How to Prevent Forklift Breakdowns in Extreme Temperatures

Forklifts are among the most important pieces of equipment used in warehouse operations. When one breaks down, productivity takes a hit, delays stack up, and costs begin to mount—sometimes faster than expected.

Understanding the specific culprits behind these failures is key to prevention, and one often-overlooked factor is the impact of temperature fluctuations. In particular, multi-temperature environments like warehouses create unique challenges that can wear down essential parts, interfere with electrical systems, and disrupt your entire operation if you’re not prepared. That’s because both extreme heat and cold present their own hazards.

In cold environments, batteries lose power faster, engine fluids thicken, and tires may stiffen or lose grip. Rubber seals can also crack, and metal components become brittle and prone to snapping under pressure. On the flip side, heat speeds up wear and tear. Engines may overheat, tires wear down quicker, and lubricants thin out, thus reducing their protective qualities. High humidity can also encourage rust on exposed surfaces.

One of the biggest hidden threats comes when forklifts move between zones. Going from a cold storage area into a warm dock—or vice versa—creates condensation inside the machine. This moisture can corrode parts, damage internal wiring, and interfere with control systems, among other things. While the damage may not be visible right away, it builds up over time and may lead to serious failures.

Even small components like filters, seals, and connectors can suffer in these conditions. Once a weak point fails, the entire forklift can come to a halt.

Knowing about all these factors, what can you do to protect your equipment and your team? Here are some safety best practices for your forklift operations in multi-temperature environments:

1) Conduct Daily Inspections—No Exceptions

The best defence against forklift failure is a strong offense. That starts with consistent inspections before each shift. Operators should visually check for cracks, leaks, worn hoses, loose parts, or signs of moisture. Once everything looks good, they should start the engine and test lights, brakes, steering, and hydraulics. If something feels off—like a delayed start or odd noise—they should report it immediately to stop small issues from becoming major breakdowns.

Temperature changes can also affect the weight and integrity of materials. Operators should inspect the forklift’s load before each task. They must ensure it’s stable, balanced, and secure. Otherwise, the forklift could tip or fail under stress—posing risks to both operators and products.

2) Equip Forklifts with the Right Parts and Accessories

Outfitting your equipment with the correct, temperature-rated forklift parts is one of the best ways to ensure safe and efficient performance. For example, winter or cold-weather-rated tires offer better grip and flexibility in cold zones. That’s because regular tires tend to harden, increasing the chance of slipping or tipping. In contrast, cold-weather models stay soft and responsive, improving control. Meanwhile, heat-resistant tires and reinforced cooling systems prevent blowouts, overheating, and early wear in hot zones. These help your equipment withstand long, hot shifts on outdoor surfaces.

Consider upgrading other accessories, too. For example, heated seats or cabs provide comfort to operators in cold zones while canopies or sunshades are perfect for summer or outdoor use. Meanwhile, weather-sealed electrical parts limit moisture damage and rust-resistant fittings are perfect for humid or coastal locations. Even small additions like these will make a big difference in performance, safety, and equipment longevity.

3) Know the Warning Signs of Forklift Failure

Forklifts don’t usually stop working without warning. There are often early signs: slower start-up, strange noises, or changes in power. These might seem like small issues, but in high-variance environments, they can quickly lead to costly downtime.

Beyond daily inspections, preventive maintenance is also key. Don’t wait for something to break. Schedule regular servicing and replace worn parts proactively as you monitor each forklift’s performance closely.

4) Prioritize Cooling and Ventilation

Forklifts should have well-maintained cooling systems. Make sure your team keeps radiators clean and coolant levels topped up, and schedule cool-down breaks between heavy-duty jobs to protect both machinery and personnel.

Remember that overheating becomes a more serious risk in hot or poorly ventilated areas, like loading docks or outdoor yards. Without proper airflow, forklifts are more likely to break down while operators can suffer from heat stress, reducing safety and focus.

Ensure good ventilation in high-traffic areas by installing industrial fans or ducting where possible. Also, use shade or barriers to block direct sunlight for your forklift parking area. Meanwhile, check that your HVAC systems are working and free from obstructions for indoor areas.