Forklifts are among the most common and most hazardous pieces of equipment in warehouses, manufacturing plants, and construction sites. OSHA estimates that forklift-related incidents cause approximately 85 fatalities and 34,900 serious injuries annually in the United States. Many of these incidents are preventable through proper daily inspections. This guide covers the OSHA requirements for forklift inspections, what to include in a daily pre-shift inspection, and provides a free downloadable checklist.
Free Forklift Inspection Checklist
Download our Word document checklist and customize it for your specific forklift types and workplace.
Download Checklist (.docx)Why Forklift Inspections Are Required
OSHA 29 CFR 1910.178 — Powered Industrial Trucks
OSHA's powered industrial truck standard is the primary federal regulation governing forklift safety. Key inspection requirements include:
- 29 CFR 1910.178(q)(7): Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily, or after each shift if trucks are used round-the-clock.
- 29 CFR 1910.178(p)(1): Only trained and authorized operators shall be permitted to operate powered industrial trucks.
- 29 CFR 1910.178(q)(1): Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.
OSHA 29 CFR 1926.602 — Construction
For forklifts used on construction sites, additional requirements apply under the construction industry standards, including operator certification and vehicle safety requirements specific to construction environments.
Manufacturer Guidelines
Forklift manufacturers provide model-specific inspection procedures in the operator's manual. These guidelines often include items beyond OSHA's minimum requirements, such as specific fluid levels, torque specifications, and component wear tolerances. Always consult the manufacturer's manual for the specific forklift models in your fleet.
ANSI/ITSDF B56.1 — Safety Standard
The American National Standards Institute (ANSI) standard B56.1, developed by the Industrial Truck Standards Development Foundation (ITSDF), provides detailed safety guidelines for powered industrial trucks. Many OSHA enforcement actions reference this standard as an industry best practice.
What to Inspect: Visual Checks (Engine Off)
The first part of the daily inspection is a walk-around visual check performed before starting the engine. The operator should look for obvious damage, leaks, and abnormalities.
| Inspection Item | Expected Result / What to Check |
|---|---|
| Fluid leaks | No puddles or wet spots under the forklift. Check for hydraulic fluid, engine oil, coolant, or fuel leaks. |
| Tires and wheels | Adequate tread depth, no cuts or chunks missing, properly inflated (pneumatic), no flat spots (cushion). Lug nuts tight. |
| Forks | No cracks, bends, or excessive wear. Fork tips aligned and not uneven. Positioning lock pins in place. Heel thickness within manufacturer tolerance. |
| Mast and chains | Chains properly lubricated with no kinks, excessive wear, or broken links. Mast rails free of damage. Chain tension equal on both sides. |
| Hydraulic hoses and cylinders | No visible leaks, cracks, abrasion, or bulging. Cylinder rods free of scoring or pitting. Connections secure. |
| Overhead guard | Securely attached, no cracks or damage. All mounting bolts in place and tight. |
| Load backrest | Securely attached and undamaged. Prevents load from shifting toward operator. |
| Operator seat and seatbelt | Seat securely mounted, adjustment mechanism functional. Seatbelt retracts and latches properly with no fraying. |
| Safety labels and data plate | Capacity data plate legible and attached. All warning labels present and readable. |
| Fluid levels (IC engine) | Engine oil, coolant, and hydraulic fluid at proper levels. Brake fluid at proper level if applicable. |
| Fuel system (IC engine) | Fuel tank cap secure, no fuel leaks. LPG tank properly secured with no damage or corrosion to fittings. |
| Battery (electric) | Battery connector secure. Electrolyte level adequate. No corrosion on terminals. Battery restraint in place. No cracks to battery case. |
What to Inspect: Operational Checks (Engine Running)
After the visual check, start the engine and test all operational systems before putting the forklift to work.
| Inspection Item | Expected Result / What to Check |
|---|---|
| Service brake | Adequate stopping power, no pulling to one side, firm pedal feel. Test at slow speed in open area. |
| Parking brake | Holds forklift on level surface and any grades in the work area. Engages and releases smoothly. |
| Steering | Responsive with no excessive play or binding. Full left and right turns operate smoothly. |
| Horn | Audible and functioning. Required at all intersections and blind spots. |
| Lights (head, tail, warning) | All lights operational, including headlights, taillights, and flashing warning lights if equipped. |
| Backup alarm | Audible alarm sounds when in reverse (if equipped). Clearly audible above ambient noise. |
| Gauges and instruments | All gauges operating within normal ranges. Hour meter recording. Warning lights function during startup then clear. |
| Mast operation (lift, lower, tilt) | Smooth operation through full range. No jerking, drifting, or hesitation. Tilt forward and back operates smoothly. |
| Side shift and attachments | If equipped, side shift operates smoothly in both directions. All attachments function properly. |
| Unusual noises or vibrations | No unusual grinding, clicking, squealing, or excessive vibrations during operation. |
| Exhaust system (IC engine) | No excessive smoke (black, white, or blue). Exhaust system intact with no leaks. Carbon monoxide concerns for indoor use. |
| Drive and transmission | Smooth forward and reverse engagement. No slipping, grinding, or hesitation on direction changes. |
Corrective Actions
When a forklift fails any inspection item, the following steps should be taken:
Immediate Response
- Immediately remove the forklift from service
- Apply an "Out of Service" tag to the ignition key area
- Report the defect to the shift supervisor
- Document the issue on the inspection form with specific details
- Do not operate the forklift until repairs are completed by authorized personnel
Repair and Return to Service
- Only authorized and qualified maintenance personnel may perform repairs
- Replacement parts must meet or exceed original manufacturer specifications
- After repairs, a qualified person must verify the forklift passes all inspection points
- Document the repair, parts used, and return-to-service date
- Remove the "Out of Service" tag only after the forklift passes re-inspection
Best Practices
Documentation and Record Keeping
While OSHA does not explicitly require written checklists, maintaining documented inspection records provides evidence of compliance during audits and protects your organization in the event of an incident. Records should include the date, time, operator name, forklift ID, all items inspected, any deficiencies found, and corrective actions taken. Inspection software automates this documentation and makes records instantly searchable.
Operator Training
OSHA 29 CFR 1910.178(l) requires all forklift operators to be trained and evaluated before operating a powered industrial truck. Training must include vehicle inspection and maintenance procedures. Refresher training is required at least every three years or when an operator is observed operating unsafely, involved in an incident, or assigned to a different forklift type. Training management software can help track operator certifications and schedule refresher training.
Download the Free Checklist
Get our forklift inspection checklist in Word format. Customize it for your specific fleet and workplace requirements.
Download Checklist (.docx)Ecesis EHS Software
Inspections
Digital inspection forms with mobile completion, photo capture, and corrective actions.
Safety Inspections
Workplace safety inspections with automated scheduling and deficiency tracking.
Preventive Maintenance
Schedule and track forklift maintenance to keep your fleet inspection-ready.
Training
Track operator certifications, schedule refresher training, and maintain compliance.
Compliance Calendar
Track inspection deadlines, recurring maintenance, and certification renewals.
Task Management
Assign and track corrective actions from failed inspection items to completion.
