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Thorough Examination for Forklifts. Why?

Spending too much on your forklift maintenance? Are you sure that your forklift trucks are safe? Every machine in use can cost ridiculous sums if not maintained properly but what is the cost for safety. Thorough examination was designed with the sole purpose of making sure that all trucks are firstly SAFE to use and ensuring that the living costs for forklift trucks are kept to a minimum through regular and thorough checks.

Below you can find all the information in regards to which parts of your forklift are checked during thorough examination as well as the reasons why.

Loler Lifting Parts

  1. Forks:

Fork arms are subject to constant abrasion and stress, making them particularly vulnerable. They must be of the correct capacity, and need to be inspected for signs of wear (meeting ISO 5057), cracks, deformation and splaying. The means of fork location and end stops are also checked.

  1. Carriage:

The fork arm carrier must be checked for distortion or cracking, along with the mounting and soundness of any load backrest extension.  If a side shift is fitted, it must move in a controlled, even manner.

  1. Attachments / Side shift (If fitted)

Permanently fitted attachments and sideshifts can be included in the truck’s usual Thorough Examination interval. If removable, they must be checked at least twice a year. To ensure safety they must be free from distortion or cracks, mounted securely, and operable in a smooth, even manner throughout their full range of movement.

  1. Load Backrest:

The load backrest should be inspected to ensure it is structurally sound and securely mounted; otherwise it may not only cause failing loads, but could become a hazard in its own right.

  1. Mast:

The mast or telescopic boom or a telehandler, must be inspected throughout its full range of extension and movement. Hydraulic systems are also carefully checked and tested.

  1. Chains:

Sudden lift chain failure is potentially lethal; however the wear, elongation or corrosion that can cause it can be very gradual and tricky to spot. Careful measurement in at lead three places is therefore essential. A change of just 3% means the chain must be replaced(below this, the examiner must judge whether the chain is safe – making experience essential).

  1. Tilt Mechanism:

The tilt must move in a controlled, even manner with no signs of damage or scoring. Hydraulic cylinders, hoses and piping are also inspected.

  1. Hydraulic Systems:

Hydraulic cylinders, reservoir, hoses and pipes must be checked carefully, as sudden loss of pressure can be catastrophic. Filters can be checked for signs of debris and if there is cause for concern, load handling parts might be subjected to a prolonged load test to rule out unacceptable descent.

  1. Rating Plate:

Clearing rating information is absolutely critical to the safe operation of any forklift truck. Capacity data plates must be securely attached, legible and have the capacity rating for the truck and any attachments fitted. If a load capacity indicator is fitted, the information should be clearly visible to the operator.

     10. Controls:

All controls, cables and linkages should be checked for correct operation, corrosion, damage and signs of potential failure. They must be securely mounted and their function clearly marked.

PUWER – Other Parts

  1. Brakes:

Brake failure is a forklift truck operator’s worst nightmare, but brakes are left unchecked in many non-CFTS inspections. All service and parking brake systems must operate as expected, and an experienced forklift truck specialist will be able to make an initial evaluation with a slow drive test. Inspection should also cover hydraulics/pneumatics, mountings, cables, linkages, pedal levels and controls.

  1. Steering:

All mechanical and hydraulic components must be inspected for damage, excessive wear, and signs of failure or corrosion. A specialist’s forklift truck engineer is also able to manoeuvre the truck at low sped to check steering response and operation.

  1. Chassis:

Where possible, the chassis should be inspected for signs of damage and cracking in welds.

  1. Seat Mountings:

The mounting must be secure, along with the panel to which it is attached. Any operator restraint (e.g. seat belt) or anti-vibration mounting is also checked for signs of damage.

  1. Seat restraint:

Any operator seat restraint (including seat belts and other devices designed to keep the operator safely seated in the event of a tipping accident) should be securely mounted, and free from damage.

  1. Safety equipment:

Safety systems can only protect workers if they operate correctly. Moreover, because operators come to depend on them, any failure can instantly cause serious unsafe practices. All safety systems should therefore be checked to ensure they function properly – including visible & audible warning devices, capacity/data plates and safety interlocks such as seat switches.

  1. Traction System:

The prime mover and transmission are checked, along with the exhaust system on IC engine(diesel and LPG) trucks, and battery and connections on electric trucks.

  1. Wheels and Tyres:

Because of the forces involved, wheel failure not only causes accidents, but can be fatal hazard in its own right. Wheels and their assemblies should be sound in condition and securely fixed. Tyres must be checked for specification, wear, damage and bonding failure. Composite wheels and tyres must be a correct combination, suitable for the application and truck. Wheel bearings also need particular attention.

  1. Overhead Guard or Cab

As well as compromising protection from failing loads, a damaged overhead guard or cab can be a clue to potentially lethal structural problems. It must therefore be checked to confirm it is sound and securely mounted. Any transparent screens must be clear and undamaged.

    10. Counter Weight:

Often a cast iron block of two tonnes or more, the counter weight is suddenly coming loose can be catastrophic – both to truck stability and as a hazard in its own right. The fastening must therefore be inspected to ensure it is secure and undamaged. Other structural components and mountings, such as fluid containers, axles and batteries, should be checked in the same way.

Y. Skembedjis and Sons Forklifts Cyprus is the only Thorough Examination certified company in Cyprus ensuring that all machines that enter the facilities are thoroughly checked minimizing the chances for a work accident due to forklift failure as well as minimizing maintenance costs with parts failure prevention.

Source. http://www.thoroughexamination.org/

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Forklifts in Cyprus – Y.Skembedjis and Sons Ltd