Forklift Inspection Checklist | Daily Safety Guide

Forklift Inspection Checklist | Daily Safety Guide

Inspection Checklists
100 Items
Comprehensive forklift inspection checklist covering all safety and operational aspects including visual inspection, hydraulic systems, brakes, tires, electrical systems, and documentation.

Forklift Inspection Checklist

A forklift inspection checklist is vital for maintaining a safe and efficient workplace. It helps operators verify that equipment is in good working condition before each use. By identifying potential issues early, it prevents accidents and reduces costly downtime. Regular checks also support compliance with safety regulations and standards. This checklist provides a simple, reliable way to keep forklifts operating safely every day.

1. Visual / Exterior Inspection

1Check for visible damage, dents, or cracks on the frame
2Inspect the paint coating, corrosion, or rust spots
3Verify overhead guard condition (no cracks, secure)
4Examine counterweight for looseness or damage
5Inspect nameplate / data plate—is it legible and intact?
6Inspect all safety decals and labels (e.g. load limit, warning signs)
7Check for missing bolts, nuts, or fasteners on exterior parts
8Inspect mirrors, guards, and covers (in place and undamaged)
9Inspect step plates, handholds, ladders (if present)
10Check that all protective guards (finger guards, chains covers) are present and intact

2. Forks, Carriage & Load Handling Assembly

1Inspect forks for cracks, bends, or wear (especially at heels)
2Check fork tip condition (no sharp edges, not worn)
3Verify fork retaining pins and clips (top clip, heel pin)
4Inspect the carriage for cracks or distortion
5Check load backrest extension for security and condition
6Inspect mast channels and rollers for wear or damage
7Check lift chains for wear, proper lubrication, and slack
8Inspect chain anchor points and pins
9Test tilt cylinders (inspect for leaks or damage)
10Operate the mast up/down, tilt forward/back to check smoothness

3. Hydraulic System

1Check hydraulic fluid level (in reservoir)
2Inspect hydraulic hoses, lines and fittings for leaks or chafing
3Examine cylinder rods for pitting, scoring, or damage
4Check all seals and gaskets for signs of leakage
5Inspect hydraulic filters (if accessible)
6Verify smooth operation of control valves (lift, tilt, side-shift if applicable)
7Check relief valve operation
8Observe hydraulic memory (if equipped)
9Inspect auxiliary hydraulic lines (if attachments present)
10Listen for abnormal hydraulic noises during operation

4. Brakes & Steering

1Test service (foot) brake for proper response
2Test parking or emergency brake
3Check brake pads / shoes / discs for wear
4Inspect brake lines and fittings for leaks/damage
5Check steering linkage, tie rods, kingpins for play or wear
6Inspect power steering system (fluid level, lines, pump)
7Verify turning radius and steering smoothness
8Test steering under load (if safe to do)
9Inspect wheels and casters for looseness, wear or damage
10Check wheel bolts/nuts torque (secure)

5. Tires / Wheels / Axles

1Inspect tire condition (cuts, chunks, wear)
2Check tire inflation (if pneumatic)
3Inspect rims for cracks, damage, corrosion
4Check for foreign objects lodged in tread
5Examine wheel bearings for play or noise
6Inspect axle housing and seals for leaks
7Check alignment of wheels
8Verify secure mounting of wheels
9Inspect inner wheels (if dual wheels)
10Check hub caps and bearing grease (if applicable)

6. Power / Fuel / Battery System

1For electric: check battery electrolyte / water levels and condition
2For electric: inspect battery cables, connectors, and insulation
3For fuel/LPG/diesel: check fuel system lines, connections, and leaks
4For LPG: inspect tank mounting, hose, regulator, vent lines
5Check engine oil level (for IC engines)
6Check coolant / radiator fluid levels
7Inspect belts (fan, alternator, etc.) for wear, tension
8Check air filter condition
9Verify fuel (or charge) sufficiency for operation
10Test charging system / alternator (if applicable)

7. Electrical / Controls / Instruments

1Test horn, backup alarm, warning sounds
2Test lights: headlight, tail, brake, turn signals (if applicable)
3Test gauges and indicators: oil pressure, temperature, charge/discharge, hour meter
4Verify instrument panel operation
5Inspect wiring harnesses for damage or chafing
6Check switches, buttons, levers for proper operation
7Check for loose terminals or connectors
8Test the key switch / ignition system
9Test any electronic safety systems (e.g. tilt lock, speed limiter)
10Check battery discharge indicator (electric forklifts)

8. Cab / Operator Compartment / Safety Devices

1Inspect seat, seat belt, mounting hardware for condition and security
2Test seat belt buckle, retraction, and locking
3Check steering wheel, column for tightness and play
4Test pedals (accelerator, brake, inching) for smooth operation
5Inspect floor mat / deck for debris or wear
6Check operator visibility (clean windows, mirrors)
7Inspect instrument cluster, warning lights, gauges (clear and readable)
8Test safety devices: presence sensors, dead-man pedal, presence switch
9Inspect fire extinguisher (if installed) and mounting bracket
10Check that operator's manual / logbook are in place and legible

9. Operational / Performance Check (Engine Running / Powered)

1Listen and observe for unusual noises or vibration
2Test engine idle and throttle response (for IC engine)
3Test lift operation under no-load and light load
4Test tilt forward/back under safe load conditions
5Test travel in forward and reverse modes
6Test speed, acceleration, deceleration behavior
7Test attachment functions (if any)
8Confirm smoothness and responsiveness of controls
9Monitor temperature, pressure gauges under operation
10Check for fluid leaks while running

10. Documentation / Safety / Post-Inspection

1Record inspection date, forklift ID, and operator name
2Log any defects or issues found
3Tag or mark forklift "Out of Service" if critical defects detected
4Ensure follow-up on maintenance / repair of deficiencies
5Verify that corrective actions have been completed
6Maintain inspection records for audit / regulatory compliance
7Confirm that any modifications are noted in documentation
8Check that inspection checklist is reviewed and updated periodically
9Ensure operators are trained and aware of inspection importance
10Perform a final walk-around before placing forklift into service
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