Regular forklift inspections are essential for identifying equipment problems before they lead to accidents, injuries, or unexpected breakdowns.
Forklifts operate in environments where damaged components, malfunctioning safety devices, or mechanical failures can put operators and nearby workers at risk.
Completing a thorough inspection before putting a forklift into service helps ensure the equipment is safe to operate and meets applicable OSHA requirements.
Forklifts (OSHA calls them Powered Industrial Trucks) are used in many industries, primarily to move materials. They can also be used to raise, lower, or remove large objects or smaller objects on pallets, in crates or other containers, and sometimes with great caution and the right safety procedures… even people.
Note: According to OSHA, over-the-road haulage trucks and earth-moving equipment that has been modified to accept forks are not considered powered industrial trucks.
OSHA Standard 1910.178 covers the requirements for forklifts of all types including rough terrain forklifts, telescoping or boom forklifts, and industrial forklifts.
Forklift Operator Training
Only trained and certified operators allowed! The first and most important rule to follow with forklifts - get trained!
Many injuries to both the operator and their co-workers occur because the user of the forklift was not trained in the specific model and type of forklift they tried to use.
OSHA Standard 1910.178(l)(1)(i) states the employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this [standard].
Forklift training should include the inspection procedures for the specific equipment operators will be using. Operators need to understand what components to check, how to recognize defects, and what to do when an unsafe condition is discovered.
Different types of forklifts have different inspection requirements. For example, an electric forklift has battery-related components that must be inspected, while a propane-powered forklift requires checks of the fuel system and associated connections. Operators should follow the manufacturer's inspection recommendations for their equipment.
Forklift Daily Inspection
One aspect of forklift training includes training forklift operators to competently complete the daily forklift inspection.
The forklift operator should inspect the forklift every day before using or before each shift when the forklift will potentially be used. When forklifts are used on site around-the-clock then the inspection can take place after each shift.
OSHA Standard 1910.178(q)(7) Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.
The forklift inspection should include both a visual check and an operational check. During the visual check, the operator should visually inspect the forklift and complete the inspection sheet. After the visual check, then the operator should do an operational pre-use check to ensure everything is operating safely.
The forklift inspection sheet should be completed and recorded per the company's requirements and any problems found during the inspection should be reported to a supervisor immediately.
Visual Forklift Inspection
A visual inspection should be completed before operating the forklift. Walk around the equipment and look for damage, leaks, missing components, and other conditions that could affect safe operation.
Depending on the forklift type and manufacturer's recommendations, the visual inspection may include:
- Forks for cracks, bending, excessive wear, or other damage
- Mast, lift chains, and hydraulic components for visible damage or leaks
- Tires and wheels for damage, excessive wear, or missing components
- Hydraulic hoses and connections for leaks or deterioration
- Overhead guard and load backrest for damage or missing components
- Seat belt and operator restraint system for damage or improper operation
- Fluid levels, where applicable
- Battery condition and connections on electric forklifts
- Fuel tanks, hoses, and connections on internal combustion forklifts
- Loose, damaged, or missing parts
Look beneath and around the forklift for evidence of fluid leaks. Any condition that could affect safe operation should be reported and evaluated before the forklift is used.
Operational Forklift Inspection
After completing the visual inspection, operators should check that the forklift's controls and safety features function properly. These checks should be performed in a safe location, following the manufacturer's instructions.
Operational inspection items may include:
- Service brakes and parking brake
- Steering operation
- Horn and other warning devices
- Forward and reverse travel controls
- Lift, lower, and tilt functions
- Hydraulic controls and attachments
- Lights and backup alarms, where equipped
- Dashboard indicators, gauges, and warning lights
- Unusual noises, vibrations, or operating conditions
Operators should pay attention to how the forklift responds during these checks. Delayed braking, unusual steering behavior, jerky movements, or other unexpected operating conditions may indicate a problem that requires attention.
What to Do When a Forklift Fails Inspection
A forklift should never be operated when an inspection reveals a condition that could affect its safe operation.
OSHA Standard 1910.178(p)(1) If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.
If a safety-related defect is discovered, remove the forklift from service, notify a supervisor, and follow company procedures for identifying the equipment as unsafe. Do not attempt to continue working with a defective forklift simply because the equipment still operates.
Repairs should be completed by authorized personnel before the forklift is returned to service. Operators should not bypass safety devices, make unauthorized repairs, or attempt temporary fixes to keep equipment operating.
Forklift Inspection Documentation
Forklift inspections should be documented to prove that the standard is being met (without a doubt) and forklift inspection sheets should be kept for a determined period of time according to the company's stated policy in case there is any reason to refer back to the checklists, including, in the event of any incident with the forklift. (Note: Cal/OSHA regulations require that daily forklift inspection records be retained for at least one year.)
Although federal OSHA requires forklifts to be examined before being placed in service, OSHA Standard 1910.178 does not specifically require employers to maintain a written daily inspection checklist. However, documenting inspections is a useful practice for tracking equipment conditions, identifying recurring problems, and verifying that reported defects have been addressed. State requirements and company policies may establish additional documentation expectations.
Your forklift checklist should guide you through what you need to visually check and what needs to be checked operationally. OSHA does not have any standards or requirements that specify exactly which items are required on the checklist so you can use the checklist your company prefers.
An effective forklift inspection checklist should be appropriate for the type of forklift being inspected and reflect the manufacturer's recommendations. The checklist should provide a clear way to identify deficiencies and document when corrective action is needed.
Inspection records can also help supervisors and maintenance personnel recognize developing equipment problems. Repeated reports of leaks, tire damage, braking problems, or other defects may indicate that additional maintenance or repairs are necessary.
Forklift inspections are an important part of preventing equipment failures and protecting operators and nearby workers. Every forklift should be examined before being placed in service, with both visual and operational checks appropriate for the equipment.
Operators must report defects immediately, and forklifts with conditions that affect safe operation must remain out of service until the necessary repairs have been completed.
Consistent inspections, proper documentation, and prompt corrective action help keep forklifts in safe operating condition and reduce the risk of workplace incidents.
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