Forklift Pre-Use Inspection Guide and Daily Checklist
A forklift should be inspected before it is used.
A structured pre-use inspection helps operators identify damage, deterioration, leaks and safety defects before the truck enters service.
GH Training's free Forklift Pre-Use Inspection Guide and Daily Checklist gives employers, supervisors and operators a practical system for checking forklifts, reporting defects and preventing unsafe equipment from being used.
Download the Free Inspection Guide
The downloadable nine-page guide includes:
- Practical pre-use inspection guidance
- Employer and operator responsibilities
- A step-by-step inspection sequence
- External and structural inspection checks
- Operator-position and functional checks
- A printable daily forklift checklist
- Defect reporting and isolation procedures
- A printable defect report form
- A supervisor and employer review checklist
Access the Forklift Pre-Use Inspection Guide
Why Forklift Pre-Use Inspections Matter
Forklifts operate around pedestrians, vehicles, racking, machinery, loading areas and valuable materials. A defect involving the brakes, steering, tyres, forks, lift chains, hydraulics or operator-restraint system can create a serious risk if it is not identified before the truck is used.
A pre-use inspection allows the operator to check the truck's visible condition and test its essential safety functions.
The inspection should normally be completed:
- At the beginning of the operator's shift
- When changing to a different forklift
- After another person has used the truck
- Following an incident, impact or suspected damage
- Whenever the truck's condition causes concern
The manufacturer's instructions and the employer's workplace procedure should always be followed.
What Should a Forklift Inspection Cover?
The exact checks depend on the forklift category, model, power source, attachments and working environment.
A typical inspection may include:
- Fork arms and locking devices
- Carriage, load backrest, mast rollers and lift chains
- Hydraulic cylinders, hoses and visible leaks
- Wheels, tyres and wheel fixings
- Overhead guard and bodywork
- Capacity plate and safety labels
- Battery, LPG cylinder or fuel system
- Operator seat and restraint
- Steps, handholds and operator area
- Steering, service brake and parking brake
- Horn, lights, beacon and warning alarms
- Hydraulic and attachment controls
- Mirrors, cameras, visibility aids and safety interlocks
- Unusual noises, smells or vibration
Additional checks may be needed for reach trucks, pivot steer trucks, multidirectional forklifts, stock pickers and specialist attachments.
What Should Happen When a Defect Is Found?
Completing a checklist does not make a defective forklift safe.
When an operator identifies a defect that could affect safety, the truck should not be used until the issue has been assessed and resolved.
- Stop and secure the forklift safely.
- Lower the forks or attachment.
- Apply the parking brake and switch off.
- Prevent unauthorised use.
- Attach a clear isolation or Do Not Use notice.
- Report the defect to the nominated person.
- Record the truck, defect and action taken.
- Authorise the truck's return to service after suitable assessment or repair.
Operators should never attempt repairs unless they are authorised and competent to complete the work.
Employer and Supervisor Responsibilities
Employers should provide operators with a clear inspection and defect-reporting procedure. This should include:
- A checklist suitable for the truck
- Time to complete the inspection properly
- Suitable lighting and a safe inspection area
- A named person to receive defect reports
- A method for isolating unsafe equipment
- Repair and maintenance arrangements
- A traceable return-to-service process
- Periodic review of completed records
Supervisors should monitor whether checks are being completed properly rather than treating the checklist as a paperwork exercise. Repeated damage, missed defects or incomplete records may indicate that further instruction, supervision or workplace controls are needed.
Pre-Use Checks Do Not Replace Maintenance
Daily inspections form part of an effective equipment-management system, but they do not replace planned maintenance, competent repairs, thorough examination where required, manufacturer servicing requirements or workplace risk assessments.
Read our Employer Responsibilities guidance and PUWER guide for more information.
Use the Checklist at Your Workplace
The downloadable checklist can be printed and adapted to reflect the forklift category, manufacturer instructions, attachments, power source, workplace conditions and company reporting procedure.
A separate checklist may be needed for specialist equipment or trucks fitted with additional systems.
Forklift Inspection Training
Operators must understand more than which boxes to tick. They should know what normal truck condition looks like, how to inspect each component, which safety functions to test, when the truck must not be operated and how the equipment is isolated.
GH Training covers pre-use inspections during appropriate forklift and material handling equipment courses delivered at customer premises.
Frequently Asked Questions
How often should a forklift pre-use inspection be completed?
The forklift should normally be inspected before it is used at the beginning of the shift. Another inspection may be appropriate following a change of truck, an incident or any concern about its condition.
Who should complete the inspection?
The check should be completed by a suitably trained and authorised operator who understands the truck and the employer's reporting procedure.
Does the inspection need to be recorded?
A written or electronic record provides evidence that the check was completed and helps employers monitor defects, repeated damage and repair history.
Can a forklift be used with a minor defect?
The defect should be reported and assessed by the employer's nominated responsible person. Operators should not decide independently that a safety defect can be ignored.
Does a daily check replace a LOLER examination?
No. A pre-use inspection does not replace maintenance, competent engineering assessment or thorough examination where required.
Arrange Forklift and MHE Training
GH Training provides AITT-accredited forklift and material handling equipment training throughout the North West, North Wales and West Yorkshire.
Courses are available for novice operators, experienced operators, conversion training, refresher training and managing and supervising MHE operations.
Request a training quotation or call 01925 500796 to discuss your workplace requirements.
