Pre-operational Checks, Inspection and Maintenance Reporting
Purpose of pre-operational checks
Pre-operational checks are conducted before each shift to ensure the forklift is safe to operate. They are not a substitute for regular maintenance but are a critical risk control. Checks include visual inspection and functional tests. Visual checks: tyres (condition and pressure), forks (cracks, wear, bend), mast chains (tension, lubrication, wear), hydraulic hoses (leaks, damage), overhead guard, backrest, seat, seatbelt, lights, horn, alarms, and data plate. Functional checks: brakes, steering, horn, lights, backup alarm, mast operation (lift, lower, tilt), and attachment operation.
Reporting defects
Any defect found must be reported to the supervisor and recorded according to site procedures. If the defect affects safety, the forklift must be tagged out and not used until repaired. Never operate a forklift with a known safety defect.
Traps in exam questions
- Skipping checks because the forklift was used previously.
- Not documenting checks or defects.
- Assuming a defect is minor and continuing to use the forklift.
- Forgetting to check the seatbelt and overhead guard.
Worked example
During a pre-start check, you notice a hydraulic leak. You should stop, report it, tag the forklift out, and not operate it until repaired. A rule of thumb: if in doubt, tag it out.
Key points
- Conduct pre-operational checks before each shift.
- Check tyres, forks, chains, hoses, guards, seatbelt, lights, horn.
- Test brakes, steering, horn, lights, mast functions.
- Report and document all defects.
- Tag out unsafe equipment and do not use it.