Minor service - counterbalance forklift (all makes, diesel/LPG/electric)
Estimated duration: 1 - 2 hours • Frequency: every 250 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine / Powertrain | ||||
| 1 | Drain and replace engine oil (10W-30 or 15W-40) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Inspect air filter element - replace if dirty | INSPECT | ☐ | |
| 4 | Drain fuel/water separator (diesel) or check LPG system for leaks (LPG) | DRAIN | ☐ | |
| 5 | Check coolant level and condition - top up if required | CHECK | ☐ | |
| Hydraulic System | ||||
| 6 | Check hydraulic oil level - top up if low | CHECK | ☐ | |
| 7 | Inspect hydraulic hoses and cylinders for leaks or damage | INSPECT | ☐ | |
| Mast and Chains | ||||
| 8 | Lubricate mast chains with chain lube | GREASE | ☐ | |
| 9 | Check mast chain tension and adjustment | ADJUST | ☐ | |
| 10 | Inspect forks for cracks, wear and heel thickness | INSPECT | ☐ | |
| 11 | Inspect overhead guard for damage or deformation | INSPECT | ☐ | |
| Lubrication | ||||
| 12 | Grease mast rollers and carriage | GREASE | ☐ | |
| 13 | Grease steer axle pivot | GREASE | ☐ | |
| Tyres and Brakes | ||||
| 14 | Inspect tyres for wear and damage | INSPECT | ☐ | |
| 15 | Check tyre pressures (pneumatic tyres only) | CHECK | ☐ | |
| 16 | Check brake fluid level | CHECK | ☐ | |
| 17 | Check park brake operation | CHECK | ☐ | |
| Electrical | ||||
| 18 | Check battery terminals and electrolyte level | CHECK | ☐ | |
| 19 | Check all lights (headlights, tail lights, indicators) | CHECK | ☐ | |
| Safety Devices | ||||
| 20 | Test horn, reversing alarm and beacon | CHECK | ☐ | |
| 21 | Check seatbelt condition and latch operation | CHECK | ☐ | |
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 (system) |
| Coolant | 50/50 ethylene glycol | 6 - 12 L |
| Transmission oil | ATF or TO-4 | 8 - 15 L (system) |
| 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.
Parts / Consumables Required
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Engine oil (10W-30 or 15W-40) | 4-8 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Air filter element - if replacing | 1 | ☐ | |
| 4 | Fuel filter / water separator (diesel) | 1 | ☐ | |
| 5 | EP2 grease cartridges | 1-2 | ☐ | |
| 6 | Mast chain lube | 1 | ☐ | |
| 7 | Coolant / brake fluid (as needed) | As req. | ☐ | |
| 8 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager