Download our Apps and get 14 Days Free Trial
Electric Counterbalance Forklift Pre-Shift Inspection Checklist
Introduction
Electric counterbalance forklifts are critical material handling equipment in warehouses, distribution centers, and manufacturing facilities. As powerful electric vehicles capable of lifting heavy loads to significant heights, they present unique safety considerations that require thorough inspection before each shift or operator change. This pre-shift inspection is not only an OSHA requirement but also an essential safety practice that helps prevent accidents, equipment damage, and operational downtime.
This comprehensive pre-shift inspection checklist guides operators through a systematic review of all critical components and functions of an electric counterbalance forklift. By diligently completing this inspection before operation, operators can identify and address potential issues before they lead to equipment failure, accidents, or injuries. Regular pre-shift inspections also extend equipment lifespan, improve operational efficiency, and demonstrate commitment to workplace safety and regulatory compliance.
Equipment Information
Pro Tips for Effective Forklift Inspection
- Circle Check Method: Always conduct inspections by walking completely around the forklift in a circle, starting and ending at the same point, to ensure no areas are missed.
- Test with Load Conditions: When possible, test lifting functions with a standard test load to verify operational capacity under working conditions.
- Document Consistently: Maintain detailed records of all inspections, noting even minor issues, to track patterns that might indicate developing problems.
- Respect Battery Safety: Always wear appropriate PPE (eye protection, gloves) when inspecting battery compartments and never use metal tools that could cause shorts.
General Visual Inspection
Battery and Electrical System
Operator Compartment
Controls and Instruments
Mast and Forks
Wheels, Tires and Brakes
Safety Features
Hydraulic System
Operational Tests
Personal Protective Equipment
Key Pre-Shift Testing Procedures
Follow these specific procedures when conducting pre-shift inspection of your electric counterbalance forklift. These steps ensure all critical safety and operational functions are properly tested.
Brake Testing Procedure
- Start in a clear, open area with no obstructions
- Test service brakes by moving forward at moderate speed and stopping
- Verify stopping distance is reasonable and forklift stops in straight line
- Test parking brake by engaging on slight incline if possible
- Verify emergency brake function if equipped
- Check for brake pedal free play and firmness
Hydraulic System Testing
- Raise forks unloaded to full height gradually
- Hold at maximum height for 30 seconds to check for drift
- Lower forks slowly to floor level
- Test tilt function fully forward and backward
- Test side-shift (if equipped) in both directions
- Check for unusual noises or jerky movements
Steering System Check
- Turn steering wheel fully in both directions while stationary
- Check for excessive play in steering wheel (not more than 1-2 inches)
- Drive forward slowly while turning to verify responsive steering
- Test steering in reverse direction
- Listen for unusual noises during steering
- Check steering effort is not excessively heavy or light
Safety Systems Verification
- Test horn to ensure clearly audible
- Check seat switch by attempting to operate while standing
- Verify deadman brake functionality
- Test all lights and warning devices
- Verify backup alarm sounds when reverse selected
- Test emergency power disconnect function
Inspection Progress
0% complete
Electronic Signature
Apply Signature
Defects & Maintenance Notes
Critical Safety Protocols
If your electric counterbalance forklift fails any part of the pre-shift inspection, follow these critical safety protocols to ensure workplace safety and proper maintenance.
Safety-Critical Defects Protocol
- Immediately tag forklift as "OUT OF SERVICE"
- Remove key and secure in designated location
- Inform supervisor immediately of safety-critical issues
- Document defects in detail on inspection form
- Place forklift in designated repair area if possible
- Ensure forklift cannot be used until repaired and certified
Non-Critical Defects Protocol
- Document all non-critical defects on inspection form
- Report defects to maintenance department
- Determine if forklift is safe for continued operation
- Apply "CAUTION" tag if appropriate
- Schedule repairs at earliest convenience
- Follow up to ensure repairs are completed
Battery Safety Issues
- For battery leaks, follow facility spill response procedure
- Disconnect battery if safe to do so
- Report battery issues to specialized technicians
- Do not attempt to jump-start forklift
- Keep sparks, flames away from battery compartment
- Document battery issues and maintenance history
Shift Handover Protocol
- Verbally communicate any defects to next operator
- Ensure inspection documentation is complete and accessible
- Leave equipment in safe condition (forks down, key removed)
- Return key to designated key control system if applicable
- Verify battery charge level is suitable for next shift
- Confirm status of any maintenance requests
Conclusion
Implementing this comprehensive Electric Counterbalance Forklift Pre-Shift Inspection Checklist is essential for maintaining equipment safety, operational efficiency, and regulatory compliance. By systematically examining all critical components before each shift, operators can identify and address potential issues before they lead to equipment failure, accidents, or injuries in the workplace.
For optimal inspection management and documentation, consider implementing the FleetRabbit APP to streamline your forklift pre-shift inspection process. The FleetRabbit platform allows digital documentation of inspections, provides real-time alerts for maintenance requirements, and creates comprehensive historical records for each piece of equipment. With the FleetRabbit software, safety managers, maintenance personnel, and operators can easily track compliance, monitor equipment condition, and ensure all forklifts are properly inspected before use.
Make electric counterbalance forklift pre-shift inspections an integral part of your workplace safety protocols with the FleetRabbit software's comprehensive inspection management solution. Whether for OSHA compliance, preventive maintenance, or operational efficiency, this digital approach significantly improves inspection thoroughness and documentation while reducing administrative burden on operators and supervisors.
Access the digital version of this checklist through the FleetRabbit APP
© 2025 Electric Counterbalance Forklift Pre-Shift Inspection Checklist | Developed by FleetRabbit | Contact us at support@fleetrabbit.com for customized inspection solutions.