Before operating a forklift, the operator must perform a pre-shift inspection. This is not optional. It is required by OSHA and is the single most important routine in forklift safety. The inspection takes five minutes. An accident caused by a failed component takes seconds.
Walk-Around Inspection
The operator starts by walking around the forklift. Look for visible leaks under the truck. Check the tires for cuts, embedded debris, or missing chunks. On pneumatic tires, check air pressure. On cushion tires, look for uneven wear. Inspect the forks for cracks, bends, or excessive wear. The fork tips should be even. Check the mast chains for proper tension and visible damage. Look for loose or missing bolts on the carriage and overhead guard.
Fluid Checks
For internal combustion forklifts, check the engine oil level, coolant level, and fuel level. Look for leaks around the engine, radiator, and hoses. For electric forklifts, check the battery charge level and inspect the battery cables for fraying or damage. Check the electrolyte level in lead acid batteries and top up with distilled water only after charging.
Function Tests
Start the forklift and test the brakes. The brake pedal should feel firm. The forklift should stop smoothly without pulling to one side. Test the horn and backup alarm. Both must be audible from the operator's seat. Test the steering. The wheel should turn smoothly without excessive play. Test the lift and tilt functions. Raise the forks fully. Lower them smoothly. Tilt the mast forward and backward. Listen for unusual noises like grinding or whining. Test the lights if the forklift operates in low light conditions.
Operational Check
Raise the forks a few inches and check that they hold position without drifting down. A drifting mast indicates a hydraulic leak. Check the parking brake. The forklift should not roll on an incline. Test the seat belt. It should latch securely and release easily.
Documentation
Record the inspection results. OSHA requires documentation that the inspection was performed. The operator must sign off on the checklist. If any defect is found that affects safety, the operator must report it immediately and refuse to operate the forklift until repairs are made.
The Bottom Line
A pre-shift inspection is not a paperwork exercise. It is the moment when a crack in a fork, a leak in a hose, or a worn brake is caught before it causes a catastrophe. The operator who skips the inspection to save five minutes is gambling with their life and the lives of everyone nearby. The inspection is required. The five minutes is cheap. The accident is expensive. Do the inspection. Every shift. Every time.