How to Do a Proper Forklift Inspection?

Utilization of tools to help human work is very necessary. With the development of industrial technology, the more advanced technological tools developed by humans to assist their work. Heavy equipment is a tool that is needed for industrial purposes today. The purpose of these tools is to make work faster. Or tackle the possibility of work that is not too accessible to human power.

In the work of lifting large goods, for example at ports or in goods warehouses, it is impossible to lift goods with human power, because the goods or material weigh tons. It won’t be possible right? Everything is done by human power. So in this case heavy equipment is the main role.

In every company warehouse there is usually a forklift for the mobilization of goods. Forklifts are capable of lifting tens to hundreds of kilograms of object weight with the help of two prongs made of ferrous metal.

What is a Forklift?

The industrial world, whether big or small, is certainly no stranger to material handling equipment. One of them is a forklift. Forklift is a vehicle that functions as a tool to move goods with a large load. This large vehicle is quite practical to use to support the production process or move goods in the warehouse.

Forklift is a type of truck that is operated to lift, move and lower heavy goods from one place to another. Objects that are lifted are objects that are difficult or too heavy for humans to lift. Forklift operation can be done indoors or outdoors, such as loading and unloading goods at ports, warehouses, factories, expeditions, supermarkets, and of course many more.

There are some who define a forklift as a walking car or a vehicle that has 2 forks that can be used to lift pallets. Forklift forks are generally compatible with pallets on the market. Usually the goods are placed on a pallet, then the goods are moved or lifted.

The role of the forklift is very important for various industries because it functions to move and lift goods. Therefore forklifts must always be in good condition in order to function optimally. Forklift maintenance is one of the priorities that should not be missed.

Forklift Parts you need to know

Knowing the parts of a forklift will make it easier for you to detect damage to forklift spare parts. For that you need to know the forklift parts and their functions.


Fork is the main part of the forklift. This section has the function of supporting and carrying goods and lifting them. The fork is made of long and straight iron. The fork has a standard length of 1070 mm or 1.07 m. However, this section can be added with a fork extension if you want a longer fork.

Before you use a forklift, you need to make sure the width, dimensions and weight capacity of the load being lifted. After that place the load on the fork and adjust the width of the fork so that the load being lifted or moved is safe.



One of the most important and main parts of a forklift is the mast. Mast on a forklift is a part that acts as a forklift pedestal. The mast is made of two thick pieces of steel with hydraulic components between them. The hydraulic function of the mast is to raise or lower goods located on the fork.


The carriage on the forklift serves to connect the fork to the forklift mast. In addition, the carriage serves as a security back for the goods above
mast lifting.

Overhead Guard

An overhead guard or what is often referred to as a forklift canopy is a forklift component whose function is to protect the operator when operating a forklift in his work. In addition, the presence of an overhead guard prevents the operator from falling goods directly from a height. The overhead guard can also protect the operator from the hot sun and rain.


Counterweight is one part of the forklift which has a function as a counterweight to the load being lifted. The counterweight is located at the back of the forklift. The main purpose of the counterweight on a forklift is to keep the forklift balanced when lifting heavy items.

The 2 most popular types of forklifts

As with other heavy equipment, forklifts can also be damaged if they are not cared for properly. Forklift maintenance is not complicated, it just requires precision and patience. Forklift maintenance and repair is divided based on the type of forklift, namely diesel and electric forklifts.

Diesel Forklifts

The most famous and most widely used diesel forklift. This type of forklift is targeted by companies and factories because of the low rental prices and easy maintenance. The ability of diesel forklifts is to lift a maximum load of 10 tons and be able to lift up to a height of 6 meters.

This type of forklift is rarely used indoors because it is diesel fuel which emits harmful gases. If the emission or waste is inhaled too much, it can cause shortness of breath and endanger health.

Electric Forklift

Electric forklifts are widely used indoors because they use batteries and can be recharged with electricity. So, this type of forklift is an environmentally friendly forklift.

This type of lifting capability is capable of lifting up to a height of 6 meters with a maximum capacity of 5 tons. Unfortunately, this electric forklift cannot be operated continuously, considering the battery capacity which can only last less than 8 hours.

Forklift inspection properly and mandatory to do

The use of forklifts is very helpful for activities in the factory. Good for lifting goods indoors and outdoors. Make sure you use the type of forklift that suits your needs so you don’t quickly damage the forklift. Forklift maintenance is fairly easy and inexpensive, so using it in moderation helps make it last longer. And for checking forklifts according to the fuel used, you can see the reviews below.

Inspection of forklifts with Diesel fuel

Diesel forklifts are one of the most widely used types of forklifts before the existence of the electric type. As the name implies, this forklift uses diesel as fuel so there are many parts that need maintenance such as the engine and other parts. Here are some ways to maintain diesel forklifts.

Fuel check

The forklift inspection that must be carried out is checking fuel and other fluids used for forklift operations such as transmission fluid, lubricating oil, and hydraulics. Ensuring all fuel and others are in standard conditions according to tool specifications helps forklifts function optimally and avoid damage. Always make sure the forklift is refueled before use so that it can function properly.


Just like other vehicles, the oil in forklifts must also be changed regularly. Always check if the forklift oil has become thick and dark in color because it must be replaced with a new one. Oil on a forklift that is not replaced regularly will cause corrosion and damage to the engine.

Battery maintenance

Battery is one of the important components in a forklift. This part should always be checked to ensure the forklift is in good condition. Battery water must be within standard limits and cannot be too much or too little. In addition, the battery must also be charged periodically to ensure its function. Do not wait for the battery water to dry completely before refilling it as this will cause damage.

In addition, make sure the cable on the battery is installed properly. The battery must also be clean and dry so it must always be checked at least once a week.

Changing the lubricant

Forklifts have moving parts such as chain joints on the front fork supports. Always make sure that this part has sufficient lubrication. Not having enough lubricant will affect the performance of the hydraulic fork and cause damage.

Tool hydraulic check

Forklifts use a hydraulic system to move the forks. Hydraulic inspection of the tool must be carried out periodically to avoid leaks in the lift and tilt cylinders. In addition, always check the pumps and hydraulic machines, including checking the liquid level whether it is in accordance with the standards.

Electric forklift inspection

Electric forklifts are one of the most widely used types of forklifts, especially for indoor work because they do not emit gas emissions like diesel forklifts. In terms of maintenance, electric forklifts must also be checked regularly to ensure their function.

Battery maintenance

The battery in a forklift is one of the most expensive critical components. These batteries cost at least a quarter to a fifth of the price of the entire unit. Therefore the battery must be a priority for maintenance on electric forklifts. The battery must be charged periodically without waiting for its capacity to run out. Recharge the forklift battery at least when the charge capacity is still 20% and do not stop the process until the battery is fully charged. This will affect the age and quality of the battery.

In addition, make sure the battery cover is open to avoid hot temperatures. Make sure the mains voltage for charging is appropriate so that the battery does not burn. Forklift batteries should be cleaned regularly to ensure there are no foreign or wet objects that could cause damage.

Periodic inspection

Periodic inspection of forklifts should be part of maintenance, especially for controllers and the battery being the most expensive component. Damage to forklift components causes the unit to not function properly. Checks should be done at least every 200 hours of use or once a month.

Maintenance of controllers

The controller is also one of the most expensive parts of a forklift but maintenance is easier than the battery. Make sure when the controller is dry to avoid damage and can function normally.

Pay attention to storage

When not in use, forklifts should be stored in a place that is not exposed to direct sunlight and rain. Likewise, when used, electric forklifts are more suitable for use in indoor areas because the electrical components are easily damaged when exposed to the weather.

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Important things to pay attention to when inspecting a forklift

Both diesel and electric forklifts need regular maintenance to ensure that there is no damage. Here are some things that must be considered when servicing a forklift.

Check before use

Every day or before use, the forklift should be inspected. This aims to identify problems early on in the machine such as brake failure or hose leaks. Not only to ensure conditions, but this check is a safety procedure before using a forklift. Inspecting the unit and identifying problems early helps save money and time on repairs rather than waiting for more serious unit damage.

Follow the maintenance instructions

If any damage is found, you should only do maintenance as recommended by the manufacturer. Most forklift units are recommended for inspection within a certain period of use. This check ensures that basic things like fluid condition changes, oil changes, brake repairs, and the like are done on time.

Check the condition of the tires

Apart from the engine and electrical parts, the tires on the forklift must also be inspected before use. Just like other automotive vehicles, forklift tires are key so that the unit can function properly. However, forklift tires wear out more quickly than ordinary vehicles due to the different areas of use.

In addition, forklift tires can also leak, deflate, and other damage that causes the unit to not function properly. Therefore the tires on the forklift must be checked including checking tire pressure and tire service.

Clean the forklift every week

Keeping the forklift clean is one of the unit maintenance procedures. Forklifts can be cleaned at least once a week. Even though it looks good from the outside, the unit may experience damage to the inside due to regular use. In addition, dust and dirt can also cause damage such as blockages in the radiator.

Periodic cleaning of the unit such as blowing the radiator, changing the filter, and the like helps keep the forklift functional. In addition, avoiding the accumulation of dirt also avoids damage or wear caused by external factors.

Immediately fix if there is a problem

Even though we have carried out periodic inspections, the potential for damage still exists, especially because the unit is used every day. If there is damage, no matter how small, it should be repaired immediately because small damage is the beginning of big damage. If not repaired immediately, minor damage will affect the performance of the forklift and also cause greater losses. Therefore, don’t wait for the forklift to be badly damaged to make repairs because the maintenance costs are not small.

Forklift maintenance is an important part that must be given special attention. Forklift is one of the heavy equipment that is the key to smooth business, therefore its function must always be considered properly. Forklift daily checks can be carried out by the operator, but repairs to the tool should be done by qualified technicians. This also applies to routine servicing, which should also be carried out by qualified technicians.

And below is an example of a forklift daily inspection checklist form that you can use to carry out checks on this versatile heavy equipment.

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About the Author: Andres Ina Rivai

Good work is always to follow good and precise procedures. Don't forget that safety and health at work are always the top priority

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