1. Pre-Operation Safety Check
- Inspect surrounding work area for obstructions and floor hazards.
- Verify operator certification and confirm PPE usage (helmet, vest, gloves).
- Document operator name, inspection date, and equipment serial number.
- Check overhead guard for structural integrity.
- Ensure fire extinguisher is mounted and pressurized.
2. Diesel Engine & Fluids
- Check engine oil level using dipstick; refill if low.
- Inspect coolant level and radiator cap condition.
- Check hydraulic and transmission fluid levels and clarity.
- Visually inspect for leaks under the engine and chassis.
- Confirm adequate diesel fuel level and secure fuel cap.
3. Forks and Mast System
- Inspect forks for bends, cracks, and locking pins in place.
- Check fork heel thickness; should not exceed 10% wear.
- Lubricate mast chains and inspect for tension consistency.
- Test lift and tilt cylinders for smooth movement.
- Ensure backrest and mast rails are securely fastened and crack-free.
4. Safety Features & Controls
- Test horn, lights, and backup alarm functionality.
- Verify operational brakes and emergency stop.
- Check seatbelt condition and latching mechanism.
- Ensure all dashboard indicators function correctly at startup.
- Review operator manual placement and visibility of warning labels.
5. Operational Testing
- Start engine and monitor for abnormal noise or smoke.
- Test forward, reverse, lift, tilt, and side-shift controls.
- Check steering for play or stiffness.
- Perform load handling simulation with rated capacity weight.
- Observe exhaust for excessive smoke during operation.
6. Compliance Documentation
- Log inspection results in daily checklist form.
- Note any defects or maintenance requirements.
- Tag forklift as operational or out-of-service accordingly.
- Submit signed inspection form to supervisor or digital system.
- Ensure all records are retained per OSHA 1910.178(q)(7) guidelines.