Every properly trained forklift operator knows that they must do a pre-operation safety inspection of their forklift and its components before operating a machine for the first time that shift. This inspection, a requirement of the Occupational Safety and Health Administration (OSHA), ensures that before an operator puts the forklift into use, they’ve verified that all of the required components are in place, and correctly maintained. By doing these regular checks, operators can help prevent accidents, reduce maintenance costs, and ensure the forklift is operating at its most efficient. These inspections are holistic, and involve the entire truck, from top to bottom, from the steering wheel to the forklift arms.
But, how exactly do you determine if a forklift fork arm passes inspection? At ICHINEN USA, we manufacture 100% heat-treated fork arms and fork arm accessories developed with quality and safety in mind. We understand how crucial to safety and efficiency fork arms are – a fork arm that needs replacing can put your lifting operations at risk. So, we decided to break down exactly what operators need to look for when inspecting their fork lift’s fork arms during their pre-operation inspection. First, let’s take a look at the components of a fork arm.
The Anatomy of a Fork Arm
Before diving into the inspection process, it’s crucial to understand the parts of a fork arm and how they work together to ensure safe and efficient lifting. In general fork arms have the following components:
- Heel: The heel is the bend where the vertical and horizontal parts meet. This is a high-stress area.
- Blade/Tine: The long, flat part that slides under the load.
- Shank: The vertical part that connects to the forklift carriage.
- Locking Pin/Clip: The mechanism that secures the fork to the forklift carriage.
When all of these pieces are properly maintained and in good condition, fork arms provide optimal lifting and ensure safe maneuverability around the worksite.
Step-by-Step Pre-Operation Checklist
While OSHA’s pre-operation checklist involves the entire forklift, use this checklist to determine the condition of your forklift’s fork arms. It is not intended to replace OSHA’s required pre-operation inspection. All operators should reference this checklist as an enhancement to their regular forklift pre-operation checklist.
- Step 1: Check for cracks and bends. Even small cracks can lead to catastrophic failure. Look for any cracks, especially at the heel. Inspect the blade and look for signs of bending or twisting.
- Step 2: Perform a fork wear thickness test. Over time, the bottom of the fork wears down from dragging and scraping. Using a fork caliper or ruler, measure the thickness of the blade near the heel. Compare this to the original thickness (should be stamped on the fork). If the thickness has been reduced by 10%, the industry standard is to replace it..
- Step 3: Check the angle and straightness. A drooping or misaligned fork can cause the load to slip or become unstable. Visually inspect the fork arm from the side to ensure the blade is parallel to the ground when the carriage is level. Use a straight edge.
- Step 4: Inspect the pins and clips. If a locking mechanism fails, a fork can slide off, leading toa dropped load and serious safety hazards. Ensure all locking pins are present, fully engaged, and not broken or loose.
- Step 5: The carriage and mounting inspection. The carriage is the direct link between the hydraulic lift and the forks. An issue here will affect the entire lifting system. Inspect where the forks attach to the carriage. Ensure there is no wear in the mounting brackets.
Safety Note: OSHA requires that all forklifts be inspected at least once daily, before being placed in service. However, operators should perform a pre-operation safety inspection of any forklift they use for the first time, no matter if it’s the beginning, middle, or end of their shift.
What to Do If You Find an Issue
If you determine that your fork arms are in need of replacement or repair, that forklift must immediately be removed from service. Using a lock-out-tag-out system, or something similar, operators should clearly mark the forklift as inoperable and report to their supervisor or management. A forklift that is not ready for service can be a significant risk to your lifting operation’s safety. Take these steps to ensure you properly report maintenance issues during your pre-operation check.
- Do NOT operate your forklift. Immediately tag out and remove it from service.
- Report the issues to your supervisor or the maintenance department.
- Document the issue and the forklift’s serial number in your operation maintenance logs
Make Safety a Habit
Taking just a few moments before operating a forklift for the first time during your shift to conduct a pre-operation inspection can prevent costly damage to machinery and product, and also potentially save lives. Just like putting on your hard hat or other protective gear, make inspecting your forklift’s fork arms daily part of your routine. Building a safe and efficient operation is everyone’s role. Don’t let worn, bent, or cracked fork arms get in the way of your ability to work safely.
If you are in need of replacement fork arms, please take a moment to look at our selection of 100% heat treated standard and premium forks. And, if you’re looking for replacement fork arm attachment accessories, ICHINEN USA is there for you, too! Contact us today to learn more!