Centers for Disease Control

and Prevention

National Institute for Occupational 

Safety and Health

Conducting a Daily Inspection of Powered 

Industrial Trucks (Forklift, Narrow-Aisle Reach 

Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

Summary

Workers use powered industrial 

trucks (PITs) to move or lift materials in warehouses, retail, manufacturing facilities, dockyards, and 

construction sites. The Occupational Safety and Health Administration (OSHA) standard 29 CFR § 

1910.178* details the safety requirements for PITs. The requirements 

of 29 CFR § 1910.178 are applicable to general industry workplaces†

. 

However, the information and recommendations in this Workplace 

Solutions document can be useful 

for construction, agricultural, longshore, maritime, and mining workplaces as well. Section (q)(7) of the 

OSHA standard requires a daily examination (inspection) of PITs before they are placed in service, or 

after each shift for vehicles used on 

a round-the-clock basis. Employers 

must provide PIT operators with 

adequate training to properly con-

*

Code of Federal Regulations. See CFR in 

References.

†

OSHA uses the term “general industry” 

to refer to all industries not included 

in agriculture, construction or maritime.

duct a PIT inspection. The National Institute for Occupational Safety and Health (NIOSH) developed 

this Workplace Solutions document 

to provide information about conducting a thorough daily inspection 

of a forklift/sit-down rider, consistent with 29 CFR § 1910.178 (q)(7), 

to reduce the likelihood of worker 

injuries during the use of PITs.

Introduction

PITs are powered by electric (battery) 

or internal combustion engines (diesel, 

gas, or liquefied petroleum gas [LPG]). 

In addition to forklifts, narrow-aisle 

reach trucks, walkie pallet lifts, and tow 

tractor/tugs, there are many other variations of PITs [OSHA n.d.]. Some examples include the following‡

: 

 Sit-down riders

 Narrow-aisle order pickers

 Narrow-aisle high-lift straddles

 Narrow-aisle side-loader platforms

‡

With the increase in ecommerce, narrow-aisle 

reach trucks and narrow-aisle order pickers are 

becoming more common in warehouses.

 Narrow-aisle side-loader highlift platforms

 Narrow-aisle turrets

 Narrow-aisle low-lift platforms

 Stacker pallets

 Walkie platform low lifts

 Walkie-pallet low lifts

 Walkie-pallet high lifts

 Tractor/walkie riders, and electric 

pallet jacks 

OSHA standard 29 CFR § 1910.178 (q)(7) 

specifies that PITs must not be placed in 

service if the inspection shows any conditions adversely affecting the safety of the 

vehicle. In addition, all defects must be reported immediately and corrected before 

the vehicle can return to service. Section 

(l)(3)(i)(J) of the OSHA standard requires 

employers to provide PIT operators with 

the training§

 needed to perform an inspection of the PIT. NIOSH investigations 

of forklift-related fatalities indicate that 

§

Training must consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written 

material), practical training (demonstrations 

performed by the trainer and practical exercises performed by the trainee), and evaluation 

of the operator’s performance in the workplace 

[29 CFR 1910.178(l)(2)(ii)].
Conducting a Daily Inspection of Powered Industrial Trucks (Forklift, Narrow-Aisle Reach Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

2

many workers are not following the procedures established by 

OSHA standards, consensus standards, or equipment manufacturers’ guidelines [NIOSH 2001; NIOSH 2020; Bobick et al. 

2020]. This document provides step-by-step, comprehensive 

information to perform a thorough inspection of a PIT/forklift/sit-down rider (internal combustion, electric, or liquefied 

petroleum gas [LPG]) consistent with 29 CFR § 1910.178 (q)(7).

Description of Exposure

Numerous hazards are associated with operating or working 

near PITs. Between 2011 and 2019, the Census of Fatal Occupational Injuries (CFOI) of the Bureau of Labor Statistics 

(BLS) reported 630 deaths related to PITs including forklifts, order pickers, and platform trucks [BLS 2019]. Daily 

PIT inspections must be properly performed to identify, report, 

and correct defects. Otherwise, overturns, hazardous spills, and 

worker injuries and deaths could result from incidents involving 

correctable issues such as faulty seatbelts, LP gas tank leaks, leaks 

involving fuel or oil, low tire pressure/cracking, frayed electrical 

wires, and inoperable backup alarms and horns. 

Recommendations

OSHA requires employers to provide PIT operators with adequate training¶

 to perform an inspection of the PIT. This document may assist employers who provide inspection training to 

PIT operators. The daily inspection process assists in identifying problems with the PIT that could cause an incident and endanger workers. In cooperation with the Industrial Truck Association, OSHA has provided general checklists for conducting a 

daily, pre-shift inspection of many different types of PITs:

Sample Daily Checklists for Powered Industrial Trucks | 

Occupational Safety and Health Administration (osha.gov)

Sample Daily Checklists for Powered Industrial Trucks | 

Occupational Safety and Health Administration (osha.gov)

NIOSH provides the following recommendations for conducting a thorough PIT inspection of a forklift/sit-down rider (internal combustion, electric, or LPG), which is used in 

many different industries.

¶

OSHA requires training every 3 years. However, if an incident occurs, 

additional training must be conducted [29 CFR 178 (l)(4)(ii)(B); Bobick 

et al. 2020].

Photo by ©Bugpai, iStock/Getty Images. 
Conducting a Daily Inspection of Powered Industrial Trucks (Forklift, Narrow-Aisle Reach Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

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General Information

The forklift operator should always follow manufacturers’ instructions for the specific type of PIT being inspected (such as 

forklift, narrow aisle reach, walkie pallet lift, or tow tractor/tug). 

 OSHA does not require the pre-operational inspections to be documented in writing; however, it may 

facilitate the daily inspection process. In addition, 

the employer may require the pre-operational inspections to be documented.

 All deficiencies and defects discovered during the 

pre-operational inspection should be reported to the 

supervisor immediately. Do not delay or wait until 

the next shift to report any deficiencies or defects. 

 Remove the PIT from service (deadline** or red tag) 

and do not return the PIT to service until all deficiencies and defects are corrected by trained technicians or PIT-certified personnel. 

Inspection (see page 4)

Inspection items that are specific to 

certain types of forklifts: (see page 5)

Acknowledgments

This document was prepared by Sarah Hughes (Division of Science Integration), Thomas Bobick (Division of Safety Research), 

and Susan Afanuh (Division of Science Integration), NIOSH.

Suggested Citation

NIOSH [2021]. Conducting a daily inspection of powered 

industrial trucks (forklift, narrow-aisle reach trucks, walkie pallet lift, and tow tractor/tug). By Hughes S, Bobick T, 

Afanuh S. Cincinnati, OH: U.S. Department of Health and 

Human Services, Centers for Disease Control and Prevention, 

National Institute for Occupational Safety and Health, DHHS 

(NIOSH) Publication No. 2022‒100, https://doi.org/10.26616/

NIOSHPUB2022100

**“Deadline” means to remove a vehicle or piece of equipment from operation or use because it is inoperative due to damage, malfunctioning, or 

needs repairs, it is unsafe, etc.

References

BLS [2019]. Injuries, illnesses, and fatalities. Washington, 

DC: Bureau of Labor Statistics, Census of Fatal Occupational 

Injuries. https://www.bls.gov/iif/oshcfoi1.htm#2019 

Bobick TG, Hause M, Socias-Morales C, Gwilliam M, Decker T 

[2020]. Forklift safety: a pilot study evaluation of retrofit lights. 

Prof Safety 65(12):41–45. 

CFR. Code of Federal Regulations. Washington, DC: U.S. 

Government Printing Office, Office of the Federal Register. 

NIOSH [2001]. Preventing injuries and deaths of workers 

who operate or work near forklifts. NIOSH Alert. Cincinnati, OH: U.S. Department of Health and Human Services, Centers for Disease Control and Prevention, National Institute 

for Occupational Safety and Health, DHHS (NIOSH) Publication No. 2001–109. https://www.cdc.gov/niosh/docs/2001-

109/pdfs/2001-109.pdf?id=10.26616/NIOSHPUB2001109

NIOSH [2020]. Fatality Assessment and Control Evaluation 

(FACE) Program. Cincinnati, OH: U.S. Department of Health 

and Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health. 

https://www.cdc.gov/niosh/face/

OSHA [no date]. Powered industrial trucks (forklifts) etool. 

Washington, DC: U.S. Department of Labor, Occupational 

Safety and Health Administration. https://www.osha.gov/

SLTC/etools/pit/forklift/types/classes.html#class1

OSHA [no date]. Sample daily checklists for powered industrial trucks. Washington, DC: U.S. Department of Labor, Occupational Safety and Health Administration. https://www.osha.gov/

training/library/powered-industrial-trucks/checklist https://

www.osha.gov/training/library/powered-industrial-trucks/

checklist-0
Conducting a Daily Inspection of Powered Industrial Trucks (Forklift, Narrow-Aisle Reach Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

4

Inspection

 Conduct the pre-start, visual inspection with the 

PIT turned off and the key removed.

 Check the fluid levels (depending on the type of 

forklift).

— Engine oil (dipstick)

— Water level (electric forklift)

— Hydraulic fluid (red cap, dipstick, the mast 

must be down, in neutral)

— Electrolyte levels (on electric forklifts)

— Do not attempt to fill fluid levels unless trained 

to do so. 

 Inspect the mast chains and hydraulic hoses for 

leaks, cracks, and other visible damage.

 Use a stick to check the chain tension. Do not put 

your hands or any other body part inside the mast. 

 Inspect the tires: 

— Tire condition (Look for chunking, cracking, 

cuts, gouges.)

— Tire pressure (Ensure that tires are not low/

flattened); do not adjust the air pressure in a 

pneumatic tire unless trained to do so.

 Inspect the wheels: 

— Check for cracks. 

— Look for abnormal wear or damage.

 Inspect the condition of the forks:

— The top clip retaining pin and heel pin (to secure extensions and attachments) are in place, 

functioning (not broken or bent).

— The fork tips are even (3 degrees or more of 

deflection up or down calls for replacement), 

not bent. 

 Ensure that the load backrest extension is functioning properly. 

 Ensure that there are no chips, cracks, or excessive wear.

 Inspect the safety plates, labels, and warning decals:

— Labels are secured to the PIT, legible, and visible.

— Labels correctly match the make, model, and 

load capacity.

— The nameplate matches the model, serial number, and any attachments.

 Inspect the overhead guard (if applicable):

— The guard is securely mounted to the PIT.

— There are no bent, twisted, cracked, or missing 

components.

— A clear line of sight from operating position to 

maximum elevation of forks and load.

 Ensure the operator manual is physically located on 

the truck and legible (easy to read).

 Check the operator compartment (no debris, check 

behind pedals, look for grease, presence of pedal 

pads and floormat).

 Inspect the operator restraint system:

— Operator seat is securely mounted to the seat 

deck.

— Seat deck latch is in place and locks the seat 

deck in the closed position.

— Operator seat adjustment is functioning properly and locks the operator’s seat in place.

— Bottom and rear seat cushions are in place 

and in good condition (no cracks or cushion 

chunks missing).

— Lateral/hip restraints are in place and securely 

mounted to the operator’s seat.

— Both sides of the seat belt are securely mounted to the seat frame and are operational and in 

good working condition (not frayed, worn, or 

cut, and if applicable the rachet lock is working properly).

 Ensure that functional finger guards are attached (if 

applicable). 

 Check underneath the PIT for signs of leakage.

 Conduct the operational inspection with the PIT 

turned on and running:

— Operate the PIT in forward and then in reverse.

— Check proper operation of all hydraulic functions (noise, leakage, levers return to neutral).

— Check accelerator pedal operation to ensure it 

is free and not binding.
Conducting a Daily Inspection of Powered Industrial Trucks (Forklift, Narrow-Aisle Reach Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

5

— Check for unusual noises.

— Test the following parts and equipment for defects or deficiencies:

• Inching control pedal (if included on the PIT)

• Brakes (foot brakes, parking brake, deadman seat brake)

• Verify there is no brake fluid leakage (test 

per the operator’s manual).

• Steering: check for proper operation; verify 

there is no hydraulic oil leakage.

• Clutch and gearshift

• Horn, lights††, and back-up alarm (must 

be operational), or any other safety devices the unit has been equipped with such as 

“blue lights” or strobes

 Check the following parts and equipment for defects 

or deficiencies:

— Hour meter

— Defroster and wiper

— Cab heater

— Gauges

— Cables and stops

— Overhead guard

— Roll over protection structure (ROPS), if present

— Battery charge status

— Fire extinguisher (inspected and charged), if 

present

Inspection items that are specific 

to certain types of forklifts: 

Electric Forklifts: 

 Inspect cables and connectors for frayed or exposed 

wires. 

††Head lights also help the operator when loading/unloading box trailers. 

Consider retrofitting forklifts with lights to increase safety measures. For 

more information, see Bobick TG, Hause M, Socias-Morales C, Gwilliam 

M, Decker T [2020]. Forklift safety: a pilot study evaluation of retrofit 

lights. Prof Safety 65(12):41–45.

 Inspect the battery for corrosion and make sure that 

the battery restraints are fastened. 

 Inspect the hood latch.

 Check the electrolyte levels, if trained to do so, while 

wearing personal protective equipment (PPE) (gauntlet gloves, rubber apron, and face shield).

 Check for correct plugging/regen operation (all 

electric types).

 Class 3 (walkie type trucks): check for proper operation of emergency reverse.

 Class 2 (reach trucks and order pickers): check operation of emergency stop and presence of mast guard 

(windshield or screen).

Internal Combustion Forklifts 

(gas or diesel): 

 Check the engine oil (dipstick). 

 Check the transmission fluid.

 Check the brake fluid reservoir.

 Check engine coolant levels (usually near the battery).

 Inspect the air filter indicator (if applicable); do not 

remove the air filter unless trained to do so.

 Inspect belts and hoses for leaks or cracks.

 Examine the radiator for cracks. 

 Inspect the hood latch.

 Check the fuel sedimenter (diesel).

LPG Forklifts: 

 Wear PPE for tank inspection (gauntlet gloves, apron, 

and face shield).

 Ensure that the LPG tank is properly and securely 

mounted (the pressure relief valve must be in the 12 

o’ clock position and not pointed toward the operator). 

 Check the LPG fuel levels in the LPG fuel tank.

 Inspect all hoses, connectors, and LPG tank restraint 

brackets. 

 Inspect the LPG tank for dents, dings, and leaks.
Conducting a Daily Inspection of Powered Industrial Trucks (Forklift, Narrow-Aisle Reach Truck, Walkie Pallet Lift, and Tow Tractor/Tug)

For More Information

More information about machine safety in various industries is available on the NIOSH website: https://www.cdc.

gov/niosh/topics/machine/

Find NIOSH products and get answers to workplace safety 

and health questions:

1-800-CDC-INFO (1-800-232-4636) 

TTY: 1-888-232-6348

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products. Furthermore, NIOSH is not responsible for the 

content of these websites.

This document is in the public domain and may be 

freely copied or reprinted. NIOSH encourages all 

readers of the Workplace Solutions to make them 

available to all interested employers and workers.

As part of the Centers for Disease Control and Prevention, 

NIOSH is the Federal agency responsible for conducting research and making recommendations to prevent work-related 

illnesses and injuries. All Workplace Solutions are based on 

research studies that show how worker exposures to hazardous agents or activities can be significantly reduced.

DOI: https://doi.org/10.26616/NIOSHPUB2022100

DHHS (NIOSH) Publication No. 2022-100

October 2021