Toyota Forklift 2FBCA25

Inspect the power cylinder for damage or wear in the sliding surfaces.

Measure the wear and out-of-round at place about 200 mm from the cylinder edge.

Inspect the piston rod for bending and damage.

Rod bending limit: 1 mm (0.004)

Inspect the piston and piston rings for wear and damage.

Inspect the 'V' packing and dust seal for wear and damage.

Warm up the hydraulic system until the hydraulic oil temperature rises to around 50° to 70°C.

Place on the standard load, properly secure it and perform the test in a spacious place to ensure safety.

Remove the toe board and fix the oil control valve low pressure hose so that it can be quickly disconnected (from tank port).

Lift Cylinder Port (Leakage Measurement):

Place on standard load, raise the forks about 50 cm and tilt the mast carefully to maximum forward position.

Disconnect low pressure hose from tank port.

After 5 minutes, measure the oil leakage for one minute.

Oil leakage limit: Maximum: 16 cc (0.004 USgal)

Warning: This procedure requires technical skills and should be performed by trained personnel only.

Measure the electrolyte specific gravity

Note: Specific gravity when fully charged: 1.280 (20°C), at end of discharge: 1.150 (20°C)

Instructions for using the hydrometer

Is the electrolyte turbid or contains impurity?

If defective, take proper measures in accordance with procedures in Trouble Shooting.

If low, add refined water (pure water) up to the prescribed level.

If the reduction of electrolyte was not caused by just the loss of water resulting from charging and evaporation but from other reasons (such as spillage during transportation), measure the specific gravity and add sulfuric acid diluted with refined water to the same specific gravity.

Important: Inspect each part and repair or replace as required.

(1) Check rust, wear or damage of the wheel cylinder insides and piston.

Cylinder & Piston Clearance: 0.025 ~ 0.126 mm (0.001" ~ 0.005")

(2) Wear, damage or deformation of piston cups

Caution: Replace cups with new one's when overhauling.

(3) Damaged or worn-out cylinder boots

(4) Damage or deformation of connecting rod

1. Outer mast to inner mast roller clearance inspection.

- Measure the clearance at about 450 mm mast overlap.

- When the roller is shifted over to one side until it contacts the outer mast, the side surface of the roller at the opposite side at the nearest point to the mast should be within 0 ~ 0.8 mm (0.032").

2. Outer mast roller to inner mast clearance inspection.

3. Lift bracket center and lower roller to inner mast clearance inspection.

- Measure the clearance with the lift bracket at highest raised position.

- When the rollers are shifted over to one side until they contact the inner mast, the side surfaces of the rollers at the opposite side at nearest point to the mast should be within 0 ~ 0.8 mm (0.032").