Forklift Pre-Use Inspection Checklist

A daily pre-use inspection is one of the simplest and most effective ways to prevent forklift accidents and catch problems before they become costly breakdowns. This page includes a free checklist you can print and use straightaway, along with guidance on what to look for and why it matters.

Why is a daily forklift inspection important?

Forklifts operate in demanding environments. Even in normal use, components wear, fluid levels drop, and small defects can develop into serious safety hazards. A daily pre-use check takes just a few minutes but can prevent accidents, reduce unplanned downtime, and help you demonstrate a proactive approach to safety compliance.

The HSE recommends that operators carry out a visual and functional check before each shift. These checks do not replace the statutory thorough examination under LOLER — but they are an important part of a complete maintenance and safety regime.

What to check before operating a forklift

Fluid levels

  • Engine oil (diesel and LPG trucks)
  • Hydraulic fluid
  • Coolant level
  • Battery water level (electric trucks)
  • Fuel or battery charge level

Tyres and wheels

  • Check for cuts, chunking, or significant wear on pneumatic tyres
  • Check solid tyres for chunks missing or flat spots
  • Check wheel nuts are tight and none are missing

Forks and carriage

  • Inspect forks for cracks, bends, or wear — especially at the heel
  • Ensure fork thickness is not worn down more than 10% from original specification
  • Check fork retention pins or hooks are secure
  • Check carriage and mast for visible cracks or damage

Mast and chains

  • Inspect chains for wear, corrosion, or damaged links
  • Check chain lubrication — chains should not be dry
  • Check chain anchor pins and sheaves
  • Operate the mast through full range — movement should be smooth with no hesitation

Hydraulic system

  • Check for visible hydraulic fluid leaks on hoses, cylinders, or fittings
  • Operate the tilt and side shift functions — movement should be smooth

Brakes and steering

  • Test the service brake — the truck should stop promptly
  • Test the parking brake — the truck should hold on an incline
  • Check steering for excessive play or unusual resistance

Lights, horn, and safety devices

  • Test the horn
  • Check working, reverse, and warning lights
  • Test the reverse alarm if fitted
  • Check the seat belt or operator restraint is functional

Overhead guard and operator protection

  • Inspect the overhead guard for visible damage or deformation
  • Check the load backrest extension is secure if fitted

What to do if you find a defect

If any defect is found during a pre-use inspection, the forklift must be taken out of service immediately and tagged to prevent use. The defect should be reported to a supervisor and logged in the maintenance record. Do not operate a forklift with a known safety defect.

Need a forklift serviced or repaired?

If your pre-use inspection reveals a problem, our experienced engineers can help. Davison Forklift provides on-site repairs, servicing, and breakdown support across the West Midlands and Shropshire. Call us today.

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