Forklift Inspection Checklist: Daily Pre-Use Check and Log
A free printable forklift inspection checklist (also called a forklift daily checklist or pre-use check) for the check before each shift: 26 checks, OK / Defect / N/A results and a result line that shows when a truck must not be used. A usage log for hour meter readings and defects is included. Excel file, no macros.
Download
Download the forklift checklist (.xlsx)
Free, no sign-up. Version 1.3.0, Excel workbook (.xlsx), about 30 KB. No macros. Built for Excel 2010 or later; also opens in LibreOffice Calc. The checklist prints on one A4 or Letter page.
Who it is for
Forklift operators doing the inspection before using a truck, and warehouse supervisors who keep the records and follow up defects. It covers counterbalance trucks (electric, LPG and diesel), reach trucks, stackers, order pickers and powered pallet trucks; checks that do not apply to a truck are marked N/A.
When a forklift inspection is done
In the US, OSHA’s rule for powered industrial trucks, 29 CFR 1910.178(q)(7), requires a truck to be examined before it is placed in service, at least daily, and after each shift where trucks are used around the clock. A truck must not be placed in service while the examination shows a condition that affects its safety. OSHA’s interpretation letters add that the rule does not require the examination to be written down, and that a truck not used every day needs the examination when it is next put into service (OSHA letter, 2005; OSHA letter, 2000).
Elsewhere, local rules and guidance apply; in the UK, for example, HSE guidance expects daily pre-use checks by the operator alongside periodic thorough examinations. A written checklist is the simplest way to show the check was done and to make sure defects are reported, wherever you are.
The pre-use inspection is not the same as maintenance or a periodic thorough examination by a competent person. It is a short check by the operator to catch damage and faults before they cause an accident.
What the checklist covers
| Part | Checks |
|---|---|
| Before starting (parked, forks lowered, power off): 15 checks | Forks and locking pins; mast and chains; hydraulic hoses and cylinders; tyres and wheels; overhead guard and load backrest; capacity / data plate; leaks under the truck; fluid levels; battery (electric); LPG cylinder (LPG); seat and seat belt or operator restraint; steps, handholds and floor plates; fire extinguisher if fitted; attachments if fitted; safety decals. |
| Operating checks (clear area, no load): 11 checks | Horn; lights, beacon and travel alarm; instruments and warning lights; steering; service brake; parking brake; travel controls; lift and lower; tilt, reach and side shift; emergency stop or isolator; unusual noise, smell or vibration. |
| Result | Counts of defects and empty checks, and one result line: All checks OK, Not finished, or DEFECT RECORDED as soon as one check is marked Defect. Boxes for the operator’s signature, who the defect was reported to, and who put the truck back in service. |
| Usage Log (200 lines) | Date, shift, truck, operator, hour meter start and end, pre-use check done, defect found, reported to, taken out of use. Hours used are worked out; an end reading below the start, a missing pre-use check, and a defect with nobody named to report it to are flagged. |
How to use it
- Print a blank checklist for each truck and shift, or fill it in on a tablet. Fill in the truck, date, shift, hour meter and operator.
- Do the parked checks first, then the operating checks in a clear area without a load.
- Mark each check OK, Defect or N/A, and describe every defect in the Comments column.
- Report a defect straight away. Do not use the truck until a competent person has checked it and decided it is safe to use.
- Keep the completed sheets for as long as your company requires, and enter each shift in the Usage Log.
- Adapt the list: add the checks in your truck manufacturer’s operator manual and remove those that never apply. The Instructions sheet explains how.