OSHA requires that all forklifts be examined at least daily before being placed into service. If the forklift is used on a round‑the‑clock basis, it must be examined after each shift. Only trained, certified operators may perform these inspections. The inspection follows a two‑phase process: a Key‑Off Visual Walk‑Around followed by a Key‑On Operational Test. Any forklift found in unsafe condition must be removed from service and tagged “Out of Service” until repaired.
Phase 1: Key‑Off Visual Walk‑Around
Before starting: Park the forklift on level ground, engage the parking brake, fully lower the forks, turn off the power, and remove the key.
Inspection Area Item to Check OK Not OK
General Condition Frame/chassis: no cracks, dents, or damaged welds ☐ ☐
Overhead guard and load backrest: no deformation or damage ☐ ☐
Data plate: present, legible, and matches load rating ☐ ☐
Safety decals and warning labels: visible and intact ☐ ☐
No fluid leaks under or around the forklift (hydraulic oil, engine oil, coolant, fuel) ☐ ☐
Forks, Mast & Hydraulics Forks: no cracks, bends, or worn heels; locking pins present and secure ☐ ☐
Mast assembly: rails, rollers, and chains not cracked, worn, or kinked; chains evenly tensioned and lubricated ☐ ☐
Hydraulic hoses: no cracks, abrasion, or bulging; no leaks at fittings ☐ ☐
Hydraulic fluid level: at correct level, not milky or foamy ☐ ☐
Carriage, backrest, and load guard: secure and undamaged ☐ ☐
Tires & Wheels Tires: correct inflation (pneumatic), adequate tread, no cuts or embedded objects ☐ ☐
Wheels: no cracks, damaged rims, or missing lug nuts ☐ ☐
Power System & Fluids Electric: Battery charge level, cables/terminals for corrosion/damage, battery securely mounted ☐ ☐
IC (Diesel/LPG/Gas): Fuel level, inspect fuel system for leaks ☐ ☐
Engine oil level (IC models) ☐ ☐
Engine coolant level (IC models) ☐ ☐
Brake fluid level ☐ ☐
Electric only: Charging connectors in good condition ☐ ☐
Safety Systems Seat belt or restraint system: functioning and undamaged ☐ ☐
Operator presence switch (seat switch): operates correctly ☐ ☐
Fire extinguisher: present and charged (if required) ☐ ☐
Phase 2: Key‑On Operational Test
Before starting: Sit in the operator‘s seat, fasten the seat belt, and start the engine or power on the electric forklift with the forks fully lowered.
Inspection Area Item to Check OK Not OK
Gauges & Indicators Gauges and warning lights: all functioning properly ☐ ☐
Hour meter: operational ☐ ☐
Battery discharge indicator (electric models): functioning ☐ ☐
Safety Equipment Horn: test for proper function ☐ ☐
Backup alarm: test for proper function ☐ ☐
Lights: headlights, tail lights, brake lights, and indicators ☐ ☐
Steering & Brakes Steering: smooth and responsive ☐ ☐
Service brake: test for proper stopping function ☐ ☐
Parking brake: test for proper holding ☐ ☐
Load Handling Lift, lower, and tilt functions: smooth operation, no unusual noises or binding ☐ ☐
Attachments: respond smoothly, free of play or binding ☐ ☐
Drive Test Drive forward and reverse slowly: smooth steering, no unexpected vibration or changes ☐ ☐
Electric Forklift – Specific Checklist
For electric forklifts, add these checks to the standard inspection:
Inspection Area Item to Check OK Not OK
Battery Electrolyte level (lead-acid): check each cell ☐ ☐
Battery case: no cracks, leaks, or bulging ☐ ☐
Battery restraint/hold-down: secure; battery must not shift during operation ☐ ☐
Main disconnect/emergency cutoff: accessible and functional ☐ ☐
Charging System Charger leads and connectors: no damage ☐ ☐
Charging area: clear of flammable materials ☐ ☐
Immediate Actions for Identified Issues
Tag the forklift “Out of Service” if any issue could adversely affect safety.
Report the issue immediately to a supervisor or maintenance team.
Do not operate until the forklift has been cleared for service by an authorized person.
Documentation
Field Entry
Date ____________________
Shift ☐ Day ☐ Night ☐ Other
Forklift Model ____________________
Forklift Serial / Unit # ____________________
Operator Name (Printed) ____________________
Operator Signature ____________________
Supervisor Review ____________________
Defects Found (describe) ____________________
Action Taken ____________________
This checklist serves as a guide; always consult your specific forklift’s Operation and Maintenance Manual for model‑specific inspection points. Adapt this template to your facility and equipment’s specific needs.