The Importance of Daily Forklift Inspections and How to Conduct Them

Forklift safety is critical in any industrial setting, protecting operators and nearby workers from accidents. One key aspect of this safety is daily forklift inspections, which help identify potential issues before they become hazardous.

These inspections ensure forklifts are running efficiently and safely by checking critical parts like brakes, tires, and fluid levels. OSHA has strict guidelines for daily forklift checks, making them a safety measure and a legal requirement.

Following these guidelines helps businesses maintain compliance and reduces the risk of costly repairs or operational downtime due to unexpected breakdowns.

Why Daily Forklift Inspections are Important?

Daily forklift inspections are important for ensuring the safety of both operators and those working nearby. Identifying potential issues early, like faulty brakes or worn tires, helps prevent accidents that could lead to serious injuries. These inspections also play a key role in avoiding sudden breakdowns, which can disrupt workflow and lead to costly repairs.

By meeting OSHA forklift inspection requirements, businesses stay compliant and prolong their forklifts' lifespan. Detecting minor problems early through daily checks ensures that forklifts run efficiently, reducing the likelihood of major failures and extending the machine's operational life.

How to Conduct Daily Forklift Inspections?

Daily inspections are typically performed in two stages: a visual check before starting the forklift and an operational check once it is powered on.

Step 1: Visual Inspection (Before Starting the Forklift)

The visual inspection should be conducted while the forklift is off, focusing on external parts of the machine. Key areas to check include:

• Tires: Inspect for proper inflation (for pneumatic tires), tread wear, cracks, and any embedded debris that could cause damage.
• Forks and Mast: Look for cracks, bends, or signs of damage to the forks and mast assembly. Ensure that the mast chain is properly lubricated.
• Fluid Levels: Check engine oil, hydraulic fluid, brake fluid, and coolant levels. Low fluid levels can cause malfunctions.
• Hoses and Cables: Examine hydraulic hoses and electrical cables for wear, leaks, or fraying signs.
• Lights and Alarms: Ensure headlights, taillights, and warning alarms (such as backup alarms) are working properly.
• Battery (For Electric Forklifts): Check the battery for charge level, signs of corrosion around terminals, and proper water levels (if applicable).
• Seatbelt: Ensure the seatbelt is operational and in good condition.
• Overhead Guard: Inspect the overhead guard for cracks, bends, or any signs of damage.

Step 2: Operational Inspection (After Starting the Forklift)

Once the visual check is complete and the forklift is turned on, an operational inspection is performed to ensure the forklift operates smoothly and safely. This includes:

• Brakes: Test the foot, parking, and emergency brakes to ensure they hold properly.
• Steering: Turn the steering wheel to check for smooth, responsive movement without resistance or unusual noises.
• Hydraulic Functions: Operate the lift, tilt, and side-shift functions to ensure smooth operation without jerks or unusual sounds.
• Mast Operation: Raise and lower the forks to confirm that the mast moves smoothly.
• Gauges and Instruments: Verify that dashboard indicators, such as fuel level, oil pressure, and battery charge, are functioning correctly.
• Transmission: Test the forklift in both forward and reverse gears to ensure smooth shifting and acceleration.
• Horn and Safety Alarms: Ensure the horn and any other safety alarms (backup alarms, for example) are loud and functional.

Documenting the Inspection

It's important to document each inspection for legal compliance and record-keeping. This can be done using a standardized checklist. If any issue is identified, the forklift should be tagged out of service, and repairs should be made before it's returned to operation.

Conclusion

Everyday forklift inspections are essential for maintaining a safe and efficient workplace. By identifying potential hazards like faulty brakes or low fluid levels, these checks help prevent accidents and costly repairs.

Following these inspection requirements set by OSHA ensures compliance with safety regulations and keeps your equipment running smoothly. Regular inspections also extend the lifespan of forklifts, minimizing the chances of unexpected breakdowns that can disrupt operations.

Making daily inspections a routine part of your operations is a simple yet effective way to protect your workers and maintain productivity in your facility.

Frequently Asked Questions

What are the OSHA Requirements for Day-to-day Forklift Inspections?

OSHA requires daily forklift inspections before each shift to ensure the equipment is safe. These inspections focus on key parts such as brakes, steering, tires, and fluid levels. If any issues are found, the forklift should be removed from service until repairs are made.

How Often are Forklift Inspections Required?

According to OSHA, continuously used forklifts must be inspected daily or after each shift. These inspections help identify potential problems before they cause accidents or damage. In some cases, businesses may also conduct more detailed, periodic inspections based on hours of operation.

What Happens If a Forklift Fails an Inspection?

If a forklift fails a daily inspection, it should be immediately taken out of service. The issue must be reported, and repairs should be made before the forklift can be used again. This ensures both operator safety and compliance with OSHA's forklift inspection requirements.