The daily examination of a powered industrial truck is a requirement for safe material handling operations. This mandatory pre-shift inspection, completed by the operator, prevents equipment failure, accidents, and costly downtime. The procedure is a legally enforced requirement designed to protect the operator and surrounding personnel. Checking the vehicle before use ensures compliance with governmental safety standards.
Pre-Inspection Requirements
Before the physical inspection begins, preparatory steps ensure the procedure is conducted safely. The forklift must be parked on a level surface with the forks fully lowered to the ground. Power must be turned off, keys removed, or the battery disconnected on electric models. The parking brake must be firmly engaged to prevent unintended movement during the walk-around check.
A daily inspection checklist, physical or digital, is required for recording the examination findings. The operator must use this document to verify all components and immediately record any noted issues. This process is mandated by regulations like OSHA 29 CFR 1910.178(q)(7). This regulation states that a truck showing any condition adversely affecting safety must be removed from service immediately.
Static Visual and Fluid Checks
Tires and Wheels
Tire condition is examined for proper inflation on pneumatic models and for significant damage on solid or cushion tires. Operators must look for deep cuts, gouges, or missing material, as these defects compromise stability and steering control. Lug nuts should be visually confirmed to be present and secure. Solid tires must be checked against the designated wear line, as excessive wear reduces the truck’s capacity and stability.
Forks and Mast Assembly
A check of the forks is required, focusing on the heel area where the blade meets the shank, a common location for fatigue cracks. Forks must be replaced if the thickness has worn down by 10% of the original specification, which lowers the load capacity by 20%. Mast assembly components, including the load backrest extension, are examined for physical damage, such as bends or distortions. Ensure the carriage retaining pins are properly secured.
Mast chains must be inspected for proper tension, typically checked with a non-conductive tool. The chains should be lubricated and free of rust, corrosion, or broken links. Any elongation exceeding 3% of the original length signals the need for immediate replacement. Hydraulic hoses and fittings running alongside the mast rails are checked for visible cracking, fraying, or bulges that indicate a failure risk.
Overhead Guard and Safety Decals
The overhead guard, which protects the operator from falling objects, is inspected for structural integrity, including loose bolts, cracks, or deformation from impact. Required safety decals, warning labels, and the capacity data plate must be present and clearly legible. The capacity plate information defines the maximum safe load for the truck. This information must correspond to the current configuration and any installed attachments.
Fluid Levels and Leaks
The operator checks all fluid levels, including engine oil, hydraulic fluid, transmission fluid, and coolant, ensuring they meet the manufacturer’s recommended range. Inspect the ground beneath the forklift and the chassis to identify active leaks, such as puddles of oil, hydraulic fluid, or fuel. Leaks from hoses, cylinders, or fittings must be noted, as they indicate a loss of system integrity and a potential fire hazard.
Battery and Charger (Electric Models) or Fuel (Internal Combustion Models)
For electric forklifts, the battery charge level must be sufficient for the planned shift. Cables and connectors are checked for corrosion, fraying, or signs of arcing. The battery restraint system is verified to ensure the unit is securely held within its compartment. Internal combustion (IC) models require checking the fuel level. Inspect the fuel cap and tank for damage, rust, or secure mounting, particularly for propane tanks.
Functional Operational Checks
Operator Controls (Steering and Accelerator)
Once the visual inspection is complete, the truck is powered on to test the operator controls. The steering system is checked by turning the wheel fully to both sides to ensure smooth, responsive movement without excessive play or binding. The accelerator pedal is tested for smooth engagement and return to the neutral position, verifying the control is not sticking or lagging.
Hydraulic System Operation
The hydraulic system controls are actuated to test the mast’s full range of motion, including lifting, lowering, and tilting. The operator observes the action for jerky movements, sluggishness, or unusual noises that may signal a problem with the hydraulic pump or fluid pressure. After the controls are released, the mast is checked for “drift.” Drift occurs when the forks slowly lower or tilt without operator input, indicating an internal hydraulic leak.
Brake System Functionality
Both the service brake (foot pedal) and the parking brake require a functional test to confirm stopping power. The service brake is tested at a slow speed in a clear area to ensure the truck stops smoothly and evenly without pulling to one side. The parking brake must be set and verified to hold the forklift stationary on an incline or under a light acceleration attempt.
Gauges and Instruments
All gauges and indicator lights on the instrument panel are verified for correct operation. This includes the hour meter, fuel or battery charge indicator, and temperature gauge. Warning lights, such as those for low oil pressure or the charging system, should illuminate momentarily upon startup and then immediately turn off. This confirms the sensors are active but not detecting a current fault. Any gauge that fails to register or any warning light that remains illuminated requires the truck to be removed from service.
Safety Feature Verification
The truck’s active safety features, designed to protect the operator and warn pedestrians, must be manually tested. This includes operating the horn to ensure it is loud enough for the work environment. The operator must test the headlights, taillights, and any required warning beacons or strobe lights for full functionality.
The backup alarm is verified to sound immediately when the direction control is placed in reverse. The operator’s seatbelt is checked for proper latching and retraction mechanisms. Confirm the seatbelt is free of cuts, fraying, or damage that could compromise its ability to restrain the operator. If the forklift has a fire extinguisher, verify its presence, secure mounting, and the charge indicator seal.
Documentation and Reporting Procedures
The final step in the daily inspection is documenting the results. Every completed checklist must be signed and dated by the operator to formally record that the examination was performed for that shift. This documentation is a legal record confirming compliance with the daily examination requirement.
If the inspection reveals any defect affecting safe operation, the operator must immediately report the issue to a supervisor. The forklift must then be tagged or marked “Out of Service” to prevent use. The truck must remain tagged out until qualified personnel complete all necessary repairs and formally certify the equipment as safe for operation.