A pre-shift inspection checklist covering the items OSHA 1910.178 requires operators to examine. Print it for the clipboard or run it from a phone — free, no signup.
| Item | What to Check | OK | Defect Found | Notes |
|---|---|---|---|---|
| Forks | Cracks, bends, wear at the heel, positioning latches engage | — | — | — |
| Mast & chains | Chain wear and lubrication, kinks, anchor pins, mast rails | — | — | — |
| Tires & wheels | Wear, chunking, pressure (pneumatic) or damage (cushion) | — | — | — |
| Hydraulics | Leaks, hose condition, cylinder drift under load | — | — | — |
| Brakes | Service brake stops smoothly; parking brake holds | — | — | — |
| Steering | Smooth, no excessive play or unusual noise | — | — | — |
| Horn | Works and is loud enough for the environment | — | — | — |
| Lights & beacons | Headlights, warning beacon, backup alarm functional | — | — | — |
| Seat belt / restraint | Present, latches, retracts, webbing not frayed | — | — | — |
| Overhead guard | No damage, bends, or missing hardware | — | — | — |
| Battery or LP system | Electric: charge, connections, hold-downs. LP: leaks, tank mounting, relief valve | — | — | — |
| Fluid levels | Engine units: oil, coolant, fuel; check for fresh leaks under truck | — | — | — |
| Data plate | Legible and matches attachments in use | — | — | — |
| Gauges & controls | All gauges read normal; lift, tilt, and travel controls respond correctly | — | — | — |
Preview of the full checklist. The OK, Defect Found, and Notes columns are left blank for the operator to fill in each shift.
OSHA's powered industrial truck standard, 29 CFR 1910.178, requires that trucks be examined before being placed in service — at least daily, or after each shift when the truck is used around the clock. The standard is equally clear about the outcome: a truck found to be in need of repair, defective, or in any way unsafe must be taken out of service until it has been restored to safe operating condition. The checklist above covers the items that examination should touch on a typical lift truck, whether electric or internal combustion.
Done consistently, the whole routine takes less time than a coffee refill — and it's the routine that catches a leaking hydraulic hose before it becomes a dropped load.
Don't note it and drive anyway. Tag the truck out, pull the key, and report the defect to whoever dispatches repairs — the truck stays out of service until it's fixed and verified. The best operations turn each defect into a work order the moment it's found, with a photo and the operator's note attached, so nothing lives only on a clipboard. If you're tracking a whole fleet this way, see our guide to fleet maintenance tracking for how to keep defect history, repairs, and PMs in one place per truck.
Most of the checklist is identical, but the power section differs. On an electric truck, check the battery's charge level, cable and connector condition, and that hold-downs are secure — and watch for electrolyte on top of the battery. On an LP truck, check the tank mounting, hose and fitting condition, and for any smell of propane. On diesel or gas units, add fluid levels — engine oil, coolant, fuel — and a look at belts and the exhaust system. The CSV's “Battery or LP system” and “Fluid levels” rows cover both; delete whichever doesn't apply to your fleet.
OSHA 1910.178 requires industrial trucks to be examined before being placed in service — at least daily, or after each shift when the truck is used around the clock. In practice that means a pre-shift inspection every day the forklift operates, and once per shift for multi-shift operations.
OSHA 1910.178 requires the examination itself, not a specific written form. But a documented checklist is the practical standard: it proves the inspection happened, creates a defect history for each truck, and is what OSHA inspectors and insurers ask to see after an incident. A signed daily sheet — paper or digital — is cheap insurance.
Under OSHA 1910.178, a truck found to be in need of repair, defective, or in any way unsafe must be taken out of service until it has been restored to safe operating condition. Tag the truck out, remove the key, report the defect, and don't return it to service until the repair is verified.
RunTight gives operators this checklist on their phone — scan the truck's QR code, tap through, and defects become work orders with photos. Free for teams up to 25.
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