Pre-Operation Inspection and Maintenance Checks
This domain tests the daily inspection routine and the boundary between operator checks and maintenance by competent persons. The exam expects a practical sequence: look, test, record, tag out and report.
Core rules
- Visual check: tyres for damage and pressure, forks for cracks and heel wear, mast chains for tension and damage, hydraulic hoses for leaks and chafing, overhead guard and backrest, data plate, seat belt, lights, horn and fire extinguisher.
- Fluid and energy checks: engine oil, coolant, hydraulic oil, fuel level, battery electrolyte and charge state, LPG cylinder security and seals.
- Operational test: steering, service brake, parking brake, horn, lights, mast raise/lower, tilt, side-shift and fork position; listen for abnormal noise.
- Defect action: stop using the truck, tag it out, remove the key where practicable, and report. Never ‘work around’ a safety defect.
- Maintenance boundary: operators do not adjust chains, repair hydraulics or modify the truck unless trained and authorised; maintenance records must be kept.
Worked example
During the check you find a crack at the fork heel and the chain is slack on one side. Reasoning: a cracked fork can fail under load and slack chain can cause mast binding or load drop. Do not lift a test load. Tag the truck out, record both defects, and route it to a competent maintenance person. The truck returns to service only after repair and documented clearance.
Traps
- Ticking the checklist from the cab without touching the forks or chains.
- Accepting ‘it passed yesterday’ as today’s inspection.
- Operating with a known leak because the shift is short.
- Adjusting chain tension without training or the correct procedure.