1. Pre-Inspection Safety Steps
- Park forklift securely on level ground, chock wheels
- Engage parking brake, lower forks, shut off engine
- Use lockout/tagout procedures and allow cool down
- Check prior maintenance records for recurring issues
- Verify fire extinguisher, PPE, and service tools are ready
2. Engine & Exhaust Inspection
- Change engine oil and filter; inspect turbo and intake
- Clean radiator and replace air and fuel filters
- Check injectors and compression pressure by cylinder
- Inspect exhaust for leaks and abnormal soot signs
- Test cold-start behavior and idling vibration
3. Hydraulic & Lift System Inspection
- Test lift, tilt, and side-shift cylinder performance
- Replace hydraulic filters and inspect for fluid contamination
- Inspect mast rollers, chain tension, and anchoring
- Lubricate all moving lift components and backrest area
- Perform drift and pressure loss test under load
4. Brake & Transmission Systems
- Check brake drum and rotor wear; bleed system
- Verify parking brake hold capability on incline
- Check transmission for leaks and smooth gear shift
- Inspect drive axle, differential, and clutch operation
- Log test results after multiple start/stop cycles
5. Electrical & Safety Components
- Test battery condition, voltage, and charging circuit
- Inspect wiring harness, dashboard panel, fuses
- Ensure horn, lights, alarm, and indicators are functional
- Inspect overhead guard, seatbelt, and fire system
- Check labeling: capacity plate, warnings, instructions
6. Load Testing & Documentation
- Perform load test at 110% capacity for 5 minutes
- Verify mast structural integrity and lift retention
- Inspect for chassis deformation post load test
- Document torque specs, adjustments, and parts changed
- Update yearly inspection records in Oxmaint system