Tyres and Wheels
- Check tyre pressure (solid/pneumatic) for appropriateness and evenness.
- Inspect tyre surface for cracks, splits, or embedded debris.
- Verify adequate tread depth (visual check or gauge measurement).
- Ensure lug nuts are tight and not missing.
- Inspect rims for damage, warping, or weld cracks.
- Check for proper tyre inflation and wear patterns.
Fluid Checks
- Verify engine oil level and condition (check color and consistency).
- Check hydraulic fluid level and clarity.
- Inspect transmission fluid level (if separate reservoir).
- Ensure brake fluid level and appearance are satisfactory.
- Check radiator coolant level and inspect for leaks.
- Confirm diesel fuel level and ensure fuel cap is tight.
- Look for any visible fluid leaks under the forklift.
Forks & Mast Assembly
- Check forks for straightness and secure mounting.
- Verify fork heel wear is below 10% of original thickness.
- Ensure locking pins and retaining clips are in place.
- Lubricate mast chains and ensure even tension.
- Inspect lift cylinder pins and bushings for security.
- Ensure backrest and carriage assembly are secure and crack-free.
- Check mast rollers and wear pads for proper condition.
Safety & Controls
- Ensure seat belt is operational and not frayed.
- Test horn, backup alarm, and lights for proper operation.
- Check steering function for smoothness and responsiveness.
- Verify that service and parking brakes engage fully.
- Ensure emergency stop/kill switch works (if equipped).
- Verify fire extinguisher is present and fully charged.
- Ensure overhead guard and operator compartment are secure.
- Confirm load capacity plate is readable and accurate.
Operational Functionality Test
- Verify engine starts without abnormal sound or excessive smoke.
- Test lift, tilt, and side-shift functions for smooth operation.
- Ensure travel in forward and reverse functions properly.
- Inspect hydraulic hoses for leaks, chafing, or damage.
- Check engine idle quality and throttle response.
- Monitor exhaust system for excessive smoke or damage.
Diesel Engine Specific
- Check air filter condition and cleanliness.
- Inspect fuel filter and water separator.
- Verify exhaust system integrity and mounting.
- Check for fuel system leaks or damage.
- Monitor engine temperature gauge during warm-up.
- Ensure diesel particulate filter (DPF) warning lights are off.
Body and Structure
- Inspect counterweight for cracks or damage.
- Check frame for bends, cracks, or broken welds.
- Verify all guards and covers are in place.
- Ensure operator seat adjustment and condition.
- Check mirrors for proper adjustment and cleanliness.
- Inspect steps and handholds for security and condition.
Documentation & Compliance
- Complete daily inspection log with all findings documented.
- Record hour meter reading for maintenance tracking.
- Note any defects found and report to supervisor.
- Verify operator certification is current and valid.
- Ensure OSHA compliance documentation is maintained.
- Tag out equipment if unsafe conditions are found.