1. Pre-Inspection Preparation
- Confirm scheduled downtime for inspection
- Gather forklift service history and OSHA records
- Procure replacement parts and certified test weights
- Set up workspace with safety signage and PPE
2. Fluid System Service
- Drain and replace engine oil, hydraulic fluid, and coolant
- Change all filters (fuel, air, hydraulic, brake)
- Bleed brake system and flush lines
- Document fluid types and volume
3. Engine & Transmission Inspection
- Check for oil leaks, smoke, or unusual vibration
- Inspect spark plugs, fuel injection, and air filter
- Test transmission under full load
- Inspect belts, clutches, and cooling fans
4. Load Testing
- Use certified weights to test 110% of rated load
- Test mast operation at various lift heights
- Observe tilt and carriage movement under load
- Document results and update capacity plate if needed
5. Safety Systems Verification
- Check horn, backup alarm, lights, and mirrors
- Inspect seatbelt, overhead guard, and fire extinguisher
- Test emergency shut-off and operator presence system
- Ensure all decals and safety placards are legible
6. Hydraulic & Mast Assembly
- Inspect lift chains, rollers, and tilt cylinders
- Lubricate pivot points and moving assemblies
- Check side-shift and fork positioning
- Test for any hydraulic leaks or pressure issues
7. Battery and Electrical Checks
- Test battery voltage and charge retention
- Clean terminals and check electrolyte levels
- Inspect fuses, relays, and wiring harness
- Verify gauge and dashboard light functionality
8. Final Compliance & Reporting
- Fill out annual inspection documentation
- Log fluid samples and wear measurements
- Upload data to Oxmaint dashboard
- Schedule next inspection and notify stakeholders