It’s that time of year again, where colder temperatures, wetter conditions and increased seasonal workloads can all put extra pressure on your forklifts.
For warehouse fleet managers, an unexpected forklift breakdown is more than an inconvenience. It can slow down picking and loading, affect delivery schedules and leave the rest of your fleet working harder to compensate.
The good news is that many common winter forklift problems can be prevented with a little preparation and regular servicing.
1. Book a Forklift Service Before the Cold Weather Arrives
One of the easiest ways to prepare your fleet for winter is to arrange servicing before temperatures start to drop.
A regular forklift service gives technicians the opportunity to identify wear, damage or developing faults before they result in an unexpected breakdown.
Depending on your equipment, servicing may include checking areas such as: brakes, steering, hydraulics and more. Finding a worn component during scheduled maintenance is far easier to manage than discovering it when a forklift stops working halfway through a busy shift.
For warehouse fleet managers, planned maintenance also makes it easier to arrange servicing around quieter periods rather than dealing with unplanned downtime.
2. Pay Extra Attention to Forklift Batteries
Lower temperatures can reduce battery performance, which means electric forklifts may not operate for as long between charges. In a busy warehouse, that can become particularly noticeable when trucks are being used across multiple shifts.
Keep an eye on battery conditions and make sure charging routines are being followed correctly. Operators should also report any forklift that suddenly struggles to hold its charge or performs differently from normal. A small change in performance can be an early warning that something needs attention.
Where forklifts are charged in dedicated battery areas, make sure the environment is kept clean, dry and appropriately ventilated and always follow the battery manufacturer’s charging and maintenance recommendations.
3. Check Your Forklift Tyres Regularly
Your tyres are your forklift’s contact with the ground, so their condition matters all year round, however during winter, it becomes even more important.
Rainwater, mud and moisture brought into warehouses from loading yards can create slippery surfaces. If a forklift’s tyres are already badly worn or damaged, traction can be reduced further.
Operators should check tyres as part of their regular pre-use inspection and look out for:
- Excessive wear
- Cuts and damage
- Flat spots
- Missing sections of solid tyres
- Incorrect inflation on pneumatic tyres
- Debris embedded in the tyre
If your forklifts regularly travel between indoor and outdoor environments, tyre condition should be a particularly important part of your winter maintenance routine.
4. Don’t Ignore Hydraulic Leaks
A small hydraulic leak might not seem urgent when your warehouse is busy, but it shouldn’t be ignored.
Leaks can indicate worn seals, damaged hoses or other problems within the hydraulic system. Left unresolved, a relatively minor issue could develop into a fault that takes the forklift out of service.
Encourage operators to report any signs of leaking fluid immediately rather than waiting until the next scheduled service.
It’s also worth checking the warehouse floor beneath parked forklifts for signs of oil or hydraulic fluid.
Catching a leak early can help prevent further damage and it can remove a potential slip hazard from your workplace too.
5. Keep Forklifts Clean
Winter conditions can mean more dirt, water, grit and debris entering your warehouse, especially around loading bays and external storage areas.
Allowing this to build up around your forklifts can make inspections more difficult and potentially contribute to wear.
Keep trucks clean, paying particular attention to areas around wheels, steps, lights and moving components.
Cleaning also gives operators another opportunity to spot damage, leaks or wear that may otherwise go unnoticed.
6. Make Daily Forklift Checks Part of the Routine
Daily pre-use checks can identify problems before a forklift begins work and should remain a key part of your fleet management routine throughout winter.
Checks should follow the manufacturer’s guidance and your company’s own safety procedures, but could cover areas including:
- Forks
- Mast and lift chains
- Tyres
- Brakes
- Steering
- Hydraulics
- Horn
- Lights and warning devices
- Seat belts and restraints
- Battery or fuel levels
- Visible leaks or damage
Just as importantly, make sure there is a clear process for reporting defects.
7. Prepare for Busy Winter Periods
For many warehouses, winter also means increased demand.
Black Friday, Christmas, year-end orders and seasonal stock movements can put additional pressure on your materials handling equipment.
If your forklifts are going to be working longer hours than usual, factor this into your maintenance planning.
Consider:
- Whether scheduled servicing is due before your peak period
- How many operational forklifts you need each shift
- Whether batteries and chargers can support additional working hours
- Which trucks are critical to your operation
- What you would do if a key forklift broke down
- Whether temporary forklift hire could provide additional capacity
Planning ahead is much easier than trying to source replacement equipment after a truck has already failed.
8. Don’t Put Off Minor Forklift Repairs
We’ve all seen it happen: a machine develops a small problem, but it’s still working, so repairing it gets pushed further down the list. During a busy winter warehouse schedule, that’s particularly tempting.
However, continuing to operate equipment with a developing fault can lead to more serious problems and potentially compromise safety.
Strange noises, reduced performance, warning lights, hydraulic issues or changes to steering and braking should all be investigated.
If something doesn’t seem right, get it checked. A quick repair now could help avoid a much longer period of downtime later.
9. Keep Your LOLER Inspections Up to Date
Servicing and LOLER inspections are related, but they aren’t the same thing.
Regular servicing focuses on keeping your forklift operating correctly and maintaining its condition. A Thorough Examination under LOLER assesses lifting equipment to ensure it is safe for continued use.
Warehouse fleet managers should keep accurate records and know when each forklift’s next inspection is due.
Don’t let a busy seasonal period cause an inspection date to slip through the cracks.
Planning LOLER inspections alongside your wider forklift maintenance schedule can make fleet management much simpler.
10. Have a Plan for Unexpected Breakdowns
Good maintenance can dramatically reduce the likelihood of unexpected problems, but no forklift fleet is completely immune to breakdowns.
That’s why it’s worth knowing exactly what you’ll do if a truck suddenly stops working.
Ask yourself:
- Who should operators report the breakdown to?
- Who will arrange the repair?
- Do you have a reliable forklift service provider?
- Could another truck safely cover the workload?
- Would you need a replacement hire forklift?
- How quickly could an engineer attend?
Having those answers before a breakdown happens can save a lot of time when your warehouse is already under pressure.
Preventative Forklift Maintenance Makes Winter Easier
The aim of winter forklift servicing is simple: spot potential problems before they disrupt your operation.
Regular maintenance can help reduce unexpected breakdowns, improve reliability, support workplace safety and extend the working life of your equipment.
For fleet managers, it also means fewer surprises.
Instead of reacting when a forklift suddenly stops working, you can schedule servicing and repairs around your operation and keep your warehouse moving.
Get Your Forklift Fleet Ready for Winter
Don’t wait for the first cold snap or an unexpected breakdown before thinking about winter forklift maintenance.
Gwynedd Forklifts provides servicing, repairs, maintenance and LOLER inspections to help businesses keep their materials handling equipment safe, reliable and ready for work.
Our experienced engineers can help identify developing problems, carry out repairs and keep your fleet working efficiently, whether you’re managing a single forklift or an entire warehouse fleet.
If your forklifts are due a service or you’d like to get your fleet prepared for the winter months, get in touch with the Gwynedd Forklifts team today.
Book your forklift service or repair and keep your operation moving this winter.