OSHA Forklift Safety Checklist - Procedure Guide

OSHA Forklift Safety Checklist – Procedure Guide

Follow these step-by-step procedures for OSHA-compliant forklift safety inspections to ensure regulatory compliance, workplace safety, and operational readiness per 29 CFR 1910.178 requirements.

OSHA-Compliant Safety Inspection Procedures

Follow these systematic safety inspection procedures to ensure compliance with OSHA 29 CFR 1910.178 requirements for powered industrial truck inspections. Each procedure is designed to identify potential safety hazards and ensure regulatory compliance while maintaining operational safety standards.

OSHA 1910.178(q)(7) Requirements

Daily Inspection Mandate: Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Only authorized and properly trained personnel shall be permitted to operate industrial trucks.

⚠️ Critical Safety Protocol

Out-of-Service Requirement: Any forklift found to have safety defects must be immediately removed from service and tagged "DANGER - DO NOT OPERATE" until all defects are corrected and verified by qualified personnel.

Pre-Inspection Safety Setup Procedure
  • Position forklift on level, stable ground away from traffic
  • Engage parking brake and lower forks to ground level
  • Turn off engine and remove key from ignition
  • Allow engine to cool if inspection involves hot components
  • Ensure adequate lighting for thorough visual inspection
  • Have inspection checklist and writing materials ready
  • Verify only certified operator is conducting inspection
  • Check operator certification is current and valid
  • Don appropriate PPE (safety glasses, work gloves)
  • Clear area of personnel and obstacles before starting
  • Review manufacturer's inspection guidelines if available
  • Document inspection date, time, and operator information
Visual Safety Inspection Procedure
  • Walk completely around forklift looking for visible damage
  • Check ground beneath forklift for fluid leaks or stains
  • Inspect tires for cuts, gouges, excessive wear, or embedded objects
  • Check tire pressure using gauge (pneumatic tires only)
  • Examine wheels and rims for cracks, damage, or loose bolts
  • Inspect forks for straightness, cracks, or excessive wear
  • Check fork thickness at heel (max 10% wear allowed)
  • Verify mast assembly has no visible cracks or damage
  • Inspect lift chains for wear, stretch, or inadequate lubrication
  • Check hydraulic cylinders for leaks or rod damage
  • Examine body and frame for structural damage or cracks
  • Verify all guards and covers are in place and secure
Overhead Guard & ROPS Inspection Procedure
  • Inspect overhead guard frame for cracks, dents, or damage
  • Check ROPS structure integrity with no deformation
  • Verify all guard mounting bolts are secure and tight
  • Examine welds for cracks or signs of fatigue
  • Test overhead guard strength by visual assessment only
  • Check windshield/windows for cracks or vision obstruction
  • Clean glass surfaces and adjust mirrors for proper visibility
  • Test wiper operation if equipped (clear movement, no streaking)
  • Verify overhead guard clearance is adequate for work area
  • Check for any modifications that could affect safety
  • Document any damage requiring immediate attention
  • Ensure guard meets manufacturer specifications
Operator Compartment Safety Check
  • Inspect operator seat for damage, wear, or loose mounting
  • Test seat adjustment mechanisms for proper operation
  • Check seat belt presence, condition, and secure mounting
  • Test seat belt buckle mechanism for proper engagement
  • Verify control levers/joysticks move smoothly without binding
  • Test steering wheel or tiller for proper response
  • Check parking brake engagement and holding capability
  • Test service brake pedal travel and response
  • Verify deadman pedal/switch activates properly
  • Test horn operation for adequate sound level
  • Check instrument panel for proper function and visibility
  • Ensure all operator controls are clearly labeled
Engine & Power System Check Procedure
  • Check engine oil level using dipstick (engine cool)
  • Inspect oil condition for contamination or metal particles
  • Check coolant level in reservoir (engine cool only)
  • Verify hydraulic fluid level with mast fully lowered
  • Check fuel level (gas/diesel) or battery charge level
  • Inspect air filter condition for dirt or damage (IC engines)
  • Check battery terminals for corrosion or loose connections
  • Verify battery water levels are adequate (lead-acid)
  • Inspect exhaust system for leaks or damage (IC engines)
  • Check radiator and cooling system for leaks or obstructions
  • Verify all fluid levels are within manufacturer specifications
  • Document any fluid levels requiring attention
Safety Systems Verification Procedure
  • Start engine and test backup alarm operation while reversing
  • Activate warning lights/strobes and verify proper function
  • Check load backrest extension is present and secure
  • Verify capacity plate is legible and properly mounted
  • Inspect all safety decals and warnings for legibility
  • Check fire extinguisher presence and charge (if required)
  • Verify operator manual/checklist is available and current
  • Test emergency shut-off accessibility and function
  • Check work lights and headlights for proper operation
  • Verify all safety interlocks function properly
  • Test dead man switch disables all functions
  • Document any safety system deficiencies found
Attachments & Load Handling Check
  • Inspect forks for cracks, especially at heel and mounting points
  • Check fork straightness and proper spacing alignment
  • Verify fork positioning mechanism operates smoothly
  • Test fork lock mechanism engages securely
  • Check carriage condition and smooth operation
  • Test side shifter operation if equipped (smooth movement)
  • Verify special attachments (clamps, rotators) operate properly
  • Inspect hydraulic hoses for wear, cuts, or leaks
  • Check quick-disconnect couplings are secure
  • Test attachment hydraulic functions under no-load conditions
  • Verify attachment capacity ratings match forklift capacity
  • Document any attachment defects or operational issues
Operational Safety Test Procedure
  • Start engine and check for smooth idle and proper gauges
  • Test forward and reverse travel with smooth acceleration
  • Verify steering response and control in both directions
  • Test lift and lower functions with smooth operation
  • Check mast tilt forward and backward within limits
  • Test side shift operation through full range (if equipped)
  • Verify parking brake holds forklift on maximum grade
  • Test service brake stopping ability within safe distance
  • Listen for unusual noises during operation
  • Check for abnormal vibrations in any function
  • Verify all gauges and indicators function properly
  • Test that all functions stop when operator leaves seat

OSHA Compliance Pro Tips

  • Only trained and certified operators may conduct forklift safety inspections per OSHA requirements
  • Document every inspection with date, time, operator name, and results for OSHA compliance records
  • Immediately remove any forklift from service if safety defects are found - tag with "DANGER - DO NOT OPERATE"
  • Maintain inspection records for at least one year or as required by company policy
  • Report all safety defects to supervisor and ensure repairs are completed before returning to service
  • Review OSHA 1910.178 regulations regularly to stay current with compliance requirements
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