FORKLIFT INSPECTION AWARENESS

TRAINING

SEASERVE TESTING SERVICES

 The risk of ignoring forklift safety
Forklifts are extremely useful in a variety of workplaces, but there is
great risk of property damage, injury or death if you:

- are not trained on forklift safety and inspection

- are not familiar with the specific forklift vehicle

- Inspecting the forklift in an unsafe manner

 What is a powered industrial truck
(P.I.T.)?
Definition: A powered vehicle used to carry, push, pull, lift, stack or tier
materials.
Another way of describing powered
industrial trucks is that they include
standard forklifts and special use
forklifts and industrial vehicles.
 Forklift Nameplate
The nameplate will list the type of forklift and the capacity

Weight

Type

Load
capacity
Forklift Operating Manual

Since there are numerous makes, models

and types of forklifts, it is important to
check for warnings in the specific forklift
operator’s manual.

The manual should be kept on the forklift

at all times.
 Forklift Stability Triangle

Almost all counterbalanced powered industrial trucks supported at three points. This is
true even if the vehicle has four wheels. The truck's steer axle is attached to the truck by
a pivot pin in the axle's center. When this point is connected to the front wheels with
imaginary lines, this three-point support forms a triangle called the stability triangle. So
long as the center of gravity remains within this stability triangle, the truck is stable and
will not tip over.
 How loads affect forklifts

A forklift balances a load with a counterweight at the back. The front

wheels act as a fulcrum or balance point. The center of gravity moves
upward when the forks are raised.
Don’t travel with a raised load
 Forklift Load Capacity

While carrying a load near the maximum allowable capacity, be aware of the
following:
Danger of tip over
Danger of losing load
Danger of being struck by falling load
 Moving the load

OSHA

Use extra caution when handling loads that approach the truck's
maximum rated capacity:
Tilt the mast & forks back and position the heaviest part of the
load against the carriage.

Travel with the mast tilted back to keep the load stable.

Never travel with the load tilted forward. Tilting the load forward
increases the load distance and makes the load less stable
 Driving on an incline
Always drive with the load on the uphill side - go backwards driving down
the incline and frontwards going up the incline to prevent tipping or losing
control of the forklift.

If no load on the forklifts, do the opposite with forks pointing down the ramp
 Forklift inspection
WALK AROUND A LIFT TRUCK

•Walk around the lift truck to check for

leakage of oil, fuel, coolant and battery
electrolyte.
•Look under the lift truck to check for oil
or water leakage.
•Visually check for any damages, cracks,
loose mounting and/or play. Give priority
in checking the following points
particularly.
Overhead guard
Fork
chain
Load backrest
Fork carriage
Mast
Fuel tank
Hydraulic oil tank
 Forklift inspection
•Visually check if the tilt cylinder rod and the rod
head are rotating in loose condition or if the lock
nut is loosened.
•Visually check lamp, lens, etc. for any
contamination and/or damages.
•Visually check the reflector for any contamination
and/or damages.

CHECKING OF TYRES AND RIMS

The tyres are the only parts of a fork lift truck that
are always in contact with the ground. They
provide grip for movement, friction for braking and
an element of suspension for safety and comfort.
The correct tyres in good condition are an
essential aid to safe and efficient operations. The
wrong tyres for the application, or tyres in poor
condition or excessively worn, are a potentially
dangerous and expensive hazard.
 Forklift inspection
CHECKING OF TYRES AND RIMS

•Pneumatic tyres must have a minimum of 1mm of

tread over the centre 75% of tread around the
complete circumference.

•Solid rubber resilient tyres may be used until they

are worn to the wear indicator, also known as the
60J line. 60J

•Press-On Band, Moulded Direct and Conical Base

Tyres may be used until 2/3rds of the original
thickness remains. They should be changed if there
is any sign of damage, deformation or the tyre
coming away from the wheel.
 Forklift inspection
CHECKING OF TANKS

•Checking of oil level in hydraulic tank is filled

to the specified level.
1. Lower the forks fully to the floor and hold the mast
vertical on a flat site.
2. Withdraw the oil gauge (integrated with the breather)
on the R.H. side of the lift truck body. Wipe hydraulic
oil off the oil gauge with a clean cloth and insert the
gauge into the tank.
3. Pull out the oil level gauge again and check that the
stuck oil is within the normal range.
• Checking the engine oil level in the oil pan is
within normal range
1. Withdraw the oil gauge. Wipe hydraulic oil off the oil
gauge with a clean cloth and insert the gauge back
into the tank.
2. Pull out the oil level gauge again and check that the
stuck oil is within the normal range.
 Forklift inspection
CHECKING OF TANKS

•Checking Of Battery Electrolyte Level

1. Check whether the battery electrolyte level is within the
normal range between the upper limit line (A) and lower
limit line (B).
2. Always keep the breather and terminal of the battery cap
on the top of the battery clean with no dust attachment.
•Checking of coolant level
1. Check whether the coolant level is within the normal
range, i.e. between FULL and LOW when the coolant in
the radiator reservoir tank in the engine hood is in a
cooled state.
• Checking of oil level in the brake reservoir tank
1. Check if the fluid level is within the normal range of up to
15 mm (0.6 in) from the under side of the cap
 Forklift inspection
CHECKING OF TANKS

•Check torqflow transmission case oil level

1. Place the machine on a level ground before starting the
work, apply the parking brake securely.
2. Close the engine hood and start the engine. Run the
engine at low idle for approximately 3 minutes.
3. After stopping the engine, open the engine hood, and
remove floor mat and floor plate.
4. Leave the machine for approximately 5 minutes after
stopping the engine to stabilize the oil level.
5. Pull out dipstick and wipe the oil off with a clean cloth.
Then insert it to the original position.
6. It is normal if the oil level is between F and L. lf the oil
level is below the L mark, add oil through oil filler port .
 Forklift inspection
CHECKING FROM THE OPERATOR SEAT

• Check the seat belt webbing and buckle, etc. are free from damage, wear or
fray.
• Check seat and steering wheel position & steel wheel play according to
manufacture specification.
• Check the pedals for correct application effort, play and for correct dimensions
of the pedal height.
• Check the horn.
• Check all the lights and reverse alarm.
• Check all the control/operation levers.
• Check the functionality of the gauges/lamps.
• Start the engine and check for any abnormal sounds
• Check weather the steering wheel is stable while moving slowly.
•Make sure the brakes are operating effectively.
•Check the travel & lift interlock function.
 Forklift inspection
FORK INSPECTION

Forks are a critical part of the everyday operation of lift trucks. The stresses,
strains and shock loadings to which these parts are subjected, make it
important to regularly inspect them and to replace them when worn or
damaged. The major causes of fork wear is as follows

•Improper Chain Adjustments

•Improper Operation of Truck

•Normal Wear From Use Over Time

•Use Beyond Rated Load Capacity

•Application Environment

•Tire Wear
 Forklift inspection
FORK INSPECTION

• Inspect For Surface Cracks

1. Pay special attention to the heel and to the welds
attaching all mounting components to the fork. Cracks
are more likely to occur at these areas. Each fork must
be tested for surface cracks with a non-destructive test.
If a crack is found, the fork must not be used.

• Inspect for straightness of blade and shank

1. Check the upper face of the blade and the front face of
the shank. If either surface is not straight, the fork must
not be used.
2. Max. allowable deviation is 0.5% of the length of shank
& blade.

• Inspect for positioning lock damage

1. Check to see that the positioning lock is in good
condition and proper working order. If the lock is not
working properly, the fork must not be used until the
positioning lock has been replaced.
 Forklift inspection
FORK INSPECTION

• Inspect For Excessive fork angle.

1. Standard forks are manufactured with a 90 degree
angle .If that angle exceeds, the fork must not be used.
2. Max. allowable deviation is 3 degree.

• Inspect for tip alignment / height difference

1. The difference in height of the fork tips must not exceed
3% of the length of the blade. If so, the forks must be
replaced.

• Inspect for wear on the forks

1. The amount of wear can be determined using calipers
for measurement. If the percentage of wear is in
excess of 10%, the forks must be replaced.
 Forklift inspection
MAST INSPECTION
• Inspect the mast for damage, distortion or cracks
• No undue wear, scoring, dirt or any foreign bodies are on
the channels
• End stop secure
• Rollers, no uneven wear or incorrect tracking.
• Sliding intact and secure.
• Make sure carriage plate has no damage or distortion,
sitting square with the mast and lubricated
• End stop bolt engaged and secured.
• Check the mast tilt angle forward and back is according to
manufacture specification, by using an inclinometer.
• Check for any abnormal sound during the operation of the
mast.
• Check for any hydraulic leakages from the mast.
 Forklift inspection
CHAIN INSPECTION
If Chains Are Not Carefully Inspected for Wear And Properly Maintained,
Ultimately They Will Fail

Chain Designation

Leaf chain shall be designated by the prefix “LH” [“BL”] for chains derived from the ISO
606 A [ASME B29.8] series, or by the prefix “LL” for chains derived from ISO 606 B series,
followed by a number of which the first two digits indicate the pitch expressed in sixteenths
of an inch and the last two digits indicate the lacing (number of plates in the outer plate
pitch and inner plate pitch).
To obtain the ASME “BL” reference, the same principle is used, except that the pitch is
expressed in eighths of an inch using only one or two digits, dependent on pitch.

The dimensions of the leaf chain can be referred from ISO 4347 which provide minimum
and maximum limits, ensuring interchangeability and connection to standard design
clevises.

Chains from different manufacturers shall never be placed together within the same
application.
 Forklift inspection
CHAIN INSPECTION

Chain nomenclature
 Forklift inspection

CHAIN INSPECTION

Determine the Chain Condition

•Elongation
•Rust Corrosion
•Cracked Plates
•Protruding Pins
•Misalignment
•Chain Anchor and Sheave Wear or Damage
 Forklift inspection
CHAIN INSPECTION

•Elongation
1. Chain elongated 3% or more should be replaced
2. This lengthening of the chain could reduce its strength
by as much as 18%

• Chain wear gauge

1. This tool is used to measure the lengthening of chains
2. When the markings on the gauge appear at the center
of the pin ends, the chain condition is acceptable
3. If the markings on the gauge appear away from the
center of the pin ends, the chain is worn out and
should be replaced

• Rust Corrosion
1. May cause side plate cracking and reduced load
carrying capacity
2. Chains must always be completely protected by a film
of lubricant
 Forklift inspection
CHAIN INSPECTION

•Cracked Plates
1. Repeated heavy loads over a period of time may crack the plates and eventually
break the chain
2. The chains must be replaced if a crack is discovered

• Protruding Pins
1. Heavy loaded chains operating with little lubrication generate friction between the
pin and plates
2. Over time, pins will slowly work out of the chain causing chain failure

• Misalignment
1. Is determined by a wear pattern on pin heads and outside plates
2. Will damage the chain and sheaves and cause internal friction in the chain

• Chain Anchors and Sheaves

1. Check chain anchors for wear, damage, and incorrect alignment
2. Anchors with worn or broken fingers must be replaced
3. Chain anchor pins and their retention should be checked and pins replaced as
necessary
 Forklift inspection
LOAD TESTING

The objective of the testing is to demonstrate that forklift is structurally sound and fit
for the use for which it was designed. Any disturbance, (dis-assembly and re-
assembly) or repair to any load bearing part or replacement of the hoist chains shall
require the mechanical handling machine to be subjected to a load test. The Lifting
Engineer shall witness all load tests.

The forklift shall be subjected to a load test of 100% SWL using, verified test weights.
The test load may be changed at the Lifting Engineer’s discretion. Where practicable
each load bearing part of the equipment is to be given one overload (i.e. each
mechanical handling machine motion shall be tested to prove the integrity of load
forks, chains, load bearing structure etc.).
•Static Load Test Hoist Ram(s)
The test weight shall be raised to between 100mm and 200mm above the ground
with the mast vertical. The maximum drop is 100mm in 10minutes.

•Static Load Test Tilt Ram(s)

The test weight shall be raised to between 100mm and 200mm above the ground
with the mast vertical. The maximum fall back is 10mm in 10minutes.
 Forklift inspection
EXAMINATION AFTER LOAD TEST

Upon completion of the test, a further thorough examination followed by a functional

examination as outlined above will be carried out to ensure that the fork lift sustained
the load test without any permanent damage / injury at the load bearing members &
that there are no cracks, permanent deformations, paint flaking, loosening of or
damage to the structural connections

REPORTING AND CERTIFICATION

After Satisfactory completion of load testing and Inspection, a Certificate of Test

Examination and testing shall be issued. However a Defect Report will be issued, if it
fails the acceptance criteria decided by the Lifting Inspector