Fleet Maintenance

The Occupational Safety and Health Administration (OSHA) mandates that all forklifts be examined at least daily before being placed in service. For forklifts used continuously, such as in round-the-clock operations, OSHA requires inspections after each shift. These regular inspections help identify and address potential safety issues promptly.

Source: OSHA Forklift Safety

During pre-operation inspections, operators should assess both the forklift's physical and operational conditions. Key components to examine include:

• Fluid levels: Check oil, water, and hydraulic fluid levels.
• Leaks and visible defects: Inspect for leaks, cracks, or other visible defects, especially in hydraulic hoses and mast chains.
• Tire condition and pressure: Ensure tires are in good condition and properly inflated.
• Forks: Examine the condition of the forks, including the top clip retaining pin and heel.
• Load backrest extension: Verify it is securely attached.
• Finger guards: Confirm they are in place and undamaged.
• Safety decals and nameplates: Ensure all are legible and in place.
• Operator manual: Confirm it is on board and legible.
• Seat belt: Check for proper function.
• Horn and other warning devices: Test for proper operation.
• Brakes and steering: Assess functionality.
• Lights: Ensure all are operational.
• Battery connections: Inspect for cleanliness and security.

Source: OSHA Forklift Safety

Regular maintenance of forklifts offers several advantages:

• Enhanced safety: Routine checks help identify and rectify potential hazards, reducing the risk of accidents.
• Improved performance: Well-maintained forklifts operate more efficiently, leading to better productivity.
• Extended equipment lifespan: Regular servicing prevents premature wear and tear, prolonging the forklift's operational life.
• Cost savings: Preventive maintenance can reduce the likelihood of costly repairs and downtime.

Source: OSHA Forklift Safety

Proper battery maintenance is crucial for electric forklifts. Key practices include:

• Regular inspections: Check the electrolyte level before recharging and record the specific gravity with a hydrometer.
• Water levels: Check the water level before charging but add water only after charging if levels are low. Use distilled or de-ionized water.
• Charging practices: Avoid overcharging or undercharging. Do not exceed the manufacturer's recommended discharge levels.
• Safety precautions: Wear appropriate personal protective equipment (PPE) when handling batteries to protect against acid splashes.
• Cleaning: Keep battery terminals clean and free from corrosion.

Source: OSHA Battery Safety

A comprehensive forklift maintenance checklist should cover both pre-operation and operational checks:

Engine Off Checks:

• Fluid levels (oil, water, hydraulic)
• Leaks, cracks, or visible defects
• Tire condition and pressure
• Fork condition
• Load backrest
• Hydraulic hoses, mast chains, cables, and stops
• Overhead guard
• Finger guards
• Safety warnings and decals
• Operator manual

Engine On Checks:

• Accelerator linkage
• Brakes
• Steering
• Drive control
• Tilt control
• Hoist and lowering control
• Horn
• Lights
• Hour meter

Source: OSHA Forklift Maintenance Checklist