How to Make a Daily Forklift Inspection Checklist

Creating a pre-shift forklift inspection checklist offers multiple benefits for your workplace. It ensures equipment readiness, improves safety, and helps prevent costly repairs by catching issues early. A structured inspection routine also supports compliance with OSHA standards and promotes a culture of safety.

Follow Manufacturer Guidelines

Your forklift’s Operation and Maintenance Manual (OMM) typically outlines daily inspection requirements. Common checks include:

• Visible damage or deterioration in performance
• Fluid leaks (fuel, oil, or coolant)
• Proper functionality of lights and optional equipment

Including these checks in your forklift operator training program is highly recommended. Most guidelines suggest inspections every 10 service hours or daily—whichever comes first.

Key Components of a Daily Forklift Inspection Checklist

A thorough inspection should include visual and operational checks across all major systems. Below are essential areas to cover:

General Checks

• Overall condition and cleanliness
• Clear travel paths free of hazards
• Review previous day’s inspection report
• Check for leaks under the forklift
• Fire extinguisher presence and condition
• Bolts, guards, chains, and hydraulic hose integrity

Brake System

• Inspect brake hoses, pipes, and joints for cracks or leaks
• Verify brake fluid level on level ground
• Test brake pedal travel and parking brake function
• Check wet disc brake systems if equipped

Cooling System

• Confirm engine coolant level
• Inspect fan belt for wear

Electrical System

For electric forklifts, include battery checks and wiring inspections:

• Inspect wires for damage
• Test headlights, warning lights, and horn
• Verify backup alarms and interlock systems
• Check battery electrolyte level (if applicable)

Engine & Fuel System

• Check engine oil level and exhaust condition
• Ensure battery is charged and secured
• Verify fuel level for IC forklifts

Frame, Chassis & Safety Features

• Inspect overhead guard, load backrest, and assist grips
• Test seat belt functionality and condition
• Ensure operator seat locks securely

Hydraulic System

• Check hydraulic oil level
• Inspect mast, forks, and lift chains for wear or cracks
• Test mast movement and tilt functions

Axles, Steering & Tires

• Check steering wheel for looseness
• Inspect wheel nuts, tires, and rims for damage
• Verify tread depth

Drive System

• Test accelerator and inching pedal
• Check transmission oil level after warming up

Documenting the Inspection

Personalize your checklist based on your specific work environment and forklift type. After completing the inspection:

• Operators should sign and date the form
• Supervisors review and log the report in the forklift’s file
• Keep records for OSHA compliance and future audits

Creating a Culture of Safety

Encourage operators to report any issues immediately. If a forklift is unsafe:

• Tag it clearly (e.g., red tag)
• Remove it from service until repairs are complete

Safety and productivity go hand in hand—never ignore inspection findings.

Final Thoughts

A daily forklift inspection checklist is more than a compliance requirement—it’s a proactive step toward reducing downtime, preventing accidents, and extending equipment life. Implementing this routine helps protect your workforce and your bottom line.