Hyster Forklift H48HD2

!WARNING: DO NOT try to correct the alignment of the fork tips by bending the forks or adding shims. Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. If either fork is damaged, replace the forks as a set.

!NOTE: Also perform below checks immediately after any collision of the truck, load or attachment.

- Replace the forks as a set if any of the below requirements is not met.

1. Check that the fork angle is less than 93°.

2. Check that the fork tips are aligned within 3% of fork length.

3. Check for absence of cracks at fork pin connection.

4. Check for absence of cracks at fork heel. See Figure 37.

- Replace any damaged or broken part that is used to keep forks locked in position.

Inspect the wear pads for wear. See Figure 36.

Replace the wear pads if thickness is 18 mm (0.709 in.) or less. When replacing wear pads, simultaneously replace all pads that are fitted in the same plane. (All lower pads, all upper pads or all side pads). Using wear pads with a different thickness will twist and damage the extension beam weldment.

Check torqueing of the hardware that retain the wear pad brackets. The required torque is 63 N•m (46 lbf ft).

Grease the tracks for the wear pads.

Sign off on the wear pads maintenance

Inspect all rubber mounts for ageing and damage. Look for traces, which indicate excessive relative movement between the frame supports and the engine and transmission brackets.

Check that mounting bolts are torqued to 165 N•m (122 lbf ft).

Sign off on the engine and transmission mounts maintenance

!WARNING: Lower the lift mechanism completely. Never allow anyone under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED.

Before making any repairs, use chains to secure the mast weldments and carriage into position so that they cannot move. Make sure the moving parts are attached to a part that does not move.

DO NOT repair a worn lift chain. Replace both lift chains when one or both lift chains are worn.

!WARNING: Adjustment or repair of the lift chains must be done by authorized personnel.

First 100 Hour inspection and Every 250 Hours

Chains cleaned for oil penetration?

Trapped water or condensation removed?

Engine oil applied onto the chains?

Inspect and lubricate the two twist Locks

Inspect the twist locks for wear and damage

Replace the twist lock if the top area has worn 6 mm (0.24 in.) or more, and if the remaining thickness of the twist lock head is 25 mm (1.00 in.) or less

Upload a photo of the twist lock for reference

Each twist lock has two grease fittings. Lubricate the grease fittings and sleeves using EP2/3 grease

Sign off on the twist locks maintenance