Section 4. Scheduled Maintenance Model 8210/8250 Maintenance Manual
Every 180 Days or 500 Deadman Hours (HD)
4-4 Publication: 1146945/001, Revised: 25 Sep 2018
Every 180 Days or 500 Deadman Hours (HD)
For Severe or Extreme operating condition
service intervals, see Table 4-1 on page 4-2 .
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.
Component Task
Battery Check the weight labeled on the battery in the pallet truck against the minimum and
maximum allowable weights on the spec tag for the pallet truck. Report any pallet
trucks that are running with batteries below the minimum or over the maximum
allowable weight. Inspect all battery connectors and leads for damage and cuts in
protective coatings. Make sure the battery has no more than 0.5 inch (13 mm) free
play in any direction.
Brakes Traveling in an open area at walking speed or less, the empty lift truck should stop in
2 to 4 ft. (0.6 to 1.2 m), Test the brake in both the upper and lower brake positions.
Traveling with a rated load and at top speed, the pallet truck should stop within
approximately six feet. Stopping distance depends on the load, floor, and tire
condition.
Examine for signs of oil on the friction disc and mating surfaces. If oil is present,
disassemble the brake and replace the friction disc. Clean the mating surfaces.
Measure for correct gap between the coil housing and pressure plate. When applied,
the gap should be between 0.001 to 0.013 in. (0.03 to 0.33 mm).Replace the friction
disc when the air gap is greater than 0.0157 in. (0.40 mm). See “Air Gap Inspection”
on page 7-36.
Make sure the rubber boot is correctly seated.
Control Handle
Assembly
Make sure steering function is smooth and responsive, without binding or excess
play. Verify lift/lower function is smooth and controllable. Verify travel function is
smooth and responsive through full range of acceleration and plugging. Verify no
codes on display. Verify function of all switches. Verify tiller arm returns to neutral
when released.
Arm Angle Switch Check the adjustment. See “Arm Angle Proximity Switch Adjustment” on page 7-81.
Drive Unit Inspect for leaks. Check fluid level. Check drive unit axle for play. See “Drive Unit
Housing Lubrication” on page 7-33.
Electrical Cables Inspect all cables for nicks or cuts (including battery pack and charger cables). Give
special attention to those cables that are not stationary, for example, cables to the
traction motor. Replace any cable that is damaged or shows signs of excessive heat.
Failure to do so may cause intermittent system shutdowns and/or electronic failures.
Forks, Pull Rod,
and Lift Linkage
Check for wear on the pull rod. Check all lift linkage bushings for wear. When
replacing bushings, inspect the pins for wear. Replace the pins if any wear is evident.
Check for wear at the lower link or fork heel. Replace any broken or missing roll pins.
Adjust downstops as necessary. See “Downstop Adjustment” on page 7-116.
Check upper link bolts for rotation.
Frame and Tractor
Checks
General visual inspection of structural members for cracks, including but not limited
to the tractor and forks.
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