Forklift CLG 835B – Yearly Inspection Procedure
Follow these detailed procedures annually to maintain peak forklift performance, OSHA compliance, and operational safety.
Pre-Inspection Preparation
- Review equipment history and service records
- Schedule forklift downtime and secure workspace
- Gather diagnostic tools and OEM manuals
- Verify technician certifications and safety protocols
- Photograph unit condition before disassembly
Engine Diagnostics & Tune-Up
- Perform compression test on all cylinders
- Check fuel injection timing and spray pattern
- Analyze exhaust for unburned fuel or particulates
- Replace filters (fuel, air, oil) and record part numbers
- Check glow plug or cold-start assist if applicable
Hydraulic System Overhaul
- Drain, flush and refill hydraulic fluid with OEM-approved grade
- Replace hydraulic filters and clean return lines
- Test lift/tilt cylinder pressure and response time
- Inspect hoses for wear, cracks, or bulges
- Check valve body for internal leaks or delayed actuation
Load Handling & Brake System Test
- Conduct load test at 110% rated capacity
- Measure braking distance from 5 mph full load
- Test parking brake engagement on incline
- Check emergency stop functionality
- Inspect brake lines, fluid, and pedal travel
Transmission & Drive Inspection
- Replace transmission oil and magnetic drain plug
- Check clutch or torque converter wear levels
- Inspect drive axle seals and differential play
- Test gear shift under various load conditions
- Lubricate U-joints and check driveshaft balance
Final Safety Compliance Checks
- Verify presence and readability of OSHA data plate
- Check functionality of backup alarm and horn
- Inspect fire extinguisher, seatbelt, and warning decals
- Test lights, mirrors, and overhead guard integrity
- Complete documentation and affix inspection sticker