Forklift

Forklift periodic inspection is the examination and testing, at least once a year by authorised engineers, of powered industrial trucks that lift and carry loads on forks. Lifting organs, hydraulic system, brakes, stability and visibility equipment and the operator protection structures are assessed. Forklifts rank first among equipment in fatal tip-over and strike accidents in warehouses and yards; therefore the inspection is not a formality but an operational life line.

Forklift Classification

The inspection approach is shared across classes; power source and duty differ:

• Diesel/LPG counterbalance forklifts (outdoor and warehouse)
• Battery forklifts (indoor; the charging station safety is evaluated separately)
• Narrow-aisle and multi-directional forklifts
• Racking types such as Reach Truck and Stacker

Periodic Inspection Items

• Forks and carrier frame: Crack and deformation at the fork heel, toe-lift measurement along the blade, retaining pin integrity; carriage rail wear and horizontal clearance.
• Hydraulic system: Cylinder leaks, hose burst risk, chain/rod tension and elongation; lift drift measurement.
• Overhead guard (OGS/FOPS): Integrity of the roof guard connections and, if repaired, certification adequacy.
• Brakes and steering: Hand and foot brake performance with load, adjustment clearances; steering box free play and manoeuvre behaviour.
• Visibility and warning equipment: Lights, indicators, horn, reverse alarm, tip-over and overload warnings, mirrors.
• Static stability: Consistency of the capacity plate with counterweight against the manufacturer curve; the rear axle must not lift in the overload scenario.
• Battery types: Battery clamping, electrolyte/charging circuit, earthing insulation and socket-cable safety.

Legislation and Standards

Forklifts are audited under Law No. 6331, the Work Equipment Regulation and the annexes on periodic control of machinery. Technical references: general safety TS EN ISO 3691-1, design ISO/ASME B56 series, fork standard ISO 2328 (class compatibility), overhead guard requirements in the ISO 22915 series. Operator training and authorisation is an integral administrative condition of the regulation.

Risks and Operator Recommendations

A large share of accidents happen when an operator without a seatbelt or without a cab guard is caught under a tipping truck, and others from losing stability while travelling with a raised or overloaded load. Capacity drops as lift height rises on the curve, so the habit of travelling low must be built; keeping the load close to the 600 mm load-centre rule protects the plate capacity. The daily shift checklist (brake, horn, leaks, fork lock) and the periodic inspection complement each other; any missing item grants the operator stop authority. In shared pedestrian areas, speed limiters, mirrors and blue-spot lights are recommended.

Outcome

At the end of the examination a signed report with compliance, findings and service recommendations is issued. Forklift inspections belong to our Lifting and Handling Machines heading. If your fleet includes Manual Pallet Trucks, Electric Pallet Trucks and Stackers, they can be merged under a single programme; see our contact page.