Internal Combustion Forklift Maintenance Checklist for Summer 2025

You know summer heat can be really tough, right? Your internal combustion forklift feels the heat too. When it gets hot, overheating can happen quickly. If you do not take care of your forklift, big problems can start. Regular checks help you find problems early and keep your forklift safe. Stay smart with forklift maintenance and have smooth work all summer.

Key Takeaways

• Check the forklift’s cooling system often. This helps stop overheating. Clean the radiator. Make sure coolant is full. Look at hoses for leaks or damage.

• Take care of the engine. Change the oil often. Clean the air filters. Put in new fuel filters. This helps the engine work well in hot weather.

• Look at tires and brakes every day. Keep tire pressure right. Watch for tires that are worn. Test the brakes to stay safe and stop accidents.

• Keep the battery and electrical parts clean. Make sure they work well. Check battery fluid. Clean the terminals. Look at wiring to stop breakdowns.

• Stay safe by making cab air better. Take breaks often. Wear the right PPE. Do not overload the forklift. This keeps you and the forklift safe.

Cooling System

When the summer heat hits, your forklift’s cooling system works extra hard. You need to pay close attention to this part. If you skip checks, you risk overheating and costly repairs. Let’s break down what you should do.

Radiator Check

Your radiator is the heart of the cooling system. You want to keep it clean and free from debris. Dust, dirt, and leaves can block airflow. This makes your forklift run hotter.

• Look for leaks or cracks.

• Check for bent fins or damage.

• Use a soft brush or compressed air to clean the radiator surface.

  Tip: If you see any green or rusty spots, that means you might have a leak. Fix it right away to avoid overheating.

Coolant Level

Coolant keeps your engine at the right temperature. If the level drops, your forklift can overheat fast.

• Always check the coolant level before starting your shift.

• Make sure the coolant is bright and clear.

• Top off with the right type if it’s low.

• Never open the radiator cap when the engine is hot.

Hose Inspection

Hoses carry coolant between the radiator and engine. If a hose fails, your cooling system can’t do its job.

• Squeeze each hose gently.

• Look for soft spots, cracks, or bulges.

• Check for leaks at the connections.

• Replace any hose that feels weak or looks damaged.

  Note: Old hoses can burst under pressure. Change them before they cause trouble.

You should inspect these parts more often in summer. The cooling system faces extra stress, and overheating is a real risk. Regular checks keep your forklift running smoothly and help you avoid downtime.

Engine & Fuel

Summer puts your forklift’s engine to the test. Hot weather and long shifts mean you need to stay on top of maintenance. If you ignore these checks, you risk breakdowns and expensive repairs. Let’s look at what you should do to keep your engine running strong.

Oil Change

Your engine works harder in the summer. High temperatures can break down oil faster, making it less effective. Old oil won’t protect moving parts, and that can lead to wear or even engine damage.

• Check the oil level before each shift.

• Look at the color and texture. If it’s dark or gritty, it’s time for a change.

• Follow your forklift’s service schedule for oil changes.

  Tip: Fresh oil helps your engine stay cool and run smoothly, especially when the heat is on.

Air Filter Clean

Dust flies everywhere in summer, especially in busy warehouses or outdoor lots. Your air filter catches this dust before it gets into the engine. When dust and debris pile up, the filter clogs quickly. That means less air gets through, and your engine can’t breathe.

• Inspect the air filter more often during summer.

• Clean or replace it if you see dirt or dust buildup.

• Use filters with higher ratings if your worksite is extra dusty.

  Note: A clean air filter keeps engine performance high and reduces the risk of costly service calls.

Fuel Filter Replace

Summer fuel can carry more contaminants. These clog your fuel filter and make it harder for the engine to get the fuel it needs. Watch for these signs that your filter needs attention:

1. Trouble starting the engine.

2. Slow acceleration, especially when carrying heavy loads.

3. Rough idling or shaking.

4. Engine stalls at idle.

5. Poor fuel economy.

6. Strong fuel smells in the cab.

7. Loud noises from the fuel pump.

8. Check engine light comes on.

If you notice any of these, replace the filter right away. Regular service keeps your engine running smoothly and avoids downtime.

Summer Diesel Use

Not all diesel is the same. Summer blends work better in hot weather. They help prevent fuel gelling and keep your engine running clean.

• Use certified summer diesel for best results.

• Schedule a mid-year tune-up to check fuel lines and injectors.

• Ask your service provider about the right fuel for your forklift.

  Alert: Using the wrong fuel can hurt engine performance and lead to expensive repairs.

Stay ahead of problems by following these steps. Your engine will thank you, and your forklift will stay reliable all summer.

Forklift Maintenance: Tires & Brakes

Keeping your forklift safe starts with the tires and brakes. Hot summer days can make these parts wear out faster. If you skip checks, you might face sudden stops or even accidents. Let’s look at what you need to do for solid forklift maintenance.

Tire Pressure

Tire pressure changes when the weather gets hot. If your tires are too soft or too hard, your forklift will not handle loads well.

• Check tire pressure at the start of every shift.

• Use a good gauge to get the right reading.

• Follow the numbers in your forklift manual.

  Tip: Hot tires can show higher pressure. Always check them when they are cool.

Tire Condition

Worn tires can cause slips or make your forklift shake. You want to spot problems before they get worse.

• Look for cuts, cracks, or bald spots.

• Check for nails or sharp objects stuck in the tread.

• Make sure all tires wear evenly.

• Replace any tire that looks damaged or worn out.

Here’s a quick table to help you spot trouble:

Brake Check

Brakes keep you and your team safe. Summer heat can make brake parts wear out faster.

• Listen for squeaks or grinding sounds.

• Test the brakes before you start moving heavy loads.

• Make sure the brake pedal feels firm, not soft.

• If you notice any problems, call for maintenance right away.

Alert: Never ignore brake issues. Quick action can prevent accidents and keep your forklift running strong.

Regular forklift maintenance for tires and brakes helps you avoid downtime and keeps everyone safe. Make these checks part of your daily routine.

Battery & Electrical

Summer heat can really stress your forklift’s battery and electrical system. If you want your forklift to start every time and run strong, you need to check these parts often. Let’s look at what you should do.

Battery Fluid

Your battery needs the right amount of fluid to work well. Hot weather makes battery fluid evaporate faster. If the fluid gets too low, your forklift might not start or could stop working during a shift.

• Open the battery cover and look at the fluid level.

• Add distilled water if the fluid is below the fill line.

• Never use tap water because it can damage the battery.

• Wear gloves and eye protection when you check the battery.

Tip: Check battery fluid at least once a week during summer. If you use your forklift a lot, check it even more often.

Terminal Clean

Dirty or corroded terminals can stop your forklift from starting. You want to keep these parts clean so power flows the right way.

• Look for white or green buildup on the terminals.

• Use a wire brush to clean off any corrosion.

• Make sure the connections are tight after cleaning.

• Apply a little battery terminal grease to stop new corrosion.

A clean terminal helps your forklift run better and makes every service check easier.

Wiring Inspect

Wires carry power to all parts of your forklift. Heat and vibration can make wires loose or damaged. If you spot problems early, you can call for service before things get worse.

• Check for cracked, frayed, or melted wires.

• Make sure all wires are connected and not hanging loose.

• If you see any damage, schedule a service right away.

Alert: Never ignore electrical problems. Quick service keeps your forklift safe and ready for work.

Hydraulic & Lubrication

Summer heat puts extra pressure on your forklift’s hydraulic system. If you want smooth lifting and safe operation, you need to check these parts often. Let’s walk through what you should do.

Hydraulic Oil Level

Hydraulic oil helps your forklift lift heavy loads. If the oil level drops, you might notice slow or jerky movements. You want to keep the oil at the right level for best performance.

• Park your forklift on a flat surface.

• Find the hydraulic oil dipstick or sight glass.

• Wipe the dipstick clean before checking.

• Add oil if the level is low. Use the type recommended in your manual.

Tip: Check the oil after every long shift. Hot weather can make oil evaporate faster.

Seal Replace

Seals keep hydraulic oil inside the system. If a seal leaks, you might see oil spots under your forklift. Leaky seals can cause big problems if you ignore them.

You want to catch leaks early. If you spot a problem, get a service technician to fix it right away.

Lubricate Moving Parts

Moving parts need lubrication to work smoothly. If you skip this step, you might hear squeaks or see parts wear out faster. Lubrication helps your forklift last longer.

• Use a grease gun to add lubricant to joints and hinges.

• Wipe away old grease before adding new.

• Check the lubrication chart in your manual for the right spots.

Alert: If you hear grinding or squeaking, stop and call for service. Quick action prevents bigger repairs.

Regular checks and proper lubrication keep your forklift working hard all summer. You avoid breakdowns and keep your team safe.

Safety Checks

Cab Ventilation

Hot summer days can turn your forklift cab into an oven. You want to keep cool and stay alert. Try these ways to improve cab ventilation and comfort:

• Install fans, vents, or air conditioning units to move hot air out of the cab.

• Use industrial fans or ceiling fans in your work area for better airflow.

• Set up evaporative coolers or misting fans if you work in a dry climate.

• Place portable air conditioners for quick cooling when needed.

• Create shaded break areas with fans and seating so you can cool off.

• Keep hydration stations close by with cold water.

• Wear cooling vests or neckbands for personal comfort.

• Make sure HVAC systems get regular maintenance.

• Use reflective roofing or insulation in your warehouse to block heat.

• Schedule the hardest jobs early or late in the day when it’s cooler.

• Learn the signs of heat stress and talk to your team if you feel overheated.

Tip: Staying cool helps you focus and keeps you safe on the job.

Fire Extinguisher

You never know when a fire might start, especially in summer. OSHA does not require a fire extinguisher on every internal combustion forklift, but it’s smart to have one nearby. This is extra important if you use LP-Gas forklifts or work near flammable liquids. Keep your extinguisher easy to reach and check it often. Make sure everyone knows where it is and how to use it. Regular maintenance of your cooling system also helps prevent overheating, which lowers fire risk.

Operator PPE

Personal protective equipment (PPE) keeps you safe. In summer, you want gear that protects but also keeps you cool. Choose lightweight, breathable gloves and safety vests. Wear a hard hat with vents. Use safety glasses that block glare. If your job allows, try a cooling vest or a neckband. Always check your PPE for damage before each shift.

Operator Breaks

Working in the heat wears you out fast. Take regular breaks in a cool, shaded spot. Drink water every 20 minutes, even if you don’t feel thirsty. Use break times to check your gear and cool down. If you feel dizzy or weak, tell your supervisor right away.

Overload Prevention

Overloading your forklift is risky, especially in summer. Too much weight can make your engine overheat and cause accidents. Follow these steps to stay safe:

1. Keep your coolant system in top shape and check coolant levels often.

2. Inspect hoses for cracks or leaks and replace them if needed.

3. Check oil and filters before every shift.

4. Watch tire pressure and look for heat damage.

5. Stick to your maintenance schedule to catch problems early.

6. Secure loads with even weight and keep forks low and tilted back.

7. Never lift more than your forklift’s rated capacity.

8. Keep the platform lowered when moving, especially on rough ground.

Alert: Safe loads and regular checks help you avoid overheating and keep your forklift running strong.

Cleaning & Upkeep

Exterior Clean

Your forklift works hard every day, especially in summer. Dust, dirt, and grime stick to the exterior fast. If you let it build up, it can hide problems and make your forklift look old. You want to keep your machine clean so you spot leaks, cracks, or rust early.

• Wipe down the body with a damp cloth at the end of each shift.

• Use mild soap and water for stubborn stains.

• Clean mirrors, lights, and windows for better visibility.

  Tip: A clean forklift helps you catch issues before they get worse. You also make your worksite safer for everyone.

Debris Remove

Debris can cause big trouble in summer. If you ignore it, dust and leaves clog air filters and cooling parts. Your forklift can overheat or lose power. You want to remove debris often to keep everything running smooth.

Here’s how regular debris removal helps you:

1. Clean forklift parts to stop dust from blocking air filters and cooling fans.

2. Check coolant levels so your engine stays cool.

3. Inspect hoses and seals for wear and replace them if needed.

4. Make sure fans work well to move hot air out.

5. Change air filters often to keep the engine breathing easy.

6. Train your team to spot signs of overheating and fire risks.

• Keep the exterior free from debris to prevent buildup.

• Replace air filters before they get clogged.

• Watch tire pressure and look for leaks in hydraulic lines.

Alert: Removing debris keeps your forklift cool and safe. You lower the risk of breakdowns and accidents.

Rust Prevent

Rust sneaks up fast in summer, especially if you work outside or near water. If you see rust, you need to act quickly. Rust weakens metal and can cause parts to fail.

• Inspect metal surfaces for orange spots or flaking paint.

• Use a wire brush to scrub away rust.

• Apply rust-resistant paint or spray to protect exposed areas.

• Store your forklift in a dry spot when you can.

Note: Keeping rust away helps your forklift last longer and work better. You save money and avoid surprise repairs.

If you use a summer forklift maintenance checklist, your forklift can work well in hot weather and with heavy loads. Checking fluids, tires, and cooling systems helps your forklift stay safe and strong. Doing regular forklift maintenance stops little problems from becoming big repairs. This saves you money, prevents breakdowns, and keeps your team safe. Plan your maintenance and teach your operators summer tips for a smooth and easy season.

FAQ

How often should I check my forklift’s coolant in summer?

You should check the coolant level every day before your shift. Hot weather makes coolant evaporate faster. If you spot low levels, top off right away. This simple step helps you avoid overheating and keeps your forklift running strong.

What signs show my forklift might overheat?

Watch for warning lights, steam from the engine, or a hot smell. If you see coolant leaks or hear strange noises, stop and check your cooling system. Quick action can save you from costly repairs.

Can I use regular diesel fuel in summer?

You need to use summer-grade diesel. Regular diesel may not work well in high temperatures. Summer blends help your engine run cleaner and prevent fuel problems. Ask your supplier for the right fuel.

How do I keep my forklift cab cool?

Try using fans, portable air conditioners, or open vents. Take breaks in shaded areas and drink water often. Wear light, breathable PPE. Staying cool helps you stay alert and safe.

What should I do if I find rust on my forklift?

Scrub small rust spots with a wire brush. Apply rust-resistant paint to protect the metal. If you see large areas of rust, call for service. Keeping rust away helps your forklift last longer.