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Appendix IV: Maintenance Checklists

  • Issued: July 1999
  • Content last reviewed: June 2009

The general safety inspection (to meet clause 25(1)(b) of the Occupational Health and Safety Act (OHSA)) and the examination to evaluate a lift truck's maximum load capability (to comply with clause 51(1)(b) of Regulation 851), should be carried out in accordance with the truck manufacturer's specifications. These examinations should cover, but not necessarily be limited to, all the items in the checklists, which follow. Items that should be included in the evaluation of the lift truck's maximum load capability are in Checklists A, B and C. The general safety inspection should cover the items in Checklist D as well.

This Guideline refers only to what should be checked in carrying out a safety inspection of a powered lift truck. No attempt has been made to say how such an examination should be carried out. Instead the Guideline details the qualifications that the competent person doing the examination should have. It is assumed that this competent person will know how to apply the manufacturer's specifications, the principles of good engineering practice and the criteria in applicable standards to determine, for each point on the checklists, whether an item passes or fails. Reliance is also placed on the competence of the maintenance technician to know whether an operational test, visual inspection or more intrusive examination is required.

Every effort should be made to obtain the manufacturer's specifications for the powered lift truck. The examination of the items listed in the following checklists should be carried out in accordance with directions in the specifications.

Checklist A - Load-handling Device

  1. Manufacturer's Specification Plates
    • truck plate
    • attachment plate
    • information shown on the capacity plate matches the truck, mast and currently installed attachments
  2. Forks
    • record fork length, width and thickness
    • in accordance with manufacturer's specifications (note any unauthorized cutting, cracks and heel wear)
    • straightness of blade and shank
    • fork angle
    • fork tip height and condition
    • tube condition
    • welded areas
      • blade and heel
      • hook mount forks
      • shaft mount forks
      • special forks
      • attachments to forks
    • latch pins (where originally provided)
  3. Attachments
    • visual and operational check
    • in accordance with manufacturer's specifications
    • attachment mounting
    • load bearing arms (straightness & twists)
    • pivot points and hinges
    • hanger brackets
    • latch pins
    • stops
    • load backrest condition
  4. Movement
    • carriage free and unobstructed
    • anchors
    • stub shafts
    • bearings
    • weldments/forkbars

Checklist B - Elevating Section

  1. Lift Chains
    • anchors
    • guards
    • elongation
    • wear (with wear gauge)
    • adjustment (as per manufacturer's specifications)
  2. Mast
    • visual and operational check of mast operation
    • mast mounting, bushings and pivots
    • rails
      • straightness
      • wear
    • cross bracing
    • pins
    • chain guiderollers
    • wear strips and guides
    • hoses, pulleys and fittings
    • latches - stops
  3. Hydraulic System
    • lift cylinders
      • anchors
      • piston head guides
      • lines
      • leaks
      • drift test
    • tilt cylinders
      • anchors
      • racking
      • rod end retainer
      • tilt angle (degrees)   Forward _____   Back _____
      • lines
      • leaks
      • drift test
    • set hydraulic pressure relief valves
    • lift/lower levers - identified and in good condition
  4. Welds and Fasteners

Checklist C - Propulsion System

  1. Brakes
    • test operation
    • wheel cylinders
    • master cylinder
    • brake lines
  2. Tires
    • check tire pressure for load-rating capacity
    • check for damage, wear and missing hardware
  3. Battery
    • minimum allowable weight from manufacturer's specifications
    • Manufacturer _______________   Model _________   Serial  No. ________
    • battery weight
    • battery position
    • battery restraining devices
    • leaks
  4. Counterweight
    • mounting
    • unauthorized additions or missing weights
    • cracks

Checklist D - General Safety

  1. Transmission
  2. Tires
    • driving and steering characteristics
    • bonding
  3. Steering
    • check steering wheel for physical damage
    • check steer axles and box
    • operational check of wheel bearings
  4. Overhead Guard
    • secured
    • breaks or cracks
    • missing pieces
    • modifications
  5. Propane Equipment
    • fuel tank mounting system secure
    • fuel tank position pin intact
    • check propane relief valves
    • check hose condition
  6. Other
    • check failsafe components of electrical controls
    • warning devices (lights, bells, whistles)
    • engine operation and emissions
    • seat (secure, belts)
    • seat and handle switches
    • fuel leaks
    • carbon monoxide (CO) emission test

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