# Off-Road Forklift Operation Safety Full-Process Inspection Guide

Full-Process Safety Inspection Guide for Rough Terrain Forklift Operations I. Pre-Operation Safety Inspection (Basic Items) Hydraulic and Fluid System Checks — Engine Oil: With the engine cold, the oil level should be at the center mark of the dipstick (Example: CAT 289D standard oil capacity 9.3L). Hydraulic Oil Temperature: In winter, preheat to above 15°C (starting is prohibited when oil temperature is below -10°C). Brake Fluid Water Content: Test with a detection pen; replace if water content exceeds 3%. Critical Structural Inspections — Mast Chains: Single-side sag ≤5mm (Measurement method: test with full load lifted to 1m height). Tires/Tracks: Inflated tire pressure deviation ≤10% (Reference: standard tire pressure 0.35MPa ±0.02); track tension: depression of 20-30mm at the center point. Safety Device Verification — OPS Rollover Protective Structure: No cracks at weld points (focus on the 4 column connection points). FOPS Falling Object Protective Structure: 1kg steel ball drop test from 3m height (no structural deformation allowed). Audible and Visual Alarms: Reverse buzzer volume ≥87dB (test distance 1m). II. In-Operation Safety Monitoring (Dynamic Items) Stability Control — Ramp Operation Angle: Empty load longitudinal ≤15° (Example: Komatsu WA380-6 limit angle); full load lateral ≤5° (differential lock must be engaged). Load Center Distance: Standard value 500mm (illustrated measurement method). Hydraulic System Alerts — Abnormal Pressure Thresholds: Stop immediately if main pump pressure fluctuation exceeds 15% of rated value; repair required if multi-way valve leakage exceeds 30ml/min. Oil Temperature Monitoring: Pause for cooling if continuous operation oil temperature exceeds 85°C. Human-Machine Interaction Standards — Blind Spot Management: Set up a 2m warning zone (360° camera system recommended); fork tips must always remain visible (refer to instructional diagram for correct viewing angle). Hand Signal Standards: Use the 8 certified command gestures per ISO 10968. III. Special Working Condition Response (Enhanced Items) Extreme Environment Operations — High-Altitude Adaptation: Turbocharger requires adjustment at 2000m altitude; power drops approximately 10% for every additional 1000m elevation. Water Fording Specifications: Maximum fording depth ≤ 2/3 of tire radius (Example: 800mm tire — do not exceed 530mm); check the differential breather valve after exiting water. Hazardous Material Handling — Flammable and Explosive Goods: Equip with copper tool sets; install spark arrestors on the exhaust system. Radioactive Materials: Cab lead shielding ≥3mm; equip with real-time radiation dose monitor. IV. Mandatory Shift Handover Checks (Documented) Fault Record Triplicate Form — Completed by Operator (symptom + time); confirmed by Mechanic (diagnosis + action); archived by Safety Officer (rectification + acceptance). Critical Component Lifecycle Tracking — Brake Pads: Wear limit 3mm (equipped with measuring caliper); Hydraulic Hoses: Service life ≤2 years (color-coding management method); Structural Welds: Monthly magnetic particle inspection. V. Emergency Response Plans Sudden Failure Response — Pressure Loss Handling: Immediately operate the emergency descent valve (red lever); engage mechanical parking brake (see diagram for operating position). Electrical Fire: Cut off power, then use CO₂ fire extinguisher; water-based extinguishing agents are prohibited. Accident Reporting Procedure — Golden 30 Minutes: Secure the scene within 5 minutes; submit preliminary report within 15 minutes; complete full evidence chain within 30 minutes. Safety Mnemonic: "Check oil, pressure, and tires daily; control ramps and loads constantly; follow regulations for special tasks; never skip shift handover records."