What does OSHA require for a forklift inspection?
OSHA requires every powered industrial truck to be examined before it is placed in service, and not placed in service if the examination shows any condition that adversely affects safety. Under 29 CFR 1910.178(q)(7) the examination is done at least daily, and after each shift where trucks run around the clock. Defects must be reported and corrected immediately, and 1910.178(q)(1) requires an unsafe truck to be removed from service until it is repaired by authorized personnel.
The standard does not prescribe a form, and OSHA does not require the daily examination to be written down. Most sites record it anyway: the record shows the check happened, which truck failed and what was done, and it is the first thing an investigator asks for after an incident.
Visual checks (truck off, forks lowered, parking brake on)
| Item | Look for | OK | Defect |
|---|---|---|---|
| Fluid leaks | Hydraulic oil, engine oil, coolant, fuel or electrolyte under the truck | ☐ | ☐ |
| Tires and wheels | Cuts, chunking, flat spots, low pressure on pneumatic tires, loose wheel nuts | ☐ | ☐ |
| Forks | Cracks at the heel, bent or uneven tips, worn heel, positioning latches locked | ☐ | ☐ |
| Load backrest extension | Fitted, secure, not bent | ☐ | ☐ |
| Mast and chains | Cracked welds, worn or kinked lift chains, missing chain pins, damaged rollers | ☐ | ☐ |
| Hydraulic hoses | Cracks, chafing, bulges, wet fittings | ☐ | ☐ |
| Overhead guard | In place, bolts tight, no cracks or bends | ☐ | ☐ |
| Data (capacity) plate | Present, legible and matching any attachment fitted | ☐ | ☐ |
| Operator compartment | Clean, seat belt works and latches, no loose objects, mirrors intact | ☐ | ☐ |
| Warning decals and operator manual | Legible, manual on the truck | ☐ | ☐ |
| Fire extinguisher (where fitted) | Charged, sealed, mounted | ☐ | ☐ |
Power source checks
| Electric trucks | ☐ | Internal combustion (LPG, gasoline, diesel) | ☐ |
|---|---|---|---|
| Battery charged; charge indicator reads in range | ☐ | Engine oil, coolant and fuel levels correct | ☐ |
| Cables and connectors not cracked, burnt or exposed | ☐ | LPG cylinder secured, pin located, relief valve facing up | ☐ |
| Battery restraint in place; vent caps fitted | ☐ | LPG hose and fittings: no damage, no smell of gas | ☐ |
| No corrosion or electrolyte on the battery top | ☐ | Belts, radiator and air filter condition | ☐ |
| Battery disconnect works | ☐ | Exhaust system intact, no excessive smoke | ☐ |
Operational checks (seated, belt on, area clear)
| Item | Test | OK | Defect |
|---|---|---|---|
| Horn | Sounds clearly | ☐ | ☐ |
| Lights, travel alarm and strobe | All working | ☐ | ☐ |
| Gauges and warning lights | Normal readings, no fault codes | ☐ | ☐ |
| Service brake | Stops smoothly and in a straight line at low speed | ☐ | ☐ |
| Parking brake | Holds the truck on a slope or against drive | ☐ | ☐ |
| Deadman / seat switch | Truck will not drive when the operator rises | ☐ | ☐ |
| Steering | Full lock both ways, no binding or excess play | ☐ | ☐ |
| Drive control | Forward and reverse smooth, no jerking | ☐ | ☐ |
| Lift and lower | Smooth, no chatter, holds height with no drift | ☐ | ☐ |
| Tilt | Forward and back smooth, holds position | ☐ | ☐ |
| Side shift and attachments | Operate correctly, no leaks | ☐ | ☐ |
| Unusual noise or vibration | None | ☐ | ☐ |
The record
| Truck ID | Hour meter | Date / shift | Operator | Result | Defects found | Reported to | Tagged out? |
|---|---|---|---|---|---|---|---|
| ☐ Pass ☐ Fail | ☐ Yes |
What happens when a forklift fails the inspection?
A truck that fails on any safety item is not driven. The operator removes the key, hangs a "Do not operate" tag, tells the supervisor and records the defect. Only authorized maintenance personnel repair it, and the truck goes back into service after the repair is checked. Minor items that do not affect safety (a torn seat cover) are recorded and planned for repair rather than ignored.
Common mistakes
- Ticking every box from the seat without walking around the truck.
- One check at the start of the day on a truck that runs three shifts.
- Defects written down while the truck keeps working.
- Paper sheets filed and never read, so the same leak is reported for a week.
- Attachments fitted without the capacity plate being updated.
Step by step
- Park and make safe. Park on level ground, lower the forks, set the parking brake and switch the truck off.
- Walk around the truck. Check leaks, tires, forks, mast, chains, hoses, overhead guard, data plate, seat belt and decals.
- Check the power source. For electric trucks check charge, cables and battery restraint; for LPG or diesel check fluids, cylinder and hoses.
- Test it running. Seated with the belt on, test horn, lights, alarms, brakes, steering, drive, lift, lower, tilt and attachments.
- Record and decide. Sign the record; if a safety item failed, remove the key, tag the truck out of service and report the defect.
A worked example
A two-shift distribution center ran eleven electric counterbalance trucks and kept paper check sheets in a binder at the charging bay. A review after a near miss showed one truck's parking brake had been marked faulty on four consecutive days while the truck stayed in use, because nobody read the sheets. The site moved the check to phones, made a failed safety item create an action for maintenance with the truck tagged out, and put open forklift defects on the shift start board. The brake was fixed the same day; repeat defects became a standing item at the weekly maintenance review.