Knowing when to inspect your forklift comes down to three operational triggers: daily pre-shift requirements, legal inspection intervals, and visible warning signs during operation.
1. Immediate Red Flags (Check Right Away)
If a machine exhibits any of the following symptoms, ground it immediately for maintenance:
- Hydraulic Leaks: Fluid pooling under the chassis or dripping mast lines.
- Mast & Chain Slack: Uneven lifting, slow response times, or strange grinding noises when elevating loads.
- Brake Creep: Spongy pedals or a parking brake that slips on incline ramps.
- Tire Chunking: Cracks, missing rubber pieces, or severe flat spots on cushion/pneumatic tyres.
- Dashboard Alarms: Active warning indicators, battery discharge spikes, or steering resistance.
2. Mandatory Inspection Timelines
- Daily Pre-Shift Checks: Required by HSE guidelines before every shift. Operators must perform visual walk-arounds (tyres, forks, fluids) and dynamic operational checks (brakes, steering, hydraulics).
- Statutory Thorough Examination: A legal requirement every 6 to 12 months (or every 4 months for machines lifting personnel) under LOLER 1998 and PUWER 1998 regulations.
| Inspection Type | Frequency | Conducted By | Primary Objective |
| Pre-Shift Audit | Start of every shift | Trained Operator | Catch immediate wear, fluid leaks, and safety device failures |
| Routine Service | Every 250–500 operating hours | Service Technician | Change oil/filters, grease joints, and adjust mechanical wear |
| Thorough Examination | Every 4, 6, or 12 months | Certified Competent Engineer | Legal compliance check covering safety-critical lift systems & chassis integrity |