Intermediate service - counterbalance forklift (all makes, diesel/LPG/electric)
Estimated duration: 2 - 3 hours • Frequency: every 500 engine hours
Equipment Details
| # | Service Action (500-Hour Additional Tasks) | Type | Done | Notes |
|---|---|---|---|---|
| Engine / Powertrain | ||||
| 1 | Replace fuel filter (diesel) | REPLACE | ☐ | |
| 2 | Replace outer air filter element | REPLACE | ☐ | |
| 3 | Replace spark plugs (LPG/petrol only) | REPLACE | ☐ | |
| 4 | Clean/inspect LPG vapouriser (LPG only) | CLEAN | ☐ | |
| 5 | Inspect exhaust system for leaks or damage | INSPECT | ☐ | |
| Hydraulic System | ||||
| 6 | Replace hydraulic return filter | REPLACE | ☐ | |
| 7 | Take hydraulic oil sample for analysis | CHECK | ☐ | |
| Transmission | ||||
| 8 | Check transmission oil level and condition | CHECK | ☐ | |
| Mast and Steering | ||||
| 9 | Inspect mast rollers for wear or excessive play | INSPECT | ☐ | |
| 10 | Inspect steer axle bushes and king pins for wear | INSPECT | ☐ | |
| Brakes | ||||
| 11 | Adjust brakes (shoes/pads) | ADJUST | ☐ | |
| 12 | Inspect brake drums/discs for wear | INSPECT | ☐ | |
| Electrical | ||||
| 13 | Test battery under load | 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 (500-Hour Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | All 250-hour parts (see 250-hr checklist) | - | ☐ | |
| 2 | Fuel filter (diesel) | 1 | ☐ | |
| 3 | Outer air filter element | 1 | ☐ | |
| 4 | Hydraulic return filter | 1 | ☐ | |
| 5 | Spark plugs (LPG/petrol only) | 4-6 | ☐ | |
| 6 | Oil sample bottle | 1 | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager