The Ultimate Forklift Checklist Guide: Safety and Inspection

Forklifts, also known as fork trucks or lift trucks, are essential tools in warehouses, construction sites, and manufacturing facilities. They make lifting, moving, and stacking heavy materials much easier, helping businesses run smoothly and efficiently. But with great power comes great responsibility — forklifts can be dangerous if not used properly.

According to the Occupational Safety and Health Administration (OSHA), forklift-related accidents cause a significant number of workplace injuries and fatalities each year. That’s why having a solid forklift safety and inspection program in place is critical.

This guide will walk you through the importance of forklift checklists, safety protocols, and inspection sheets to help keep your workplace compliant and safe.

Why Forklift Inspections and Safety Checklists Matter

Forklift inspections aren’t just about following the rules—they’re about keeping everyone safe. A quick daily check can catch small issues before they turn into serious problems, preventing accidents and costly breakdowns. A well-maintained forklift runs more smoothly, lasts longer, and helps avoid unexpected downtime.

OSHA requires daily forklift inspections to ensure these machines are safe to operate. Typically, workers use a forklift inspection sheet or checklist to document their findings. This not only keeps the workplace compliant but also provides a clear and organized way to spot and fix potential hazards. If any issues arise, they should be reported to a supervisor right away, and the forklift should not be used until it’s fully safe.

By making inspections a routine part of the workday, businesses can create a safer environment for everyone while keeping operations running efficiently.

Key Components of a Forklift Inspection Checklist

A proper forklift inspection isn’t just a formality — it’s a crucial step in ensuring safety and keeping equipment in top shape. A good checklist covers both daily pre-use inspections and routine maintenance to catch potential issues before they turn into bigger problems.

Pre-Use Inspection Checklist

Before getting behind the wheel, forklift operators should take a few minutes to do a thorough check. This quick inspection helps prevent accidents and keeps the forklift running smoothly. Here’s what to look for:

• Tires: Check for any wear, damage, or low inflation (if the tires require air).
• Forks: Look for cracks, bends, or any signs of damage that could affect lifting.
• Hydraulics: Make sure there are no leaks and that the lifting mechanism works without issues.
• Fluid Levels: Check oil, engine coolant, and hydraulic fluid to ensure they’re at the right levels.
• Brakes: Test the brakes to make sure they’re responsive and working properly.
• Lights & Horn: Confirm that headlights, brake lights, warning lights, and the horn are all functioning.
• Seatbelt: Ensure the seatbelt is in good condition and fastens securely.
• Steering: Turn the wheel to check for smooth and easy operation.
• Battery (for electric forklifts): Check the charge level and make sure all connections are secure.
• Overhead Guard: Ensure it’s securely in place and free from any visible damage.
• General Condition: Do a final walk-around to look for anything unusual, like loose parts, leaks, or other visible issues.

Taking a few moments to go through this checklist can make a big difference in workplace safety. If any issues come up, report them immediately and don’t use the forklift until it’s been checked and repaired. A little prevention goes a long way in avoiding costly repairs and dangerous situations.

Daily Inspection Checklist

In addition to the pre-use inspection, a forklift daily inspection checklist should cover more detailed checks to keep the equipment in top shape. This may include:

• Document Issues: Write down any problems found during the pre-use inspection.
• Clean: Remove debris or spills that could affect operation.
• Lube: Make sure moving parts are lubricated.
• Safety Devices: Check safety features (e.g. alarms, backup cameras) are working.
• Operational Check: Test the forklift to listen for unusual noises.

Forklift Safety Checklist

A forklift safety checklist is for operational safety and OSHA compliance. Key items include:

• Operator Training: Make sure all operators are certified.
• Forklift Operator Training: Make sure operators are trained on advanced technology like AR training to improve safety and efficiency.
• Load Capacity: Don’t exceed the forklift’s rated capacity.
• Stability: Make sure loads are balanced and secure.
• Pedestrian Safety: Separate forklift traffic from pedestrian areas.
• Speed Limits: Enforce speed limits.
• Parking: Park on a level surface with forks down and parking Brake engaged.
• IC Engine Models: Follow specific pre-operation inspection checklists for IC engine forklifts to ensure safety and OSHA compliance.

Forklift Inspection Sheets

A forklift inspection sheet is a record of each inspection. It serves several purposes:

• Compliance: Proof of OSHA compliance.
• Accountability: Hold operators and maintenance people accountable for finding and fixing issues.
• History: Tracks forklift maintenance history to find recurring problems.
• Communication: Communication between operators, supervisors and maintenance people.

A good inspection sheet should have:

• Date and time of inspection.
• Operator’s name.
• Forklift number.
• Checklist items with space for comments.
• Operator and supervisor signature.

Forklift Safety Best Practices

Beyond inspections, there are best practices for forklift safety that can help reduce accidents. Here are some:

Operator Training and Certification

OSHA requires all forklift operators to complete a training program and get certified. Training should cover:

• Safe operating techniques.
• Load handling and stability.
• Hazard recognition and avoidance.
• Emergency procedures.

Regular Maintenance

Regular maintenance is key to keeping forklifts in good working order. This includes:

• Scheduled servicing.
• Replacing worn or damaged parts.
• Fixing issues found during inspections.

Workplace Design

Designing a safe workplace can reduce forklift hazards. Consider:

• Clearly marked walkways.
• Adequate lighting.
• Signs for speed limits and hazards.
• Designated loading and unloading zones.

Encourage a Safety Culture

Encourage a safety culture by:

• Getting employees to report hazards.
• Recognizing and rewarding good behavior.
• Holding regular safety meetings and training sessions.

Common Forklift Hazards and How to Avoid Them

Understanding common forklift hazards can help operators and supervisors take proactive measures to prevent accidents. Some of the most common hazards include:

Tip-Overs

Tip-overs are a leading cause of forklift accidents. They often occur due to:

• Overloading.
• Improper load handling.
• Sharp turns at high speeds.

Prevention Tips:

• Always adhere to the forklift’s load capacity.
• Keep loads low and stable during transport.
• Avoid sudden stops and sharp turns.

Struck-By Accidents

Pedestrians and other workers are at risk of being struck by a forklift, especially in busy environments.

Prevention Tips:

• Use horns and warning lights to alert pedestrians.
• Designate separate pathways for forklifts and pedestrians.
• Ensure operators have a clear line of sight.

Falls from Height and Seat Belt Usage

Falls can occur when operators or workers stand on the forks or use the forklift as a makeshift lift.

Prevention Tips:

• Never allow riders on the forklift unless it is designed for multiple occupants.
• Use proper equipment (e.g., scaffolding or lifts) for elevated work.

Mechanical Failures

Mechanical failures, such as brake or steering malfunctions, can lead to accidents.

Prevention Tips:

• Conduct regular inspections and maintenance.
• Address issues immediately.

Forklift Safety Training: A Cornerstone of Workplace Safety

No matter how well a forklift is maintained, safety ultimately depends on the operator. OSHA requires all forklift drivers to complete proper training, which includes both classroom instruction and hands-on experience.

Forklift Operation

Operators need to know how to handle a forklift confidently and safely. This includes:

• Starting, stopping, and steering with control.
• Navigating tight spaces without risking collisions.
• Handling loads carefully to prevent tipping or falling objects.

Load Handling

Improper load handling is one of the biggest causes of forklift accidents. Training should cover:

• Understanding load limits and keeping stability in mind.
• Positioning and securing loads correctly to prevent shifting.
• Avoiding overloading or unevenly distributing weight.

Hazard Recognition

A trained operator should be able to spot potential dangers before they cause problems. This means:

• Identifying workplace hazards like slippery floors, narrow aisles, or overhead obstacles.
• Knowing the forklift’s limits and avoiding unsafe maneuvers.
• Recognizing early signs of mechanical failure and reporting them immediately.

Emergency Procedures

Knowing how to react in an emergency can prevent injuries and save lives. Training should include:

• What to do if the forklift tips over or is involved in a collision.
• How to safely exit the forklift in case of an emergency.
• The importance of reporting accidents and near-misses to improve workplace safety.

A well-maintained forklift combined with well-trained operators creates a safer, more efficient work environment. By making maintenance and safety training a priority, businesses can reduce accidents, extend equipment life, and keep operations running smoothly.

Creating a Forklift Safety Program

A strong forklift safety program is about more than just following rules—it’s about building a workplace culture where safety comes first. When everyone is committed to preventing accidents, the workplace becomes more efficient, productive, and secure. Here’s what makes a forklift safety program truly effective:

Clear Policies and Procedures

To ensure everyone is on the same page:

• Develop written policies covering forklift operation, maintenance, and inspections.
• Make sure all employees understand these policies and know how to follow them.

Regular Safety Audits

Regular check-ins help keep safety practices up to date:

• Conduct audits to spot hazards and areas for improvement.
• Use audit findings to update safety protocols and training programs as needed.

Employee Involvement

A workplace safety program works best when everyone is engaged:

• Encourage employees to report potential hazards and share suggestions for improvement.
• Recognize and reward safe behavior to reinforce a culture of accountability.

Continuous Improvement

Safety is an ongoing effort, not a one-time task:

• Regularly review and update safety protocols to keep up with new challenges.
• Stay informed about changing regulations and industry best practices to maintain compliance.

By making safety a shared responsibility, businesses can reduce accidents, improve efficiency, and create a safer work environment for everyone.

Conclusion

Forklifts are essential for productivity, but they also come with risks if not used and maintained properly. A strong safety program — including regular inspections, proper training, and a culture of awareness —helps prevent accidents and keeps operations running smoothly.

Using a forklift inspection checklist and safety checklist isn’t just about compliance with OSHA regulations— it’s about protecting workers and preventing costly breakdowns. By staying proactive with inspections and maintenance, businesses can create a safer, more efficient work environment.

Safety isn’t a one-time task — it’s an ongoing commitment. Regularly reviewing and updating safety protocols ensures that everyone stays prepared for new challenges. With the right approach, businesses can maximize the benefits of forklifts while keeping their teams safe and productive every day.