Forklift / Powered Industrial Truck Safety Audit

Audit date

Facility / location name

Auditor name

Number of powered industrial trucks in use at this facility

Written PIT safety program exists and is accessible to supervisors

Program should cover operator training, pre-shift inspection, fuel handling, maintenance, and operating rules.

Program has been reviewed and updated within the past 12 months

Check the revision date on the program document.

All PIT types in use match the approved designations for the operating area

Example: electric trucks (E/EE) required in areas with flammable vapors; D/DS/G/LP trucks allowed in general warehousing. Check 1910.178(d) table.

Notes on program documentation

Record any gaps, outdated sections, or items needing revision.

Each operator has received training specific to each truck type they operateCritical

Training must cover the specific truck type (stand-up reach, sit-down counterbalance, order picker, etc.) — generic classroom-only training is insufficient per 1910.178(l)(3).

Operator training includes a practical, hands-on evaluation component

Written or verbal testing alone does not satisfy the evaluation requirement. The evaluation must include observing the operator actually driving the truck.

Refresher training process in place with documented triggers

Refresher must be triggered by: unsafe operation observed, accident or near-miss, unsatisfactory evaluation, different truck type assignment, or workplace change. Check that the policy names these triggers.

Re-evaluations conducted at least every 3 years for each operator

1910.178(l)(4)(iii) requires an evaluation of each operator's performance at least once every three years.

Notes on operator training and certification

Recent pre-shift inspection records are available and complete

Spot-check the last 5–10 inspection records. Look for blanks, missing dates, or identical entries across multiple days that suggest records are not being completed in the field.

Inspection covers all required items

Checklist should include at minimum: brakes, steering, controls, warning devices (horn, lights), mast/forks/attachments, tires, fuel/battery, fluid levels, and load backrest.

Defective trucks are tagged out of service and removed from use until repairedCritical

Look for any trucks with visible defects currently in operation. Check whether there is a clear 'remove from service' tag or lockout process.

Defect reporting process is documented and operators know how to use it

Operators must have a clear, simple way to report defects — verbal report to supervisor, written tag on truck, or electronic log.

Notes on pre-shift inspection program

Designated battery charging area is ventilated to prevent hydrogen gas accumulation

Charging releases hydrogen gas. Area must have ventilation (natural or mechanical) sufficient to prevent buildup. No open flames or smoking signs must be posted.

Battery charging area has fire protection (extinguisher) and an eyewash station

Battery acid can cause chemical burns. An eyewash station within 10 seconds travel is best practice; check local fire code for extinguisher type.

Battery replacement equipment (hoist, roller conveyor, or equivalent) is available

Batteries are extremely heavy. Safe lifting equipment must be available to prevent musculoskeletal injury during battery swaps.

LP gas (propane) trucks in use at this facility?

LP container exchange is performed outdoors or in a well-ventilated area

LP exchange must not occur near open flames, ignition sources, or inside enclosed buildings without ventilation per 1910.178(g).

LP cylinders stored in designated area, secured upright, away from heat sources

Full and empty cylinders must be stored separately. No storage near exits or in egress paths.

Refueling procedures prohibit open flames, smoking, and running engines during fueling

Applies to all fuel types including gasoline, diesel, and LP. Confirm the written procedure addresses these prohibitions.

Notes on refueling and battery charging

No unauthorized modifications made to any truckCritical

Any modification affecting capacity or safe operation requires manufacturer written approval and updated capacity/rating plates (1910.178(a)(3)). Common violations: welded attachments, counterweight additions, mast extensions.

Safety devices intact on all trucks (horn, lights, warning devices, overhead guard, load backrest)

Check that overhead guards are not removed or damaged. Load backrests must be in place when loads could fall back toward the operator.

Trucks equipped with operator restraints (lap bars, seatbelts) have them in usable condition

If the truck design includes a restraint system, it must be functional and operators must use it.

Photo — load capacity plate on a representative truck

Capture one clear photo showing the plate is legible and matches the truck.

Notes on truck condition and modifications

Speed limit postings are visible in forklift operating areas

Speed limits must be posted and enforced. Common standard: 5 mph indoor, slower in pedestrian-heavy areas.

Policy prohibits unauthorized riders on trucks

No riders permitted unless the truck is designed for a second operator position. This is one of the most common PIT fatality scenarios.

Policy requires forks to travel in lowered position when not lifting

Elevated forks while traveling is a common tip-over and pedestrian-injury cause. Confirm the rule is in writing and operators are following it during the audit walk.

Policy prohibits elevating personnel on forks or pallets

Personnel must not be lifted on forks, pallets, or unsecured platforms. An approved man-basket with fall protection is required for elevated personnel work.

Ramp and dock procedures are documented and drivers are trained on them

Tip-overs on ramps are a leading cause of PIT fatalities. Grade changes, dock plates, and dock levelers should be covered in the operating procedures.

Photo — traffic management signage or lane markings

Capture pedestrian/forklift separation markings or speed-limit postings.

Notes on operating rules and traffic management

Policy prohibits exceeding rated truck capacity

Overloading is a leading cause of tip-overs. Confirm operators know the truck's rated capacity for their most common loads, and that there is a process to verify unknown load weights.

Policy requires loads to be secured or stable before travel

Unstable or unsecured loads are both a tip-over hazard (for the truck) and a falling-object hazard (for pedestrians).

Use of non-standard attachments covered in training and capacity plates updated

Any attachment (slip-sheet attachments, rotators, side-shifters) reduces rated capacity. Updated capacity plates must be installed when attachments are added.

Notes on load handling

Maintenance records kept for all trucks

Records should include the truck ID, date of service, work performed, and technician name. Regular maintenance intervals should be defined and tracked.

Procedure in place to safely support elevated trucks or loads before working beneath them

1910.178(p)(2): trucks must not be raised while an employee is underneath unless the truck is adequately blocked or the load is otherwise positively retained.

Trucks are not operated with known defects pending investigation

Temporary operations with identified defects are prohibited unless the defect is marked as non-safety-critical and a plan for repair is documented.

Auditor signature

Notes on maintenance and repairs