Forklift Inspection and Maintenance

Forklifts are built to do tough work, but they’re not indestructible. Like any piece of heavy equipment, powered industrial trucks (PITs) must be regularly inspected and properly maintained to stay safe and reliable.

Daily inspections and scheduled maintenance are required by OSHA. Without them, even small mechanical issues can go unnoticed until they cause a serious accident. Employers are responsible for making sure that forklifts are inspected at the start of each shift and removed from service if found to be unsafe.

What OSHA Requires

Under 29 CFR 1910.178, OSHA mandates that all forklifts be examined every day they are in use. For forklifts that are used around the clock, inspections must be done at the beginning of each shift. These checks aren’t optional – they’re a core part of safe equipment operation.

The goal is to identify any defects or issues that could affect the safety of the operator or others nearby. If a safety-related defect is found, the forklift must be taken out of service immediately until it has been repaired and deemed safe to use again. Continuing to operate damaged or unsafe equipment can result in OSHA citations and serious liability.

What Should Be Inspected?

While OSHA doesn’t prescribe an exact checklist, inspections generally include both visual and operational checks, including but not limited to:

Visual Checks

• Leaks
• Tire damage
• Cracked forks
• Missing safety decals
• Fuel and fluid levels
• Battery charge

Operational Tests

• Brakes
• Horn
• Steering
• Controls
• Mast function
• Lights
• Seatbelt

Many employers use a standardized inspection form to document these inspections. Whether it’s on paper or digital, keeping a record of each inspection helps demonstrate compliance and allows you to track trends or recurring issues.

Preventive Maintenance Programs

In addition to daily checks, forklifts need routine preventive maintenance. The frequency of this maintenance depends on the type of forklift, hours of operation, manufacturer recommendations, and environmental conditions. For example, a forklift operating indoors in clean conditions may have very different needs than one exposed to dust, weather, or extreme temperatures.

Preventive maintenance often includes fluid changes, filter replacements, brake inspections, battery care, lubrication, and other manufacturer-specified service points. Having a maintenance schedule in place not only extends the life of your equipment but also significantly reduces the risk of unexpected failure.

A common misconception is that OSHA requires an annual inspection done by a third party. While this is not a federal requirement, employers are responsible for ensuring that all forklifts are kept in a safe operating condition and repaired by qualified personnel. Depending on the equipment, workplace conditions, or insurance policies, a third-party service may be used to meet preventative maintenance needs.

Who’s Responsible?

Forklift operators are responsible for conducting the daily inspections before using the equipment. Supervisors should ensure inspections are done consistently and review checklists to follow up on any flagged issues. Maintenance personnel are responsible for addressing any defects, performing repairs, and completing scheduled service.

It’s also important that operators feel comfortable reporting issues without fear of being blamed or penalized. A strong safety program depends on open communication and shared responsibility.

The Bottom Line

Inspections and maintenance aren’t just about compliance; they’re about preventing accidents before they happen. A single oversight can lead to injuries, damaged products, or costly downtime. By making equipment checks and routine service a daily habit, employers can protect their workers, extend the life of their forklifts, and stay in compliance with OSHA requirements.

For help ensuring the safe operation of your business’s PITs, contact Walden’s EHS team at 860-846-4069.