Forklifts are mechanical vehicles extremely common in many industries. They are key tools in daily operations and supply chains in manufacturing plants, warehouses, and retail applications. This equipment is frequently used and has contact with people, which is why regular forklift inspections are crucial for the safety of both the operator and people in the vicinity. Using a not fully functional forklift can have many negative consequences in the form of property damage, dismissals, fines, injuries, and even death. Every year there are 95,000 accidents involving forklifts, including fatal accidents. Many of these incidents could be avoided.

Forklift Inspections – Regulations

Every owner of this type of vehicle knows that their obligations include registration, maintaining documentation, as well as regular maintenance inspections of forklifts. These are short-distance transport devices (UTB), so depending on the type of vehicle, some of them require acceptance testing by UDT (Technical Supervision Authority).

Forklifts Not Subject to UTD Technical Supervision

Registration obligation and conducting technical inspections, as well as UDT acceptance, do not apply to vehicles that are not equipped with a lifting mechanism. These are, for example, lifting pallet trucks, push trucks, or tow trucks.

UTD supervision also does not apply to forklifts with manual lifting mechanisms. This type of vehicle does not require any external control.

Forklifts Subject to UTD Technical Supervision

The Technical Supervision Authority covers mobile lifting trucks with mechanical lifting drive. They can be subject to technical supervision:

  • full – requires notification to UTD, approval for operation, ad-hoc inspections, conducting periodic tests every 12 months, while maintenance inspections of forklifts take place every 30 days in this case. This includes mobile trucks with boom and mechanical drive, with operator lifted together with the load, platform trucks, or those with operator seat.
  • limited – requires notification to UTD, approval for operation, ad-hoc inspections, maintenance inspections of forklifts take place every 60 days in this case, periodic inspections every 2 years. This includes trucks with mechanical drive and lift, guided or remotely controlled.

Forklifts – Types of Inspections

Forklift inspections are necessary for legal reasons and aim to ensure optimal safety. Each test should be conducted within the timeframe that depends on UTD recommendations, as well as guidelines from the manufacturer. The most important forklift inspections are: daily inspection, maintenance inspections, periodic and ad-hoc inspections.

Daily Inspection

At the beginning of each shift, the operator is obligated to check the forklift and report any defects to the supervisor. The basis here is checking tires for damage and their inflation level. It is also important to check fuel, water, and oil in forklifts powered by combustion engines for leaks and proper levels. In the case of electric vehicles, it is necessary to check the battery charge level. Verification of brake functionality and warning signal. All these elements are recorded in the operation logbook.

Maintenance Inspection

Maintenance inspections of forklifts are performed by maintenance technicians or forklift service centers. This type of testing allows for the detection of various types of defects or equipment failures. Maintenance inspections of forklifts are also recorded in the operation logbook. The person conducting this test records all types of observations regarding the vehicle’s condition. Repair of any defects or replacement of worn components is then carried out.

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Periodic Inspection

Periodic inspections are conducted by inspectors from the Technical Supervision Authority. During this type of testing, the technical condition of the vehicle is checked, as a result of which the permit for equipment operation is extended or revoked. While a periodic UDT forklift inspection is being performed, the equipment maintenance log is checked, as well as the inspection book and electrical measurement protocols. Necessary documents of employees involved in operation and maintenance of vehicles are also reviewed. In addition, individual forklift systems are inspected, as well as operator cabin equipment.

Ad-hoc Testing

This type of testing is also conducted by UDT inspectors. It can take the form of operational ad-hoc testing, which aims to confirm that all changes that have occurred in the equipment such as: repair, modernization, disassembly, component replacement meet all safety standards. It can also be post-accident or post-failure ad-hoc testing. It is conducted after receiving notification regarding dangerous damage or an accident related to forklift operation.