What must be done daily before using a forklift?

Maintaining Efficiency: A well-functioning forklift performs optimally, ensuring smooth, efficient material handling.

Your Daily Pre-Operation Forklift Checklist: Visual Inspection (Engine Off)
Before even starting the forklift, a thorough visual inspection is required. Walk around the entire machine, systematically checking each area.
Tires and Wheels:
Check: Look for excessive wear, cuts, cracks, gouges, or missing chunks in solid tires. For pneumatic tires, check proper inflation pressure. Inspect wheel nuts for looseness and look for any foreign objects lodged in the treads.
Why: Damaged tires can cause instability, reduce braking effectiveness, and lead to blowouts or tip-overs. Improper inflation affects stability and load capacity.
Forks:
Check: Inspect for cracks, bends, twists, or excessive wear (especially at the heel, where they bend at the carriage). Ensure the fork tips are not severely worn or bent. Check that the locking pins are present and properly engaged to secure the forks to the carriage.
Why: Damaged forks can fail under load, leading to dropped materials, serious injury, or equipment damage.
Mast and Hoist Chains:
Check: Look for any signs of cracks, bends, or damage to the mast channels and rollers. Inspect the hoist chains for proper tension (they should be equally tensioned), broken or stretched links, rust, or signs of wear. Check for any obstructions or debris within the mast channels.
Why: A compromised mast or chain can lead to uncontrolled load descent or mast failure, causing catastrophic accidents.
Hydraulic System:
Check: Inspect all hydraulic hoses, cylinders, and fittings for leaks, cuts, fraying, bulges, or crimps. Check the hydraulic fluid level.
Why: Hydraulic leaks can lead to loss of lifting power, erratic controls, fire hazards, and environmental contamination. Low fluid levels can damage the hydraulic pump.
Overhead Guard and Load Backrest:
Check: Ensure the overhead guard is securely attached, free from cracks, bends, or damage. Verify the load backrest is in place and securely fastened.
Why: The overhead guard protects the operator from falling objects, and the load backrest prevents loads from shifting backward into the operator's compartment.
Fluid Levels (for IC Forklifts):
Check: Engine oil, hydraulic fluid, coolant, brake fluid, and fuel level.
Why: Proper fluid levels are critical for engine health, hydraulic function, and preventing overheating.
Battery (for Electric Forklifts):
Check: Inspect battery cables and connectors for damage, corrosion, or looseness. Ensure battery retaining straps/clamps are secure. For lead-acid batteries, check electrolyte levels (ensure proper watering) and look for excessive corrosion on terminals.
Why: Faulty battery connections can cause arcing, overheating, power loss, and even fires. Improper battery maintenance severely shortens battery life and can lead to dangerous conditions.
Propane Tank (for LP Forklifts):
Check: Ensure the tank is securely mounted and upright. Inspect the tank, hose, and connections for any signs of leaks (smell, frost buildup). Check the hose condition for cracks or kinks.
Why: Propane leaks are highly flammable and pose severe explosion and fire risks.
General Cleanliness:
Check: Remove any debris, trash, or obstructions from the operator's compartment, around the pedals, and from the mast area.
Why: Debris can obstruct controls, fall into moving parts, or become a fire hazard.
Your Daily Pre-Operation Forklift Checklist: Operational Inspection (Engine On)
After the visual check, start the forklift and perform these functional tests in a safe, open area, away from pedestrians and other equipment.
Steering:
Check: Test for smooth operation and excessive play in the steering wheel. Ensure it responds correctly.
Why: Faulty steering can lead to loss of control and collisions.
Brakes (Service and Parking):
Check: Test the service brake (foot brake) for smooth and effective stopping power. It should bring the forklift to a complete stop without excessive pedal pressure or pulling to one side. Engage and test the parking brake to ensure it holds the forklift securely, especially on an incline.
Why: Braking system failures are a leading cause of forklift accidents.
Lifting and Tilting Mechanisms:
Check: Operate the lift control to raise and lower the forks through their full range of motion. Listen for unusual noises. Test the tilt control (forward and backward) to ensure smooth operation without jerking or shuddering.
Why: Proper hydraulic function is essential for safe load handling and stability. Malfunctions can lead to dropped loads or tip-overs.
Horn:
Check: Activate the horn to ensure it is working loudly and clearly.
Why: The horn is a critical warning device for pedestrians and other operators.
Lights and Alarms:
Check: Test all headlights, taillights, brake lights, directional signals (if equipped), and the strobe light (if equipped). Activate the backup alarm to ensure it sounds when reversing.
Why: Proper lighting and audible alarms are essential for visibility and warning in various operating conditions.
Gauges and Controls:
Check: Verify that all dashboard gauges (e.g., fuel level, battery charge, engine temperature, oil pressure) are functioning and show normal readings. Test all operational controls (accelerator, forward/reverse lever/buttons) for smooth and responsive action.
Why: Functioning gauges provide vital information about the forklift's operational status. Responsive controls ensure the operator has full command of the machine.
Unusual Noises or Vibrations:
Check: Listen carefully for any unusual engine noises, hydraulic pump whining, grinding, squealing, or excessive vibrations during operation.
Why: These can indicate underlying mechanical problems that require immediate attention.

The Reporting and Documentation Mandate
If, during any part of the daily inspection, a defect or condition is found that affects the safe operation of the forklift, the issue MUST be immediately reported to a supervisor, and the forklift must be removed from service. It should not be used until the defect has been corrected and the forklift is deemed safe for operation.
Many companies utilize standardized pre-shift forklift inspection checklists or forms. These forms provide a systematic way to perform the checks, record findings, and document the forklift's status before each shift. This documentation is crucial for compliance, maintenance tracking, and accident investigation.
Beyond the Checklist: The Role of Training
It is critical to remember that these daily checks must only be performed by properly trained and certified forklift operators. Operator training, as mandated by OSHA and other regulatory bodies, covers not only safe operating practices but also the procedures for daily inspections, hazard recognition, and reporting protocols. An untrained individual attempting these checks or operating a forklift poses a significant risk.
Conclusion: Daily Diligence for Lifelong Safety
The question "What must be done daily before using a forklift?" underscores a fundamental principle of industrial safety: proactive vigilance. The seemingly simple routine of a daily pre-operational inspection is an indispensable practice that safeguards lives, protects valuable assets, and ensures seamless operations. By consistently performing these visual and operational checks, operators become the first line of defense against potential hazards, contributing to a culture of safety that benefits everyone in the workplace. This daily diligence isn't just a requirement; it's the foundation of responsible and productive forklift operation.