Free · no email required

The daily forklift inspection checklist

The standard pre-shift examination, item by item, with what to look for on each one. Print it, photocopy it, put it on a clipboard. If you would rather it lived on a phone, start a free trial.

What OSHA actually requires

29 CFR 1910.178(q)(7) requires that a powered industrial truck is examined before being placed in service, and not less than once per shift. 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.

  1. Wheel lug nuts secure Out of service

    None missing, none loose.

  2. Fork carriage and attachments secure Out of service

    Carriage plate, side shift, clamps, or other attachments mounted correctly.

  3. Warning decals and safety labels

    Present and readable.

  4. Operator compartment clean

    No loose tools, trash, grease, or anything that could interfere with the controls.

  5. Steps and handholds

    Clean, dry, secure. No damage.

  6. Fire extinguisher

    Present, charged, secured in its bracket, inspection tag current.

  7. Frame, counterweight, and body damage

    No new cracks, dents, or damage since last shift.

  8. Brake fluid level Out of service

    Between the marks on the reservoir. A level that keeps dropping is a leak somewhere, not a top-up.

  9. Mast chain stretch measured Out of service

    Measure across a set number of links and compare with the manual. Chains stretch before they break, and a stretched pair loads unevenly.

  10. Seat belt anchorage and retraction Out of service

    Pull hard on the belt — it must lock. Check the bolts at both ends are tight and the webbing is not frayed where it passes the frame.

  11. Overhead guard and counterweight fasteners Out of service

    Every bolt present and tight. Vibration walks them loose over months, which is why a daily look is not enough.

  12. Tire wear measured

    Cushion tires down to the wear line, or pneumatic tread below the manufacturer figure, means replacement. Worn tires change how the truck stops and how stable it is with a load up.

  13. Hydraulic fluid condition

    Milky means water in it, dark or burnt-smelling means it has been hot. Either way it is a fluid change, not a top-up.

With the truck running

Key on, in a clear area, seatbelt on.

  1. Side shift and attachments

    Full travel both directions, holds position.

  2. Unusual noises, smells, or vibration Out of service

    Anything that was not there yesterday.

  3. Anything else to report

    Optional. Leave blank if nothing.

  4. Mast drift test Out of service

    Raise a typical load, hold, and watch for ten minutes. Dropping more than the manual allows means a cylinder or valve is passing.

  5. Parking brake holds on a slope Out of service

    On the steepest ramp on site, loaded to a typical weight. It either holds or it does not.

  6. Steering free play

    Turn the wheel until the wheels move. More free play than the manual allows is linkage wear.

  7. Hour meter reading recorded for service

    Write the reading down. Service intervals are counted in hours, not months, and nobody can schedule the next one without it.

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)

  1. LP tank securely mounted Out of service

    Tank strap or clamp latched and tight. Tank does not move in the bracket.

  2. LP tank locating pin seated in index hole Out of service

    The pin on the bracket must sit in the hole on the tank collar so the tank cannot rotate.

  3. LP pressure relief valve pointed up Out of service

    The relief valve must point at the 12 o'clock position, away from the operator.

  4. LP hose and fittings Out of service

    No cracks, splits, chafing, or kinks. Quick-disconnect fully seated.

  5. 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.

  6. LP tank condition Out of service

    No dents, gouges, deep rust, or damage to the collar or foot ring. Requalification date current.

  7. LP fuel level

    Enough for the shift. Note the gauge reading.

  8. LP hose and regulator condition Out of service

    Cracking, stiffness or chafing anywhere along the hose, and the regulator dry and free of oil residue. Hoses have a service life even when they look sound.

Electric

  1. Charger unplugged and cable stowed Out of service

    Never move the truck with the charger connected.

  2. Battery restraint and hood latch Out of service

    Battery hold-down in place. Compartment cover or hood latched.

  3. Battery case condition Out of service

    No cracks, no bulging, no electrolyte on top of the battery.

  4. Battery terminals and connector Out of service

    No corrosion, no exposed or frayed wire, connector not burnt, melted, or discolored.

  5. Electrolyte / water level

    Flooded lead-acid only. Plates covered. Vent caps in place and tight.

  6. State of charge

    Enough charge for the shift. Note the percentage or the discharge indicator reading.

  7. Battery cables routed clear

    Cables not pinched, not resting on sharp edges, not dragging.

  8. Battery watered if needed

    PPE on, and use whatever the battery is set up for — watering gun or a filling system. Only after charging, never before.

  9. Battery connector and cable insulation Out of service

    Burnt or pitted contacts, cracked insulation, or a connector that is hot after charging. All of them are a fire starting.

Diesel

  1. Engine oil level

    Between the marks on the dipstick.

  2. Coolant level

    At the fill line in the overflow tank. Check only when the engine is cold.

  3. Fuel level and no fuel leaks Out of service

    Cap secure. No smell of fuel, no wet spots on lines or tank.

  4. Belts and hoses

    Correct tension, no cracking, glazing, or fraying.

  5. Air filter and engine compartment

    Filter indicator not in the red. No rags, debris, or oil buildup around the engine.

  6. Exhaust system

    Muffler and pipe secure, no leaks, no black soot around joints.

  7. Transmission fluid level

    Within range on the dipstick.

  8. DEF level

    If the truck is equipped with a DEF 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.