Forklift Inspection Checklist: Daily Checks and OSHA Requirements

Last updated: October 2026

A quick inspection before every shift is one of the simplest ways to keep forklift operators safe and catch small problems before they turn into expensive repairs. OSHA requires forklifts to be examined before they are placed in service, and a written checklist makes sure nothing gets missed.

This guide covers what OSHA requires, a complete daily forklift inspection checklist, extra checks for electric, internal combustion and narrow-aisle trucks, how to inspect forks, and what to do when a forklift fails inspection. You can also download our free electric forklift inspection report or run inspections digitally with the FleetNow Inspect app.

In this guide:

• OSHA forklift inspection requirements
• Daily forklift inspection checklist
• Electric forklift checks
• Internal combustion forklift checks
• Reach truck and order picker checks
• How to inspect forklift forks
• What to do if a forklift fails inspection
• Digital inspections with FleetNow Inspect
• FAQs

OSHA’s powered industrial truck standard, 29 CFR 1910.178, sets the basic inspection rules for forklifts:

• Inspect before use. Forklifts must be examined before being placed in service, and at least daily (1910.178(q)(7)).
• Inspect after each shift on round-the-clock operations. If a forklift runs around the clock, it must be examined after each shift.
• Remove unsafe trucks from service. A forklift that is defective or in any way unsafe must be taken out of service until it is repaired (1910.178(p)(1) and (q)(1)).
• Use authorized personnel for repairs. All repairs must be made by authorized personnel.

OSHA does not require written records of daily inspections, but a signed checklist or digital report is the easiest way to show that inspections are being done and to track recurring problems. Always follow the inspection steps in your forklift’s operator’s manual, too.

A daily inspection has two parts: a visual check with the forklift parked and turned off, and an operational check with it running. Park on a level surface, lower the forks to the ground, set the parking brake and turn the key off before you start the visual check.

Visual check (forklift off):

Operational check (forklift running):

Write down the make, model, serial number, hours, date and operator name on each checklist so every report can be matched to the right truck.

Along with the daily checklist, check these items on electric forklifts:

• Battery charge level before the shift
• Battery cables and connectors for fraying, cracks, corrosion or exposed wires
• Battery restraint or hold-down is in place and secure
• Electrolyte levels on flooded lead-acid batteries (check after charging, and wear eye and hand protection)
• On-board and off-board chargers work properly
• Hood and battery cover latches close securely

Download our free electric forklift inspection report (PDF) to print and use on your trucks.

For gas, diesel and LP cushion and pneumatic tire forklifts, also check:

• Engine oil and coolant levels
• Air filter condition
• Radiator for damage, leaks and debris
• Belts and hoses for cracks and wear
• LP tank is secured in its bracket, the valve and hose are in good condition, and there is no smell of gas
• Fuel level on gas and diesel trucks
• Exhaust system for leaks, damage and excess smoke
• Hood latch closes securely

For reach trucks, order pickers and other narrow-aisle trucks, also check:

• On-truck and off-truck chargers work properly
• Forks, backrest and the reach mechanism are in good condition and extend and retract smoothly
• Brake pedal and deadman or operator presence controls stop the truck
• No hydraulic or battery leaks
• On order pickers, the platform gate closes and latches, and the harness and lanyard are in good condition

Forks carry every load, so they deserve a closer look than a daily walkaround. Industry guidance says to:

• Take a fork out of service when the blade or shank has worn 10% from its original thickness. A 10% loss in thickness cuts the fork’s capacity by about 20%.
• Check that the angle between the blade and shank is within 3 degrees of the original spec.
• Check that the fork tips are level, with no more than a 3% height difference across the blade length.
• Look for cracks at the heel and welds, and check that the positioning locks and hooks work.
• Have forks inspected in detail by a trained person at least every 12 months, and more often on heavy-use trucks, as called for in the ASME B56.1 safety standard.

Never weld or heat-straighten a cracked or bent fork yourself. Replace it, or have the fork manufacturer evaluate it.

1. Stop. Do not operate the forklift.
2. Tag it out. Remove the key or disconnect the battery and tag the truck “Do Not Operate” so no one else uses it.
3. Report it. Tell your supervisor right away and note the problem on the checklist.
4. Repair it. Have authorized personnel make the repair.
5. Re-inspect it. Inspect the truck again before it goes back into service, and keep the report with its records.

Paper checklists get lost, smudged and skipped. FleetNow Inspect is FleetNow’s equipment inspection app. It lets your team run daily, quarterly, annual and rental inspections from a phone or tablet, with:

• Standard, ready-to-use inspection reports, plus fully customizable reports
• Photo documentation of equipment condition and maintenance needs
• Easy access to past inspection reports for every machine
• Integration with the FleetNow marketplace, so you can add inspection reports and photos to your listings when you sell

In a FleetNow case study, mechanics ran 73% more inspections with the app than with paper.

An inspection checklist is also a good guide when you buy a used forklift. Ask the seller for recent inspection reports, and check the items above before you buy. FleetNow lists used forklifts from dealers and owners across the country, including Toyota, Hyster, Yale, CAT, Clark, Crown and Mitsubishi models. Need to reach higher on rough ground? Browse used telehandlers.