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REPAIRS TO FORK ARMS FOR FORK-LIFT TRUCKSINTRODUCTION1 This circular gives information regarding the repair of fork arms for fork-lift trucks, and alerts enforcement officers to certain bad practices which may cause an arm to fail. STANDARDS2 The relevant standards for fork arms are as follows:
3. BS ISO 2330:1995 is a performance standard and includes impact and fatigue tests for proving the quality of fork arms. Manufacturers make their own decisions on how to meet this performance standard, and select materials and manufacturing methods accordingly. The materials from which fork arms are made will thus cover a range of alloy steels. It should be noted that the method of manufacture will also vary in that the top hook may be forged integral with the shank, or may be welded on subsequently. Bottom hooks are usually welded on. 4. BS ISO 5057: 1993 gives recommendations on the inspection of fork arms and deals with surface cracks, fork angle (ie the difference in height from the ground of the fork tips when fitted on a truck), wear etc. It also recommends that repairs should only be carried out by the fork arm manufacturer or an expert of equal competence. 5 A common reason for rejection is when wear of the heel exceeds 10% of the original thickness of the fork arm. This wear is usually caused by the forks rubbing along the ground in use and can occur due to failure to adjust the truck load chain(s) to provide the necessary clearance. 6 The reason for the standard recommending that repairs are only carried out by the fork arm manufacturer or an expert of equal competence may not be clearly understood by the truck owner. If welding is to be carried out, for example, to replace the top hook, the repairer should be aware of the steel specification from which the original components were made. The correct material for the replacement part, the correct welding consumable and the correct welding method can then be selected. The welding method can include weld preparation, preheating stress-relieving and re-heat treatment to the manufacturer's specification. Use of ”mild steel" materials and ordinary jobbing welding methods are likely to result in an unsatisfactory and unsafe repair. 7 It should be noted that the BS considers that surface cracks and wear are not suitable for repair by welding. Reputable repairers do not recommend welding at the heels of forks to replace metal removed by wear because, for example, localised heating and mismatch of materials or errors in heat treatment are likely to adversely affect the performance of the fork arm. 8 After welding repairs, resetting etc., the standard recommends that the fork arms are tested to at least 2.5 times their capacity. 9 Although HSE has little evidence that failure of fork arms is leading to accidents, the potential for accidents is obvious, particularly when hazardous substances are being handled. ENFORCEMENT APPROACH10 HSE would welcome feedback, via the ELO on any accidents caused by failure of new or repaired fork arms, and on any aspects of repairs and repairers. |
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EXAMINATION PROCEDURE AND DISCARD CRITERIA FOR FORK-LIFT TRUCK LIFT CHAINS INTRODUCTION 1 This circular summarises information which is published by the British Industrial Trucks Association (BITA) regarding the maintenance, examination procedure, discard criteria and lubrication for fork lift truck lift chains. BACKGROUND 2 The Lifting Operations and Lifting Equipment Regulations 1998 require the thorough examination of lifting equipment at appropriate intervals to ensure its safe use. The intervals should be specified by a competent person, who should take account of the risks involved, including where and how the truck is used. 3 As a general guide, recommended intervals are:
In both cases the competent person may specify alternative intervals for thorough examination if experience shows they are appropriate. 4 BS 5594: 1986 (ISO 4347: 1985) gives guidance on appropriate characteristics of “Leaf chains, clevises and sheaves” which are used on fork-lift trucks. These chains are of the plate-link or leaf-chain type, comprising several flat links joined together by pins, similar in principle to a roller-chain. The effects of stretch, wear and corrosion on these chains are far less obvious than for round-link chains because the individual links and pins cannot be separated for a detailed examination to be carried out. Wear etc. on chains of this type may therefore not be apparent in a superficial external examination, but the effects are no less serious. BITA RECOMMENDATIONS 5 Guidance is frequently sought by occupiers and enforcement officers on lubrication, and on what criteria should be used in deciding whether a particular chain is suitable for further use, or whether it should be scrapped and cut up. The appendix summarises recommendations which are mentioned by the above British Standard in the Foreword, and are published by the British Industrial Truck Association (BITA) and its member companies in their truck servicing recommendations. Other organisations may employ differing procedures and criteria which are equally effective. 6 The procedure in the appendix is recommended by BITA for chains which are subject to normal conditions of use. Where trucks are to be used in arduous conditions, eg, for 3-shift working, in a cold store, in an abrasive or corrosive atmosphere etc, or over very rough ground, the suggested examination procedures may need to be varied, and the advice of the truck manufacturer/supplier should always be sought 7 Currently, the BITA procedure recommends removal of the chain every 6 months (see Appendix). This may not be necessary if an adequate examination and measurement can be carried out in situ. However, it is considered that chains should be removed from the truck for examination at least every 2 years. Provided the discard criteria in the BITA recommendations have not been exceeded, chains in general service may be used for periods greater than 6000 hours, or 3 years if the competent person agrees. 8 While this circular is intended to apply primarily to fork-lift truck chains, a similar approach may be applicable to other mechanical handling appliances using such chains, eg hoist blocks, hoists, etc APPENDIX (paras 4 and 5) SUMMARY OF BITA RECOMMENDATIONS Maintenance/ lubrication 1 At 250 hours or one month truck-use intervals, whichever is the shorter, and with the chain in a slack condition, the chain should be lubricated with a suitable spray. The truck manufacturer should be consulted for his recommendations. Examination 2 At regular intervals, not exceeding 6 months, the following procedure should be adopted:
3 The condition of the sheave, anchor and anchor pins should be checked for signs of significant wear or distortion prior to refitting. Chain life 4 It is recommended that all chains, chain anchors and anchor pins used in cold-stores should be replaced after a period not exceeding 4000 hours, or 2 years truck operation, whichever is the shorter. 5 It is also recommended that chains in general use should be replaced after a period not exceeding 6000 hours, or 3 years truck operation, whichever is the shorter. Replacement and shortening of chains 6 The practice of joining chain lengths is not recommended, and chains from different manufacturers should not be placed together on the same truck.
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Lighting Requirements for Fork Lift Trucks Fact sheetLighting Requirements for Fork Lift Trucks FactsheetThe requirements concerning the lighting of all vehicles used on the public road are contained in The Road Vehicles Lighting Regulations 1989 (RVLR), as amended. If the vehicle is not used on the public road then the provisions of RVLR do not apply. Fork lift trucks are not specifically mentioned in RVLR, but by virtue of their function and use they are usually considered to fall within the general definition of a 'works truck', which is: "a motor vehicle (other than a straddle carrier) designed for use in private premises and used on a road only in delivering goods from or to such premises, to or from a vehicle on a road in the immediate neighbourhood or in passing from one part of any premises to another or to other private premises in the immediate neighbourhood, or in connection with road works while at or in the immediate neighbourhood of the site of such works." If a fork lift truck is only used on the public road between sunrise and sunset and is not fitted with any front or rear position lamp then under Regulation 4(3) of RVLR the vehicle is exempt from having to be fitted with any lamp or reflector. Many fork lift trucks would not be able to take advantage of this exemption without their use on the road being curtailed, especially during the winter months. Regulation 18 of RVLR requires vehicles to be fitted with lamps, reflectors, rear markings and devices, as specified in Schedule 1 of these regulations. Table 1 of this schedule lists the types of lamp with which motor vehicles with three or more wheels are required to be fitted, and specifies the exceptions to the requirement for each lamp type. These exceptions typically refer to the vehicle type, maximum speed and 'first used' date, but sometimes refers to the weight or dimensions of the vehicle. Assuming a fork lift truck was first used on or after 1st April 1986 and is not a particularly long or heavy vehicle, then the determining factor for the types of lamp that the vehicle is required to be fitted with is the maximum speed of the vehicle. The maximum speed is: "the speed which a vehicle is incapable, by reason of its construction, of exceeding on the level under its own power when fully laden." The table below lists the types of lamp that a fork lift truck is required to be fitted with, according to its maximum speed.
As regards the number and positioning of each lamp type, these requirements are specified in RVLR. Warning BeaconsA fork lift truck having a speed not exceeding 25 mph or any trailer drawn by such a vehicle is permitted to be fitted with an amber warning beacon. (RVLR, Reg. 11(2)(l)(iv)) However, if the vehicle is used on an unrestricted dual-carriageway, other than crossing it by the quickest manner practicable, then the fitment of an amber warning beacon is obligatory and it must be kept lit when the vehicle is used on such a road. (RVLR, Reg. 17 & 26) Any amber warning beacon fitted, whether voluntarily fitted or required by regulation, must be fitted in compliance with the requirements of Schedule 16 of RVLR. Schedule 16 requires the centre of the lamp to be not less than 1200 mm above the ground, and the light to be visible from at least one beacon (but not necessarily the same beacon) from any point at a reasonable distance from the vehicle (i.e. through 360 degrees). Further Information
For
further information on the lighting requirements for fork lift trucks or
any other road vehicle can be found in The Road
Vehicles Lighting Regulations 1989.
Vehicle
Standards and Engineering 4 The information in this leaflet is provided by way of advice. Only the courts can provide an authoritative interpretation of regulations. It is the responsibility of the vehicle owner/driver to ensure that the vehicle at all times, when used on the public roads, complies with the appropriate legislation. These Regulations are published as Statutory
Instruments (SIs) and can be obtained from |
