Hyster Forklift H250HD

Tag and remove hydraulic lines from twist lock motor and disconnect wiring from splitter box

Remove four bolts holding plate in place

Slide out twist lock assembly by pulling on hydraulic motor end

Place twist lock assembly on flat area

Remove four socket head bolts and slide out hydraulic motor

Remove four socket head screws attached to collet and ring

Retract attachment to 20-ft position and shut down engine

Disconnect hydraulic lines at chain end and disconnect electrical plugs at chain end

Remove bracket holding chain and hose clamp closest to chain

Start engine and extend extension beam approximately 1200 mm allowing removal of pin at rod end of extension cylinder

Remove snap ring and pin from rod end of extension cylinder

Retract attachment to 20-ft position and shut down engine

Using a crane or lift truck, pull extension beam out approximately 1200 mm. Carefully guide hose/cable chain into center frame

Remove two bolts holding interface box and reposition box to prevent damage

NOTE: Hydraulic hoses and electrical cable are inside bent tube with a limited diameter. This does not allow individual replacement of hoses or electrical cable.

Disconnect hydraulic hoses and electrical cable at lower side of beam.

Connect a string to one of the hoses and pull out hoses from higher end.

Replace any defective hoses or cables and tape hoses, cable, and string together.

NOTE: Tape hoses and cables in such a way that each hose coupling is at a different position and can move separately in order to follow bend in tube. Make sure each hose is marked.

Pull attached string and guide upper end of taped hose bundle into tube.

Connect hoses at correct connections.

Sign off on the hose replacement

The lifting hooks are safety critical components due to the fact that it is the hook that carries all the load when picking up and carrying a container. Hooks are a wearing part and should be inspected for wear and or damage on a regular basis.

1. Check hook for cracks. Replace hook if damaged.

2. Check inside angle of hook. New hooks have 22 mm (0.87 in.) of material between flat portion of hook and top of hook. The hook should be replaced if worn area leaves less than 15 mm (0.59 in.) from start of wear area to flat portion of hook. See Figure 9 and Figure 10.

3. Check wear area of hook where corner casting of container is carried. This area should be inspected and when wear is more than 5% of original thickness, hook should be replaced. See Figure 9 and Figure 10.

4. Check tightness between nuts and threads of hook. Hook should be replaced if threads of hook become worn. See Figure 9.

5. The pin that hook is secured through can wear and should be replaced if excess play is discovered.

Inspect main attachment components for damage, cracks, and distortion

Inspect signal and control systems for correct operation

Check hydraulic pressures periodically

Check all hydraulic cylinders for leaks and reseal if necessary

Inspect all hydraulic hoses for damage and leakage. Replace any damaged or leaking hoses

Sign off on the forklift maintenance