Core Safety Guidelines for Electric Forklifts in Winter (Structured Technical Manual)

Winter safety risks of electric forklifts mainly stem from four core issues caused by low temperatures: reduced tire grip, battery performance degradation, limited visibility, and stiff components. A full-process safety management system must be established around four dimensions: "environment adaptation, equipment pre-inspection, operational specifications, and emergency response". Below are quantitative standards and actionable operational guidelines:

I. Environmental Safety Control (Mitigate Low-Temperature Hazards)

(I) Anti-Slip Treatment of Operating Areas

Ground Condition Requirements:

• Remove ice and snow from the site before daily operations (using industrial salt or snow-melting agents with a spreading rate ≥20g/㎡) to ensure no standing water or ice (ice thickness ≤1mm is considered safe; operations must stop immediately if exceeding this limit).
• Install anti-slip mats (rubber material with a friction coefficient ≥0.7) or apply anti-slip coatings (low-temperature resistant to -30℃, surface roughness Ra ≥12μm after drying) on ramps and turning points.

Site Signage Enhancement:

• Install "Low Temperature & Anti-Slip" warning signs in ice-prone areas (e.g., warehouse entrances/exits, near washing bays) and equip flashing warning lights (brightness ≥500cd) for nighttime operations.
• Widen operating channels by 20% (one-way channel ≥3m) to reserve emergency avoidance space and prevent collisions during sudden braking.

(II) Visibility Assurance Measures

Standardized Defrosting and Demisting:

• Immediately activate the windshield defrost function after starting the forklift (warm air temperature ≥40℃, wind speed set to medium-high) and wipe the outer window glass with anti-fog agent to ensure no fog/ice residue within 10 minutes.
• Prohibit pouring hot water on the windshield (risk of glass cracking) or scraping ice with hard objects (avoid scratching glass and affecting visibility).

Lighting System Upgrade:

• Inspect the brightness of headlights, turn signals, and brake lights (high beam irradiation distance ≥30m, low beam ≥15m) and replace dimmed bulbs (replace if brightness is 50% below standard).
• Install LED auxiliary spotlights (power ≥30W, color temperature 3000K-5000K) in extreme rain/snow weather to enhance short-range illumination.

II. Equipment Safety Pre-Inspection (Eliminate Low-Temperature Fault Hazards)

(I) Special Inspection of Core Components (Mandatory Before Daily Startup)

(II) Low-Temperature Adaptability Debugging

Preheating and Test Operation:

• Idle for 5-10 minutes after startup (extended to 10-15 minutes in winter); Test steering, lifting, and tilting functions sequentially (repeat each action 3 times, no jamming = normal).
• Begin operations only when hydraulic oil temperature reaches ≥15℃ and battery temperature ≥5℃.

Safety Device Calibration:

• Inspect safety belts (secure buckle, smooth retraction, breaking strength ≥22kN) and limiters (accurate lifting height limit, error ≤50mm).
• Test reverse alarms (volume ≥85dB) and emergency stop buttons (immediately cut off power when pressed).

III. Operational Specifications (Reduce Human Error Risks)

(I) Safe Driving Guidelines

Speed Control:

• Maximum speed ≤8km/h on flat surfaces (30% reduction in winter); ≤3km/h on turning points, ramps, or icy roads. Prohibit sudden acceleration/braking (braking distance is 2-3 times longer than normal temperature).
• Follow "low speed uphill, low gear downhill" principles; Prohibit neutral gliding. When parking on ramps, engage the parking brake first, then wedge wheels with triangular blocks.

Load Handling:

• Reduce load capacity by 20% in winter (e.g., max 2.4 tons for a 3-ton rated forklift) to avoid battery and hydraulic system overloading.
• When lifting goods, raise forks 10-15cm off the ground first, then drive slowly to the target location. Prohibit sudden turns/stops (prevent cargo slipping).

(II) Prohibited Operations in Special Scenarios

Prohibited Behaviors:

• No rapid turns or overtaking on icy roads (risk of rollover); No overloading or unbalanced loading (cargo center of gravity offset ≥10% causes instability).
• No operations during battery heating or charging (prevent fire due to poor heat dissipation); No towing other vehicles with forklifts (winter components are fragile, prone to mechanical damage).

Personnel Protection Requirements:

• Operators must wear anti-slip shoes (sole friction coefficient ≥0.6) and cold-resistant gloves (waterproof/anti-slip, no impact on control sensitivity). Prohibit loose clothing (avoid entanglement in mechanical parts).
• Rest for 5 minutes every 30 minutes during outdoor operations to prevent cold injury; Fasten seat belts during operation, no body parts protruding outside the vehicle.

IV. Emergency Response Plans (Rapidly Address Emergencies)

(I) Emergency Handling of Common Faults

Battery Faults:

• If leakage or swelling occurs, stop operations immediately, turn off power, evacuate to a safe area (distance ≥10m), and contact professionals (no unauthorized disassembly).
• Use dry powder fire extinguishers (MFZ/ABC5 type) for lithium-ion battery fires; Never spray water directly (risk of explosion).

Brake Failure:

• Immediately activate emergency lights and sound the horn to warn others; Slowly pull the manual parking brake (no sudden full application); Use ramp resistance or obstacles to assist deceleration (avoid head-on collisions).

Skidding/Loss of Control:

• If the forklift skids, release the accelerator pedal immediately, gently apply brakes (pulsed braking), and slightly adjust the steering wheel in the direction of the skid (no sharp turns). Stop slowly after stabilizing the vehicle.

(II) Emergency Support Preparation

Material Reserves:

• Equip the operation site with emergency toolkits (including triangular blocks, tow ropes, anti-slip chains, fire extinguishers, first-aid kits); Store spare batteries, brake fluid, and hydraulic oil (winter-specific models) in warehouses.

Personnel Training:

• Conduct special winter safety training (including low-temperature fault handling and emergency drills) before winter to ensure all operators master anti-slip, anti-freezing, and fire-fighting skills (100% training pass rate).
• Establish a 24/7 emergency response mechanism; Maintenance personnel must arrive at the scene within 30 minutes of fault reporting.

V. Safety Management Closed-Loop (Long-Term Guarantee Mechanism)

1. Daily Safety Morning Meeting: Hold 10 minutes before operations to announce weather and site conditions, emphasize safety precautions, and record operators' physical status (prohibit operations if fatigued or suffering from cold discomfort).
2. Weekly Safety Inspection: Led by safety managers, conduct comprehensive inspections of forklift components, operation sites, and emergency supplies. Rectify hidden dangers immediately (100% rectification rate).
3. Monthly Safety Review: Analyze winter operation safety data (fault frequency, violations, hidden danger rectification) to optimize safety control measures and update operational specifications.

Core Safety Principle:

The key to electric forklift safety in winter lies in "prevention first, slow and steady operation, and effective emergency response". Reduce objective risks through environmental modification, eliminate fault hazards via equipment pre-inspection, and minimize human errors with standardized operations—ultimately achieving the goal of "zero accidents" during winter operations.