Industrial Safety & Compliance · SOP

Counterbalance Forklift Pre Shift Daily Inspection

This SOP covers the mandatory daily pre-shift inspection procedure for counterbalance forklifts to ensure safe operation and compliance with CSA B335-15 / OSHA 1910.178 standards. Operators must complete this inspection before each shift.

Estimated Time

15 min

Difficulty

Beginner

Regulation

CSA B335-15 / OSHA 1910.178

Version

1.0

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Purpose

The purpose of this SOP is to establish a standardized procedure for the daily pre-shift inspection of counterbalance forklifts. This inspection identifies potential safety hazards, mechanical defects, and fluid leaks that could lead to equipment failure or accident. A documented inspection reduces liability and ensures compliance with regulatory requirements.

Scope

This procedure applies to all counterbalance forklifts (electric, LPG, diesel) used in warehouse and industrial environments. It covers visual and operational checks of the mast, forks, tires, brakes, steering, lights, horn, and safety devices. This inspection must be performed at the beginning of each shift by the assigned operator.

Safety Precautions

LOTOLockout/tagout the forklift if any defect is found. Do not operate until repaired.
PPEWear appropriate PPE: hard hat, safety glasses, steel-toed boots, high-vis vest.
AREAEnsure the inspection area is well-lit and free of other traffic or pedestrians.
LOADDo not perform inspection with a load on the forks. Forks must be fully lowered.

Required Tools & Materials

Inspection checklist (paper or digital)
Flashlight
Work gloves
Clean rag
Lockout/tagout kit
Tire pressure gauge (if pneumatic tires)
Fork wear gauge (if available)

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Procedure: Step-by-Step

1 Prepare for inspection: Park the forklift on level ground. Lower the forks fully to the floor. Turn off the engine and remove the key. Engage the parking brake.

2 Visual inspection of mast and chains: Inspect the mast rails for cracks, bends, or excessive wear. Check lift chains for tension, lubrication, and broken links. Look for any hydraulic leaks along the mast.

3 Inspect forks: Examine both forks for cracks, bends, and wear on the heel and blade. Use a fork gauge if available to measure thickness against minimum allowed. Ensure forks are properly aligned and locked.

4 Inspect tires and wheels: Check all tires for cuts, embedded debris, uneven wear, and proper inflation (if pneumatic). Verify wheel nuts are tight. For solid tires, check for chunking or separation.

5 Check fluid levels: With the engine off, check engine oil, hydraulic oil, coolant, and brake fluid levels (as applicable). Top off if necessary. Look for any fluid leaks on the ground or around components.

6 Operational test of controls: Start the engine (battery/electric: turn on key). Test steering for smooth operation, brakes (service and parking), accelerator, lift/lower, and tilt functions. Listen for abnormal noises.

7 Verify safety devices: Check horn, forward and reverse lights, backup alarm, seatbelt operation, overhead guard integrity, and warning decals. Ensure fire extinguisher (if equipped) is charged and accessible.

8 Document inspection results: Complete the inspection checklist, noting any defects or deficiencies. If any safety-critical issue is found, lockout/tagout the forklift and notify supervision immediately. Do not operate until repaired.

Counterbalance Forklift Pre Shift Daily Inspection

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