Forklift Pre-Operation Inspection Checklist
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Why this inspection matters#
OSHA 29 CFR 1910.178(q)(7) requires that a powered industrial truck be examined before it is placed in service, and that it not be placed in service if the examination shows any condition adversely affecting safety. That examination must be made at least daily — and where trucks run around the clock, after each shift. The check is the operator's, done right before taking the truck out, not a task handed to someone else later.
A pre-shift inspection catches the hydraulic, brake, and steering defects that lead to tip-overs and struck-by incidents — the leading sources of forklift injuries. If the examination turns up a defect that affects safe operation, 1910.178(p)(1) requires the truck to be taken out of service immediately and kept out until it is repaired. Only operators trained and evaluated under 1910.178(l) are authorized to operate — and inspect — the truck.
Complete the visual walk-around with the key off, then the operational checks with the engine running. Any FAIL is a tag-out, not a note to fix later.
How to use this checklist#
Fill in the date, inspector, location, and equipment ID. Work top to bottom, marking each item Pass, Fail, or N/A, and record specifics in the notes column. If any item fails, remove the truck from service, tag it, and record the corrective action before the truck returns to work. The inspection is signed by the operator and countersigned by the supervisor.
Forklift pre-operation inspection items#
| # | Inspection item | Pass | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 | Tires are properly inflated, free of large cuts, and show no excessive wear. | ☐ | ☐ | ☐ | |
| 2 | Forks are straight, not bent or cracked, and the heel is at least 90 percent of original thickness. | ☐ | ☐ | ☐ | |
| 3 | Fork positioning latches engage properly and hold the forks in place. | ☐ | ☐ | ☐ | |
| 4 | Mast and lift chains move smoothly with no kinks, broken links, or excessive wear. | ☐ | ☐ | ☐ | |
| 5 | Hydraulic hoses and cylinders show no visible leaks, cracks, or chafing. | ☐ | ☐ | ☐ | |
| 6 | Hydraulic fluid level is within marks; no leaks under the truck. | ☐ | ☐ | ☐ | |
| 7 | Engine oil, coolant, and fuel/battery levels are correct; no leaks visible. | ☐ | ☐ | ☐ | |
| 8 | Battery (electric) terminals are clean, hold-down is secure, electrolyte at proper level. | ☐ | ☐ | ☐ | |
| 9 | LP tank (propane) is properly mounted, valve closed when not in use, no hose damage. | ☐ | ☐ | ☐ | |
| 10 | Service brake stops the truck firmly without pulling; no excessive pedal travel. | ☐ | ☐ | ☐ | |
| 11 | Parking brake holds the truck on a slight incline. | ☐ | ☐ | ☐ | |
| 12 | Steering operates smoothly with no excessive play. | ☐ | ☐ | ☐ | |
| 13 | Horn sounds clearly when pressed. | ☐ | ☐ | ☐ | |
| 14 | Backup alarm sounds when reverse is engaged. | ☐ | ☐ | ☐ | |
| 15 | All lights work: headlights, work lights, strobe/beacon, brake lights. | ☐ | ☐ | ☐ | |
| 16 | Seat belt is intact, retracts, and latches securely. | ☐ | ☐ | ☐ | |
| 17 | Operator presence sensor (seat switch) shuts down lift and travel when the seat is empty. | ☐ | ☐ | ☐ | |
| 18 | Overhead guard and load backrest are in place, undamaged, and securely fastened. | ☐ | ☐ | ☐ | |
| 19 | Data plate is legible and matches the truck; no unauthorized modifications. | ☐ | ☐ | ☐ | |
| 20 | Operator has a current certification for this truck class and the work environment. | ☐ | ☐ | ☐ |
Corrective actions taken#
Describe any issues found and the steps taken to correct them. A truck with any failed safety item stays out of service until repaired.
Inspection sign-off#
- Inspector signature: __________________________
- Supervisor signature: __________________________
- Inspection result: ☐ All items passed ☐ Issues require follow-up
Related toolbox talks#
- Forklift & Pedestrian Safety
- Struck-By Hazards
- Personal Protective Equipment (PPE)
- Workplace Housekeeping
Disclaimer#
This checklist is a general guide based on OSHA 29 CFR 1910.178. Always follow your site-specific procedures, the manufacturer's operator manual, and the regulations that apply to your jurisdiction and truck type.