Toyota Propane Forklift 250h Preventive Maintenance
Inspecting your forklifts like clockwork can extend their lifespans, helping you avoid costly repairs by catching any issues early.
Niagara Pallet & Recyclers Ltd
05/21/2025
Toyota Propane Forklift 250h Preventive Maintenance
Inspecting your forklifts like clockwork can extend their lifespans, helping you avoid costly repairs by catching any issues early.
Engine Propane Forklift 250h PM
This procedure outlines the weekly maintenance tasks for propane Toyota forklifts engine, focusing on key systems such as the main body, lubrication, fuel, cooling, LPG fuel and catalytic converter.
Main Body Inspection
Check proper starting and abnormal noise
Inspect rotating condition at idling
Inspect rotating condition during acceleration
Check exhaust gas condition
PCV System Inspection
Lubrication System
Check oil level
Check for oil leaks
Fuel System
Inspect for dirt and clogging of fuel filter and element
Check for fuel leaks
Inspect Operation of carburetor link mechanism
Cooling System
Inspect coolant level in radiator and for leaks
Inspect rubber hose degradation
Inspect radiator cap condition
Inspect fan belt tension, looseness, and damage
LPG Fuel System
Inspect for damage or gas leak on pipe and joint
Inspect LPG container installation section for looseness and damage
3-Way catalytic converter system
Carbon monoxide measurement
Hydrocarbon measurement
Power Transmission Propane Forklift 250h PM
This procedure outlines the steps for inspecting the power transmission system at 250 hours or 6 weeks, focusing on the clutch, manual transmission, differential and torque converter. Each section includes specific checks and measurements to ensure proper functioning and identify any potential issues.
Clutch Inspection
Measure clutch pedal play
Ensure the clutch pedal play is within the specified range.
Inspect for abnormal sound and functioning of the clutch connection
Inspect clutch master cylinder function and check for leaks
Inspect fluid level in clutch system
Manual Transmission Inspection
Inspect fluid level in manual transmission
Inspect gear function and check for abnormal noise
Inspect for leaks in manual transmission
Differential Inspection
Inspect oil level in differential
Check for leaks in differential
Torque Converter & Transmission Inspection
Inspect operating mechanism function and looseness
Inspect control valve and clutch functions
Inspect inching valve function
Inspect for leaks in torque converter & transmission
Check for loose joints in torque converter & transmission
Wheel Propane Forklift 250h PM
This procedure outlines the steps for inspecting and maintaining the wheels of forklifts every 250 hours. It includes checking tire pressure, inspecting for damage, ensuring nuts are tight, and cleaning tire grooves. Additionally, it covers checking wheel bearings and inspecting rims and disc wheels for damage.
Wheel Inspection
Check tire inflation pressure
Measure the tire pressure to ensure it is within the recommended range.
Inspect tire cuts, damage, and uneven wearing
Visually inspect the tires for any cuts, damage, or signs of uneven wear.
Inspect for loose rim and hub nuts
Ensure that all rim and hub nuts are properly tightened.
Inspect tire groove depth
Check the depth of the tire grooves to ensure they meet safety standards.
Remove metal chips, pebbles, and other foreign matter from tire grooves
Clean the tire grooves to remove any debris that may affect performance.
Inspect rim, side bearing, and disc wheel for damage
Check for any cracks, deformations, or other damage to the rim, side bearing, and disc wheel.
Check for abnormal sound and looseness of front wheel bearing
Listen for unusual noises and check for any looseness in the front wheel bearings.
Check for abnormal sound and looseness of rear wheel bearing
Listen for unusual noises and check for any looseness in the rear wheel bearings.
Steering Propane Forklift 250h PM
This procedure outlines the steps for inspecting the steering system of a propane forklift at the 250-hour mark, focusing on the steering wheel, steering valve, power steering, and knuckle.
Steering Wheel Inspection
Check for play and looseness in the steering wheel
Inspect the steering for proper function
Steering Valve Inspection
Check for oil leaks in the steering valve
Inspect looseness of mounting
Power Steering Inspection
Inspect power steering for oil leaks
Check for looseness of mounting and linkage looseness
Inspect power steering hose for damage
Knuckle Inspection
Check for king pin looseness
Inspect for cracks and deformation in the knuckle
Braking Propane Forklift 250h PM
This procedure outlines the steps for inspecting the braking system of a propane forklift, including the brake pedal, parking brake, brake pipe, reservoir tank, master cylinder and wheel cylinder, brake drum and brake shoe, and backing plate. Each component is checked for wear, damage, leaks, and proper function to ensure safe operation.
Brake Pedal Inspection
Check brake pedal play and reserve
Test brake pedal for proper braking effect
Parking Brake Inspection
Test parking brake for proper braking effect
Inspect linkage and cable for looseness and damage
Inspect operating force
Brake Pipe Inspection
Check brake pipe for leaks, damage, and proper mounting
Reservoir Tank Inspection
Check brake fluid level in reservoir tank
Inspect reservoir tank for leaks and damage
Master Cylinder and Wheel Cylinder Inspection
Inspect master and wheel cylinders for function, wear, damage, leaks and mounting looseness
Brake Drum and Brake Shoe Inspection
Check clearance between drum and lining
Material Handling Propane Forklift 250h PM
This procedure outlines the steps for inspecting the material handling system of a propane forklift at 250 hours, focusing on the forks, mast and lift bracket, chain and chain wheel, and various attachments.
Fork Inspection
Check for abnormality of fork and stopper pin
Inspect misalignment between left and right fork fingers
Examine cracks at fork root and welded part
Mast and Lift Bracket Inspection
Check for deformation and damage of each part and crack at welded part
Check mast and lift bracket for looseness
Inspect wear and damage of mast support bushing
Examine wear, damage and rotating condition of rollers
Check wear and damage of roller pins
Inspect wear and damage of mast trip
Chain and Chain Wheel Inspection
Check tension, deformation and damage of chain
Inspect chain lubrication
Elongation of chain
Check abnormality of chain anchor bolt
Inspect wear, damage and rotating condition of chain wheel
Various Attachments Inspection
Check abnormality and mounting condition of each part
Hydraulic Propane Forklift 250h PM
This procedure outlines the steps for inspecting the hydraulic system of a propane forklift at 250 hours, focusing on cylinders, oil pump and tank, control lever and valve, and hydraulic piping.
Cylinder Inspection
Check for loosening and damage of cylinder mounting
Inspect deformation and damage of rod, rod screw, and rod end
Verify cylinder operation
Check for natural drop and natural forward tilt (hydraulic drift)
Inspect for oil leak and damage
Check wear and damage of pin and pin support
Inspect lifting speed
Check for uneven movement
Oil Pump and Tank Inspection
Check oil pump for oil leak and abnormal sound
Check oil level and for contamination in hydraulic oil tank
Inspect oil leak
Control Lever and Valve Inspection
Check for loose linkage in control lever
Verify operation of control lever
Check relief valve and tilt lock valve functions
Inspect control valve for oil leaks
Hydraulic Piping Inspection
Inspect hydraulic piping for deformation and damage
Check for loose joints in hydraulic piping
Inspect for oil leaks
Electrical Propane Forklift 250h PM
This procedure outlines the steps for inspecting and maintaining the electrical system of a propane forklift at 250 hours. It includes checks on the distributor, ignition system, starting and charging system, battery, electrical wiring, fuses, preheater, and engine stopping system.
Ignition System Inspection
Check for cracks on distributor cap
Inspect spark plug for burning and gap
Inspect distributor side terminal for burning
Check distributor cap center piece for wear and damage
Starting Motor Inspection
Check pinion gear meshing status
Battery Inspection
Check battery fluid level
Electrical Wiring and Fuses Inspection
Inspect wiring harness for damage
Check fuses
Safety Devices Propane Forklift 250h PM
This procedure outlines the steps for inspecting safety devices on a propane forklift after 250 hours of operation. It includes checks for the head guard, back-rest, lighting system, horn, direction indicators, instruments, backup buzzer, rear-view mirror, seatbelt, seat switch, and OPS functions.
Safety Devices Inspection
Inspect head guard for cracks at welded portion
Check for any visible cracks at the welded portions of the head guard.
Inspect head guard for deformation and damage
Look for any signs of deformation or damage on the head guard.
Inspect back-rest for loosening of mounting
Ensure that the back-rest is securely mounted and not loose.
Inspect back-rest for deformation, crack, and damage
Check the back-rest for any deformation, cracks, or other damage.
Check lighting system function and mounting condition
Verify that all lights are functioning properly and are securely mounted.
Check horn function and mounting condition
Ensure the horn is operational and properly mounted.
Check direction indicator function and mounting condition
Test the direction indicators to ensure they are working and properly mounted.
Check instruments for proper function
Verify that all instruments are functioning correctly.
Check backup buzzer function and mounting condition
Ensure the backup buzzer is operational and securely mounted.
Inspect rear-view mirror for dirt and damage
Check the rear-view mirror for cleanliness and any signs of damage.
Inspect rear reflection status of rear-view mirror
Ensure the rear-view mirror provides a clear reflection.
Check seat for loosening and damage of mounting
Verify that the seat is securely mounted and not damaged.
Inspect seat for seatbelt damage and function
Check the seatbelt for any damage and ensure it functions properly.
Inspect seat switch function
Test the seat switch to ensure it is functioning correctly.
Check OPS functions
Verify that the Operator Presence System (OPS) is functioning as expected.
SAS inspection
Check for proper functions
Inspect for loosening and damage at sensor mounting
Inspect for damage, deformation, oil leakage and loosening of functional parts
Inspect for loosening and damage of wire harnesses
Greasing
Source: Niagara Pallet & Recyclers Ltd (Community Member)