DAILY FORKLIFT SAFETY CHECKLIST

Operating a forklift may seem straightforward, but it requires attention to detail, routine safety checks, and consistent maintenance to ensure the safety of both the operator and those around them.
 
Before each use, a daily forklift inspection checklist can help identify potential hazards and equipment issues that might otherwise lead to accidents or breakdowns.
 

Start with a Visual Inspection

A quick visual inspection helps catch and visible issues that might not be noticeable once the machine is in operation. Before even starting the forklift, take a walk around and look for the following:
Tyres: Check for damage, wear and proper inflation (if pneumatic). Worn tyres can reduce stability an make the forklift harder to control.
Forks and Mast: Look for cracks, bends or other visible damage on the forks and mast components. Ensure they’re not warped or showing signs of excessive wear.
Chains and Hoses: Inspect hydraulic hoses and lifting chains for any signs of wear, fraying, leaks or breaks.
Overhead Guard: Ensure the guard is securely in place, protecting the operator from any falling objects.
Seat Belt and Restraints: Check that all restraints are intact and fully functional. A secure seatbelt is crucial for operator safety.
Lights, Mirrors and Warning Alarms: Confirm that mirrors, lights and alarms are in place and functioning to alert nearby pedestrians.
 

Check Fluid Levels

Forklifts require several fluids to operate smoothly and safely. Low or absent fluid levels can lead to mechanical issues or overheating:
Engine Oil: Check the dipstick to ensure the oil level is within the recommended range. Low oil can damage the engine over time.
Hydraulic Fluid: The hydraulic system is essential for lifting and manoeuvring. Low hydraulic fluid can make the forklift harder to control or prevent it from lifting loads.
Coolant: A coolant check ensure that the engine won’t overheat during operation.
Brake Fluid: Check the levels of brake fluid to ensure the brakes will perform reliably, as braking issues are a significant safety hazard.
 

Inspect the Battery (for electric forklifts)

If you’re working with an electric forklift, the battery needs daily inspections to maintain its charge and ensure longevity.
Battery Charge: Ensure the battery is fully charged to avoid unexpected shutdowns or loss of power during operation.
Electrolyte Levels: Check that electrolyte levels in each battery cells are correct, and refill as needed with distilled water.
Cables and Connectors: Inspect the cables and connectors for any corrosion, cracks or wear. Loose or damaged connections can lead to a sudden loss of power.
 

Brake Test

Testing the brakes daily ensures safe stopping, which is critical for maintaining control. Check:
Service Brake: Test by slowly moving the forklift forward and stopping to ensure the brakes engage properly.
Parking Brake: Engage the parking brake to confirm it holds the forklift in place, even on a slight incline.
Foot Brake: Make sure the foot brake has a solid feel and engages without requiring excessive pressure.
 

Steering and Controls Check

Forklifts rely heavily on responsive steering and controls for accurate and safe operations, make sure to:
Steering Wheel: Ensure the steering wheel moves smoothly without excessively play or resistance.
Control Levers: Test all control levels, including lift, tilt and side shift functions, to confirm smooth operation.
Gauges: Check that all gauges, especially fuel or battery charge indicators, are working withing safe levels.
 

Test the Horn and Warning Devices

Forklifts typically operate in busy areas where pedestrians and other vehicles are present, making it essential to alert others to the forklift’s presence:
Horn: Test the horn to ensure it is loud and functional, as it’s often the first line of alert for people nearby.
Backup Alarm: For reverse movements, check that the backup alarm works, as it’s essentials for warning people of the forklift’s direction.
Lights and Indicators: Ensure all lights, including head, tails and indicator lights, are working, particularly if you’re working in low light conditions.

Examine the Load Handling Attachments

If your forklift has any additional attachments, such as clamps, rotators, or push-pulls, insect these components:
Attachment Condition: Look for any signs of damage, leaks, or wear that could compromise the attachment’s performance.
Attachment Controls: Test the control functionality to ensure they’re responsive and move as expected.
 

Perform and Operational Test

Once the visual inspection and fluid check are complete, perform and short operational test before beginning any serious lifting or driving:
Drive Forward and Reverse: check that the forklift moves smoothly in both forward and reverse without strange noises or resistance.
Lift and Lower the Mast: Test the mast by lifting and lowering it to ensure it moves slowly and without jerking.
Tilt and Side Shift: Test the tilt and side shift functions, if equipped, to ensure the mast operates smoothly and can handle slight adjustments.
 

Documentation and Reporting

If any issues are discovered during the inspection, they should be documented immediately and reported to the appropriate supervisor. Documenting issues ensures accountability and enables quick resolution, minimising downtime and maintaining safety standards.

 
Implementing a daily forklift inspection checklist is one of the simplest and most effective ways to prevent accidents and equipment damage. By spending a few minutes each day on these checks, operators can help create a safer workplace, reduce repair costs, and extend the life of the forklift. Remember, safety is everyone’s responsibility.