Forklifts are a common sight in many industries. Whether used in warehouses, retail applications or elsewhere, these vehicles are crucial tools in the daily operations of many businesses. Because of this frequent level of use, however, many operators and nearby pedestrians become complacent regarding safety protocols. This complacency can have many ill effects, including asset damage, employee discipline, fines, injury, and even death.

1. Forklifts are a common sight in many industries. Whether used in warehouses, retail
applications or elsewhere, these vehicles are crucial tools in the daily operations of many
businesses. Because of this frequent level of use, however, many operators and nearby
pedestrians become complacent regarding safety protocols. This complacency can have many
ill effects, including asset damage, employee discipline, fines, injury, and even death.
According to the Operational Safety and Health Administration (OSHA), an average of 100
employees are killed each year in forklift accidents, and as many as 95,000 total forklift
accidents occur on an annual basis.1
In many cases, these accidents are avoidable. While
forklifts are carefully designed with safety in mind, safety protocols must be followed correctly
for operators and pedestrians to be protected. Failure to behave properly around these heavy,
powerful vehicles is much more dangerous than many may realize, and thus operator or
bystander negligence frequently contribute to accidents.
The Importance of Inspection
Beyond behavioral causation, injuries and fatalities also stem from detectable
equipment failure when employees do not properly inspect and assess equipment
before use. OSHA, forklift manufacturers and many companies encourage that
forklifts be inspected before operation, but these inspections are often neglected
or poorly documented. Safety is an obvious reason that these inspections should be conducted
regularly, and so is compliance—thousands of dollars in fines could be levied based on failure
to determine forklift safety prior to operation.
Protecting company reputation, finances, property and lives against this sort of failure
and related accidents typically requires only one measure be taken—pre-operation forklift
inspections carried out according to a thorough checklist. Besides the safety and compliance-
related aspects of regular forklift inspection, there is also a cost-savings component related
to proactive discovery of issues and predictive maintenance, as discovering problems sooner
limits downtime and cost to address.
Creating and adhering to a pre-operation inspection regiment need not be difficult—you simply
need to familiarize yourself with best practices for detecting hazardous conditions before they
cause issues.
Pre-Operation Inspections: What Must You Do?
In its 29 CFR 1910.178 standard language, OSHA states that forklifts must be
inspected either daily or after each shift in cases where vehicles are in round-the-
clock use. If problems are discovered, they must be reported and the forklift must
be removed from service immediately.
While there are no mandates in the standard as to precisely how the inspections must be
conducted, there are suggested best practices readily available. Forklift manufacturers, for
instance, often provide best practice checklists with operating manual materials explaining
how inspections should be conducted, and extra copies of checklist log books can be acquired
from forklift dealerships. OSHA also offers suggestions for carrying out these inspections. By
all accounts, both a visual pre-ignition check (before keys are inserted into the forklift) and
operational check (forklift engine running) should be conducted.
1
An average of 100
employees are killed each
year in forklift accidents,
and as many as 95,000 total
forklift accidents occur on
an annual basis. In many
cases, these accidents
are avoidable.
Pre-Operation Forklift Inspections:
Why They Matter and What to Check
Revised as of 12/18/2014
MUST
DO

2. Pre-Operation Inspections: What Should You Do?
There are a few best practices by which you should abide to
ensure equipment is in proper shape before operating a forklift.
Most importantly, operators should be trained on how to conduct
pre-operating inspections, and proper safety equipment should
always be worn and used by operators and pedestrians. Training can often
be attained from equipment manufacturers, if necessary.
Results of inspections should be rigorously logged, showing other users of the equipment that
inspections were performed. Copies of log pages should be given to supervisors to document
any issues discovered, bolstering safety and serving as evidence of the inspection in case of
an audit. Finally, equipment with issues should not only go unused, but should be locked out
immediately, as waiting or removing the key—which can be replaced easily since forklift keys
are universal—can increase risk.
Abiding by these best practices can save lives and many headaches, and thus it is important to
have the proper protocols and checklists in place to ensure forklift equipment is always safe
and approved for use.
What Should Go in a Checklist?
If you do not have a pre-operational checklist for your forklifts established, do not
worry—they are fairly intuitive. Manufacturers often provide sample checklists that
are updated and customized as necessary as equipment and company needs shift,
and referencing these directions are your best bet. If you wish to create your own
checklist, however, the following is a list of the sorts of items that should be included:
• Check fluid levels (oil, water, and hydraulic fluid, for example)
• Check for leaks, cracks and visible defects everywhere on the forklift
• Check mast chains visually; avoid use of hands
• Test mast chain tension by lifting the load backrest to eye level—the mast chains should be
level; any tilting may signify stretching or broken rollers
• Check tire condition, pressure, and look for any cuts or gouges
• Determine fork condition, remembering to check the top clip retaining pin and heel
• Ensure load backrest extension functions properly
• Check functionality of finger guards
• Ensure safety decals and nameplates are legible and match the forklift model
• Check that the operators’ manual and log book are present and legible
• Ensure the operators’ manual compartment is clean of debris
• Test all functional safety devices, such as seat belts and horns
• Check the brakes, steering controls and other operational items for proper function
Depending on the type of forklift you are using, there may be other propulsion-specific aspects
to check:
Electric
• There is no fraying or exposed wires in cables or connectors
• Battery restraints are functional
• Electrolyte levels are proper
• The hood latch is operational
Internal combustion
• Engine oil and engine coolant levels are proper
• Air filters are clean and in place
• The radiator is free of cracks or other defects
• The hood latch is operational
2
SHOULD
DO

3. Liquid Propane
• The tank is properly mounted, fits with the vehicle profile, has all restraints and brackets
attached, and has no dents or cracks
• No leaks can be detected
• The pressure relief valve is facing upward
• Hoses and connectors are attached and functional
Protect Yourself and Your Employees
Proper pre-operation inspection protocols are proven means of avoiding injury and
death, and they are not difficult to manage. They are also essential to maintaining
compliance and company reputation, making it worth the few minutes it takes to
inspect your equipment before putting it to use. By being proactive and thorough in
your operations, you’ll save yourself time, money and stress long-term.
If you need more suggestions or assistance in creating checklists or protocols, resources such as
webinars and reference material on safety best practices are readily available—do not hesitate
to talk to your dealership. Seek out education where necessary to ensure maximum forklift
safety, and you’ll be poised for maximum productivity and minimal setbacks in your forklift-
related operations.
References
1. “Worker Safety Series: Warehousing”. Occupational Safety and Health Administration.
https://www.osha.gov/Publications/warehousing.html
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