Forklift PDF

MAINTENANCE PROCEDURES
Maintenance Procedures

Issue Date Revision By Latest Review Amendment Page 1
May 2011 4 RP May 2012 Re‐written and extended


Introduction:

The provision of safe plant and work equipment and its maintenance in a safe condition is
stated within the company health and safety policy and is regarded as essential to control risks
from dangerous parts of machinery and plant notably (piling rigs). The aim of these procedures
is to introduce and maintain formal systems for maintenance and servicing of piling rigs and
associated ancillary equipment.

The quality of maintenance is a major contributory factor affecting safety and operational
costs. It affects the operating life of plant and also the risk of accidents during or following
maintenance. The possibility of a fatal accident is present in many maintenance activities and
includes the company’s maintenance work. Safety during maintenance is heavily reliant on
human activity and accordingly management will take positive steps to ensure maintenance
staff are sufficiently trained and competent to carry out their work safely. This manual
contains the procedures and instructions for general machine safety and maintenance work.

Objectives:

The aim of these procedures is:

1.1 To meet statutory duties provide and maintain safe work equipment

1.2 To enable the company to demonstrate that a programme of routine maintenance
of plant and machinery is in place and being followed

1.3 To clarify with personnel the formal arrangements for machine safety and their duties
for compliance.
Scope

The machinery safety procedures apply to all types of work equipment and all areas where
plant and work equipment is used.

Contents and Related Documents

1. Machine safety policy recognising statutory requirements and allocation of
responsibilities to implement the policy.

2. Maintenance Responsibilities



Green Piling Plant
3. Operator plant report sheet page 10

4. Operator daily inspection checklist
Driven page 11
CFA page 13
Forklift page 15

5. Operator weekly inspection checklist
Driven page 12
CFA page 14
Forklift page 16

6. Fitters service report sheet page 17

Third Party Plant *

7. Access Platform page 18

8. Concrete Pump page 19

9. Concrete Drum page 20

 Third party plant is plant usually hired in from plant supply companies. Routine daily
pre‐use and in‐use inspections are required to be carried out by Green Piling Operatives
but more and other maintenance and repairs will normally be carried out by hire
company. Sheets used for control herein are not necessarily an exhaustive list but all
requirements should be detailed in instructions with plant ant during familiarisation at
delivery.



Objective

To provide a system that will ensure that the company does not put personnel at risk during operations
involving the use of work equipment. To meet statutory duties and, or, industry standards to provide
and maintain safe work equipment.

Responsibility

Responsibility for communication and compliance with this policy rests with the Directors of the
company.

The Directors shall nominate a responsible person to manage implementation of this policy.

Preparation of the machine safety policy is the responsibility of the Safety Advisor.

Responsibility for ensuring the machine safety policy is administered on site rests with the Contracts
Manager, Rig Foreman and the Maintenance Engineer.

Each responsible person nominated shall be given sufficient time, resource, training and information to
carry out their responsibilities effectively.

The Provision and Use of Work Equipment Regulations 1998 (PUWER 98) make more explicit the
general duties contained in the HSW Act. The Regulations apply to all work equipment, including second
hand, hired or leased equipment. The provisions of the Supply of Machinery (Safety) Regulations 1992,
as amended, apply to machinery manufactured on or after 1 January 1993. Note (PUWER) (LOLER) and
industry standards are applicable to Piling Rigs.

Interpretation

The following definitions and terms are important in understanding the requirements laid down by
(PUWER98) Regulations.

Inspection
This means a visual or more rigorous inspection, as required by regulation 6 carried out by a
competent person, and may include appropriate testing.

Work equipment
This includes all plant, machinery, tools or installations for use at work — the definition will cover
large machines such as piling rigs right through to complete entities such as ladders, hydraulic jacks,
air tools, spanners etc.

Use


This includes any activity that may be associated with the work equipment, such as starting, stopping,
programming, setting, transporting, repairing, modifying, maintaining, servicing and cleaning. Unless
otherwise stated the requirements of these Regulations are absolute, ie they must be achieve.
Application
The Regulations apply to:
– work equipment provided by employers for use by their employees at work
– work equipment provided by self‐employed persons for their own use at work
– persons who have control of work equipment, or who use, supervise or manage it.
– the way work equipment is used.

The guidance points out that the duty on employers also extends to personal work equipment
provided by the employees, where the employer agrees to this practice and that on multi‐occupancy
sites arrangements should be made for one employer to be responsible for compliance. The "co‐
operation and co‐ordination" requirement under regulation 11 of the Management of Health and
Safety at Work Regulations 1999 (MHSW) is relevant.

The Company shall ensure the following:

Suitability
Equipment provided for work is constructed or adapted so as to be suitable for its intended purpose.
This includes taking account of reasonably foreseeable working conditions, inherent health and safety
risks where the equipment is to be used and any risks associated with the equipment itself. Work
equipment must only be used for tasks, and under the conditions, for which it is suitable. "Suitable" in
this regulation means suitable with respect to the health and safety of any person. Regulation 3(1) of
MHSW, ie risk assessment, is relevant.

Maintenance
Work equipment is maintained in an efficient state, in efficient working order, in good repair, and
where a maintenance log is required, ie under other legislation (eg CHSWR96) or (LOLER) such logs
must be kept up to date. However, the accompanying guidance does recommend that maintenance
records are kept.

Inspection
Where the safety of work equipment depends on the installation conditions, the work equipment is
inspected after installation and before it is used for the first time, or after it has been installed at a
new location or premises. The inspections are to ensure that the work equipment has been installed
correctly and is safe to use. In addition, work equipment which is exposed to conditions which may
cause deterioration and consequent danger as a result of that deterioration must be inspected at
suitable intervals, and whenever exceptional circumstances have occurred that may have had adverse
effects on the safety of the work equipment. The inspections are to ensure that health and safety
conditions are maintained, and that defects are identified and corrected quickly.
Records of all inspections must be made and kept until the next inspection has been completed and
recorded. No work equipment may leave an employer's undertaking, or be used in the undertaking, if
supplied by another person, unless there is accompanying physical evidence that the last inspection
was carried out. Note; Construction (Health, Safety and Welfare) Regulations 1996 — have specific
inspection requirements.



Specific Risks
Ensure that where the work equipment poses a specific risk to health and safety, the use and
maintenance of such equipment will be restricted to designated persons who have received adequate
training in the operations they have been designated to carry out.

Information and Instructions; Training
Make available to all persons using work equipment adequate health and safety information, and
where appropriate written instructions on the use of such equipment. In addition shall also provide
adequate health and safety training in the use of the work equipment, including any associated risks
and necessary precautions with specific attention given to young or inexperienced persons.

Conformity with EC Requirements
Take reasonable action to ensure that work equipment provided for use after 31 December 1992 has
been designed and constructed in compliance with any essential requirements that are contained in
any relevant UK legislation which implements appropriate EC "product" Directives.

Dangerous Parts of Machinery
Take reasonable measures to prevent access to dangerous parts of machinery or stop the movement
of any dangerous machinery before any part of a person enters a danger zone. A "danger zone"
means any zone in or around machinery in which a person is exposed to a risk to their health and
safety arising from contact with a dangerous part.

Protection Against Specified Hazards
Take reasonable measures to prevent, or if this is not reasonably practicable then to adequately
control, exposure to any of the "specified hazards" arising from the use of work equipment. The
"specified hazards" are: falling or ejected articles or substances; component rupture or disintegration,
equipment overheating or catching fire and unintended or premature discharges or explosions.

High or Very Low Temperature
Ensure that work equipment, components or any articles or substances which are at high or very low
temperatures are protected so as to prevent burn, scald or sear injuries through contact with the
offending surface.

Controls and Control Systems
Ensure, where appropriate, that start and operating controls (ie controls that change speed, pressure,
etc) are fitted to work equipment, and that where these controls are fitted, they can only be operated
by a deliberate action. Provide work equipment with readily accessible stop controls, where
appropriate, that will bring the equipment to a safe condition in a safe manner. Ensure, again where
appropriate, that work equipment is provided with readily accessible emergency stop controls, unless
these controls are unnecessary by the nature of the hazard and the time required to bring the
equipment to a complete stop as a result of activating a normal stop control. ensure that safe systems
of work are devised to prevent persons being in a danger zone created by the starting of a piece of
work equipment, or where that is not reasonably practicable by ensuring an audible, visible or other
suitable warning is given when work equipment is about to start.


Isolation from Sources of Energy
Employers must ensure that work equipment is provided with a clearly identifiable and readily
accessible means of isolating it from its energy source, where appropriate. Reconnection of the
equipment to the energy source must not expose persons using the equipment to any risks to their
health and safety.
Stability Employers must ensure all work equipment is stabilised where necessary to protect health
and safety. The guidance expands on this duty by suggesting that equipment liable to fall over,
collapse or overturn must be fixed to the ground, stabilised, tied, fastened or clamped as appropriate.

Maintenance Operations
Ensure, so far as is reasonably practicable, that work equipment is constructed or adapted to allow
maintenance work that involves a risk to health and safety to be carried out while the equipment is
shut down or inactive. Where this is not possible the maintenance operations will be carried out in
such a way that the person doing the maintenance work is not exposed to health and safety risks and
appropriate measures are taken for their protection. To Implement and maintain the written machine
safety procedures and safe systems of work contained in the Work Equipment Maintenance
Procedures File.

Employees Carried on Mobile Work Equipment
Mobile work equipment will not be used to carry employees unless it is suitable for that purpose and
incorporates measures to reduce any risks to safety (including risks from wheels or tracks), as low as is
reasonably practicable.

Rolling Over of Work Equipment
Risks to employees riding on mobile work equipment from its rolling over will be minimised by:
(a) Assessing ground conditions prior to rig operation
(b) incorporating structures that restrict work equipment from doing anything other than roll on its
side, or that provide sufficient clearance to anyone being carried if it does roll over further
(c) providing any device offering comparable protection.

In the case of fork lift trucks ensure suitable restraining systems are fitted and worn, to prevent
anyone operating the truck being crushed in the event of the work equipment rolling over.

Keeping Information
Information recorded on external and internal examination/inspection reports will be kept available
for inspection for two years after it is made.

Monitoring of Compliance
A senior Manager shall carry out a random sample to examine compliance with this policy.

Documentation
Maintenance procedures file
Rig – Daily inspection checklist Driven CFA Forklift
Rig – Weekly inspection Checklist Driven CFA Forklift
Plant Report Sheet Piling Rig
Service Report Sheet Piling Rig



Detailed Responsibilities

Directors:

Establishing a system for the on‐going maintenance of all plant, machinery and ancillary
equipment.

Organising the external inspection of all plant and work equipment in accordance with
statutory regulations and, or, industry standards.

Implementing a procedure for the periodical inspection and examination of plant and
machinery in accordance with statutory regulations.

Implementing a procedure for the periodical inspection and examination of lifting items in
accordance with the Lifting Operations and Lifting Equipment Regulations (LOLER).

Implementing a system of periodical monitoring of machine safety procedures.

Fitter:

Maintaining a formal system for the on‐going maintenance of all plant, machinery and ancillary
equipment.

Organising the external inspection of all lifting items in accordance with the Lifting Operations
and Lifting Equipment Regulations (LOLER).

Carrying‐out periodical machine maintenance in accordance with operating manual
recommendations and company rules.

Maintaining an up to date record of maintenance schedules, inspection records, service reports
and ensuring copies of inspection reports are retained by the piling rig operators as required.

Carrying out machine repairs sufficient to ensure the safety of work equipment. Retaining a
record of the close out of reported repairs on the Service Report Sheet.

Bringing to the attention of the Directors significant defects or damage that could affect the
safe operation of work equipment. Instructing machine (rig operators) to stop work if, of the
opinion that the machine is unsafe to operate.
Complying with company rules and attending relevant training sessions as required to maintain
an up to date knowledge of machine safety regulations i.e. (PUWER).



Assessing the suitability of new work equipment prior to commissioning and introduction in
the work place.

Involvement in the risk assessment of plant, machinery and ancillary work equipment.

Contracts Manager:

Monitoring of rig operators safety check documentation.

Reporting to the Directors and Fitter any significant defects or damage that could affect the
safe operation of work equipment. Instructing machine (rig operators) to Stop work if, of the
opinion that the machine is unsafe to operate.

Instructing new or temporary piling rig operators on the company rules regarding machine
safety checks and maintenance procedures.

Operators

Complete daily/weekly operator inspection reports in accordance with company procedures.
These checklists are intended for all rigs therefore some items may not be applicable and
obviously need not be checked. The thoroughness of the inspections requires a degree of
common sense. For example if the rig has not been used for several months by the operator a
thorough daily inspection will take several hours, but conversely if the rig has been used by the
same operator week in week out a cursory inspection will suffice.

Maintain accurate statutory and internal inspection records as applicable to the piling rig,
lifting items and ancillary equipment. Record on the Plant Report Sheet the identification
numbers of the lifting equipment with the rig.

Report to the Contracts Manager and Fitter any significant defects or damage that could affect
the safe operation of work equipment. Stop work if of the opinion that the piling rig is unsafe
to operate.




DRIVEN PILING RIG
RIG No:
DAILY INSPECTION CHECKLIST
1. Check function of cab warning lights.
2. Check function of console switches.
3. Check cab panels and window glass.
4. Check Mirrors and Visibility Aids
5. Check Audible Warning horns operate
6. Check function of levers, pedals and locks.
7. Check brakes.
8. Check operation of swing lock pin if fitted.
9. Check proper function of overhoist switches.
10. Check fuel tank level – top up when required.
11. Check engine oil level – top up when required.
12. Check engine coolant level – top up when required.
13. Check the hydraulic oil level in the tank.
14. Check for hydraulic oil, fuel oil, engine oil and water drips.
15. Visually inspect hydraulic hoses for damage.
16. Check boom foot pins and locks.
17. Check hook safety catches.
18. Check ropes, anchors and pins for damage.
19. Grease hammer.
20. Check lifting cylinder for leaks.
21. Check visually all structural parts; pay special attention to lifting parts (chains & shackles), lifting cat and
guide claws.
22. Check condition of ram block and guide claws plastic wear pads – change if necessary.
23. Check the condition of the rubber rebound ring – change if necessary.
24. Check the condition of the drive cap cushion – change if necessary.
25. Check clearance between ram block and top plate. Tighten nuts if necessary ‐ if there is no clearance;
26. change the absorbers of the lifting bracket.
27. Tighten loose bolts. Especially check bolts of the guide claws.
28. Check the condition of the ram block top limit and change if necessary.
29. General cleaning.
30. Grease the cross joint nipples.
31. Check that the emergency stops of engine are in working order before start of each shift.
32. Visual inspection of gas bottles and cutting equipment.
Operator to complete all the above checks daily 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


DRIVEN PILING RIG
RIG No:
WEEKLY INSPECTION CHECKLIST
1. Grease the slewing ring ball races (lubrication pipes with grease nipples are in the hydraulic compartment).
2. Grease the nipples in the upper and lower slide.
3. Grease the nipples in the upper and lower swivels of the inclination cylinders.
4. Grease the nipples in the stabilisers, if fitted.
5. Grease the nipples in the leader guides.
6. Apply grease with a brush to the bottom of the horizontal slide.
7. Grease the nipples of the leader lift device.
8. Check the bearings of the sheaves (the bearings are lubricated for life).
9. Check the condition of the ropes.
10. Grease the slewing ring pinion gear.
11. Check the play of the track frame slide beams.
12. Check the bearings and the top limit switch in the cathead.

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


CFA RIG
RIG No:
DAILY INSPECTION CHECKLIST
1. Check function of cab warning lights.
2. Check function of console switches.
3. Check cab panels and window glass.
4. Check Mirrors and Visibility Aids
5. Check Audible warning horns operate.
6. Check function of levers, pedals and locks.
7. Check brakes.
8. Check operation of swing lock pin if fitted.
9. Check proper function of overhoist switches.
10. Check fuel tank level – top up when required.
11. Check engine oil level – top up when required.
12. Check engine coolant level – top up when required.
13. Check the hydraulic oil level in the tank.
14. Check for hydraulic oil, fuel oil, engine oil and water drips.
15. Visually inspect hydraulic hoses for damage.
16. Check boom foot pins and locks.
17. Check hook safety catches.
18. Check ropes, anchors and pins for damage.
19. Grease mast.
20. Check lifting cylinder for leaks.
21. Check visually all structural parts; pay special attention to lifting parts (chains & shackles), lifting cat and
guide claws.
22. Tighten loose bolts. Especially check bolts of the guide claws.
23. General cleaning.
24. Grease the cross joint nipples.
25. Check that the emergency stops of engine are in working order before start of each shift.
Operator to complete all the above checks daily 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


CFA PILING RIG
RIG No:
WEEKLY INSPECTION CHECKLIST
1. Grease the slewing ring ball races (lubrication pipes with grease nipples are in the hydraulic compartment).
2. Grease the nipples in the upper and lower slide.
3. Grease the nipples in the upper and lower swivels of the inclination cylinders.
4. Grease the nipples in the stabilisers, if fitted.
5. Grease the nipples in the mast guides.
6. Apply grease with a brush to the bottom of the horizontal slide.
7. Grease the nipples of the leader lift device.
8. Check the bearings of the sheaves (the bearings are lubricated for life).
9. Check the condition of the ropes.
10. Grease the slewing ring pinion gear.
11. Check the play of the track frame slide beams.
12. Check the bearings and the top limit switch in the cathead.

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


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


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?












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MAINTENANCE PROCEDURES

Daily Inspection Checklist: Yard Forklift Truck

KEY OFF Procedures

WEEKLY CHECKLIST FOR POWERED INDUSTRIAL TRUCKS

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