Forklifts are essential equipment in warehouses, distribution centers, and industrial sites. But what happens when your forklift won’t start? Whether it’s due to a dead battery or an electrical malfunction, moving a forklift that won’t start can be challenging and potentially dangerous. This article provides practical, safe, and OSHA-compliant methods on how to move a forklift that won’t start, including dead electric forklifts and electric pallet jacks. We’ll also explore how to charge a dead forklift battery to get your equipment back in operation quickly.
Understanding the Challenges of Moving a Dead Forklift
A dead electric forklift, especially one with a dead battery, poses unique challenges. Unlike gas-powered forklifts, electric forklifts often have electromagnetic parking brakes that engage when power is lost. This prevents the forklift from rolling freely and requires specific steps to move it safely without causing damage.
Attempting to push or tow a dead forklift incorrectly can damage the transmission, brake system, or structure, and create safety hazards for operators and bystanders. Therefore, knowing the right methods and precautions is critical.
How to Move a Forklift That Won’t Start
How to Move a Dead Electric Forklift
1. Tow with Another Forklift (Most Common and Safe Method)
- Use a Larger Operating Forklift: Attach a heavy-duty tow bar or chain rated for at least twice the dead forklift’s weight.
- Attach Properly: Connect the tow bar to the designated towing points on the rear frame or tow eye. Never attach to the mast or forks, as this can cause structural damage.
- Set Dead Forklift to Neutral: If possible, release the parking brake. Some forklifts require a temporary power source to disengage the electromagnetic brake.
- Move Slowly: Keep the speed below 2 km/h (1.2 mph) on flat, smooth surfaces.
- Use a Spotter: Have someone walk alongside to monitor clearance and stability.
This method is widely recommended in warehouses and follows OSHA best practices, minimizing downtime and risk.
2. Use Temporary Power to Release the Brake
Many electric forklifts use electromagnetic brakes that lock when power is lost. To release:
- Connect a Temporary Power Source: Use 24V or 36V power by linking two or three 12V car batteries in series to the forklift’s auxiliary power port or main battery connector.
- Turn the Key to ON: The brake should release with an audible click.
- Move Quickly: Keep the temporary power connected or reconnect the main battery promptly.
Important: Use correct voltage and proper cables to avoid damaging the controller or motor. This method is ideal near charging stations.
3. Manually Release the Parking Brake
Some forklift models (like Yale, Toyota, Crown) have manual brake release mechanisms:
- Consult the Operator’s Manual: Locate the manual release lever or bolt.
- Use Proper Tools: Remove protective covers and turn the release mechanism.
- Ensure Safety: Perform on flat ground with wheel chocks in place to prevent rolling.
- Use Two People: One to release the brake and one to guide movement.
- Re-engage Brake After Moving: Always set the brake back immediately after relocation.
4. Remove the Battery to Free the Wheels
- Use Battery Hoists or Cranes: Batteries can weigh between 800 to 4,000 lbs.
- Remove Battery Pack: This reduces weight and may allow manual brake release.
- Last Resort: This method requires trained personnel and proper equipment.
- Reinstall Battery Before Operation: Never operate the forklift without the battery installed.
How to Move a Forklift with a Dead Battery
Moving a forklift with a dead battery is essentially the same as moving a dead electric forklift. The key is to release the electromagnetic brake and ensure the forklift is in neutral. If the forklift lacks a manual brake release, temporary power or towing with another forklift is necessary.
How to Move a Dead Electric Pallet Jack
Electric pallet jacks also have electromagnetic brakes and dead batteries that prevent movement. To move a dead electric pallet jack:
- Use Manual Release: Many models have a manual brake release lever.
- Tow or Push: On smooth, flat surfaces, push manually if the brake is released.
- Use Temporary Power: Similar to forklifts, apply temporary voltage to release brakes.
- Avoid Damage: Never force movement if the brake is engaged.
How to Charge a Dead Forklift Battery Safely and Efficiently
Charging a dead forklift battery correctly is vital to extend battery life and minimize downtime.
Preparation Steps
- Inspect Battery: Check for leaks, corrosion, and physical damage.
- Check Electrolyte Levels: Top up with distilled water if necessary.
- Clean Terminals: Remove corrosion using baking soda and water.
- Ensure Proper Ventilation: Charge in a well-ventilated area to avoid hydrogen gas buildup.
Charging Process
- Use Compatible Charger: Industrial chargers designed for forklift batteries.
- Slow Charging is Best: Charge at 10-15% of the battery’s amp-hour rating to avoid overheating.
- Pulse Charging: Can help reverse sulfation in deeply discharged batteries.
- Monitor Temperature: Avoid overheating; stop charging if battery becomes hot.
- Charging Duration: Lead-acid batteries may take 12-24 hours; lithium-ion batteries typically charge faster (3-8 hours).
Safety Tips
- Wear acid-resistant gloves and goggles.
- Avoid sparks or open flames near the battery.
- Connect positive terminal first, then negative.
- Never charge a frozen battery.
- Follow manufacturer and OSHA guidelines.
Additional Tips and Best Practices
- Always Use Personal Protective Equipment (PPE): Steel-toed boots, gloves, and eye protection.
- Document Movements: Notify maintenance teams immediately.
- Avoid Moving Alone: Always have at least two people involved.
- Use Wheel Chocks: Prevent unintended rolling during manual brake release.
- Regular Maintenance: Prevent battery failure with routine watering, terminal cleaning, and equalization charging.
- Plan for Emergencies: Have an emergency action plan including contact info for professional equipment movers.
Conclusion
Knowing how to move a forklift that won’t start is essential for maintaining workflow and safety in your facility. Whether you’re dealing with a dead electric forklift, a forklift with a dead battery, or a dead electric pallet jack, the safest methods involve towing with another forklift, temporary power to release brakes, manual brake release, or battery removal as a last resort.
Proper charging of a dead forklift battery is equally important to restore operation and extend battery life. Always prioritize safety by using the right tools, following manufacturer instructions, and involving trained personnel.
For more detailed guidance and professional assistance, consider consulting your forklift manufacturer or certified equipment movers. Share this article with your team to help reduce downtime and keep your operations running smoothly!
