Pre-Inspection Preparation
- Schedule downtime and ensure technician authorization
- Review previous maintenance records and issues
- Secure necessary tools, testing equipment, and supplies
Battery System Service
- Perform full battery load test and document capacity
- Inspect terminals, cables, and connectors for wear or corrosion
- Test charger operation and monitor charging cycle efficiency
- Inspect cooling systems and battery ventilation
Hydraulic System & Fluids
- Check hydraulic fluid levels and replace contaminated fluid
- Inspect hoses and connections for leaks or wear
- Test hydraulic system pressure and cooling performance
- Service brake fluids and verify brake performance
Mast, Forks, and Structural Components
- Lubricate mast chains and inspect for proper tension
- Inspect forks and carriage for damage or wear
- Check mast functions including lift, tilt, and reach operations
- Inspect frame and overhead guard for damage or stress cracks
Safety Systems & Controls
- Test emergency stops, horns, lights, and alarms
- Verify operator presence system and seat restraints
- Check all interlock devices and safety switches
- Ensure operator compartment remains hazard-free
Performance Benchmarking
- Test drive, lift, tilt, and steering systems under load
- Measure travel speed, lift speed, and energy consumption
- Document performance results and compare with specifications
- Note any components requiring repairs or adjustments
Final Documentation
- Complete inspection log and attach performance records
- Schedule any necessary maintenance or repairs
- Update compliance tracking systems