MAINTENANCE PROCEDURES

Maintenance Procedures

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

Introduction:

Theprovisionofsafeplantandworkequipmentanditsmaintenanceinasafeconditionis
statedwithinthecompanyhealthandsafetypolicyandisregardedasessentialtocontrolrisks
fromdangerouspartsofmachineryandplantnotably(pilingrigs).Theaimoftheseprocedures
istointroduceandmaintainformalsystemsformaintenanceandservicingofpilingrigsand
associatedancillaryequipment.

Thequalityofmaintenanceisamajorcontributoryfactoraffectingsafetyandoperational
costs.Itaffectstheoperatinglifeofplantandalsotheriskofaccidentsduringorfollowing
maintenance.Thepossibilityofafatalaccidentispresentinmanymaintenanceactivitiesand
includesthecompanysmaintenancework.Safetyduringmaintenanceisheavilyrelianton
humanactivityandaccordinglymanagementwilltakepositivestepstoensuremaintenance
staffaresufficientlytrainedandcompetenttocarryouttheirworksafely.Thismanual
containstheproceduresandinstructionsforgeneralmachinesafetyandmaintenancework.

Objectives:

Theaimoftheseproceduresis:

1.1 Tomeetstatutorydutiesprovideandmaintainsafeworkequipment

1.2
Toenablethecompanytodemonstratethataprogrammeofroutinemaintenance
ofplantandmachineryisinplaceandbeingfollowed

1.3
Toclarifywithpersonneltheformalarrangementsformachinesafetyandtheirduties
forcompliance.

Scope

The machinery safety procedures apply to all types of work equipment and all areas where
plantandworkequipmentisused.

ContentsandRelatedDocuments

1.

2.

Machinesafetypolicyrecognisingstatutoryrequirementsandallocationof
responsibilitiestoimplementthepolicy.
MaintenanceResponsibilities

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
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MAINTENANCE PROCEDURES

GreenPilingPlant
3.
Operatorplantreportsheet

page10

4.
Operatordailyinspectionchecklist

Driven

page11
CFA

page13
Forklift

page15

5.
Operatorweeklyinspectionchecklist

Driven

page12
CFA

page14
Forklift

page16

6.Fittersservicereportsheet

page17

ThirdPartyPlant*

7.
AccessPlatform

page18

8.
ConcretePump

page19

9.
ConcreteDrum

page20

Thirdpartyplantisplantusuallyhiredinfromplantsupplycompanies.Routinedaily
preuseandinuseinspectionsarerequiredtobecarriedoutbyGreenPilingOperatives
butmoreandothermaintenanceandrepairswillnormallybecarriedoutbyhire
company.Sheetsusedforcontrolhereinarenotnecessarilyanexhaustivelistbutall
requirementsshouldbedetailedininstructionswithplantantduringfamiliarisationat
delivery.

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

Objective

Toprovideasystemthatwillensurethatthecompanydoesnotputpersonnelatriskduringoperations
involvingtheuseofworkequipment.Tomeetstatutorydutiesand,or,industrystandardstoprovide
andmaintainsafeworkequipment.

Responsibility

ResponsibilityforcommunicationandcompliancewiththispolicyrestswiththeDirectorsofthe
company.

TheDirectorsshallnominatearesponsiblepersontomanageimplementationofthispolicy.

PreparationofthemachinesafetypolicyistheresponsibilityoftheSafetyAdvisor.

ResponsibilityforensuringthemachinesafetypolicyisadministeredonsiterestswiththeContracts
Manager,RigForemanandtheMaintenanceEngineer.

Eachresponsiblepersonnominatedshallbegivensufficienttime,resource,trainingandinformationto
carryouttheirresponsibilitieseffectively.

TheProvisionandUseofWorkEquipmentRegulations1998(PUWER98)makemoreexplicitthe
generaldutiescontainedintheHSWAct.TheRegulationsapplytoallworkequipment,includingsecond
hand,hiredorleasedequipment.TheprovisionsoftheSupplyofMachinery(Safety)Regulations1992,
asamended,applytomachinerymanufacturedonorafter1January1993.Note(PUWER)(LOLER)and
industrystandardsareapplicabletoPilingRigs.

Interpretation

Thefollowingdefinitionsandtermsareimportantinunderstandingtherequirementslaiddownby
(PUWER98)Regulations.

Inspection
Thismeansavisualormorerigorousinspection,asrequiredbyregulation6carriedoutbya
competentperson,andmayincludeappropriatetesting.

Workequipment
Thisincludesallplant,machinery,toolsorinstallationsforuseatworkthedefinitionwillcover
largemachinessuchaspilingrigsrightthroughtocompleteentitiessuchasladders,hydraulicjacks,
airtools,spannersetc.

Use

IssueDate
May2011

Revision
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RP

LatestReview
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Amendment
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MAINTENANCE PROCEDURES

Thisincludesanyactivitythatmaybeassociatedwiththeworkequipment,suchasstarting,stopping,
programming,setting,transporting,repairing,modifying,maintaining,servicingandcleaning.Unless
otherwisestatedtherequirementsoftheseRegulationsareabsolute,ietheymustbeachieve.
Application
TheRegulationsapplyto:

workequipmentprovidedbyemployersforusebytheiremployeesatwork

workequipmentprovidedbyselfemployedpersonsfortheirownuseatwork

personswhohavecontrolofworkequipment,orwhouse,superviseormanageit.

thewayworkequipmentisused.

Theguidancepointsoutthatthedutyonemployersalsoextendstopersonalworkequipment
providedbytheemployees,wheretheemployeragreestothispracticeandthatonmultioccupancy
sitesarrangementsshouldbemadeforoneemployertoberesponsibleforcompliance.The"co
operationandcoordination"requirementunderregulation11oftheManagementofHealthand
SafetyatWorkRegulations1999(MHSW)isrelevant.

TheCompanyshallensurethefollowing:

Suitability
Equipmentprovidedforworkisconstructedoradaptedsoastobesuitableforitsintendedpurpose.
Thisincludestakingaccountofreasonablyforeseeableworkingconditions,inherenthealthandsafety
riskswheretheequipmentistobeusedandanyrisksassociatedwiththeequipmentitself.Work
equipmentmustonlybeusedfortasks,andundertheconditions,forwhichitissuitable."Suitable"in
thisregulationmeanssuitablewithrespecttothehealthandsafetyofanyperson.Regulation3(1)of
MHSW,ieriskassessment,isrelevant.

Maintenance
Workequipmentismaintainedinanefficientstate,inefficientworkingorder,ingoodrepair,and
whereamaintenancelogisrequired,ieunderotherlegislation(egCHSWR96)or(LOLER)suchlogs
mustbekeptuptodate.However,theaccompanyingguidancedoesrecommendthatmaintenance
recordsarekept.

Inspection
Wherethesafetyofworkequipmentdependsontheinstallationconditions,theworkequipmentis
inspectedafterinstallationandbeforeitisusedforthefirsttime,orafterithasbeeninstalledata
newlocationorpremises.Theinspectionsaretoensurethattheworkequipmenthasbeeninstalled
correctlyandissafetouse.Inaddition,workequipmentwhichisexposedtoconditionswhichmay
causedeteriorationandconsequentdangerasaresultofthatdeteriorationmustbeinspectedat
suitableintervals,andwheneverexceptionalcircumstanceshaveoccurredthatmayhavehadadverse
effectsonthesafetyoftheworkequipment.Theinspectionsaretoensurethathealthandsafety
conditionsaremaintained,andthatdefectsareidentifiedandcorrectedquickly.
Recordsofallinspectionsmustbemadeandkeptuntilthenextinspectionhasbeencompletedand
recorded.Noworkequipmentmayleaveanemployer'sundertaking,orbeusedintheundertaking,if
suppliedbyanotherperson,unlessthereisaccompanyingphysicalevidencethatthelastinspection
wascarriedout.Note;Construction(Health,SafetyandWelfare)Regulations1996havespecific
inspectionrequirements.

IssueDate
May2011

Revision
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By
RP

LatestReview
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Amendment
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MAINTENANCE PROCEDURES

SpecificRisks
Ensurethatwheretheworkequipmentposesaspecificrisktohealthandsafety,theuseand
maintenanceofsuchequipmentwillberestrictedtodesignatedpersonswhohavereceivedadequate
trainingintheoperationstheyhavebeendesignatedtocarryout.

InformationandInstructions;Training
Makeavailabletoallpersonsusingworkequipmentadequatehealthandsafetyinformation,and
whereappropriatewritteninstructionsontheuseofsuchequipment.Inadditionshallalsoprovide
adequatehealthandsafetytrainingintheuseoftheworkequipment,includinganyassociatedrisks
andnecessaryprecautionswithspecificattentiongiventoyoungorinexperiencedpersons.

ConformitywithECRequirements
Takereasonableactiontoensurethatworkequipmentprovidedforuseafter31December1992has
beendesignedandconstructedincompliancewithanyessentialrequirementsthatarecontainedin
anyrelevantUKlegislationwhichimplementsappropriateEC"product"Directives.

DangerousPartsofMachinery
Takereasonablemeasurestopreventaccesstodangerouspartsofmachineryorstopthemovement
ofanydangerousmachinerybeforeanypartofapersonentersadangerzone.A"dangerzone"
meansanyzoneinoraroundmachineryinwhichapersonisexposedtoarisktotheirhealthand
safetyarisingfromcontactwithadangerouspart.

ProtectionAgainstSpecifiedHazards
Takereasonablemeasurestoprevent,orifthisisnotreasonablypracticablethentoadequately
control,exposuretoanyofthe"specifiedhazards"arisingfromtheuseofworkequipment.The
"specifiedhazards"are:fallingorejectedarticlesorsubstances;componentruptureordisintegration,
equipmentoverheatingorcatchingfireandunintendedorprematuredischargesorexplosions.

HighorVeryLowTemperature
Ensurethatworkequipment,componentsoranyarticlesorsubstanceswhichareathighorverylow
temperaturesareprotectedsoastopreventburn,scaldorsearinjuriesthroughcontactwiththe
offendingsurface.

ControlsandControlSystems
Ensure,whereappropriate,thatstartandoperatingcontrols(iecontrolsthatchangespeed,pressure,
etc)arefittedtoworkequipment,andthatwherethesecontrolsarefitted,theycanonlybeoperated
byadeliberateaction.Provideworkequipmentwithreadilyaccessiblestopcontrols,where
appropriate,thatwillbringtheequipmenttoasafeconditioninasafemanner.Ensure,againwhere
appropriate,thatworkequipmentisprovidedwithreadilyaccessibleemergencystopcontrols,unless
thesecontrolsareunnecessarybythenatureofthehazardandthetimerequiredtobringthe
equipmenttoacompletestopasaresultofactivatinganormalstopcontrol.ensurethatsafesystems
ofworkaredevisedtopreventpersonsbeinginadangerzonecreatedbythestartingofapieceof
workequipment,orwherethatisnotreasonablypracticablebyensuringanaudible,visibleorother
suitablewarningisgivenwhenworkequipmentisabouttostart.

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

IsolationfromSourcesofEnergy
Employersmustensurethatworkequipmentisprovidedwithaclearlyidentifiableandreadily
accessiblemeansofisolatingitfromitsenergysource,whereappropriate.Reconnectionofthe
equipmenttotheenergysourcemustnotexposepersonsusingtheequipmenttoanyriskstotheir
healthandsafety.
StabilityEmployersmustensureallworkequipmentisstabilisedwherenecessarytoprotecthealth
andsafety.Theguidanceexpandsonthisdutybysuggestingthatequipmentliabletofallover,
collapseoroverturnmustbefixedtotheground,stabilised,tied,fastenedorclampedasappropriate.

MaintenanceOperations
Ensure,sofarasisreasonablypracticable,thatworkequipmentisconstructedoradaptedtoallow
maintenanceworkthatinvolvesarisktohealthandsafetytobecarriedoutwhiletheequipmentis
shutdownorinactive.Wherethisisnotpossiblethemaintenanceoperationswillbecarriedoutin
suchawaythatthepersondoingthemaintenanceworkisnotexposedtohealthandsafetyrisksand
appropriatemeasuresaretakenfortheirprotection.ToImplementandmaintainthewrittenmachine
safetyproceduresandsafesystemsofworkcontainedintheWorkEquipmentMaintenance
ProceduresFile.

EmployeesCarriedonMobileWorkEquipment
Mobileworkequipmentwillnotbeusedtocarryemployeesunlessitissuitableforthatpurposeand
incorporatesmeasurestoreduceanyriskstosafety(includingrisksfromwheelsortracks),aslowasis
reasonablypracticable.

RollingOverofWorkEquipment
Riskstoemployeesridingonmobileworkequipmentfromitsrollingoverwillbeminimisedby:
(a)Assessinggroundconditionspriortorigoperation
(b) incorporatingstructuresthatrestrictworkequipmentfromdoinganythingotherthanrollonits
side,orthatprovidesufficientclearancetoanyonebeingcarriedifitdoesrolloverfurther
(c)
providinganydeviceofferingcomparableprotection.

Inthecaseofforklifttrucksensuresuitablerestrainingsystemsarefittedandworn,toprevent
anyoneoperatingthetruckbeingcrushedintheeventoftheworkequipmentrollingover.

KeepingInformation
Informationrecordedonexternalandinternalexamination/inspectionreportswillbekeptavailable
forinspectionfortwoyearsafteritismade.

MonitoringofCompliance
AseniorManagershallcarryoutarandomsampletoexaminecompliancewiththispolicy.

Documentation
Maintenanceproceduresfile
RigDailyinspectionchecklist
Driven CFA Forklift
Driven CFA Forklift
RigWeeklyinspectionChecklist
PlantReportSheetPilingRig
ServiceReportSheetPilingRig

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

DetailedResponsibilities

Directors:

Establishingasystemfortheongoingmaintenanceofallplant,machineryandancillary
equipment.

Organisingtheexternalinspectionofallplantandworkequipmentinaccordancewith
statutoryregulationsand,or,industrystandards.

Implementingaprocedurefortheperiodicalinspectionandexaminationofplantand
machineryinaccordancewithstatutoryregulations.

Implementingaprocedurefortheperiodicalinspectionandexaminationofliftingitemsin
accordancewiththeLiftingOperationsandLiftingEquipmentRegulations(LOLER).

Implementingasystemofperiodicalmonitoringofmachinesafetyprocedures.

Fitter:

Maintainingaformalsystemfortheongoingmaintenanceofallplant,machineryandancillary
equipment.

OrganisingtheexternalinspectionofallliftingitemsinaccordancewiththeLiftingOperations
andLiftingEquipmentRegulations(LOLER).

Carryingoutperiodicalmachinemaintenanceinaccordancewithoperatingmanual
recommendationsandcompanyrules.

Maintaininganuptodaterecordofmaintenanceschedules,inspectionrecords,servicereports
andensuringcopiesofinspectionreportsareretainedbythepilingrigoperatorsasrequired.

Carryingoutmachinerepairssufficienttoensurethesafetyofworkequipment.Retaininga
recordofthecloseoutofreportedrepairsontheServiceReportSheet.

BringingtotheattentionoftheDirectorssignificantdefectsordamagethatcouldaffectthe
safeoperationofworkequipment.Instructingmachine(rigoperators)tostopworkif,ofthe
opinionthatthemachineisunsafetooperate.
Complyingwithcompanyrulesandattendingrelevanttrainingsessionsasrequiredtomaintain
anuptodateknowledgeofmachinesafetyregulationsi.e.(PUWER).

IssueDate
May2011

Revision
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By
RP

LatestReview
May2012

Amendment
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MAINTENANCE PROCEDURES

Assessingthesuitabilityofnewworkequipmentpriortocommissioningandintroductionin
theworkplace.

Involvementintheriskassessmentofplant,machineryandancillaryworkequipment.

ContractsManager:

Monitoringofrigoperatorssafetycheckdocumentation.

ReportingtotheDirectorsandFitteranysignificantdefectsordamagethatcouldaffectthe
safeoperationofworkequipment.Instructingmachine(rigoperators)toStopworkif,ofthe
opinionthatthemachineisunsafetooperate.

Instructingnewortemporarypilingrigoperatorsonthecompanyrulesregardingmachine
safetychecksandmaintenanceprocedures.

Operators

Completedaily/weeklyoperatorinspectionreportsinaccordancewithcompanyprocedures.
Thesechecklistsareintendedforallrigsthereforesomeitemsmaynotbeapplicableand
obviouslyneednotbechecked.Thethoroughnessoftheinspectionsrequiresadegreeof
commonsense.Forexampleiftherighasnotbeenusedforseveralmonthsbytheoperatora
thoroughdailyinspectionwilltakeseveralhours,butconverselyiftherighasbeenusedbythe
sameoperatorweekinweekoutacursoryinspectionwillsuffice.

Maintainaccuratestatutoryandinternalinspectionrecordsasapplicabletothepilingrig,
liftingitemsandancillaryequipment.RecordonthePlantReportSheettheidentification
numbersoftheliftingequipmentwiththerig.

ReporttotheContractsManagerandFitteranysignificantdefectsordamagethatcouldaffect
thesafeoperationofworkequipment.Stopworkifoftheopinionthatthepilingrigisunsafe
tooperate.

IssueDate
May2011

Revision
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By
RP

LatestReview
May2012

Amendment
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MAINTENANCE PROCEDURES

IssueDate
May2011

Revision
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By
RP

LatestReview
May2012

Amendment
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DRIVENPILINGRIG
DAILYINSPECTIONCHECKLIST

RIGNo:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Checkfunctionofcabwarninglights.
Checkfunctionofconsoleswitches.
Checkcabpanelsandwindowglass.
CheckMirrorsandVisibilityAids
CheckAudibleWarninghornsoperate
Checkfunctionoflevers,pedalsandlocks.
Checkbrakes.
Checkoperationofswinglockpiniffitted.
Checkproperfunctionofoverhoistswitches.
Checkfueltankleveltopupwhenrequired.
Checkengineoilleveltopupwhenrequired.
Checkenginecoolantleveltopupwhenrequired.
Checkthehydraulicoillevelinthetank.
Checkforhydraulicoil,fueloil,engineoilandwaterdrips.
Visuallyinspecthydraulichosesfordamage.
Checkboomfootpinsandlocks.
Checkhooksafetycatches.
Checkropes,anchorsandpinsfordamage.
Greasehammer.
Checkliftingcylinderforleaks.
Checkvisuallyallstructuralparts;payspecialattentiontoliftingparts(chains&shackles),liftingcatand
guideclaws.
Checkconditionoframblockandguideclawsplasticwearpadschangeifnecessary.
Checktheconditionoftherubberreboundringchangeifnecessary.
Checktheconditionofthedrivecapcushionchangeifnecessary.
Checkclearancebetweenramblockandtopplate.Tightennutsifnecessaryifthereisnoclearance;
changetheabsorbersoftheliftingbracket.
Tightenloosebolts.Especiallycheckboltsoftheguideclaws.
Checktheconditionoftheramblocktoplimitandchangeifnecessary.
Generalcleaning.
Greasethecrossjointnipples.
Checkthattheemergencystopsofengineareinworkingorderbeforestartofeachshift.
Visualinspectionofgasbottlesandcuttingequipment.

OperatortocompletealltheabovechecksdailyandverifyRiginsatisfactoryconditionbyinitialling
anddatingthePLANTREPORTSHEET
ANYNECESSARYREPAIRS,MODIFICATIONSORHOLDDECISIONSHALLBERECORDEDONTHEPLANT
REPORTSHEET

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

DRIVENPILINGRIG
WEEKLYINSPECTIONCHECKLIST

RIGNo:

Greasetheslewingringballraces(lubricationpipeswithgreasenipplesareinthehydrauliccompartment).
Greasethenipplesintheupperandlowerslide.
Greasethenipplesintheupperandlowerswivelsoftheinclinationcylinders.
Greasethenipplesinthestabilisers,iffitted.
Greasethenipplesintheleaderguides.
Applygreasewithabrushtothebottomofthehorizontalslide.
Greasethenipplesoftheleaderliftdevice.
Checkthebearingsofthesheaves(thebearingsarelubricatedforlife).
Checktheconditionoftheropes.
Greasetheslewingringpiniongear.
Checktheplayofthetrackframeslidebeams.
Checkthebearingsandthetoplimitswitchinthecathead.

Operator to complete all the above checks weekly and verify Rig in satisfactory condition by
initialling and dating the PLANT REPORT SHEET
ANY NECESSARY REPAIRS, MODIFICATIONS OR HOLD DECISION SHALL BE
RECORDED ON THE PLANT REPORT SHEET

IssueDate
May2011

Revision
4

By
RP

LatestReview
May2012

Amendment
Rewrittenandextended

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MAINTENANCE PROCEDURES

CFARIG
DAILYINSPECTIONCHECKLIST

RIGNo:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Checkfunctionofcabwarninglights.
Checkfunctionofconsoleswitches.
Checkcabpanelsandwindowglass.
CheckMirrorsandVisibilityAids
CheckAudiblewarninghornsoperate.
Checkfunctionoflevers,pedalsandlocks.
Checkbrakes.
Checkoperationofswinglockpiniffitted.
Checkproperfunctionofoverhoistswitches.
Checkfueltankleveltopupwhenrequired.
Checkengineoilleveltopupwhenrequired.
Checkenginecoolantleveltopupwhenrequired.
Checkthehydraulicoillevelinthetank.
Checkforhydraulicoil,fueloil,engineoilandwaterdrips.
Visuallyinspecthydraulichosesfordamage.
Checkboomfootpinsandlocks.
Checkhooksafetycatches.
Checkropes,anchorsandpinsfordamage.
Greasemast.
Checkliftingcylinderforleaks.
Checkvisuallyallstructuralparts;payspecialattentiontoliftingparts(chains&shackles),liftingcatand
guideclaws.
Tightenloosebolts.Especiallycheckboltsoftheguideclaws.
Generalcleaning.
Greasethecrossjointnipples.
Checkthattheemergencystopsofengineareinworkingorderbeforestartofeachshift.

OperatortocompletealltheabovechecksdailyandverifyRiginsatisfactoryconditionbyinitialling
anddatingthePLANTREPORTSHEET
ANYNECESSARYREPAIRS,MODIFICATIONSORHOLDDECISIONSHALLBERECORDEDONTHEPLANT
REPORTSHEET

IssueDate
May2011

Revision
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By
RP

LatestReview
May2012

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Rewrittenandextended

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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

CFAPILINGRIG
WEEKLYINSPECTIONCHECKLIST

RIGNo:

Greasetheslewingringballraces(lubricationpipeswithgreasenipplesareinthehydrauliccompartment).
Greasethenipplesintheupperandlowerslide.
Greasethenipplesintheupperandlowerswivelsoftheinclinationcylinders.
Greasethenipplesinthestabilisers,iffitted.
Greasethenipplesinthemastguides.
Applygreasewithabrushtothebottomofthehorizontalslide.
Greasethenipplesoftheleaderliftdevice.
Checkthebearingsofthesheaves(thebearingsarelubricatedforlife).
Checktheconditionoftheropes.
Greasetheslewingringpiniongear.
Checktheplayofthetrackframeslidebeams.
Checkthebearingsandthetoplimitswitchinthecathead.

Operator to complete all the above checks weekly and verify Rig in satisfactory condition by
initialling and dating the PLANT REPORT SHEET
ANY NECESSARY REPAIRS, MODIFICATIONS OR HOLD DECISION SHALL BE
RECORDED ON THE PLANT REPORT SHEET

IssueDate
May2011

Revision
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RP

LatestReview
May2012

Amendment
Rewrittenandextended

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Daily Inspection Checklist: Yard Forklift Truck

KEY OFF Procedures

The vehicle inspection
Overhead guard
Hydraulic cylinders
Mast assembly
Lift chains and rollers
Forks
Tyres
Fuel gauge
Mirrors
Check the engine oil level
Examine the battery
Inspect the hydraulic fluid level
Check the engine coolant level

KEY ON Procedures
Test the standard equipment
Front, tail, and brake lights
Fuel gauge (if diesel)
Windshield wiper
Heater

ENGINE RUNNING Procedures

Check the gauges
Oil pressure indicator lamp
Ammeter indicator lamp
Ammeter
Hour Meter
Water Temperature Gauge
Test the standard equipment
Steering
Brakes
Horn
Safety seat (if equipped)
Check the operation of load-handling attachments
Check the transmission fluid level

IssueDate
May2011

Revision
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RP

LatestReview
May2012

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WEEKLY CHECKLIST FOR POWERED INDUSTRIAL TRUCKS

Overhead Guard - Are there broken welds, missing bolts, or damaged areas?
Hydraulic Cylinders - Is there leakage or damage on the lift, tilt, and attachment functions of
the cylinders?
Mast Assembly - Are there broken welds, cracked or bent areas, and worn or missing stops?
Lift Chains and rollers
Is there wear or damage or kinks, signs of rust, or any sign that lubrication is required?
Is there squeaking?
Forks
Are they cracked or bent , worn, or mismatched?
Is there excessive oil or water on the forks?
Tyres - What do the tyres look like?
Are there large cuts that go around the circumference of the tyre?
Are there large pieces of rubber missing or separated from the rim?
Are there missing lugs?
Is there bond separation that may cause slippage?
Battery Check
Are the cell caps and terminal covers in place?
Are the cables missing insulation?
Hydraulic Fluid - Check level?
Gauges - Are they all properly working?
Steering
Is there excessive free play?
If power steering, is the pump working?
Brakes
If pedal goes all the way to the floor when you apply the service brake, that is the first
indicator that the brakes are bad. Brakes should work in reverse, also.
Does the parking brake work? The truck should not be capable of movement when the
parking brake is engaged.
Lights - If equipped with lights, are they working properly?
Horn - Does the horn work?
Safety seat - if the truck is equipped with a safety seat is it working?
Load Handling Attachments
Is there hesitation when hoisting or lowering the forks, when using the forward or
backward tilt, or the lateral travel on the side shift?
Is there excessive oil on the cylinders?
Engine Oil - Check levels.
Engine Coolant - Visually check the level. Note: Never remove the radiator cap to check the
coolant level when the engine is running or while the engine is hot. Stand to the side and turn
your face away. Always use a glove or rag to protect your hand.
Transmission Fluid - Check levels?
Windshield Wipers - Do they work properly?
Seat Belts - Do they work?
Control Lever - Does the lever operate properly?
Gripper Jaws - (found on order pickers) Do the jaws open and close quickly and smoothly?

IssueDate
May2011

Revision
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RP

LatestReview
May2012

Amendment
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