Before using a manual forklift (also known as a hand pallet truck or pump truck), conducting a thorough pre-use inspection is crucial to ensure safety, prevent accidents, and prolong equipment lifespan. Here’s a step-by-step checklist of what to inspect:

1. Structural Integrity

Fork Arms:

Check for cracks, bends, or excessive wear on the forks.

Ensure the fork tips are not damaged or uneven.

Verify that the fork width is appropriate for the load.

Frame & Mast:

Inspect for dents, corrosion, or deformation in the frame or mast.

Ensure all welds are intact and free of cracks.

Handle/Control Lever:

Check for bends, cracks, or loose connections in the handle.

Ensure the release lever (for lowering the forks) operates smoothly.

2. Hydraulic System (for Pump Trucks)

Pump & Cylinder:

Test the hydraulic pump by raising and lowering the forks several times.

Look for leaks (oil or hydraulic fluid) around the pump, cylinder, or hoses.

Ensure the forks lower smoothly and do not drop suddenly.

Seals & Hoses:

Inspect hoses for cracks, bulges, or loose fittings.

Check seals around the cylinder for leaks.

3. Wheels & Rollers

Load Wheels (Under Forks):

Ensure wheels rotate freely without wobbling or binding.

Check for flat spots, cracks, or excessive wear on the tires.

Verify that axles and bearings are not loose or noisy.

Steering Wheels (Rear Wheels):

Test steering for smooth operation (if applicable).

Inspect for worn or damaged tires.

4. Safety Features

Load Backrest (if equipped):

Ensure it is securely attached and free of damage.

Overload Protection (if applicable):

Check that any overload valves or mechanisms function properly.

Warning Labels & Decals:

Verify that safety labels (e.g., capacity, operating instructions) are legible.

5. Operating Controls

Pump Handle:

Ensure it locks securely in the upright position.

Check for smooth operation when pumping and releasing.

Brakes (if equipped):

Test any parking or service brakes for effectiveness.

6. Load Capacity & Stability

Check Rated Capacity:

Confirm the forklift’s maximum load capacity (usually marked on the unit).

Never exceed this limit.

Load Stability:

Ensure the load is centered and secure on the forks.

Check for uneven weight distribution that could cause tipping.

7. Environmental & Operational Checks

Work Area:

Inspect the operating area for obstacles, uneven floors, or wet/oily surfaces.

Ensure adequate lighting and ventilation.

Operator Readiness:

Wear appropriate PPE (safety shoes, gloves, high-visibility vest).

Ensure the operator is trained and authorized to use the forklift.

8. Documentation & Reporting

Inspection Log:

Record the inspection date, findings, and any maintenance performed.

Report Defects:

If any issues are found (e.g., leaks, damaged forks, worn wheels), tag the forklift as "Out of Service" and report it to a supervisor or maintenance team immediately.

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