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Scheduled maintenance checklist for rough terrain forklifts at 500-hour intervals.
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Service Items
Mark the applicable column for each item: P = Pass | F = Fail | N/A = Not applicable. Record notes for any F.
| # | Check | P | F | N/A | Notes / Action |
|---|---|---|---|---|---|
| Engine | |||||
| 1 | Engine oil drained and replaced with OEM-specified grade | ||||
| 2 | Engine oil filter replaced | ||||
| 3 | Fuel filter(s) replaced (primary and secondary) | ||||
| 4 | Air filter element inspected, cleaned or replaced | ||||
| 5 | Drive belts checked for wear, cracking and correct tension | ||||
| 6 | Coolant level and concentration tested, topped up as required | ||||
| Hydraulics | |||||
| 7 | Hydraulic oil level checked and topped up to correct level | ||||
| 8 | Hydraulic return-line filter replaced | ||||
| 9 | Hydraulic hoses inspected for leaks, chafing and deterioration | ||||
| 10 | Lift, tilt and auxiliary cylinder rods checked for scoring or leaks | ||||
| Mast & Carriage | |||||
| 11 | Mast channels and roller bearings lubricated | ||||
| 12 | Lift chains inspected for stretch, wear and correct tension | ||||
| 13 | Fork tines inspected for cracks, bending and heel wear | ||||
| Steering & Axles | |||||
| 14 | Steering linkage, tie rods and ball joints checked for wear | ||||
| 15 | Axle pivot pins and bushings lubricated and inspected | ||||
| 16 | Differential and axle oil levels checked, topped up as required | ||||
| # | Check | P | F | N/A | Notes / Action |
|---|---|---|---|---|---|
| Brakes | |||||
| 17 | Service brake pads/shoes measured and within specification | ||||
| 18 | Brake fluid level checked, system bled if required | ||||
| 19 | Park brake engagement and holding capacity tested | ||||
| Tyres | |||||
| 20 | Tyre tread depth and condition inspected (all four tyres) | ||||
| 21 | Tyre pressures checked and adjusted to manufacturer specification | ||||
| Electrical | |||||
| 22 | Battery terminals cleaned, secure and corrosion-free | ||||
| 23 | All lights operational (head, tail, work, indicators, reverse alarm) | ||||
| 24 | Wiring harness inspected for damage, chafing or loose connections | ||||
| Safety Devices | |||||
| 25 | Seat belt condition and latch mechanism checked | ||||
| 26 | ROPS / FOPS structure inspected for cracks or deformation | ||||
| 27 | Horn, reverse alarm and safety decals in serviceable condition | ||||
Defects & Corrective Actions (list any item marked F: reference item # from checklist)
| Item # | Defect description | Corrective action / parts used | Rectified by / date |
|---|---|---|---|
Declaration
I declare that I have completed this 500-hour service in accordance with the manufacturer's maintenance schedule and applicable Australian Standards. All defects identified have been recorded and reported to the responsible person. The unit must not be returned to service until all critical defects are rectified.