Forklift inspections are a critical component of workplace safety and OSHA compliance. Every year, approximately 85 workers are killed and 34,900 are seriously injured in forklift-related incidents according to OSHA data. Many of these accidents could be prevented through proper pre-operation inspections that identify mechanical defects before they cause failures.
OSHA Standard 29 CFR 1910.178(q)(7) requires that powered industrial trucks be examined before being placed in service. This is not optional. Operators must inspect their equipment at the beginning of each shift.
What is a Forklift Inspection?
A forklift inspection is a systematic safety check performed by trained operators before operating powered industrial trucks. The inspection covers visual and operational components to ensure the equipment is safe to use. Inspections identify worn parts, fluid leaks, brake problems, and other defects that could cause accidents or equipment failures.
There are three main types of forklift inspections: pre-operation (daily) inspections performed by operators, periodic inspections conducted weekly or monthly, and thorough examinations performed annually by qualified technicians. Each serves a different purpose in your overall maintenance and safety program.
OSHA Forklift Inspection Requirements
OSHA requires forklift inspections under 29 CFR 1910.178, which covers powered industrial trucks in general industry. The standard mandates that trucks be examined before being placed in service. If any conditions are found that could affect the safe operation of the truck, the operator must report them immediately, and the truck must be taken out of service until repairs are made.
Key OSHA Requirements
- Pre-shift inspection required before each work shift (29 CFR 1910.178(q)(7))
- Defective trucks must be taken out of service until repaired
- Only trained and authorized operators may operate forklifts
- Operators must report any defects affecting safe operation
- Documentation of inspections is strongly recommended for liability protection
Penalties for Non-Compliance
OSHA can issue citations and fines for forklift safety violations. Serious violations can result in penalties up to $15,625 per violation (2024 rates). Willful or repeated violations can reach $156,259 per violation. Beyond fines, failure to maintain proper inspections increases liability if accidents occur.
Types of Forklift Inspections
Pre-Operation (Daily) Inspection
This is the most common inspection type, performed by the operator at the start of each shift. It takes 5-10 minutes and covers visual checks (fluid leaks, tire condition, fork damage) and operational checks (brakes, steering, horn, lights). Any defects found should be reported immediately.
Periodic Inspection (Weekly/Monthly)
Periodic inspections go beyond daily checks to include brake testing, hydraulic system evaluation, and more thorough component inspection. These typically take 15-20 minutes and may be performed by maintenance personnel or supervisors.
Thorough Examination (Annual)
Annual thorough examinations are comprehensive inspections performed by qualified technicians. They include complete brake testing, load testing, chain and fork measurement, and detailed component inspection. These examinations produce documented reports and often identify wear patterns that require component replacement.
Complete Forklift Inspection Checklist
Use this comprehensive checklist to ensure you cover all critical inspection points. The checklist is divided into visual inspection items (engine off) and operational inspection items (engine running).
Visual Inspection Items (Engine Off)
- Fluid leaks: Check under the forklift for oil, hydraulic fluid, fuel, or coolant leaks
- Tires: Look for cuts, gouges, chunking, and proper inflation on pneumatic tires; check solid tires for excessive wear
- Forks: Inspect for cracks, bends, and wear (replace if thickness is reduced 10% from original)
- Mast and carriage: Check for damage, proper chain tension, and smooth operation
- Overhead guard: Ensure it is secure with no damage or missing bolts
- Data plate: Verify it is legible and attached
- Safety labels: Check that warning labels are present and readable
- Load backrest: Ensure it is secure and undamaged
- Battery (electric): Check electrolyte level, cable connections, and case condition
- Fuel system (IC): Check fuel level, cap seal, and look for leaks
Operational Inspection Items (Engine Running)
- Steering: Check for excessive play (should not exceed 2 inches free play)
- Service brakes: Test stopping ability and pedal feel
- Parking brake: Must hold forklift on incline when loaded
- Horn: Test for proper operation (required by OSHA)
- Backup alarm: Verify alarm sounds when traveling in reverse
- Lights: Test headlights, taillights, and warning lights if equipped
- Hydraulic controls: Check lift, lower, tilt, and attachment functions
- Mast operation: Raise to full height and check for smooth, quiet operation
- Gauges: Verify all gauges show normal readings
- Seat belt: Check condition and proper latching
Electric Forklift Specific Items
- Battery charge level: Must be adequate for shift
- Battery connections: Check for corrosion and tight fit
- Charging receptacle: Look for damage or wear
- Battery restraint: Verify battery is properly secured
- Hour meter: Record hours for maintenance scheduling
Internal Combustion (IC) Forklift Specific Items
- Engine oil level: Check dipstick before starting
- Coolant level: Verify in overflow tank (never open radiator cap when hot)
- Air filter: Visual check for obvious contamination
- Exhaust system: Look for leaks, damage, or missing parts
- Fuel: Adequate supply for shift
How to Perform a Forklift Inspection
Follow this step-by-step process to ensure consistent, thorough inspections every time. Developing a standard routine helps prevent skipping critical items.
- Step 1: Approach and walk around the forklift, looking for obvious damage, leaks, or hazards
- Step 2: Check fluid levels (oil, hydraulic, coolant, fuel/battery)
- Step 3: Inspect tires, wheels, and lug nuts
- Step 4: Examine forks, mast, chains, and carriage
- Step 5: Check operator compartment, seat, and safety equipment
- Step 6: Start the engine and listen for unusual sounds
- Step 7: Test all operational controls (steering, brakes, hydraulics)
- Step 8: Verify horn, lights, and warning devices
- Step 9: Complete inspection documentation
- Step 10: Report any defects and remove from service if necessary
Forklift Inspection Documentation
While OSHA does not explicitly require written inspection records, documentation is strongly recommended. Proper records demonstrate your safety program compliance, provide liability protection, track recurring issues, and support maintenance scheduling.
What to Include in Inspection Reports
- Date and time of inspection
- Forklift identification (unit number, serial, model)
- Operator name and signature
- Hour meter reading
- Checklist of all items inspected
- Pass/fail status for each item
- Description of any defects found
- Corrective actions taken
- Supervisor verification if required
How Long to Keep Records
Industry best practice is to retain forklift inspection records for a minimum of 3 years. Some companies keep records for the life of the equipment. Digital inspection systems make long-term storage easy and provide instant retrieval during audits.
When to Remove a Forklift from Service
OSHA requires that defective forklifts be taken out of service until repairs are completed. The following conditions require immediate removal from service:
- Brake failure or inadequate stopping ability
- Steering problems or excessive play
- Hydraulic leaks or control failures
- Damaged forks (cracks, bends, or excessive wear)
- Mast or carriage damage
- Missing or inoperative safety devices (horn, lights, backup alarm)
- Fluid leaks that create slip hazards
- Tire damage affecting stability
- Overhead guard damage
- Any condition that could affect safe operation
Tag-Out Procedure
When a forklift must be removed from service, attach a prominent tag stating "DO NOT OPERATE" with the reason and date. Remove the key and notify your supervisor. The forklift should not return to service until repairs are completed and verified by a qualified person.
Forklift Inspection Best Practices
- Train all operators: Every operator should know how to perform proper inspections
- Use standardized checklists: Consistent forms ensure nothing is missed
- Inspect at the same time: Beginning of shift inspections catch overnight problems
- Never rush: A thorough inspection takes 5-10 minutes and is worth the time
- Report everything: Even minor issues should be documented for tracking
- Verify repairs: Re-inspect after maintenance before returning to service
- Supervisor spot checks: Periodic verification ensures operators follow procedures
Common Forklift Inspection Mistakes
- Rushing through inspections without actually checking items
- Skipping operational tests (brakes, steering, hydraulics)
- Failing to document findings
- Ignoring minor issues that become major problems
- Operating equipment with known defects
- Not removing defective equipment from service
Digital Forklift Inspection Solutions
Paper inspection forms have significant limitations: they get lost, are hard to read, and make tracking trends difficult. Digital inspection solutions solve these problems while providing additional benefits.
- Photo documentation: Capture images of defects for maintenance teams
- Timestamped records: Prove when inspections were completed
- Automatic storage: No lost paperwork, instant retrieval
- Trend tracking: Identify recurring problems across your fleet
- Maintenance integration: Route defects directly to work orders
- Compliance reporting: Generate audit-ready reports instantly
- Offline capability: Complete inspections without network connection
Frequently Asked Questions
How often should forklifts be inspected?
OSHA requires inspection before each shift. If multiple operators use the same forklift in a day, each operator should verify the inspection is current for their shift. Many operations also perform weekly or monthly periodic inspections and annual thorough examinations.
Who can perform forklift inspections?
Daily pre-operation inspections should be performed by trained, authorized forklift operators. Periodic and thorough examinations may require qualified maintenance technicians or third-party inspectors depending on the scope of the inspection.
What happens if a forklift fails inspection?
If any condition is found that could affect safe operation, the forklift must be taken out of service immediately. Tag the equipment, remove the key, report to your supervisor, and do not operate until repairs are completed and verified.
Are forklift inspection records required by OSHA?
OSHA does not explicitly require written inspection records, but documentation is strongly recommended. Records demonstrate compliance, provide liability protection, and are expected during OSHA inspections. Many states have additional requirements.
How long should a forklift inspection take?
A thorough pre-operation inspection takes 5-10 minutes. Do not rush. The time invested prevents accidents, equipment damage, and costly downtime. Operators who skip inspections to save time often face much larger problems later.
Conclusion
Forklift inspections are a fundamental requirement for workplace safety and OSHA compliance. By implementing consistent inspection procedures, training all operators, and maintaining proper documentation, you protect your workers, your equipment, and your business.
The investment of 5-10 minutes per shift for a proper pre-operation inspection prevents accidents, reduces maintenance costs, and demonstrates your commitment to safety. Whether you use paper forms or digital solutions, the key is consistency and thoroughness.
Ready to streamline your forklift inspections? ForkliftTracker provides digital inspection tools that make compliance easy. Complete inspections on any device, capture photo documentation, and generate audit-ready reports instantly. Start your free trial today.