Appearance
Forklift Preventative Maintenance Checklist
Template Name: Forklift PM (Default)
Total Items: 103
Sections: 12
This document contains the complete forklift preventative maintenance checklist with all sections, items, and descriptions. Use this as a reference for expanding or modifying the checklist.
1. Visual Inspection
Item 1: Oil/Coolant Leaks
Description: Inspect under and around the forklift for signs of oil or coolant leaks.
Item 2: Carriage, Mast & LBR Assembly
Description: Examine the carriage, mast, and load backrest for damage, cracks, or deformation.
Item 3: Forks and Fork Pins
Description: Check that forks and fork pins are straight, undamaged, and securely attached.
Item 4: Mast Chains, Rollers & Hoses
Description: Inspect mast chains, rollers, and hoses for wear, proper tension, and leaks.
Item 5: Tire & Wheel Condition
Description: Inspect tires and wheels for cuts, excessive wear, or missing lug nuts.
Item 6: Seat & Seat Belt Condition
Description: Ensure seat and seat belt are present, undamaged, and functioning properly.
Item 7: Decals & Capacity Plates
Description: Verify that all safety decals and capacity plates are present and legible.
Item 8: Overhead Guard Condition
Description: Check the overhead guard for bends, cracks, or missing hardware.
Item 9: Check Cylinders for Leaks
Description: Inspect all visible hydraulic cylinders for leaks or damage.
2. Engine Compartment
Item 1: Blow Out Engine Compartment
Description: Use compressed air to clean debris and dust from the engine compartment.
Item 2: Check Condition of Air Filter
Description: Inspect and replace the air filter if dirty or clogged.
Item 3: Change Engine Oil & Filter
Description: Drain engine oil, replace with new oil, and install a new oil filter as specified.
Item 4: Check hood Latch, Hinges & Hood Strut
Description: Confirm hood latch, hinges, and strut function smoothly and securely.
Item 5: Inspect Air Intake Hoses & Clamps
Description: Examine air intake hoses and clamps for cracks, leaks, or loose fittings.
Item 6: Check Ring Gear Condition
Description: Inspect ring gear for visible damage or abnormal wear.
Item 7: Check Hood Insulation & Hood Condition
Description: Ensure hood insulation is intact and hood is free of damage.
Item 8: Engine Noise / Smoke / Idle RPMs
Description: Start the engine and check for abnormal noises, smoke, or incorrect idle speed.
Item 9: Exhaust System / Muffler / Catalyst
Description: Examine the exhaust system, muffler, and catalyst for leaks, noise, or damage.
Item 10: Check for Engine Oil Leaks
Description: Look for evidence of engine oil leaks under and around the engine.
Item 11: Check Vacuum Lines / PCV Valve
Description: Inspect vacuum lines and PCV valve for cracks, leaks, or blockages.
3. Electrical Inspection
Item 1: Check Headlights, Strobe, Taillights
Description: Verify all headlights, taillights, and strobe lights operate correctly.
Item 2: Clean Battery Terminals / Load Test
Description: Clean corrosion from battery terminals and perform a battery load test.
Item 3: Inspect Wire Harness / Connections
Description: Check wire harnesses and electrical connections for wear or loose fittings.
Item 4: Check Neutral Safety Switch
Description: Test the neutral safety switch for correct operation.
Item 5: Check All Gauges & Hour Meter
Description: Ensure all dashboard gauges and the hour meter function accurately.
Item 6: Condition of Fuse Panel / Relay Box
Description: Open and inspect the fuse panel and relay box for corrosion, damage, or missing fuses.
Item 7: Inspect Alternator / Record Voltage
Description: Inspect the alternator for damage and record operating voltage output.
4. Hydraulic Inspection
Item 1: Inspect Fluid Level & Quality
Description: Check hydraulic fluid level and assess fluid for contamination or discoloration.
Item 2: Inspect Pump / Control Valve
Description: Visually inspect pump and control valve for leaks or damage.
Item 3: Check Hydraulic Valve Levers
Description: Operate all hydraulic levers to ensure smooth and proper function.
Item 4: Check Pump Drive Shaft & U-Joints
Description: Inspect the pump drive shaft and U-joints for wear or looseness.
Item 5: Remove & Clean / Replace Tank Breather
Description: Remove the tank breather, clean or replace as needed.
Item 6: Inspect All Hoses & Fittings
Description: Examine all hydraulic hoses and fittings for cracks, leaks, or abrasion.
Item 7: Inspect Cylinders for Leaks
Description: Check hydraulic cylinders for oil leaks or physical damage.
5. Brake
Item 1: Check Fluid Level & Quality
Description: Inspect the brake fluid reservoir for proper level and clear, uncontaminated fluid.
Item 2: Test PB Operation, Check Cables
Description: Test parking brake operation and inspect cables for wear or binding.
Item 3: Test Service Brake Operation
Description: Depress the service brake and confirm the forklift stops smoothly and promptly.
Item 4: Check Pedal Pads & Inching Pedal Cables
Description: Inspect pedal pads for wear and inching pedal cables for proper function.
Item 5: Check Wheels & Cylinder for Leaks
Description: Look for brake fluid leaks around wheel cylinders and brake assemblies.
Item 6: Check Brake / Inching Pedal Linkage
Description: Inspect brake and inching pedal linkage for looseness or damage.
Item 7: Check Brake / Inching Pedal Free Play
Description: Verify correct amount of free play in brake and inching pedals.
6. Steering
Item 1: Inspect Steering Cylinder for Leaks
Description: Check steering cylinder for hydraulic leaks or visible damage.
Item 2: Inspect Gear Box & Steer Column
Description: Inspect the steering gear box and column for proper operation and leaks.
Item 3: Check King Pins & Spindles
Description: Check king pins and spindles for excessive play or wear.
Item 4: Test Steer Wheel Bearings
Description: Spin and rock steer wheels to check for noisy or loose bearings.
Item 5: Check Steer Axle Mounts & Stops
Description: Ensure steer axle mounts and stops are secure and undamaged.
Item 6: Check Steering tie Rods & Pings
Description: Inspect tie rods and pins for looseness or excessive wear.
Item 7: Check Steer Wheel Bearings
Description: Verify steer wheel bearings turn smoothly without noise or resistance.
Item 8: Inspect Steer Wheel Lug Nuts / Rim / Cap
Description: Check steer wheel lug nuts for tightness and inspect rim/cap for damage.
Item 9: Check Steering Hoses at Cylinder & Box
Description: Inspect steering hoses at both the cylinder and box for leaks or wear.
7. Differential & Transmission
Item 1: Check Fluid Levels & Condition
Description: Inspect differential and transmission fluid levels and assess for contamination.
Item 2: Check for Abnormal Noise
Description: Listen for unusual noises from differential or transmission during operation.
Item 3: Check Drive Wheel Bearings & Lug Nuts
Description: Inspect drive wheel bearings for play and verify lug nuts are tight.
Item 4: Check Mounts & Bolts
Description: Check that all mounts and bolts are secure and undamaged.
Item 5: Check for Leaks
Description: Inspect the differential and transmission for signs of oil leaks.
Item 6: Check Drive Shaft & U-Joints
Description: Examine drive shaft and U-joints for excessive play or wear.
Item 7: Check Shift Lever Linkage / Cables
Description: Test shift lever linkage and cables for proper adjustment and smooth operation.
Item 8: Replace Fluid & Filters per OEM Spec
Description: Replace differential and transmission fluids and filters according to manufacturer specification.
8. Ignition System
Item 1: Test Ignition Switch
Description: Turn the ignition switch to verify smooth operation and proper start.
Item 2: Check Coil / Coil Packs
Description: Inspect ignition coil or coil packs for damage or signs of arcing.
Item 3: Check Distributor Cap & Rotor
Description: Remove and check distributor cap and rotor for wear or corrosion.
Item 4: Check Spark Plug Condition & Wires
Description: Remove and inspect spark plugs and wires for fouling or damage.
9. Mast & Carriage
Item 1: Check Lift Chains & Anchors
Description: Inspect lift chains and anchors for wear, proper lubrication, and correct tension.
Item 2: Check Cylinders for Leaks
Description: Examine all mast cylinders for hydraulic leaks or damage.
Item 3: Check Cylinder Brackets
Description: Inspect cylinder brackets for secure attachment and absence of cracks.
Item 4: Check Hose Pulleys & Chain / Hose Guards
Description: Check that hose pulleys, chain guards, and hose guards are intact and functional.
Item 5: Check Tilt Cylinder Mounts & Pins
Description: Verify tilt cylinder mounts and pins are secure and show no excessive wear.
Item 6: Check Trunion Bushings / Mounts
Description: Inspect trunion bushings and mounts for wear or looseness.
Item 7: Check Forks, Pins & Carriage Condition
Description: Examine forks, pins, and carriage for cracks, bending, or other defects.
Item 8: Check Hoses for Leaks
Description: Inspect hydraulic hoses on mast and carriage for leaks, abrasion, or damage.
Item 9: Check Mast Shims & Side Play
Description: Check mast shims for tightness and look for excessive side play in mast.
Item 10: Check Carriage & Mast Rollers
Description: Inspect rollers for flat spots, wear, or improper rotation.
Item 11: Check Mast Rails for Wear
Description: Look for wear, cracks, or bending along mast rails.
Item 12: Check Side Shift Bushings
Description: Inspect side shift bushings for excessive wear or movement.
10. Cooling System
Item 1: Blow Out Radiator
Description: Use compressed air to remove dust and debris from the radiator fins.
Item 2: Coolant Level, Condition & Leaks
Description: Check coolant level, ensure coolant is clean, and inspect for leaks.
Item 3: Check Radiator Condition & Shroud
Description: Inspect radiator and fan shroud for damage or obstructions.
Item 4: Check Water Pump for Leaks & Play
Description: Check water pump for coolant leaks or excessive shaft play.
Item 5: Check Belt Condition & Tension
Description: Inspect all drive belts for cracks, fraying, and correct tension.
Item 6: Check Fan Blade Condition
Description: Examine fan blades for cracks, chips, or loose mounting.
Item 7: Cooland Good To (°F)
Description: Verify coolant protection is adequate for expected low temperatures using a tester.
11. Fuel System
Item 1: Check LP Tank, Hoses & Fittings
Description: Inspect LP tank, hoses, and fittings for leaks, damage, or loose connections.
Item 2: Drain LPG Regulator
Description: Drain condensation from the LPG regulator per manufacturer instructions.
Item 3: Check LP System for Leaks
Description: Use leak detector solution or sniffer to check LP system for leaks.
Item 4: Check LPG Lockoff Operation
Description: Test LPG lockoff valve for proper engagement and operation.
Item 5: Check Carburetor & Linkages
Description: Inspect carburetor and throttle/choke linkages for smooth movement and secure attachment.
Item 6: Check throttle Pedal Linkages / Cable
Description: Check throttle pedal linkages and cable for free movement and secure connections.
Item 7: Check Governor for Proper Operation
Description: Inspect and test governor for correct operation and smooth throttle response.
Item 8: Change Diesel Fuel Filters
Description: Replace diesel fuel filters according to the service schedule.
Item 9: Drain Water Separator / Sediment Filter
Description: Drain water separator and sediment filter of any collected water or contaminants.
12. Final Inspection
Item 1: Test Horn Operation
Description: Press horn button to verify loud, consistent sound.
Item 2: Does Back Up Alarm Sound in Reverse
Description: Shift into reverse and confirm the backup alarm activates.
Item 3: Test Brake Lights / Turn Signals / BU Lights
Description: Check that all brake lights, turn signals, and backup lights function properly.
Item 4: Test Strobe Light for Proper Operation
Description: Activate the strobe light and ensure it flashes correctly.
Item 5: Test Seat Belt
Description: Buckle and unbuckle seat belt to confirm proper latching and release.
Item 6: Test Operator Presence System
Description: Confirm that the operator presence system disables movement when the seat is unoccupied.
Item 7: Check All Work Lights
Description: Turn on all work lights and confirm they illuminate properly.
Item 8: Test Both Service & Parking Brake
Description: Apply both brakes and ensure they hold the forklift stationary.
Item 9: Test Forward & Reverse Travel
Description: Drive forklift forward and in reverse to confirm smooth operation.
Item 10: Test All Hydraulic Functions
Description: Operate all hydraulic controls and ensure smooth, correct response.
Item 11: Test Seat Belt Alarm
Description: Confirm seat belt alarm sounds if the seat belt is not engaged during operation.
Item 12: Wipe Down Forklift, Dash Area
Description: Clean the forklift and dashboard area of dirt and debris.
Item 13: Install PM Sticker
Description: Place the preventative maintenance sticker in the designated area to indicate service is complete.
Notes
- All items are marked as required in the system
- Condition ratings are not pre-set in templates (set during PM completion)
- This checklist serves as the default template for forklift preventative maintenance
- Items can be expanded or modified as needed for specific equipment requirements