Key Pre-Shift Testing Procedures
Follow these specific procedures when conducting pre-shift inspection of your electric counterbalance forklift. These steps ensure all critical safety and operational functions are properly tested.
Brake Testing Procedure
- Start in a clear, open area with no obstructions
- Test service brakes by moving forward at moderate speed and stopping
- Verify stopping distance is reasonable and forklift stops in straight line
- Test parking brake by engaging on slight incline if possible
- Verify emergency brake function if equipped
- Check for brake pedal free play and firmness
Hydraulic System Testing
- Raise forks unloaded to full height gradually
- Hold at maximum height for 30 seconds to check for drift
- Lower forks slowly to floor level
- Test tilt function fully forward and backward
- Test side-shift (if equipped) in both directions
- Check for unusual noises or jerky movements
Steering System Check
- Turn steering wheel fully in both directions while stationary
- Check for excessive play in steering wheel (not more than 1-2 inches)
- Drive forward slowly while turning to verify responsive steering
- Test steering in reverse direction
- Listen for unusual noises during steering
- Check steering effort is not excessively heavy or light
Safety Systems Verification
- Test horn to ensure clearly audible
- Check seat switch by attempting to operate while standing
- Verify deadman brake functionality
- Test all lights and warning devices
- Verify backup alarm sounds when reverse selected
- Test emergency power disconnect function
Critical Safety Protocols
If your electric counterbalance forklift fails any part of the pre-shift inspection, follow these critical safety protocols to ensure workplace safety and proper maintenance.
Safety-Critical Defects Protocol
- Immediately tag forklift as "OUT OF SERVICE"
- Remove key and secure in designated location
- Inform supervisor immediately of safety-critical issues
- Document defects in detail on inspection form
- Place forklift in designated repair area if possible
- Ensure forklift cannot be used until repaired and certified
Non-Critical Defects Protocol
- Document all non-critical defects on inspection form
- Report defects to maintenance department
- Determine if forklift is safe for continued operation
- Apply "CAUTION" tag if appropriate
- Schedule repairs at earliest convenience
- Follow up to ensure repairs are completed
Battery Safety Issues
- For battery leaks, follow facility spill response procedure
- Disconnect battery if safe to do so
- Report battery issues to specialized technicians
- Do not attempt to jump-start forklift
- Keep sparks, flames away from battery compartment
- Document battery issues and maintenance history
Shift Handover Protocol
- Verbally communicate any defects to next operator
- Ensure inspection documentation is complete and accessible
- Leave equipment in safe condition (forks down, key removed)
- Return key to designated key control system if applicable
- Verify battery charge level is suitable for next shift
- Confirm status of any maintenance requests