Fork inspections requirements

A A MIMIMUMMIMIMUM of of 1212 Month Month Inspection of Forklift ForksInspection of Forklift Forks

Show me that Inspection Sheet the OHS Officer Will

Ask!

Fork Inspection & MaintenanceFork Inspection & Maintenance

Forks are a critical part of the everyday operation of lift trucks. The stresses, strains and shock loadings to which these parts are subjected, make it important to regularly inspect them and to replace them when worn or damaged.

Fork Inspection & MaintenanceFork Inspection & MaintenanceWhy You Should Inspect Your Forks!

When Worn or Damaged Forks are Not Replaced . . . The Potential for Fork Failure is Significantly Increased

Do you Do you HaveHave

a a InspectioInspectio

nnTool?Tool?

Rated load capacity. Are the forks rated to carry the loads they are handling?

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.

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.

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 lubrication 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.

Fork Inspection & MaintenanceFork Inspection & MaintenanceHow Does Fork Wear and

Damage Occur? Improper Chain Adjustments Improper Operation of Truck Normal Wear From Use Over

Time Use Beyond Rated Load Capacity Application Environment Tire Wear

Fork Inspection & MaintenanceFork Inspection & MaintenanceWhat Can Routine Fork Inspections Do

For You? Reduce Downtime Due to Fork

Failure May Prevent Personal Injuries or

Property Damage Due to Fork Failure

Help Point Out Operator Error or Abuse

Fork Inspection & MaintenanceFork Inspection & MaintenanceHow to Determine Fork Condition

Inspect For Surface Cracks Check For Straightness Of The Blade

Or Shank Check For Excessive Fork Angle Check For Different Heights of Fork

Tips Inspect For Positioning Lock Damage Inspect For Normal Wear Over Time

Straightness of Blade and ShankThe straightness of the upper face of the blade and the front face of the shank shall be checked. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively, the fork must not be returned to service until it has been repaired in accordance with Regulations

Fork Angle (upper face of blade to load face of the shank)Any fork that has a deviation of greater than 3° from the original specification must not be returned to service. The rejected fork shall be reset and tested in accordance with legislation

Difference in Height of Fork TipsThe difference in height of one set of forks when mounted on the fork carrier shall be checked. If the difference in tip heights exceeds 3% of the length of the blade, the set of forks shall not be returned to service until repaired in accordance with legislation.

Positioning Lock (when originally provided)It shall be confirmed that the positioning lock is in good repair and correct working order. If any fault is found, the fork shall be withdrawn from service until satisfactory repairs have been affected.

Wear Fork Blade and Shank – The fork blade and shank shall be thoroughly checked for wear, special attention being paid to the vicinity of the heel. If the thickness is reduced to 90% of its original thickness, the fork shall not be returned to service.– Fork Hooks (where originally provided) – The support face

of the top hook and the retaining faces of both hooks shall be checked for wear, crushing and other local deformations. If these are apparent to such an extent that the clearance between the fork and the fork carrier becomes excessive, the fork shall not be returned to service until repaired in accordance with legislation

– Legibility of Marking (when originally provided)If the fork marking in accordance with legislation is not clearly legible, it shall be renewed. Marking shall be renewed per instructions from original supplier.

Fork Inspection & MaintenanceFork Inspection & Maintenance1. Inspect For Surface cracks

Fork Inspection & MaintenanceFork Inspection & MaintenanceInspect For Surface Cracks Pay special attention to the heel and

to the welds attaching all mounting components to the fork. Cracks are

more likely to occur at these areas. Each fork must be tested for surface cracks with a non-destructive test, such as magnaflux, every six months. If a crack is found, the fork must not be used.

Fork Inspection & MaintenanceFork Inspection & Maintenance2. Check For Straightness Of

The Blade or Shank


Check For Straightness Of The Blade Or Shank

Check the upper face of the blade and the front face of the shank. If either surface is not straight, the fork must not be used.

Fork Inspection & MaintenanceFork Inspection & Maintenance3. Check For Excessive Fork

Angle

Fork Inspection & MaintenanceFork Inspection & MaintenanceCheck For Excessive Fork Angle

Standard forks are manufactured with a 90 degree angle. If that angle exceeds 93 degrees, the fork must not be used.

Fork Inspection & MaintenanceFork Inspection & Maintenance4. Check For Different Heights

Of Fork Tips

Fork Inspection & MaintenanceFork Inspection & MaintenanceCheck For Different Heights of Fork Tips

The difference in height of the fork tips must not exceed 3% of the length of the blade. If so, the forks must be replaced.

Fork Length 48 In. 72 In. 96 In. 3% 1.44 In. 2.16 In. 2.88

In.

Fork Inspection & MaintenanceFork Inspection & Maintenance5. Inspect For Positioning Lock

Damage

Fork Inspection & MaintenanceFork Inspection & MaintenanceInspect For Positioning Lock Damage (Hook Type Forks) Check to see that the positioning

lock is in good condition and proper working order. If the lock is not working properly, the fork must not be used until the positioning lock has been replaced.


6. Inspect For Normal Wear Over Time


Inspect For Normal Wear Over TimeOver the course of their effective life forks wear. The principal areas of wear are the heel and blade. The amount of wear can be determined using calipers for measurement. If the percentage of wear is in excess of 10%, the forks must be replaced.


Never weld, grind, heat, or attempt to repair forks. Damaged or worn forks must be replaced.


Wear Vs. Capacity Wear Vs. Capacity

20 40 60 80 100

Percentage of Reduction in Blade Thickness

Pe

rce

nta

ge

of

Ori

gin

ial

Fo

rk S

tre

ng

th

A Fork Reduced By A Fork Reduced By 10% In Blade 10% In Blade Thickness Has Lost Thickness Has Lost 20% Of Its Original 20% Of Its Original Strength And Should Strength And Should Not Continue To Be Not Continue To Be Used.Used.

100

80

60

40

20

0


What Will You Receive From The Inspection?

You Will Receive A Management Report Summarizing The Fork Condition And Recommended Action For Each Truck In Your Fleet.

May We Schedule Your Fork Inspection

Now?

Law

Fork inspections requirements