Inspection Preparation
- Schedule downtime and apply lockout/tagout protocol
- Gather maintenance history and service manuals
- Verify battery is charged to operational levels
- Wear PPE and assemble checklist forms
Battery Diagnostics
- Conduct full discharge test under simulated load
- Check each battery cell voltage and specific gravity
- Inspect battery tray, cables, and charger function
- Document battery performance for replacement forecast
Hydraulic & Brake Systems
- Inspect hydraulic hoses, cylinders, and seals
- Flush or top-up hydraulic and brake fluid reservoirs
- Test all motions: lift, tilt, side-shift, and brakes
- Check for smooth and vibration-free operation
Structure, Mast & Chain Components
- Inspect forks for deformation or surface cracks
- Lubricate chains, inspect tension and alignment
- Check mast rollers and guide tracks
- Ensure frame, counterweight, and panels are damage-free
Operational Safety & Load Testing
- Test seatbelt, emergency stop, backup alarm, and lights
- Perform load test using 110% rated capacity
- Check performance under full lift height and tilt
- Log certification of load test results
Final Documentation
- Log all findings in inspection report
- Update digital records and maintenance history
- Schedule any flagged service actions
- Submit signed form to facility supervisor