Tyres and Wheels
- Annual Special:Perform a detailed inspection of tyre tread depth, ensuring it is above the recommended minimum.
- Annual Special:Check tyre sidewalls for signs of cracking, bulging, or dry rot.
- Annual Special:Ensure even wear across the tyres and replace if necessary.
- Inspect all wheel rims for cracks, warping, or signs of significant damage.
- Annual Special:Check and clean the wheel bearings, ensuring they are properly lubricated and in good condition.
- Annual Special:Inspect the alignment and balance of wheels.
- Inspect the valve stems and caps for leaks or damage.
Fluid Checks
- Annual Special:Change the engine oil and replace the oil filter.
- Annual Special:Inspect hydraulic fluid for contamination, and replace fluid if necessary.
- Annual Special:Perform a complete brake fluid flush and ensure fluid is within the proper range.
- Annual Special:Replace the transmission fluid if needed.
- Annual Special:Perform a coolant system flush, ensuring proper coolant mixture and level.
- Inspect the fuel system for any leaks, corrosion, or rust and clean the system as needed.
- Inspect all hoses and pipes for signs of wear or corrosion, replacing any that are damaged.
- Annual Special:Check the condition of the air filter and replace it if dirty.
- Annual Special:Test and inspect the fuel injectors for proper operation and cleanliness.
Forks & Mast Assembly
- Annual Special:Inspect the entire mast assembly for cracks, corrosion, or damage.
- Annual Special:Inspect and clean all mast rollers, ensuring they are lubricated and function smoothly.
- Lubricate all lift chains, ensuring proper tension and operation.
- Annual Special:Replace any worn or damaged pins and bushings in the mast and lift cylinders.
- Perform a full inspection of the backrest and carriage assembly for signs of damage or misalignment.
- Ensure that the lifting and tilting mechanisms operate smoothly and without abnormal resistance.
- Annual Special:Test all hydraulic cylinders and hoses for leaks or damage, replacing any faulty parts.
- Annual Special:Check and adjust the lift height, ensuring it meets the manufacturer's specifications.
Brakes & Safety Systems
- Annual Special:Perform a complete brake system inspection, checking pads, rotors, and drums for wear.
- Annual Special:Measure brake pad thickness and replace if it falls below the recommended level.
- Test parking brake for secure engagement and proper operation.
- Annual Special:Inspect brake hoses for cracks or leaks and replace if necessary.
- Test emergency stop systems and ensure they are functioning properly.
- Inspect the fire extinguisher and ensure it is fully charged and compliant with regulations.
- Check seatbelt and harnesses for wear and ensure proper operation.
- Annual Special:Inspect the overhead guard for any structural weaknesses and ensure proper mounting.
- Test backup alarms, horn, and lights to ensure full functionality.
- Inspect load capacity plate for readability and update if necessary.
- Annual Special:Check for any damage or misalignment in the safety guard systems, such as side barriers or guard rails.
Hydraulics and Operational Functions
- Annual Special:Test the entire hydraulic system for proper operation and leaks.
- Annual Special:Replace hydraulic hoses that show signs of wear, abrasion, or damage.
- Annual Special:Inspect hydraulic tanks for cleanliness and integrity, replacing filters as needed.
- Annual Special:Perform load testing to check the lifting capabilities of the forklift.
- Lubricate all moving parts of the hydraulic mast, ensuring smooth operation.
- Inspect the side-shift mechanism for proper operation and lubrication.
- Check for any unusual noises in the lift and tilt systems and address them immediately.
Engine and Exhaust System
- Annual Special:Perform a comprehensive engine inspection, including checking for oil leaks and unusual vibrations.
- Annual Special:Replace spark plugs and inspect the ignition system for wear or malfunctions.
- Annual Special:Clean or replace the air intake filter and clean the intake manifold.
- Annual Special:Inspect and clean the turbocharger (if equipped) for any damage or buildup.
- Inspect the exhaust system for any signs of leaks, corrosion, or unusual noise.
- Check the condition of the muffler and exhaust pipes, replacing any damaged components.
- Annual Special:Clean and test the radiator for blockages, leaks, and proper airflow.
- Inspect and clean the cooling fan and its drive system.
Battery and Electrical Systems
- Inspect battery terminals for corrosion and clean if necessary.
- Annual Special:Test battery voltage and charge capacity.
- Annual Special:Inspect all electrical connections for signs of corrosion, damage, or loose wiring.
- Check and test all electrical components, including dashboard lights, gauges, and operational systems.
- Annual Special:Inspect and test the alternator to ensure proper charging of the battery.
- Check the fuse box for blown fuses and replace as needed.
- Inspect all wiring and electrical components for fraying, wear, or exposure.
- Inspect and clean the battery charging system, including cables and connectors.
Transmission & Drive System
- Annual Special:Perform a complete inspection of the transmission system, ensuring smooth shifting and operation.
- Annual Special:Check the condition of the drive belt or chain and replace it if it shows signs of wear or damage.
- Annual Special:Inspect the clutch system (if applicable) for proper adjustment and wear.
- Annual Special:Check the condition of the drive axle, inspecting for signs of wear or leaks in the differential.
- Annual Special:Test the drive system under load to ensure proper power transfer and no unusual noises or vibrations.
- Inspect the parking brake for smooth operation and engagement.
General Inspection
- Annual Special:Conduct a thorough inspection of the forklift body for visible signs of damage, corrosion, or wear.
- Annual Special:Inspect all structural components, including the frame, for cracks or damage.
- Clean the forklift thoroughly, removing any dirt or debris that could cause future issues.
- Annual Special:Inspect and replace all safety decals, warning labels, and other signs as needed.
- Check that the operator's manual is up to date and easily accessible.
- Perform a complete inspection of the cab, ensuring all controls are functional and accessible.
- Annual Special:Check operator's seat condition for wear and adjust or replace it as necessary.
- Annual Special:Inspect the lifting chains for damage, stretch, or uneven wear.