Forklift pre-start checklist: base template and example

When to do a forklift pre-start

• WorkSafe Victoria says to do a pre-operation check, following the manufacturer's recommendations, at the start of each shift, before the first use of the day, and whenever the operator changes.
• Operators need a licence. Safe Work Australia's forklift information sheet says forklift operators must hold a high risk work forklift licence, unless they're a supervised trainee.
• Rules vary by state and territory, so see what applies in each state below, and follow the manufacturer's manual for your forklift.

Need a traffic plan? See WorkSafe Victoria's guide to forklift traffic management plans.

Forklift rules in your state

Forklift operators need a high risk work licence in every state and territory, but each regulator publishes its own guidance. We're not a regulator, so check yours:

• New South Wales: SafeWork NSW's forklift safety guide for operators

• New South Wales: for workers on foot, see SafeWork NSW's guide for people working near forklifts

• Victoria: Victoria has its own OHS laws. See WorkSafe Victoria

• Western Australia: WorkSafe WA's guidance note on working safely with forklifts

• Queensland: WorkSafe Queensland

• South Australia: SafeWork SA

• Tasmania: WorkSafe Tasmania

• Northern Territory: NT WorkSafe

• Australian Capital Territory: WorkSafe ACT

The national guidance is Safe Work Australia's forklift information sheet

Controls to think about

• WorkSafe Victoria's forklift safety guidebook (May 2024) says the key control is keeping forklifts and pedestrians apart, using barriers, exclusion zones and signs.
• Lock out faulty forklifts. WorkSafe Victoria says defects must be reported, and to have a system to take a forklift out of service if a defect makes it unsafe.
• Wear the seatbelt where one is fitted. WorkSafe Victoria also suggests low-cost retrofits like seatbelt interlocks and pedestrian proximity sensors.

Forklift hazards and the controls to match

Every site is different, but these are forklift hazards that often get missed, with the kind of control the pre-start should prompt for each:

• Pedestrians in the same space: separate walkways, barriers and exclusion zones, and a horn and lights that work.

• Tipping over when turning, on slopes or with a raised load: travel with the load low, slow down on turns, and wear the seatbelt. Don't jump out.

• Lifting people on the forks or a pallet: never. Use an EWP, or a work box designed for that forklift and fitted to the manufacturer's requirements.

• Attachments reducing capacity: check the load chart for the attachment fitted, not just the data plate for bare forks.

• Loads falling from height: check the load is stable and secured, and stay within the rated height and weight.

• Loading docks: chock or restrain the truck so it can't move, and check dock plates and edges before driving on.

• Changing LPG cylinders: trained people only, engine off, in a ventilated area away from ignition sources, and check the connection for leaks.

• Charging electric forklift batteries: ventilated charging areas, no ignition sources, and eye protection when handling battery acid.

What to include in a forklift pre-start

• The site, date, operator and their licence number
• The make, model, asset ID, hour meter and fuel type
• Machine checks: tyres, forks, mast, chains and hydraulics
• Horn, lights, reverse alarm, seatbelt, brakes and steering
• Load chart, fire extinguisher, and LPG or battery connections
• Site checks, confirmation it's safe to use, a photo, and sign-off by the operator and supervisor

Common gaps in a forklift pre-start

Before the shift starts, check the pre-start doesn't have these gaps. Your site may look for more:

• The operator's licence number isn't recorded, or the licence class doesn't match the forklift.

• The hour meter isn't recorded, so services can't be tracked.

• The attachment fitted isn't recorded, so nobody checks the right load chart.

• The forks and chains are ticked without anyone looking for cracks, wear or bent tines.

• Defects are reported but the key stays in the forklift, so it's still used.

Filled-in forklift pre-start example

Example only, not for use as your own checklist. This is the base template filled in for a fictional job: a 2.5 t LPG counterbalance forklift in a bakery's dispatch area. Click the page to enlarge it.

Your own checks must follow the manufacturer's manual for your forklift. If anything fails, don't use it: report it and lock it out of service.

How to fill one in

1. Fill in the site, date, operator and licence number, then the forklift details.
2. Walk around the forklift and check the tyres, forks, mast and chains, and look for leaks.
3. Get on and test the horn, lights, alarm, seatbelt, brakes and steering.
4. Check the site: ground, pedestrian separation, racking and overhead clearance.
5. If everything passes, tick the confirmation, add a photo and sign it off. If anything fails, report it and lock the forklift out.

Get your forklift pre-start into the app

This form is in the Shadow Forms app. Your team can fill it in on site, add photos and sign it, then send it straight to the office.

The PDF and Word versions are copies only. If you have your own branded version, or want this one adjusted to your business, we can add it to the app. Upload a form, or get in touch.

Using a boom lift? Get the free boom lift pre-start checklist.

Checking machine guards? Get the free machine guarding inspection checklist.