Battery System Overhaul
- Conduct full load and capacity testing for all battery cells
- Inspect terminals, cables, and connectors for wear or corrosion
- Clean and re-torque battery connections to specifications
- Evaluate battery management systems and record performance data
- Plan replacement or refurbishment if required
Electric Motor Comprehensive Service
- Inspect motor windings, insulation resistance, and grounding
- Measure amperage draw under load conditions
- Disassemble as needed for internal inspection and bearing checks
- Clean motor housings and cooling systems thoroughly
- Document service findings and plan for replacements if necessary
Hydraulic System Full Service
- Drain and replace all hydraulic fluids and filters
- Conduct pressure tests and adjust valves as per specifications
- Inspect cylinders, hoses, and seals for leaks or damage
- Lubricate all hydraulic components according to the service schedule
- Verify full operation of lift, tilt, and auxiliary hydraulic functions
Structural & Frame Integrity Assessment
- Inspect the frame, overhead guard, and mast welds for cracks or fatigue
- Check fasteners, pins, and bushings for tightness and wear
- Measure and document fork wear and deformation
- Conduct load tests where required to verify structural soundness
- Plan repairs or reinforcement for any structural issues found
Safety Systems Certification
- Inspect and test brakes, horn, lights, alarms, and emergency stops
- Verify operator restraint systems, including seat belts and interlocks
- Conduct thorough operational safety tests under load conditions
- Document compliance with OSHA and ISO safety standards
- Issue annual safety certification upon passing all tests
Performance & Documentation Review
- Compare current operational data with historical records and benchmarks
- Summarize service findings and corrective actions performed
- Update digital maintenance logs and certification records
- Schedule follow-up services for deferred maintenance tasks
- Prepare final annual inspection report for company records