What is a forklift daily inspection checklist?

A forklift daily inspection checklist is a form used by operators to systematically check the safety and operational condition of a forklift before it is used at the start of a shift. It covers tyres, mast, forks, hydraulics, brakes, steering, lights, warning devices and safety features. The checklist ensures the forklift is safe to operate and creates a documented record for compliance and maintenance purposes.

Is a daily forklift inspection a legal requirement in Australia?

Yes. Under the Work Health and Safety Regulations, a person conducting a business or undertaking (PCBU) must ensure that plant, including forklifts, is inspected before use to confirm it is safe. Safe Work Australia guidance and state codes of practice for forklifts specify pre-operational inspections as a fundamental safety control. Failing to conduct daily inspections can result in enforcement action by the regulator.

Who is responsible for completing the forklift inspection?

The operator assigned to the forklift for that shift is responsible for completing the pre-start inspection. However, the PCBU (employer) holds the primary duty of care to ensure the inspection process is in place, that operators are trained to perform it, and that defects are actioned. Supervisors should review completed checklists and verify that defect reports are followed up.

What should I do if I find a defect during the inspection?

If a critical defect is found, such as brake failure, a cracked fork, hydraulic failure or a damaged overhead guard, the forklift must be immediately tagged out of service and not operated until the defect is repaired. Minor defects such as a dim light or low fluid level should be recorded on the checklist and reported to the supervisor for scheduling. The key rule is: if in doubt, do not operate.

How long should completed forklift inspection checklists be retained?

There is no single statutory retention period across all Australian jurisdictions, but best practice is to retain completed forklift inspection records for a minimum of five years. This aligns with general WHS record-keeping expectations and provides sufficient history for regulatory audits, insurance claims and incident investigations. Some organisations retain records for the life of the asset plus two years.

Is this forklift daily fleet inspection checklist free to download?

Yes. This forklift daily fleet inspection checklist is completely free to download and use. Open the template in your browser and select Print then Save as PDF. No MapTrack account is required. If your fleet needs digital forklift inspections on mobile devices with automatic defect escalation, photo capture, operator signature and compliance reporting across multiple sites, MapTrack can handle that. Book a demo to see how it works.

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Free forklift daily fleet inspection checklist (PDF-ready). Cover pre-start safety checks for tyres, mast, forks, brakes and hydraulics. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a forklift daily fleet inspection?

A forklift daily fleet inspection checklist is a structured form used to verify that a forklift is safe to operate before the start of each shift. The checklist guides the operator through a systematic review of critical systems including tyres and wheels, mast and forks, hydraulics, brakes, steering, lights, warning devices and safety features such as the seat belt, overhead guard and load backrest. In Australia, the Work Health and Safety Regulations require that powered industrial trucks (forklifts) be inspected before use to ensure they are in safe working condition. Safe Work Australia and state regulators treat the pre-operational inspection as a fundamental control measure for forklift-related injuries.

For fleet operators managing multiple forklifts across warehouses, distribution centres or manufacturing facilities, a standardised daily inspection form ensures every unit receives the same level of scrutiny regardless of which operator is assigned. Completed checklists create a documented maintenance trail that supports regulatory audits, insurance claims and due diligence under the model WHS Act. When combined with a defect reporting process, the daily inspection also feeds into preventive maintenance scheduling, helping to reduce unplanned breakdowns and extend the service life of the fleet.

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Benefits of using this forklift daily fleet inspection

Operator safety: identify hydraulic leaks, brake faults, tyre damage or mast defects before the forklift is loaded and in motion.
WHS compliance: meet the pre-operational inspection requirements under the Work Health and Safety Regulations and Safe Work Australia guidelines.
Reduced downtime: catch minor issues such as low fluid levels or worn forks early, before they escalate into major repairs or component failure.
Fleet standardisation: ensure every forklift in the fleet receives the same daily checks, regardless of operator, shift or site.
Audit trail: signed daily inspection records provide documented evidence for WHS audits, insurance claims and regulatory inspections.
Asset longevity: consistent daily inspections support preventive maintenance schedules and help extend the working life of each forklift.

Benefits of digitising forms in MapTrack

When you digitise forklift checklists in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Monitor odometer and service-interval triggers across your entire fleet.
Capture fuel receipts and trip logs alongside vehicle inspection data.
Compare vehicle downtime and repair costs to inform replacement decisions.

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What to include in a forklift daily fleet inspection

This forklift daily fleet inspection covers 9 key areas:

Forklift and operator details: date, shift, operator name, forklift make/model, serial or fleet number, hour meter reading.
Tyres and wheels: tyre condition, pressure (pneumatic), chunking (solid), wheel nuts, no debris in treads.
Mast and forks: fork tips not cracked or bent, mast rails and rollers, chains and anchors, load backrest, carriage plate.
Hydraulics: lift, tilt and side-shift operation, no visible hose or cylinder leaks, fluid level.
Brakes: service brake, park brake hold on incline, inching pedal (if fitted).
Steering: smooth operation through full lock, no excessive play, power steering fluid level.
Lights and warning devices: headlights, tail lights, strobe/beacon, reversing alarm, horn.
Safety features: seat belt or restraint, overhead guard, mirrors, fire extinguisher, data plate legible.
LPG / battery (fuel source): gas bottle secure, no leaks, fittings tight; or battery charge level, terminals clean, electrolyte level.

How to use this forklift daily fleet inspection

Record the date, shift, operator name, forklift details and hour meter reading at the top of the form.: Cross-check the forklift serial or fleet number against the assignment sheet to ensure you are inspecting the correct unit. Note the hour meter reading to support interval-based maintenance scheduling.
Perform a walk-around inspection with the forklift powered off.: Check tyres for cuts, chunking or embedded objects. Inspect forks for cracks, bends or uneven wear. Look under the forklift for fluid puddles. Verify the overhead guard, load backrest and data plate are intact. Check the seat belt or operator restraint.
Start the forklift and test operational controls.: With the park brake engaged, start the engine or activate the battery. Test the steering through full lock in both directions. Raise, lower, tilt forward and tilt back the mast. Test the side-shift if fitted. Check the service brake and inching pedal.
Test lights, warning devices and the horn.: Activate headlights, tail lights and the strobe or beacon. Engage reverse to check the reversing alarm. Press the horn to confirm it is audible. Verify mirrors are fitted and adjusted for the operator.
Check the fuel source: LPG bottle or battery.: For LPG forklifts, confirm the gas bottle is secured in its bracket, fittings are tight and there is no gas odour. For electric forklifts, check the battery charge level, inspect terminals for corrosion, and verify electrolyte levels are within the marked range.
Record the inspection results, note defects and sign the checklist.: Mark each item as pass, fail or not applicable. Describe any defects in the notes section with the item number. If a critical defect is found, tag the forklift out of service and report it to the supervisor immediately. Sign and date the completed form.

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How often should you complete this checklist?

A forklift daily inspection must be completed at the start of every shift before the forklift is used. Where a forklift is operated across multiple shifts, an inspection should be performed at each shift changeover. Safe Work Australia recommends that pre-operational checks be conducted by the operator assigned to the forklift for that shift. In addition to daily checks, a more comprehensive periodic inspection should be carried out by a qualified technician at intervals specified by the manufacturer, typically every 200 to 250 hours or quarterly, whichever comes first.

Frequently asked questions

What is a forklift daily inspection checklist?: A forklift daily inspection checklist is a form used by operators to systematically check the safety and operational condition of a forklift before it is used at the start of a shift. It covers tyres, mast, forks, hydraulics, brakes, steering, lights, warning devices and safety features. The checklist ensures the forklift is safe to operate and creates a documented record for compliance and maintenance purposes.
Is a daily forklift inspection a legal requirement in Australia?: Yes. Under the Work Health and Safety Regulations, a person conducting a business or undertaking (PCBU) must ensure that plant, including forklifts, is inspected before use to confirm it is safe. Safe Work Australia guidance and state codes of practice for forklifts specify pre-operational inspections as a fundamental safety control. Failing to conduct daily inspections can result in enforcement action by the regulator.
Who is responsible for completing the forklift inspection?: The operator assigned to the forklift for that shift is responsible for completing the pre-start inspection. However, the PCBU (employer) holds the primary duty of care to ensure the inspection process is in place, that operators are trained to perform it, and that defects are actioned. Supervisors should review completed checklists and verify that defect reports are followed up.
What should I do if I find a defect during the inspection?: If a critical defect is found, such as brake failure, a cracked fork, hydraulic failure or a damaged overhead guard, the forklift must be immediately tagged out of service and not operated until the defect is repaired. Minor defects such as a dim light or low fluid level should be recorded on the checklist and reported to the supervisor for scheduling. The key rule is: if in doubt, do not operate.
How long should completed forklift inspection checklists be retained?: There is no single statutory retention period across all Australian jurisdictions, but best practice is to retain completed forklift inspection records for a minimum of five years. This aligns with general WHS record-keeping expectations and provides sufficient history for regulatory audits, insurance claims and incident investigations. Some organisations retain records for the life of the asset plus two years.
Is this forklift daily fleet inspection checklist free to download?: Yes. This forklift daily fleet inspection checklist is completely free to download and use. Open the template in your browser and select Print then Save as PDF. No MapTrack account is required. If your fleet needs digital forklift inspections on mobile devices with automatic defect escalation, photo capture, operator signature and compliance reporting across multiple sites, MapTrack can handle that. Book a demo to see how it works.

Applicable regulatory standards

This template aligns with the following regulations and standards:

Work Health and Safety Regulations 2011 - Part 5.1 Management of risks of plant
Safe Work Australia Code of Practice: Managing risks of plant in the workplace
AS 2359 Series - Powered industrial trucks (forklift safety standards)
Safe Work Australia Guidance: Forklifts at the workplace
State WHS Codes of Practice for forklifts (e.g. NSW, VIC, QLD)

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