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Forklift Inspection Checklist and Fork Wear Card
Last verified: July 29, 2026 · Utility version: 2026-07-29
Use this printable worksheet to record a powered industrial truck's required pre-use examination and hand observed defects to authorized personnel. OSHA requires the examination before service, at least daily and after each shift when a truck is used around the clock. OSHA does not specifically require a checklist, and the cited federal standard does not require documentation. Add every model-specific item required by the truck manufacturer and your employer. If the examination shows a condition that adversely affects safety, do not place the truck in service.
Truck and examination identification
Power type
Pre-use examination worksheet
| Category | Observe or check under employer and manufacturer procedures | OK | Defect observed | N/A | Notes |
|---|---|---|---|---|---|
| Manuals and markings | Operator manual, safety decals, data plate, capacity markings, and attachment markings — present, legible, and matching installed equipment. | ||||
| Forks | Forks and fork-retaining hardware — visible damage, wear, unequal tip height, and locking condition. | ||||
| Mast and carriage | Mast, carriage, chains, rollers, and stops — visible damage or abnormal condition; do not enter the mast. | ||||
| Hydraulics | Hydraulic components — visible leaks or damage; do not touch fluid. | ||||
| Tires and wheels | Tires, wheels, bands, and hardware — visible damage, excessive wear, or loose or missing hardware. | ||||
| Guards | Overhead guard, load backrest, finger guards, and other guards — visible condition. | ||||
| Operator area | Seat, operator restraint, steps, handholds, and operator compartment — visible condition and cleanliness. | ||||
| Fluid levels | Fluid levels required by the model-specific procedure — check only when trained and authorized. | ||||
| Electric trucks | Battery, restraint, connector, cable, and compartment visible condition. | ||||
| LPG, gasoline, and diesel trucks | Tank or cylinder, restraints, hoses, connections, and fuel-system visible condition; odor or a visible leak is reported under the applicable procedure. | ||||
| Internal-combustion trucks | Belts, hoses, radiator, exhaust, visible fluid leaks, unusual heat, or unusual noise; observe only. | ||||
| Warning devices | Horn, warning devices, lights, alarms, and indicators where equipped or required. | ||||
| Steering and brakes | Steering, service brake, and parking brake under the authorized operational check. | ||||
| Travel and hydraulic controls | Travel, lift, lower, tilt, and attachment controls under the authorized operational check. | ||||
| Attachments | Attachments and auxiliary controls — visible condition and matching capacity markings. | ||||
| Abnormal behavior | Warning lights, displayed codes, alarms, unusual vibration, heat, noise, or behavior. | ||||
| Cleanliness | Truck cleanliness — lint, excess oil, grease, or debris noted. | ||||
| Model-specific item | Employer or manufacturer model-specific item: ______________________________ |
Examination result
Fork-wear reference for qualified personnel
The calculations below summarize three measured criteria highlighted in the Cascade Fork Safety Guide. That guide quotes ANSI/ITSDF B56.1-2012; it is not presented here as the current edition of the standard or as a complete fork inspection. Cracks, straightness, fork angle, tip alignment, locking components, markings, surface condition, and the controlling current manufacturer and employer requirements can also determine rejection.
| Measurement | Cited guide criterion | Worksheet calculation |
|---|---|---|
| Blade or shank thickness | The cited guide says not to return a fork to service when thickness has been reduced to 90% of original thickness. | Original thickness × 0.90 = cited minimum thickness |
| Tip-height difference across mounted pair | The cited guide says that when the difference exceeds 3% of blade length, the pair is not returned until repaired. | Blade length × 0.03 = cited maximum difference |
| Blade or shank straightness | The cited guide says that when deviation exceeds 0.5% of blade length or shank height, the fork is not returned until repaired. | Blade length or shank height × 0.005 = cited maximum deviation |
The same guide describes more than 10% fork wear as approximately a 20% reduction in fork strength. Do not infer rated capacity from appearance or these calculations. Use qualified inspection personnel, the correct inspection tool, the current controlling manufacturer documentation, and applicable employer procedures.
Fork measurement worksheet
Service-request handoff
What OSHA requires—and what it does not
29 CFR 1910.178(q)(7) requires examination before placement in service, at least daily, and after each shift for round-the-clock use. A truck may not be placed in service if the examination shows a condition that adversely affects safety; defects must be reported and corrected. OSHA's July 28, 2004 interpretation states that OSHA does not specifically require a checklist. Its February 7, 2000 interpretation states that the cited federal standard does not require documentation. Employers may impose stricter procedures, and the manufacturer's model-specific inspection items still apply.
Sources and limitations
- →29 CFR 1910.178 — Powered Industrial Trucks
- →OSHA Standard Interpretation, July 28, 2004 — no specific checklist requirement
- →OSHA Standard Interpretation, February 7, 2000 — documentation not required by standard
- →OSHA eTool — Powered Industrial Trucks: Pre-operation
- →OSHA Training Library — Powered Industrial Trucks Checklist
- →ITSDF — B56 Standards page
- →Cascade Fork Safety Guide (PDF)
The Cascade guide is a manufacturer-published secondary reference that quotes ANSI/ITSDF B56.1-2012. ITSDF's current B56 standards page should be checked for the current edition. This worksheet does not replace that current standard, the truck manufacturer's controlling manual, employer procedures, or qualified personnel.
Request service
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