# Comprehensive Safety Inspection Guide for Rough Terrain Forklift Operations

Guide to Full-Process Safety Inspection for Rough Terrain Forklift Operations I. Pre-Operation Safety Inspection (Basic Items) Fluid System Check — Engine Oil: When cold, the oil level should be at the midpoint 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: Use a test pen; if water content exceeds 3%, replacement is mandatory. Key Structure Inspection — Mast Chain: One-side sag ≤5mm (Measurement method: inspect at 1m lift height with full load). Tires/Tracks: Pneumatic tire pressure deviation ≤10% (Reference: standard tire pressure 0.35MPa±0.02); Track tension: 20-30mm deflection at the midpoint. Safety Device Verification — OPS Rollover Protective Structure: No cracks at weld points (Focus on the 4 pillar connection points). FOPS Falling Object Protection: 1kg steel ball drop test from 3m height (No structural deformation allowed). Audible and Visual Alarm: Reverse buzzer volume ≥87dB (Test distance 1m). II. In-Operation Safety Monitoring (Dynamic Items) Stability Control — Slope Operation Angle: Unloaded longitudinal ≤15° (Example: Komatsu WA380-6 limit angle); Loaded lateral ≤5° (Differential lock must be engaged). Load Center Distance: Standard value 500mm (Measurement method shown in diagram). Hydraulic System Warning — Abnormal Pressure Threshold: If main pump pressure fluctuation exceeds 15% of rated value, stop immediately; If multi-way valve leakage exceeds 30ml/min, maintenance is required. Oil Temperature Monitoring: If oil temperature exceeds 85°C during continuous operation, pause and cool down. Human-Machine Interaction Standards — Blind Spot Management: Set up a 2m warning zone (360° camera system preferred); Fork tips must always be visible (Correct viewing angle shown in instructional diagram). Hand Signal Standards: Use the 8 command gestures certified under ISO 10968. III. Special Working Condition Response (Enhanced Items) Extreme Environment Operations — High Altitude Adaptation: Turbocharger adjustment required at 2000m altitude; Power decreases approximately 10% for every 1000m increase in altitude. Water Crossing Standards: Maximum water crossing depth ≤2/3 of tire radius (Example: 800mm tire not to exceed 530mm); After exiting water, inspect differential breather valve. Hazardous Material Handling — Flammable and Explosive Goods: Equip with copper tool set; Install spark arrestor on exhaust system. Radioactive Materials: Cab lead plate protection ≥3mm; Equip with real-time radiation dose monitor. IV. Mandatory Shift Handover Inspection Items (Documented) Fault Record Triplicate Form — Operator fills in (Phenomenon + Time); Mechanic confirms (Diagnosis + Measures); Safety Officer files (Rectification + Acceptance). Key Component Life Tracking — Brake Pads: Wear limit 3mm (Equipped with measuring caliper); Hydraulic Hoses: Service life ≤2 years (Color-coded management method); Structural Welds: Monthly magnetic particle inspection. V. Emergency Response Plan Sudden Fault Response — Pressure Loss Handling: Immediately operate emergency lowering valve (Red lever); Engage mechanical parking brake (Operation position shown in diagram). Electrical Fire: Cut off power then use CO₂ extinguisher; Water-based extinguishing agents are prohibited. Accident Reporting Procedure — Golden 30 Minutes: Scene secured within 5 minutes; Preliminary report within 15 minutes; Complete evidence chain secured within 30 minutes. Safety Mantra: "Check oil and tire pressure daily, control slope and load constantly, follow rules for special operations, handover records are indispensable."