OSHA requires a forklift inspection before each shift, or after each shift if the forklift is used continuously. Only trained and certified operators may perform these inspections. Any forklift found in unsafe condition must be removed from service and tagged “Out of Service” until repaired.
Inspections follow a two-phase process: a Key-Off Visual Inspection (walk-around) and a Key-On Operational Test.
Phase 1: Key-Off Visual Inspection (Walk-Around)
General and Safety Systems
Frame/chassis: Check for cracks, dents, or damaged welds.
Overhead guard and load backrest: Check for deformation, cracks, or damage.
Data plate: Ensure it is present, legible, and matches load rating.
Safety decals: Confirm they are visible and intact.
Seat belt: Check for proper function and any fraying or damage.
Fire extinguisher: Ensure it is present and charged (if required).
Forks, Mast & Hydraulics
Forks: Check for cracks, bends, straightness, and worn heels (maximum 10% thickness reduction allowed). Ensure locking pins are present and secure.
Mast assembly: Inspect rails, chains, and rollers for cracks, wear, or kinks. Check for proper chain tension and lubrication.
Hydraulic system: Inspect hoses for leaks, cracks, abrasion, or bulging. Check fluid level and that it is not milky or foamy.
Attachments: If equipped, verify they are secure and undamaged.
Tires, Wheels & Undercarriage
Tires: Inspect for cuts, cracks, excessive wear, embedded objects, or other damage. Check inflation pressure (if pneumatic).
Wheels: Check for cracks, damaged rims, or missing lug nuts.
Leaks: Look under the forklift for evidence of hydraulic oil, engine oil, coolant, or fuel leaks.
Power System & Fluids
General fluid levels: Check hydraulic fluid, brake fluid, and coolant.
For Electric Forklifts: Inspect battery charge level, cables, and connectors for wear or corrosion. Ensure the battery is securely mounted.
For Internal Combustion (IC) Forklifts: Check fuel level (diesel, propane, or gas), oil level, and inspect the fuel system for leaks.
Phase 2: Key-On Operational Test
Start-Up and Safety Systems
Gauges and indicators: Check all warning lights, hour meter, and battery discharge indicator (for electric models) are functioning properly.
Horn and alarms: Test the horn, backup alarm, and any warning beacons.
Lights: Test headlights, tail lights, brake lights, and indicator lights.
Operator presence system: Verify seat switch and any interlocks operate correctly.
Parking brake: Test for proper holding.
Driving and Controls
Steering: Check for smooth, responsive movement without grinding or tight spots.
Service brake: Test for proper stopping function.
Controls: Test lift, tilt, and side-shift functions for smooth operation and listen for unusual noises.
Drive test: With forks lowered, drive forward and reverse slowly, checking for smooth steering and no unexpected vibration.
Immediate Actions for Identified Issues
Tag the forklift “Out of Service” if any issue could adversely affect safety.
Report the issue immediately to a supervisor or maintenance team.
Do not operate until the forklift has been cleared for service by an authorized person.
Summary
OSHA requires daily forklift inspections before each shift. The inspection is a two-phase process: a Key-Off Visual Walk-Around covering the frame, forks, mast, tires, hydraulic system, and power source, followed by a Key-On Operational Test of the horn, lights, brakes, steering, and lifting controls. Any safety-related defect requires the forklift to be removed from service and tagged “Out of Service” until repaired. All inspections should be documented and logged. This checklist serves as a guide; always consult your specific forklift’s Operation and Maintenance Manual.