Thorough Inspection of Forklifts - Risks, Control Measures & Methodology

Thorough Inspection of Forklifts

The objective of this guide is to define minimum requirements for in-service inspections and should be mandatory used, unless a specific regulation in force is available in a country. In this latter case, the criteria enclosed could be added for a professional management of a lifting equipment park.

This is the free synthesis of the following:

Lifting Operation and Lifting Equipment Regulations 1998 (LOLER),

French Regulation which came in force on March 1st 2004 for inspection of lifting equipment and their hoisting accessories,

It gives a general indication of some of the main requirements focused on priority to safety criteria and it is organised to be fulfilled during the inspection.

       The Risks, Control Measures & Methodology of Thorough Inspection of a Forklift is detailed below -

1.  Access to the cabin and to the cockpit
RISKS	CONTROL MEASURES	METHODOLOGY
Risk of falling during access to the driving position.	To secure access to the driving position of steps, ladders, or recovery handles shall be installed on access to the cockpit or to the cabin.	Verify that the footsteps, ladders or recovery handles are firmly attached to the chassis and are in good condition (no distortion, breaks...).
	These devices including walkways shall be equipped with anti- slip surfaces.	Ensure that access points are properly identified.
		In the case of a gateway, check the condition of the guards and baseboards.
When you go to the cabin to check the equipment, respect the rule of three points
To up and down the cabin you shall have alternately feet and one hand in support, and then both hands and one foot
in support (always facing the equipment).
2.  Connections, brackets, assemblies, joints
RISKS	CONTROL MEASURES	METHODOLOGY
Destruction or collapse of the equipment or part of the equipment due to localized distortion ruptures of connecting elements contributing to the strength of the equipment.	The connecting parts shall resist by proper: design, calculation, manufacturing and construction methods and proper maintenance.	Check by visual inspection of accessible parts that the assembled elements have no defect which may reduce their robustness and stability.
		Verify the absence of relative movements of components when the equipment is moving.
3.  Mast, ladder
RISKS	CONTROL MEASURES	METHODOLOGY
Rollover or destruction of the equipment resulting from an improper composition of the setting up of the masts, failure of one of its components or an improper setting up with the constraints.	Replacement or maintenance of components in compliance with the Manufacturer’s instructions.	Check by visual inspection:  - The condition of the frame, welds (no cracks, tears, peeling, distortion or severe corrosion) -    The condition of the mast -    The absence of excessive clearance -    The proper implementation of assembly devices.
Degradation of components subject to distortion due to working stress.	Constructive provisions to ensure damage due to excessive working stress.
		For bolted parts no clearance should be raised (risk of loosening the bolts).
		In the presence of appreciable clearance in the structure report to the Manufacturer to determine the possible action to take.
4.  Bumper Plate, bumpers
RISKS	CONTROL MEASURES	METHODOLOGY
Drop of the load or supporting elements caused	Proper design allowing a correct strength level and durability of joints between frame and handling system and devices:               Slots          Locks          End stops	A visual inspection of mechanical parts without dismantling will be performed to detect any apparent anomalies such as excessive wears, tendency to fracture, deterioration, lack or loss of elements (for example end stops).
by excessive clearance, undocking or breakage of any mechanical parts.
Ask the driver to perform operations to ensure that:
Stops and bumpers are in place on forks (risk of falling when setting the spacing) and properly moved in position of the fork carriage (risk of crushing fingers)
Devices for locking the fork are in place
Rollers are not seized
Clearance between fork carriage and framework deck is acceptable.
Check that the fork carriage is in good condition, with no:
Large distortions
Cracks
Fractures.
5.  Running Gear (Caterpillar, pneumatic)
RISKS	CONTROL MEASURES	METHODOLOGY
Risk of rollover for equipment whose stability is ensured by the running gear (self- propelled).	Always use running gear recommended by the manufacturer regarding twinning, pressure, the widths of track shoe etc....	Check the tire treads and solid rubber tire (no apparent canvas, no bulge and no cut). Check that the tires of the wheels on same axle are of the same type and size.
		Check that wheel rims are not distorted and they have no crack.
		Check that all nuts are in place and safety pins are properly positioned on the removable circles.
		Check that caterpillars are tighten (No broken track shoe, no seized-up roller, good condition of bull wheels).
For machines with pneumatic tires, the criteria for replacement tires are the same as for your vehicle:
Wear
Tear
Bulge
Protrusion
Cut
Exfoliation
Visible carcass of the tire
Check that the wheel rims are in good condition with no apparent distortion, and properly secured
Solid tires. Bandages. criteria for replacement tires or tires are full:
Wear
Cut
Bulge
Exfoliation
6.  Frame, Counterweight
RISKS	CONTROL MEASURES	METHODOLOGY
Drop the load, rollover of the forklift.	Components should be properly designed to ensure sufficient stability and robustness of the equipment.	Parts of the frame could present defects such as cracks, distortion, corrosion, weld fractures. They can cause failures and fall of the load.
	The frame (supporting the motor unit, the mast and the counterweight) could be bent, cracked, corrugated, broken, and could be cause of structural damages and accidents.	Perform a visual inspection of accessible parts to check there are no anomalies or degradations of different parts of the frame.
Check that frame parts do not show abnormalities such as:
Deformations,
Corrosions,
Fractures,
Cracking.
Fastening of counterweights should be in good condition.
In case where the battery serves as a counterweight, ensure that the weight matches the mass graved on the Manufacturer’s plate.
7.  Stabilizers
RISKS	CONTROL MEASURES	METHODOLOGY
Destruction of the equipment following the failure or blocking of stabilizers.	Distribution device of responses made by the support of the equipment consistent with the strength of the soil.	Check that the support conditions are correct.
Drop in load due to the imbalance of the machine and lack of stability	Blocking to meet the tolerances of inclination allowed by the manufacturer.	Verify that the additional means to check the stability of the equipment comply with manufacturer's instructions.
	Following types of materials and conditions of use:	Check, when the system includes cylinders, the presence of check-valves, their good condition and operation.
	Additional means (stabilizers, supports or anchors) can be implemented to check the stability of the equipment.	Verify that the stabilizers are working properly and they can be operated in their full travel.
	All cylinders of the stabilizers whose failure could cause loss of stability must be fitted with manual or automatic locks.
	The automatic locking hydraulic cylinders shall be provided by controlled check-valves.	Check the state of:
	The blocking provided by fixed mechanical systems does not require locks: nut and bolt.	Ducts and fittings to the chassis,
		Base-plates and attachments to cylinders,
		Beams,
		Cylinders,
		Locks in transport position,
		Axles stopping pins.
		Visually check mechanical locks.
		During a load test check that stabilizer position cannot change by actionning commands.
		Check by a test load that the position of the stabilizer cannot change notably during the relief of a support and action on the levers of power stabilizers.
		This operation shall be carried out of the complete absence of all movement and of all electrical or mechanical supply
		Suspension Lock:
		Some cranes are fitted with devices for securing the front and / or backwards suspension in order to check their stability during operations on stabilizers and tires.
		Blocking can be achieved by mechanical or hydraulic.
		When carried out by hydraulic cylinders, check the presence and operation of locking devices normally-closed and pilot operated.
		This operation shall be carried out of the complete absence of all movement and of all electrical or mechanical supply.
Verify that the stabilizers and beams extensions have no anomalies such as:
Distortions,
Corrosion,
Breaks,
Cracking,
Large clearance,
Deformation of the plate support,
Not clearly identified command,
Load charts based on different blocking configurations not displayed in the cabin.
8.  Power supply limitation
RISKS	CONTROL MEASURES	METHODOLOGY
Accidental starting, residual energy can cause uncontrolled movements.	An easily accessible device shall perform the functions of switching off and separation.	Test the operation of the separation device if any.
	In case of an electrical installation, all poles shall be switched off, with the possibility of mechanical lock in the opened position.
Check the proper functioning of the device to isolate the unit from its power source.
9.  Equipment, wiring system, cooling units
RISKS	CONTROL MEASURES	METHODOLOGY
Risk of projection or uncontrolled movement of the pipes in case of break.	The rigid and flexible pipes carrying fluids, more particularly under high pressure, shall be able to withstand the foreseen internal and external stresses strains.	Verify, by visual inspection, the conservation status of equipment and pipes, their fixing, connections and if any oil leaks are existing
Loss of power/torque.	They must be securely fastened and protected against external events of any kind.
Loss of control of the suspended load. Loss of stability of the equipment.	The necessary measures shall be taken in case of rupture of these pipes, in order to avoid uncontrolled movements or high-pressure jets.	For hydraulic pipes, check their visual status and tightness (connections to devices, cylinders ...), as well as the retaining position system and appropriate protective devices (jacket, duct ...) protecting against the risk
		of rupture, bursting projection.
Check the condition of the pipes and the lack of:
Cuts,
Cracks,
Earthing system,
Fittings clearly not adapted to flexible pipes,
Brazing or welds for repair,
Replacement of rigid pipe by a flexible pipe between a controlled check-valve and cylinder,
Insufficient radius of curvature of the pipe,
Holding device in the case of leak or burst.
Check the condition of the cylinders, (body and rod) and lack of:
Distortions,
Scratches on the piston rods,
Hydraulic leaks,
Brazing or welds for repair (more particularly on the base of the cylinder body).
10.  Lighting, signing, traffic lights, flashing beacons
RISKS	CONTROL MEASURES	METHODOLOGY
Traffic accidents may be due to the lack of lighting on the truck or insufficient lighting of working zones or areas.	When trucks are supposed to be used during nightfall or are expected to circulate in poorly lit areas, they must be equipped with warning devices.	Check, if any, proper condition and operation of lighting equipment installed on the vehicle.
	In case where the device is operated on a highway, it must be signaled towards to other vehicles with a flashing beacon and lighting devices in compliance with the highway regulation.
11.  Constitution, fastening device, foot rack
RISKS	CONTROL MEASURES	METHODOLOGY
Operator's injuries as a result of:     Fire and rapid destruction of the cabin,    Shearing or crushing when moving near fixed elements,    Clashes with the projections.	The cab shall be arranged so that the driver is able to see the operation at any time.	Check by visual inspection the condition of the cabin.
	The cabins shall be equipped with screens to prevent contact between the operator and moving parts.
	The cabin floor is by design or by adding a coating to be non-slip type.
Poor visibility causing errors on operation.
Check the good condition of:
The structure and fastening devices and trim panels of the cabin,
The supporting the driving position,
The operator’s visibility is not hindered by the addition of elements such as panels, photos, stickers,
The protective devices against the risks of shear,
The cabin (no strain or tear sheet protruding that may injure the operator when accessing or during work).
12.  Operator's protection
RISKS	CONTROL MEASURES	METHODOLOGY
The operator of the crane, when he controls the equipment from the cockpit located at the lower place of the crane, must be protected by a safety roof against falling.	Safety roof designed and manufactured with materials of sufficient strength characteristics.	Check the good condition and fastenings of the safety roof.
13.  Protection of the accessible mobile elements
RISKS	CONTROL MEASURES	METHODOLOGY
Crushing, shearing of staff by a mobile element or any mechanical element in motion.	The manufacturer shall determine the means of protection to be implemented to protect against the risk of contact with mobile elements.	Check that initial protections of mobile elements installed by the manufacturer have not been removed and ensure the effectiveness of their fastenings.
	Prevent, by posting the potential risks and prevent access by unauthorized persons.
	Install adequate safeguards on every pulleys, drums and gears, potentially accessible.
14.  Seat, seat belt
RISKS	CONTROL MEASURES	METHODOLOGY
Fall and projection of the driver in case of imbalance of the forklift or accidental crash during driving.	Setting up a device type seat belt with automatic locking in case of safety block with belt drum.	Check the general condition of the belt, its anchor points on the chassis, its system of opening and closing and locking of the belt winder.
15.  Working visibility (glass transparencywind shield wipers, rearview mirror)
RISKS	CONTROL MEASURES	METHODOLOGY
Improper visibility & difficulty to travel. Crushing or accidental strike with site	The driving position of the crane shall be arranged that the driver during operation is able to see the load and movable parts of the equipment.	Check that windows are cleaned and fixed.
personnel.	The windows must be completely transparent.	Check the good conditions of the mirror and of the windshield wiper.
Check:
The rearview mirror,
Windshield wipers.
16.  Seat
RISKS	CONTROL MEASURES	METHODOLOGY
Loss of control of the load due to failure of seat.	The driver's seat, if it exists, shall be secured to the cabin and arranged to allow easy driving of the equipment.	Perform visual inspection of the state and the fixing (connecting bolts, seat belts and seat adjusting mechanism).
Operator injury.	Convenient position and condition of the seat safe for the operating personnel and well maintained.
17.  Start / Stop
RISKS	CONTROL MEASURES	METHODOLOGY
Non voluntary movement of the equipment (switching on/off of the prime mover) or of one of its parts as a result of an inadvertent action of the operator.	Easily accessible secured device to start and stop from the driving position.	Check the condition of the main power switch. Perform test run.
Accident damage to crane components especially when the crane is undergoing maintenance work.	Proper ergonomic design of main switch
	Main switch with LOTO (Lock Out Tag Out) system or in similar.
Check the status of the device “ON-OFF”
Fixing
Identification
Protection (cover, bellows…)
18.  Lock-out of use (tagging out)
RISKS	CONTROL MEASURES	METHODOLOGY
Using the device by an unauthorized person.	Lock out of the access to the cab and or lock out of the main switch on the ground floor.	Check the closing of the door of the cab and the operation of the locking device.
19.  Other emergency stops
RISKS	CONTROL MEASURES	METHODOLOGY
Crushing or accidental strike with site personnel resulting from uncontrolled movements caused by a failure of the control circuit.	Installation of emergency shutdown system isolating either the power supply or function triggered by undesired functioning of the crane.	Check the ease of accessibility to the emergency shutdown switch. Check the proper functioning of the emergency shutdown switch.
Accidental starting when operating on the mechanisms or device of the equipment.
20. Indicators, signaling and warning devices
RISKS	CONTROL MEASURES	METHODOLOGY
No warning of the driver about configuration and devices status at any time:	Install all the necessary indicators to the safe operation of the equipment (speed, pressure, electromagnets, locking containers, overheating and cable overlap).	Check all the gauges and indicators, prior to starting the equipment.
-  Malfunction of indicators and warning devices can mislead the equipment operator (operator will not be aware of the present working condition of the equipment).		Check that all the gauges are indicating the various parameters, once the equipment is started.
-  Equipment failure due to lack of fuel, coolant over heating, transmission or engine oil overheating.		Check that gauges like engine and oil temperature gauges are properly functioning during operation.
-  Toppling of the equipment when load is lifted due to unlevelled setting.		Check the accuracy of the level gauge installed on the equipment using a portable level gauge.
21. Identification of control devices
RISKS	CONTROL MEASURES	METHODOLOGY
Undesired movement of the load or mishandling causing a dangerous movement of the load.	Control devices clearly identified.	Check the identification of control devices and perform a correlation test (i.e. check the labeling of all equipment control and engage each control to check their functions are as per display).
	Functions in line with the labeled display of the actuator.
Check:
The proper functioning of controls,
The consistency of the movements and pictograms,
The proper functioning of the horn,
The condition and operation of the lighting work,
The automatic return to neutral (fail safe),
The proper functioning of the emergency stop,
	The presence and condition of the device to prevent non-voluntary operations.
22.  Automatic return to neutral point
RISKS	CONTROL MEASURES	METHODOLOGY
Continuous functional movements, when the operator has ceased the movement by releasing the operating actuators.	Automatic return back of actuators to neutral point upon release.	Check the actuators return back to neutral point upon release and all the functions cease to operate.
Inadvertent movement causing accidental displacement of the load.		Check the control and locking devices for proper functioning.
23.  Warning signals
RISKS	CONTROL MEASURES	METHODOLOGY
Crushing or accidental strike with site personnel resulting from movement of the load or of the equipment.	Sound and flashing light sources to warn personnel within the working area.	Ensure that the horn and the light signals of travel work properly.
24.  Protecting devices against unwilling or non-voluntary operations
RISKS	CONTROL MEASURES	METHODOLOGY
Non voluntary movement of the control device causing a fortuitous movement of the load.	Service devices designed to prevent the start of one movement of the crane if not intended by the operator.	Verify the effectiveness of protection against involuntary operation of service devices.
25.  Other unit(s), drawbar
RISKS	CONTROL MEASURES	METHODOLOGY
Loss of control of the forklift due to a failure of the drawbar.	Ensure the automatic return on the rest position is secured with full stop of commands away from the operating areas.	Check the proper operation of controls translation commands according to the inclination of the drawbar (reversal movement device in optimum position).
		Check when the handle is released:
		It automatically returns to its upper rest position,
		The power drive unit is turned off, and the brake engaged,
		When the drawbar is in its lowest position, the power drive unit is turned off and the brake engaged.
Check:
Good operating condition of the lever, handle, drawbar,
Effectiveness of the device in automatic return (smooth movement) of the drawbar to reach its rest position.
26.  Fasteners, clips, straps, clamps
RISKS	CONTROL MEASURES	METHODOLOGY
Degradation, sliding or breakage of the cable causing the drop of the load.	Cable ties (clips, anchor or lock pins) complying with the manufacturer's instructions.	Check that the cable ties are set in accordance with the manufacturer’s instructions.
Slip off the load along with hook block from the wire rope.		Check that the ties of the fixed points of the cables are correctly implemented.
		Check for rigidity, damage or deformation of clips, anchor pins/lock pins.
		Check for loose nuts and condition of locking pins.
Check:
The fasteners of the endpoints show no abnormalities, such as correct position of the cables with respect
to fasteners and properly positioned and secured on the device they are connected,
That the devices do not show abnormalities such as cracks, unscrewing ...
The cables at the end of fasteners on the equipment do not slip or rupture of wire ropes.
27.  Fastening devices
RISKS	CONTROL MEASURES	METHODOLOGY
Drop or slipping of the load.	Use of accessories according to the manufacturer’s instructions. No homemade or inadequate repairs.	Check by visual inspection the condition of the fastening devices
Injury of people in the working area..		(no distortion, no wear, no corrosion, no crack...).
28.  Main runners and lines, guys (Wire ropes or chains)
RISKS	CONTROL MEASURES	METHODOLOGY
Drop of the load due to failure of the lines.	Install suspension lines fitted to the constraints and conditions of use.	Check by visual inspection the mains runners and lines.
	Many causes can generate a rapid wear and failure of the lifting component: Wire ropes & chains:
	Mismatch of cable or chain to use,
	Mismatch of cable diameters versus grooves of the pulleys,
	Wrong stranding or wrong mode of winding of the cable on the drum,
	Wrong duty ratio (load/ Safe Working Load),
	Poor implementation of fasteners.
Wire ropes
Ensure the cables are not worn or defective an check the proper condition of cables. Apply the cables removable criteria:
Broken or cut strands
Flat areas caused by wearing
Reduction of the diameter over than 10%
Excessive distortion, crashing…
Note: ISO 4309 provides details on:
Maintenance, installation, testing and removal of cables,
Failure of a strand or the core of a cable,
Rupture of external and close wires of a cable (one or two rope lays),
Apparent and significant wears (that occur on the portion of the cable in contact with pulleys or friction areas),
Corrosion (with complete disposal as soon as a wire is attacked and starts to lose its section),
Important distortion (cable bent, flattened, unstrained ...),
Reduction of section when the cable is winded on pulleys.
Pay attention to:
Parts of the cable subjected to simple bending (on drum),
Parts of the cable subjected to alternating bending (on pulleys),
Parts of the cable subjected to permanent bending (pressure pulley balancing),
The ends of the cable clamps (drum, fixed point),
Any portion of the cable subjected to a deflection,
Any portion of the cable subjected to any force other than pure tension.
CHAINS
Check by visual inspection that the chains are not worn or defective. Terms for disposal :
The strength of a chain being the strength of the weakest link, it should
discard the chain that have a link :
-    worn (max 10% ND of the wire),
-    bent
-    elongated (max 10% of rope lay)
-    flattened
-    un-stranded
-    cracked
ROLLER AND BUTT-JOINED LINK CHAINS
Chains:
Ensure that the chains do not show wear or defects likely to reduce their strength,
Check the condition of chains,
Apply the criteria for removal of chains.
For butt-joined link and roller chains ask for replacement of the whole chain where they are:
Twisted,
Having a broken link or bent link ...
Which is longer over 3% of the nominal length.
29.  Drums, pulleys, rope blocks, drive pinions, windlasses
RISKS	CONTROL MEASURES	METHODOLOGY
Degradation, disruption of cable due to poor surface of the drum or of the pulley, to a winding ratio is too low or its escape from the drum or from the pulley.	The manufacturer determines the special design to overcome these risks.	Ensure that minimum 3 wraps of the wire rope remain on the winch drum when the hook is at the lowest position.
	They also concern the installation of anti-bleeding on the pulleys and guard cables on the drums	Ensure that the number of eligible layers and diameter of the wire rope is as per manufacturer’s specification.
		Check by visual inspection the condition of the drum and pulleys (surface flanges) and check the fit to the profile of the cable drum grooves.
Check the good condition:
No unwanted marking on drum grooves,
Presence of a cable guide device,
Presence of the anti-ungroove system,
Presence of stop devices on the axis,
No excessive clearance on the pulleys.
30.  Speed limiting device (no runaway)
RISKS	CONTROL MEASURES	METHODOLOGY
Loss of the speed control during descent of the load, over-speed. Possibility of mechanical failure and / or loss of balance in the equipment.	The mechanisms involved in the movements of elevation and descent shall be equipped with speed limiters.	Check by visual inspection the status of the power-train and its supply.
		Perform a safe working load test and direction of travel of the load. Check the function of over speed limiter in engine.
		Check the functioning of controlled load lowering mechanism.
Check the general condition:
Of the different devices (engine, gearboxes, couplings, cylinders):
Fixing,
Clearance,
Wear,
Distortion.
In its supply (cables, ducts, junction boxes, fittings ...):
Fixing,
Distortions,
Crashes,
Leakages.
Verify the effectiveness of speed limiter by implementing the tests described hereafter :
Ask the operator to hoist the load (low speed if available), Stop the lifting,
Check that the load does not initiate a downward movement
Load hoisted, ask the operator to lift once again:
Ensure load up without starting a downward movement,
Stop the lifting,
Check that the load does not initiate a downward movement.
Duplicate the procedure for every available speed on the equipment.
Lift down for each existing speed.
Ensure that during the descent of the load, it keeps a constant speed.
31.  Locking devices and any other brakes
RISKS	CONTROL MEASURES	METHODOLOGY
Use by a non-authorized person or unlocking of accessories, bringing drop of the load and roll over of the equipment.	Manual or/and automatic locking of movement or equipment by design or by lock	Check the general status and the proper functioning of brakes and locking devices.
	protection/holding interlocks or safety locks.
32.  Hoist brake
RISKS	CONTROL MEASURES	METHODOLOGY
Loss of control of the suspended load due to lack of efficiency or failure of the stopping devices, and injury to personnel.	Hoisting mechanisms fitted with breaking system or equivalent devices able to stop or to maintain on position the highest loads (including overloads for testing).	Check the condition and proper functioning of the braking systems, including fittings, hydraulic system and other components if it does not require disassembly of covers or guards.
	Stop and lock of the stop functions automatically ensured when the operator is no more acting and even in case of interruption of power supply.	Check the effectiveness of the braking system by carrying out brake test with test load.
During the downward movement of the load, make several intermediate stops and check that the load does not slip down.
The load shall not move downward during an extended stop.
Ensure that:
The control system has no distortion,
That the braking system are type of “stop at rest”
33.  Power and gear transmission system
RISKS	CONTROL MEASURES	METHODOLOGY
Drop of the load or loss of control of the movement resulting from the failure, insufficient or total loss of horizontal and vertical power and gear transmission system.	Condition and use of the equipment as per manufacturer's instructions.	Check by visual inspection that the state of mechanism is not likely to cause malfunctions.
Loss of movement control due to an important clearance or the separation of elements of bodies contributing to the transmission of movements.	All connecting members and transmission components in place, rigidly fixed and tightened, and periodically maintained.	Check by visual inspection the good conditions of mechanisms without removing: gears, couplings, clutches, chain or belt transmissions (adequate tightening and sufficient tension), shafts bolting and mounting bolts (in place and rigidly and adequately tightened).
	No homemade components used.	Ensure by testing for correct operation of mechanisms (noise, clearance…).
		Check the lack of oil leakage from gear box, oil seals and the sufficient lubrication of power transmission components.
Check the condition of the pipes and the lack of:
Cuts,
Cracks due to aging or overheating,
Metal braid,
Fittings clearly not adapted to flexible pipes,
Brazes or welds for repair,
Replacement of rigid pipe by a flexible pipe between a controlled check- valve and cylinder, insufficient bend radius of piping,
Check the condition of the cylinders, (body and rod) and lack of:
Distortion,
Scratches on the piston rod,
Hydraulic leaks,
Brazes or welds for repair.
Ensure that I case of failure of flexible pipes, the load will not move downward and those devices are connected to the cylinder by a rigid pipes in case they are not flanged on the cylinder.
34.  Travel brake and parking brake
RISKS	CONTROL MEASURES	METHODOLOGY
Travel brake	Travel brake	Travel brake
Loss of control by the driver, following failure of devices able to secure and maintain stopped the forklift.	A braking system to be used during operation, controlled by the driver from his driving position, without setting out the operating device.	Verify, by visual examination, the presence and location of the braking system and its operating device.
	This device must act on the wheels and running gears available symmetrically on both sides of the whole equipment (wheels and running gears of the vehicle).	Check by a loading test performed under the conditions as defined above, the stopping distance of the forklift.
Checked by visual inspection:
Presence and location of the braking system
Condition of its operating device (lever, pedal ...)
Anti-slip brake pedal.
Check by load testing:
Braking is effective in normal operation and in case of emergency braking.
Stopping distance is sufficient and accurate,
Braking is balanced (identical braking on the wheels) with no skidding during braking.
RISKS	CONTROL MEASURES	METHODOLOGY
Parking brake	Parking brake	Parking brake
Inadvertent movement of the forklift when the driver is not at his work station.	A brake can be put into action directly from the cab by the driver and able to keep the forklift tied-up, including during the strongest gusts of wind.	Stop the forklift on any slope
		Ensure the effectiveness of the brakes by one of the following tests:
	The brake can be automatic action when the driver leaves his driving seat.	Ask the driver to act on the brakes, the forklift traveling at very low speed,
		Attempting to start when brakes are locked.
Check by visual inspection:
presence and location of the braking system,
condition of its operating device (lever, pedal ...).
35.  Limit stops relating to lifting motions
RISKS	CONTROL MEASURES	METHODOLOGY
Distortion or failure of the components or cable causing the drop of the load or the rollover of the equipment due to overrun the amplitude of the lift.	Safety systems are defined by the manufacturer. The instructions specify their functions and thresholds setting.	Read carefully the manufacturer’s instruction (record safety devices). Check the condition and operation of the limit switch during testing. Check if available the automatic slowdown movement before its stop.
	These systems can be composed of all lifting limiting devices operating in both directions of movement of the hook.
	The stop mechanism may require some pre-slowdown.
Check  the  adjustment of  the  limit  switch  is  not affected by other movement of the boom (lifting, slewing and erection)
36.  Security drawbar
RISKS	CONTROL MEASURES	METHODOLOGY
To be crushed by the drawbar when the equipment is ordered to move backwards.	Install an attendance contact pressure on the top of the drawbar that reverses the translational motion.	Check by testing the proper functioning of the "anti-crush" available on drawbar.
	Use a two-hand control system which mobilized both hands during movement.	Try to move the forklift with one hand (two fingers) or with one hand and any other part of the body (elbow, knee).
		Squeeze two handles out of synchronization (timing offset upper than half second) Squeeze two handles. Depress one handle. Press again without releasing the first one. Check the immediate shutdown without taking off again.
Checked by testing the proper functioning of the "anti-crush" installed on the beam type truck
37.  Control of the forklift by the driver
RISKS	CONTROL MEASURES	METHODOLOGY
Presence of the driver outside the protection zone.	To control the presence of the driver in his cab, it is necessary to install contacts seat, pedals or any contact forcing the driver to keep his legs inside the clearance limit of the truck.	Ensure by testing the proper functioning of contacts.
Shearing hazards due to mobility of the forklift.
Check the good condition of the device and the operational system allowing the power cut off (this fail safe
could be located under the seat or on the floor)
38.  Static Proof load test
Preamble
Records of any major repairs or replacements shall be verified before commencing the tests.
If any wire rope or chain has been replaced, test certificates for the wire rope or chain shall be reviewed and attached to the equipment test certificate
Complete thorough examination shall be performed from the first to the last point described on the previous page of this guide
All safety switches shall be checked for correct operation. Any safety switch overridden during the test shall be re-set and checked for correct functioning after the load test
A line pull test shall be limited to the maximum wire rope pull per line or chain in any configuration.
Test personnel shall be positioned so that they are unlikely to be injured should there be a mishap.
The test area shall be cordoned off to prevent any unauthorized entry to site.
All equipment certificates shall be endorsed with the information necessary to ensure there is no ambiguity as
to equipment rigging at the time of test. All test certificates for equipment shall have load capacity charts
enclosed for verification.
Proof load test of the equipment shall be performed at three different positions of the boom/mast:
Minimum length
Intermediate length
Maximum length
Proof load test shall be performed under 125% of the Safe Working Load (SWL) of each position unless otherwise  specified by the manufacturer. Surveyor shall ensure the accuracy of the weight of the test load.
Surveyor shall ensure that the fly jib and fly hook shall be deducted to determine the test load.
Test load shall be lifted at the slowest speed at a maximum height of 20 cm and for a minimum duration of 15 minutes.
Operator shall take necessary precaution to avoid dynamic or shock loading.
At the end of the test, surveyor shall check that the descent of the load is within acceptable limits specified by the manufacturer.
Surveyor shall ensure that integrity of equipment structure, boom, hook, winch, wire rope and all load bearing members are intact.
To ensure the integrity of the winch a maximum line pull test shall be performed at any of the configurations.
During the tests, stability must be ensured without the addition of external load or devices not covered in normal operation.
39.  Dynamic proof load test
Preamble
Records of any major repairs or replacements shall be verified before commencing the tests.
If any wire rope or chain has been replaced, test certificates for the wire rope or chain shall be reviewed and attached to the equipment test certificate.
Complete thorough examination shall be performed from the first to the last point described on the previous page of this guide
All safety switches shall be checked for correct operation. Any safety switch overridden during the test shall be re-set and checked for correct functioning after the load test
A line pull test shall be limited to the maximum wire rope pull per line or chain in any configuration.
Test personnel shall be positioned so that they are unlikely to be injured should there be a mishap.
The test area shall be cordoned off to prevent any unauthorized entry to site.
All equipment certificates shall be endorsed with the information necessary to ensure there is no ambiguity as to equipment rigging at the time of test. All test certificates for equipment shall have load capacity charts enclosed for verification.
With a load of 110% of the SWL equipment is tested for all its functions.
Boom/mast shall not be extended and lowered from the set position.
Main hoist brake shall hold the proof load.
At the end of the test, surveyor shall check that there is no descent of the load.
Surveyor shall ensure that integrity of equipment structure, boom, hook, winch, wire rope and all load bearing members are intact.
During the tests, stability must be ensured without the addition of external load or devices not covered in normal operation.