Section 7. Component Procedures
Model 5200 High-Level Orderpicker
Mast Disassembly and Shimming
Mast Section
4. Use spare shim(s) as a gauge to determine the amount required to move the bearings outward to make contact with the inner telescopic. 5. Move the carriage to the top of the inner telescopic and repeat the process for the top set of bearings. 6. Remove the carriage from the inner telescopic.
16. Install the pulleys for the over-the-mast hoses and cables. 17. Secure the main carriage and telescopics in place so that they do not move while standing the assembly back up. 18. Install all the other items removed during the disassembly process after laying the assembly down.
7. Install half of the total shim thickness required to each roller boss. 8. Reinstall the roller bearings. 9. Use a suitable lifting device and reinstall the carriage into the inner telescopic. Check for tightness while moving the carriage to the bottom of the inner telescopic. 10. Use a pry bar to check for bearing tightness. If a thin shim can be inserted between the bearing and the inner telescopic, remove the carriage and install the shim between the bearing and the roller boss. Do not apply excessive pressure to the bearings with the pry bar. 11. Use a suitable lifting device and reinstall the carriage, checking for tightness. Make sure the carriage can be moved in and out by hand. 12. When the correct fit is obtained, measure the gap between the top of the platform and the inner telescopic on both sides. If the gap between the platform and the inner telescopic is not within 1/16 in. (1.59 mm) of each other, remove the platform.
Mast assembly may swing free when lifting. Use extreme caution. 19. Attach the hoist to the mast assembly and stand the mast back up. Install all the other items removed during the disassembly process prior to laying the assembly down. 20. Attach the tractor to the mast. 21. Install the remaining components. 22. Connect the hoses and cables inside the tractor compartment. Set spring tension so the cables just stay on the pulleys. Higher tension causes premature failure. Maximum spring tension is 5 to 7 in. lb. (0.57 to 0.79 Nm).
Make sure all mast stops are installed and securely tightened before operating the lift truck. 23. Reinstall the battery.
13. Take shims from the top roller on the side that is farthest away and install them on the opposite side. Repeat this procedure until 1/16 in. (1.59 mm) is obtained. If all shims are on one side of the top rollers, remove shims from the bottom roller on the side that is farthest away and install them on the opposite side.
24. Reconnect the battery connector and turn the key switch ON.
14. Repeat this procedure until the required clearance at the top of the platform is obtained.
27. Adjust the free lift chains so the top of the fork just in front of the platform is at a minimum of 2.75 in. (70 mm) from the floor and the tips are at a maximum of 3.5 in. (89 mm) from the floor.
15. Install the carriage and the carriage stops.
25. Adjust the lift chains. 26. Adjust the main lift chain so the top of the inner telescopic is even with the outer telescopic +/- 0.125 in. (3.2 mm) And both chains have equal tension.
28. Install the forks and mast guard.
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Publication Number: 1043922A, Revised: 2 Sept 2015
