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Forklift inspection checklist - What must be done daily before using a forklift?

Reading time: 13 min 57 sec.

Table of Contents

1. Summary
2. Forklift inspection
3. Weight classification
4. Forklift Inspection Checklist
5. FAQs
6. Choose Lift Parts Warehouse to buy Forklift Parts
7. Takeaways

Summary

Forklift inspections should help keep the equipment in safe working condition. It is ideal for inspecting forklifts daily, but at minimum, operators should complete inspections every time they go out on a route or before use after being serviced or when issues are identified.

Forklift inspection

A Forklift inspection checklist typically contains 17 inspections for standard equipment and up to 50 inspections for specialized equipment. The information below guides on how to inspect forklifts, steps involved in completing an inspection, point values associated with each section of the checklist, required documentation needed during an inspection, and additional notes that may need to be addressed depending on the weight class of the forklift being inspected.

Forklift inspectors have discretion over what points are deducted if evidence of conditions impacting safety is found. Inspections may include all or some of the following conditions:

The Forklift inspection checklist is separated into three different weight classes; light, medium, and heavy. The weights for each class are general guides because they can vary depending on the type of forklift being used (i.e., powered Pallet Jacks typically fall in the lower end of the lightweight category). It is important to remember that operators must inspect Forklifts according to specific requirements based on what type of equipment they are operating.

For Forklifts with multiple attachments fitted to them, an operator should refer to both their Forklift Inspector's Checklist and Truck Mounted Attachment Inspection Sheets. Inspectors should always use their discretion when performing Forklift inspections. Forklifts are complex pieces of equipment, and many times unexpected situations can come up while inspecting them, so Forklift inspectors should have the ability to adapt their inspection methods accordingly.

Forklift
Forklift inspections checklist

Weight classification

The weight classifications for Forklifts are as follows:

Light Weight Forklifts (LW) - Forklifts weighing less than 3,500 pounds with a maximum lift height of 4 feet 6 inches;

Medium-weight Forklift (MW) - Forklifts ranging from 3,500 pounds to 33,000 pounds 1000kgs with a maximum lift height of either 8 feet or 10 feet; and

Heavy-weight Forklift (HW) - Forklifts that exceed 33,000 pounds or 10,000 kgs. Forklifts in this category can have a maximum lift height of either 18 feet or 21 feet.

Forklift Inspection Checklist

The Forklift's Electrical System and Forklift Battery Inspection

Is the forklift equipped with a battery that has enough power to operate all installed equipment?

  • If there is no key for the forklift, make sure to look inside the Forklift cabin for an electrical disconnect switch (if it's not located inside the Forklift cabin, check underneath). Turning off the battery disconnect switch will cut the power supply to the forklift's electrical system.

  • If the forklift is equipped with a battery disconnect switch. The forklift should be inspected for corrosion, leaking batteries (should only be cleaned up if it is in an enclosed area such as outside or a garage), replace any damaged cables or wires.

  • Inspect the Forklifts' electrical components for loose connections, corroded switches and connectors, frayed wiring, broken housings, and covers.

Is there sufficient forklift capacity to safely handle all operating conditions?

  • Ensure that Forktruck's lift height does not exceed the maximum recommended by the manufacturer.

  • Check total capacity of Forklifts, including attachments, to ensure the forklift is capable of safely handling all operating conditions.

  • During forklift inspection, the forklift should have the required capacity, with recommended modifications in place if needed. If the forklift does not have sufficient lift capacity forklift may require additional lower deck plates. Forklift inspectors must inspect lift capacity charts issued by manufacturers to determine the combined weight of all Forklift loads lifted or moved onto or off the forks.

The Forktruck's Frame And Frame Components Inspection

  • Look for broken welds on Bucket Frames and Lower Structural members.

  • Forklift Inspectors should check Forklifts' frames for corrosion, deterioration, cracks (forklift frame is unsafe if there are any signs of cracking), gouges, and dents.

  • Forklift inspectors must inspect internal forklift structures to ensure it's not bent, broken, or missing parts. Forklift inspection includes checking all internal components like mast sections, boom sections including outriggers (if equipped), side braces (for front-end loaders), and control levers.

Is the forklift equipped with a Load Backrest Plate?

If the forklift does not have a Load Backrest Plate made by the original manufacturer, replace it immediately to avoid serious injury. Fork Lift Inspection requires checking lower structural members for cracks or broken welds. Forklift Inspection includes The control lever, backrest plate, and support struts. Forklift inspectors must make sure that all components of a Forklift are in good working order& Forklifts' inspections should include checking forks (for bends, cracks, or other damage), safety locks (to ensure they latch securely), and fork pockets to make sure there's no distortion;

  • Inspect the Forktruck Lifting Mechanism(s) for missing safety devices.

  • Ensure that the Load Backrest Plate is not over 3mm thick whenever using non-original equipment replacement backrest plates.

  • For the Boom section, check Lower Structural members to ensure they're not bent, cracked, or otherwise damaged; Forklift Inspection should include Forklift inspection for corrosion, cracks, chips, and gouges. Forklifts' inspections should include checking boom section, including outriggers (if equipped). Forklifts are required to be inspected before operating them.

Check if the forklift's mast section is not bent, cracked, or otherwise damaged.

  • Inspect Forktruck Draft Gearbox Assembly for wear and damage.

  • Inspect the Forklift forks for bends, cracks, or other damage. Forklifts' inspections should include checking fork pockets to make sure there's no distortion in the pockets.

  • Ensure all controls work properly before forklift operation, including lift control lever(s)& reach rod(s), attachments being installed and removed, and Forklift brakes.

Forklift Mast, Boom, And Fork Attachments Inspection

  • Inspect Forktruck boom section including outriggers (if equipped for damage or cracks in welds& inspect Forklift mast section to ensure there's no bending, cracking, or other damage.

  • Forklifts' inspections should include checking outrigger cylinders for leaks and that the lift cylinder is either new or has been replaced within the last 3 years of inspection.

Safety Latch Cylinders

Forklift Inspectors must check Forklift safety latch cylinders to see if they're worn and for signs of cracks, pitting, and corrosion. Ensure that the Forklift mast will not slip through the fork pockets when fully raised forks. Forklift Inspect Forklifts' inspection for safety latch cylinders.

Forktruck Fork Pockets

Fork inspectors must check fork pockets to ensure there's no distortion or damage, especially on Forklift forks& ensure that the forklift will not slip through the fork pockets when forks are fully raised. Forklifts' inspections should include checking of Fork pockets to see if they're distorted or damaged and that the Forklift mast is not slipped through the fork pockets when forks are fully lifted; Transmissions: Ensure that transmission components (gears, fork connections) are in good condition with no signs of excessive wear before operating a Forktruck. In preparation for an inspection, remove any loose items from inside the cab to prevent them from being thrown around during Forklift inspection—Forktruck Inspect Forklifts' inspection for transmissions.

Forktruck Mast Locks

Fork inspectors must check fork pockets to see if they're distorted or damaged and that the Forklift mast is not slipped through the fork pockets when forks are fully lifted& ensure that the Fork Lift mast locks securely in all positions required for the operation of the forklift. Fork trucks have a lower structural member known as a "mast lock" at each side of its mast section, which prevents it from slipping out of the fork pockets when forks are raised. Ensure that the vertical surfaces of the ramps are free from cuts, gouges, or other damage [Ramps can be checked by using a tape measure to make sure that it is straight and not bent or warped]. Forklift Inspect Forklifts' inspection for mast locks being secured in all required positions.

For a forklift, mast locks must be securely in place at the rear of the fork truck's mast before operating the forklift. Ensure that Forklift Mast Locks are secure in all required positions before operating the forklift. Fork trucks have a lower structural member known as a "mast lock" at each side of its mast section, which prevents it from slipping out of the fork pockets when forks are raised.

Forktruck Relief Valve/Oil Drain Plug

Check Forklift Oil drain plug to ensure no leaks are present, or there are no signs of damage& check Forktruck Forklift relief valve to see whether it's leaking or damaged Forktrucks have an oil drain plug, which is removed every day before the forklift is put into service. Ensure that Forklift Relief Valve/Oil Drain Plug is not leaking or damaged.

Forktruck Battery Safety Latch

Forktruck inspectors must check fork pockets to make sure there's no distortion& check Forklift battery safety latch to ensure it latches securely in place after installing Forklift battery Forklifts' inspections should include checking for proper operation of Forklift battery safety latch. A lot of fork truck accidents occur during battery installation or removal. Inspectors should ensure that the Forktruck batteries are securely held in position with a positive lock (secondary latch). Fork trucks have a battery safety latch used to secure the Forklift's Forklift truck batteries in place. Ensure that Forklift Battery Safety Latch locks Forklift Truck Batteries securely in place after installation;

Forktruck Horn

Forklift inspectors should check fork pockets for damage & fork trucks' horn to see if it works properly and safely& ensure no loose items on Fork Lift Forklifts must be equipped with a warning device (horn) that can be heard by persons operating or approaching the machine from any direction. Inspectors should verify that all warning devices are mounted, operate properly, and do not emit unusual or unauthorized noises such as air leaks, the rattling of hardware, etc. "Horn is not working" Fork Truck Inspection should be done to Forktruck Forklift's horn before operating forklift.

Forktruck Mirrors

Forklift inspectors must check for Fork Lift Fork truck mirrors to ensure they are securely attached& before operating Forktruck, make sure no loose items are in a cab or on forklifts' forks when they are in a cab or on forklifts' fully raised. When inspecting a forklift, ensure that the Fork Lift mirrors and reflectors are present, secure, and mounted properly. Inspect Fork Lifts by checking for proper operation of horns and warning signals. Also, look for any loose objects in the machine's cab that could become projectiles during an accident situation.

Hydraulic Controls

Ensure all controls operate smoothly& ensure no Forklift Forklifts operate Fork Lifts w/damaged hydraulics Forktrucks Fork Trucks must be inspected for leakage and correct operations of all hydraulic cylinders. Inspect Fork Lifts by verifying that all controls operate smoothly.

Forktruck Brakes

Inspect the Fork Lift brake system to ensure it functions. Stopping power is not less than the maximum gross weight on each side of Forktruck Fork truck brakes must be tested and verified as operating properly and safely before initiating Forklift operation (including fork trucks) and during breaks.

Steering System

Verify that fork lifts' steering machines are free from excessive play or binding& ensure forks move up & down properly when the steering wheel is turned. Inspecting a forklift should include Forklift Forktrucks for loose parts, missing parts, and broken parts. Forklifts must be inspected for proper operations of Fork Lift Fork truck's steering systems. Inspect Fork Lifts by verifying that the Forktruck fork pockets are free from damage.

Guards Over Hydraulic Cylinders

Check how well guards over hydraulic cylinders are operating& ensure no points are sharp, which could injure operators prevent Fork Truck accidents by making sure all load-bearing components are properly guarded to protect personnel working in or around Forklift safety inspection should include checking that guard over hydraulic cylinders move smoothly without binding.

Operator Restraints

Before starting the engine, check operator restraints to ensure they're intact, secure & can't slip out& ensure Forklift Forklifts are inspected for safety Forktrucks Fork Trucks are equipped with safety restraints. Inspect Fork Lifts by verifying that operator restraint belts are secure and can't slip off Forklift driver seats.

FAQs

What must be done daily before using a forklift?

Forklifts are essential to warehouses and storage facilities. Forklifts can help you handle materials faster and more efficiently, but they must be used properly to prevent accidents that may result in permanent injury or death. Forklift inspections help workers stay safe.

Who is responsible for forklift inspection?

Forklift inspectors are responsible for documenting a pre-use inspection form before the forklift is powered up for use. Forklift operators should check items on the list before moving any loads with the machine's assistance.

What areas of a vehicle or machine name does an inspector check during a pre-use inspection?

A comprehensive pre-use inspection includes checking all vital components of both the automobile itself and the attached load. Forklift inspectors must ensure that all mechanical and electrical components are in proper working order before they attempt to operate a forklift. Forklifts must be inspected every day they are used and before transporting anything on their forks or side lift (if equipped).

Who should complete such inspections?

Forklift operators, warehouse employees, and those responsible for building inspections within warehouses should all know how to conduct pre-use inspections each day. Forklifts with air brakes require certified air brake technicians to inspect them and make necessary repairs.

What components of a vehicle or machine does an inspector check during a pre-use inspection?

Forklift inspectors should look over the entire vehicle for signs of damage, leaks, loose bolts, missing parts, and other safety issues. Forklift inspectors should ensure that the horn, lights, signals, and other electrical components are working properly. Forklifts with a counterweight or attached load must be lifted off their forks to check underneath them for any damage. Forklifts should be raised high enough to check beneath them without raising them so high that they lose stabilization from being too far up in the air.

Inspectors also need to look over the suspension system for wear and slack to keep it at peak performance levels. Hoses connecting hydraulic components must not show leaks, loose connections, or swelling under pressure. Safety guards must protect workers from moving parts on a device without compromising their ability to access important parts underneath or behind them. Forklift operators must be aware of any obstructions to prevent potential accidents from occurring.

What are the most common problems forklifts have?

Forklifts have many issues that can present a major safety hazard to those around them, especially if they involve loose bolts and other components that come off during operation. Forklift inspectors should watch out for leaks and damage to electrical and hydraulic lines, which can cause serious malfunctions and even explosions in some cases.

Forklift inspections help operators spot these dangers before anyone gets hurt. Forklifts with broken headlights and taillights, no horn, and malfunctioning brakes cannot be operated safely. Operators who neglect pre-use inspections may face deadly consequences down the line. Some inspectors may even refuse to allow forklifts with missing or damaged parts to be operated. Forklift inspector training prepares people for this responsibility.

Who must be trained in properly completing inspections?

Forklift inspectors need specific training on conducting thorough pre-use inspections every day. Forklift operators should know how to inspect their equipment, but having an outside party present during each inspection is the best way to find problems before they cause accidents. Forklift inspection courses help workers stay safe by offering comprehensive information about various forklifts and the individual components that make them run safely and smoothly.

Choose Lift Parts Warehouse to buy Forklift Parts

At Lift Parts Warehouse, you can buy parts for forklifts and lift trucks with confidence, knowing that every part is backed with our 100% guarantee to give your equipment optimum performance.

Takeaways

  • Forklifts with broken headlights and taillights, no horn, and malfunctioning brakes cannot be operated safely.

  • Forklifts are complex pieces of equipment, and many times unexpected situations can come up while inspecting them, so Forklift inspectors should have the ability to adapt their inspection methods accordingly.

  • Ensure that the Forklift mast will not slip through the fork pockets when fully raised forks.