A forklift pre-use inspection is a mandatory daily examination of all powered industrial trucks before they are placed into service. OSHA regulation 29 CFR 1910.178(q)(7) requires that all forklifts be examined at least daily, and forklifts used on a round-the-clock basis must be examined after each shift.
Two-Phase Inspection Process
The inspection consists of two distinct phases: a visual check with the key off, followed by an operational check with the engine running or power engaged.
Visual Check (Key Off/Power Off):
Fluid levels (engine oil, hydraulic fluid, coolant)
Tires for cuts, gouges, proper inflation (pneumatic), and tread wear
Forks for cracks, bends, heel wear, and secure retaining pins
Mast and carriage for damage, smooth channels, and secure end stops
Lift chains for tension, lubrication, and broken links
Overhead guard and load backrest for deformation or cracks
Safety decals and capacity plate (must be legible)
Hydraulic hoses and cylinders for leaks or chafing
Operator compartment for debris and grease
Seatbelt for fraying or latch damage
For electric forklifts: battery cables, connectors, electrolyte levels, and battery restraints
For LPG forklifts: properly mounted tank, pressure relief valve position (pointing up), hoses, connectors, and tank for dents or cracks
Operational Check (Key On/Engine Running):
Horn and backup alarm (must be audible)
Lights (head, tail, warning)
Steering for smooth operation and excessive play
Service brakes for proper stopping without pulling to one side
Parking brake for secure holding
Lift and tilt functions (smooth operation, no unusual noises)
Attachment controls (side shift, clamp, etc.)
Seatbelt and operator presence interlock systems
Dashboard indicators and hour meter
What to Do If Deficiencies Are Found
If any safety-related defect is discovered, the forklift must be removed from service immediately. The operator should attach an "Out of Service" tag to the controls, report the defect to a supervisor, and record the issue on the inspection form.
Specific conditions requiring immediate removal:
Hazardous sparks or flames from exhaust
Temperatures exceeding normal operating range
Leaks in the fuel system
Any condition that adversely affects the safety of the vehicle
Documentation and Recordkeeping
The completed inspection must be documented, and records must be maintained according to company procedures. The inspection form should include: forklift identification number, date, time, shift, operator name, and clear notation of any defects found. If no defects are found, the inspection still must be documented.
Preventive Maintenance Integration
Daily inspections focus on immediate safety concerns, but they should be integrated into a broader preventive maintenance program. Preventive maintenance should be performed according to the manufacturer's scheduled recommendations.
The Bottom Line
A forklift pre-use inspection is not optional—it is required by law. The two-phase process (visual + operational) takes approximately 5-10 minutes and identifies potential failures before they cause accidents. Any safety defect discovered requires immediate removal from service, tagging, and repair before the forklift can be operated again.