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OSHA SAMPLE CHECKLISTS

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.

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.

 

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