Fork & Chain Inspection Checklist

Forks and chains lift hundreds of thousands of pounds each shift, and unchecked wear on either can cause a load to come crashing to the ground, potentially resulting in severe damage to property and even the death of an employee.

That’s one reason OSHA requires a daily inspection of each lift truck in operation. But while the agency offers some guidance through an online tool (click here to use it), the agency provides few specifics on what to inspect or how to inspect it. Below are some specific areas to inspect to help ensure forks and chains are in safe operating order.

Fork Inspection. Knowledge of metallurgy or its equivalent is not necessary to perform OHSA inspections, but operators must nonetheless pay attention to these key metal-related areas when examining forks.

• Rated load capacity. Are the forks rated to carry the loads they are handling? An excellent online calculator is available here.

• Surface cracks. Inspect each fork top and bottom for surface cracks. Pay close attention to the heel area and the welds to the areas that attach the forks to the lift truck. These areas are most likely to develop cracks. If a crack is found, the fork must be replaced before the lift truck is put back into service. OHSA does not permit a damaged fork to be repaired.

• Straightness of the blade and shank. If either the shank or the blade has any sort of bend, the fork must be replaced before the lift truck is put back into service.

• Excessive angle. If the shank and blade angle exceed 93 degrees, the fork must be replaced before the lift truck is put back into service.

• Fork tip height variances. If the fork tips exceed 3 percent of the length of the blade, the forks need to be replaced before the lift truck is put back into service. For example, for 48-inch forks, the differences in the heights of the tips of your blades cannot exceed 1.44 inches.

• Positioning lock. If the positioning lock is inoperable, it must be replaced before the fork is put back into service on the lift truck.

• Normal wear. Use calipers to measure the heel and the blade for wear. These are the areas that wear most quickly. Once wear reaches 10 percent, the fork must be replaced. Ten percent wear results in a 20-percent reduction in rated fork capacity and represents a significant exposure for accident.

Chain Inspection. Forklift chains endure tremendous stress during operation and are subject to additional damage and wear by environmental conditions such as dust, rain and industrial chemicals. Carefully inspect chains for the following:

• Chain elongation. Elongation of more than 3 percent indicates a 15-percent reduction in strength and means the chain should be replaced.

• Rust and corrosion. Chains showing any rust or corrosion should be replaced. For maximum protection, chains must be completely lubricated at all times.

• Plate cracking. Inspect closely for cracks. The discovery of any crack means the chain should be replaced before the forklift is put back into service.

• Protruding or turned pins. Lack of lubricant results in friction between the plates and the pins, causing the pins to twist and turn their way out of place. The result is chain failure.

• Misalignment. Look for wear patterns on pinheads or outside plates. Continued operation will result in damage to the chain and sheaves, potentially causing the chain to fail.
  

• Chain anchors and sheaves. Inspect anchors for misalignment, damage or undue wear. Anchors with worn or broken fingers must be replaced.

MHI strives to help operators maintain compliance with OSHA regulations, but more importantly, we help maintain both forklifts and chains, ensuring employees are safe and productive.

MHI inspects thousands of forklifts each year and would be glad to help inspect your forks and chains. As forklift service professionals, we can perform these inspections quickly and thoroughly, and assist you in teaching your operators effective inspection techniques. Contact your local MHI branch to set up an inspection.

OSHA Forklift Requirements – It’s Much More Than Just Training

Level of inspection activity is picking up.  With the recession beginning to ease, a lot of companies have been forced to cut back, to do more with fewer people and relocating many employees to new jobs they may have never done.  With this in mind you can see where OSHA would have reason to be sure that these employees are being protected in the workplace.  However when we think of OSHA and material handling we all-too-often think simply of operator training and the guidelines for keeping forklift operators and pedestrians safe extends far beyond the scope of training.  But before we address these areas of concern let’s take a quick look at some of the lesser-known conditions when operator training is required:

• When an operator has been observed to operate the vehicle in an unsafe manner 1910.178(I)(4)(ii)(A)
• The operator has been in a near-miss accident 1910.178(I)(4)(ii)(B)
• The operator has received an evaluation that reveals that the operator is not operating the truck safely 1910.178(I)(4)(ii)(C)
• The operator is assigned to a different type of truck (1910.178(I)(4)(ii)(D)
• A condition in the workplace changes in a manner that could affect safe operation of the truck 1910.178(I)(4)(ii)(E)

During the recession forklifts have been shuffled and employees re-assigned.  Being sure they are up-to-date for the new conditions is essential to a safe facility and keeping compliant with OSHA regulations.  Now, let’s look at some of the conditions that could put your OSHA inspection in peril.

Wheel chocks – If your forklifts are parked on an incline not only must the brakes be set and engine in neutral, but the wheels must be chocked.  Does your facility have wheel chocks at locations in your facility (dock ramps) where these are required? OSHA does not give an incline degree so think conservatively.  It is better to be over-prepared than under-prepared.   Your facility must provide wheel chocks for semi-trailers to keep them secured against the dock during loading and unloading.  Are all your semi-trailer wheel chocks available and in good working condition?

Horns – Are all the horns working on your lift trucks? OSHA requires “sound the horn at cross aisles and other locations where the vision is obstructed.” 1910.178 (n) (4) To further protect employees and ensure a safe facility back-up alarms are a best practice.  Back-up alarms are not a requirement, but if they are installed on one truck they must be installed on all trucks and in good working condition.  Are your lifts equipped and are they all in good working order?

Lock-outs – If a forklift is in need of repair it must remain out of service until repairs are made.  How do you ensure that this forklift is not used by an unsuspecting employee? Lock- out kits prevent forklift from being used by employees until they are repaired and returned to service.

Seat Belts – Are your lift truck’s seat belts all in good working order? The forklift operator is required to use a seat-belt.  MHI has bright orange belts that assist floor managers and supervisors visually check that seatbelt rules are being followed.

Fire Extinguishers – Depending upon Class of potential fire, employees must be provided with fire extinguishers so that their distance from an extinguisher is no more than 50ft (class B hazard area) to 75ft (Class A and D).  It is good practice to equip each lift truck with an extinguisher, particularly if you use Internal Combustion engine trucks.

Lighting – Are your forklifts appropriately equipped with working lights where lighting is less than 2 lumens per square foot 1910.178 (h) (2)? This generally means all forklifts that enter a semi-trailer equipped with an opaque or solid roof, will require lights on your lift truck.  New LED lights provide an exceptionally long life, lowering replacement costs.

Battery Changing – Is your battery changing station safe? If you’re using a crane, has it been inspected recently for safety? Do you have the appropriate personal equipment for changing batteries (gloves, goggles etc…) and are there appropriate warning signs? Our AMP Battery and Charger Division is available to perform battery room safety inspections at your facility.

Daily Inspections – Are your forklifts being inspected before each shift by your operators? OSHA provides and excellent e-tool for safe forklift operational inspections on their site: http://www.osha.gov/dcsp/products/etools/pit/operations/servicing.html#PreOperation

While not specifically covered in OSHA’s requirements, an inspection by an OSHA official will also target these areas.

Tires – Chunked tires or severely worn tires present a significant hazard for operators and pedestrians alike.  MHI sells and installs all types of forklift tires on site.  Gauges – Are all the gauges and indicators in good working order on each of your lift trucks? This includes hour meters, oil pressure, temperature and any other gauge installed by the manufacturer.

Forks – When was the last time your forks were inspected for wear, cracks or other unsafe conditions? Your MHI sales rep is available to inspect your forks and provide a very competitive price for replacement.

While this is just a partial list, OSHA will want to be satisfied that you have in place a program for ensuring a safe forklift fleet.  The Planned Maintenance Program (PMP) from MHI will help keep your forklift fleet in peak operating condition and operators and pedestrians as safe as possible.

We hope this list helps you to understand that when it comes to a safe forklift fleet operator training is just one facet of a safe and productive working environment.  If you want a partner that will work with you to make sure you achieve this, Material Handling Inc should be your next call.

When it comes to forklift safety, parts and planned maintenance programs no company beats MHI.  Our team of professionals has been doing it for decades and we would appreciate the opportunity to earn your business.  Visit us at www.mhiusa.net to learn more about us, and the next time a need arises, give us a call.  You will be glad you did.

OSHA Forklift Requirements – It’s Much More Than Just Training

Unlike Any Other Truck on the Market!

In Capacities of 5,000 through 6,500lbs, the New Linde 1313 Series of LPG Powered, Cushion Tire Forklifts are literally unlike any other truck on the market today. Utilizing 60 years of Hydraulic Propulsion expertise, this new series will provide your operation with Lower Operating Costs, Higher Operator Productivity, and Less Environmental Impact than ANY other internal combustion truck.

Lowest Operating Cost

The key to lowest operating cost rests in the 1313’s exclusive Hydrostatic Drive System. Using a fluid drive system allows Linde engineers to eliminate components that are the biggest cost items on all competitors’ trucks- Brakes, Transmission, and Engine. With the Linde 1313 you will appreciate:

• No Brake Maintenance
• No Transmission Maintenance
• 1,000 hour Service Intervals
• Sealed Undercarriage with No Overheating

Higher Operator Productivity

It is fact that operators are more productive throughout the day in equipment that is designed ergonomically. With the assistance of Porsche design engineers the Linde 1313 sets a new standard in operator comfort with every machine:

• 50% Less Movement Required to Transport Loads
• Armrest Hydraulic Controls
• Premium Comfort Seat
• Best in Class Visibility
• Shock Mounted Components to Reduce Vibration
• Swing-down LP Tank

Lowest Environmental Impact

Today being a good steward of our natural resources is not only a good idea, but it is required by different Federal and State regulations. As the standards become stricter the Linde 1313 stays ahead of the curve with the lowest environmental impact of any forklift in its class. Groundbreaking design offers:

• 30% Lower Fuel Consumption
• Lowest Engine Emissions of Any Forklift Manufacturer (Tested by California Air Resources Board)
• 50% Less Tire Wear
• Longer Equipment Economic Life
• 80% Reduction in Waste Oil and Filters

Seeing is Believing

To fully appreciate this leap forward in forklift technology the Linde 1313 series must be experienced in person. Here at MHI we are stocked with demonstrator models as we anticipate a high demand for this equipment. Please call us to arrange a free on-site demonstration of this remarkable equipment today!

• C25 LPG 5,000lbs Pneumatic- $247.96/month
• TMX 15 (3-wheel electric w/ batt & chg)- $412.06/month
• C25C LPG 5,000lbs Cushion- $306.46/month

Clark has awarded Material Handling Inc. for their outstanding contributions to the market place in promoting CLARK through trucks and parts sales, in 2009, and continuing to provide outstanding service to CLARK customers in their respective territories. MHI is very proud to have been selected as one of six dealers in the country to receive this prestigious award. Thank you to our MHI family and to our loyal customers!

CGH-25, 5,500lbs Capacity
Forks- 27″ x 48″ or 21″ x 48″
Only- $199.00
Plus FREE Local Delivery

Service Department Wash and Inspection Special

$150 includes transport to one of our service centers where your truck will be steam cleaned and inspected for any possible repairs. If repairs are needed you will be contacted for approval before any work additional work is performed.