What safety checks and preparations are essential before using a forklift?

Operating a forklift is a high-risk activity that requires strict adherence to safety protocols to protect operators, co-workers, equipment, and inventory. According to the Occupational Safety and Health Administration (OSHA), forklift-related accidents cause over 85 fatalities and 34,900 serious injuries annually in the United States alone. Globally, the numbers are even more alarming—with most accidents traced back to inadequate pre-operation safety checks and insufficient preparations. For forklift operators, facility managers, and safety supervisors, understanding what safety checks and preparations are essential before using a forklift is not just a legal requirement, but a critical step in preventing accidents, minimizing downtime, and ensuring compliance with 2026’s stringent global safety standards (OSHA 1910.178, ISO 3691, EU Directive 2006/42/EC).

This technical article provides a detailed, step-by-step guide to the mandatory safety checks and preparations required before operating any type of forklift—including counterbalance, reach truck, rough-terrain, and order picker models. It covers four core areas: pre-operation equipment safety checks, operator readiness preparations, workplace environment assessments, and post-check documentation. Each section includes actionable steps, common pitfalls to avoid, and 2026’s latest safety updates (such as smart inspection tools and digital checklists). Whether you’re a new operator, a seasoned professional, or a manager responsible for a forklift fleet, this guide will ensure you implement a consistent, compliant pre-use safety routine that reduces risk and protects your team.

It’s important to emphasize that pre-operation safety checks and preparations are not optional. In nearly every country, regulatory bodies require operators to complete a thorough inspection before each use of a forklift—failure to do so can result in fines, legal liability, and, most importantly, serious accidents. A well-executed pre-use routine takes just 5–10 minutes but can prevent costly damage, injuries, and even fatalities. By the end of this article, you’ll have a clear understanding of every essential check and preparation, along with best practices to integrate them into your daily workflow.

1. Pre-Operation Equipment Safety Checks: The Foundation of Forklift Safety

The most critical step before using a forklift is a comprehensive inspection of the equipment itself. This ensures the forklift is in safe working condition, free from defects that could cause malfunctions during operation. The checks should be performed in a systematic order—starting from the exterior and moving to the interior, then to critical components like the engine, hydraulics, and brakes. Below is a detailed breakdown of each essential equipment check, aligned with 2026 global safety standards.

1.1 Exterior Visual Inspection

Begin by inspecting the forklift’s exterior for visible damage, leaks, or irregularities. This step helps identify issues like cracked frames, damaged tires, or fluid leaks that could compromise safety. Key checks include:

• Frame and Body: Check for cracks, dents, or rust on the frame, mast, and forks. A cracked frame can weaken the forklift’s structural integrity, increasing the risk of tip-overs. Ensure the forks are straight, free from bending or cracks, and that the fork locks are secure. Check for missing or damaged fork hooks, which can cause loads to slip.

• Tires: Inspect tires for wear, damage, and proper inflation (for pneumatic tires). For solid tires, check for cuts, chunks missing, or uneven wear. For pneumatic tires, verify the pressure matches the manufacturer’s recommendations—underinflated tires can cause instability, while overinflated tires increase the risk of blowouts. Check for foreign objects (e.g., nails, debris) embedded in the tires, which can lead to punctures.

• Fluid Leaks: Check the ground beneath the forklift for signs of fluid leaks (oil, hydraulic fluid, coolant, or fuel). Leaks can indicate a damaged hose, seal, or reservoir. If a leak is detected, check the corresponding fluid level (covered in Section 1.3) and report the issue immediately—do not operate the forklift until the leak is repaired.

• Lights and Signals: Ensure all lights and signals are in working order, including headlights, taillights, brake lights, turn signals, and warning lights (e.g., low fuel, hydraulic pressure). Test the horn to ensure it is loud and clear—critical for alerting pedestrians and co-workers of the forklift’s presence.

1.2 Interior Cab Inspection

Next, enter the cab and inspect the interior controls, seating, and safety features. The cab should be clean, free from clutter, and equipped with all necessary safety equipment. Key checks include:

• Seat and Seatbelt: Ensure the seat is adjustable and stable, with no loose parts. Check the seatbelt for fraying, damage, or broken buckles—always wear a seatbelt during operation, as it can prevent serious injury in the event of a tip-over. Verify that the seatbelt retracts properly and locks when pulled.

• Controls and Instruments: Inspect all controls (steering wheel, pedals, levers, and switches) for proper operation. Ensure the steering wheel is tight, with no excessive play. Test the brake pedals (service brake and parking brake) to ensure they are responsive. Check the instrument panel for warning lights or error codes—pay special attention to low fuel, low hydraulic pressure, and battery charge indicators. Verify that the speedometer, tachometer, and hour meter are working correctly.

• Safety Equipment: Ensure the cab is equipped with all mandatory safety equipment, including a fire extinguisher (charged and within easy reach), a first aid kit (stocked and up-to-date), and an emergency stop button (functional and clearly labeled). For electric forklifts, check that the charging cable is in good condition and properly stored—never leave the charging cable on the ground where it can be damaged.

1.3 Fluid Level Checks

Fluids are critical to the forklift’s operation—low or contaminated fluids can cause component failure, overheating, or malfunctions. Check the following fluid levels, following the manufacturer’s instructions for proper measurement:

• Fuel or Battery Charge: For internal combustion (IC) forklifts, check the fuel level—ensure there is enough fuel to complete the shift. For electric forklifts, verify the battery charge level (using the instrument panel) and check the battery water level (for flooded lead-acid batteries—covered in our previous guide). Never operate an electric forklift with a low charge, as it can cause the battery to fail mid-operation.

• Hydraulic Fluid: Check the hydraulic fluid level using the dipstick or sight glass. The fluid should be between the “min” and “max” marks. Ensure the fluid is clean and free from contamination (e.g., dirt, debris)—contaminated hydraulic fluid can damage pumps and valves. If the fluid level is low, add the manufacturer-recommended hydraulic fluid (do not mix different types).

• Engine Oil and Coolant: For IC forklifts, check the engine oil level using the dipstick—ensure it is within the recommended range. Check the coolant level in the radiator (only when the engine is cool) to prevent overheating. For electric forklifts, skip this step, but check the battery coolant level if applicable (for lithium-ion batteries).

1.4 Critical Component Checks

After completing the exterior, interior, and fluid checks, test the forklift’s critical components to ensure they are working properly. These components include the hydraulics, brakes, and mast—all of which are essential for safe operation. Key checks include:

• Hydraulic System: Start the forklift (following proper startup procedures) and test the hydraulic controls. Lift the forks to full height, lower them, and tilt the mast forward and backward. Ensure the hydraulics operate smoothly, with no jerky movements or unusual noises. Check for hydraulic fluid leaks while the system is under pressure—leaks that were not visible during the exterior check may appear when the hydraulics are active.

• Brakes: Test both the service brake (foot brake) and parking brake (hand brake). For the service brake, drive the forklift slowly (in a safe, open area) and apply the brake—ensure it stops quickly and smoothly, with no pulling to one side. For the parking brake, engage it while the forklift is on a slight incline (if available) to ensure it holds the forklift securely. If the brakes are spongy, unresponsive, or make unusual noises, do not operate the forklift.

• Mast and Chains: Inspect the mast chains for wear, rust, or damage. Check for loose links, broken pins, or missing lubrication. Ensure the chains are properly tensioned—too loose, and they can slip; too tight, and they can wear out prematurely. Test the mast’s lifting and tilting functions again to ensure smooth operation. Check the mast rollers for wear or damage, which can cause the mast to bind or operate unevenly.

2. Operator Readiness: Essential Preparations for the Person Behind the Wheel

Even if the forklift is in perfect condition, an unprepared operator can still cause accidents. Operator readiness is a critical part of pre-use preparations—ensuring the operator is physically and mentally fit, properly trained, and aware of their responsibilities. Below are the essential preparations every operator must complete before using a forklift.

2.1 Verify Certification and Training

First and foremost, the operator must be formally certified to operate the specific type of forklift they are using. Certification must be up-to-date (renewed every 3 years in most countries) and cover the forklift’s make and model. Before starting the forklift, operators should confirm their certification is valid and that they have received training on any new features or updates to the equipment (e.g., smart safety features introduced in 2026).

If the operator is new or has not used the specific forklift model before, they must receive additional training and supervision from a certified trainer—never allow an untrained or uncertified person to operate a forklift. In 2026, many facilities are implementing digital certification verification systems, allowing operators to scan their certification before accessing the forklift.

2.2 Physical and Mental Fitness Check

Operating a forklift requires physical dexterity, strength, and mental alertness. Before using a forklift, operators should assess their own physical and mental condition. Key considerations include:

• Physical Fitness: Ensure you are able to operate the controls (steering wheel, pedals, levers) with precision. Check for any injuries (e.g., sprains, strains) that could impair your ability to control the forklift. If you are fatigued, dizzy, or experiencing any physical discomfort, do not operate the forklift—fatigue is a leading cause of forklift accidents.

• Mental Alertness: Ensure you are focused and free from distractions. Avoid operating a forklift if you are under the influence of drugs, alcohol, or prescription medications that cause drowsiness or impair judgment. In 2026, many workplaces require pre-shift drug and alcohol testing for forklift operators—compliance with these tests is mandatory.

• Personal Protective Equipment (PPE): Wear all required PPE before operating the forklift. Standard PPE includes safety shoes (with steel toes), high-visibility vests, and safety glasses. Depending on the workplace, additional PPE may be required (e.g., gloves, hard hats, or hearing protection for noisy environments). Ensure your PPE is in good condition and fits properly—ill-fitting PPE can be a distraction and reduce protection.

2.3 Review Operational Tasks and Hazards

Before starting work, review the day’s operational tasks to understand the specific requirements and potential hazards. This includes:

• Task Details: Confirm the type of load you will be handling (weight, size, shape), the route you will be taking, and any specific instructions (e.g., stacking height, unloading locations). Ensure you understand the load capacity of the forklift and that the load does not exceed this capacity—overloading is a common cause of tip-overs.

• Hazard Identification: Review the workplace for potential hazards, such as pedestrians, uneven surfaces, overhead obstacles (e.g., pipes, beams), narrow aisles, or wet floors. Identify areas where visibility is poor (e.g., blind corners) and plan your route accordingly—use horn signals when approaching blind corners or pedestrian crossings.

• Emergency Procedures: Refresh your memory of emergency procedures, including what to do in the event of a tip-over, collision, or equipment failure. Know the location of the nearest fire extinguisher, first aid kit, and emergency stop buttons. Ensure you know how to safely evacuate the forklift in case of an emergency.

3. Workplace Environment Assessment: Ensuring a Safe Operating Area

The workplace environment plays a critical role in forklift safety. Even a well-maintained forklift and a prepared operator can be at risk if the operating area is unsafe. Before using a forklift, conduct a thorough assessment of the workplace environment to identify and mitigate potential hazards. Below are the essential environmental checks.

3.1 Pedestrian Safety Checks

Pedestrian-forklift collisions are among the most common forklift accidents. Before operating the forklift, ensure the workplace is safe for both operators and pedestrians. Key checks include:

• Pedestrian Traffic: Check for high pedestrian traffic areas (e.g., break rooms, entrances, loading docks) and ensure there are clear pedestrian walkways marked with paint or signs. Look for pedestrians who may be distracted (e.g., using phones, carrying large items) and alert them to your presence.

• Warning Signs and Barriers: Ensure warning signs (e.g., “Forklift Operation Area,” “Yield to Forklifts”) are visible and properly placed. Use barriers or cones to separate forklift operating areas from pedestrian walkways, if possible. In 2026, many facilities are using smart pedestrian detection systems that alert operators to nearby pedestrians—ensure these systems are working properly.

• Loading Docks: If operating near loading docks, check that the dock plates or bridges are secure, rated for the forklift’s weight, and free from damage. Ensure the dock doors are closed when not in use, and that there are guardrails to prevent falls. Check for pedestrians near the dock edge, as they may be at risk of falling off or being hit by the forklift.

3.2 Surface and Route Checks

The condition of the operating surface and route can significantly impact forklift stability. Before using the forklift, check the surface and route for irregularities. Key checks include:

• Surface Condition: Ensure the operating surface is flat, level, and free from debris (e.g., pallets, boxes, tools). Check for potholes, cracks, or uneven surfaces, which can cause the forklift to tip over. For outdoor operation, check for mud, snow, or ice—these can reduce traction and increase the risk of slipping.

• Route Clearance: Verify that the route you will be taking has adequate clearance for the forklift and its load. Check for overhead obstacles (e.g., pipes, beams, lights) that could hit the mast or load. Ensure aisles are wide enough for the forklift to maneuver—narrow aisles increase the risk of collisions with walls, racks, or other equipment.

• Slopes and Inclines: If operating on slopes or inclines, check that the slope is within the forklift’s recommended limits (typically 10–15 degrees for most models). Always travel with the load uphill and empty downhill to maintain stability. Ensure the slope is free from debris and that there is no risk of the forklift sliding.

3.3 Weather and Environmental Conditions (Outdoor Operation)

For outdoor forklift operation, weather conditions can pose additional risks. Before using the forklift outdoors, check the weather forecast and assess the current conditions. Key considerations include:

• Rain, Snow, or Ice: Wet or icy surfaces reduce traction—slow down and increase stopping distance. Avoid sudden turns or braking, which can cause the forklift to skid. For snow, clear the operating area before use and use snow tires or chains if necessary.

• Wind: Strong winds can affect the stability of the forklift, especially when carrying tall or lightweight loads. Avoid operating the forklift in high winds if possible—if operation is necessary, reduce speed and keep the load as low as possible.

• Temperature: Extreme temperatures (hot or cold) can affect the forklift’s performance. In hot weather, check the engine coolant level more frequently to prevent overheating. In cold weather, allow the engine to warm up before operation and check for frozen fluids or components.

4. Post-Check Documentation: Compliance and Accountability

In 2026, regulatory bodies around the world require detailed documentation of pre-operation safety checks and preparations. Documentation not only ensures compliance but also provides a record of the forklift’s condition, helping to identify recurring issues and improve safety practices. Below are the essential documentation steps to complete after the checks and preparations.

4.1 Complete the Pre-Operation Inspection Checklist

Most facilities provide a pre-operation inspection checklist (either paper or digital) that operators must complete before using a forklift. The checklist should include all the checks outlined in this guide (exterior, interior, fluid levels, critical components) and require the operator to mark each item as “pass” or “fail.” Key points for documentation include:

• Date and Time: Record the date and time of the inspection.

• Forklift Information: Include the forklift’s make, model, serial number, and hour meter reading.

• Operator Information: Sign and print your name to confirm you completed the inspection.

• Defects or Issues: If any defects or issues are identified, record them in detail (e.g., “hydraulic fluid leak near the mast,” “left front tire low on pressure”). Report the issues to your supervisor immediately and do not operate the forklift until the defects are repaired. Note the date and time the issue was reported and any follow-up actions taken.

4.2 Digital Documentation (2026 Best Practice)

Many facilities are transitioning to digital pre-operation checklists in 2026, using mobile apps or cloud-based systems. Digital documentation offers several advantages over paper checklists, including:

• Real-Time Reporting: Defects are reported immediately to supervisors, reducing response time.

• Data Tracking: Digital systems track inspection history, allowing managers to identify recurring issues (e.g., frequent tire wear on a specific forklift).

• Compliance: Digital checklists ensure all required checks are completed—operators cannot skip items. The system automatically stores records for regulatory audits.

• Photographic Evidence: Many digital systems allow operators to take photos of defects (e.g., fluid leaks, damaged forks), providing clear documentation for repairs.

4.3 Communication with Supervisors and Maintenance Teams

Documentation is only effective if the information is communicated properly. After completing the inspection, inform your supervisor of any defects or issues. If the forklift is unsafe to operate, tag it with a “Do Not Operate” sign to prevent other operators from using it. Maintenance teams should be notified promptly to repair the issue, and the repair status should be recorded in the inspection checklist.

5. Common Mistakes to Avoid in Pre-Use Checks and Preparations

Even with proper training, operators often make mistakes during pre-use checks and preparations—mistakes that can lead to accidents. Below are the most common mistakes and how to avoid them: