As summer temperatures continue to rise, the challenges of operating electric forklifts in high-heat environments have become increasingly apparent. Issues such as motor overheating, battery thermal runaway, and poor controller heat dissipation have emerged as major 

pain points for sectors including logistics warehousing, ports and terminals, and construction sites. How can electric forklifts be operated safely and efficiently in high temperatures? A reporter interviewed industry experts to compile a professional guide for addressing these challenges.

I. Three Major "High-Risk Zones" for Heat: Motors, Batteries, and Controllers

The primary sources of heat for electric forklifts in summer stem from three core components:

Motor System: Prolonged high-load operation, frequent starting and stopping, and ramp-climbing tasks cause the motor to continuously generate significant heat. If cooling air ducts become clogged with dust, heat accumulation can trigger overheating protection mechanisms 

or even burn out components.

Power Battery: Lithium-ion batteries face multiple risks when operating in high-temperature environments. Sustained ambient temperatures above 45°C accelerate the degradation of internal battery materials, leading to capacity loss and increased internal resistance; in extreme 

cases, the decomposition of the SEI layer and separator failure can trigger thermal runaway. Lead-acid batteries, meanwhile, face issues such as rapid electrolyte evaporation and plate sulfation.

Controller (Electronic Control System): Acting as the "brain" of the electric forklift, the controller contains power components—such as IGBTs and MOSFETs—that generate substantial heat. In high-temperature environments, if the heat-dissipation baseplate becomes coated with 

oily dust, cooling efficiency plummets; this can result in anything from restricted performance to permanent damage.

II. Cutting-Edge Technology: Smart Cooling Systems Hold the Key to Solutions

To tackle heat dissipation challenges, industry-leading companies have introduced innovative solutions.

Differentiated Smart Cooling: New high-voltage lithium-battery forklifts utilize an independent "one-pump-per-unit" cooling architecture. Temperature sensors monitor the real-time temperature of motors and controllers, allowing for independent, on-demand control 

of fans and water pumps; this achieves precise heat dissipation while reducing energy consumption.

Active Battery Thermal Management: For lithium batteries, smart Battery Management Systems (BMS) can automatically adjust discharge power based on cell temperature and initiate pre-cooling procedures during charging. Some high-end solutions employ air-cooling 

or liquid-cooling technologies to effectively maintain cell temperatures within the optimal operating range.

III. Practical Tips: A Guide to Preventing "Heatstroke" in Operations and Maintenance

Experts recommend that enterprises implement protective measures across three areas: operational protocols, routine maintenance, and environmental management.

Operational Level:

Staggered Operations: Avoid the peak heat period between 11:30 AM and 3:00 PM; implement shift rotations and prevent equipment from running at full load continuously for more than four hours.

Charging Management: Allow batteries to cool naturally for at least 45 minutes before charging; ensure charging areas are well-ventilated and strictly prohibit charging under direct, intense sunlight.

Maintenance Level:

Airflow Path Cleaning: Regularly clear dust and debris (such as willow catkins) from motor housings, controller heat sink baseplates, and radiator fins to ensure unobstructed airflow.

Bolt Tightening: High-current connection bolts on motors and controllers are prone to loosening due to vibration, which can lead to overheating and burnout; regular inspection and tightening are required.

Tires and Hydraulics: Maintain standard tire pressure and strictly prohibit splashing water on tires to cool them down in high heat; use summer-grade hydraulic oil to prevent seal failure caused by excessive oil temperatures.

Emergency Response:

Lithium Battery Fires: Strictly prohibit the use of water! Use ABC dry powder fire extinguishers or cover the fire with sand/soil to cut off the air supply.

High-Temperature Shutdowns: If the dashboard displays an overheat warning, stop the vehicle immediately and move it to a cool, shaded area to cool down naturally; forced restarts are strictly prohibited.

IV. Industry Outlook: From Passive Protection to Active Thermal Control

As the market penetration of lithium-ion forklifts increases, the industry is shifting from a "repair-after-failure" model to "full-lifecycle thermal management." By integrating temperature sensors, smart Battery Management Systems (BMS), and liquid or air cooling systems, 

the new generation of electric forklifts is capable of stable operation in ambient temperatures of 45°C. Experts advise enterprises to prioritize "measured performance data under high-temperature conditions" and "cooling system redundancy" during procurement, and to 

establish specialized summer inspection protocols to eliminate heat-related risks before they escalate.