1.

0 Introduction

A forklift is a powered industrial truck used to lift and move materials over short distances. Forklift
has a power operated forked platform attached at the front that can be raised and lowered for
insertion under a cargo to lift or move it. Forklifts serve the needs of various industries including
warehouses and other large storage facilities.

Forklift Truck Components

Some common forklift parts are shown in Figure 1, 2 and 3.

Figure 1: Forklift Components

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 Figure 2: Control Levers Figure 3: Mast Assembly

Figure 4: Engine Compartment

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2.0 Terms
2.1 Competent Person
A person who has such practical and theoretical knowledge and experience of the lifting
equipment to be thoroughly examined which enables them to detect defects or weaknesses
and to assess and report on their importance in relation to the safety and use of the lifting
equipment
2.2 Fork
An implement with two prongs used to lift load.
2.3 Mast
The vertical upright assembly of the forklift on which forks are attached and is used to lift,
lower and tilt the load.
2.4 Counter Weight
A mass attached to the rear frame of the forklift to counter balance the load being lifted.
2.5 Working Load Limit (W.L.L)
Maximum capacity of the forklift that it can lift safely.
2.6 Testing
It involves the functional movement of all the parts of the forklift followed by load and overload
testing.
2.7 Load Testing
Lifting the load up to the marked capacity of the equipment.
2.8 Over load Testing
Lifting of load slightly above the maximum capacity of the equipment.

3.0 Scope of Work

A thorough examination of equipment shall be carried out as per BS EN ISO 3691-1:2015, BS ISO
22915-1: 2016 and for fork arms BS 5639-1.

4.0 Pre-Examination

4.1 Receive the job/ work order for the job having details of equipment and contact person.
4.2 Coordinate with site management, discuss and agree the program of work to be carried.
Effective line of communication with site staff attending the thorough examination.
4.3 Equipment manual, maintenance log book record and previous certificate if any, must be
required for technical verification

4.4 Valid certificate of operator and lifting gears to be used during testing is also required /verified.

4.5 Checklist and Test procedure should be at hand prior to commencing activity.

5.0 Site Risk Assessment

5.1 Barricade and isolate the test area of the forklift, restrict the unauthorized access in the test
area.
5.2 Check the ground surface is free from any obstructions and is level, making movement of
forklift easy.
5.3 Check there is sufficient head room for forklift to operate and lift load at height.

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6.0 Thorough Examination

6.1 Verification of Equipment manual, maintenance Log Book / Record and previous certificate
must be required for technical verification during inspection / test.
6.2 The inspector shall equip himself with appropriate safety apparel, equipment and tools.
6.3 The purpose of the planned periodic thorough inspection is to verify the condition and function
of Forklift components
6.4 Fork Inspection
o Check for the markings of the forks on either side of it.
o Inspect the top and bottom fork shank hooks and hook welds for wear and Cracks. If
defects are detected, replacement of the hooks or repairs to cracked welds should
only be carried out by a qualified welder in accordance with the manufactures
procedures.
o A close examination of the fork heel should be undertaken in this high stress area.
Cracks usually propagate near the inside of the heel. Repairs are not to be
considered, replacement forks are necessary.
o Wear on the fork blade thickness should not exceed 10% of the blade thickness.
Repairs are not to be considered.
o Check alignment of the tips of the fork blades. Reject if the difference in height is in
excess of 5% of the length of the blade. Repairs are not to be considered.
o Check the straightness of the upper face of the fork blades; deviations should not
exceed 1.0% of the length of the blade, i.e. 9mm in a blade of 900mm. repairs are
not to be considered.
o Check the angle between the upper face of the blade and the front face of the
shank. This angle should not exceed 95 degrees ( a distortion of 5 degrees).
Repairs are not to be considered.
o Thoroughly inspect all special load handling attachments as installed or as used by
the materials handler.

6.5 Hoisting Chain

o Check for correct chain adjustments, slack hoisting chains allow the forks to ground
with consequential loss of material in the area of the heel
o Loose chains are also subjected to dynamic loading.
o Should loose chains be evident, or any sign of chain wear whatsoever have the
chains removed and cleaned, measure for elongation and inspect closely for cracks
in the leaf links.
o The maximum amount of wear on a leaf chain is 3% elongation (ASME B29.8)
o Examine all anchor pins and bores for wear. Reject if there is a reduction in pin
diameter of 8% and corresponding bore increase.

6.6 Safety warning notices

o There are many safety warning notices applicable to rider operated fork lift, not all
are applicable in all situations.
o Only recommended those which are deemed necessary.
o Too many signs are confusing.
o Typical safety warning notices
 Trained operators only.
 Capacity chart.

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  Fasten your belt

6.7 Electrical
o Check the battery terminals are properly connected and insulated.
o Check all the electrical wires are properly insulated.
o Check functioning of all the lights and indicators.
6.8 Testing
o The inspector shall verify that the Forklift is in good construction, sound material, of
adequate strength and free from patent defect.
o As per relevant standards and check list, the inspector shall conduct inspection and
tests that are deemed necessary and timely as to the condition and age of the
Forklift being examined
o When considered required by inspector, visual inspection can jointed by methods of
NDT that determine the condition of any part of Forklift
o Prior commencing the inspection, the Forklift should be maintained well, be n good
working, free from dirt.
o Test all warning devices and lights to assure they are in operable condition
o Check for any hydraulic leak on pipes, fittings, hoses and rams.
o Check steering rods and linkages.
o All inspections and tests shall be carried out with the Forklift on firm level ground, in
a safe working area.
o Special attention shall be given to critical and high stress areas that are subject to
the most wear and tear during routine material handling operations
o It is important to ascertain the duty cycle as some machines are operated three
shifts a day with correspondingly high rate of wear, when certifying the Forklift that it
is fit for further service.
o It is essential that all wheels and tires are maintained in very good condition as truck
stability is dependent on this for lifting and travelling with the load.
o Check the security of all wheel fixings and for damage, tires for bulges, cracks,
gouges or any other apparent damage. Equal tire pressures are essential.
o Check brakes for any irregularities in operation.
o It is essential that a load chart similar to that of a crane with a telescopic boom is on
board the Forklift.
o Some larger rough terrain Forklift have a safe load or load moment indicator
installed. Check indications against a known load, radius, boom length and boom
angle. Check function of overload detection and warning indication. Verify that in an
overload situation; only motions that permit the materials handler to a safe condition
remain operative.
o Check all welded joints
6.9 Function Testing
o Function tests are carried out with no loads to established the satisfactory operation
of all control devices and to ensure that unlade specified speeds are obtained.
o Check for the tilt and lift mechanism of the cylinders in un-laden condition.
o Check for the signs of any seal leakages in hydraulic cylinders, immediate action to
be taken if any leakages observed.
o Check for the operating controls are performing as per marked directions, steering
mechanism, brakes and lights are working properly.

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7.0 Load Test at Rated Capacity
7.1 Testing process to be started with the safe working load in the beginning.
7.2 A load equivalent to the rated full load shall be raised approximately 1.0 meter from the ground
and left elevated for a period of ten minutes, if there is internal hydraulic leakage then the
creep age must not exceed 100mm in specified time for equipment up to capacity of 10000kg
and 200mm for equipment above the capacity of 10000kg (4.6.3.1 of BS EN ISO 3691-1:2015),
during tilt due to internal failure of hydraulic shall not allow more than 5 degree forward
movement at rated capacity (4.6.3.4 of BS EN ISO 3691-1:2015) .
7.3 On completion of the test, a further thorough examination of the Forklift should be carried out.

8.0 Overload Detection Device

8.1 An overload detection device shall be provided, which gives a clear signal in the cage and
prevents normal starting, in the event of overload in the cage. The overload is considered to
occur when the rated load is exceeded by 20%.
8.2 This European Standard specifies a method of detecting overload, but does not require the
provision of a load-moment detecting device as moment is covered by the stability and stress
calculations in conjunction with the overload detecting device.
8.3 The design and installation of overload indicators and detectors shall take into account the
need to test the Forklift with overloads without dismantling and without affecting the
performance of the indicator or detector.
8.4 If interruption of the power occurs, all data and calibration of the overload detection device
shall be retained.
8.5 Devices shall be protected to prevent damage from shock, vibration and the general use of
hoists including erection, operation, dismantling and maintenance as well as environmental
influences as intended by the manufacturer.

9.0 Re-inspection after load test

9.1 Equipment shall be re-inspected to observe any deformation, damage or leakages happened
to the test equipment.

11.0 Stability of Forklift

11.1 If combined center of gravity (CG) of forklift falls inside the stability triangle then the forklift will
lift the load and remain stable.
11.2 If combined CG falls outside the stability triangle then it will make the lift unstable and forklift
may tip over. (illustrations are given below)

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12.0 Non-Destructive Testing

During thorough examination of a Forklift the competent person might consider it appropriate to
apply NDT techniques to assess the integrity of components. These techniques can assist in the
detection of any material cracks or defects that might grow in service and ultimately lead to failure.
BS EN 473 contains guidance on qualification and certification of NDT personnel and, unless the
operator is working to a detailed written procedure, they should be qualified to Level Two in
accordance with BS EN 473:2000.

The three most common types of NDT used are as follows:

12.1 Magnetic particle examination

In this technique a magnetic field is induced in the area under examination whilst the surface is
flooded with ferrous particles suspended in a liquid. Any cracks or defects cause a
discontinuity in the magnetic field which in turn causes the ferrous particles to cluster over the
defect, indicating its presence by a dark line. This technique is only suitable for magnetic
materials (most structural steels and some stainless steels) and only detects surface defects
and large defects just below the material surface.

12.2 Dye penetrant

In this technique the surface of the material is flooded with a liquid dye which penetrates into
any surface cracks or defects. After a specified period the dye is cleaned off and the surface
sprayed with an absorbent “developer” which draws the dye from any defects indicating the
presence of the defect. The technique is often employed on non-ferrous materials such as
aluminum alloys, but can only locate surface defects.

12.3 Ultrasonic examination

In this technique pulses of high frequency sound waves are transmitted from the surface of the
material into its interior. Any defects or discontinuities cause the sound waves to be reflected
back to the surface where they can be detected and, by measuring the time delay from the
time of transmission, an estimate of the defect’s depth below the surface can be made. The
technique can be used for a wide range of materials and detects both surface and subsurface
defects. However, it requires both a skilled operator and specialist equipment and would
normally be carried out by a specialist firm.

13.0 Reporting
The written reports shall contain the following information as a minimum:

13.1 Client details

13.2 Unique identification number
13.3 Make and Model
13.4 Type of inspection
13.5 Safe Working Load
13.6 Proof Load applied
13.7 Year of manufacture
13.8 Date of Test and Examination
13.9 Location where the test was carried out

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14.0 Acceptance / Rejection Criteria

Type of Defect Acceptance / Rejection Criteria

Manufacturer’s Plate Shall be readable

Straightness of blade Within 1% of blade length

Fork angle Not greater than 5 degree of original angle

Difference not greater than 5% of blade
Height of fork tips
length
Fork Thickness Wear within 10% of blade thickness

Chain anchor pins Pin dia wear <8% of original value

Elongation less than 3% of original value
Leaf of chain
(ASME B29.8)
Malfunction of Brake Not Acceptable

Worn tires Not Acceptable

Hydraulic oil leakage Not Acceptable

100mm where capacity is ≤ 10t
Load creep
200mm where capacity is >10t
Damage Mast Not Acceptable

15.0 Defective Equipment

15.1 Where the test is not satisfactory, a responsible representative of the user shall be informed by
means of a defect report.
15.2 If the test Engineer considers the defect to be in dangerous nature, then arrangements must
be made to ensure that the Forklift is not used until remedial work has been carried out.

16.0 Reference

BS EN ISO 3691-1:2015
BS ISO 22915-1:2016
BS 5639-1

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