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Free Forklift Maintenance Checklist Templates

Template Library >  Warehouse Checklists > Forklift Maintenance Checklists

Maintain the safety and efficiency of your forklifts with our comprehensive forklift maintenance checklist templates. Streamline your maintenance processes, ensure your equipment remains in top condition and compliant with industry standards. Available for free in PDF or in-app.
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Ensure Safety and Performance with Forklift Maintenance Checklist Templates

A forklift maintenance checklist template ensures systematic care by guiding your team through essential maintenance tasks. It helps prevent costly breakdowns and ensures your forklifts are always ready for operation.

With our forklift preventive maintenance checklist template, you can:

  • Perform routine checks to avoid unexpected downtime.
  • Identify and resolve maintenance issues before they escalate.
  • Ensure compliance with safety and regulatory standards.
  • Extend the lifespan and reliability of your forklifts.
Goaudits checklist report example
Sample PDF Report

With the GoAudits Inspection App, you can:

  • Eliminate paperwork: conduct efficient digital audits
  • Customize this template or easily create your own
  • Save time with instant reports & assign corrective actions
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Engine Off Checks

1. Are the tires inflated and free of excessive wear or damage?


Photo Comment



Upload

2. Are the lug nuts tight?


Photo Comment



Upload

3. Are the axles and other moving components clear?


Photo Comment



Upload

4. Are the mast and forks not cracked, worn, bent, or excessively rusty?


Photo Comment



Upload

5. Are the mast lift chains and rollers in good condition?


Photo Comment



Upload

6. Are the hydraulic lines free of damage?


Photo Comment



Upload

7. Are the fluid levels good?


Photo Comment



Upload

8. Is the operator’s manual on board?


Photo Comment



Upload

9. Are all visible cables and hoses free of damage?


Photo Comment



Upload

10. Is the data plate legible and up to date?


Photo Comment



Upload

11. If the forklift has a seat belt, does it work?


Photo Comment



Upload

Engine On Checks

1. Do the lights, horn, and other safety features work properly?


Photo Comment



Upload

2. Are the lift cylinders in good condition? Are they free of scars?


Photo Comment



Upload

3. Does the forklift operate smoothly after moving it to the length of a truck?


Photo Comment



Upload

4. Do the parking brake, brakes, accelerator, and turn signals work properly?


Photo Comment



Upload

5. Is the steering smooth and responsive?


Photo Comment



Upload

6. Can you raise the forks up and down fully?


Photo Comment



Upload

7. Are the cables and hoses wrapped around the guide rails seamlessly?


Photo Comment



Upload

8. Are the attachments undamaged, secure, and operational?


Photo Comment



Upload

9. Does tilt control operate smoothly without chatter?


Photo Comment



Upload

10. Are the instruments and gauges working?


Photo Comment



Upload

Lubrication

1. Is the chassis-mast attachment lubricated regularly?


Photo Comment



Upload

2. Is the engine air filter changed?


Photo Comment



Upload

3. Are all the breathers cleaned?


Photo Comment



Upload

4. Is the engine oil and filter changed?


Photo Comment



Upload

5. Are fluid levels regularly checked?


Photo Comment



Upload

6. Are battery terminals cleaned and coated?


Photo Comment



Upload

Electrical

1. Are switches inspected?


Photo Comment



Upload

2. Are contact tips checked?


Photo Comment



Upload

3. Is the drive control system checked?


Photo Comment



Upload

4. Is the time delay system inspected?


Photo Comment



Upload

5. Are all motors, including hoist, drive, and steer motors checked?


Photo Comment



Upload

6. Is the commutator examined?


Photo Comment



Upload

7. Is the blowout system checked?


Photo Comment



Upload

8. Are brushes inspected?


Photo Comment



Upload

9. Are battery connectors checked?


Photo Comment



Upload

10. Are springs inspected?


Photo Comment



Upload

Hydraulic

1. Are cylinders inspected?


Photo Comment



Upload

2. Are pumps checked?


Photo Comment



Upload

3. Are valves inspected?


Photo Comment



Upload

4. Are all hoses, tubes, and fittings checked?


Photo Comment



Upload

Gas

1. Is the radiator inspected?


Photo Comment



Upload

2. Are belts checked?


Photo Comment



Upload

3. Are spark plugs inspected?


Photo Comment



Upload

4. Is the muffler checked?


Photo Comment



Upload

5. Is the distribution point examined?


Photo Comment



Upload

6. Are instruments inspected?


Photo Comment



Upload

7. Is the ignition switch inspected?


Photo Comment



Upload

8. Are hoses for LPG forklifts checked?


Photo Comment



Upload

9. Are engine accessories inspected?


Photo Comment



Upload

10. Is the fuel filter checked?


Photo Comment



Upload

General

1. Is the steering system inspected?


Photo Comment



Upload

2. Are brake adjustments checked?


Photo Comment



Upload

3. Is the parking brake inspected?


Photo Comment



Upload

4. Is the horn tested and checked?


Photo Comment



Upload

5. Are nuts, bolts, and cotter pins inspected?


Photo Comment



Upload

6. Are lights and alarms checked?


Photo Comment



Upload

7. Are tires inspected?


Photo Comment



Upload

8. Are battery water levels checked?


Photo Comment



Upload

PREVIEW FULL TEMPLATE
Engine Off Checks

1. Are the tires inflated and free of excessive wear or damage?


Photo Comment



Upload

2. Are the lug nuts tight?


Photo Comment



Upload

3. Are the axles and other moving components clear?


Photo Comment



Upload

4. Are the mast and forks not cracked, worn, bent, or excessively rusty?


Photo Comment



Upload

5. Are the mast lift chains and rollers in good condition?


Photo Comment



Upload

6. Are the hydraulic lines free of damage?


Photo Comment



Upload

7. Are the fluid levels good?


Photo Comment



Upload

8. Is the operator’s manual on board?


Photo Comment



Upload

9. Are all visible cables and hoses free of damage?


Photo Comment



Upload

10. Is the data plate legible and up to date?


Photo Comment



Upload

11. If the forklift has a seat belt, does it work?


Photo Comment



Upload

Engine On Checks

1. Do the lights, horn, and other safety features work properly?


Photo Comment



Upload

2. Are the lift cylinders in good condition? Are they free of scars?


Photo Comment



Upload

3. Does the forklift operate smoothly after moving it to the length of a truck?


Photo Comment



Upload

4. Do the parking brake, brakes, accelerator, and turn signals work properly?


Photo Comment



Upload

5. Is the steering smooth and responsive?


Photo Comment



Upload

6. Can you raise the forks up and down fully?


Photo Comment



Upload

7. Are the cables and hoses wrapped around the guide rails seamlessly?


Photo Comment



Upload

8. Are the attachments undamaged, secure, and operational?


Photo Comment



Upload

9. Does tilt control operate smoothly without chatter?


Photo Comment



Upload

10. Are the instruments and gauges working?


Photo Comment



Upload

Lubrication

1. Is the chassis-mast attachment lubricated regularly?


Photo Comment



Upload

2. Is the engine air filter changed?


Photo Comment



Upload

3. Are all the breathers cleaned?


Photo Comment



Upload

4. Is the engine oil and filter changed?


Photo Comment



Upload

5. Are fluid levels regularly checked?


Photo Comment



Upload

6. Are battery terminals cleaned and coated?


Photo Comment



Upload

Electrical

1. Are switches inspected?


Photo Comment



Upload

2. Are contact tips checked?


Photo Comment



Upload

3. Is the drive control system checked?


Photo Comment



Upload

4. Is the time delay system inspected?


Photo Comment



Upload

5. Are all motors, including hoist, drive, and steer motors checked?


Photo Comment



Upload

6. Is the commutator examined?


Photo Comment



Upload

7. Is the blowout system checked?


Photo Comment



Upload

8. Are brushes inspected?


Photo Comment



Upload

9. Are battery connectors checked?


Photo Comment



Upload

10. Are springs inspected?


Photo Comment



Upload

Hydraulic

1. Are cylinders inspected?


Photo Comment



Upload

2. Are pumps checked?


Photo Comment



Upload

3. Are valves inspected?


Photo Comment



Upload

4. Are all hoses, tubes, and fittings checked?


Photo Comment



Upload

Gas

1. Is the radiator inspected?


Photo Comment



Upload

2. Are belts checked?


Photo Comment



Upload

3. Are spark plugs inspected?


Photo Comment



Upload

4. Is the muffler checked?


Photo Comment



Upload

5. Is the distribution point examined?


Photo Comment



Upload

6. Are instruments inspected?


Photo Comment



Upload

7. Is the ignition switch inspected?


Photo Comment



Upload

8. Are hoses for LPG forklifts checked?


Photo Comment



Upload

9. Are engine accessories inspected?


Photo Comment



Upload

10. Is the fuel filter checked?


Photo Comment



Upload

General

1. Is the steering system inspected?


Photo Comment



Upload

2. Are brake adjustments checked?


Photo Comment



Upload

3. Is the parking brake inspected?


Photo Comment



Upload

4. Is the horn tested and checked?


Photo Comment



Upload

5. Are nuts, bolts, and cotter pins inspected?


Photo Comment



Upload

6. Are lights and alarms checked?


Photo Comment



Upload

7. Are tires inspected?


Photo Comment



Upload

8. Are battery water levels checked?


Photo Comment



Upload

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  • Easily capture & attach photos, directly on your mobile device.
  • Instantly generate and share detailed reports after the inspection.
  • Track corrective actions, view historical trends, improve standards.
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What is a Forklift Maintenance Checklist?

A forklift maintenance checklist is a structured document that outlines specific maintenance tasks necessary for ensuring the safe and efficient operation of forklifts. This checklist typically includes various components to be checked, such as:

  • Tire conditions
  • Safety features (lights, brakes, etc.)
  • Hydraulic systems
  • Overall mechanical condition

Importance of Using a Forklift Maintenance Checklist Template

Consistency is key in forklift maintenance, and a standardized checklist template ensures thorough and accurate checks every time. Here’s why using a forklift maintenance sheet is crucial:

  1. Minimizes Oversight: A checklist prevents operators from overlooking critical components during routine inspections.
  2. Improves Efficiency and Longevity: Regular maintenance guided by checklists ensures that forklifts operate efficiently, reducing fuel consumption and maximizing productivity. This ultimately leads to a better return on investment by extending the equipment’s useful life.
  3. Enhances Safety: Identifying issues early reduces the risk of accidents, safeguarding operators and surrounding workers.
  4. Documentation and Compliance: Checklists provide a record of maintenance activities, are essential for compliance with safety regulations, and are useful during audits.
  5. Reduced Costs: Proactive maintenance prevents minor issues from turning into expensive repairs or downtime.

👉 Case Study: How Miniclipper Logistics uses digital checklists to achieve an audit response rate of 97%

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OSHA Rules and Regulations for Forklift Maintenance

The Occupational Safety and Health Administration (OSHA) has set forth clear rules regarding forklift maintenance and safety. Compliance with these regulations is non-negotiable for a safe work environment.

Key OSHA guidelines include:

  • Pre-Operational Checks: OSHA requires daily inspections before forklifts are put into use. These checks must cover components like brakes, steering, tires, and safety devices.
  • Documentation: Records of maintenance and repairs must be maintained for accountability and compliance.
  • Addressing Defects: Any forklift found to have significant defects must be taken out of service until repairs are completed.

Non-compliance can lead to fines, legal issues, and, more importantly, increased risk of accidents. A well-implemented forklift maintenance sheet is an effective tool for meeting OSHA standards.

👉 Forklift Safety Inspection Checklists: access our library of free checklist tools to manage forklift safety inspections.

Types of Forklift Maintenance Checklists

Forklifts come in various types, each requiring a tailored maintenance checklist. Here’s an overview:

Battery Powered or Electric Forklift Maintenance Checklist

Electric forklifts are eco-friendly and require special care to maintain their efficiency. Important components of an electric forklift preventive maintenance checklist include:

  • Battery charge levels and proper electrolyte levels.
  • Electrical connections and wiring for signs of corrosion or damage.
  • Tires for proper inflation and tread wear.
  • Safety devices such as horns and lights for functionality.
  • The charger system for proper operation.

👉 OSHA Electric Forklift Truck Inspection Checklist: Use this checklist to ensure forklifts adhere to OSHA guidelines.

Internal Combustion Engine Forklift Maintenance Checklist

Internal combustion (IC) forklifts, powered by diesel or gasoline, require regular attention to their engines and fuel systems. Key areas to be assessed include:

  • Engine oil and coolant levels.
  • Air and fuel filters for clogs or damage.
  • Exhaust system for leaks or excessive smoke.
  • Brakes and tires for wear and tear.
  • Hydraulic systems for leaks or abnormal noises.

Liquid Propane (LP) Forklift Preventive Maintenance (PM) Checklist

LP forklifts are commonly used indoors due to their cleaner emissions. Key maintenance tasks include:

  • Checking propane tanks and connections for leaks.
  • Checking the fuel system for proper pressure and flow.
  • Evaluating engine performance and ensuring low emissions.
  • Monitoring coolant and oil levels.
  • Reviewing safety features like seat belts and backup alarms.

👉 OSHA Propane Forklift Truck Inspection Checklist: Use it to conduct thorough checks for your propane forklift’s safety and operational features.

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Creating a Forklift Maintenance Schedule

An effective maintenance schedule categorizes tasks based on their frequency. Below are the most common intervals for forklift maintenance:

Daily Forklift Maintenance Checklist

Daily maintenance checks are the first line of defense against equipment issues. Tasks typically include:

  • Checking fluid levels (oil, water, hydraulic fluid).
  • Inspecting tires for proper inflation and visible damage.
  • Verifying the operation of brakes, horns, and lights.
  • Checking the mast for smooth movement and unusual noises.
  • Looking for visible leaks or damage.

👉 Forklift Operator Daily Checklist: Here’s a free template to help you get started.

Monthly Forklift Maintenance Checklist

Monthly checks provide a more in-depth examination. These include:

  • Examining the hydraulic system for wear or leaks.
  • Replacing air and oil filters as needed.
  • Assessing the drive belt for tension and damage.
  • Testing the battery capacity (for electric forklifts).
  • Checking the exhaust system (for IC forklifts).

Annual Forklift Maintenance Checklist

Annual examinations are comprehensive and often require professional expertise. These involve:

  • Full engine diagnostics.
  • Assessment and possible replacement of major components like brakes, transmission, and tires.
  • Thorough evaluation of safety systems such as load backrests and overhead guards.
  • Mast and carriage alignment and lubrication

How to Maintain Forklifts Using Forklift Preventive Maintenance Checklists?

Start by training operators to perform daily checks, focusing on key components like brakes, tires, fluid levels, and safety devices. Equip them with clear, standardized checklists tailored to the specific forklift type, ensuring no critical area is overlooked. Regularly documenting these inspections is essential; it provides a maintenance history, highlights recurring issues, and ensures accountability.

Promptly addressing any identified problems prevents minor issues from escalating into costly repairs or unsafe conditions. Supervisors should periodically review maintenance records to ensure compliance and identify trends that may require attention. For more complex issues, annual servicing, or repairs requiring specialized knowledge, partnering with certified forklift technicians is recommended.

By embedding these practices into your routine, you create a proactive maintenance culture that minimizes downtime, extends equipment lifespan, and ensures safety and regulatory compliance.

👉 Warehouse Audit Checklists: Explore our extensive library of checklists used to perform checks for various warehouse equipment.

Other Popular Inspection Checklists:

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