1. Setup and History Review
- Clean forklift for inspection visibility
- Review previous yearly and monthly maintenance logs
- Ensure lockout/tagout is applied before maintenance
- Prepare full inspection toolkit and safety gear
2. Engine & Transmission
- Replace engine oil, oil filter, and fuel filter
- Flush and refill radiator coolant system
- Inspect injector performance and belt tension
- Check transmission fluid, linkage, and operation under load
3. Hydraulic and Mast Assembly
- Check all hydraulic cylinders for leaks and response
- Inspect hoses, pump, and tank for wear and function
- Lubricate fork carriage, mast rails, and lift chains
- Test full lifting capacity and tilt range
4. Brake & Steering Systems
- Evaluate service brakes, parking brakes, and emergency stop
- Inspect steering column, power assist, and linkage
- Refill brake fluid and inspect master cylinder
- Road test for steering responsiveness under load
5. Tyres and Suspension
- Check all tyre tread depth, wear patterns, and pressure
- Inspect rims, valve stems, and mounting bolts
- Evaluate suspension system and rear axle alignment
6. Electrical & Battery Systems
- Test battery voltage and charge status
- Inspect cables, terminals, and fuses
- Test all indicators, horns, alarms, and lighting
- Inspect starter motor and alternator under load
7. Safety Equipment and Final Checks
- Verify seat belt condition and label visibility
- Check load capacity plate, fire extinguisher, and mirrors
- Inspect cab structure and operator seat frame
- Ensure OSHA and company signage is in place
8. Year-End Documentation
- Complete checklist and maintenance logs
- Submit photos and comments via digital app or paper
- Review findings with maintenance supervisor
- Schedule next inspection cycle for the following year