Forklifts and material handling equipment are an essential asset in many industries within their daily operations and due to the frequent level of use, it’s easy for operators and businesses to become complacent in safety protocols. As a result, unidentified issues may cause damage to the machine or injury to the user.
According to the UK Material Handling Association there are over 1300 forklift truck accidents a year, which means on average there are five accidents every workday in the UK.
THE IMPORTANCE OF INSPECTION
We recommend that forklifts and other material handling equipment to be inspected before operating, but these inspections are often neglected due to time pressure or are poorly documented. It’s not just a safety reason that inspections should be carried out but also it is a compliance check for the business that could avoid fines to the business due to the failure to identify safety issues.
As well as protecting company reputation and lives, there is a cost saving element by being able to discover maintenance issues early which can help limit or prepare for downtime whilst the truck is being repaired and potentially be a less expensive repair before it becomes a bigger issue.
Carrying out inspections is not difficult, but it does take a high level of operator discipline and support/procedures from the business. For larger workplaces with high staff volume, the daily checklist should involve a completion and sign-off for each item.
If problems are discovered, they must be reported, and the forklift must be removed from service immediately.
Here is our example checklist
PLACE HIGH-PRIORITY ITEMS AT THE TOP OF THE CHECKLIST
The day’s list should prioritize the elements that most likely to require attention. For example, fuel levels, battery condition and safety signalling should take precedence over general body condition. Fuel levels require regular and frequent action.
CONDUCT SPOT CHECKS
Employees should check the items off before use every day; however, by conducting regular spot checks to make sure each component and maintenance item gets the full attention it deserves.
Sometimes a problem is not imminent, but still requires documentation or reporting.
RESPOND TO REPORTED ISSUES IMMEDIATELY
Don’t let each daily check take place without follow-up action. If a signal or wire seems to be malfunctioning, take the lift truck out of rotation and get the problem fixed or the part repaired right away. This will reinforce the message that safety checks matter.
WHAT SHOULD GO INTO A PRE-OPERATION FORKLIFT CHECKLIST?
Your forklift manufacturer often provides sample checklists, however, if you wish to create your own checklist the following checkpoints will be handy to include in your daily forklift inspection:
- Check fluid levels such as oil, water, and hydraulic fluid
- Check for leaks, cracks, and visible defects everywhere on the forklift
- Check mast chains visually; avoid the use of hands
- Test mast chain tension by lifting the load backrest to eye level—the mast chains should be level and any tilting may signify stretching or broken rollers
- Check tyre condition and look for any cuts in tread/deformation of the wheel.
- Determine fork condition, remembering to check the top clip retaining pin and heel
- Ensure load backrest extension functions properly
- Ensure safety decals and capacity plates are legible and match the forklift model
- Check that the operators’ manual and logbook are present and legible
- Test all functional safety devices, such as seat belts and horns
- Check the brakes, steering controls, and other operational hydraulic functions
Depending on the type of forklift you are using, there may be other propulsion-specific aspects to check:
ADDITIONAL ELECTRIC FORKLIFTS PRE-OPERATION CHECKLIST
Here are a few items worth checking on your electric forklifts:
- There are no fraying or exposed wires in cables or connectors
- Electrolyte levels are proper
- The hood latch is operational
- Look for corrosion around the battery cells
- Ensure cell caps are secure
REACH TRUCKS AND ORDER PICKERS PRE-OPERATIONS CHECKLIST
Here are a few items worth checking on your reach trucks and order pickers
- No damage, bend, or looseness in the forks or backrest
- Brake pedal is effective
- No leaks can be detected
- Ensure reach mechanism is fully functional
