1. Pre-Inspection Preparation
- Review previous maintenance records and inspection history.
- Park forklift on level ground and isolate with lockout/tagout.
- Clean exterior to reveal any hidden damage or fluid leaks.
- Gather all tools, safety PPE, and calibration instruments.
2. Fluid & Filter Replacement
- Drain and replace engine oil and install a new oil filter.
- Flush hydraulic and transmission fluid systems.
- Inspect coolant and fuel system; replace filters and test quality.
- Document all fluid changes with date, time, and batch codes.
3. Safety System Checks
- Test brakes (main & parking), emergency stop, horn, and lights.
- Inspect fire extinguisher charge and seatbelt functionality.
- Ensure visibility of load plate and warning labels.
- Verify overhead guard, tilt lock, and safety switches are operational.
4. Load Testing
- Perform static test at 100% and 125% rated capacity.
- Observe for instability, abnormal noise, or deflection.
- Ensure lift, tilt, and fork positioning systems respond correctly.
- Document load test results and flag any irregularities.
5. Engine & Exhaust Inspection
- Conduct full engine compression and valve clearance test.
- Inspect turbocharger, intake, and muffler for soot, leaks, or clogs.
- Check exhaust integrity and emissions within standard range.
- Lubricate throttle linkages and governor controls.
6. Electrical System Verification
- Test battery charge, terminals, fuses, and grounding points.
- Verify alternator output and dashboard diagnostics lights.
- Test start circuit, shutoff relay, and all safety interlocks.
7. Mast & Fork Assembly
- Inspect forks for cracks, uneven wear, and heel thickness.
- Lubricate chains, rollers, and mast bushings.
- Ensure proper alignment of tilt and side-shift mechanisms.
- Test lift height calibration and hydraulic performance.
8. Final Documentation & Sign-Off
- Record inspection date, hour meter, and technician details.
- Summarize findings, actions taken, and components replaced.
- Capture digital photos of critical areas for recordkeeping.
- Upload report to Oxmaint APP for centralized maintenance logs.