1. Setup and Equipment History
- Review prior month’s maintenance records
- Gather inspection tools and calibration devices
- Ensure forklift is clean and stationary
- Apply lockout/tagout if servicing begins
- Record hour meter reading and location info
2. Fluid & Fuel System Check
- Inspect engine oil level and quality
- Check hydraulic and brake fluid for contamination
- Examine coolant level and radiator pressure cap
- Inspect fuel tank, cap seal, and fuel line routing
- Drain diesel water separator if needed
3. Forks, Mast, and Lift Mechanism
- Measure fork heel thickness and check fork alignment
- Inspect mast rollers, chain wear, and tension
- Lubricate mast guides and verify tilt function
- Check cylinder operation and pin wear
- Ensure carriage and backrest are secure
4. Tyres, Wheels, and Suspension
- Check for tyre cracks, cuts, and tread depth
- Inspect wheel bolts, bearings, and inflation
- Test axle alignment and suspension rebound
- Rotate tyres if uneven wear is observed
5. Brakes & Safety Components
- Test foot brake and parking brake function
- Measure brake pad wear and inspect lines
- Test horn, lights, alarms, and emergency stop
- Check seat belt, fire extinguisher, and mirrors
6. Battery & Electrical Systems
- Inspect battery terminals and water levels
- Check alternator output and fuse continuity
- Test warning lights, display meters, and switches
- Secure battery covers and brackets
7. Documentation and Follow-Up
- Log findings in digital checklist app
- Photograph any damage or part wear
- Plan replacement or repair scheduling
- Submit checklist to maintenance supervisor