specific forklift model and brand. Many manufacturers offer training and certification programs for authorized service providers.
• Experience Matters: Look for a mechanic with extensive experience servicing and repairing forklifts. A seasoned professional will be able to diagnose problems quickly and efficiently.
• Transparent Communication: Choose a service provider who is upfront about repair costs and estimated turnaround times. Clear communication fosters trust and a smooth repair process.

Find your local experts

While a mechanic may be a great solution, you should also consider finding the local guys specialising solely in forklift sales and servicing.

Here’s why dedicated forklift specialists might be the perfect fit for your needs:

Deep Expertise: Forklifts are complex machines with unique requirements. A specialist service provider dedicates their entire operation to understanding the intricacies of various forklift models and brands. This translates to a team of technicians with in-depth knowledge of forklift diagnostics, repair procedures, and proper maintenance practices.

Comprehensive Parts Inventory: Downtime due to unavailable parts can be a nightmare. Forklift specialists typically maintain a large inventory of parts specific to the brands they service. This means less waiting for essential components and a quicker turnaround time for repairs.

Streamlined Service: When you deal with a dedicated forklift specialist, you’re not just another customer on a long list. You benefit from a streamlined service experience. From initial diagnosis to repair completion, you’ll deal with a team familiar with your specific fleet and needs, ensuring efficient communication and swift problem resolution.

Focus on Safety: Forklift specialists understand the safety-critical nature of these machines. They prioritise stringent safety protocols during repairs and maintenance, ensuring your forklifts meet all regulatory requirements and operate at peak safety levels.

Training and Certification: Many specialist businesses invest heavily in training and certification for their technicians. This ensures your forklift is serviced by mechanics who are up-to-date on the latest advancements and manufacturer recommendations, leading to higher-quality repairs and extended forklift lifespans.

One-Stop Shop Convenience: A dedicated forklift specialist can often cater to all your forklift needs under one roof. This includes sales of new and used forklifts, parts supply, preventative maintenance services, and comprehensive repairs. This one-stop shop approach saves you time and simplifies your forklift management process.

Building a Relationship: Regularly partnering with a dedicated forklift specialist fosters a valuable working relationship. The service team becomes familiar with your specific fleet, anticipating potential issues and proactively recommending preventative measures. This collaborative approach leads to a higher level of service and long-term cost savings.

Exploring Long-Term Forklift Rentals as an Alternative

Owning a forklift can be a sound investment for many New Zealand businesses. But what happens when your trusty machine throws a wrench into your operations with an unexpected breakdown? Repairs can be costly, and depending on the severity of the issue, downtime can significantly impact your productivity.

Here’s where exploring long-term forklift rentals emerges as a compelling alternative, particularly when dealing with potential problems.

The Burden of Unexpected Repairs: Forklifts, like any machinery, are susceptible to breakdowns. When you own a forklift, the responsibility of repairs falls entirely on you. This can translate into significant upfront costs for parts and labour, especially for complex repairs.

Minimised Downtime with Rentals: Time is money, especially in the fast-paced world of New Zealand industry. With a long-term forklift rental, the burden of repairs shifts to the rental company. If your forklift encounters a problem, the rental company will typically provide a prompt replacement, minimising your downtime and ensuring your operations keep moving.

Predictable Costs with Rentals: Long-term forklift rentals offer predictable monthly payments that encompass the cost of the equipment, routine maintenance, and most repairs. This eliminates the risk of unexpected repair bills and allows for more accurate budgeting.

Flexibility to Match Your Needs: Rental companies offer a wide range of forklifts to suit diverse needs. With a long-term rental, you can easily swap your current forklift for a different model with a specific lifting capacity or feature set, should your requirements change. This flexibility ensures you have the right tool for the job at any given time.

Avoiding Equipment Obsolescence: The forklift industry is constantly evolving. With long-term rentals, you gain access to newer, more fuel-efficient, and potentially safer models as technology advances. This eliminates the concern of your owned forklift becoming outdated and potentially less efficient over time.

Focus on Your Core Business: Owning a forklift requires dedication to ongoing maintenance, repairs, and parts management. Long-term rentals free you from these responsibilities, allowing you to focus your resources and expertise on your core business activities.

When Does Owning Make Sense?

While long-term rentals offer several advantages for managing potential problems, owning a forklift can still be the better option in some scenarios. Here’s when ownership might be preferable:

• High Utilisation Rates: If you use your forklift frequently and consistently, the overall cost of ownership may be lower than a long-term rental agreement.
• Customisation Needs: If your operations require significant modifications to the forklift, ownership allows you greater freedom for customisation.
• Tax Considerations: In some cases, owning a forklift might offer tax advantages over renting. It’s always best to consult with a qualified accountant to assess your specific situation.

The decision between owning a forklift and a long-term rental hinges on your specific needs and risk tolerance. If you prioritize minimizing downtime, predictable costs, and flexibility in the face of potential problems, a long-term rental can be a compelling solution.

However, if high utilisation rates, customisation requirements, or potential tax benefits make ownership more attractive, then owning your forklift might be the better course of action.

Conclusion: A Roadmap to Minimise Forklift Downtime

By understanding common forklift faults and taking a proactive approach to maintenance, you can ensure your machines operate optimally. Regular servicing, prompt attention to warning signs, and seeking professional assistance when necessary are the cornerstones of a smooth-running forklift operation.

If you have any specific questions or experiences with forklift faults, feel free to share them in the comments below. By fostering a knowledge-sharing environment, we can collectively navigate the ever-evolving world of forklift maintenance in Aotearoa.