What this daily check is for
Here is a brief OSHA shift exam for a powered industrial truck (above). Fill it out right on screen; download into either CSV or PDF format. The form capture the fuel type, hour meter, shift, and unit. It has an OK/Defect/N/A entry for power source, safety devices, masts and forks, and truck condition. There’s a spot to record any defects, a signature line if the truck was removed or put back in service, etc.
The code is 29 CFR 1910.178. The governing rule is paragraph (q)(7). Check industrial trucks before using them. Such examinations shall be made at least daily." If the trucks operates continuously, then you make the exam at the end of each shift. If the examination reveals a condition which adversely affects safety, you do not put the truck into service. Report defects immediately and correct.
Information on operator training, including the exam the operator will give, can be found under 1910.178(l), specifically paragraph (l)(3)(i)(J).
This is a short version of every shift exam. If you want to do the full station walk for identification, mast hardware, hydraulics, tires, power unit, controls, and operational function as individual stations, you will use the published Forklift Inspection Checklist. The items are in OSHA's eTool order for pre-operation and operational inspection. They're also in OSHA-ITA sample daily checklists. Note that OSHA doesn't have an official blank for the exam. Most employers show proof that it was done by filling out a sheet.
First, you fill in the truck and shift information. Date, operator, unit number, hour meter reading, shift and power/fuel type are what it asks. The OSHA-ITA sample daily sheets do the same. They ask for the truck number, hour meter, and shift so they can tie any defect back to a specific unit and tour. They ask you to choose between Gasoline, Diesel, Electric battery, LP gas, and Other. Your selection determines which power-source rows remains live and which you mark as N/A.
Next is the condition of the truck. Next is the condition of the truck. Check for any leaks on batteries, coolant, hydraulic oil or fuel. According to 178(p)(4), you don't operate with a fuel-system leak until it's corrected. Then you visually inspect for any leaks on batteries, coolant, hydraulic oil or fuel. According to 178(p)(4), you don't operate with a fuel-system leak until it's corrected.
What it is not
- It is not the full BenchTab Forklift Inspection Checklist. That page splits the look into more stations. This page is the daily or shift exam only.
- It is not a CMV pre-trip walkaround under 49 CFR 392.7 and not a 49 CFR 396.11 driver vehicle inspection report. Gladhands, fifth wheels, 4/32 inch steer tread, and air-brake pop-out are highway items.
- It is not the annual ANSI/ITSDF B56.1 fork inspection in section 6.2.8 (not more than 12 months). That is a mechanic job. This form does not set fork-thickness or chain-stretch Pass/Fail numbers, because 1910.178 does not state them.
- It is not a full battery-room charging procedure under 1910.178(g), and it is not the OEM dealer checklist that shipped with a specific model (for example Crown form OF 3772).
How to fill each block
Next, you inspect tires for pressure and condition (gouges, cuts). This is backed by both Toyota and OSHA eTool daily lists. Inspect the lugs and wheels. Confirm that the overhead guard is attached unless conditions does not permit. Do this if conditions allow. Debris and grease should not be present in the operator compartment. Trucks must be kept clean and free from excess grease, oil and lint according to 178(q)(10).
Only visually check hydraulic hoses, mast cables and stops. Don't put your hands inside the mast. Use a stick or other device as shown in the eTool for chain tension. Check that the operators manual is legible and in the container.
Then you look at the forks. And the mast. It’s another visual pass, followed by brief functional testing. Mismatched, worn, bent, or cracked forks are no good. Heel and top clip retaining pin is checked. Missing stops, bent areas or broken welds is checked on the mast assembly. Rust, kinks or other obvious damage are checked on rollers and lift chains. Load backrest is ensured to be secure if needed. 178(e)(2) where load type poses hazard.
Try tilting up/down and lifting/dropping with the motor running. Operator is told in Crown’s Daily Safety Check to attempt all hydraulic functions in an uncongested area. Mark a defect if a cylinder weeps oil or a function hesitates. No made-up numbers here on this sheet, like fork-blade thickness that fails, or a calculated percentage of chain stretch.
Check safety devices
Examine nameplate/data plate, 1910.178(a)(6): Nameplates and markings must stay in place and be legible.
Ensure capacity, model, serial, and attachments is correct for this truck. If the plate is missing or unreadable, don't operate it.
Check operator restraint (seat belt). 1910.178(q)(6): Do not remove the restraint device. According to OSHA’s July 28, 2004 interpretation, operators must wear installed restraint devices. Test horn, 1910.178(n)(4): Horn must work at blind crossing. Test lights as equipped. Test parking brake hold, Truck should not move. Test service brake, steering, and backup alarm (mark N/A if the truck doesn't have one).
Check the power source.
Mark N/A for any family this truck does not have.
For LP gas, check that the tank is mounted and restrained.
Check the locator pin.
Make sure the relief valve points up.
Check hoses for leaking or fraying.
Ensure there is no frost or propane odor.
Wear protective gear on LP fittings.
For electric, check the charge or discharge indicator.
Ensure battery restraint is fastened.
Check cables and connectors for exposed or frayed wires.
Check electrolyte with gloves, rubber apron, and face shield.
1910.178(p)(5) prohibits checking electrolyte or gasoline with an open flame.
What varies
For diesel and IC, check coolant and engine oil.
Never touch a hot radiator cap.
Check air filter as shown by the manufacturer.
Check for fuel leaks.
If there is hazardous overheating, sparks, or flames from the exhaust, take the truck out of service. Follow rules 178(q)(8) and 178(q)(9).
List all the defects.
Choose the service status
Remove Truck from Service if any defect adversely affects Safety
Under sections 1910.178(p)(1) and (q)(1), an unsafe truck must be kept out of service until authorized personnel return it to service.
Report defects immediately.
After you finish
Sign when truck is safe for current shift. Sign if you removed it. Supervisor signature only if the employer requires it.
OSHA 1910.178 Applies to General Industry in US.
Other Rules Apply to Agriculture, Maritime, and Construction.
State-Plan OSHA States May Add Recording Rules.
This is Not a Blank by a State Official.
The first three check blocks apply to electric, LP, diesel and gasoline trucks. The power-source block gets honest N/A marks. Default is sit-down counterbalance. You still give this daily exam to reach, order picker, and walkie trucks. Add your OEM extras to Notes: Walkie reverse, order-picker interlock. Rough-terrain forklifts don’t follow this indoor B56.1 / 1910.178 sheet; they follow ANSI/ITSDF B56.6.
There is no written daily checklist required by OSHA. According to their Feb 7, 2000 interpretation, "The decision regarding what information to document and for how long it should be retained is left up to the employer." And according to their July 28, 2004 letter, "While there is no specific OSHA requirement to use a checklist…employers must ensure that their trucks are properly inspected."
You follow the operator manual from each OEM and the employer procedure. According to Hyster, Crown, Yale and Toyota, the operator inspects before work and stops if something doesn't look right. If the fleet has an OEM sheet then you use it. They're model-specific. If you want a copy of the completed form to leave this tab, you can download it as a filled PDF or CSV. Answers will remain here. The next visitor will see a blank form.
Give the signed record to the employers maintenance process, or supervisor. Until authorized personnel get the truck back into service, the unsafe truck remains out of service. OSHA is not notified from this page. Your CMMS does not red-tag the truck. There’s no refresher training for an incident as required by 1910.178(l)(4).
Not a substitute for the OEM or a licensed inspection
The form appears at the top of the page. The preview image and printable PDF appear below the form.
This is not a replacement for a qualified mechanic. It is not a substitute for 29 CFR 1910.178, ANSI/ITSDF B56.1, or the truck’s OEM procedure. This is not legal advice. Do not invent OK / Defect limits that the cited OSHA or OEM text does not state; A record keeping template only.