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What are the specific operating steps for preheating indoor electric forklifts in winter?

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Specific Preheating Operation Steps for Indoor Electric Forklifts in Winter

This preheating process is formulated based on ambient temperature classification, specifying the operation subject, step details, quantitative judgment criteria, and abnormal handling measures. It is applicable to indoor electric forklifts powered by lead-acid/lithium batteries and can be directly incorporated into work instructions.

I. Pre-preparation Before Preheating (Operator: Operator; Frequency: Before Each Operation)

1. Confirmation of Environment and Equipment Status

  1. Record the indoor temperature of the operation area, and classify the preheating grade according to three levels: ≤5℃ (cold storage/low-temperature area), 5–10℃ (non-heated area), and 10–20℃ (regularly heated area).
  2. Perform a 5-minute pre-shift inspection: Ensure the battery power is ≥80%, hydraulic oil level is normal, tire pressure meets the standard, braking system is sensitive, and there is no leakage or abnormal noise. Only after confirming the equipment is in good condition can preheating be started.
  3. For forklifts operating in cold storage, first drive them to a 5–10℃ transition buffer zone and park for 5 minutes to avoid condensation on components caused by sudden temperature changes.

2. Tool and Safety Preparation

  1. Wear cold-proof gloves and anti-slip labor protection shoes; set up operation warning signs, and ensure no personnel or obstacles are in the preheating area.
  2. For lithium battery forklifts, confirm that the battery preheating device is turned on (if equipped); for lead-acid forklifts, check that the charging plug is disconnected to avoid accidental charging during preheating.

II. Graded Preheating Operation Steps (Core Process)

1. 10–20℃ (Regularly Heated Area): Basic Preheating Process (Total Duration: 5–10 min)

StepOperation Action

Operation 

Duration

Quantitative Judgment Criteria
1Connect the forklift power supply, shift to neutral, and pull the parking brake30sNo fault lights on the dashboard, and the battery voltage display is stable
2Under no-load condition, repeatedly operate the fork lifting and lowering actions (lift to the maximum height → lower to the minimum position)3minThe hydraulic system operates without jamming, lifting and lowering speed is uniform, and there is no abnormal noise
3Operate the mast tilting actions (tilt forward to the limit → tilt backward to the limit), and cycle 5 times2minThe tilt cylinder responds sensitively without delay
4Release the parking brake, drive straight and turn at low speed (≤3km/h), and make 2 round trips2–5minThe steering system is light and flexible, and the braking distance is ≤2m (at no-load speed of 3km/h)
JudgmentHydraulic oil temperature ≥15℃ (if equipped with an oil temperature gauge) and battery temperature ≥10℃, then the forklift can be put into normal operation--

2. 5–10℃ (Non-heated Area): Enhanced Preheating Process (Total Duration: 10–15 min)

StepOperation Action

Operation

 Duration

Quantitative Judgment Criteria
1Connect the power supply, turn on the battery preheating device (if equipped), shift to neutral, and preheat the battery3minFor lithium battery forklifts, the battery temperature rises to ≥10℃; for lead-acid forklifts, the voltage fluctuation is ≤0.5V
2Perform a composite cycle of fork lifting/lowering and mast tilting under no-load condition, and pause for 10 seconds after each lifting/lowering action5minThe response time of the hydraulic system is ≤1.2 times the standard value, and no "jamming" occurs
3Drive at low speed (≤2km/h), alternately step on the accelerator and brake pedals lightly to test power and braking performance2–7minAcceleration is smooth without jolting, braking is stable without deviation, and tire grip is good
4Stop the forklift for 1min, and check for hydraulic pipeline leakage and electrical component odor1minNo leakage, no burning smell, and dashboard parameters are normal
JudgmentHydraulic oil temperature ≥18℃ and battery voltage is stable, then the forklift can be put into light-load operation (≤50% of the rated load), and switch to heavy-load operation after 5 minutes of running--

3. ≤5℃ (Cold Storage/Low-temperature Area): Special Preheating Process (Total Duration: 15–20 min)

StepOperation Action

Operation

 Duration

Quantitative Judgment Criteria
1

Park the forklift in the transition buffer zone, 

connect the external battery preheater, 

and preheat the battery to 10–15℃

5minThe battery temperature sensor shows the target temperature is reached, and no overheating alarm is triggered
2

Start the forklift, continuously cycle hydraulic actions under no-load condition

 (lifting + tilting + side shifting, if equipped), 

and lightly step on the accelerator to maintain hydraulic system pressure during the process

8minHydraulic oil temperature rises to ≥20℃, and all actions are smooth without jamming
3

Drive at low speed (≤1km/h),

 complete a full set of actions including straight driving, turning, and braking in the buffer zone, and cycle 3 times

2–7minSteering is not heavy, and the braking distance is ≤1.5m (under no-load condition)
4Conduct light-load preheating: Fork up goods with 30% of the rated load, lift/lower twice and drive 10m to test equipment stability2minNo power interruption, no mast shaking, and no hydraulic system pressure drop
JudgmentBattery temperature ≥12℃ and hydraulic oil temperature ≥20℃, then the forklift can enter the cold storage for operation, and the duration of the first operation shall not exceed 30 minutes--

III. Acceptance and Abnormal Handling After Preheating

1. Acceptance Criteria

  • Power System: Smooth acceleration, no sudden voltage drop, and normal battery endurance display.
  • Hydraulic System: Sensitive action response, no leakage or noise, and the fork lifting/lowering synchronization meets the standard.
  • Braking and Steering System: Braking without deviation, steering is light and flexible, and no jamming occurs.

2. Abnormal Handling Process

Abnormal PhenomenonHandling MeasuresResponsible Subject
Hydraulic action delay or jammingExtend the preheating duration by 5–10min; if the problem persists, stop the forklift to check whether the hydraulic oil type is low-temperature grade (ISO VG 32/46), and contact maintenance personnelOperator / Maintenance Technician
Large battery voltage fluctuation or insufficient powerStop preheating, move the forklift to the insulated charging area to recharge; for lithium battery forklifts, check whether the preheating device is faultyOperator / Equipment Administrator
Excessively long braking distance or braking deviationAdjust the brake clearance, check the brake fluid viscosity; clean foreign objects in the tire tread pattern and confirm the ground is anti-slipMaintenance Technician

IV. Management Requirements

  1. Preheating operation shall be included in the mandatory pre-shift items for operators. The equipment administrator shall conduct random checks on preheating records daily to ensure a 100% implementation rate.
  2. A preheating check-in point shall be set up in the transition buffer zone for forklifts operating in cold storage, where the start/end time of preheating and temperature data shall be recorded.


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