Forklift Pre-Shift Inspection
OSHA requires forklifts to be examined before being placed in service, at least daily, or before each shift when they’re used around the clock. A few minutes of checking catches the bad brakes, worn chains and cracked forks that cause tip-overs and dropped loads.
- Forklift operators
- Warehouses
- Construction
Visual check (engine off)
- Forks: no cracks (especially at the heel), bends or uneven tips; locking pins in place
- Lift chains: no broken links, kinks, rust or uneven tension; properly lubricated
- Mast and carriage: no damage; rollers and channels OK
- Hydraulic hoses and cylinders: no leaks, cuts or bulges; fluid level OK
- Tires: proper inflation (pneumatic) or no chunking and wear past the line (solid)
- Overhead guard and load backrest: in place and undamaged
- Seat belt or operator restraint: present and working
- Data plate (capacity plate): present and readable
- Fluid levels: engine oil, coolant, brake fluid as applicable
- No leaks under the truck
Power source
- Propane: tank secured with the relief valve pointing up and aligned; hose and connections not cracked or leaking (no hissing or smell); tank in date. Change tanks outdoors or in a ventilated area, away from ignition sources, with gloves.
- Electric: battery connectors and cables undamaged, battery secured, charge level OK, no acid leaks. See Battery Safety.
- Gas or diesel: fuel level, no leaks; never refuel with the engine running.
Operational check (engine on)
- Horn works
- Lights, backup alarm and warning lights work
- Service brakes and parking brake hold
- Steering is smooth without excess play
- Lift, lower, tilt and side shift work smoothly with no jerking or drifting
- Gauges and warning indicators normal
- No unusual noises, smells or smoke
Found a problem? Don’t drive it. OSHA requires trucks with defects affecting safety to be taken out of service until repaired. Tag it, report it, and use another truck. Only authorized people should repair forklifts.
Forks wear out
Forks wear on the bottom, especially at the heel. A common rule from industry standards is to remove forks from service when the heel thickness has worn about 10%, because the fork has lost much of its strength. Check with a fork caliper during periodic inspections.
Keep a record
OSHA doesn’t require written daily checklists, but most employers use them. A signed checklist shows the check was done and documents problems for the mechanic.
Standards & references
- 29 CFR 1910.178(q)(7): Examination before being placed in service
- OSHA eTool: Powered industrial trucks
- See also: Forklifts · Forklifts in Trucks & Trailers
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