Controller will not power up
Dead or resetting controllers: power supply, logic board and contactor drive checked separately.
Fleet electronics · Forklifts
Forklift and warehouse-truck controller repair
Star Automations repairs electric forklift and warehouse-truck controllers, traction and pump motors and speed sensors. Send the controller model and the fault code and we confirm repairability before you ship. Star Automations is an independent multi-brand repair company and is not an OEM service centre.
01Repair
Common faults we repair
Rental fleets, warehouses and 3PL yards run on 24 V to 80 V electric trucks. A dead controller or a noisy traction motor parks the truck, and the usual answer is a new unit.
Overcurrent and MOSFET faults
Failed power MOSFETs, gate drivers and current sensing on DC and AC controllers.
Fault codes that return
Throttle, steering, encoder and motor-temperature faults traced to the failed part.
Traction motor noise or weak torque
Bearings, brushes or commutator, and speed-sensor or encoder faults.
Overheating
Heat-damaged boards, cooling and thermal sensors.
Speed sensor and encoder faults
Sensors and encoders on traction and pump motors tested and replaced.
Units we repair
- Curtis controllers
- Zapi controllers
- Sevcon controllers
- Inmotion controllers
- Traction and pump motors (AC and DC)
- Speed sensors and encoders
Star Automations is an independent multi-brand repair company and is not an OEM service centre. Brand names are used only to say which units we repair. Send the model and we confirm before you ship.
02Who it is for
Who sends us these units
Rental and 3PL fleets
Mixed fleets with trucks out of warranty and a need to keep them running.
Independent forklift service firms
Controller and motor repair for jobs your team does not want to swap.
Warehouse and factory operators
Single failed units and repeat batches from one site.
03Process
From model number to tested unit in five steps
Findings come before repair.
Send the model
Make, model, fault and a photo, on WhatsApp or the request form.
Courier or pickup
Units should be sent de-energised and disconnected. Pickup can be arranged.
Findings
Findings first: the failed part and the repair options, before any work is approved.
Repair and functional check
Repair on your approval, then a power-up and functional check on the functions the fault affected.
Report and dispatch
Printed report with findings, parts replaced and test readings, sent back with the unit.
Can you repair a Curtis, Zapi or Sevcon controller?
Yes. Star Automations repairs Curtis, Zapi, Sevcon and Inmotion controllers. Send the model number, fault code and a photo and we confirm repairability before you ship.
Do you repair the traction motor as well?
Yes, traction and pump motors are repaired with their speed sensor or encoder, so the controller and motor problem can be separated.
Do I need to send programming files?
If the controller needs settings loaded after repair, send the parameter sheet or programmer file. We note this on the quote.
Is Star Automations an OEM service centre?
Star Automations is an independent multi-brand repair company and is not an OEM service centre.
How fast can a repair be done?
Emergency same-day, urgent 3 working days and standard 7 working days are available where the fault and parts allow. The timeline is stated on the quote.
Send the model and the fault.
WhatsApp or call +91 97866 22233, or email info@starautomations.com.