Daily Forklift Inspection Checklist

Forklifts are indispensable in warehouses, distribution centers, and manufacturing plants, but they are also one of the leading causes of serious workplace injuries and fatalities. OSHA standard 29 CFR 1910.178 requires that powered industrial trucks be inspected before being placed in service each day, and after each shift if used around the clock. A thorough daily forklift inspection checklist is not just a regulatory obligation—it is a critical safety practice that identifies mechanical defects, fluid leaks, and safety device failures before the truck enters operation, protecting operators and everyone working nearby.

Why Daily Forklift Inspection Matters

Forklift-related incidents account for roughly 85 fatalities and 34,900 serious injuries each year in the United States, according to OSHA data. Many of these incidents are directly linked to mechanical failures that a proper pre-use inspection would have caught—failed brakes, inoperative horns, leaking hydraulic lines, or worn tires. Beyond safety, daily inspections also reduce operating costs by catching developing problems early, before they escalate into expensive repairs or catastrophic component failures. OSHA can issue citations and fines for each day a forklift is operated without a documented pre-use inspection, making compliance both a safety and financial imperative.

Daily Forklift Inspection Checklist

1. Pre-Operation Visual Inspection (Engine Off)

Before starting the forklift, the operator should conduct a walk-around visual inspection to identify any obvious damage, leaks, or deficiencies. This takes only a few minutes but can prevent a serious incident.

• Check for fluid leaks under and around the forklift including oil, coolant, and hydraulic fluid
• Inspect tires for cuts, gouges, excessive wear, and proper inflation on pneumatic tires
• Verify forks are straight, not cracked, and wear does not exceed 10% of original thickness
• Check mast chains for proper tension, lubrication, and absence of damaged links
• Ensure the operator restraint system, seat belt or operator presence sensor, is functional

2. Fluid Levels and Engine Compartment

Proper fluid levels are essential for safe and efficient forklift operation. Low oil or coolant can cause engine seizure, while low hydraulic fluid can result in loss of lifting or steering control.

• Check engine oil level and condition on internal combustion forklifts
• Verify coolant level in the radiator or overflow tank is at the proper mark
• Inspect hydraulic fluid reservoir level and check for discoloration or contamination
• Check battery electrolyte levels and cable connections on electric forklifts
• Verify fuel level or battery charge is sufficient for the planned shift

3. Operational Checks (Engine Running)

Once the engine is started or the electric motor is powered on, the operator must test all controls and safety devices to confirm proper operation before driving the forklift into the work area.

• Test the horn and verify it produces a clearly audible sound
• Check all lights including headlights, tail lights, and warning flashers
• Test the backup alarm to confirm it sounds when reverse is engaged
• Operate the mast through its full range—lift, lower, tilt forward, and tilt back—and check for smooth operation
• Verify the parking brake holds the forklift on a slight incline

4. Steering and Brake Testing

Steering and braking systems are the most critical safety controls on a forklift. Any deficiency in these systems means the truck must be taken out of service immediately until repairs are completed.

• Check steering for excessive play, stiffness, or unusual noises
• Test service brakes for firm pedal feel and ability to stop the forklift smoothly
• Verify the inching or creep pedal functions correctly on automatic transmission forklifts
• Test the deadman brake or neutral safety switch to confirm it prevents unintended movement

5. Mast, Carriage, and Attachment Inspection

The mast and carriage are the business end of the forklift, and their proper operation is essential for safe load handling. Hydraulic leaks, worn rollers, or damaged forks can cause loads to shift or fall.

• Inspect mast rails and rollers for wear, damage, and proper lubrication
• Check hydraulic hoses and cylinders for leaks, cracks, or abrasion
• Verify the load backrest extension is secure and undamaged
• Confirm any attachments such as clamps, rotators, or side-shifters are properly mounted and functional

6. Safety Equipment and Accessories

Forklifts must be equipped with specific safety features and the operator must verify their presence and condition at the start of each shift. Missing or damaged safety equipment is grounds for removing the forklift from service.

• Confirm the overhead guard is intact, properly mounted, and free from significant damage
• Verify the data plate is legible and matches the truck's actual configuration and capacity
• Check that the fire extinguisher is mounted, accessible, and within its inspection date
• Ensure mirrors and any camera systems are clean, properly adjusted, and functional

7. End-of-Shift Checks

At the end of the shift, the operator should perform a brief review to identify any issues that developed during operation and ensure the forklift is properly parked and secured for the next operator or overnight.

• Report any defects, unusual noises, or performance issues discovered during the shift
• Park the forklift in its designated area with forks lowered flat to the floor
• Set the parking brake, turn off the ignition, and remove the key
• Plug in electric forklifts for charging if required per the charging schedule

Best Practices for Daily Forklift Inspection

• Never skip the inspection: Even when time is tight, the pre-use inspection is mandatory and must be completed before operating the forklift.
• Train every operator: All forklift operators must know how to perform the daily inspection and understand what constitutes a deficiency requiring removal from service.
• Take trucks out of service immediately: Any defect affecting safety—brakes, steering, mast, or safety devices—means the truck cannot be operated until repaired.
• Retain records: Keep inspection records for at least the duration recommended by your company policy or regulatory requirements, typically a minimum of one year.
• Standardize the process: Use the same checklist format across your entire fleet so operators can inspect any truck without confusion.

How Checksheets Helps

Checksheets digitizes your daily forklift inspection process, making it fast and foolproof for operators to complete on a phone or tablet before every shift. Mandatory fields ensure no check is skipped, and photo capture lets operators document damage or defects instantly. When a deficiency is flagged, the system automatically notifies maintenance and tags the truck as out of service until the issue is resolved. Managers get a real-time dashboard showing which trucks have been inspected, which are out of service, and which inspections are overdue—providing complete fleet visibility and OSHA-ready documentation at the touch of a button.

Protect your operators and stay compliant with ease. Checksheets makes daily forklift inspections a seamless part of your operation, ensuring every truck is safe before it moves a single pallet.