Stop, Look & Check: The OSHA-Mandated Daily Forklift Pre-Shift Checklist
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Non-Negotiable Safety: Your OSHA-mandated daily forklift check compliance starts before the key turns. Use this two-part, pre-shift checklist to keep your operators, equipment and inventory safe every single day.
Did you check your brakes this morning?
Skipping the daily pre-shift inspection is the fastest way to turn a 5-minute task into an expensive, shift-stopping accident. Get compliant with this essential two-part checklist.
Every minute counts in your warehouse operations. But before the shift starts, there’s one non-negotiable step for operators: the daily forklift inspection.
This check isn't just good practice—it's OSHA compliance (specifically 29 CFR 1910.178(q)(7)) and the one of the best ways to keep your operators, inventory and equipment safe.
This post provides a straightforward, two-part checklist that every operator and safety manager should follow before the key is turned. Remember: If an issue is found, the machine must be tagged and taken out of service immediately.
Part 1: The Visual Pre-Operation Walk-Around (Key Off)
Before powering up, the operator must conduct a thorough visual inspection of the lift truck. These are the mandatory "look and feel" checks that spot damage before it becomes a hazard.
| AREA TO INSPECT | WHAT TO LOOK FOR | WHY IT MATTERS |
|---|---|---|
| Forks & Load Attachments | Look for cracks, bends, distortion or excessive wear (especially at the heel). Check that the retaining pin is secure. | Damaged forks can snap under load, causing catastrophic product loss and injury. |
| Mast, Carriage & Chains |
Check mast rails and carriage components for physical damage. Look for excessive slack or breaks in the lift chains. Ensure lubrication is visible. | Faulty mast operation can cause loads to shift or drop unexpectedly. |
| Overhead Guard & Backrest |
Check the overhead guard for structural damage or loose mounting bolts. The load backrest must be intact. | Protects the operator from falling objects and prevents loads from shifting backward. |
| Tires & Wheels | Inspect tires for chunking, flat spots, excessive wear or cracking. Check lug nuts for tightness. | Worn tires reduce traction, stability and braking effectiveness. |
| Fluids & Leaks | Check the ground beneath the forklift for any signs of hydraulic or battery fluid leaks. Inspect hydraulic hoses for bulges, splits or abrasion.. | Leaks indicate potential system failure and can create slip hazards. |
| Decals & Capacity Plate | Confirm the data plate (which lists load capacity) is visible, readable and matches the attachment being used. | Critical for preventing dangerous overloading and tip-overs. |
Part 2: The Functional Test (Key On)
Once the visual check is complete and the equipment is safe to start, the operator must test all critical operational functions.
| FUNCTION TO TEST |
ACTION TO TAKE | STATUS CHECK |
|---|---|---|
| Brakes | Test the service brake (foot pedal) and parking brake. | Must stop smoothly and hold the truck stationary on an incline (if applicable). |
| Steering | Turn the steering wheel fully left and right. | Must operate smoothly without excessive play or binding. |
| Warning Devices | Test the horn, backup alarm and all lights (headlights, warning strobes, brake lights). | All devices must be functioning and audible/visible. |
| Hydraulic Controls | Test the lift/lower and tilt functions. | Movement should be smooth, without jerky motions, shuddering or sinking. |
| Safety Devices | Check the seatbelt for damage and ensure the seat interlock (if equipped) is working correctly (the truck should not operate when the seat is empty). | Seatbelt must latch securely. |
The Non-Negotiable Rule: Tag It Out
This is the most critical instruction for your team: If an operator finds any condition during the pre-shift check that could adversely affect the safety or operation of the forklift, they must immediately remove the unit from service. This means:
- Tagging the machine with an "Out of Service" tag or similar warning.
- Reporting the defect immediately to the shift supervisor or the maintenance team.
By making this two-part check a non-negotiable part of the daily routine, your operators become the first line of defense—keeping your electric fleet running reliably and safely every single day.
Beyond the Checklist
Go Digital
Paper checklists meet the minimum compliance standard—maintaining consistent and accurate records. If you're looking to streamline this critical process, for instance, connected technology monitors can digitize the entire daily inspection at startup, instantly creating and storing audit-ready records, significantly streamlining compliance efforts.
Compliant & Competent
It's also worth noting that a competent operator is a safe and efficient one. To verify every driver is fully compliant and trained on controls, stability and the proper execution of this daily safety check, consider a forklift operator certification training program.
The Payoff: Safety & Uptime
The daily pre-shift inspection, though brief, is a powerful tool in preventing accidents and unplanned downtime. By empowering your operators to identify and tag defects immediately, you establish a proactive safety culture that protects your team and your assets.
A five-minute check ensures a full shift of reliable, compliant, and productive operation, which is the ultimate goal for any successful warehouse operation. Reminder: consult your operator's manual for the full checklist specific to your forklift model.
Ready to ensure your operators are competent and compliant? Get your staff trained up with OSHA-certified forklift operator training with Raymond Storage Concepts—includes learning the controls, practicing maneuvers, the proper way to perform a daily check and much more. Contact our training team at raymondsci.com/operator-training today to get started.
