Forklift Drivers: Site and Vehicle Inspections

This article about the importance of inspections is an introduction to learning how to safely operate a forklift. This information will provide a step up in knowledge so when you start your formal forklift training you’ll be in a good position with better understanding and confidence.

Site inspections, pre-operational and operational forklift vehicle inspections are excellent workplace safety practices to integrate into your working day as a forklift driver.

The following video clip about how to operate a forklift was produced for TAFE and explains the inspections that you need to do as a forklift driver.

Site inspections

Site inspections are important to identifying hazards like:

1.     Pot-holes and uneven surfaces

2.     Overhead service lines

3.     Power lines

4.     Surrounding buildings

5.     Site gateways and entrances to buildings

6.     Pedestrians

7.     Surface Inclines

8.     Weather

Forklift vehicle inspections

Forklift operators should preform two inspections before the vehicle moves:

• Pre-operational visual inspection with key off

• Operational inspection with engine running

1.    Pre-operational check

Before the machine is turned on, visually inspect the following:

• Oil level

• Water level

• Hydraulic fluid level

• Hydraulic hoses (look for leaks, cracks, or any other defects)

• Mast chains (look for cracks, breaks, or any other defects). Use a stick or similar device to check the chain tension. The forklift operator should never place a hand into the mast.

• Tyres, including condition and pressure (be sure to inspect for cuts and gouges)

• Wheel nuts

• Forks (check the condition, including the top clip retaining pin and heel

• Loaded backrest extension

• Finger guards

• Safety decals and nameplates (make sure they are all in place and legible; check that the information on the nameplate matches the model and service numbers and attachments)

• Operator manual (make sure it’s there on the truck and that it’s legible and complete–no missing or torn pages, etc.)

• Operator compartment (check for debris, grease, etc.)

• Safety belt and all other safety devices (make sure they’re all working properly

Electric Forklifts — pre-operation inspection

Electric Forklifts must have the following items and parts inspected and checked before operating the vehicle:

• Cables and connectors (look for frayed, exposed, or otherwise damaged wires)

• Battery restraints

• Electrolyte levels (always use proper personal protective equipment, such as a face shield, rubber apron, and rubber gloves, when checking the electrolyte level)

• Hood latch.

Internal Combustion Forklifts — pre-operation inspection

Internal Combustion Forklifts must have the following items and parts inspected and checked before operating the vehicle. Always use proper personal protective equipment, such as a face shield, long sleeves, and gauntlet gloves, when making these inspections

• Liquid propane tank (properly mounted; check for dents and cracks, that it fits within the profile of the tank)

• Pressure relief valve (make sure it’s pointing up)

• Hoses

• Connectors

• Tank restraint brackets

• Check for leaks.

Liquid Propane Forklifts — pre-operation inspection

Forklifts powered with liquid propane must have the following items and parts inspected and checked before operating the vehicle:

• Engine oil

• Brake reservoir

• Engine coolant

• Air filter

• Belts and hoses

• Radiator

• Hood latch

2.    Pre-start check

Mounting the Forklift

You could get hurt while attempting to mount a forklift. Hazards include:

• Hitting your head on the overhead cage

• Slipping, tripping, and falling, especially when feet slip off the step

Here are some ways to avoid these hazards:

• Make sure your hands are clean and dry. Don’t have anything in your hands.  

• Wear appropriate shoes or boots that avoid skids — check your shoes for grease or anything else slippery

• Use the handhold and get a good grip. Don’t grab the steering wheel as a way to mount the forklift because the steering wheel may move and cause you to lose your balance

• Be careful with your footing at all times.

• Pull your body up into the forklift. Don’t jump.

Operational Forklift Inspection

After the pre-operational inspection (with key off) is complete and you’ve mounted the forklift, it’s time for a operational forklift inspection.

You’ll conduct this second inspection with the engine running. During the operational inspection, check:

• Accelerator linkage

• Inch control (if present)

• Brakes

• Steering

• Drive control, including both forward and reverse

• Tilt control, including forward and back

• Hoist and lowering control

• Attachment control

• Horn

• Lights

• Back-up alarm (if present)

• Hour meter

In addition to all of the above, observe for unusual noises or vibrations. If you detect any, report them immediately.

3. Driving the forklift

Before you begin to move the forklift, make sure your way is clear by looking in your direction of traffic. Sound your horn and/or use a spotter if your vision is obstructed.

Once you’re sure your path is clear, proceed with caution down the path of travel and watch for dangerous curves, blind spots, intersections with pedestrian traffic, and/or any other hazards.

Clear visibility while operating the forklift

Operating a forklift with blocked or partially blocked visibility increases the chances of an accident.

Poor visibility can lead to hazards including:

• Collisions

• Falling load

• Forklift fall off a loading dock

• Hitting pedestrians

To avoid these hazards, we make sure to we have the following in check:

• Keep a clear view

• Look in all directions around you before you begin

• When operational, always look in the direction you’re going. Look behind you when operating in reverse

• Use rear view mirrors whenever possible

• Where possible, use concave mirrors when entering buildings or aisles and/or when approaching corners or other blind spots

• If lighting is dim use headlights. Use headlights when operating at night, outdoors, and/or in any area where additional lighting would improve quality. Moving from a bright to a dark area, or from dark to bright, can temporarily disrupt visibility.

• Drive slowly into and out of warehouses or other buildings.

• Be cautious on loading docks and stay away from edges, which can be hard to see

• Slow down and sound the horn at cross aisles and other locations where vision can be obstructed.