Forklift Checklists for Daily and Pre-Operational Use

Importance of Using Forklift Checklists

Using forklift checklists ensures safety and compliance as you conduct inspections. This helps prevent potential issues caused by malfunctioning or damaged equipment, ensure equipment longevity, and comply with safety regulations such as OSHA.

OSHA Forklift Requirements

OSHA has established several important requirements for forklift operation and safety. For instance, forklift operators are required to be trained and certified by OSHA before they can legally operate in the workplace. Using a standardized checklist before a forklift operation, helps operators maintain a safety culture consistently and provide proper documentation of compliance.

And when it comes to forklift inspections, all industrial trucks need to be examined before use, and forklifts should not be used when the inspection reveals any condition adversely affecting the safety of the vehicle.

4 Essential Forklift Tips for Operators

Failure to inspect powered industrial trucks before use is one of the most cited OSHA violations in terms of forklift safety. Here are some tips to help forklift operators conduct inspections and perform maintenance checks easily.

Tip #1: Inspect from the outside-in during engine off checks

It can be easier for operators to perform the necessary pre-use inspections by practicing the outside-in technique for assessing the safety of a forklift. 

Tip #2: Investigate unusual noises during engine checks

Forklift operators should immediately report unusual noises or vibrations during operational inspections. Common issues from unusual noises in the engine often involve the brakes, controls, and steering of the forklift. Look out for leaks in the compartment especially when the engine is running. Test the breaks, controls, and steering to ensure that they are functioning properly. 

Tip #3: Be mindful of potential hazards for removal from service

While driving, be alert for potential fire, leakage, overheating, and mechanical breakdown. If any of these defects among other safety issues are detected, forklift operators should stop, park the vehicle, and get help. While meeting deadlines and getting the job done matters, your safety and the safety of those around you matter more.

Tip #4: Schedule preventive maintenance inspections regularly

Regular maintenance is crucial to keep the safe operation of forklifts. A sign that could mean lift trucks are overdue for their adequate maintenance is when they skid or slide while in operation because of grease and spills. During preventive maintenance, check if powered industrial trucks are free of debris and lint to avoid improperly working controls.

The Impact of an Inefficient Forklift Inspection Process

Your forklift operators need to lift heavy loads, safely navigate through aisles, and watch out for pedestrians. They need to do all these and more as quickly as possible. Aside from those responsibilities, they also need to conduct regular forklift inspections. Whether you’re a supervisor in a warehouse, construction site, or manufacturing plant, the gravity of the forklift inspections conducted by your operators can’t be taken for granted. 

Forklifts are crucial in your business’ logistics, thus you ensure inspections are performed consistently and efficiently. You are aware of the extreme consequences a single, inoperable forklift can cause to your operations.

E-commerce giants eBay and Amazon estimate their forklifts’ downtime value at whopping costs of $3,750 and $3,000 per minute, respectively. Reduce eBay’s downtime value by 95%, and smaller businesses can still lose a significant amount of $11,250 per hour. 

On top of an inoperable forklift’s financial impact, other repercussions can include employees getting stressed because of the tense environment and, ultimately, your company’s reputation suffering due to unfulfilled customer demands.

Forklift inspections can mean the difference between profit and loss, which is why they need to be completed as effectively and efficiently as possible. If your operators currently use paper checklists for forklift inspections and you’ve begun to recognize its pitfalls, you might be looking for a solution that can resolve those drawbacks. Take a look at your current forklift inspection process and see if a more modern and digital solution is what you and your operators need.

What Should be Included in a Forklift Safety Checklist?

The contents of a forklift safety checklist should, at the minimum, include all essential parts of the forklift being checked and consider the type of inspection to be done involving the forklift. The most basic forklift checklist is divided into two sections: pre-start or pre-operational and after starting the engine.

Pre-start or Pre-operational

During pre-start, the following, among other things, are checked:

• Tires and rims
• Engine oil, hydraulic oil, battery fluid, coolant level, and hydraulic levels
• Possible leaks
• Visible damage
• Locking mechanism
• Rams
• Battery
• Engine bay
• Load plate
• Overhead and backrest guards
• Operator’s seat
• Controls
• Seat belt

After Starting the Engine

The following are checked after starting the engine to make sure they will function during operations:

• Controls, pedals, and indicators
• Revers buzzer and beacon
• Lights and flashing strobe
• Steering wheel
• Park brake and foot brake
• Hydraulic lift

Forklift Checklist Sample Report

Once the inspection is completed, forklift operators can generate a report to share with anyone relevant for documentation and proactively set tasks in case of any issues found :

Forklift Daily Checklist Sample PDF Report | SafetyCulture