Minor service - rough terrain / all-terrain forklift (all makes, diesel)
Estimated duration: 1.5 - 2.5 hours • Frequency: every 250 engine hours
Equipment Details
| # | Service Action | Type | Done | Notes |
|---|---|---|---|---|
| Engine / Powertrain | ||||
| 1 | Drain and replace engine oil (15W-40) | DRAIN/FILL | ☐ | |
| 2 | Replace engine oil filter | REPLACE | ☐ | |
| 3 | Inspect outer air filter element - replace if dirty | INSPECT | ☐ | |
| 4 | Inspect inner (safety) air filter element | INSPECT | ☐ | |
| 5 | Drain fuel/water separator | DRAIN | ☐ | |
| 6 | Check coolant level, hoses and clamps | CHECK | ☐ | |
| Hydraulic System | ||||
| 7 | Check hydraulic oil level - top up if low | CHECK | ☐ | |
| 8 | Inspect hydraulic hoses for leaks, chafing or damage | INSPECT | ☐ | |
| 9 | Inspect boom/lift and tilt cylinders for rod seal leaks | INSPECT | ☐ | |
| 10 | Inspect steering cylinders for leaks or damage | INSPECT | ☐ | |
| 11 | Inspect quick-hitch hydraulic couplings (if fitted) | INSPECT | ☐ | |
| Mast / Boom | ||||
| 12 | Lubricate mast chains (chain-type) or inspect boom pivot pins and bushes | GREASE | ☐ | |
| 13 | Check mast chain tension and adjustment (chain-type) | ADJUST | ☐ | |
| 14 | Inspect forks/attachment for cracks, wear and heel thickness | INSPECT | ☐ | |
| 15 | Inspect overhead guard and ROPS/FOPS for cracks or damage | INSPECT | ☐ | |
| Axles and Differentials | ||||
| 16 | Check front axle oil level - top up if low | CHECK | ☐ | |
| 17 | Check rear axle oil level - top up if low | CHECK | ☐ | |
| 18 | Inspect axle breathers - clean or replace if blocked | INSPECT | ☐ | |
| 19 | Check axle seals for oil leaks | INSPECT | ☐ | |
| Lubrication (15 - 25 Grease Points) | ||||
| 20 | Grease steering knuckles | GREASE | ☐ | |
| 21 | Grease axle oscillation pins | GREASE | ☐ | |
| 22 | Grease mast rollers and carriage / boom pivots | GREASE | ☐ | |
| 23 | Grease drive shaft universal joints | GREASE | ☐ | |
| 24 | Grease all remaining pivot points and nipples | GREASE | ☐ | |
| Tyres and Brakes | ||||
| 25 | Inspect tyres for cuts, sidewall damage and tread depth | INSPECT | ☐ | |
| 26 | Check tyre pressures against specification plate | CHECK | ☐ | |
| 27 | Check brake fluid level | CHECK | ☐ | |
| 28 | Test park brake operation | CHECK | ☐ | |
| 29 | Test service brake operation | CHECK | ☐ | |
| Electrical | ||||
| 30 | Check battery terminals and electrolyte level | CHECK | ☐ | |
| 31 | Check all lights (headlights, tail lights, work lights, indicators) | CHECK | ☐ | |
| Safety Devices | ||||
| 32 | Test horn, reversing alarm and beacon | CHECK | ☐ | |
| 33 | Check seatbelt condition and latch operation | CHECK | ☐ | |
| 34 | Inspect ROPS/FOPS structure for cracks or damage | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Approx. Capacity |
|---|---|---|
| Engine oil | 15W-40 | 8 - 14 L |
| Hydraulic oil | ISO VG 46 | 40 - 80 L (system) |
| Coolant | 50/50 ethylene glycol | 10 - 18 L |
| Axle oil (front/rear) | 80W-90 or 85W-140 GL-5 | 3 - 6 L per axle |
| Transmission oil | ATF or TO-4 | 10 - 18 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 rough terrain forklifts (2.5 - 5 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 (15W-40) | 8-14 L | ☐ | |
| 2 | Engine oil filter | 1 | ☐ | |
| 3 | Outer air filter element - if replacing | 1 | ☐ | |
| 4 | Inner (safety) air filter element - if replacing | 1 | ☐ | |
| 5 | Fuel/water separator element (diesel) | 1 | ☐ | |
| 6 | EP2 grease cartridges | 2-3 | ☐ | |
| 7 | Mast chain lube | 1 | ☐ | |
| 8 | Coolant / brake fluid / axle oil (as needed) | As req. | ☐ | |
| 9 | Rags, drip tray, waste oil container | - | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Supervisor / Workshop Manager