I. Power System Performance Enhancement (Core: Resolve Battery Capacity Fade and Motor Startup Difficulties at Low Temperatures)

Battery Low-Temperature Adaptation and Thermal Insulation

1. Model Selection OptimizationPrioritize low-temperature lithium batteries (e.g., low-temperature LiFePO₄ batteries with an operating temperature range of -30℃ to 55℃). Compared with traditional lead-acid batteries, their low-temperature capacity retention rate is improved by 30%–50% (capacity retention ≥70% at -20℃, while lead-acid batteries only achieve around 40%).
2. Active Thermal Insulation Measures
   • Install a battery insulation cover (adopting a polyurethane insulation layer with thickness ≥20mm) or configure a battery heating system (automatically heating to 10℃–15℃ in low temperatures) to ensure the battery operating temperature is ≥0℃.
   • For outdoor parking, remove the battery pack and store it in a warm warehouse (temperature ≥5℃) to avoid prolonged static storage of the battery in low temperatures.
3. Charging Management
   • Use a low-temperature intelligent charger that supports charging at -20℃. Preheat the battery to above 5℃ before charging, and control the charging current within 0.1C–0.2C (to prevent lithium plating caused by high-current charging).
   • Avoid parking the forklift with a depleted battery. Maintain a remaining charge ≥50% in low temperatures to prevent battery sulfation or lithium precipitation.

Motor and Electronic Control System Optimization

1. Motor PreheatingBefore operation, start the motor for no-load preheating for 3–5 minutes to raise the temperature of the motor windings to above 5℃, reducing startup resistance and copper loss.
2. Electronic Control Parameter AdjustmentOptimize low-temperature working condition parameters through the controller background, such as increasing the motor starting torque (10%–15% higher than normal temperature) and limiting the maximum speed (to avoid motor overload at low temperatures).
3. Moisture and Condensation PreventionInstall desiccants (silica gel desiccant, 200g per cubic meter) in the motor and electronic control box. Regularly inspect the terminals for oxidation to prevent short circuits caused by condensation at low temperatures.

II. Transmission System Performance Enhancement (Core: Reduce Low-Temperature Friction Resistance and Ensure Fit Precision)

Lubrication System Upgrade

1. Strictly implement the low-temperature gear oil standards for gearboxes/drive axles you formulated previously (GL-4 75W-90 or GL-5 80W-140 with a pour point ≤-30℃). Compared with summer-grade oil, transmission resistance is reduced by 25%–30%.
2. Adopt low-temperature lithium-based grease (dropping point ≥180℃, applicable temperature ≤-20℃) for the bearings of the traveling mechanism, with a filling volume of 1/2–2/3 of the bearing clearance, to avoid jamming caused by grease solidification in low temperatures.

Precision Clearance Control

1. Adjust the gear meshing clearance to 0.15–0.30mm and the wheel bearing clearance to 0.05–0.10mm to compensate for low-temperature shrinkage, preventing dry friction due to excessive tightness or impact due to excessive looseness.
2. Control the steering tie rod ball joint clearance within 0.3mm and fill it with low-temperature grease to ensure flexible and smooth steering.

Traveling Mechanism Anti-Skid and Stability

1. ｒｅｐｌａｃｅ with snow anti-skid tires (tread depth ≥15mm, rubber hardness ≤60 Shore A) in environments ≤-10℃. Adopt herringbone or block tread patterns to improve grip by over 40%.
2. Increase the tire pressure by 0.1–0.2MPa compared with normal temperature, and increase the wheel bolt torque by 5%–10% to prevent loosening or slipping caused by low-temperature shrinkage.

III. Hydraulic System Efficiency Assurance (Core: Resolve Increased Hydraulic Oil Viscosity and Slow Operation)

Hydraulic Oil Low-Temperature Upgrade

1. ｒｅｐｌａｃｅ with low-temperature anti-wear hydraulic oil that meets the following specifications: pour point ≤-35℃, kinematic viscosity at 40℃ ≥46mm²/s (e.g., L-HV 46 low-temperature hydraulic oil). Compared with ordinary hydraulic oil, its low-temperature fluidity is improved by 30%, effectively alleviating problems such as slow mast lifting and tilting jamming.
2. Completely drain the old oil during replacement (including the hydraulic oil tank, pipelines, and cylinder dead corners) to avoid mixing of old and new oil, which would reduce low-temperature performance.

Hydraulic System Preheating and Thermal Insulation

1. Perform no-load cyclic operation of the hydraulic system for 5–10 minutes before operation (repeatedly lifting and tilting the mast), and start load operation only after the hydraulic oil temperature rises above 10℃.
2. Install an insulation cover on the hydraulic oil tank, and apply low-temperature anti-rust grease to the cylinder piston rod to prevent rust and jamming at low temperatures.

Low-Temperature Modification of Seals

IV. Operation and Management Specifications (Core: Reduce Wear Under Low-Temperature Conditions and Extend Battery Life)

Operation Process Optimization

1. Avoid frequent start-stop and sudden acceleration. Frequent motor startups in low temperatures increase energy consumption and reduce battery life by 15%–20%. Maintain a constant speed (≤5km/h) during driving.
2. Control the load within 70%–80% of the rated capacity. Increased resistance of the transmission and hydraulic systems in low temperatures means overloading will exacerbate component wear and battery consumption.

Daily Maintenance Enhancement

1. Check the level and temperature of oils (gear oil, hydraulic oil, power steering oil) before daily operation to ensure no leakage or emulsification.
2. After outdoor operation, promptly clean snow and ice from the transmission mechanism and battery surface to prevent component jamming caused by freezing.

Warm Warehouse Scheduling Management

Quantitative Reference for Core Performance Improvement Effects