1. Pre-Inspection Planning
- Gather prior inspection reports and service history
- Verify lockout/tagout and cooling protocol is followed
- Assemble calibrated tools and OEM documentation
- Print checklist and allocate 4–6 hours minimum
2. Fluid Replacements & System Flush
- Drain and refill engine oil, hydraulic, transmission, and brake fluids
- Flush radiator and cooling system thoroughly
- Replace oil, fuel, air, and hydraulic filters
- Document fluid types and quantities used
3. Structural & Frame Inspection
- Inspect mast, forks, chassis, and carriage for cracks or deformation
- Use dye penetrant or ultrasonic crack detection if available
- Check fork thickness vs original spec (must be >90%)
- Review weld integrity, backrest security, and tilt function
4. Engine Performance Testing
- Run compression test across all cylinders
- Adjust valve clearance per OEM recommendations
- Inspect injectors, fuel lines, and turbocharger (if equipped)
- Perform exhaust analysis for emissions compliance
5. Load Handling & Lift System
- Conduct static and dynamic load testing at 100% & 150% capacity
- Check chain tension, tilt cylinders, and lift height
- Inspect hoses, carriage rollers, and hydraulic cylinder seals
- Lubricate mast, guide rails, and pivot joints
6. Brake & Safety Components
- Inspect disc/drum brake components, lines, and fluids
- Test parking brake hold on incline
- Inspect fire extinguisher, horn, seatbelt, safety decals
- Test lights, warning alarms, and backup signal
7. Electrical & Battery Systems
- Test battery voltage, alternator, and charging system
- Clean terminals and ensure secure mounting
- Inspect fuse box, gauges, and sensor feedback
8. Documentation and Compliance
- Record all test results and measurements
- Note repairs, parts replaced, and follow-up actions
- Complete OSHA and ISO audit trail documentation
- Sign off by certified inspector with date and license #