Forklift Pre-Shift Inspection Checklist (Free)

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16 critical items still open - these are the highest-risk gaps.

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Walkaround

No visible leaks of hydraulic fluid, fuel, oil or coolant under the truckCRITICALOverhead guard and load backrest are present, secure and undamagedCRITICALForks are straight, with no cracks, heel wear or bent tipsCRITICALFork positioning latches or locking pins are present and workingMast, chains and rollers are free of damage, with no loose or kinked chainsCRITICALTires or wheels are in good condition, with no deep cuts, chunking or missing sectionsData plate and capacity plate are present and legibleTruck body, steps and floor plate are clean and free of oil or debris

Power source

Battery is charged, with cables, connectors and restraints secure (electric truck)No exposed or damaged battery cables, and vent caps are in place (electric truck)Fuel level is adequate and tank, hose and cap are secure (LPG or fuel truck)CRITICALLPG cylinder is correctly mounted and free of leaks, with valve and pressure relief intactCRITICALEngine oil, coolant and hydraulic fluid levels are in rangeNo unusual smell, smoke or noise when powered on

Controls and operation

Service brake stops the truck smoothly and does not pull to one sideCRITICALParking brake holds the truck on a slight slopeCRITICALSteering is smooth, with no excessive play or stiffnessCRITICALAccelerator, direction control and inching controls respond correctlyLift, lower, tilt and any side-shift attachments operate smoothly and hold positionCRITICALDead-man seat switch or operator presence system worksCRITICALDashboard gauges and warning lights work, with no active fault codes

Safety devices

Seat belt or operator restraint is present and latchesCRITICALHorn works and is audible over ambient noiseCRITICALHeadlights, work lights, brake lights and backup alarm workBlue spot or red zone safety lights work, if fittedMirrors are clean and correctly adjusted, if fittedFire extinguisher is present, charged and in date, if required by site rulesOperator has a valid training record and site authorization for this truck typeCRITICAL

Reporting and handover

Inspection date, time, truck number, hour meter and operator name are recordedAny defect is described in writing and reported to the supervisorCRITICALA truck with a safety-critical defect is tagged out and removed from serviceCRITICALSupervisor signs off the defect and the repair before the truck returns to serviceCompleted checklist is filed for audit and maintenance planning

Any failed critical item means the truck must be removed from service and tagged out until repaired and signed off. Non-critical failures should still be reported and scheduled for maintenance.

Link inspections to maintenance

Want failed inspection items to create maintenance work orders in your ERP? We can discuss how that could work.

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How to use the checklist

Do the walkaround first with the truck off, then power on and test the controls. Tick each item as you check it and note the truck number and hour meter. If a critical item fails, stop, tag the truck out and tell your supervisor. Export the completed list to PDF for your records.

Check with the truck on level ground and the forks lowered
Never use a truck that has a failed critical item
Record defects in writing, not just verbally

The rule behind it

In the US, OSHA 29 CFR 1910.178 requires powered industrial trucks to be examined before being placed in service and not used if the examination shows a condition that adversely affects safety. Where trucks are used around the clock, examination is required after each shift. Other countries have comparable rules, so align this list with your local regulation and your truck manufacturer manual.

Electric, LPG and diesel trucks

The power source section applies by truck type. Electric trucks need battery, cable and charger checks, LPG trucks need cylinder mounting and leak checks, and engine trucks need fluid and exhaust checks. Delete the lines that do not apply to your fleet before printing so operators do not tick boxes by habit.

Common mistakes

The checklist loses value when it becomes a signature ritual. Typical failures are checking after the shift starts, ticking items without testing them, and not removing defective trucks. Supervisors should spot-check a few items each week and review repeat defects for maintenance patterns.

Frequently Asked Questions

How often should a forklift be inspected?

At least daily before use, and after every shift when a truck runs multiple shifts. Operators do the pre-shift check, and a qualified technician does scheduled preventive maintenance on top of it.

What makes a forklift unsafe to use?

Any defect that affects safe operation, such as faulty brakes, steering, lift or tilt, a missing guard or horn, damaged forks, leaks or a failed restraint. These are marked critical in this list.

Does a pallet jack need an inspection?

Yes. Electric pallet jacks are powered industrial trucks and need a pre-shift check. Manual pallet jacks should still be checked for wheels, handle, hydraulics and forks, using a shortened version of this list.

Who should keep the records?

The operator completes the form and the supervisor reviews it. Keep records for as long as your policy or local regulation requires, so you can show audits and spot repeat defects.

If your maintenance system tracks forklifts as assets, we can help turn failed inspection items into work orders automatically.

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