When people think about forklift maintenance, they often focus on winter.
Cold starts.
Frozen fluids.
Snow and ice.
But after years in the forklift industry, I’ve found that summer can be just as hard on equipment—and in some cases, even harder.
As temperatures rise, forklifts face a unique set of challenges that can impact both their reliability, productivity, operator safety, & maintenance costs. And while a forklift may run perfectly in April, the same truck can begin showing problems when temperatures climb into the 90s and beyond.
Here are some of the biggest issues operators and managers should be paying attention to this summer.
Every forklift generates heat.
The engine creates heat.
The transmission creates heat.
The hydraulic system creates heat.
The battery creates heat.
When outside temperatures increase, the equipment has less ability to dissipate that heat effectively. As a result operating temperatures rise, components experience more stress, cooling systems work harder and all around, failures become more likely. Many summer breakdowns aren’t caused by a defective component. They’re caused by a component operating outside its ideal temperature range.
Internal Combustion Forklifts Face Cooling Challenges
LP, gas, and diesel forklifts rely heavily on their cooling systems. Unfortunately, many operators don’t notice cooling issues until the truck overheats.
What are some of the key problems that pop up in summer time though, what should your team look out for?
A radiator that performs adequately in spring may struggle during extreme summer temperatures.
I’ve seen forklifts run perfectly at 70°F and begin overheating regularly at 95°F. The issue wasn’t a failed engine. The issue was a cooling system that was barely keeping up. Summer simply exposed the weakness.
Many people assume electric forklifts are immune to summer problems. They’re not. In fact, extreme heat can create significant challenges for battery-powered equipment.
Heat accelerates chemical activity inside the battery.
While this may seem beneficial, it often leads to increased water consumption, faster deterioration, higher maintenance requirements and thus a shortened battery life. During summer months, battery watering schedules become even more important. Thats why, ignoring battery maintenance during hot weather can permanently reduce battery performance.
Lithium batteries generally perform better in hot weather than lead-acid batteries. However, they still generate heat during charging & heavy-duty operation. Modern lithium systems include sophisticated battery management systems, but excessive heat can still impact long-term battery health.
The biggest misconception is that many people believe lithium batteries are maintenance-free. While maintenance requirements are significantly reduced, proper charging practices and temperature management still matter.
Forklift tires take a beating during summer.
Especially in:
Hot pavement can dramatically increase tire temperatures.
And the larger the forklift, the more significant the effect becomes.
Hydraulic systems depend on fluid viscosity. As temperatures increase hydraulic oil becomes thinner which can lead to a few things. The primary concern is going to be increased internal leakage causing the system efficiency to decrease.
Some signs of hydraulic heat stress include slower lift speeds, reduced performance, increased operating temperatures and even unusual hydraulic noise. Most operators don’t think about hydraulic temperatures until performance starts suffering. By then, the system may already be under significant stress.
Summer affects more than just the equipment. It also affects the people running it and odperator fatigue can increase when temperatures climb.
Especially in outdoor operations inside non-air-conditioned equipment during long shifts. Heat saps your energy and focus leading to reduced concentration, slower reaction times, increased fatigue and good old fashioned dehydration.
Many safety incidents occur because operators become physically exhausted. Not because they’re poorly trained.
As forklift size increases, so do the cooling demands. A 5,000 lb warehouse truck and a 50,000 lb forklift may both operate in summer heat. But they don’t experience it the same way.
High-capacity forklifts often work longer duty cycles with heavier loads across rougher applications. And these applications generate tremendous amounts of heat.
Cooling system maintenance becomes absolutely critical.
The best summer breakdown is the one that never happens. Before temperatures peak, operators and maintenance teams should inspect:
Small problems become expensive problems much faster during hot weather.
Most people worry about forklifts when winter arrives.
But some of the toughest conditions a forklift will face all year occur during the hottest days of summer.
The good news?
Most heat-related problems are preventable.
A little attention to cooling systems, batteries, tires, and preventative maintenance can go a long way toward keeping equipment productive when temperatures start climbing.
And when your forklifts stay running, your operation keeps moving.
Special Note: If you’re still reading, like and share. It’s appreciated. At Forklift Exchange, we help customers determine whether new, used, refurbished, or rebuilt equipment makes the most sense for their application. If you’re planning a purchase and would like a second opinion, I’d be happy to discuss your options. Send me a message.
At Forklift Exchange, we help customers determine whether new, used, refurbished, or rebuilt equipment makes the most sense for their application. If you’re planning a purchase and would like a second opinion, I’d be happy to discuss your options.
Jason Flaska
Forklift Exchange
📞 630-842-0779
📧 jasonf@forkliftexchange.com
#Forklifts #MaterialHandling #WarehouseOperations #IndustrialEquipment #ForkliftMaintenance #ElectricForklifts #LithiumBatteries #Logistics #SupplyChain
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