Pre-Inspection Preparation
- Review maintenance logs and last annual report
- Park forklift on level surface and apply lockout/tagout
- Clean all surfaces for accurate inspections
- Verify tools, PPE, and diagnostic kits are ready
Engine & Exhaust System Inspection
- Perform compression test on all cylinders
- Inspect turbocharger, muffler, and exhaust manifolds
- Check for vibration, oil leaks, and abnormal noise
- Analyze emissions and replace air filter if needed
Hydraulic System & Mast Function
- Flush hydraulic oil and install new filter
- Inspect and lubricate lift/tilt chains and side-shift
- Check for leaks in cylinders, hoses, and tank
- Perform full mast lift test under load
Brake, Wheels & Structural Review
- Inspect brake drums, pads, and test parking brake
- Perform wheel bearing service and tyre wear check
- Conduct weld crack check on mast, forks, overhead guard
- Check rim alignment, wheel nuts, and torque
Safety Systems Verification
- Test horn, lights, backup alarm, seatbelt, and fire extinguisher
- Check overhead guard condition and bolt torque
- Verify safety decals, capacity plate, and LOTO signage
- Ensure emergency stop and interlocks function correctly
Battery & Electricals
- Clean terminals, check voltage, and replace battery if weak
- Inspect alternator, starter, and dashboard indicators
- Check electrical wiring for damage or fraying
- Test fuse box and relays
Inspection Report & Certification
- Document all test values and defects
- Assign corrective actions and parts replacement plan
- Attach photos of damage, wear points, and serial tags
- Finalize report and sign OSHA 1910.178(q)(7) compliance form