23.

MAINTENANCE SCHEDULE CHART

23. MAINTENANCE SCHEDULE CHART
Perform maintenance at intervals of months or operation hours, whichever occurs first.

Service Item Page

First month or initial 200 hours service (only after the first one month)

Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank 3-17

Change oil in engine oil pan 3-17

Replace engine oil filter cartridge 3-17

Check, adjust engine valve clearance 3-17

Tighten (retorque) engine cylinder head bolts 3-17

Clean TORQFLOW transmission strainer 3-17

Change oil in differential case 3-17

Change oil in TORQFLOW transmission case 3-17

Tighten bolts and nuts (especially lug nuts, overhead guard, load backrest operator’s seat mounting bolts and nuts) 3-17

Check before operation items (for details, see “15.1 CHECK BEFORE OPERATION”) 3-17

Every 2 weeks or every 100 hours service

Grease lift chain 3-17

Every month or every 200 hours service

Check wheel rims for deformation, cracking and damage 3-17

Check wheel bearings for play and abnormal noise 3-17

Check hydraulic cylinders for looseness, deformation, cracking, damage and wear 3-17

Check all piping/tubing/connectors for oil leakage, deformation or damage 3-17

Check operation of hydraulic cylinders 3-18

Check hydraulic drift of lift cylinder 3-18

Check hydraulic drift of tilt cylinders 3-18

Check movement of work equipment control lever(s) 3-18

Check forks and fork stopper for deformation, cracking, damage and wear 3-18

Check forks for unevenness and twisting 3-18

Check mast for deformation, cracking, damage and wear 3-18

Check mast roller for play 3-18

Check chain and chain wheel for deformation, damage, rust and poor lubrication 3-18

Check chain wheel bearing for play 3-18

Check chain anchor bolt for deformation and damage 3-18

Check gear box for oil leakage, looseness of mount 3-18

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23. MAINTENANCE SCHEDULE CHART

Service Items (continued) Page

Every month or every 200 hours service (continued)

Check mounting condition of power steering, check for looseness at connections 3-18

Check brake link for play, looseness, damage and wear 3-18

Check brake piping/tubing for damage, leakage, looseness, contact, looseness of brake tubing clips and disconnec-
3-18
tion at fittings

Check clearance between brake drum and lining, check brake for grabbing, dragging or pulling 3-19

Check shift lever for play, meshing 3-19

Check for oil leakage from transmission and differential cases 3-19

Check oil level in TORQFLOW transmission, add oil as necessary (Do not overfill) 3-19

Check pedal height when inching pedal is depressed 3-19

Check starting of engine 3-19

Check idling speed (Gasoline and LPG) 3-19

Check, clean radiator fins, check for damage 3-19

Check for catching, stalling and knocking when accelerating 3-19

Check and clean air cleaner element 3-20

Check operation of governor (maximum speed) 3-20

Check piping/tubing and connections/fittings for fuel/gas leakage 3-20

Check fuel filter and fuel strainer for cracking, damage

3-20
Check and drain water separator (diesel engine lift trucks)

Check radiator hoses for cracking, damage 3-21

Check operating condition of radiator cap, check installation 3-21

Check fan for deformation, cracking, and damage 3-21

Check fan for looseness and mounting 3-21

Check, adjust fan belt tension 3-21

Check, adjust alternator belt tension 3-21

Check distributor cap (gasoline), distributor inside (IC ignition system) for cracking or damage 3-21

Check clearance of distributor points, check contact surface for roughness 3-21

Check spark plugs for burning, burning of insulator 3-21

Change oil in engine oil pan (Gasoline and LPG trucks with TB42 engines) 3-21

Replace engine oil filter (TB42) 3-21

Replace fuel filter (TB42) 3-22

Check spark plugs (TB42) 3-22

Change governor oil (TB42) 3-22

Change oil in engine oil pan (Diesel engine trucks with 6D102E engines) 3-23

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 23. MAINTENANCE SCHEDULE CHART
Service Items (continued) Page

Every month or every 200 hours service (continued)

Replace engine oil filter (6D102E) 3-23

Drain water from fuel filter (6D102E) 3-24

Replace fuel filter (6D102E) 3-24

Check operation of starting switch; check meshing of pinion gear 3-25

Check specific gravity of battery electrolyte 3-25

Check wiring connections for looseness 3-25

Check ignition timing 3-25

Check overhead guard, load backrest for deformation, cracking, damage and looseness 3-25

Check operator’s seat mount for looseness and damage; Check LPG cylinder mounting bracket 3-25

Grease all lubrication points 3-26

Every 3 months or every 600 hours service

Drain water from water separator and replace fuel filter cartridge (diesel engine lift trucks) 3-26

Replace oil filter cartridge 3-26

Grease fuel injection pump governor, change governor oil 3-26

Check oil level in transmission case, add oil as necessary 3-26

Check oil level in differential case, add oil as necessary 3-26

Every 6 months or every 1,200 hours service

Check steering link for bending, damage and wear 3-26

Check knuckle for play, deformation and damage 3-26

Check for marked variation in minimum turning radius 3-26

Change oil in differential case 3-27

Change oil in TORQFLOW transmission case 3-28

Replace torque converter oil filter 3-28

Change brake oil/fluid 3-28

Check, adjust valve clearance 3-28

Measure compression pressure 3-28

Check, adjust fuel injection timing, check and inspect fuel injection nozzles (diesel) 3-29

Check PCV blow-by gas reduction system for clogging, damage 3-29

Check distributor cap centerpiece for wear 3-29

Replace fuel filter element 3-29

Clean inside of cooling system; Clean radiator 3-29

Replace air cleaner element 3-30

Change oil in hydraulic tank, replace hydraulic line filter, clean hydraulic tank strainer, clean inside of hydraulic tank 3-31

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23. MAINTENANCE SCHEDULE CHART

Every 2,000 hours of service

Replace LPG mixer air valve diaphragm, under normal operating conditions. Replace more often in cold or severe
3-31
service applications. Replace O-ring for LPG tank valve.

Every 2,000 hours of service

Replace LPG mixer air valve diaphragm (normal operating conditions). Replace more often in cold or severe
3-31
service applications. Replace O-ring for LPG tank valve.

Every 12 months (year) or every 2,400 hours service

Check operation of brake master cylinder, check for oil leakage, damage and wear 3-31

Check operation of wheel cylinders, check for oil leakage, damage and wear 3-31

Check operation of brake drum, check for damage and wear 3-31

Check brake linings for wear 3-31

Check operating condition of brake shoe 3-31

Check brake adjustment lever and ratchet for wear and damage 3-31

Check brake spring for deterioration 3-31

Check brake back plate for deformation and cracking; Check mounting condition 3-32

Check air tightness of brake piping/tubing 3-32

Check axle for deformation, cracking and damage 3-32

Check mounting condition of differential 3-32

Check root (base) of forks for cracking (use color check) 3-32

Check roller shaft of loading equipment for cracking and damage 3-32

Check mast support for damage and wear 3-32

Check operation of relief valve; Check relief pressure 3-32

Replace air breather 3-32

Replace water separator (diesel); Clean inside of fuel tank (gasoline/LPG and diesel lift trucks) 3-32

Check fuel injection pressure, injection amount, injector condition 3-32

Tighten (retorque) engine cylinder head bolts 3-32

Check frame and cross member for cracking and damage 3-32

3-16