Forklift Daily Inspection Checklist | Free Download
Forklifts are among the most essential yet potentially dangerous machines in workplaces such as warehouses, logistics hubs, and construction sites.
Mechanical failure or unsafe operation can lead to serious injuries, property damage, or even fatalities.
That’s why daily pre-start inspections are a key safety requirement under most safety management systems.
This article provides a complete Forklift Daily Inspection Checklist and a free downloadable A4 PDF template to help you maintain compliance and ensure operator safety.
📥 Download the template:
Why Daily Forklift Inspections Matter
- Prevents accidents: Identifies issues before operation begins.
- Ensures compliance: Meets OSHA and workplace safety requirements.
- Extends equipment life: Detects leaks, wear, and mechanical defects early.
- Builds accountability: Keeps operators responsible for equipment condition.
Key Sections of the Checklist
1. General Condition
- Check for visible damage to forks, mast, carriage, or frame.
- Ensure no oil, fuel, or hydraulic leaks.
- Verify service tags are up to date.
2. Controls
- Test the horn, lights, indicators, and backup alarm.
- Check steering and brakes (both service and parking).
3. Hydraulics
- Operate lift, lower, and tilt functions; ensure smooth performance.
- Inspect hydraulic hoses and fittings for leaks or cracks.
4. Tyres & Wheels
- Confirm tyres are free of damage or excessive wear.
- Wheel nuts must be secure, rims not cracked.
5. Safety Devices
- Verify the seat belt, overhead guard, and load backrest extension are functional.
- Ensure all safety decals and warning labels are legible.
6. Attachments
- Inspect clamps, rotators, or other attachments for secure fitting and functionality.
7. Forks, Mast & Chains
- Forks not bent or worn; locking pins present.
- Chains properly lubricated and tensioned.
8. Battery & Electrical
- Battery terminals clean and tight.
- Cables and connectors intact; emergency disconnect functional.
9. Visibility
- Clean mirrors and windshields.
- Verify lights and wipers (if fitted) are working.
10. Load Handling & Capacity
- Ensure the capacity plate is legible.
- Avoid overloading beyond rated limits.
11. Fire Safety
- Fire extinguisher present and inspected monthly.
12. Housekeeping & Documentation
- Operator’s area free from loose objects.
- Checklist filled out and defects reported to the supervisor.
📋 Forklift Inspection Checklist (Excerpt)
| Area | Inspection Item | OK | Not OK | N/A | Notes / Action |
|---|---|---|---|---|---|
| General | No leaks, damage, or missing parts | ☐ | ☐ | ☐ | |
| Controls | Horn and lights operational | ☐ | ☐ | ☐ | |
| Hydraulics | No leaks, smooth lifting action | ☐ | ☐ | ☐ | |
| Tyres | Good tread; no cuts or loose nuts | ☐ | ☐ | ☐ | |
| Safety Devices | Seat belt, backrest, and guard intact | ☐ | ☐ | ☐ | |
| Documentation | Pre-start form completed and signed | ☐ | ☐ | ☐ |
👉 Download the complete PDF template:
How to Use the Checklist
- Before every shift, the operator conducts a visual and operational inspection.
- Tick each item as OK, Not OK, or N/A.
- Log defects in the Defects & Action Log.
- Report issues immediately—do not operate defective forklifts.
- Supervisor reviews and signs off each inspection.
Best Practices for Forklift Safety
- Inspect before use, not after. Never assume the previous operator reported issues.
- Tag and isolate any forklift with a serious defect.
- Train operators to recognize early warning signs (e.g., hydraulic jerks, brake fade).
- Maintain proper records—keep completed checklists for at least 3 months.
- Conduct monthly maintenance by a qualified mechanic in addition to daily checks.
Common Forklift Hazards (and Controls)
| Hazard | Control |
|---|---|
| Overturning | Operate at safe speed, avoid sharp turns, inspect tyres. |
| Falling Loads | Check mast/forks, use rated loads, maintain balance. |
| Collision | Use horns, mirrors, spotters; maintain visibility. |
| Leaking Fluids | Inspect hydraulics daily; repair leaks promptly. |
| Electrical Damage | Inspect cables and charging areas for damage. |
Conclusion
Forklift safety begins with a consistent daily inspection routine.
By using this checklist, you ensure that mechanical and safety systems are reliable, reducing breakdowns and preventing accidents.
Download the free PDF today and make it part of your daily safety routine.
For more checklist and templates visit The HSE Tools.
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