Before using a forklift, a thorough pre-operation inspection is crucial to ensure safety, prevent accidents, and maintain the equipment's longevity. Here’s a detailed checklist of what should be checked:

1. General Condition & Documentation

Inspection Records: Verify that the previous shift’s inspection records are complete and that any reported issues have been addressed.

Forklift Identification: Ensure the forklift is the correct model for the task and that all identification plates (e.g., load capacity, serial number) are legible.

2. Exterior Inspection

Body & Frame: Check for cracks, dents, or welds that may indicate structural damage.

Fork Condition:

Inspect forks for bending, cracking, or excessive wear (especially at the heels and tips).

Measure fork thickness; if worn beyond 10% of the original dimension, replace them.

Ensure the load backrest is intact and securely attached.

Tires:

For pneumatic tires: Check for cuts, bulges, or uneven wear. Verify proper inflation pressure.

For cushion tires: Look for chunks missing or tread separation.

Ensure tires are free of debris that could cause instability.

Mast & Lift Mechanism:

Inspect chains, rollers, and pins for wear or damage.

Check for hydraulic leaks (e.g., oil stains under the mast).

Verify that the mast raises, lowers, and tilts smoothly without jerking or unusual noises.

3. Fluid Level Checks

Fuel (Internal Combustion Forklifts):

Check diesel/gasoline/LPG levels and ensure no leaks in fuel lines or tanks.

Engine Oil: Verify oil level is within the recommended range on the dipstick.

Hydraulic Fluid: Check for proper level and signs of contamination (e.g., milky appearance indicating water ingress).

Coolant (if applicable): Ensure coolant level is adequate and the system is leak-free.

Battery (Electric Forklifts):

Check electrolyte levels (for wet-cell batteries) and top up with distilled water if needed.

Inspect battery terminals for corrosion and ensure connections are tight.

Verify battery charge level (if equipped with a gauge).

4. Safety Features & Controls

Brakes:

Test the service brake (foot pedal) and parking brake (hand lever) for responsiveness.

Ensure the forklift stops smoothly without pulling to one side.

Steering:

Check for excessive play in the steering wheel.

Verify that the forklift responds accurately to steering inputs.

Lights & Signals:

Test headlights, taillights, brake lights, and turn signals for proper operation.

Ensure the strobe light (if equipped) is functional for high-visibility areas.

Horn: Sound the horn to confirm it’s loud and clear.

Seat Belt: Check that the seat belt is intact and latches securely.

Mirrors: Adjust mirrors to provide maximum visibility and ensure they’re crack-free.

Fire Extinguisher (if mounted): Verify it’s charged and accessible.

5. Operator Compartment

Seat Adjustment: Ensure the seat can be adjusted forward/backward and tilted for comfort.

Controls: Test all levers, pedals, and switches (e.g., lift, tilt, horn) for smooth operation.

Gauges & Indicators: Check that the speedometer, hour meter, and warning lights (e.g., low fuel, overheating) are functional.

Floorboard: Inspect for debris or spills that could cause slipping.

6. Functional Test

Start the Engine/Power Up:

Listen for unusual noises (e.g., knocking, grinding) during startup.

Check for smoke or unusual odors (e.g., burning oil).

Drive Test:

Move the forklift forward and backward in a straight line to test steering and braking.

Perform a lift/lower test to ensure the mast operates smoothly under load (use a test weight if possible).

Load Handling:

If a load is attached, verify it’s secured and centered on the forks.

Test tilt function to ensure the load remains stable.

7. Environmental & Worksite Checks

Floor Conditions: Scan the area for oil spills, debris, or uneven surfaces that could affect stability.

Overhead Obstructions: Check for low ceilings, pipes, or hanging loads that may pose a risk during operation.

Pedestrian Traffic: Identify high-traffic zones and plan routes to minimize interactions with pedestrians.

8. Documentation & Reporting

Log Inspection Results: Record all checks in the forklift’s inspection log, noting any defects or maintenance needs.

Tag Out if Unsafe: If issues are found, tag the forklift as “out of service” and report it to a supervisor immediately.

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