Free checklist · Material handling
Forklift inspection checklist (free, printable)
This forklift inspection checklist covers the daily pre-shift check OSHA requires under 29 CFR 1910.178(q)(7): a walk-around with the key off (forks, chains, mast, tires, fluids, data plate), then operating tests with the truck running (brakes, steering, lift, tilt, horn, lights). It's free: print it for the clipboard, or put it on a QR sticker so operators check from their phones.
- How often
- Before each shift
- The rule
- OSHA 29 CFR 1910.178(q)(7)
- Items
- 30 checks
- Takes
- About 8 minutes
By the CheckBadges team · Updated
Layout
Forklift inspection checklist
Before each shift
| Item | OK | Problem | N/A |
|---|---|---|---|
| Walk-around (key off, forks down) | |||
| ForksNo cracks, bends or uneven tips; heels not worn thin; fork locks engaged | |||
| Carriage and load backrestBackrest bolted on, not bent or cracked; carriage rollers in place | |||
| Lift chainsEven tension both sides; no kinked, rusty or cracked links; anchor pins secure | |||
| Mast channels and rollersNo cracks or bent channels; rails clear of debris; rollers turn | |||
| Hydraulic cylinders and hosesNo leaks, wet fittings, cuts or bulges; no fresh drips under the truck | |||
| Tires and wheelsNo chunks, cuts or flat spots; wheel nuts tight; air tires at pressure | |||
| Overhead guardNot bent or cracked; no missing bolts or broken welds | |||
| Counterweight and bodyCounterweight bolts tight; hood and covers latched; no new damage | |||
| Data plate and decalsData plate on and readable; capacity matches any attachment fitted | |||
| Fire extinguisherMounted, gauge in the green, pin and seal in place | |||
| Fluids and fuel (key off) | |||
| Engine oilBetween the dipstick marks | |||
| CoolantAt the line in the overflow tank; radiator not clogged | |||
| Hydraulic oilBetween the marks with the forks fully lowered | |||
| LPG cylinderPinned in the bracket, relief valve up, hose tight, no gas smell | |||
| Battery, connector and cablesNo damage or corrosion; battery held in; charger unplugged | |||
| Fuel or charge levelEnough for the shift; refuel or charge before it runs low | ☐ Full ☐ 3/4 ☐ 1/2 ☐ 1/4 ☐ Refuel or charge | ||
| In the seat (key on) | |||
| Hour meterReading from the meter or display | ________ hours | ||
| Seat and seat beltSeat locks in position; belt latches, retracts and isn't cut or frayed | |||
| Gauges and warning lightsGauges work; no warning lights stay on after start-up | |||
| HornLoud enough to be heard over the work area | |||
| Lights, alarm and mirrorsLights, travel alarm and mirrors work and are clean, if fitted | |||
| Operating checks (truck running) | |||
| Service brakesStops smoothly and straight; pedal firm, not spongy | |||
| Parking brakeHolds the truck still against light throttle | |||
| Inching pedalSlows travel while the hydraulics keep working | |||
| SteeringTurns smoothly both ways; no binding, wander or excess play | |||
| Forward and reverseSmooth both ways; no jerking, grinding, slipping or hesitation | |||
| Lift and lowerRaises and lowers smoothly; chains even; holds height with no drift | |||
| TiltTilts forward and back smoothly; holds the angle with no drift | |||
| Side shift and attachmentsWork smoothly both ways; attachment secure and on the data plate | |||
| Noise, smoke and smellsNo odd noise, heavy smoke, exhaust sparks or burning smell | |||
Problems found and action taken:
If anything is a problem, don't use the machine: tag it out and report it. Free checklist from checkbadges.com — put it on a QR sticker and operators can fill it in on their phone.
What to check on a forklift, item by item
Walk-around (key off, forks down)
- Forks — No cracks, bends or uneven tips; heels not worn thin; fork locks engaged
- Carriage and load backrest — Backrest bolted on, not bent or cracked; carriage rollers in place
- Lift chains — Even tension both sides; no kinked, rusty or cracked links; anchor pins secure
- Mast channels and rollers — No cracks or bent channels; rails clear of debris; rollers turn
- Hydraulic cylinders and hoses — No leaks, wet fittings, cuts or bulges; no fresh drips under the truck
- Tires and wheels — No chunks, cuts or flat spots; wheel nuts tight; air tires at pressure
- Overhead guard — Not bent or cracked; no missing bolts or broken welds
- Counterweight and body — Counterweight bolts tight; hood and covers latched; no new damage
- Data plate and decals — Data plate on and readable; capacity matches any attachment fitted
- Fire extinguisher — Mounted, gauge in the green, pin and seal in place
Fluids and fuel (key off)
- Engine oil — Between the dipstick marks
- Coolant — At the line in the overflow tank; radiator not clogged
- Hydraulic oil — Between the marks with the forks fully lowered
- LPG cylinder — Pinned in the bracket, relief valve up, hose tight, no gas smell
- Battery, connector and cables — No damage or corrosion; battery held in; charger unplugged
- Fuel or charge level — Enough for the shift; refuel or charge before it runs low (Full / 3/4 / 1/2 / 1/4 / Refuel or charge)
In the seat (key on)
- Hour meter — Reading from the meter or display (reading, in hours)
- Seat and seat belt — Seat locks in position; belt latches, retracts and isn't cut or frayed
- Gauges and warning lights — Gauges work; no warning lights stay on after start-up
- Horn — Loud enough to be heard over the work area
- Lights, alarm and mirrors — Lights, travel alarm and mirrors work and are clean, if fitted
Operating checks (truck running)
- Service brakes — Stops smoothly and straight; pedal firm, not spongy
- Parking brake — Holds the truck still against light throttle
- Inching pedal — Slows travel while the hydraulics keep working
- Steering — Turns smoothly both ways; no binding, wander or excess play
- Forward and reverse — Smooth both ways; no jerking, grinding, slipping or hesitation
- Lift and lower — Raises and lowers smoothly; chains even; holds height with no drift
- Tilt — Tilts forward and back smoothly; holds the angle with no drift
- Side shift and attachments — Work smoothly both ways; attachment secure and on the data plate
- Noise, smoke and smells — No odd noise, heavy smoke, exhaust sparks or burning smell
How often a forklift has to be inspected
A forklift has to be examined at least once a day before it's used, and after every shift where trucks run around the clock. That's 29 CFR 1910.178(q)(7): trucks "shall be examined before being placed in service", the examination "shall be made at least daily", and "Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift."
The same paragraph sets the pass mark. A truck "shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle", and "Defects when found shall be immediately reported and corrected." The rule doesn't list items, which is why the manufacturer's daily checks and a checklist like this one fill the gap.
A few points people get wrong:
- A truck that sits idle doesn't need the daily check. OSHA has said the examination is due before a truck is put back in service, not on days nobody uses it (OSHA letter, March 3, 2005).
- There is no OSHA annual forklift inspection. Planned maintenance and periodic inspections come from the manufacturer and the ANSI/ITSDF B56.1 standard, not from 1910.178.
- On construction sites, 29 CFR 1926.602(c) points forklifts to the ANSI B56.1 requirements for inspection and maintenance. Follow the manufacturer's daily checks there too.
- In the UK, HSE's lift truck guidance (L117) asks operators to check the truck at the start of each shift "and document the results". See forklift pre-use checks in the UK.
The full rule, with the letters behind it, is in OSHA forklift inspection requirements.
How to do the check
The check follows the sheet: walk around with the key off, check fluids, get in, then test everything with the truck running.
- Park it safely. Level ground, forks flat on the floor, parking brake on, key off. Hydraulic oil only reads correctly with the forks fully lowered.
- Walk around the truck. Start at the forks and work back: carriage, chains, mast, hoses, tires, overhead guard, counterweight. Look closely at the fork heels, where cracks start.
- Check fluids and fuel. Engine oil and coolant on engine trucks, hydraulic oil on all of them, then the LPG cylinder or the battery.
- Get in and belt up. Write down the hour meter, start the truck and watch for warning lights that stay on.
- Test it in a clear area. Horn and lights, then brakes, steering, drive both ways, lift, lower, tilt and any attachment. Raise the empty forks a few feet and watch both chains take up evenly.
- Record the result. OK, Problem or N/A on every line, a note on every problem, your name and the date.
- Don't use a truck that fails. Tag it, take the key and tell your supervisor.
Once an operator knows the truck, a careful check takes about 5 to 10 minutes. A check that takes 60 seconds is usually a ticked sheet, not an inspection; see pencil whipping.
The defects that take a forklift out of service
Any condition that makes the truck unsafe takes it out of service, not just bad brakes or steering. OSHA has said a gauge that isn't working usually makes a truck defective, and that "Broken welds, missing bolts, or damage to the overhead guard would indicate that a truck is unsafe" (OSHA letter, June 17, 2004).
| Defect | Why it matters |
|---|---|
| Cracked, bent or worn fork | A fork can snap under load with no warning |
| Brakes, parking brake or steering not right | The operator can't stop or control the truck |
| Kinked, cracked or unevenly tensioned lift chain | The carriage and load can drop |
| Hydraulic leak, or a mast or tilt that drifts | A raised load can come down or tip on its own |
| Fuel leak or LPG smell | Fire; OSHA says no truck may run with a fuel system leak (1910.178(p)(4)) |
| Damaged overhead guard or missing seat belt | No protection from falling objects or in a tip-over |
| Horn, lights or travel alarm not working | People on foot can't hear or see the truck coming |
| Missing or unreadable data plate | Nobody can tell what the truck can lift; OSHA requires plates kept legible (1910.178(a)(6)) |
What to do when something fails
Take the truck out of service on the spot: park it, tag the controls, take the key and report it. OSHA's rule is direct: a truck "found to be in need of repair, defective, or in any way unsafe" must be "taken out of service until it has been restored to safe operating condition" (1910.178(p)(1)), and "All repairs shall be made by authorized personnel" (1910.178(q)(1)).
Hang an out-of-service tag on the steering wheel and write what's wrong on it. Don't keep a defective truck around "as a spare": OSHA has said an employer who does could be cited (OSHA letter, September 13, 2004). The full process, from tag to sign-off, is in what to do when equipment fails inspection.
Keeping the record
OSHA doesn't require a written record of the daily forklift check, but a dated record is the only way to show it happened. OSHA has said in interpretation letters that the examination doesn't have to be written down and that how long to keep any records is up to the employer (2000, 2004). The employer still has to make sure the checks happen, and after an accident, a month of blank days says they didn't.
The forklift record OSHA does require is the operator's training certification under 1910.178(l)(6): the operator's name, the training and evaluation dates, and who did them. For retention and what a good inspection record contains, see forklift inspection records and equipment inspection record keeping.
Doing it on a phone
You can run this exact checklist from a QR sticker on each truck instead of a clipboard. With CheckBadges, operators scan the sticker with their own phone and work through the list in the browser, with no app or login. Anything marked Problem emails you with photos straight away, and the next operator who scans that truck sees it before starting. It's free for 3 machines.
Skip the clipboard
Put this forklift inspection checklist on a QR sticker.
- Operators scan the sticker with their own phone's camera. No app, account or password.
- Anything marked Problem emails you right away, with photos, and warns the next operator.
- Every check is saved by machine with who did it and when. Print one or export a CSV.
Free for 3 machines. Every item above is already filled in — edit anything. No card.
Forklift 1
Forklift inspection checklist
Frequently asked questions
Does OSHA require a written forklift inspection checklist?
No. OSHA requires the daily examination in 29 CFR 1910.178(q)(7) but, as it has said in interpretation letters, not a written record of it. Most employers keep one anyway, because a dated checklist with the operator's name is the only proof the check was done.
How long does a forklift inspection take?
About 5 to 10 minutes for an operator who knows the truck: a walk-around with the key off, the fluids, then operating tests. Much less than that usually means items are being ticked without being looked at.
Who is allowed to inspect a forklift?
OSHA doesn't say who must do the daily examination, only that it's done. In practice the trained operator does it at the start of the shift, and the employer is responsible for making sure it happens. Repairs are different: only authorized personnel may make them (1910.178(q)(1)).
What happens if a forklift fails its daily inspection?
It can't be used. Under 1910.178(q)(7) a truck with any condition adversely affecting its safety must not be placed in service, and defects must be reported and corrected immediately. Tag it out, take the key and tell your supervisor.
Do forklifts need an annual inspection?
Not under OSHA's rules, which require the daily examination only. Manufacturers set planned maintenance by hours run. In the UK, the lifting parts of a lift truck need a LOLER thorough examination at least every 12 months, or every 6 months if it's used to lift people.
How often should a forklift be inspected if it runs 24 hours a day?
After every shift. 1910.178(q)(7) says trucks used on a round-the-clock basis "shall be examined after each shift", so a three-shift operation examines each truck three times a day.
Keep reading
- OSHA forklift inspection rulesOSHA requires forklifts to be examined before use at least daily, and after each shift if run around the clock. What to check, who does it, records and fines.
- Forklift inspection appA forklift inspection app your operators don't install: they scan a QR sticker on the truck to do the daily check. Defects email you and warn the next shift.
- Forklift pre-shift inspectionHow to do a forklift pre-shift inspection: a walkaround with the truck off, the seat and controls, operating tests with it running, and what to do if it fails.
- Electric forklift inspection checklistFree electric forklift daily checklist: battery charge, connector, cables, water level and restraint, plus forks, chains and brakes. Print it or use QR codes.
- Propane forklift inspection checklistFree propane forklift daily checklist: LPG cylinder pin, relief valve, hose and leaks, then engine, forks, brakes and controls. Print it or use QR codes.
- WarehousesWarehouse forklift checklists on a QR sticker per truck. Operators and temps scan with their phone, no app or login. Problems email you and warn the next shift.
Do your forklift checks by QR code.
Stick a QR code on every machine and operators do the pre-use check on their own phone — no app, no login. Free for up to 3 machines; try it with your real machines before you sign up.