Posted: February 17, 2025

How to Troubleshoot Common Issues with Propane Forklifts

Keeping Your Equipment—and Your Business—Running Smoothly

Propane forklifts are a reliable, cost-effective, and efficient alternative to electric and diesel models, with advantages like consistent power, quick refueling, and lower emissions. It’s why they’re the go-to choice for warehouses, construction sites, and distribution centers. However, like any equipment, propane forklifts can occasionally experience issues. Knowing how to troubleshoot common problems can help minimize downtime, but it’s also important to recognize when it’s time to call in a professional to avoid safety risks or costly repairs.

Engine Won’t Start

If your propane forklift won’t start, consider these possible causes:

• Fuel Supply Issues: Be sure the propane tank valve is fully open and properly connected. A loose or partially closed valve can restrict fuel flow. If you suspect a leak, turn off the propane and contact a professional.
• Vaporization Problems: While rare here, cold weather can prevent propane from vaporizing properly, leading to starting issues. If safely warming the tank doesn’t help, have a technician inspect the regulator and fuel lines.
• Clogged Fuel System: Debris or oil buildup in the fuel system can block fuel flow. Regularly clean or replace the fuel filter and regulator to prevent problems.
• Ignition or Battery Issues: Weak batteries, corroded terminals, or faulty spark plugs will prevent the engine from starting. If replacing the battery or spark plugs doesn’t resolve the issue, consult an expert to check the ignition system.

Engine Stalls or Runs Rough

If your forklift starts but doesn’t run smoothly or stalls unexpectedly, try these troubleshooting steps:

• Low Fuel Pressure: It can make you say, “Duh,” but a nearly empty propane tank can result in low pressure. Swap in a full tank and see if performance improves. If not, the regulator may need professional servicing.
• Dirty Air or Fuel Filters: A clogged air filter can restrict airflow, causing inefficient combustion. Cleaning or replacing filters regularly can prevent this, but if the issue persists, call a technician.
• Improper Carburetor Adjustment: The air-to-fuel ratio must be properly balanced for smooth operation. If the engine runs too lean or too rich, have an expert tune your carburetor.

Loss of Power

If your forklift loses power during operation, check for these potential causes:

• Frozen Regulator: Moisture can freeze in the fuel regulator when it’s very cold or very humid, which can restrict propane flow. If this happens frequently, have a technician inspect the system for underlying issues.
• Worn Spark Plugs: Old or fouled spark plugs cause misfires, reducing engine power. Replacing spark plugs is a simple fix, but if the engine continues to struggle, have a pro take a look.
• Blocked Fuel Lines: A kinked or clogged fuel line can restrict propane flow. If you notice fuel delivery issues despite a full tank, an expert can diagnose and replace damaged lines.

Strong Propane Smell or Leaks

If you smell propane while operating the forklift, take immediate action: Shut off the propane tank valve and do not restart the forklift. Then call an expert. Any propane leak or persistent fuel smell requires expert attention to ensure safety and compliance with workplace regulations. Move the forklift to a well-ventilated area to prevent gas buildup.

Preventative Maintenance = Peak Performance

Regular inspections and maintenance can help prevent many common propane forklift issues. Work with your team to establish best practices for replacing empty propane tanks, and proper start- and end-of-shift checklists, and establish a regular maintenance schedule for your forklifts.

The pros at Miami Gas will evaluate your needs and set up a customized program and delivery schedule—daily, weekly, monthly, or will-call—and then set you up with sturdy, safe storage cages for your cylinders. We’ll thoroughly train your workers in the safe handling of propane cylinders. And you’ll get the cylinders you need, when you need them.

Having a great team—both internal and external—can make a big difference in safety. Find out why we’re the first choice for commercial propane and forklift cylinder exchange in the metro-Miami area. Contact us for more information today.