Major service - counterbalance forklift (all makes, diesel/LPG/electric)
Estimated duration: 4 - 6 hours • Frequency: every 1,000 engine hours
Equipment Details
| # | Service Action (1,000-Hour Additional Tasks) | Type | Done | Notes |
|---|---|---|---|---|
| Hydraulic System | ||||
| 1 | Drain and replace hydraulic oil (ISO VG 32/46) | DRAIN/FILL | ☐ | |
| Transmission | ||||
| 2 | Drain and replace transmission oil (ATF/TO-4) | DRAIN/FILL | ☐ | |
| Cooling System | ||||
| 3 | Flush and replace coolant (50/50 ethylene glycol) | DRAIN/FILL | ☐ | |
| Engine / Powertrain | ||||
| 4 | Replace inner air filter element | REPLACE | ☐ | |
| 5 | Clean fuel tank and inspect for contamination | CLEAN | ☐ | |
| 6 | Inspect alternator and starter motor | INSPECT | ☐ | |
| Mast and Chains | ||||
| 7 | Replace mast chains (if stretch exceeds specification) | REPLACE | ☐ | |
| 8 | Inspect mast lift and tilt cylinders for wear and leaks | INSPECT | ☐ | |
| 9 | Full fork inspection per AS 2359 (measure heel thickness, check for cracks at heel radius) | INSPECT | ☐ | |
| 10 | Inspect overhead guard structure for damage or deformation | INSPECT | ☐ | |
| Brakes | ||||
| 11 | Full brake overhaul (new shoes/pads, check wheel cylinders) | REPLACE | ☐ | |
| Steering | ||||
| 12 | Inspect steering gear/rack for wear and play | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 10W-30 or 15W-40 | 4 - 8 L |
| Hydraulic oil | ISO VG 32 or 46 | 30 - 60 L (full change) |
| Coolant | 50/50 ethylene glycol | 6 - 12 L (full system) |
| Transmission oil | ATF or TO-4 | 8 - 15 L (full change) |
| Brake fluid | DOT 3 or DOT 4 | As required |
| Mast chain lube | Chain and cable lubricant | As required |
| Grease | EP2 lithium complex | As required |
Specifications are general guidelines for typical counterbalance forklifts (1.5 - 7 t). Always refer to the manufacturer's service manual for your specific make and model. Capacities vary by machine size. At the 1,000-hour service, hydraulic oil and transmission oil are being fully changed.
Parts / Consumables Required (1,000-Hour Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | All 500-hour parts (see 500-hr checklist) | - | ☐ | |
| 2 | Hydraulic oil (ISO VG 32/46) | 30-60 L | ☐ | |
| 3 | Transmission oil (ATF/TO-4) | 8-15 L | ☐ | |
| 4 | Inner air filter element | 1 | ☐ | |
| 5 | Coolant (full system) | 6-12 L | ☐ | |
| 6 | Mast chains (if replacing) | 1 set | ☐ | |
| 7 | Brake shoes/pads | 1 set | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager