1. Battery and Charging System
- Inspect all cells and ensure electrolyte covers plates by 1/4"
- Top-up only after charging using distilled water
- Test specific gravity using a hydrometer
- Clean terminals and apply protective grease
- Check charger settings and cable condition
2. Electric Motor & Controller
- Inspect motor brushes and commutator for wear
- Check motor temperature post-operation
- Look for cable insulation damage or loose connectors
- Check controller for error codes
- Ensure proper ventilation and cooling fan function
3. Drive and Brake System
- Check tyres for wear, cuts, and correct inflation
- Inspect wheel bearings and grease if needed
- Test parking and service brakes for response
- Listen for abnormal drive noises
- Inspect drive coupling and transmission
4. Mast, Forks, and Lift Assembly
- Inspect mast rollers, chains, and pins
- Lubricate mast slides and lift chains
- Check forks for cracks, misalignment, or wear
- Measure heel wear – must be less than 10%
- Ensure smooth tilt/lift operations
5. Operational Safety
- Test horn, reverse buzzer, lights, and indicators
- Check seatbelt and restraint system
- Verify overhead guard and decals are intact
- Inspect operator presence system
- Ensure emergency stop functions properly
6. Compliance & Records
- Log battery readings and inspections digitally
- Note maintenance actions taken this week
- Ensure OSHA documentation is updated
- Review past defects and confirm resolution
- Schedule follow-up inspections or repairs