What is an electric reach truck?

An electric reach truck is a specialized warehouse forklift designed for narrow aisles and reaching high-level stacking. They are typically designed to operate in aisle widths ranging from 2.6 - 3 m, and can reach a height of almost 12 m while carrying loads ranging from 800 - 2500 kg. This means that operating them requires maximum caution as mistakes can be costly and fatal. To ensure safe operation, the operator must perform the following inspections before the start and over the course of their shift.

Before start inspection

Before operating the reach truck, perform the following inspections

• Fluid levels

Check all fluid levels specified by the manufacturer, including hydraulic fluid and brake fluid where applicable. To check the hydraulic fluid, pull the dipstick out from the holder, wipe it with a clean cloth, insert it back inside the holder, pull it out again and check that fluid level is at the marked point. If it has fallen below the required level, top it off again with the recommended fluid, and note the date and time of refill on the backside of your checklist paper. If your reach truck follows a different mechanism, then follow the instruction manual

• Tyres

Make sure the tyres are not excessively worn-out, and that they do not have any cuts or major damage

• Lights

Ensure that the head, tail, turn signal and warning lights are clean and free from damage

• Seatbelt

Wear the seatbelt. Ensure that it is not too loose and latches securely. Unbuckle and ensure it retracts automatically. Also watch out for any fraying.

• Operating manual

Ensure that you have access to the provided reach truck operating manual at all times for quick access when need arises

• Safety decals and capacity nameplate

Decals are labels printed on different parts of the forklifts containing warnings and safety tips while the nameplate mentions the capacity of the reach truck. Both of them should always be legible

• Charging points

Make sure that the reach truck’s own charging port and the warehouse charging outlet are functional

• Forks

Make sure there are no cracks or bends in the forks.

• Mast

Inspect the mast of the reach truck for excessive wear, damage or loose components.

• Leaks

Before operating the forklift, make sure there are no puddles of fluid underneath it as those can signal leaks.

Running inspection

Once you have performed the pre-operation inspections, power up the truck, and perform the following additional safety checks. Make sure you are performing these inspections in a designated area of the warehouse, free from any objects or pedestrians.

• Sounds

Some operational sounds are normal and expected. Others are not. Watch out for any unusually loud humming, grinding, or screeching sounds.

Also make sure that the reach truck’s own horn and backup alarms are working properly

• Lights

One by one, check each of the reach-truck’s lights (warning, head, tail, and turn signal) are fully operational and illuminate without flickering or dimming

• Movements

Move the vehicle forwards and backwards. Perform the lifting, lowering and tilting maneuvers. Turn the steering wheel clockwise and anticlockwise. Make sure all these movements are happening smoothly and without any noise or delays. Also, make sure the emergency stop feature is working properly.

IMPORTANT: Make sure you are wearing safety goggles before beginning actual work. You do not want debris falling in your eyes while lifting thousands of pounds of stock three stories above your head

Troubleshooting common faults

Truck won’t start

As a first step, check whether the emergency stop button is pressed. Turn it off, and try to start again. If it still wouldn't turn on, check the battery. If the reach-truck operates on lead-acid batteries, make sure the connectors are not loose or oxidized. If there are white or greenish deposits on the terminals, clean them with a specialized solution.

Humming or grinding sounds

While operating, if you hear a humming sound, it often indicates an issue with the hydraulic system. Ensure the hydraulic fluid is at the proper level. To do so, locate the dipstick attached to the hydraulic compartment, pull it out, wipe it with a clean cloth, insert it again, and check the level. If it is below the desired level, top it off with the recommended fluid, and note down the date and time of the top-off in your inspection log. This ensures that if there are any leaks they can become apparent with a timeline of fixes.

If you hear a grinding sound while lifting or lowering the fork, it is often a sign that the lifting chains need to be lubricated. Read the operators manual for instructions. Again, do not forget to record it in your inspection log.

When to stop and report?

Screeching sounds during movement

A screeching sound in the middle of a movement can signal an issue with the ball-bearings of the wheels. If you hear this sound, report it to your superior instead of attempting any fix yourself as this is something only a qualified expert can reliably do.

Brakes

If applying the brakes produces screeching sounds, or the braking distance is longer than unusual, slowly drive the reach truck to a safe spot, and place a large sign saying “BROKEN - DO NOT OPERATE” in all caps, and report the issue to your manager. Do not attempt to fix the issue or drive the truck in this condition.

Reach/Retract issues

Sometimes the reach and retract functions of the reach truck stop working properly. Usually this is a result of insufficient hydraulic fluid. If, however, the fluid is at its proper level, then there is probably something wrong with the solenoid valve or position sensor. If you suspect that to be the case, report it to your immediate superior. Do not try to fix it yourself.

Conclusion

A few minutes of daily inspection can save hours of downtime. Therefore, care must be taken to ensure all the items in the checklist are checked off, and any issues, major or minor, are reported as early as possible to prevent costly replacements. Some of these issues are easier to manage with modern solutions. For example, using Li-ion powered reach trucks instead of lead-acid batteries, as they have very low maintenance requirements and provide greater charge density. If you are interested in employing Li-ion battery powered electric reach trucks, please reach out to our customer support at Meenyon for reliable, time-tested and budget friendly solutions.

FAQs

How often should electric reach trucks be inspected?

They should be inspected before the beginning of each shift.

Why is a daily inspection important?
Because preventive maintenance reduces the likelihood of injuries and is much cheaper than major repairs.

What if I find an issue during the inspection?

That is what the inspection is for. If it is a minor issue, fix it yourself, and log it. Otherwise, report it to your manager

What should I do if my electric reach truck won’t start?

Check the emergency stop button, battery connectors, and battery charging level. If basic troubleshooting steps don’t solve the problem, report it.

Are Li-ion reach trucks easier to maintain than lead-acid models?

Yes. They do not require regular watering, charge faster, and can operate for longer periods of time.

References

• Oregon State University Environmental Health & Safety. Electric Forklift Operator's Daily Checklist.
• Southeast Industrial Equipment. Reach Truck Daily Operator Check List.
• Samco Vina. Common Reach Truck Issues and Quick Fixes.