Forklift Pre-Operation Inspection Checklist

What is a forklift inspection checklist? A forklift inspection checklist is a mandatory pre-operation safety form required by OSHA 1910.178(q)(7) before operating any powered industrial truck (PIT). Forklifts are involved in approximately 85 deaths and 34,900 injuries annually. This checklist covers electric, propane, and diesel forklifts, verifying brakes, steering, hydraulics, and safety devices are functional before each shift.

Industry: Construction / Warehousing / Manufacturing
Frequency: Before each shift / Daily
Estimated Time: 10-15 minutes
Role: Forklift Operator / Warehouse Worker
Total Items: 55
Compliance: OSHA 1910.178 (Powered Industrial Trucks), OSHA 1926.602(c) (Construction), ANSI/ITSDF B56.1, PUWER 1998 (UK), NR-11 (Brazil)

Operator Qualification

Per OSHA 1910.178(l), operators must be trained and certified.

Operator training certification current?
Certified for this forklift type?
Familiar with this specific unit?
Operator fit for duty (no impairment)?

Visual Walkaround Inspection

Complete 360-degree inspection before entering cab.

No fluid leaks visible (oil, hydraulic, coolant)?
Tires/wheels in good condition?
All lug nuts present and tight?
Forks free of cracks, bends, excessive wear?
Fork positioning pins in place?
Load backrest secure and undamaged?
Mast chains properly lubricated, no damage?
Mast rails clean and undamaged?
Overhead guard secure and undamaged?
Data plate legible (capacity, warnings)?

Power Source (Fuel/Battery)

Check fuel system or battery based on forklift type.

Fuel level adequate (LPG/diesel)?
LPG tank secure, hose connections tight?
No LPG leaks detected (smell test)?
Battery charge adequate (electric)?
Battery connections clean and secure?
Battery case/cover undamaged?
Electrolyte level OK (if applicable)?
Charging plug/connector undamaged?

Fluids & Engine (IC Trucks)

Check fluid levels and engine condition for internal combustion forklifts.

Engine oil level OK?
Coolant level OK?
Hydraulic oil level OK?
Transmission fluid OK?
Brake fluid level OK?
Belts and hoses in good condition?
Air filter indicator OK?
Exhaust system intact, no excessive smoke?

Operational Checks

Start forklift and test all controls and safety devices.

Horn functional?
Backup alarm functional?
All lights functional (head, tail, warning)?
Strobe/warning light functional (if equipped)?
All gauges/indicators reading normally?
Steering operates smoothly?
Service brake stops forklift effectively?
Parking brake holds forklift stationary?
Accelerator operates smoothly?
Inching/brake pedal functions correctly?
...and 1 more items

Hydraulic & Mast Functions

Test all hydraulic functions through full range of motion.

Lift and lower functions smoothly?
Mast raises to full height?
Tilt forward functions?
Tilt back functions?
Side shift functions (if equipped)?
No hydraulic leaks during operation?
Cylinders operate smoothly (no jerking)?
No excessive mast drift when raised?

Safety Devices & Equipment

Verify all safety devices and required equipment.

Seatbelt functional and worn?
Mirrors clean and properly positioned?
Fire extinguisher present and charged?
Capacity placard visible and legible?
All safety interlocks functioning?
Dead-man switch functional (if equipped)?