1. Pre-Inspection Safety
- Park forklift on reinforced, level surface
- Lower forks completely and shut off engine
- Apply lockout/tagout and allow engine cooling
- Use PPE: gloves, safety boots, eyewear
- Inspect environment for safe clearance
2. Structural Integrity Check
- Inspect mast and carriage welds for cracks
- Check frame stress points and overhead guard
- Ensure counterweight mounting is secure
- Inspect fork heel wear and mounting
- Measure fork blade deflection
3. Hydraulic System
- Check for hose leaks, bulges, or abrasions
- Inspect fluid level and clarity
- Test lift, tilt, and side-shift controls
- Verify pressure relief valve settings
- Monitor fluid temperature after warm-up
4. Engine & Exhaust Inspection
- Check oil level, filter, and leakage
- Inspect air intake and exhaust for blockages
- Ensure proper coolant level and no overheating
- Check fuel lines and filter
- Test start-up for abnormal noise/smoke
5. Brake & Safety Systems
- Test service and parking brakes with load
- Inspect brake fluid level and pad wear
- Test seat belt, horn, alarms, lights
- Verify load plate and warning decals
- Check fire extinguisher and emergency stop
6. Battery & Electricals
- Inspect terminals for corrosion and tightness
- Check voltage levels and charger status
- Verify lighting, gauges, and signals
- Inspect cable routing and insulation
- Test alternator and starter operation
7. Tyres, Axles & Steering
- Check tyre pressure and wear pattern
- Inspect rims and hub bolts
- Verify axle alignment and bearing play
- Check steering linkage for play or noise
- Test full steering range under load