Free forklift pre-start checklist
Free forklift pre-start checklist (PDF-ready). Daily inspection before use: mast, forks, hydraulics, lights, horn, tyres and compliance. Download free.
Updated 2 May 2026
Forklift Pre-Start Checklist
Forklift daily inspection: complete before first use
Overhead Guard, Mast & Forks
Hydraulics & Controls
Lights, Horn & Safety
Tyres, Engine / Battery & Fluids
Documentation & Compliance
Operator Sign-off
Signature
Print name
Date & time
Supervisor / Reviewer Acknowledgement
Signature
Print name
Date
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These templates are free general guides provided as-is. They do not constitute legal, safety or compliance advice. You are responsible for ensuring any form meets your specific workplace obligations, industry standards and applicable regulations.
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Key takeaways
- The MapTrack forklift pre-start checklist contains 30 checks across 5 sections. Sections covered: Overhead Guard, Mast & Forks, Hydraulics & Controls, Lights, Horn & Safety, Tyres, Engine / Battery & Fluids, Documentation & Compliance.
- A shift-start check of forks, chains, tyres, hydraulics, brakes, seatbelt and warning devices, recorded per truck before first use.
- Fork heels and chains wear invisibly in daily use. The pre-start is where cracks, bends and stretch get caught.
- A truck that fails pre-start is tagged out where it stands. The record of that decision is what protects the operator who made it.
- The model WHS Regulations place the duty to manage risks from powered industrial trucks on the PCBU, and pre-start records are the working evidence.
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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.
Get the free templateEnter your email above to download the full forklift pre-start checklist as a PDF.Back to download formHow 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)
Forklift pre-start checklist preview
The numbers behind this forklift pre-start checklist
Every figure below is sourced and dated, so you can quote it in a toolbox talk, a budget case or a board paper without having to chase the original report.
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<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Forklift pre-start checklist</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Forklift details: forklift ID, hours/meter, make/model, date, operator name and site/location.</li>
<li style="margin:4px 0;">Overhead guard, mast and forks: overhead guard secure, mast and chains, fork condition and locks, carriage and backrest, load capacity plate.</li>
<li style="margin:4px 0;">Hydraulics and controls: lift/lower, tilt, side shift, hoses and oil level, steering, brakes.</li>
<li style="margin:4px 0;">Lights, horn and safety: lights, horn, reversing alarm, seatbelt, seat, fire extinguisher, decals.</li>
<li style="margin:4px 0;">Tyres, engine/battery and fluids: tyres or wheels, engine oil and coolant or battery (electric), fuel/LPG, leaks, exhaust (IC).</li>
<li style="margin:4px 0;">Documentation and compliance: design registration, operator licence, keys and start/stop check.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/forklift-pre-start-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Forklift pre-start checklist</a> by MapTrack</p>
</div>Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.
Cite this template
Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.
The MapTrack forklift pre-start checklist contains 30 checks across 5 sections.
- Short attribution
- MapTrack Forklift pre-start checklist, https://www.maptrack.com/templates/forklift-pre-start-checklist
- Reference list
- MapTrack. (2026). Forklift pre-start checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/forklift-pre-start-checklist
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/forklift-pre-start-checklist.
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