Annual System Overview
- Review forklift service history and previous inspection reports
- Confirm technician and supervisor certifications
- Document forklift serial number and inspection year
- Verify OSHA 1910.178(q)(7) compliance reference
- Inspect environment for safety hazards during servicing
Diesel Engine Overhaul
- Change engine oil and filters; document hours
- Inspect fuel injectors and replace if necessary
- Test radiator cooling system for flow and leaks
- Verify turbocharger (if equipped) functionality
- Check exhaust for leaks, noise, and emissions compliance
Brake System and Safety Controls
- Replace brake fluid and inspect lines for corrosion
- Test emergency stop and parking brake functionality
- Verify overhead guard and load backrest for damage
- Inspect seat belts and all safety decals/labels
- Ensure fire extinguisher is charged and accessible
Hydraulic System Inspection
- Flush hydraulic fluid and replace filters
- Inspect mast cylinders and hoses for leaks
- Load test lift chains and fork operation under capacity
- Check tilt cylinder operation and limit settings
- Lubricate all grease fittings on mast assembly
Transmission & Drive Inspection
- Check transmission fluid level and condition
- Test gear shifting under full load
- Inspect axle seals, driveshaft, and joints
- Monitor vibrations or noise during operation
- Document operational performance and log findings
Electrical & Lighting Verification
- Test battery voltage, terminals, and charging circuit
- Inspect warning lights, horn, backup alarm, indicators
- Check fuse box and wiring for exposed or burnt areas
- Inspect alternator and starter relay system
- Log any observed electrical faults and corrective actions
Load Testing & Final Certification
- Conduct static and dynamic load test with certified weights
- Monitor lifting operation, stability, and alignment
- Issue load test report with pass/fail rating
- Complete OSHA compliance documentation
- Attach annual certification tag to unit