Forklift Service Essentials
Regular and proper forklift service is essential to keeping your forklift running safely. The government requires an annual inspection of your lifting devices - learn how you can keep compliant with their regulations.
Today we are going to share with you all of the forklift service essentials to keep your lift trucks operating safely and efficiently.
We have over 40 years in the material handling industry and we would love to share our expertise and experience with you.
We'll take a look at the recommendations and guidelines set out for forklift service by the Canadian Centre for Occupational Health and Safety. So, let’s get started.
Learn what the Canadian Centre for Occupational Health and Safety recommends for forklift service
Do's and Don'ts of Forklift Service
According to the Ministry of Labour, forklift owners need to keep their lifting equipment in "good condition to prevent mechanical or operational failures."
Also according to the Ministry of Labour, you need to "review preventative maintenance and inspection reports and follow the manufacturers' instructions for recommended maintenance schedules and practices."
Here are some of the most essential forklift service recommendations as outlined by the Canadian Centre for Occupational Health and Safety (CCOHS).
Forklift Service Do's
1. Follow your manufacturer's maintenance and servicing schedule. Your manufacturer will outline when each type of service should be done.
It is important to have it done when recommended to avoid costly repairs and to keep your forklift running smoothly.
2. When working on lead-acid batteries or battery-charging equipment, always wear the proper personal protective equipment including:
Safety goggles
Face shields
Aprons, gloves, and rubber boots
If you are changing an LPG fuel tank, then you should always wear leather gloves. The following video shows you how to properly change a gas tank.
Wear protective gloves when changing the LPG tank on your forklift
3. Always attach a chain hoist to the counterweight before you try to remove it.
4. Always cover the top of your battery with insulating material and always handle your battery with care.
5. Securely support your forklift hood upright or remove it completely before you begin working on it.
6. Always keep your work area clean and tidy, cleaning up any liquids such as hydraulic fluids or oil that may have been spilled. Tidy up your parts, cans, tools and other obstacles as well.
Keep your working area well ventilated
7. Make sure that your area is well ventilated before you run LPG, gas, or diesel forklifts.
8. Use a hoist or leverage tools when lifting or moving heavy parts and equipment.
9. Ensure your forklift truck or forks are securely supported by approved blocks before you begin to do any forklift service beneath it.
Forklift Service Don't s
1. Don't begin removing the wheels of your forklift until you have securely placed your forklift on blocks so that it doesn’t move when you are working on it.
2. Don't let hoisting chains, tools, or other metal objects come in contact with your battery terminals.
3. Don't let any unqualified person service or maintain your forklift equipment. This includes working on attachments that you are unfamiliar with.
Only a trained professional should work on your forklift
4. Don't start up your forklift or begin driving it until you have found out why it is in for servicing. Don't start it when it is on a lift hoist or wheel stands.
5. Don't start any repairs before first checking the operator's daily checklist. At the beginning of each shift, your operator must do a pre start checklist. Refer to this list for any issues that were detected.
6. Don't start up your engine until you have checked that you have removed all of your tools and extra parts.
7. Don't light a match, smoke, or weld if you are in or near a battery charging area or refuelling spot.
Learn what parts of your forklift need to be inspected before each shift
Forklift Service: Things to Inspect
The following are some additional tips and things to inspect as recommended by the CCOHS:
1. Take a close look at the bolts holding the counterweight to the body of your forklift. If any bolts look worn out or if any are missing, you need to replace them.
2. During your annual inspection of if you have noticed any cracks appearing before this inspection, you should do magnetic particle testing.
This type of testing is non-destructive and will help you discover any defects of cracks at or near the surface of the metal.
See how magnetic particle testing is carried out
3. Use magnetic particle testing to inspect other parts of your forklift such as your hoses, couplings, fittings and connections to the cylinders in the main mast assembly, as well as your tilt control system.
4. Take a close look at your forks to make sure that none of the sections are twisted, bent, distorted or damaged. If you see any defects, you should test them out.
5. Test to see that your forklift is able to lift and handle the maximum recommended capacity limit.
You need to carefully inspect the various parts of your forklift - Image Source: Created by Tynt22 using Adobe Photoshop. [CC BY-SA]
Types of Forklift Service Report Inspections
The Canadian Centre for Occupational Health and Safety recommends three different types of forklift service report inspections: a planned maintenance inspection, an annual planned maintenance inspection, and a lifting capacity inspection.
All of these inspections need to be done by a "trained, qualified maintenance technician."
Planned Maintenance Inspection:
Your forklift manufacturer will probably have a recommended interval for carrying out your planned maintenance inspection. If they do not, then this inspection needs to take place about every 200 hours.
Annual Planned Maintenance:
Once a year or every 2000 hours (whichever one comes first), you should perform an annual planned maintenance inspection.
Wayco can perform your annual forklift service inspections
Listing Capacity Inspection:
A lifting capacity inspection needs to be carried out as often as your forklift manufacturer recommends it - at least once a year.
This will determine whether or not your forklift is capable of lifting and carrying the maximum load that is specified on its nameplate.
In addition to annually, this type of inspection also needs to be done each time the forklift is purchase by a new owner and before it is being used for the first time.
The Annual lifting inspection needs to be carried out by a competent person.
The Occupational Health and Safety Act defines a competent person as someone who is trained, knowledgeable, experienced and qualified to thoroughly examine your lifting equipment, and has the appropriate and theoretical knowledge of the equipment.
Wayco Can Perform Your Annual Forklift Service Inspections for You
At Wayco we have trained personnel who meet the OHSA requirements to be able to carry out your annual forklift truck safety inspection.
Upon completion of our full vehicle inspection, we will let you know the exact condition of your equipment and once it is found to be in proper working order, we will certify your equipment for you.
You need to have this type of up-to-date inspection documentation available to show government inspectors when they come to your facility. Contact Wayco today to set up your annual inspection.
Need a New Forklift? Wayco Has the Best Forklift Warranties in the Business
If you are in the market for a new or used forklift, talk to the professionals at Wayco. Wayco offers the best warranties in the business for both new and used forklifts so you can purchase with confidence!
“Our company shopped around for the most competitively priced lift equipment repairs and rental services in the KW region and found Waco Multi Lift Inc. Their repair rates were lower than the other companies out there and the service is prompt and professional for our in house lift trucks. ..” […Read more]
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2021 Guide to Forklift Inspection
You are required by law to carry out a regular forklift inspection on all your power lifting devices, from fork trucks to pallet jacks; whether they are gas, electric, propane or diesel
Remember, you are required by law to carry out a regular forklift inspection on all your power lifting devices, from fork trucks to pallet jacks; whether they are gas, electric, propane or diesel, to ensure their safety. Book your inspection today with Wayco's competent inspection personnel.
If You Own a Forklift, You Must Get It Inspected
As a forklift or lifting device owner, it is your responsibility to make sure that you get all of the inspections done that are required by law. Lifting devices include equipment such as forklift trucks, cranes, hoists, lifts, and elevating platforms.
It is a good idea to establish procedures that will ensure the regular inspection and repair of your lift trucks, and make sure that these inspections get carried out in a timely fashion.
There Are Two Types of Forklift Inspections: Load-Handling Capacity & General Safety and Maintenance
Load-Handling Capacity Inspections
The load-handling capacity inspection is done to find out whether or not your lifting device is capable of handling its maximum rated load. For example, if a device has a maximum load capacity of 3,000 lbs., then the inspector will determine if that piece of equipment is indeed capable of safely lifting 3,000 lbs.
The following is a forklift inspection checklist of all the areas that should be examined during a load-handling capacity inspection:
Load-handling capacity inspections determine if your lifting device is capable of handling its maximum-rated load
Checklist A: The Load-Handling Device
Manufacturer's Specification Plates
Forks
Attachments
Movement
Checklist B: The Elevating Section
Lift Chains
Mast
Hydraulic System
Welds and Fasteners
Checklist C: The Propulsion System
Brakes
Tires
Battery
Counterweight
The government provides a checklist of areas that need to be checked during a forklift inspection
General Safety and Maintenance Inspections
The guidelines set out by the government of Ontario for the general safety and maintenance of lifting devices are fairly general.
They require that "any equipment is maintained in good condition" as well it needs to be "constructed and equipped in a way to adequately ensure the safety of all workers."
They do, however, provide a checklist of areas that should be examined as part of a general safety and maintenance forklift inspection:
Checklist D: The General Safety of the Powered Lift Truck
Transmission
Tires
Steering
Overhead Guard
Propane Equipment
Other
You need to do an initial inspection before you use your forklift for the first time
An Initial Forklift Inspection Must Be Done When You Purchase a Forklift
You are required to have your lifting devices inspected by a "competent" person before you use it for the first time. You need to make sure that its lifting capacity is what the manufacturer says it is.
New Lifting Devices: Any new forklift equipment that you purchase needs to be examined before you use it for the first time.
The purchaser - not the seller - is responsible for making sure that this takes place. this is because a forklift dealer could make modifications to the forklift that alter the manufacturer's specifications and make them invalid.
Used Lifting Devices: When you purchase a used forklift device, you also have to make sure that the lifting capacity matches the manufacturer's specifications. You have to have this done by a "competent" person before you use it for the first time.
Leased Lifting Devices: Unlike new and used purchases, it is the responsibility of the company supplying the leased lift truck to carry out the initial inspection of the load capacity. You, the purchaser, are responsible for any ongoing inspections.
Ongoing Inspections Must Be Done at Least Annually
According to clause 51(1)(b) of the Occupational Health and Safety Act, you need to do a forklift inspection "as often as necessary but not less frequently than recommended by the manufacturer and in any case at least once a year."
If you use your forklift for single shifts, which equals about 2,000 hours, then once a year will meet this requirement. If you use your forklift more often than this, then you should have it inspected after every 2,000 hours of use.
You should also have it examined more often if you are operating your devices in severe environmental conditions, such as in areas that are extremely hot or in corrosive environments.
You should have it inspected after every 2,000 hours of use.
A Pre Shift Inspection Must Be Done Before Each Use
A pre-shift inspection must be carried out before you operate your forklift every time. At the beginning of each shift, you need to carefully inspect your lifting device.
During your daily maintenance check, you should take a careful look at the following:
Forks - look for weld breaks, raise and lower the forks with and without a load
Tires - check to see if there are any chunks of rubber missing
Piston - check to make sure there are no leaks or drips
Hydraulic hoses - look for any punctures or cuts in the hoses
Chain - make sure that the tension on the chain is tight
Carriage - look for any weld breaks
Seat belt - make sure it is in good repair
Propane tank (if it has one) - make sure it isn't loose
Radiator - make sure that there isn't any debris or trash caught in it
Emergency brake and accelerator - make sure that they are functioning properly
Controls - ensure that they are all in good repair
Safety lights, battery, alarms, & horn - make sure they are all functioning properly
Fluid levels - check your engine oil, fuel, radiator water, and hydraulic fluid levels
If you find that during your inspection any of the above items are unsafe or need to be repaired, your forklift needs to be taken out of service, red-tagged, and repaired before you use it again. The following video will demonstrate how to effectively carry out a pre-shift inspection.
Find out how to perform a pre shift inspection
Here's What to Expect When You Have a Government Inspection
From time to time, your lifting devices may be inspected by a government forklift safety inspector.
If you follow the recommended guidelines for having your equipment inspected annually and you perform all of the required maintenance and service, then your inspection should go well.
The following video produced by the Ontario Ministry of Labour will give you a good idea about how a government inspection is carried out and what areas they will be looking at.
Follow the recommended guidelines for having your equipment inspected annually and perform all of the required maintenance and service, and your government inspection should go well
A Forklift Inspection Needs to Be Done By a "Competent" Person
You will need to get someone who is considered "competent" by the OHSA (Ontario Health and Safety Association) According to the OHSA a "competent" person is one who has "knowledge, training, and experience to organize the work and its performance." If you have the following knowledge and skills, you should be qualified to carry out these inspections:
A knowledge of the personal safety practices required to carry out routine and periodic inspections of lift trucks currently in use
Familiarity with the terms used by the Ontario Ministry of Labour's Guideline, of the documents mentioned in the Guideline, as well as industry terminology
The ability to understand lift truck manuals, manufacturer's specifications, drawings, and parts lists
A good knowledge of the purpose and function of all the devices, accessories, and components usually found on powered lift trucks and being able to inspect them to determine whether or not they are working properly
A working knowledge of electrical and electronic control circuit principles
A working knowledge of mechanical principles of structures, machines, mechanisms, etc.
A working knowledge, if applicable, of pneumatic principles
Please Note: It usually takes about 5 years of experience in field service work to acquire these qualifications.
Wayco can do your inspections for you
Wayco Has Competent Personnel to Perform Your Necessary Forklift Inspections for You
At Wayco, we have competent technicians on staff who are fully qualified and experienced in performing the annual and initial lifting device inspections for you as required by the Ministry of Labour.
During our full vehicle inspection, we will carefully examine all of the sections required to make sure that your devices are running properly and safely.
Once your vehicles have been thoroughly inspected and found to be in proper working order, we can certify your equipment for you.
You should keep this safety documentation organized and readily available when a government inspector shows up. Contact ForkliftHub today to schedule your lifting equipment inspection.
Trust Your Forklift Inspections and Maintenance to Wayco
ForkliftHub will help you make sure that your forklifts are well-maintained. They will track and pre-schedule all maintenance work for you so that they are properly serviced. This will help you avoid expensive downtime and you won't have to remember to schedule or book your service work. We'll do it for you.
Wayco also has an incredibly fast response time so you won't have to wait to get your lift trucks back in operation. We can usually have our service tech at your location within 2 to 3 hours and we also guarantee same day.
Wayco Offers Top Quality Service on All Forklift Makes and Models
If you are looking for top-quality forklift maintenance and service, contact ForkliftHub. Our fully equipped service and parts department is open 24 hours a day, 365 days a year.
Our qualified technicians are capable of properly performing maintenance services and inspections of all types. Our knowledgeable staff can keep your equipment in top working condition which means lower repair costs and higher machine efficiency. Contact Wayco today for all of your forklift maintenance and repair needs.
