What should you check in a forklift pre-start?

A forklift pre-start typically covers overhead guard and mast (chains, rollers), forks and carriage (condition, locks, backrest), hydraulics (lift, tilt, side shift, hoses, oil), controls (steering, brakes), lights and horn, seatbelt and seat, tyres, engine or battery and fluids, and documentation (design registration, operator licence). Complete the check before each use or at the start of each shift.

Is a forklift pre-start checklist required by law?

Requirements vary by jurisdiction and industry. In Australia, workplace health and safety obligations often require that forklifts and plant are maintained and fit for use; many organisations use pre-start checklists to demonstrate due diligence. Check your local regulations and company policy.

Can I use a digital or mobile app for forklift pre-starts?

Yes. Digital pre-start forms on phone or tablet are widely used for forklifts. They keep evidence, photos and timestamps attached to each forklift and support compliance and audits. MapTrack lets you build pre-start forms (including from this template), complete them on mobile, including offline, and attach results to the asset record. Book a demo to see how.

What regulations apply to forklift pre-start inspections in Australia?

Forklift inspections are governed by the WHS Regulations 2011, Part 5.1 (Management of risks of plant), the AS 2359 series (Powered industrial trucks) and state and territory WHS codes of practice for forklift use. The WHS Act requires the PCBU to ensure forklifts are maintained, inspected and safe for use. Operators must hold a current High Risk Work Licence (LF class) to operate a forklift in Australia. Safe Work Australia publishes a Code of Practice for Managing Risks of Plant in the Workplace that provides practical inspection guidance.

Is this forklift pre-start checklist free to download?

Yes. This forklift pre-start checklist is completely free to download and use. Open the HTML file in any browser and use Print then Save as PDF to generate a printable copy. No MapTrack account is required. Use the checklist for counterbalance forklifts, reach trucks, order pickers and other powered industrial trucks. If you later want digital pre-start forms with photo capture, automatic defect alerts and compliance tracking across your forklift fleet, MapTrack can help.

How often should fork arms be tested for wear and damage?

AS 2359.8 recommends that fork arms be subjected to non-destructive testing at intervals not exceeding 12 months or after 10,000 operating hours, whichever comes first. Between formal tests, operators should inspect fork tips daily during pre-start checks for visible cracks, bending, uneven wear or heel section thinning. Fork arms must be taken out of service if the thickness at any point has been reduced to 90 per cent or less of the original manufactured thickness. Record all fork arm inspections in your maintenance log.

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Free forklift pre-start checklist (PDF-ready). Daily inspection before use: mast, forks, hydraulics, lights, horn, tyres and compliance. Download free.

Jarrod Milford

Commercial Director

Updated 2 May 2026

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What is a forklift pre-start checklist?

A forklift pre-start checklist (or forklift daily inspection) is a structured list of tasks and inspections to perform before a forklift is used each shift. It helps operators and supervisors confirm the forklift is safe and fit for use, reducing the risk of accidents, breakdowns and non-compliance. The checklist should be completed daily or before each use and is a preventive measure to catch problems, such as mast damage, fork wear, hydraulic leaks, brake faults or missing load capacity plates, before they escalate. In Australia, forklift operators must hold a High Risk Work Licence (LF class) and the WHS Regulations require the PCBU to ensure forklifts are inspected and maintained so they remain safe for use. AS 2359 (Powered industrial trucks) provides additional design, maintenance and inspection standards. A documented pre-start inspection is the accepted method for demonstrating compliance and providing an audit trail for regulators, insurers and incident investigations.

The WHS Regulations 2011, Part 5.1 (Management of risks of plant) specifically requires the PCBU to manage risks associated with powered mobile plant, which includes forklifts. This means ensuring that pre-operational checks are conducted, defects are reported and rectified before use, and records of inspections are maintained. The AS 2359 series covers forklift design, stability, maintenance intervals and inspection requirements, including specific guidance on fork arm testing (AS 2359.8) which recommends non-destructive testing of fork arms at 12-month intervals or after 10,000 operating hours. Safe Work Australia publishes a Code of Practice for Managing Risks of Plant in the Workplace that reinforces the requirement for daily pre-start inspections and provides practical guidance on inspection scope and record-keeping. Forklift incidents remain one of the most common causes of serious workplace injury in Australian warehousing and logistics, and a thorough pre-start inspection is the first line of defence against hydraulic failures, brake defects and mast chain breakages that contribute to tip-overs and crush injuries.

Learn more about pre-start inspections in MapTrack.

Benefits of using this forklift pre-start checklist

Fewer financial losses: spot minor issues before they become costly repairs or downtime.
Defects before use: uncover problems that could cause damage or injury when the forklift is started or operated.
Compliance: meet regulatory and organisational requirements and demonstrate due diligence.
Preventive maintenance: keep forklifts in good order and reduce unexpected failures.
Consistency and accountability: a standardised approach so important checks aren't missed.
Recordkeeping: maintain a record of pre-starts for maintenance history and audits.

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).
Auto-schedule pre-start forms so operators are prompted before every shift.
Flag overdue pre-starts on the dashboard so nothing leaves the yard unchecked.
Link each pre-start to the asset record for a complete inspection history.

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What to include in a forklift pre-start checklist

This forklift pre-start checklist covers 8 key areas:

Forklift details: forklift ID, hours/meter, make/model, date, operator name and site/location.
Overhead guard, mast and forks: overhead guard secure, mast and chains, fork condition and locks, carriage and backrest, load capacity plate.
Hydraulics and controls: lift/lower, tilt, side shift, hoses and oil level, steering, brakes.
Lights, horn and safety: lights, horn, reversing alarm, seatbelt, seat, fire extinguisher, decals.
Tyres, engine/battery and fluids: tyres or wheels, engine oil and coolant or battery (electric), fuel/LPG, leaks, exhaust (IC).
Documentation and compliance: design registration, operator licence, keys and start/stop check.
Declaration: confirmation that the check was completed, defects reported and forklift not used until safe.
Signature: operator signature, print name and date/time.

How to use this forklift pre-start checklist

Complete forklift and operator details at the top of the checklist.: Record the forklift asset ID, make and model, hours or meter reading, fuel type (LPG, diesel or electric) and your name, licence number and the date. Confirm your forklift licence (LF class HRWL) is current.
Go through each item and inspect the corresponding component. Mark Pass or Fail (and add notes if needed).: Start with the overhead guard and mast chains for wear or stretch. Check fork tips for cracks, thinning or uneven wear. Test hydraulic lift, tilt and side shift for smooth operation and inspect hoses for leaks or chafing.
If any item fails, note it and do not use the forklift until it's rectified or approved. Report defects per your procedures.: Record each defect with a description and location. Tag the forklift out of service for critical items such as mast chain damage, brake failure or missing load capacity plate. Notify the supervisor immediately for rectification.
Sign and date when the check is complete. Keep the form for your records or export/save as PDF.: Confirm all items are marked Pass, Fail or N/A. Print your name, sign and record the date and time. In MapTrack, submit the inspection to attach it to the forklift asset record with photos of any defects.

In MapTrack, you can run digital pre-starts attached to each asset. Each submission is stored as a timestamped PDF against the asset record.

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How often should you complete this checklist?

Complete a forklift pre-start inspection (forklift daily inspection) before each use or at the start of each shift. Many organisations require a daily pre-start for forklifts; some require a check before every session or shift change. If the forklift has been sitting unused, has had repairs, or was used by another operator, do a fresh check. In addition to daily pre-starts, follow the manufacturer scheduled service intervals for deeper mechanical and hydraulic inspections. Your company policy, site safety management plan or contract may specify additional frequency. When in doubt, complete the checklist each time you use the forklift. In MapTrack, you can schedule pre-starts and periodic services and track compliance across your entire forklift fleet.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

WHS Regulations 2011, Part 5.1 - Management of risks of plant
AS 2359 series - Powered industrial trucks (design, maintenance and inspection)
Safe Work Australia Code of Practice - Managing Risks of Plant in the Workplace
OSHA 29 CFR 1910.178 (Powered industrial trucks)

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