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Sample Daily Checklists for Powered Industrial Trucks
The following checklists are intended to assist in providing training on OSHA's powered industrial truck operator standards. They are not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970 or for any standards issued by the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA). OSHA wishes to acknowledge that this checklist and related graphics was developed in cooperation with the Industrial Truck Association as part of the OSHA-ITA Alliance. The OSHA standard for powered industrial truck training [29 CFR 1910.178(l)] requires that an employer provide training to truck operators on a variety of topics. Among these topics are vehicle inspection and maintenance that the operator will be required to perform. The following checklists are being provided as part of OSHA's ongoing effort to assist employers and employees in ensuring that a safe and healthful workplace is provided. The lists serve as a guide only and may not be totally inclusive. Each type of powered industrial truck is unique and checklists pertinent to each type of vehicle should be modified accordingly. It is recommended that the manufacturer's instructions on vehicle maintenance and owner's and operator's responsibilities also be consulted. The OSHA standards for powered industrial trucks must be reviewed to ensure compliance.  There are two general types of powered industrial trucks: electric (battery) powered and internal combustion engine (gas/LPG/diesel) powered. Each of these general types has a variety of different configurations and attachments. Your workplace may have a variety of trucks that are being operated. ALL OPERATORS MUST BE TRAINED TO OPERATE ALL TYPE OF INDUSTRIAL TRUCKS THEY WILL BE OPERATING.  Daily, pre-shift inspection of powered industrial trucks is required by OSHA standards. Depicted below are the major types of industrial trucks and some of the most common variations. The drawings of the trucks depicted below are intended to represent the typical configuration of trucks for each type. They do not include all available options, attachments or configurations. Electric Motor Powered Industrial Trucks Standup End Control Rider Sitdown Rider Narrow Aisle Reach Narrow Aisle High Lift Straddle Narrow Aisle Order Picker Narrow Aisle Sideloader Platform Narrow Aisle Sideloader High Lift Pallet Narrow Aisle Turret Narrow Aisle Low Lift Platform Stacker Pallet Walkie Platform Low Lift Walkie Pallet Low Lift Tractor Walkie/Rider Walkie Pallet High Lift   Internal Combustion Engine Powered Industrial Trucks - Gas/LPG/Diesel Counterbalanced Forklift Gas/LPG Cushion Tire Counterbalanced Forklift Gas/LPG/Diesel Pneumatic Tire Tow Tractor Gas/LPG/Diesel Rough Terrain Forklift Gas/LPG/Diesel Vertical Mast Daily checklists for each type of industrial truck are available from the truck manufacturer. You may choose to use a checklist for each type of industrial truck in your workplace or compile one that can be used for any type of truck. Refer to the owner's manual, specifications and manufacturer's recommendations to modify the checklist for trucks being operated in your workplace. Below are sample checklists for internal combustion and electric trucks. These lists can be modified to suit your workplace needs. Operator's Daily Checklist - Internal Combustion Engine Industrial Truck - Gas/LPG/Diesel Truck Record of Fuel Added Date   Operator   Fuel   Truck#   Model#   Engine Oil   Department   Serial#   Radiator Coolant   Shift   Hour Meter   Hydraulic Oil   SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT) Have a qualified mechanic correct all problems. Engine Off Checks OK Maintenance Leaks – Fuel, Hydraulic Oil, Engine Oil or Radiator Coolant     Tires – Condition and Pressure     Forks, Top Clip Retaining Pin and Heel – Check Condition     Load Backrest – Securely Attached     Hydraulic Hoses, Mast Chains, Cables and Stops – Check Visually     Overhead Guard – Attached     Finger Guards – Attached     Propane Tank (LP Gas Truck) – Rust Corrosion, Damage     Safety Warnings – Attached (Refer to Parts Manual for Location)     Battery – Check Water/Electrolyte Level and Charge     All Engine Belts – Check Visually     Hydraulic Fluid Level – Check Level     Engine Oil Level – Dipstick     Transmission Fluid Level – Dipstick     Engine Air Cleaner – Squeeze Rubber Dirt Trap or Check the Restriction Alarm (if equipped)     Fuel Sedimentor (Diesel)     Radiator Coolant – Check Level     Operator's Manual – In Container     Nameplate – Attached and Information Matches Model, Serial Number and Attachments     Seat Belt – Functioning Smoothly     Hood Latch – Adjusted and Securely Fastened     Brake Fluid – Check Level     Engine On Checks – Unusual Noises Must Be Investigated Immediately OK Maintenance Accelerator or Direction Control Pedal – Functioning Smoothly     Service Brake – Functioning Smoothly     Parking Brake – Functioning Smoothly     Steering Operation – Functioning Smoothly     Drive Control – Forward/Reverse – Functioning Smoothly     Tilt Control – Forward and Back – Functioning Smoothly     Hoist and Lowering Control – Functioning Smoothly     Attachment Control – Operation     Horn and Lights – Functioning     Cab (if equipped) – Heater, Defroster, Wipers – Functioning     Gauges: Ammeter, Engine Oil Pressure, Hour Meter, Fuel Level, Temperature, Instrument Monitors – Functioning     Operator's Daily Checklist - Electric Industrial Truck Record of Fluid Added Date   Operator   Battery Water   Truck#   Model#   Hydraulic Oil   Department   Serial#       Shift   Drive Hour Meter Reading   Hoist Hour Meter Reading   SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT) Have a qualified mechanic correct all problems. Motor Off Checks OK Maintenance Leaks – Hydraulic Oil, Battery     Tires – Condition and Pressure     Forks, Top Clip Retaining Pin and Heel -- Condition     Load Backrest Extension – Attached     Hydraulic Hoses, Mast Chains, Cables & Stops – Check Visually     Finger Guards – Attached     Overhead Guard – Attached     Safety Warnings – Attached (Refer to Parts Manual for Location)     Battery – Water/Electrolyte Level and Charge     Hydraulic Fluid Level – Dipstick     Transmission Fluid Level – Dipstick     Operator's Manual in Container     Capacity Plate Attached – Information Matches Model, Serial Number and Attachments     Battery Restraint System – Adjust and Fasten     Operator Protection Sitdown Truck - Seat Belt – Functioning Smoothly Man-up Truck – Fall protection/Restraining means - Functioning     Brake Fluid – Check level     Motor On Checks (Unusual Noises Must Be Investigated Immediately) OK Maintenance Accelerator Linkage – Functioning Smoothly     Parking Brake – Functioning Smoothly     Service Brake – Functioning Smoothly     Steering Operation – Functioning Smoothly     Drive Control – Forward/Reverse – Functioning Smoothly     Tilt Control – Forward and Back – Functioning Smoothly     Hoist and Lowering Control – Functioning Smoothly     Attachment Control – Operation     Horn – Functioning     Lights & Alarms (where present) – Functioning     Hour Meter – Functioning     Battery Discharge Indicator – Functioning     Instrument Monitors – Functioning     ALL OPERATORS MUST BE TRAINED AND EVALUATED ON THE TYPES OF INDUSTRIAL TRUCKS AND ATTACHMENTS THEY WILL BE OPERATING.