Pre-Maintenance Preparation
- Schedule maintenance during planned downtime
- Gather required tools, parts, and PPE
- Review forklift maintenance history and notes
- Implement lockout/tagout safety procedures
- Ensure clear, well-lit maintenance area
Engine and Powertrain Service
- Change engine oil and replace oil filter
- Replace air filter if operating in dusty environments
- Service fuel system: replace fuel filter and check for water contamination
- Check and adjust drive belt tension and wear
- Inspect cooling system, including hoses and radiator
Hydraulic System Inspection
- Replace hydraulic fluid filter
- Inspect hydraulic fluid condition and top off if needed
- Inspect hydraulic hoses, fittings, and cylinders for leaks or damage
- Test hydraulic functions: lift, tilt, and side shift under load
- Lubricate mast chains and moving components
Brake and Safety Systems Testing
- Inspect brake system components for wear and adjust as needed
- Test emergency stop functionality
- Verify operation of horn, lights, and alarms
- Check seat belt condition and operation
- Verify fire extinguisher presence and charge status
Structural and Mechanical Inspection
- Inspect forks and mast for cracks, bends, or excessive wear
- Measure fork thickness and heel wear
- Check wheel bearings and lug nut tightness
- Inspect tyres for wear, proper inflation, and alignment
- Tighten all bolts and fasteners
Documentation & Reporting
- Complete maintenance checklist and sign-off
- Record maintenance activities in service log
- Report any findings requiring additional repairs
- Schedule next monthly maintenance service