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The OSHA daily forklift inspection checklist
The standard daily examination, item by item, with what to look for on each one: the forklift (or fork truck) inspection sheet most warehouses keep on a clipboard. Print it, photocopy it, hang it by the charger. To run it on a phone instead, start a free trial.
Running propane or electric? Use the propane checklist or the electric checklist, with only that truck’s checks plus its weekly and monthly ones.
What OSHA requires
29 CFR 1910.178(q)(7) requires that a powered industrial truck is examined before being placed in service, at least daily — and after each shift where trucks run around the clock. If the examination shows the truck is not in safe operating condition, it must be taken out of service until it has been repaired.
OSHA does not require you to keep a written record of it. What a record does is prove the examination happened — which is the part that matters when an inspector, an insurer or a lawyer asks.
Before you start the truck
Key off. Walk around it.
Fluid leaks under the unit Out of service
Look at the floor where the unit was parked. Any puddle of oil, hydraulic fluid, coolant, or fuel.
Tires and wheels Out of service
No chunking, gouging, flat spots, or exposed cord. Pneumatic tires at correct pressure.
Forks Out of service
No cracks, bends, or excessive wear. Heel wear under 10%. Tips even. Fork pins and locks in place.
Mast chains Out of service
Even tension on both sides, no kinks, no broken or stretched links, properly lubricated.
Hydraulic hoses, fittings, and cylinders Out of service
No leaks, cracks, chafing, or bulges. Fittings tight.
Hydraulic fluid level
Within the marked range on the dipstick or sight glass.
Overhead guard Out of service
Securely mounted, no cracks, bends, or missing bolts.
Load backrest extension Out of service
Present and securely attached.
Data / capacity plate Out of service
Attached, legible, and matches any attachment installed on the unit.
Seat belt Out of service
Latches, retracts, webbing not frayed or cut.
Seat and seat switch Out of service
Seat securely mounted. Operator presence switch works.
With the truck running
Key on, in a clear area, seatbelt on.
Hour meter reading
Enter the current hours.
Gauges and warning lights Out of service
All gauges read normal. No warning or fault lamps stay lit after startup.
Horn Out of service
Sounds clearly.
Backup alarm Out of service
Sounds when the unit is put in reverse.
Lights and beacon
Every light the unit has, including any strobe or beacon, working.
Service brake Out of service
Unit stops firmly and travels straight. No grabbing, no soft or sinking pedal.
Parking brake Out of service
Holds the unit on an incline.
Deadman / operator presence control Out of service
Truck will not travel or lift when the operator is off the seat or off the pedal.
Steering Out of service
Smooth through full travel. No excessive play, binding, or wandering.
Forward and reverse control Out of service
Engages smoothly in both directions. No delay, no lurching.
Lift and lower Out of service
Smooth through the full range of the mast, no binding or jerking.
Tilt forward and back Out of service
Smooth, no chatter, stops where commanded.
Hydraulic drift check Out of service
Raise the forks, hold, and watch. The carriage must not drift down and the mast must not drift forward.
Unusual noises, smells, or vibration Out of service
Anything that was not there yesterday.
Anything else to report
Optional. Leave blank if nothing.
Depending on what it runs on
These only apply to some trucks. A propane sit-down needs the tank checks; an electric reach truck needs the battery ones.
Propane (LP)
LP tank mounted correctly Out of service
Strap or clamp latched and tight, and the tank does not move. The locating pin sits in the hole on the tank collar. The relief valve points straight up, away from the operator.
LP tank and hose condition Out of service
Tank free of dents, gouges, deep rust, or damage to the collar or foot ring, with a current requalification date. Hose has no cracks, splits, chafing, or kinks, and the quick-disconnect is fully seated.
No smell of propane Out of service
If gas is detected, shut the tank valve and tag the truck out immediately. Do not start it.
Electric
Charger unplugged and cable stowed Out of service
Never move the truck with the charger connected.
Battery restraint and hood latch Out of service
Battery hold-down in place. Compartment cover or hood latched.
Battery case condition Out of service
No cracks, no bulging, no electrolyte on top of the battery.
Battery terminals and connector Out of service
No corrosion, no exposed or frayed wire, connector not burnt, melted, or discolored.
State of charge
Enough charge for the shift. Note the percentage or the discharge indicator reading.
Diesel or gasoline
Engine oil level
Between the marks on the dipstick.
Coolant level
At the fill line in the overflow tank. Check only when the engine is cold.
Fuel level and no fuel leaks Out of service
Cap secure. No smell of fuel, no wet spots on lines or tank.
Items marked Out of service take the truck out of service when they fail. The rest still need reporting, but they do not necessarily stop the shift — that call belongs to whoever runs your floor.