The forklift is a crucial piece of machinery across various industries, and it comes in many shapes and sizes, from dock stockers to telehandlers. They are versatile and can perform many different tasks even within the same workday, making them a cornerstone of industries as diverse as freight, construction, retail, and farming.
Because these machines are so fundamental to the daily operation of many businesses, it’s important to keep them in good shape. Keeping a daily inspection checklist for forklifts can help ensure your lifts stay operational for longer while also keeping the workplace safer.
Forklifts can get a lot of run time throughout the day, sometimes up to 18, depending on the number of shifts. When a piece of equipment gets this much use, it may seem like a waste of time to stop at the beginning of each shift and perform a multi-point inspection. After all, if something goes wrong during operation, your drivers are sure to know about it, right? Unfortunately, that’s not always the case.
Critical pieces can wear down over time and begin failing long before any noticeable problems arise. Additionally, the hoses and other components may come loose throughout the day without totally failing. If you begin operating the lift the next day without checking, it could lead to a catastrophic failure during operation. By completing a daily forklift inspection checklist, you and your teams can catch problems before they arise and perform proactive maintenance to prevent more costly repairs.
Daily inspections also make your workplace safer. While forklifts are invaluable to many businesses, they’re also potentially dangerous machines and must be treated as such. Preventing an incident, like a hydraulic failure, doesn’t just save money; it could also save lives.
There are many different styles of forklifts made by many different manufacturers, and each has its specific needs. Always refer to the owner’s manual and the manufacturer’s instructions when designing a daily forklift inspection checklist. That said, here are a few general suggestions for what must be done before using a forklift each day.
First, there are a few steps you should take before even starting the lift. This is known as a pre-operational check1.
Start by checking that all hydraulic hoses are properly connected. Look near these connections and on the floor to ensure there are no leaks. A hydraulic leak will mean the forklift won’t function properly and needs to be addressed as soon as possible.
Give the lift a once-over to verify that there are no defects, damaged parts, or missing components.
Confirm that the tires are properly pressurized and that the forks are secured.
Step into the operator compartment and start inspecting the area. Look for all the vehicle safety notices, and make sure you have a clean and unobstructed working space.
Verify that all controls are present and usable, then make sure any in-vehicle safety devices are in working order. Some lifts have seat locks and seat belts, while others require harnesses.
Once you’ve completed the above, you can finally turn on the lift and perform an operational check. Here’s what that process looks like:
Checking the power supply is another essential step for all equipment. For forklifts powered by liquid propane, it’s crucial that the propane tank is mounted properly and strapped down with intact restraints to prevent too much movement and jostling2.
These lifts also have a pressure relief valve that generally needs to be pointed up. Make sure the tank is in good shape, free of leaks, dents, or cracks, and that the hoses are all securely fastened. If the tank doesn’t fit well, discontinue operation until an appropriate replacement is found.
Electric forklifts are powered by heavy batteries that need to be properly secure to ensure they don’t come loose during the workday. Make sure the battery’s connectors aren’t overly corroded, and check that all cables are firmly attached. Double- and triple-check that the battery is restrained, and that the battery covering is well secured.
Forklifts that run on combustion energy rely on many of the same mechanisms that a gas car needs to run. When starting your day, confirm that all fluids (oil, coolant, and brake fluids, usually) are at optimal levels and that the radiator and air filter are in good condition.
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During a daily pre-shift inspection, all forklift operators should check the machine’s hoses and hydraulic components to ensure that nothing is leaking or broken. They should also check the floor for further signs of a leak3.
It’s crucial to assess the overall condition of the lift, too. Check that the lift is clean and free of objects that could come loose during operation and walk around the lift to inspect it for signs of damage and structural weakness. This should include inspecting the forks for damage like cracks and bends.
Finally, operators will want to double and triple check that any safety belts, harnesses, or other restraint systems are fully functional.
Once the machine is started, check that all systems are operating properly and that no warning lights are illuminated. During this step, it’s important to verify that the horn is in working order.
Forklift operators need to be the masters of their machines and become familiar with all their features and quirks, as this will make inspections go more smoothly. In general, though, there are a few major ways that operators can learn to identify hazards.
First, look for anything that seems immediately wrong. Missing pieces, detached hoses, major damage, and other dramatic changes in the lift are easy-to-spot indicators that a lift needs attention before operation4.
Second, it’s always best to err on the side of caution. If something doesn’t seem like a problem but doesn’t look exactly right, take a step back and recheck the lift. Get a second opinion, if needed. This is also true during operation. If the lift experiences a hiccup, or if it doesn’t seem to perform perfectly, stop all work and get it checked out.
If a forklift fails daily inspection, the operator needs to immediately report it to management and contact maintenance for further diagnostics. A lift that’s failed inspection should never be operated without receiving a thumbs up from the maintenance team. It shouldn’t be powered up, and it shouldn’t be driven, as it is a major safety hazard until all issues have been solved.
Knowingly operating a faulty lift may also result in fines for the operator or their employer.
Once the issue has been reported to the proper teams, the operator should mark the forklift as inoperable. This ensures that no one else tries to use the forklift in the meantime5.
Daily forklift safety inspections are a crucial step in keeping a workplace safe and compliant. These checks are the first line of defense against serious workplace accidents, and they help keep operators, team members, and bystanders safe throughout the course of a working day.
By preventing a faulty lift from being used, operators are stopping potential critical accidents before they can even happen.
Missing even a single daily forklift inspection can lead to serious consequences. Forklifts are powerful machines that weigh several tons, and when they fail during operation, the ensuing accidents can be extremely dangerous.
Death, dismemberment, and permanent injury of the operator or bystanders are all clear and present dangers, even when a forklift is operating properly. A compromised lift drastically increases the odds of such a serious accident occurring during the shift.
Operators who neglect their daily inspections may also be found negligent if an accident leads to a lawsuit, and OSHA may impose fines on the operator and/or the employer6.
Luckily, keeping track of your daily forklift inspections is easy. OSHA publishes forklift inspection checklists that all operators and employers can access for free. These lists can guide the operators through a step-by-step inspection process to gauge whether a lift is eligible for operation. By thoroughly following these guidelines, operators can drastically reduce the chances that they’ll have a mechanical or safety failure-related accident while on the job.
