Model 5200 High-Level Orderpicker
Section 4. Scheduled Maintenance Every 180 Days or 500 Deadman Hours (HD)
Table 4-3.
Every 180 Days or 500 HD Hours
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first. Component
What to do
Refer to
Forks
Examine for excessive wear, bends, cracks, welding arcs, excessive heat, or unauthorized modifications. Replace if found. Check fork up tilt. It must be between level and 0.5 in. (12.7 mm) maximum. Check fork tip height. Verify they are within 0.25 in. (6.3 mm) of each other (31 in. [787 mm] and longer) or 0.125 in. (3.2 mm) of each other (under 31 in. [787 mm]) at the tips.
Page 7-119
Frame and Baseleg Checks
General visual inspection of structural members for cracks, including but not limited to baselegs, main frame, and tractor.
Hardware
Check bolt torque of major components (motors, pumps, brake, drive unit, and mast-to-tractor mounting bolts). If the fastener was previously marked with a paint pen when torqued, look at the markings to verify the fastener has not moved. If the fastener has moved or is in question, remove the fastener, clean the threads, and apply the appropriate thread-locking compound. Install the fastener and torque to the correct value, turning it in the tightening direction. Use a paint pen and mark the fastener for future inspection. If the fastener was not previously marked with a paint pen, determine the correct torque values. Set the torque wrench to 85% of the required torque value and check the torque of the fastener, turning it in the tightening direction. If the fastener does not move, use a paint pen and mark the fastener for future inspections. If the fastener moves, remove the fastener, clean the threads, and apply the appropriate thread-locking compound. Install the fastener and torque to the correct value. Use a paint pen and mark the fastener for future inspections. Replace any broken or missing hardware.
Page A-1
Horn
Check that the horn sounds correctly when activated. Check mounting bracket insulators.
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Hydraulic Hoses
Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace faulty hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks immediately. Inspect over-the-mast hoses for correct tension. Make sure over-the-mast pulleys spin freely and show no signs of wear.
Hydraulic Tank
Check fluid level.
Page 3-6
Lift Chains
Check adjustment. Inspect center cylinder chain anchors and springs. Inspect for excessive stretch or wear (tool P/N 939-10606).
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Lubrication
Lubricate all grease points on the drive unit and load wheels. Apply grease to the steer gear on the drive unit. Coat all lift chains with spray lubricant.
Page A-2
Mast
Wipe old grease off mast uprights and apply new grease. Inspect anti-rattle pads. Examine mast bearings. Inspect mast and carriage stops for tightness and wear. Inspect the outside of the main frame for wear. Inspect rails for abnormal wear, metal flakes, or shavings. Repair any grooves worn in the mast deeper than 1/8 in. (3 mm).
Page 7-108
Publication Number: 1043922B, Revised: 2 Sept 2015
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