Just wondering if anyone out there has this problem of getting forklift operators to conduct the basic checks - radiator water, battery water, engine oil and brake oil - before using the forklift?
In my workplace, most if not all, would just jump on and drive.
My immediate concern here is the checking of radiator water. Not many people know how to safely open the radiator cap esp when the engine is still hot. So, injury can happen if one is not careful. One school of thought is to use wet rag to cover the cap and turn it, while another school thinks that one should use DRY rag.
Can someone share their wisdom?
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Hi chewingyu,
As mentioned in previous posts, training is a must. You can't successfully put in a system unless it is implemented correctly. Quiet often a verbal one off training session does not always hit its intended audience and a more visual approach is needed. Scafftag not only offer a tagging inspection product but also FREE inspection posters that can help with your implementation by displaying these around your work place. Our Forkliftag is a durable, weatherproof inspection tagging system with an easy-to-follow checklist to be completed daily by the operator. The checklist is found on the front side of the insert whilst the facility to record up to 30 inspections can be found on the reverse side. The insert is placed in a holder that is permanently attached to your forklift. The holder also displays the warning message "Do Not Use" which can be quickly displayed by simply removing the insert if an inspection finds a fault. Inserts may also be filed away once fully completed, providing an audit trail of your inspections. A more comprehensive paper trail can be achieved by using our Black Book. The book not only contains risk assessment guidance, operator training records and registers but detailed carbon copy reports of all your inspections & faults. Why not check out our website today to download a Forkliftag brochure and view our entire product range which help make your workplace safer!
Why is any one checking the fluid levels when the fork lift is hot ? (unless it is at the change of shift ? not mentioned in your query ? ) The logbook we use is simple and the daily check is done at the begining of each day of use which in Australia is compulsory and must be recorded, common sense is the required if you don't have that how did you get a forklift licence ? Check the web for an australian supplier of logbooks put in OH&S logbooks they have 38 various books for many industries.
Lift Truck inspections will NOT be done unless there is an enforced policy by the employer, it's that simple. Water: most newer truck have an overflow tank and the water is checked in this tank visually. Radiators with an overflow tank are vaccuum sealed and we should not open the cap. We also don't know how hot the water might be.
If the employer cannot prove they have a documented inspection for the start of each shift, it is the employer that could be charged.
The key to any successful inspection is the K.I.S.S. theory, "Keep It Simple Stupid". In other words, the safety items must be working, i.e., brakes, horn, back-up alarm and/or flashing light. Add a few more things like fluid leaks and that's it. A good inspection is a visual walk around + a mechanical/hydraulic check that will take 2 to 2 1/2 minutes and it's just the critical things that need to be recorded on the checklist.
One final thing: if you have more than 1 driver on the lift truck for that shift, the inspection should be kept on the lift truck for the entire shift so all drivers can confirm it has been done and finally, each driver, every time they get on a lift truck, they should take 2 seconds to ensure all safety items mentioned above are still working. Nothing documented, just a check and if any are not working it's instant lockout or tag out - remove the key.
Training is a must for Pre-shift safety inspection. Operators should also know how to classify Okay/Not Okay/Major and Minor issue. The challenge is, how would you ensure that operator performs inspections PRIOR to operation?
Access Control Group offers system which forces each operator to perform an electronic checklist, if not he/she can't use the equipment. Any failure is sent instantly to desired personnel via email and optionally lift truck can be placed in Tag Out mode so only supervisors or mechanics can use the truck. The system, also eliminates paper checklist.
In addition to the checklist, it also monitors abuse, utilization and maintenance based on actual utilization so you can avoid over/under maintenance. You look up them on web as Access Control Group, Mountainside, NJ. or assetor.net.
We use operator daily inspection cards. On this card is a list of all items to be checked by each operator before there shift. Before this type of procedure can be used it's recommended you train the operators on how to inspect your units; this should also be part of operator training certifacation. Once this is implemented it's up to the Supervisors to make sure the operators are doing the inspections properly. Your Maintenace tech should be able to tell if these inspections are being completed. These inpection cards include safety items such as, front and rear lights, alarms, horn, strobe etc... Fluid levels such as, engine oil, coolant, transmission & brake fluid, hyd, Operational inspection such as, brakes mast, carriage, attachments, travel etc... Tire wear & unit damage. We have a total of 21 items the operator checks before operating the forklift. Once your procedures are in place, there need to be be training and supervison.
Do the machines in question not have a header (Overflow, reservoir) tank?
If yes then they really shouldn't need to top up the radiator itself as that is what the tank is for.......to compensate for gains and loss in fluid from the rad.
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