One of the most frequent questions we hear from operators and employers is how often should the operators inspect their forklift they’re using. The inspection helps the operators to detect flaws of the equipment during pre-operation to maintain the optimum operational capability of the truck.
Operators have to inspect their powered industrial trucks at least once on a daily basis, if the warehouse operation is 24x7 and the forklift is also utilized in the same frequency, then the truck should be inspected before the beginning of every shift to detect any faults and mechanical issues that might occurred during the previous shift. This forklift inspection requirement is in compliance with OSHA’ standard at 1910.178(q)(7).
If the operator is able to spot any possible troubles and would-be problems early, he must report it to this supervisor immediately to tag the forklift out. Doing this could prevent simple problem to escalate to a bigger one. The forklift can then be sent to undergo maintenance and repair.
How Often Should You Do the Inspection?
The frequency of forklift inspections depends on the type of usage and the specific regulations in the jurisdiction where the forklift is operated. In many countries and regions, there are specific safety regulations governing the operation and maintenance of forklifts.
Here's a general guideline based on standards set by the Occupational Safety and Health Administration (OSHA) in the U.S. and common industry practices:
Daily or Pre-Shift Inspection:
- Forklifts should be inspected at the beginning of each shift or daily if they are used around the clock.
- Operators should check for any visible defects, including checking the tires, forks, seat belts, brakes, warning devices, and fluid levels.
- If the forklift is powered by an internal combustion engine, the exhaust and fuel systems should also be checked.
- If any unsafe conditions are found, the forklift should be tagged out and not used until the necessary repairs are made.
Periodic Maintenance and Inspection:
- Beyond daily inspections, periodic maintenance checks are essential to ensure the longevity and safe operation of the forklift.
- The frequency of these checks can be based on the number of operational hours, monthly intervals, or other criteria, and it would typically include more in-depth inspections and potential parts replacements.
Annual or More Comprehensive Inspections:
- Some organizations or local regulations may require more in-depth annual inspections by qualified technicians. These inspections could include checking major components, hydraulic systems, lifting mechanisms, and other critical areas for wear, damage, or malfunction.
After an Incident:
- If the forklift is involved in an accident or mishap, it should be immediately inspected to ensure it's safe for continued use.
Operators should always maintain a log of inspections and any repairs or maintenance performed. Keeping these records can help in identifying recurrent issues and ensure compliance with local regulations.
It's crucial to train operators in proper inspection techniques and what to look for, ensuring forklifts remain safe and operational. Always consult the manufacturer's guidelines for specific maintenance and inspection recommendations for a particular forklift model.
Read this related article: Pre-Operational Checks on Forklifts: Why and How to Perform
However, OSHA Doesn’t Need the Forklift Inspection to be Documented
In the latest OSHA Powered Industrial Truck 1910.178 standard, you would not find any requirement that the inspection has to be documented. However, doing so is a good practice because of two-fold reasons. First, carrying out a forklift inspection and recording will be able you to monitor the equipment’s general condition just like servicing your car and logging it into your maintenance record. Second, in the event the company premise is inspected by an OSHA assessor, you can present documentary proof that the forklift has undergone such daily inspection in compliance with 1910.178(q)(7).
If you are thinking how long do you keep forklift inspection records, it is all up to your discretion and judgment to decide how long you should keep the record as long as you can retrieve it during OSHA workplace safety audit.
Keeping a Forklift Inspection Checklist
One of the most important parts of safe forklift operation in the workplace is performing a forklift inspection. It is to identify small fault to prevent it from becoming a serious one.
The forklift operators who are in close contact need to know that they compelled to report any problem with the truck by checking its general condition and signs of wear and tear. Reporting the potential issues early helps prevent the forklift to become unsafe during work operation.
You can use a forklift inspection checklist to record any issues. An innovative checklist has to contain visual and operational pre-use inspection.
The visual pre-use check contains the overall condition of the truck;
- Cleared flooring without any foreign object littered on the floor
- Fire extinguisher provision and it has to be appropriate for that type of forklift; fluid levels such as engine oil, water, and fuel levels
- Fully charged battery
- Loosed or missing nuts and bolts, part and component of the truck, chains and pins, and hoses and fittings
- Condition of the tires
- Condition of the mast and forks
- Condition of warning lights and horns
- Presence of seatbelt and resistant harness, condition overhead guard and protector
The operational pre-use inspection contains the following tasks:
- The condition of the foot brake and inching pedals, it is too loose or hard to press
- Parking brake and dead man seat brake if it holds and in working state
- Are dash gauges working
- Is the steering, tilt and lift mechanisms operates effortlessly
- Are the lights including the warning lights working properly
- Checking of the forklift’s data plate to verify its load capacity
- The equipment’s mast full height
- Condition of the transmission, does it respond accordingly when it is reversed or move forward
- Are the instruments panels lit up and work accurately
Any forklift that is found unsafe during the inspection must be removed to be serviced or repaired. Such recording must be done in order to monitor its maintenance schedule. Its record should also be kept in case the forklift involved in an accident to verify its maintenance record.
Maintenance of Forklift Inspection Checklist
The forklift inspection checklist is to ensure that your equipments are being kept in good working condition and are safe to operate.
If you are needing one for your record, here are the downloadable forms you can keep:
- Daily Forklift Inspection Checklist
- Weekly Forklift Inspection Checklist
- Monthly Forklift Inspection Checklist
These forms are not ours but are distributed to be used. You can edit or modify according to your liking and need.
Inspection Tips for Forklift Truck Operators
Forklift truck operators should inspect their forklift daily. A pre-shift inspection should be conducted at the beginning of each shift. The operator should also perform a post-shift inspection at the end of each shift.
Here are some tips for conducting a forklift inspection:
- Check the fluid levels in the forklift. The engine oil, transmission fluid, and hydraulic fluid should all be at the proper levels.
- Inspect the tires for wear and tear. Check the tread depth and pressure.
- Inspect the forks for damage. Look for cracks, bends, or other damage.
- Check the mast for damage. Look for cracks, bends, or other damage.
- Inspect the lift chains for wear and tear. If the chains are worn, they need to be replaced.
- Check the condition of the battery. If the battery is old or damaged, it needs to be replaced.
- Check the load backrest for damage.
- Inspect the fuel system for leaks.
- Check all lights and indicators.
- Test the horn.
- Check the brakes.
- Inspect the steering system.
Forklift Truck Maintenance Tips
More comprehensive maintenance should be carried out at regular intervals, as specified in the operator manual.
Forklift trucks are subject to wear and tear, and so it is important to carry out regular maintenance to ensure that they remain safe and reliable. Basic maintenance should be carried out at the end of each shift, and more comprehensive maintenance should be carried out at regular intervals, as specified in the operator manual.
Some of the key maintenance tasks that should be carried out include checking the engine oil level, tire pressures and condition, and the brakes. These checks will help to ensure that the forklift truck is safe to use and is operating at peak performance.
If you are unsure about how to carry out any of the maintenance tasks, then it is advisable to seek professional help. There are many qualified Forklift Truck Maintenance Technicians who will be able to carry out the work for you.
Forklift Truck Repairs
Forklift trucks are one of the most important pieces of equipment in a warehouse or factory. They are used to move heavy loads of materials around, and if they are not in good working condition, they can pose a serious safety hazard.
Operators should inspect their forklift trucks on a daily basis, and perform a more thorough inspection at least once a week. During the daily inspection, operators should check the tires, brakes, steering, and hydraulics for any signs of wear or damage. The weekly inspection should include a check of the engine, transmission, and electrical system.
If any problems are found during an inspection, the forklift truck should be taken out of service immediately and repaired by a qualified technician. Forklift truck repairs can be expensive, so it is important to catch any problems early.
Operators should also be sure to read the operator’s manual for their particular model of forklift truck, as it will contain important information on how to properly maintain and operate the machine. By following these simple tips, operators can help keep their forklift trucks in good working condition and minimize the risk of accidents or injuries.
Consult the Manufacturer's Manual
Operators should inspect their forklift trucks on a regular basis to ensure that they are in good working condition. Forklift trucks are subject to wear and tear and can be damaged easily if not properly maintained.
Operators should check the condition of the forklift truck's tires, brakes, steering, and suspension on a daily basis. They should also inspect the engine, transmission, and hydraulic system regularly.
Forklift trucks should be serviced and repaired as needed to maintain their safe operating condition. Operators should consult their owners' manuals for specific maintenance and repair schedules.
Operators should always follow the manufacturer's instructions when inspecting, servicing, or repairing their forklift trucks. Improperly maintained forklift trucks can be dangerous and can pose a serious hazard to both the operator and other people in the vicinity.
Taking the Forklift Out of Service
Forklift truck operators should inspect their vehicles regularly to ensure they are in good working order and to identify any potential problems. Accessories such as forks, tires and lights should be checked daily, while other parts such as the engine, hydraulic fluid levels and brakes should be checked weekly.
It is important to carry out these inspections as they will help to keep the forklift truck in good working condition and prevent any accidents from happening.
If any problems are identified during the inspection, then the forklift truck should be taken out of service immediately and repaired before it is used again.
Operators should also be trained in how to carry out these inspections properly so that they know what to look for and how to fix any problems.
Report Any Problems
Forklift trucks are one of the most important pieces of equipment in any warehouse or factory. They are used to move heavy loads of merchandise and materials around the facility. Because they are so important, it is essential that forklift operators inspect their trucks on a regular basis.
There is no set schedule for how often operators should inspect their trucks, but it is generally recommended that they do so at least once per shift. During an inspection, operators should check the tires, brakes, lights, and engine. They should also make sure that the load is properly balanced and that the forks are in good condition.
Operators should report any problems they find during an inspection to their supervisor. By catching problems early, operators can help prevent accidents and injuries.
To Conclude This
The operators should inspect the forklift at least daily and during every work shift. Maintaining the record is a good custom you can do as an employer. Accidents involving forklifts happen anytime, if you had one and injury and death was the case, OSHA could go to the scene to conduct the investigation and scrutinize the record. They will request you for the involved forklift’s inspection and maintenance documents. Failure to provide, may hold you liable.
Your question on how often should operators inspect their forklift had been answered. We hope we’ve enlightened you on this issue. If you have any more inquiries and follow up questions, don’t hesitate to contact us, we will try to respond to you as soon as possible.
