1. Pre-Inspection Safety & Documentation
- Verify last yearly service records and operational hours.
- Ensure certified technician and supervisor are assigned.
- Lockout/Tagout procedures applied to the equipment.
- Drain fluids for engine, hydraulics, and brake systems.
- Gather all required replacement parts and technical bulletins.
2. Diesel Engine Overhaul
- Replace oil, oil filter, air filter, and fuel filters.
- Perform compression check and fuel injector cleaning.
- Test ignition system and inspect turbocharger.
- Flush cooling system and inspect radiator/fan.
- Evaluate exhaust and emissions systems for leaks.
3. Hydraulic System Inspection
- Drain and replace hydraulic fluid with OEM-recommended grade.
- Replace hydraulic filters and inspect tank interior.
- Examine all hoses and seals for cracks or abrasion.
- Load test mast system and calibrate hydraulic pressure.
- Lubricate mast rollers, fork hinge pins, and cylinders.
4. Transmission and Drive System Service
- Replace transmission fluid and filter.
- Inspect drive belts, drive axle, and differential for damage.
- Service clutch (if applicable) and verify torque settings.
- Check wheel alignment, hub nuts, and tire wear.
- Re-torque all critical fasteners to spec.
5. Brake and Safety System Certification
- Inspect brake pads, drums, fluid levels, and master cylinder.
- Replace any cracked or leaking brake hoses.
- Test emergency stop system and parking brake engagement.
- Verify overhead guard, seat belt, and backup alarms.
- Affix updated OSHA 1910.178 compliance label.
6. Electrical & Battery System Review
- Test alternator, battery charge capacity, and voltage.
- Inspect battery cables and terminals for corrosion.
- Verify fuse box integrity and replace failed components.
- Test lights, horn, indicators, gauges, and dashboard electronics.
- Ensure wiring harnesses are secured and undamaged.