06-FOR-PM-265 - Forklift Service

• Date:

  Date

• Service Hours Interval:

• Make / Model:

• Engine Hours:

• Serial Number:

• Plant Number:

• Prepared by:

• Location:

  Select

ENGINE MAIN BODY

• Check start up condition, low idling, acceleration, engine stop and knocking - Interval 200hrs

  Select

• Clean air cleaner - Interval 200hrs

  Select

• Check air cleaner clogging - Interval 1200hrs

  Select

• Replace air cleaner element - Interval 1200hrs

  Select

• Check exhaust gas colour - Interval 1200hrs

  Select

• Check valve clearance and compression pressure - Interval 1200hrs

  Select

• Check abnormal noise and vibration - Interval 2400hrs

  Select

• Check cylinder head bolt retightening - Interval 2400hrs

  Select

LUBRICATION SYSTEM

• Replace oil pan oil - Interval 200hrs

  Select

• Clean crank breather - Interval 200hrs

  Select

• Check oil pan oil level - Interval 200hrs

  Select

• Replace oil filter cartridge - Interval 600hrs

  Select

• Check for oil leaks - Interval 1200hrs

  Select

FUEL SYSTEM

• Check for fuel leaks - Interval 200hrs

  Select

• Check governor motion at max. rpm - Interval 200hrs

  Select

• Check fuel filter for cracks or damage - Interval 200hrs

  Select

• Replace oil & lubricate fuel injection pump governor - Interval 600hrs

  Select

• Check fuel filter water drain (diesel powered truck) - Interval 600hrs

  Select

• Replace fuel filter cartridge (diesel powered truck) - Interval 600hrs

  Select

• Fuel filter element replacement (gasoline powered truck) - Interval 1200hrs

  Select

• Inspect & maintain injection timing & volume - Interval 1200hrs

  Select

• Check fuel filter clogging - Interval 2400hrs

  Select

• Check for link movement - Interval 2400hrs

  Select

• Check throttle valve & choke valve condition - Interval 2400hrs

  Select

• Check injection nozzle, injection pressure & condition - Interval 2400hrs

  Select

• Clean fuel tank - Interval 2400hrs

  Select

COOLING SYSTEM

• Check radiator for hose cracks or damage - Interval 200hrs

  Select

• Check cooling fan installation condition, no cracks deformation or damage - Interval 200hrs

  Select

• Check cooling fan belt & alternator belt tension - Interval 200hrs

  Select

• Clean radiator fins & check for damage - Interval 200hrs

  Select

• Check water level, sub tank & radiator - Interval 1200hrs

  Select

• Check fan belt for slackening / damage - Interval 1200hrs

  Select

• Cooling system interior cleaning - Interval 1200hrs

  Select

• Check for water leaks - Interval 2400hrs

  Select

• Check radiator cap condition - Interval 2400hrs

  Select

CLUTCH & BRAKING SYSTEM

• Check clutch & brake pedal for play & pedal height when depressed - Interval 200hrs

  Select

• Check brake link play & loosening - Interval 200hrs

  Select

• Check brake hose & piping installation condition & wear, any leaks or damage present - Interval 200hrs

  Select

• Check brake drum & brake shoe clearance between the lining - Interval 200hrs

  Select

• Check clutch operating condition - Interval 1200hrs

  Select

• Replace clutch & brake oil - Interval 1200hrs

  Select

• Check stroke & braking effect on pedal brake & park brake - Interval 1200hrs

  Select

• Check clutch & brake oil level & refilling - Interval 2400hrs

  Select

• Check clutch release cylinder parts - Interval 2400hrs

  Select

• Check master cylinder cup & seals - Interval 2400hrs

  Select

• Check brake valve operating condition - Interval 2400hrs

  Select

• Check brake servo system operating condition - Interval 2400hrs

  Select

• Check brake shoe & lining wear, drum & shoe operating condition (wear & damage), backing plate installation condition (deformation or cracks) & brake spring operation - Interval 2400hrs

  Select

• Check parking brake lever & rachet for wear & damage - Interval 2400hrs

  Select

• Check brake hose & piping for air, water or oil tightness - Interval 2400hrs

  Select

• Check wheel cylinder cup & seal - Interval 2400hrs

  Select

TRANSMISSION & DIFFERENTIAL

• Check oil level & if any leaks present - Interval 200hrs

  Select

• Check inching pedal condition, pedal height & operation - Interval 200hrs

  Select

• Check shift lever for play & engagement condition - Interval 200hrs

  Select

• Check oil level & refilling - Interval 600hrs

  Select

• Replace oil - Interval 1200hrs

  Select

• Replace strainer - Interval 1200hrs

  Select

• Replace line filter cartridge - Interval 1200hrs

  Select

• Check shift lever installation condition - Interval 2400hrs

  Select

STEERING SYSTEM

• Check for oil leaks - Interval 200hrs

  Select

• Check gearbox mounts for loosening - Interval 200hrs

  Select

• Check power steering mounts, condition & loosening at connection - Interval 200hrs

  Select

• Check knuckle play, deformation & damage at connection - Interval 1200hrs

  Select

• Check fluctuation in min. turning radius - Interval 1200hrs

  Select

• Check power steering oil level & if any leaks present - Interval 2400hrs

  Select

• Check rod & arm for loosening, play & damage - Interval 2400hrs

  Select

• Check ball joint dust boot crack & damage - Interval 2400hrs

  Select

• Check steering wheel operation (feel & play) - Interval 2400hrs

  Select

WORK EQUIPMENT

• Check general working equipment operating condition - Interval 200hrs

  Select

• Check fork & fork stopper for deformation, cracks, damage - Interval 200hrs

  Select

• Check fork disarray or sagging - Interval 200hrs

  Select

• Check mast roller for play & mast for deformation, cracks, damage - Interval 200hrs

  Select

• Lubricate chain - Interval 100hrs

  Select

• Check chain & chain wheel for deformation, cracks, damage & rusty lubrication - Interval 200hrs

  Select

• Check chain wheel bearing for play & anchor bolt for deformation, cracks, damage & rusty lubrication - Interval 200hrs

  Select

• Check for crack at bottom of fork (use dye penetration check) - Interval 2400hrs

  Select

• Check mast support portion & roller shaft for wear & damage - Interval 2400hrs

  Select

• Check chain tension & elongation - Interval 2400hrs

  Select

HYDRAULICS

• Check hydraulic cylinder loosening, deformation, damage, cracks & wear - Interval 200hrs

  Select

• Check hydraulic cylinder operation & condition - Interval 200hrs

  Select

• Check tilt cylinder natural drift & natural forward tilting - Interval 200hrs

  Select

• Check control lever operating condition - Interval 200hrs

  Select

• Check pipping for damage, oil leaks, deformation - Interval 200hrs

  Select

• Check pipping clamps are secure, not slipping off - Interval 200hrs

  Select

• Replace hydraulic tank oil & clean hydraulic tank - Interval 1200hrs

  Select

• Replace hydraulic line filter & clean strainer - Interval 1200hrs

  Select

• Replace air breather - Interval 2400hrs

  Select

• Check relief valve operating condition & relief set pressure - Interval 2400hrs

  Select

• Check hydraulic pump & hydraulic motor operating condition - Interval 2400hrs

  Select

ELECTRICAL SYSTEM

• Check ignition timing, inspect ignition plug - Interval 200hrs

  Select

• Check distributor cap for cracks & damage - Interval 200hrs

  Select

• Check distributor cap for cracks & damage, contact point deterioration & clearance - Interval 1200hrs

  Select

• Check advancer operating condition - Interval 2400hrs

  Select

• Check wiring, connection, loosening or damage - Interval 200hrs

  Select

• Check starter motor engagement of pinon gear - Interval 200hrs

  Select

• Check battery – Every Service

  Select

Tyres

• Check front wheel for bearing play & rim for deformation, cracks & damage - Interval 200hrs

  Select

• Check tyre air pressure, wheel nut & bolt loosening - Interval 1200hrs

  Select

• Check tyre crack damage, tread depth & tyres for abnormal wear - Interval 2400hrs

  Select

• Check axle deformation, cracks or damage - Interval 2400hrs

  Select

MAIN BODY

• Check overhead guard & load backrest for deformation, cracks & damage - Interval 200hrs

  Select

• Check operators condition & damage - Interval 200hrs

  Select

• Check main body panels for damage or loosening - Interval 2400hrs

  Select

• Check exhaust muffler & pipe installation condition & damage - Interval 2400hrs

  Select

• Check frame & cross member for cracks or damage - Interval 2400hrs

  Select

• Check direction signal lamp & alarm operating condition - Interval 2400hrs

  Select

• Check instrument operating condition, check reading - Interval 2400hrs

  Select

• Grease all points – Every service

  Select

Damage and further Repairs Required

• Description

ADDITIONAL PARTS USED

• Part Description:

Sign Off:

• Name & Signature

  Sign