1. Pre-Inspection Safety Setup
- Position forklift on flat ground and switch off engine
- Engage parking brake and apply wheel chocks
- Wear appropriate PPE before beginning inspection
- Gather service manual, inspection form, and tools
- Review previous month’s log for recurring issues
2. Diesel Engine & Cooling System Check
- Check engine oil level and examine for soot or discoloration
- Inspect cooling system components and radiator hoses
- Ensure coolant level and antifreeze ratio are correct
- Start engine and monitor for unusual noise or smoke
- Check air intake system and clean or replace filter
3. Hydraulic Systems Inspection
- Check hydraulic fluid level and color for contamination
- Inspect hoses and connectors for wear or leakage
- Test all hydraulic functions (lift, tilt, side shift)
- Check mast cylinder and backrest assembly condition
- Lubricate all hydraulic moving joints and pivots
4. Brake & Safety Feature Testing
- Test both parking and service brakes under load
- Inspect emergency stop, horn, lights, and backup alarm
- Check seatbelt mechanism and overhead guard integrity
- Inspect and test fire extinguisher readiness
- Ensure all safety signage and capacity plates are readable
5. Forks, Wheels, and Load Components
- Inspect fork heels and shanks for wear and cracks
- Measure fork thickness and alignment against spec
- Check wheels and tyres for pressure and visible damage
- Inspect bearings and rim for play or fractures
- Verify load rating plate visibility and fork locking pins
6. Battery & Electrical System Check
- Inspect battery terminals for corrosion
- Check battery voltage and recharge if required
- Test all lights, indicators, and dashboard displays
- Secure all wiring and check for signs of insulation damage
- Ensure battery cover is in place and secure
7. Final Documentation & Reporting
- Log all inspection points and checklist status
- Record any issues or abnormalities identified
- Schedule necessary repairs and part replacements
- Submit completed form to supervisor or digital system
- Reset service counters if applicable