Toyota Forklift 50-4FD100-135: Every 6 Weeks or 250 Hours Maintenance

Steering wheel: Inspection Method - I: Inspection, repair or replacement if required

• Play, loosening and looseness

• Function

Steering valve

• I: Inspection, repair or replacement if required -Oil leak

• T: Retightening - Loosened mounting

Tie rod and bell crank:

• T: Retightening - Looseness, loosening and damage

Steering knuckle

• T: Retightening - Kingpin looseness

Power steering

• I: Inspection, repair or replacement if required - Oil leak

• T: Retightening - Loosened mounting

Steering synchronizer: I: Inspection, repair or replacement if required

• Function

• Loosened or damaged sensor mounting

• Functional parts damage and deformation

• Loosened of damaged wire harness

Brake valve:

• I: Inspection, repair or replacement if required - Brake valve function

• I: Inspection, repair or replacement if required - Braking performance

• M: Measurement, repair or adjustment if required - Uneven braking

Parking brake switch: I: Inspection, repair or replacement if required

• Switch function

• Braking performance

Brake hose and pipe: I: Inspection, repair or replacement if required

• Leak, crack and mounting state

• Loosened joint or clamp

Air com- pressor and air tank: I: Inspection, repair or replacement if required

• Air cleaner clogging

• Water draining from air tank

• Air compressor regulator function

Center brake drum and lining: I: Inspection, repair or replacement if required

• Clearance between drum and lining

Wheel: I: Inspection, repair or replacement if required

• Tire pressure

• Tire cracks and damage

• Abnormal tire wear

• Tire tread depth

• Metal piece, stone and other foreign matter on tire

• Rim side ring and disc wheel damage

• Rear wheel bearing looseness

• Abnormal sound from rear wheel bearing

Transmis- sion & torque con- verter: I: Inspection, repair or replacement if required

• Oil leak and oil level

• Control valve and clutch functions

• Inching valve function

Propeller shaft and drive shaft

• T: Retightening - Loosened joint

• I: Inspection, repair or replacement if required - Axle shaft twist and crack

Planetary gear: I: Inspection, repair or replacement if required

• Oil leak and oil level

Battery: I: Inspection, repair or replacement if required

• Fluid level

Electrical wiring: I: Inspection, repair or replacement if required

• Loosened or damaged connection

• Wire harness damage and clamp loosening

• Fuses

Starting motor: I: Inspection, repair or replacement if required

• Pinion gear meshing state

Charger: I: Inspection, repair or replacement if required

• Charging function

Fork: I: Inspection, repair or replacement if required

• Fork deformation and wear

• Fork root and tooth weld crack and wear

• Fork shifter damage and wear

Mast and lift bracket: I: Inspection, repair or replacement if required

• Deformed or damaged part and crack at welded portion

• Roller bearing looseness

• Mast and lift bracket looseness

• Chain greasing condition

• Chain deformation, damage and rusting

Mast and lift bracket

• I: Inspection, repair or replacement if required - Chain tension

• I: Inspection, repair or replacement if required - Chain anchor bolt abnormality

• I: Inspection, repair or replacement if required - Chain wheel deformation and damage

• T: Retightening - Chain wheel bearing looseness

Various attachments: I: Inspection, repair or replacement if required

• Abnormality and mounting condition of each part

Cylinders (lift and tilt)

• T: Retightening - Rod, rod screw and rod end loosening, deformation and damage

• I: Inspection, repair or replacement if required - Cylinder operation

• I: Inspection, repair or replacement if required - Natural drop and natural forward tilt

• I: Inspection, repair or replacement if required - Oil leak and damage

• I: Inspection, repair or replacement if required - Pin and cylinder bearing wear and damage

• I: Inspection, repair or replacement if required - Cylinder mounting loosening and damage

• I: Inspection, repair or replacement if required - Uneven movement

• M: Measurement, repair or adjustment if required - Lifting speed

Oil pump: I: Inspection, repair or replacement if required

• Oil leak and abnormal sound

• Drive gear wear

Hydraulic tank: I: Inspection, repair or replacement if required

• Oil level and contamination

• Oil leak

Control lever: I: Inspection, repair or replacement if required

• Loose mounting

• Operation

Oil control valve: I: Inspection, repair or replacement if required

• Oil leak

• Lift lock valve and tilt lock valve functions

Hydraulic hose and piping

• T: Retightening - Oil leak, looseness, loosening, deformation and damage

• I: Inspection, repair or replacement if required - Hydraulic hose replacement

Lighting system and direction indicator: I: Inspection, repair or replacement if required

• Action

• Lighting or flashing status, fouling and damage

Horn: I: Inspection, repair or replacement if required

• Sounding condition

• Action

Back-up buzzer: I: Inspection, repair or replacement if required

• Sounding condition

• Action

Rearview mirror: I: Inspection, repair or replacement if required

• Rear reflection on status

• Dirt and damage

Instruments: I: Inspection, repair or replacement if required

• Action

Exhaust pipe and muffler: I: Inspection, repair or replacement if required

• Muffler rubber mount

• Loosened or damaged mounting

Seat: I: Inspection, repair or replacement if required

• Seatbelt condition

• Loosened or damaged mounting

• Seatbelt damage and function

Others: L: Lubrication

• Chassis parts grease-up condition

• Steering link system and universal joint grease-up