Hyster H360HD2 Forklift - 250 Hours Maintenance, Technician

Check that all safety labels are installed at the correct locations on the lift truck and can be read.

• Pass
• Flag
• Fail

Label Replacement

• Remove the old label

• Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of the old paint with a cleaning solvent.

• Partially remove the paper from the back of the label. Do not touch the adhesive surface.

• Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface and remove the rest of the paper at the back. Make sure that all air is removed from under the label and the corners and edges are tight.

All retaining hardware for carriage, mast pivots end tilt cylinder rod ends are tightened and in good condition.

• Pass
• Flag
• Fail

Check welds for cracks immediately if any unusual noise is heard during lifting or maneuvering of a load. An immediate check must be made also after any collision of the truck, load or attachment.

• Pass
• Flag
• Fail

Procedure

• Slowly raise and lower the mast several times without a load. Raise the mast to its full extension height at least once. The mast components must raise and lower smoothly in the correct sequence.

• Check proper tracking of header hoses.

• Check for excessive play of rollers and bearing blocks.

• The inner weldment and the carriage must lower completely.

• Check for leaks of hydraulic components.

• Raise the mast 1 m (3 ft) with a capacity load. The inner weldment and the carriage must raise smoothly. Lower the mast. All moving components must lower smoothly.

• Lower the load to approximately 0.3 m (1 ft) from the floor. Tilt the mast forward and backward. The mast must tilt smoothly and all tilt cylinders must stop evenly.

• Check that the controls for the attachment operate the functions of the attachment correctly as described in the Operating Manual. See the symbols by each of the controls.

• Perform Leak Checks for lift cylinders and tilt cylinders if excessive creep is suspected.

MAST PIVOT PINS - Lubrication After 250 Hours

• Lubricate 2 fittings under no load condition. Use multipurpose grease with MoS2 additive. For details, see Approved Oils, Fluids, and Grease.

• For proper lubrication, the mast should be lifted.

• Place blocks under the mast and tilt the mast forward until the drive tires start lifting off of the ground.

• The carriage and the mast must stay in the lowered position during this procedure. See Approved Oils, Fluids, and Grease.

Mast, Carriage, and Attachment functions are all acceptable

• Pass
• Flag
• Fail

Describe any problems found

Lubrication - Carriage Load Roller

• Add grease through the grease nipple until grease escapes from the sides of the load roller. See Approved Oils, Fluids, and Grease and Figure 48.

Lubrication - Inner Mast Load Rollers

• Raise the inner mast until the holes in the sides of the outer mast provide access to the lube fittings of the rollers. Add grease through the grease fitting until grease escapes from the sides of the load roller. See Approved Oils, Fluids, and Grease and Figure 48.

Forks Inspection and Maintenance

Make sure the bottom of the fork is at least 90% of the original thickness. If either fork is worn, replace the forks as a set.

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

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

• Check for absence of cracks at fork pin connection.

• Check for absence of cracks at fork heel.

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

Forks pass the above checks

• Pass
• Flag
• Fail

Lubrication - Fork Pins, Carriage Pins, Carriage Sliding Surfaces

• Replace any fork pin, or any side shift apron pin, if found bent or damaged. See 2-Stage Mast 4000SRM1647.

• Lubricate the fork pin area with grease where the forks and fork guides travel.

• For side shift carriages, lubricate the fitting on the apron brackets.

• Reposition forks and carriage to make sure the entire area of travel is lubricated. See Approved Oils, Fluids, and Grease

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.

Lift chains are #2 in the diagram.

• Yes
• No
• N / A

Oil film on the lift chains is acceptable

Call a mechanic to have the lift chains inspected and re-lubricated if a problem is found.

• Pass
• Flag
• Fail

When the oil film is still intact, check absence of following conditions:

• Broken, damaged or missing chain link plates

• Damaged, turned or protruding link pins

• Replace both lift chains if either of these two problems is observed

• Check the chain anchors and chain pins for cracks and damage. Replace if cracked or damaged.

The three above problems were not observed

• Pass
• Flag
• Fail

Lubricate both lift chains:

• Lubricate every 250 Hours, but at least every 3 Months. Make sure chains are slack during re-lubrication. Use engine oil SAE 15W-40.

• Allow sufficient time for the oil to penetrate before the chains are put under tension again.

• Slacken the chains. This may require setting the forks or attachment on a support such as a wooden block or container.

• Clean the chains as necessary to allow penetration of oil into the chain links. Remove debris, grease and thick oil.

• Make sure that any trapped water or condensation is removed.

• Apply engine oil onto the chains. Do not use grease.

• Wipe excess oil.

Lubrication application is acceptable

• Pass
• Flag
• Fail

Hoses are not aged, kinked, crushed, or twisted

• Pass
• Flag
• Fail

Hose covers do not have cuts, cracks, or exposed reinforcement

• Pass
• Flag
• Fail

Check proper hose tension

• Pass
• Flag
• Fail

Check hoses and fittings for hydraulic leaks

• Pass
• Flag
• Fail

Check the clamps and sheaves for defective or broken parts

• Pass
• Flag
• Fail

Check for proper tracking during operation and lifting

• Pass
• Flag
• Fail

Precautions

• Follow the procedures described in the section: Remove Wheels from Lift Truck and the section: Adding Air Pressure to the Tires.

• Adjusting tire pressure is allowed only if residual air pressure exceeds 80% of the pressure as indicated on the nameplate.

• If the tire is removed from the truck and flat on the ground, the technician should not have any body part within the diameter of the tire when adjusting the tire pressure. See Figure 59.

• Wheels can explode and cause injury or death if the above procedures are not followed.

• Air pressure in pneumatic tires can cause tire and wheel parts to explode. The explosion of wheel parts can cause serious injury or death. Remove all of the air from the tires before the tires are removed from the lift truck.

Steps

• Keep the tires at the correct air pressure as specified on the lift truck name plate. Using a tire pressure gauge, check the tire pressure when the tires are at ambient temperature.

• If it is necessary to add air to a tire that is warm, check one of the other tires on the same axle and add air to the tire that has lowest pressure so that the air pressures are equal. The air pressure of warm tires must always be equal to or greater than the specification for air pressure for cold tires.

• Check the tires for damage. See Figure 60. Inspect the tread and remove any objects that will cause damage. Remove any wire, straps, or other material wrapped around the axle.

• Sand down or smooth over torn chunks of tire to reduce later damage.

• Check for loose or missing hardware.

• Check for bent or damaged rims. Inspect wheel components for deformation, corrosion and fractures.

Check if the yellow indicator on the hydraulic oil breather cap is raised.

If the indicator is fully raised or almost fully raised, replace the filter element in the hydraulic oil breather.

• Pass
• Flag
• Fail

Does the filter element need replacing at this time?

• Yes
• No
• N / A

Steps

• Remove the hydraulic oil breather cap and clean the inside of the breather cap.

• Insert a new filter element and replace the hydraulic oil breather cap.

• Push the yellow indicator down.

Intake piping conditions

• Pass
• Flag
• Fail

Coolant hose conditions

• Pass
• Flag
• Fail

Did you replace damaged or questionable hoses at this time?

• Yes
• No
• N / A

Procedure

• Check that the key is in the OFF position and the engine is stopped.

• Check the drive belt for wear and damage.

• Small cracks that run across the belt are acceptable. A drive belt with cracks that run the length of the belt or missing pieces are not acceptable. See Figure 10.

• Check proper belt tension. It should feel snug.

Fan Belt condition is acceptable

• Pass
• Flag
• Fail

Radiator assembly condition is acceptable

• Pass
• Flag
• Fail

Visual Checks

• Clean surfaces as you are working to help locate future leaks.

• Start checking the underside of reservoirs, filters, radiators, hydraulic valves and radiators.

• All hoses and hose connections should be dry on the outside.

• Check the condition of radiator and heater hoses. Soft or cracked hoses need to be replaced before a leak occurs.

• Be aware of internal leaks. Although no outside leakage is visible, it is possible that fluids from one system (coolant, brake oil) leak into a different system (engine sump, planetary gear). Always make a note of the volumes being topped up.

Include the specifics of any fuel, oil, DEF, or coolant fluid topped off during this process

Operating Hours

Meter name

Drain the water from the fuel/water separator

Drain water from the separator regularly, and any time that the warning light is ON in the instrument panel during operation.

• Open the drain valve by turning the valve counter clockwise until draining occurs.

• Drain water into a cup until clean fuel flows from the valve.

• Close the valve.

Steps

• Open the hood and check for leaks and abnormal conditions.

• Clean any oil or fuel spills. This will help identify leaks or problems in the future.

• Make sure all surfaces are free of oil, lubricants, fuel, and organic dust or fibers (paper, wood, cotton, wool, etc.).

• Remove all foreign materials.

Engine compartment condition is acceptable

• Pass
• Flag
• Fail

DEF Tank Cap condition is acceptable

• Pass
• Flag
• Fail

Oil level is within the:

• Green area

• Yellow area

• Red area

Approximate amount of hydraulic oil added, if any

Operating Hours

Meter name

Do not operate the lift truck until the problem is corrected.

Procedure

• Check transmission oil level with the engine running at idle and the park brake applied.

• For the location of the dipstick and fill tube, see Figure 53. Keep oil level at the "FULL" mark on the dipstick.

• Add transmission oil as required. See Approved Oils, Fluids, and Grease.

• Check for leaks if oil must be added and record added volume and hour meter reading.

Transmission Oil level is acceptable

• Yes
• No
• N / A

Coolant level is acceptable

• Pass
• Flag
• Fail

Was more coolant added?

• Yes
• No
• N / A

Approximate amount of oil added, if any

Operating Hours

Meter name

Steps

• Remove magnetic oil plugs in differential and planetary drives to check oil level and verify size of wear particles.

• If particles are large shiny chips, check for damages on bearings and gears before continuing operation.

• If particles are coarse, check wheel bearing pre-tension.

• The situation is normal if a fine powder has been collected.

Gear oil level in differential and planetary gears must be checked separately

• The gear oil level in the differential is correct when the gear oil is even with the plug at the front of the housing.

• The gear oil level in the planetary gears is correct when the "level line" on the planetary cover is parallel to the floor and oil is even with the plug.

• Add clean gear oil as required. See Approved Oils, Fluids, and Grease. Check for leaks if oil must be added. Record added volume and hour meter reading.

Approximate amount of oil added, if any

Operating Hours, if oil was added

Meter name

Reservoir is filled to an acceptable level

• Pass
• Flag
• Fail

Steps

• Make sure the seat belt is in good condition and the end of the seat belt fastens correctly in the latch.

• Make sure the seat belt pulls and retracts from the retractor assembly smoothly.

• Pull the seat belt with a sudden jerk to verify that the retractor assembly will lock the seat belt.

• Replace the seat belt assembly when it is worn or damaged, or when the retractor does not function correctly. See Figure 49.

• Make sure the seat rails lock securely in position, but move freely when unlocked.

• Make sure the seat rails attach securely to the seat suspension.

• The seat suspension must be securely bolted to the cab floor. Repair as required.

• Make sure the latch for the steering column operates correctly. The latch must NOT allow the column to move unless the latch is released. Repair as required.

Procedure

• Verify that all warning lights and indicator lights will light up.

• After two seconds all warning lights will be OFF, except for the Wait to Start Light, Central Warning Lights, Brake System Low Pressure Warning Light, and the Parking Brake Warning Light.

• Start the engine after the Wait to Start Light is OFF.

Procedure

• With the engine running at idle, check the gauges and indicator lights for correct operation.

• Have any failed light gauge, horn or alarm repaired immediately.

• Check for presence of fault codes on the display and rectify as required.

Horn, lights, gauges, alarms, and controls are working acceptably

• Pass
• Flag
• Fail

Were any fault codes seen during the inspection process?

• Pass
• Flag
• Fail

Check that the control levers for the transmission, mast, attachment, and the pedals operate as described in the Operating Manual.

• Pass
• Flag
• Fail

Describe any problems found

Procedure

• Check the operation of the parking brake.

• The parking brake must apply when the knob for the parking brake is pulled, and must release when the knob is pushed.

• The park brake must be able to hold the truck with a capacity load on a 15% grade (a slope that raises 1.5 m every 10 m (1.5 ft every 10 ft)). Repair the parking brake if it fails these requirements.

• Check the operation of the service brakes.

• The service brake must apply when pushing the brake pedal and/or the inching pedal.

• The service brake must be able to hold the truck with a capacity load on a 20% grade when applying 108 N•m (24.28 lbf ft) to the brake pedal. A 20% grade is a slope that raises 1 m every 5 m (1 ft every 5 ft).

• Repair the service brake if it fails these requirements.

The parking brake and service brake are functioning acceptably

• Pass
• Flag
• Fail

Describe any problems found

Steering system is working acceptably

• Pass
• Flag
• Fail

Check correct operation of the Operator Presence System.

• Run the engine and verify normal operation of transmission and hydraulic functions.

• Raise yourself from the seat for more than 2.5 sec.

• Verify that hydraulic lift, lower and tilt functions do not operate as long as you are raised from the seat.

• Verify that the transmission has been disengaged.

• Verify that hydraulic lift, lower and tilt functions operate again after you have re-seated.

• Verify that the transmission can be re-engaged.

To re-engage the transmission the operator must either:

• Depress the inching brake pedal more than 75%.

• Move the gear selector into the NEUTRAL position and then move the gear selector into travel mode.

• Make a direction change using the MONOTROL® pedal.

The spreader and TWIST module are working acceptably

• Pass
• Flag
• Fail

Inspect and lubricate the two Twist Locks

• Inspect every 250 hours 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. See Figure 54.

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

Twist Locks are in acceptable condition

• Pass
• Flag
• Fail

Twist Locks have received new lubrication

• Pass
• Flag
• Fail