OSHA Forklift Inspection Checklist (Free Printable)

• Overhead guard and load backrest secure, no cracks.
• Forks straight, no cracks, heels ≥ 90% of original thickness.
• Mast rails, chains, and rollers — no wear or missing pins.
• Tires — no chunks missing, correct pressure (pneumatic), no delamination (cushion).
• Hydraulic hoses and cylinders — no leaks or damage.
• Data plate legible.
• Seat belt operational.
• Fire extinguisher present, in date.
• Housekeeping — no fluids under truck, no loose items in operator compartment.

• Parking brake holds.
• Horn sounds.
• Lights and strobes working.
• Backup alarm functions.
• Steering — no excessive play.

• Service brake holds and stops smoothly.
• Directional controls respond correctly.
• Lift and tilt controls smooth, no drift.
• Attachments (sideshift, clamps) function.
• Gauges — hour meter, temperature, fuel/battery, hydraulic pressure.
• Unusual noises or vibration.

• LP gas: tank securely mounted, positioning pin aligned, hose not chafing, valve accessible.
• Diesel/gas: fuel level, oil level, coolant, no leaks, air filter.
• Electric: battery voltage, water level (if applicable), cables and connectors intact, restraint bar/hood latched.

If an operator marks a fail on any safety-critical item, the site procedure should trigger four steps:

1. Immediate shutdown: turn off the ignition, pull the key, or disconnect the battery plug.
2. Physical tag-out: attach an "OUT OF SERVICE - DO NOT OPERATE" tag to the steering wheel or main control handle.
3. Key control: place the key or disconnect lock in a lockout box controlled by maintenance or the safety manager.
4. Documented escalation: record the tag-out on the facility maintenance log.

Under 29 CFR 1910.178(p)(1), a truck found in need of repair must be taken out of service until it has been restored to safe operating condition.

• Weeks of sheets checked off with the same pen, handwriting and uniform checkmarks down every column.
• A "completed" multi-point inspection time-stamped a minute after the driver clocked in.
• Completed logs for trucks that were down for repair during that shift.
• Fix: supervisors spot-check logs against the truck's real condition, and use checklists matched to each truck's fuel source and class.

Log each inspection with the truck ID, date/time, operator name, and any defects. Trucks with unsafe defects must be tagged out of service until repaired. Employers typically keep at least 12 months of inspection records.