Forklift Pre-Operation Safety Inspection Checklist

This forklift pre-operation inspection checklist ensures all powered industrial trucks are inspected at least daily per OSHA 29 CFR 1910.178(q), which requires operators to check forklifts before each shift. Defective or unsafe industrial trucks must be removed from service immediately. Covers all standard inspection points for LP gas, electric, and diesel forklifts per OSHA requirements and ANSI/ITSDF B56.1 safety standards.

Industry: Warehouse / Manufacturing / Logistics
Frequency: Before Every Shift (Daily Minimum)
Estimated Time: 10-15 minutes
Role: Certified Forklift Operator / Warehouse Safety Supervisor
Total Items: 29
Compliance: OSHA 29 CFR 1910.178 (Powered Industrial Trucks), ANSI/ITSDF B56.1 Safety Standard for Forklifts, NFPA 505 (Fire Safety Standard for Industrial Trucks), OSHA 29 CFR 1910.178(l) Operator Training Requirements, UK PUWER 1998 (Work Equipment Regulations)

Operator Controls & Instruments

Test all operator controls for proper function before moving the forklift.

Horn sounds clearly when activated?
Headlights and warning lights functional (if equipped)?
All gauges and instrument warning lights functional and normal readings?
Steering operates smoothly in both directions with no binding or excessive play?
Service brakes stop forklift smoothly at low speed with no pulling or noise?
Parking brake holds forklift stationary on test grade or flat surface?

Mast, Forks & Attachments

Inspect mast and fork condition for structural integrity and load-carrying capability.

Fork blades free of visible cracks, especially at heel and blade-shank junction?
Fork tips even and level side-to-side (within 3mm/1/8" difference)?
Fork blade thickness within 10% of original specification at heel wear area?
Mast lift chains lubricated, intact, and no twisted or stretched links?
Mast raises/lowers and tilts smoothly with no jerking, unusual noise, or binding?
Overhead guard present and undamaged (no bent or missing bars)?
Load backrest extension present (for loads above operator's head level)?

Power System (Electric / LP Gas / Diesel)

Inspect the forklift power system for safety. Power system defects can cause fire, explosion, or loss of power.

Battery charge level adequate for shift (electric) - above 20% charge?
Battery connector in good condition with no burned pins or loose connection?
Battery electrolyte level adequate and no electrolyte on top of battery (electric)?
LP tank properly secured in bracket, valve closed when not in use (LP models)?
Fuel level adequate for shift (LP, diesel, or gas models)?
No fuel, oil, or hydraulic fluid leaks visible under or around forklift?

Tires & Chassis Condition

Inspect tires and chassis structural condition. Tire failure causes tipover, the leading cause of forklift fatalities.

Cushion tires free of chunking, cuts through to rim, or flat spots?
Pneumatic tires properly inflated and no sidewall damage or embedded objects?
Counterweight present and secure (no missing bolts or cracks)?
Capacity plate present, legible, and matches attachments currently installed?
Chassis and frame free of visible cracks or significant damage?

Safety Compliance & Documentation

Verify operator certification, training documentation, and safety compliance items.

Operator holds current forklift certification for this equipment class?
Previous shift inspection reviewed - all noted defects repaired or addressed?
Operating area free of pedestrians and safe to begin operations?
Operator understands rated capacity for today's intended loads and attachments?
Pre-operation inspection recorded in forklift inspection log?

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Why Use This Forklift Pre-Operation Safety Inspection Checklist?

This forklift pre-operation safety inspection checklist helps warehouse / manufacturing / logistics teams maintain compliance and operational excellence. Designed for certified forklift operator / warehouse safety supervisor professionals, this checklist covers 29 critical inspection points across 5 sections. Recommended frequency: before every shift (daily minimum).

Ensures compliance with OSHA 29 CFR 1910.178 (Powered Industrial Trucks), ANSI/ITSDF B56.1 Safety Standard for Forklifts, NFPA 505 (Fire Safety Standard for Industrial Trucks), OSHA 29 CFR 1910.178(l) Operator Training Requirements, UK PUWER 1998 (Work Equipment Regulations), India IS 4660 Forklift Safety Standards, Australia AS 2359 Industrial Truck Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Forklift Pre-Operation Safety Inspection Checklist cover?

This checklist covers 29 inspection items across 5 sections: Operator Controls & Instruments, Mast, Forks & Attachments, Power System (Electric / LP Gas / Diesel), Tires & Chassis Condition, Safety Compliance & Documentation. It is designed for warehouse / manufacturing / logistics operations and compliance.

How often should this checklist be completed?

This checklist should be completed before every shift (daily minimum). Each completion takes approximately 10-15 minutes.

Who should use this Forklift Pre-Operation Safety Inspection Checklist?

This checklist is designed for Certified Forklift Operator / Warehouse Safety Supervisor professionals in the warehouse / manufacturing / logistics industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.