A forklift daily inspection is a mandatory pre-shift examination required by OSHA to identify safety defects before the vehicle is placed into service. Under 29 CFR 1910.178(q)(7), all powered industrial trucks must be examined at least daily—and forklifts used on a round-the-clock basis must be examined after each shift. Failing to conduct these inspections can result in OSHA fines up to $16,550 per violation.
Who Can Perform the Inspection
Only trained and certified operators who have been evaluated in accordance with OSHA standards should perform daily forklift inspections. If a safety-related defect is found, the forklift must be removed from service immediately and tagged with "DANGER - DO NOT OPERATE" until repairs are completed.
The Two-Phase Inspection Process
OSHA requires both a visual (key off) inspection and an operational (key on) check.
Visual Inspection (Key Off)
General Condition
Overall condition and cleanliness of the forklift
Clear travel paths free of hazards
Review previous day's inspection report for outstanding issues
Check for fluid leaks under the forklift (oil, coolant, hydraulic fluid, fuel)
Structural Components
Frame and chassis for cracks, dents, or damaged welds
Overhead guard, load backrest, and mast uprights for deformation or damage
Finger guards and safety decals in place and legible
Nameplate information matches model and serial numbers
Operator manual present and legible
Mast and Forks
Mast assembly for cracks or damage
Lift chains and rollers—check tension with a stick (never hands)
Forks for cracks (especially at the heel), bends, or excessive wear
Top clip retaining pin and fork positioning mechanism
Fork wear: replace if thickness has worn more than 10%
Tires
Tire condition for cuts, gouges, and embedded debris
Proper inflation pressure for pneumatic tires
Hydraulic System
Hydraulic fluid level
Hydraulic hoses for leaks, cracks, chafing, or bulges
Hydraulic cylinders for leaks
Operational Check (Key On / Engine Running)
Brakes
Service brake: forklift stops smoothly without pulling to one side
Parking brake: holds the forklift on a grade
Steering
No grinding, excessive play, or tight spots
Controls
Accelerator and inching pedal function properly
Forward and reverse drive control
Lift, lower, tilt, and attachment controls
Safety Devices
Horn: loud enough to be heard across the floor
Headlights, taillights, brake lights, and warning lights
Backup alarm activates when reversing
Seatbelt: latches securely and retracts properly
Gauges
Oil pressure, ammeter, water temperature, and hour meter
Battery discharge indicator (electric)
Electric Forklift-Specific Checks
Electric forklifts require additional checks beyond the standard inspection:
Battery cables and connectors for fraying or exposed wires
Battery restraints (hold-downs)
Electrolyte levels in lead-acid batteries
Battery charge level—avoid discharging below 20%
Hood latch
Clean battery terminals free of corrosion
Internal Combustion (LPG/Propane)-Specific Checks
For LPG or propane forklifts, inspect the following:
Propane tank is properly mounted and secured
Pressure relief valve pointing up
Hoses and connectors for damage or leaks
Tank restraint brackets
Tank for dents, cracks, or rust
Engine oil level
Engine coolant level
Fuel level gauge
Documentation and Recordkeeping
OSHA requires written records of all inspection findings, defects, and corrective actions taken. Each inspection log should include:
Forklift identification number, model, and serial number
Date and time of inspection
Operator's name
Inspection results (pass or flag defects)
Any defects found and corrective actions taken
Retention period: While OSHA does not specify a minimum retention period, experts recommend keeping inspection records for 6 to 12 months.
What to Do If the Forklift Fails Inspection
If any safety-related defect is found:
Remove from service immediately
Tag with "DANGER - DO NOT OPERATE" until repairs are completed
Report to supervisor
Document the defect in inspection logs
Do not operate until repairs are completed and the forklift is re-inspected
The bottom line: Daily forklift inspections are a legal requirement under OSHA 29 CFR 1910.178(q)(7). The two-phase process—visual (key off) and operational (key on)—takes under 10 minutes and can prevent accidents, extend equipment life, and avoid costly fines. Always document inspections and immediately remove unsafe forklifts from service.