Form library · Logistics and supply chain

Pallet truck inspection checklist

A pre-use check for hand pallet trucks and powered pedestrian pallet trucks. Scan the asset label and capacity plate, and compare the heaviest load you will move with the rated capacity. Then work through the named checks: forks and tips, load rollers, entry and exit rollers, steering wheels, axles and push rods; the hydraulic pump, seals and leaks, holding a raised load, the lift, neutral and lower control, lowering, handle and return spring; the chassis welds and plate. Powered trucks add the battery, charger lead, emergency disconnect, belly button and tiller brake. Check the floor on the route too. The result is safe to use or do not use. For forklifts, use the forklift and vehicle inspection checklist.

For warehouse, store and goods-in teams, and their supervisors, who check pallet trucks at the start of a shift and need a dated record with photos.

Written for Great Britain (PUWER 1998). The checks work anywhere; take the inspection duties from your local law.

Asset number and capacity plate from a label scan, with the heaviest load as a percentage of rated capacity
Seven fork and wheel checks and eight hydraulic, control and handle checks, each saying what acceptable looks like
Six extra checks for powered pedestrian trucks, shown only when you pick that type
Route checks for the floor, slopes and dock plates, and obstructions
Live tiles for checks acceptable, needing action and not checked, then safe to use or do not use with the reason

Try it blank ↓See it completed ↓Use it in SiteSurvey Download the completed form (PDF)

Ready to use from the form library, and every question is yours to edit. Try it for a small trial fee, cancel any time.

Try it on your phone

Try it on this phone

Fill in the pallet truck inspection checklist on your phone now

See how the pallet truck inspection checklist looks on your phone

Scan the code with your phone camera. It opens the real form, no sign-up needed.

Open the live example and fill it in, just as your team would on site. No sign-up needed.

See it on this phone

Every question is editable. Add this form to your account, then change the wording, add or remove questions and options, and make it fit your own jobs.

Or start your trial with this form ready →

What should a pallet truck inspection checklist cover?

A pallet truck check is useful when it names the truck by its asset number, records what each part looked like, tests the hydraulics with a load on, and ends with a clear safe to use or do not use. A failed truck then has a reason, a tag and a name against it, not just a cross in a box.

Last updated 28 October 2026. Facts checked by the SiteSurvey team on 28 October 2026 against HSE, what is lifting equipment? (equipment not covered by LOLER), Provision and Use of Work Equipment Regulations 1998, regulation 4, suitability of work equipment, Provision and Use of Work Equipment Regulations 1998, regulation 5, maintenance, Provision and Use of Work Equipment Regulations 1998, regulation 6, inspection and HSE INDG478, Risk assessment of pushing and pulling (RAPP) tool.

How to do a pallet truck pre-use check

Check the truck empty first, then with a pallet on the forks.

Record the truck
Scan the asset label or capacity plate, pick the type, and enter the rated capacity and the heaviest load you will move.
Check the forks and wheels
Look along the forks and tips, pump them up to see they rise level, then check the load rollers, entry rollers, steering wheels and axles.
Test the hydraulics and handle
Pump to full height, look for oil, raise a pallet and watch for creep, try each control position and lowering, then let the handle go to test the spring.
Check the frame and route
Look at the chassis welds and plate, test the powered controls if it has them, and check the floor, slopes and obstructions on the route.
Give the result
Mark it safe to use, or do not use with the reason, the tag number and who was told. List repairs with an owner and a date, and sign.

What makes a pallet truck check useful

Hydraulics: seals and leaks, and holding a raised load

PT-07, 06:10, start of shift. Pump lifts to full height. Oil weeping from the ram seal with fresh drips under the pump. With a 900 kg pallet raised, the forks crept down about 40 mm in two minutes. Do not use: tagged DNU-31, moved to the quarantine bay, shift manager told at 06:25, spare truck in use.

Fictional example. Record the actual evidence and approved arrangements for your job.

A common recording mistake

Checking the truck empty only, so a pump that will not hold a load, or a load roller that binds under weight, is never found.

What happens next

Keep the truck out of use until the repair is done, repeat this check before it goes back on the floor, and fix any route problem you found the same day.

Try the pallet truck inspection checklist form live

Answer a few questions and watch it adapt. Your answers are not saved, and any photos you add are deleted within the hour.

Live form: Pallet Truck Pre-use InspectionOpen full screen ↗

Fill it in right here

This is the real form as your team would use it: questions appear as you answer, scores work themselves out and you can add photos and signatures. No sign-up needed. Or open a completed example to see every answer, photo and score filled in.

Want to see one filled in? See a completed pallet truck inspection checklist report (PDF), made by SiteSurvey from a fictional site visit.

Every question in the pallet truck inspection checklist template

A pre-use check for a hand pallet truck or a powered pedestrian pallet truck: asset number and capacity plate by label scan, the heaviest load against the rated capacity, then named checks for the forks and tips, load and entry rollers, steering wheels, hydraulic pump and seals, lift and lowering control, handle and return spring, chassis welds and plate, battery, belly button and tiller brake on powered trucks, and the route. Result tiles, safe to use or do not use, actions and sign-off. 8 sections and 114 questions. Follow-up questions and guidance appear only when an answer calls for them, so the person on site never sees the ones that do not apply.

Make it your own: every question is editable

This is a starting point, not a fixed form. Once it is in your SiteSurvey account you can reword any question, add or remove questions, sections and answer options, and add your own logo, so it fits the way your team works and the jobs you do.

Details you only enter once

Add this form to a project in SiteSurvey and it fills in what the project already knows, so nobody on site retypes it and every form on the job uses the same names. Anything filled in can still be changed.

Project: the project name
Site address: the site address, from the space or the project
Business or site operator: the project's customer

Check details

ProjectShort answer
Filled in from the project in SiteSurvey.
Fills in from the project name
Site addressShort answer
Fills in from the site address, from the space or the project
Business or site operatorShort answer
Fills in from the project's customer
Location (GPS)Short answer
Date of the check*Date
Checked by*Short answer
Time of the checkTime
Reason for the check*Choose one
- Start of shift
- Before first use today
- After a repair
- After damage, a collision or an overload
- Other
Other reasonShort answer
Shown when “Reason for the check” is “Other”
Area or zone where it is usedShort answer
For example goods in, chill store, aisle 12, back of store.
CheckA pre-use check by the operator or a supervisor. Check each item the way the manufacturer's instructions describe. It is not a service or a repair: a truck with a fault comes out of use until it is fixed.
GuidanceHSE says pallet trucks are not covered by LOLER, because the consequence of the load falling off is very low, but used at work they must be maintained for safety and may need inspecting under PUWER. PUWER 1998 regulation 5 requires work equipment to be kept in efficient working order and good repair; regulation 6 requires equipment exposed to conditions that cause dangerous deterioration to be inspected at suitable intervals, with the result recorded.

Truck

Scan the asset label and capacity plateScan a label: asset number, serial number, make, model, rated capacity
Optional. Scan the asset tag or capacity plate to fill in the numbers.
Asset number*Short answer
Type*Choose one
- Manual hand pallet truck
- Powered pedestrian pallet truck
- Manual pallet truck with weigh scale
- Other
MakeShort answer
ModelShort answer
Serial numberShort answer
Rated capacity from the plate (kg)*Number
Heaviest load planned today (kg)Number
Optional. The heaviest pallet the truck will move, from the delivery note or label.
Heaviest load as % of rated capacityWorked out by the form
Shown only when the answers above make it relevant
WarningThe heaviest load is more than the rated capacity. Do not move it with this truck: split the load or use equipment rated for it. PUWER regulation 4(3): work equipment is used only for operations it is suitable for.
Shown only when the answers above make it relevant
Date of the last service or inspectionDate
From the service label or maintenance record.
Days since thenWorked out by the form
Shown only when the answers above make it relevant
Photo of the truck and capacity platePhotos

Forks and wheels

GuidanceCheck with the truck empty and the forks lowered, then pump them up. Tilt the truck or look underneath for the rollers.
Forks and fork tipsChoose one
Straight, no cracks, bends or twisting. Tips not split or worn through.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Forks rise level with each otherChoose one
Pump with no load: both forks rise evenly and the truck sits level.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Load rollersChoose one
Turn freely. No flat spots, chunks missing, or strapping and film wrapped round them.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Entry and exit rollers at the fork tipsChoose one
Present and turn freely, so the forks ride over the pallet boards.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Steering wheelsChoose one
Tread intact, no chunks missing, turn freely, nothing wrapped round the axle.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Wheel axles, pins and retaining clipsChoose one
All present. No wobble in any wheel.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Push rods and linkages under the forksChoose one
Not bent or loose. They move as the truck lifts.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Photos of any faultPhotos
Needing actionWorked out by the form
Not checkedWorked out by the form

Hydraulics, controls and handle

Hydraulic pump lifts the forksChoose one
Forks rise to full height in the usual number of strokes.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Seals and leaksChoose one
No oil on the pump body, the floor or the forks.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Holds a raised loadChoose one
With a load raised, the forks do not creep down.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Lift, neutral and lower controlChoose one
The lever or trigger selects each position and stays in it.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Lowering is controlledChoose one
Forks come down smoothly, not with a drop.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
HandleChoose one
Not bent or cracked. Grip and any hand guard intact.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Handle return springChoose one
The handle returns upright by itself when let go.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Brake or parking brake, if fittedChoose one
Holds the truck still. Not applicable if none is fitted.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Photos of any faultPhotos
Needing actionWorked out by the form
Not checkedWorked out by the form

Frame, markings and power

Chassis and weldsChoose one
No cracks at the welds, the fork roots or the pump mounting.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Capacity plate fitted and readableChoose one
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Asset number or ID label readableChoose one
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
GuidancePowered pedestrian pallet truck. Test the controls with the forks lowered, in a clear area, before taking a load.
Shown when “Type” is “Powered pedestrian pallet truck”
Battery chargeChoose one
The charge indicator shows enough charge for the shift.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Battery connector, cables and charger leadChoose one
No damage, burn marks or bare wires.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Key switch and emergency disconnectChoose one
The emergency disconnect cuts all power.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Belly button (emergency reverse) on the tiller headChoose one
Pressed while moving towards you, the truck reverses away.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Tiller brakeChoose one
The truck brakes with the tiller fully up and fully down.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Drive forward and reverse, speed control and hornChoose one
Smooth in both directions; the horn sounds.
- Acceptable
- Action needed
- Not checked
- Not applicable
Shown when “Type” is “Powered pedestrian pallet truck”
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Photos of any faultPhotos
Needing actionWorked out by the form
Not checkedWorked out by the form

Route

GuidanceA pallet truck is pushed and pulled. The route matters as much as the truck: wet, uneven or sloping floors make the load harder to start, steer and stop.
Floor along the routeChoose one
Dry, clean, level, firm and not damaged. HSE's pushing and pulling tool rates a floor like this as good.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Slopes, ramps and dock plates on the routeChoose one
Kept to a minimum, in good repair, and dock plates secure.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Route clear of obstructions, kerbs and cablesChoose one
Enough room to steer and stop the load.
- Acceptable
- Action needed
- Not checked
- Not applicable
What needs doing, or why not checkedNotes
Shown only when the answers above make it relevant
Photos of the route problemPhotos
Needing actionWorked out by the form
Not checkedWorked out by the form

Result

Truck checks acceptableWorked out by the form
Needing actionWorked out by the form
Not checkedWorked out by the form
Route problemsWorked out by the form
Truck checks acceptable (%)Worked out by the form
Result*Choose one
- Safe to use
- Do not use: taken out of service
WarningA truck check needs action, but the truck is marked safe to use. Fix it and check again first, or take the truck out of service.
Shown only when the answers above make it relevant
WarningDo not use. Label the truck, move it out of the working area if it can be moved safely, and tell the supervisor.
Shown when “Result” is “Do not use: taken out of service”
Why it is out of service*Notes
Shown when “Result” is “Do not use: taken out of service”
Tag or label numberShort answer
Shown when “Result” is “Do not use: taken out of service”
Where it is nowShort answer
Shown when “Result” is “Do not use: taken out of service”
Supervisor or maintenance told*Short answer
Shown when “Result” is “Do not use: taken out of service”
CheckThe truck is fine but the route has a problem. Fix it or choose another route before moving loads.
Shown only when the answers above make it relevant

Actions and sign-off

Items needing actionWorked out by the form
ResultWorked out by the form
Actions
Repeat for each action. Each one asks:
- Action*Notes
- PriorityChoose one
  - Urgent: do not use
  - Before next use
  - At the next service
- Who will do it*Short answer
- Due byDate
- Status*Choose one
  - Open
  - In progress
  - Done, checked
- Photo when donePhotos
  Shown when “Status” is “Done, checked”
Actions still openWorked out by the form
Decision*Choose one
- No further action
- Repair, then repeat this check before use
- Replace the truck
Date of the repeat checkDate
SummaryNotes
Operator nameShort answer
Operator signature*Signature
Supervisor nameShort answer
Supervisor signatureSignature

See it filled in

A completed pallet truck inspection checklist report, made by SiteSurvey from a fictional site visit: every answer, the photos, the guidance that applied and the sign-off, ready to send as a PDF.

See completed form (PDF) ↗

Pallet truck inspection checklist FAQs

Does LOLER apply to pallet trucks?

No. HSE lists pallet trucks, where the consequence of the load falling off is very low, among the equipment not covered by LOLER, so they do not need a LOLER thorough examination. HSE adds that when this equipment is used at work it will need to be maintained for safety and may, in some cases, be subject to inspection under PUWER.

Source: HSE, what is lifting equipment? (equipment not covered by LOLER).

How often should a pallet truck be inspected?

The law does not set a number. PUWER regulation 6 requires work equipment that is exposed to conditions causing deterioration liable to result in dangerous situations to be inspected at suitable intervals, and after exceptional circumstances, with the result recorded until the next inspection. Follow the manufacturer's service intervals, and a check at the start of each shift, like this one, catches faults between services.

Source: Provision and Use of Work Equipment Regulations 1998, regulation 6, inspection.

What do I do if a pallet truck fails the check?

Do not use it. Label it, move it out of the working area if that is safe, and tell your supervisor or maintenance. PUWER regulation 5 requires work equipment to be maintained in an efficient state, in efficient working order and in good repair. The form records the reason, the tag number, where the truck is now and who was told.

Source: Provision and Use of Work Equipment Regulations 1998, regulation 5, maintenance.

Can I move a pallet heavier than the capacity plate?

No. The rated capacity on the plate is the most the truck is made to carry, and PUWER regulation 4 requires work equipment to be used only for operations and under conditions for which it is suitable. The form works out the heaviest load as a percentage of the rated capacity and shows a red note if it is over.

Source: Provision and Use of Work Equipment Regulations 1998, regulation 4, suitability of work equipment.

Why does a pallet truck check include the route?

Because a pallet truck is pushed and pulled by hand. HSE's pushing and pulling tool (INDG478) treats pallet trucks as large, steerable wheeled equipment and scores both the condition of the equipment, such as its wheels, bearings and brakes, and the floor surface, rating a dry, clean, level, firm floor in good condition as good. A wet or damaged floor makes the same load harder to start, steer and stop.

Source: HSE INDG478, Risk assessment of pushing and pulling (RAPP) tool.

Does the form work for electric pallet trucks?

Yes. Pick powered pedestrian pallet truck as the type and six more checks appear: battery charge, battery connector and charger lead, key switch and emergency disconnect, the belly button emergency reverse, the tiller brake, and drive, speed and horn. Ride-on trucks and forklifts have their own checks; use the forklift and vehicle inspection checklist for those.

Asset inspections software Forklift and vehicle inspection checklist Manual handling risk assessment Warehouse safety checklist Pallet racking inspection checklist Loading and unloading checklist All forms in the library

Related templates

Templates that go with the pallet truck inspection checklist form

Forklift inspection checklist

Daily check before using a van, car, forklift or other mobile plant. Failed items get a photo and a note, with the result, who it was reported to and a supervisor sign-off.

6 sections · 71 questions · See every question →

Stock take template

A stocktake record with count locations, item references, book and physical quantities, calculated variances, recounts and adjustment approval.

5 sections · 41 questions · See every question →

Trailer inspection checklist

A trailer walkaround record covering identification, coupling, braking connections, wheels, lights, bodywork, loading and defect reporting.

5 sections · 50 questions · See every question →

Warehouse safety checklist

A warehouse walk-through covering aisles, storage, pedestrian routes, loading areas, handling, emergency access and corrective actions.

5 sections · 61 questions · See every question →

Browse all 428 forms in the library