Forklift Service Schedule: Engine Oil, Filters and Intervals
HandyMax diesel and LPG forklifts share one service schedule. The first service is due at 30 hours or 3 months. After that: the air filters every 100 hours or 3 months; the engine oil, transmission fluid, brake fluid and the oil, fuel and transmission filters every 300 hours or 3 months; the gear oil and coolant every 500 hours or 6 months; and the hydraulic oil every 500 hours or 12 months. Whichever comes first, hours or months. LPG models add spark plug and gas checks. This is the schedule on the red Maintenance Guide decal on your forklift. It covers the HMF25-D30, HMF25-T45, HMF35-D30, HMF35-T45 and HMF55, the rough-terrain HMF35RT and HMF40RT, the all-terrain HMAT35, and the LPG HMF25G and HMF35G. Our electric forklifts have their own checklist: call us for it.
The service schedule
| Item | What to use | Every (whichever comes first) |
|---|---|---|
| First service | — | 30 h / 3 months |
| Air filters | Replace. Clean them every 8 h, more often in dust | 100 h / 3 months |
| Engine oil | 15W-40 | 300 h / 3 months |
| Engine oil filter | Replace | 300 h / 3 months |
| Fuel filter (diesel) | Replace | 300 h / 3 months |
| Transmission fluid | ATF Dexron III | 300 h / 3 months |
| Transmission filter | Replace | 300 h / 3 months |
| Brake fluid | DOT 3 | 300 h / 3 months |
| Lift chains | Lubricate | 300 h / 3 months |
| Gear / diff oil | 80W-90 | 500 h / 6 months |
| Coolant | Hybrid (HOAT) | 500 h / 6 months |
| Hydraulic oil | ISO 46 | 500 h / 12 months |
| Grease | NLGI 2 | Keep all grease points lubricated |
All intervals are hours or months, whichever comes first. Read the hours off the hour meter. If your machine only does a few hours a year, the months still apply.
Extra items for LPG forklifts (HMF25G, HMF35G)
| Item | What to do | Every |
|---|---|---|
| Spark plugs | NGK FR2B-D | Inspect every 200 h. Replace at 3,600 h / 18 months |
| Vaporiser | Drain the condensate | 200 h |
| LPG filter and leak check | Soapy water only, never a flame | 12 months, and at every bottle change |
Check for gas leaks with soapy water only, never with a flame. Close the bottle valve and park outside overnight. LPG models have no diesel fuel filter.
The first service at 30 hours
The first service is due at 30 hours or 3 months, whichever comes first, while new parts are still bedding in. Don't skip it. After that, follow the regular intervals in the table above.
Daily checks before you start
Run through these before the first start of each day:
- Fuel level
- Engine oil level
- Hydraulic oil level
- Coolant level
- Brake fluid level
- Brakes and parking brake
- Steering and horn
- Tyres and wheel nuts
- Forks: cracks, bends and wear
- Lift chains and anchor pins
- Mast and cylinders: leaks
- Overhead guard and backrest
- Seat belt
- Lights, buzzer and gauges
- Oil and water leaks
- Report any faults
LPG models: also check the LPG bottle is secure and in date, and the valve and hose for leaks.
HMAT35: also check the transmission fluid level, tyre pressure, mast and guide rollers, lift chain tension, and the tilt and side-shift cylinders. Drain the air tank and grease the machine.
Which oils and fluids to use
| Fluid | Specification | Notes |
|---|---|---|
| Engine oil | SAE 15W-40 | 15W-40 engine oil |
| Transmission fluid | ATF meeting GM Dexron III | For the transmission and torque converter. Don't use engine oil or gear oil. |
| Hydraulic oil | ISO 46 | The same grade across the HandyMax range. ISO 46 hydraulic oil |
| Gear / diff oil | SAE 80W-90 | Axles. 80W-90 gear oil |
| Coolant | Hybrid (HOAT) | Don't mix coolant types: mixing can leave deposits that block the radiator. coolant concentrate |
| Brake fluid | DOT 3 | DOT 3 brake fluid |
| Grease | NLGI 2 |
Transmission fluid and hydraulic oil are two separate systems with two different oils. Never top up one with the other.
Before you start any service
Park on level ground, lower the forks to the ground, apply the parking brake and stop the engine. Never work under a raised carriage.
Parts for your service
Each model's page lists the part numbers of its filters in the specifications table, with links to order them. A filter service kit has the filters for a regular service (contents vary by model):
- Filter service kit — HMF25 and HMF35 (D30 and T45)
- Filter service kit — HMF35RT and HMF40RT
- Filter service kit — HMAT35
For the HMF55 and the LPG models, order the filters one by one from the model's page, or call us. Filters: air filters, engine oil filters, fuel filters and transmission filters. Oils: 15W-40 engine oil, ISO 46 hydraulic oil, 80W-90 gear oil, coolant concentrate and DOT 3 brake fluid.
How-to videos
How to change the engine oil and filter
HMF25, HMF35, HMF55, HMF35RT and HMF40RT
How to change the fuel filter
HMF25, HMF35, HMF55, HMF35RT and HMF40RT
How to change the transmission fluid
HMF25 and HMF35
How to change the gear / diff oil
HMF25 and HMF35
How to change the hydraulic oil
HMF25, HMF35, HMF55, HMF35RT and HMF40RT
How to change the coolant
HMF25, HMF35, HMF55, HMF35RT and HMF40RT
How to change the brake fluid
HMF25, HMF35, HMF55, HMF35RT and HMF40RT
How to clean and change the air filter
HMF35RT and HMF40RT
How to clean and change the air filter (all-terrain)
HMAT35 (same air filter as our wheel loaders)
Keep your service records
Servicing is the owner's responsibility, as the decal says. Keep a record of each service (the date and the hour-meter reading) and keep the invoices for the oils and filters you use: they are your warranty evidence. Use only genuine HandyMax parts. Improper servicing, or damage from dust, may affect your warranty.
Refill capacities
Capacities differ from model to model. They are listed in the specifications table on each model's page. If yours isn't there, call us.
Frequently asked questions
How often does a HandyMax forklift need servicing?
First service at 30 hours or 3 months. Then the air filters every 100 hours or 3 months; the engine oil, transmission fluid, brake fluid and the oil, fuel and transmission filters every 300 hours or 3 months; the gear oil and coolant every 500 hours or 6 months; and the hydraulic oil every 500 hours or 12 months, whichever comes first.
What transmission fluid goes in a HandyMax forklift?
ATF that meets GM Dexron III. It is not the same oil as the hydraulic oil (ISO 46), and engine oil or gear oil should never go in the transmission.
Do LPG forklifts need anything extra?
Yes. Inspect the spark plugs every 200 hours and replace them at 3,600 hours or 18 months, drain the vaporiser every 200 hours, and change the LPG filter and leak-check the system every 12 months and at every bottle change.
Is the all-terrain HMAT35 serviced the same way?
Yes, same intervals and same oils. Its daily check adds the transmission fluid level, tyre pressure, guide rollers, chain tension and draining the air tank.
Can I do the servicing myself?
Yes. Routine servicing is the owner's responsibility. Use genuine HandyMax filters and the oils listed above, follow the videos, and keep your records and invoices.
Talk to us
Not sure which filters fit your machine? Call us on 03 9769 2888 or 1300 077 999, or visit us at 2/22 Park Drive, Dandenong South VIC 3175.
