Ensuring the safety and efficiency of forklift operations is crucial for workplace safety. Regular checks, both daily and weekly, are essential to prevent accidents, reduce wear and tear, and maintain productivity.
This blog outlines the necessary forklift truck checks, providing a guide for operators, supervisors, and health & safety managers. By conducting these checks, you can help your business remain compliant with safety regulations, reduce downtime, and boost efficiency.
- What is a Forklift Check?
- Why Should I Perform Forklift Truck Checks
- Daily Forklift Checks
- Weekly Forklift Checks
- Forklift Truck Check FAQs
What is a Forklift Check?
A forklift check is a routine inspection performed on a forklift to ensure it is safe and operational before and during use. These checks are crucial for identifying any issues or potential hazards that could affect the forklift’s performance or safety, helping prevent accidents and breakdowns.
Why Should I Perform Forklift Truck Checks?
Forklift checks are important for several key reasons:
- Legal Compliance
Health and safety regulations, such as the Provision and Use of Work Equipment Regulations 1998 (PUWER), require that work equipment is regularly inspected and maintained. Failing to perform required forklift checks can result in legal penalties, fines, or even the suspension of business operations. Regular checks also ensure the forklift remains compliant with safety certifications and accreditation requirements.
- Ensuring Safety
Forklifts are powerful machines that can pose significant risks to operators and nearby workers if not properly maintained. Regular checks help identify potential hazards, such as faulty brakes, worn tyres, or malfunctioning safety features (e.g., seatbelts), reducing the likelihood of accidents, injuries, or fatalities. Ensuring that a forklift is in safe working condition protects both the operator and everyone else in the workplace.
- Preventing Downtime
Minor issues, if left unchecked, can turn into major mechanical failures, leading to costly repairs and prolonged downtime. Daily and weekly forklift checks help catch problems early, allowing for timely maintenance and reducing the risk of unexpected breakdowns. This leads to increased operational efficiency and productivity.
- Extending Equipment Lifespan
Proper maintenance through regular checks helps extend the lifespan of the forklift. By addressing small issues early, you can prevent wear and tear from escalating into irreparable damage. Well-maintained forklifts tend to last longer, providing a better return on investment.
- Improved Performance
Forklifts in good working order operate more smoothly, reducing fuel consumption and wear on mechanical parts. Regular checks ensure optimal performance, contributing to more efficient and safer operations.
By implementing routine forklift checks, businesses can enhance safety, comply with regulations, reduce operational costs, and maintain high productivity.
Daily Forklift Checks
Daily forklift checks are quick, pre-operation inspections performed by the operator at the start of each shift or when taking over from another operator. These checks focus on ensuring that the forklift is safe to use throughout the day and helps in detecting any immediate issues that could pose a danger to the operator or others in the workplace.
The main inspection checks include:
- Visual Inspection
This step involves a thorough walkaround to identify any visible defects or damage to the forklift. There are 22 components of a forklift that should be assessed, but it is mandatory for the operator to carry out a full and correct check of 14 of these items:
- Fork Arms/Attachment – Each fork arm should be checked for wear, cracks and
- distortion. It is critical to pay attention to the fork hooks and carriage plate as the constant movement between these points causes wear and fracture.
- Carriage Plate – The carriage plates should have no signs of damage and sit square to the mast. The end stop bolts must be engaged and secure. The fork locking pins must fully engage into the castellations.
- Mast – Checks should be made to the outer mast sections for damage, distortions and cracks. In addition the inner mast channels or runners must be inspected for undue wear, scoring or excessive dirt.
- Mast Rollers and Slides – Mast slides must be intact and not loose, the mast guide rollers, including reach channel rollers must not show signs of uneven wear, incorrect tracking, flat spots and scoring.
- Lift Chains – Check lift chains for evidence of deterioration, loose or worn pins, damaged pin rivet heads,worn, cracked or missing links and signs of rust on link plates.
- Lift Chain Pulleys – Chain pulleys should have no obvious damage, uneven wear
- and flat spots. The chains running over pulleys should show signs of tracking correctly between the riveted end of the chain pins and the inner walls of the pulley flanges
- Rated Capacity Plate – The rated capacity plate must be fitted, it must be secure, clear and legible and display, at least, the maximum weight the lift truck can pick up, the load centre and the
- maximum lift height.
- Hydraulic Systems – All hydraulic rams, seals and couplings must be checked for damage and leaks. Particular attention should be given to where the piston emerges from the outer cylinder for any oil, corrosion and scoring on the piston
- Wheels – The wheel rim and hub should be examined for damage, cracks and scoring. Inspect the stub axles and steering assembly for excessive dirt or any foreign bodies. There should also be no obvious signs of missing or loose wheel nuts.
- Tyres – Individual tyres should be checked for punctures and pressures, adequate and even tread across the same axle, damage, flat spots and deep cuts. Check the tyre side wall for evidence of deterioration and cracks.
- Hydraulic Controls – All hydraulic driven parts (mast height, reach carriage, tilt mechanisms etc.) must be run to their end positions, to lubricate all the moving parts, checking for their serviceability, smooth operation, obvious leaks and that there is sufficient oil in the tank.
- Drive and Braking – Forward and reverse should be engaged to ensure their smooth operation and positive response to the accelerator pedal. The parking brake should be tested by slowly driving and then applying the brake, the truck must stop.
- Steering – Check for excessive play in the steering wheel before starting the truck. Avoid turning the wheels of the truck whilst stationary, this may subject the steering mechanism and tyres to unnecessary wear or strain.
- Audible Warnings – If there is an audible warning device, check that it activates and can be heard. The machine must not be operated if the horn is defective.
- Safety Features Check
Forklifts have various safety systems designed to protect both the operator and those working in the vicinity. During the daily check, the operator should ensure all these systems are fully functional before using the forklift. These checks include:
- Seatbelt: Ensure the seatbelt is working properly and isn’t frayed or damaged.
- Horn, Lights, and Warning Alarms: Check that all safety alarms (such as the reversing alarm), horn, and lights (headlights, brake lights, and warning lights) are functioning properly.
- Mirrors: Make sure mirrors are clean, adjusted, and intact for good visibility around the vehicle.
- Emergency Stop Controls: Test emergency stop switches or buttons to ensure they are working correctly.
- Interlocks: Physically and visually check any additional interlocks or gauges to ensure they are functioning in accordance with the specific manufacturer’s operating handbook.
3. Operational Checks
After the visual and safety checks, the operator should conduct a brief operational test to verify that the forklift runs smoothly. Failure to carry out these operational checks can result in accidents or breakdowns that could pose a risk to life to the operator and those around the forklift.
- Brakes and Parking Brake: Ensure both the service brakes (foot brake) and parking brake are functioning properly. The parking brake should hold the forklift securely in place when engaged.
- Steering: Check for smooth and responsive steering. Any stiffness or unusual noises during steering could indicate a problem.
- Hydraulic Controls: Test the forks by raising, lowering, tilting, and extending them to ensure the hydraulic system is working correctly without any delays or abnormal sounds.
- Transmission and Movement: Engage the forward and reverse gears to check the smoothness of movement and acceleration.
4. Documentation
Most workplaces require operators to complete a daily inspection checklist, this can be completed digitally. Any issues identified during the daily checks should be reported to the supervisor or maintenance team immediately, and the forklift should not be used until repairs are made.
Weekly Forklift Checks
Weekly forklift checks are more detailed inspections typically performed by a supervisor, maintenance technician, or trained personnel. These checks go beyond the daily visual and operational checks to assess the long-term condition of the forklift. Weekly inspections help prevent mechanical failures by addressing wear and tear issues that aren’t always visible during daily checks.
The areas covered in weekly checks include:
1. Battery Check (Electric Forklifts)
For electric forklifts, weekly checks should include an inspection of the battery’s condition such as charge level, water levels and connections and cables.
2. Tyre Pressure and Wear
Proper tyre maintenance is crucial for forklift stability and handling, especially when carrying heavy loads. A weekly tyre check involves checking and adjusting the tyre pressure, inspecting the tyres for excessive wear, punctures or other damage, and ensuring that the tyre tread is not too worn down.
3. Lubrication of Moving Parts
Forklifts have various moving components that require proper lubrication to function smoothly. A weekly check should ensure that the mast rollers and chains should be properly lubricated to reduce friction and wear. These parts are under constant stress when lifting and lowering loads. Also, ensure the steering joints and linkages are lubricated for smooth operation.
4. Fork Condition and Attachments
In addition to the daily visual check, a more detailed inspection of the forks and attachments should be done weekly. Ensure the forks are not bent or misaligned as bent forks can reduce load stability leading to accidents. Also, verify that all locking pins and attachment mechanisms are secure and functioning correctly, especially if you use specialised attachments (e.g., side-shifters or carton clamps).
5. Exhaust System
If the forklift is powered by gas, diesel, or propane, the exhaust system should be checked weekly for leaks, blockages, or excessive emissions. A malfunctioning exhaust system can cause harmful fumes to build up in the work area, creating health hazards.
6. Record Keeping
Weekly checks should be documented in a maintenance log. This helps keep track of the forklift’s condition over time, making it easier to spot recurring issues or predict when major repairs might be needed. Regular records also serve as proof of compliance with safety and maintenance regulations, therefore these records must be kept for a minimum of two years.
Forklift Truck Check FAQs
What happens if I skip regular forklift checks?
Skipping regular forklift checks increases the risk of accidents, mechanical failures, and costly repairs. It can also lead to non-compliance with health and safety regulations, resulting in fines or legal consequences for your business.
Can I perform checks myself, or should a professional be involved?
Operators are responsible for daily checks, but weekly checks should ideally be done by a supervisor or a trained maintenance technician to ensure any potential issues are identified early.
How long does a forklift check take?
A daily forklift check usually takes around 10-15 minutes, as it focuses on quick visual and operational checks. Weekly checks can take longer, anywhere from 30 minutes to an hour, depending on the level of inspection required and the condition of the forklift.
How long to keep forklift inspection records?
For annual forklift truck inspections, a thorough examination must be performed. For these inspections, records must be kept for a minimum of two years to ensure legal compliance.
Forklift Operator Training with HL Training
Regular forklift truck checks are an essential part of workplace safety and forklift maintenance. By performing daily and weekly checks, you can reduce the risk of accidents, extend the life of your equipment, and ensure compliance with health and safety regulations.
Elevate the forklift safety in your workplace by enrolling your team in HL Training Forklift Operator Training designed for a vast range of forklift types to help them stay up-to-date with best practices for daily and weekly forklift checks.
Contact our team today to learn more about our in-house, on-site and online training courses!
