Daily operational test for forklifts
Forklifts are vehicles for in-house goods transport. They must be able to lift heavy loads reliably, quickly and precisely. This makes them extremely important for smooth operative processes in a company. Also, they are expensive to purchase. The daily testing routine is therefore part of the forklift operator training. Consistent compliance with this testing routine serve reliable prevention of avoidable damage. Read this article to find out what is important when carrying out daily maintenance of your forklift.
Why is the daily testing routine so important?
Forklifts are complex vehicles with a number of different technologies. Today, most industrial trucks are driven with a combustion engine. The diesel forklift or gas lift truck does not only drive the rear wheels, it also provides the mechanical energy for the hydraulic pump. In turn, this provides the necessary operating pressure to move the various actuators. Ensuring a reliable supply of hydraulic oil to the linear and radial motors is also a technical challenge. The more complex the forklift truck is, the more can go wrong. If just one component fails, this often leads to a long day in the workshop, during which the industrial truck is not available. In turn, this slows down the in-house transport processes or even brings them to a standstill.
The daily test routine also helps ensure safety. A faulty forklift truck can be a very dangerous vehicle that can cause serious or even fatal injuries to bystanders, it is therefore essential that the vehicle operator checks the vehicle before starting work.
Many companies have very strict regulations about daily checks of industrial trucks. If regulations are specified, the driver will be liable for any damage that occurred during his shift. Repairs can often total several months salary, which is why forklift operators should take the daily checks before starting work very seriously .
Daily check points on the forklift truck.
In this list, we describe the maximum checkpoints necessary when checking a forklift truck. If the forklift truck is operated with an electrical motor instead of a combustion motor, the motor oil cooling water and fuel do not need to be checked.
The following must be checked before use:
A) Checks on stationary vehicles
1. Walk-around check and visual inspection
2. Check the engine oil level
3. Check the fuel
4. Check cooling water (if applicable)
When walking round the stacker inspecting it, look for suspicious leaks. If there are any leaks of engine oil, fuel, hydraulic oil or coolant, the vehicle may not be started. In this case, the maintenance team needs to be informed immediately and binding agent spread about. Oil stains in particular need to be removed immediately due to the risk of slipping.
But caution: Modern cabin stackers may be equipped with an air conditioning system that discharges excess condensation to the outside. This may look like a leak, but it is a normal part of the operating process.
Other checkpoints are, for instance, damaged lamps, windows, cracks in the casing or loose wires. It is especially important to check whether the fork prongs are locked into position correctly. Otherwise, they could slip out, especially on lifting mechanisms with slewing gear.
Checking the oil level ensures that the engine still has enough lubricant. This is very important. If oil has leaked from the nozzle of the dipstick, this is an indication of engine damage. Likewise, brown foam is an indication of a faulty cylinder head gasket. Here, too, the stacker should not be started, instead the maintenance team should be contacted.
Checking the fuel is particularly important on diesel stackers. A stacker that has been driven until empty requires a complex venting process. The vehicle will not be available during this time.
Gas cylinders are checked to ensure that they are tightly in position and mounted correctly. Batteries must be cleaned, may not leak and the contacts may not be corroded.
B) Checks to be carried out whilst the engine is running
The engine is started, the idle gear engaged and the handbrake pulled. Also, all the lights and the warning indicators are switched on. Now the stacker operator should walk around the vehicle one more time. The hydraulics can be best checked when the engine is running. Leaks are now immediately evident. Also, listen for suspicious noises. Pedals and the steering should still have a good grip and no play. A worn stacker is a dangerous vehicle.
c) Function test
The stacker appears intact and there are no obvious faults. Then all the functions are checked. First, a brake test is carried out. The stacker is moved a few meters, then the operator takes their foot from the gas pedal. The stacker must initiate the braking process immediately. If it does not come to a standstill, the transmission is disengaged and the stacker is brought to a complete stop with the handbrake. Everything else needs to be carried out by the mechanic.
After the driving and brake test, the function of the lifting mechanism is tested. The forks are moved once all the way up and down again. If the fork carrier has hydraulic slewing gear, it is actuated completely once. Then the hydraulics are checked again for leaks. Now a test run is conducted, and brought to a halt at the halfway point. The load may sink, it must be kept at the same height even when the engine is switched off.
Always document tests
Ideally, the company will give the stacker operator a detailed checklist. The stacker operator can work through and archive this list. This ensures that both parties have met their duty of care with respect to checking and occupational safety. Any abnormalities should be discussed immediately with workshop or forklift dealer.