Model 5200 High-Level Orderpicker

Static Precautions

Electronic circuit boards can contain Electrostatic Discharge Sensitive (ESDS) devices.

Static charges can accumulate from normal operation of the lift truck as well as movement or contact between non-conductive materials (plastic bags, synthetic clothing, synthetic soles on shoes, Styrofoam coffee cups, and so forth.)

Accumulated static electricity can be discharged to a circuit board or component by touching the parts. Electrostatic Discharge (ESD) is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur withou t seeing or feeling it.

Whenever working on or near ESDS devices, follow these precautions.

•Wear an ESD wrist strap. The wrist strap should be equipped with a 1 megohm resistor to dissipate static charges slowly.

•Connect the wrist strap plug to the ground jack on the lift truck. See Figure2-1. If you cannot use the ground jack, connect the ground clip to an unpainted, grounded surface on the lift truck frame.

Section 2.Safety

Static Precautions

•If you are removing or installing static-sensitive components, place them on a correctly grounded anti-static mat.

•To transport static sensitive components, including failed components being returned, place the components in an anti-static bag or box (available from your local authorized Raymond Sales and Service Center).

Test the wrist strap and related accessories before each use to make sure they are working correctly.

Figure2-2 shows the components of the Raymond anti-static field service kit, P/N1-187-059. The kit includes a wrist strap, ground cord, and static-dissipative work surface (mat). Fo llow the instructions packaged with the kit.

Wrist straps (P/N1-187-058/001) are available in quantities of 25.

A wrist strap tester (P/N1-187-060/100) is also available.

Contact your local Raymond Sales and Service Center for information.

•Handle circuit boards by the edges only. Avoid touching the edge connectors.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 2.Safety

Jacking Safety

Jacking Safety

Jacking Lift Truck

Some maintenance procedures require the lift truck to be jacked up. To safely jack the truck:

1.Lower the forks completely. Remove any load.

2.Place all controls in neutral.

3.Block the wheels to prevent movement of the vehicle.

4.Turn the key switch OFF and disconnect the battery connector.

5.Place the jack under the designated jacking points. See Figures 2-3 and 2-4 .

6.Always use solid blocks to support the vehicle. Never rely on jacks or chains to hold the vehicle.

Model 5200 High-Level Orderpicker

Use extreme care when the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Attach a chain to the top of the mast and an overhead hoist to stabilize the mast if jacking more than described in this procedure. Keep hands and feet clear while jacking the lift truck. After the lift truck is jacked, place solid blocks or jack stands beneath it to support it. Do not rely on the jack alone to support the lift truck.

Operator Platform

When it is necessary to perform a procedure with the operator platform elevated, place a safety stand between the carriage and baseleg as follows.

1.Use the lift knob and raise the operator platform until you have enough clearance to perform the procedure.

2.Place a safety stand or block between the carriage and a baseleg and carefully lower the operator platform onto the safety stand. See Figure2-5

3.Turn the key switch OFF and disconnect the battery connector.

Publication Number: 1043922B, Revised: 2 Sept 2015

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 2.Safety

Emergency Lower Valve

Emergency Lower Valve

In the event that it is necessary to lower the carriage from the ground, do the following:

1.Remove the tractor cover. The Emergency Lower Valve is located on the lift/lower manifold. See Figure2-6

2.Depress the red button on the top of the valve and rotate it 1/4 turn counterclockwise or until the button pops up, allowing the operator platform to lower by its own weight.

NOTE: With S/W versions below 1.9 the key switch must be off and the battery unplugged. With S/W version 1.9 and above, the key switch can be ON or OFF.

NOTE: Leaving the valve open prevents the operator platform from elevating.

3.To close, depress the button and turn clockwise until it clicks in place. This allows the operator platform to elevate when the main lift control is operated.

Model 5200 High-Level Orderpicker

Publication Number: 1043922B, Revised: 2 Sept 2015

Tie-Down for Transport

Vertical Transport

To transport this lift tr uck in an over-the-road vehicle or rail car, follow these steps:

1.Lower the operator platform and locate the lift truck in the center of the transport vehicle.

2.Turn the key switch OFF and disconnect the battery connector.

NOTE: If guide rollers are present, place straps through the guide rollers and secure to the floor; skip to step 4.

3.If guide rollers (used for rail guidance) are not present: a.Install eye-bolts (3/4 in. [19 mm] thread size) in the holes in the bumper. See Figure2-7. b.Secure the chain from the eye-bolts to the vehicle bed. See Figure2-8.

4.Strap the lift truck from the bumper or guide roller to the floor of the transport vehicle.

5.Chock the drive wheel to prevent tractor-first movement.

6.Place a block between the baselegs and platform, 7.5 in. (190.5 mm) from the front edge of the platform.

7.Position an additional adjustable chain or strap perpendicular to the forks over the operator platform and attach it to the vehicle bed. This prevents tip-over during transport. See Figure2-8.

Horizontal Transport

1.Remove the forks from the carriage.

2.Replace the cap and screen in the hydraulic reservoir with shipping cap and screws.

3.Band down the carriage and battery rollers.

4.Remove the dipstick, and plug the drive unit.

5.Remove the bottom two bumper plate bolts (to be reinstalled after shipping).

6.Use two hoists in conjunction and lay the lift truck on the cradle.

7.Install long bolts through the holes in the bumper and secure to the cradle.

8.Band the lift truck to the cradle.

9.Secure the forks to the cradle below the mast.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 2.Safety

Towing

To tow this lift truck, follow these steps:

1.Lower the operator platform and remove any load.

2.Turn the key switch OFF and disconnect the battery connector.

3.Using a suitable towing vehicle, lift the tractor end of the lift truck until the drive tire is no more that 1 in. (25.4 mm) off the floor.

4.Tow the lift truck slowly in the tractor-first direction.

NOTE: If you must tow the lift truck flat on the ground, you must install the brake release bolts provided. See Figure2-9 and Figure2-10 .

Steering is disabled while you are towing, so you need to manually turn the drive unit to steer.

Model 5200 High-Level Orderpicker

Publication Number: 1043922B, Revised: 2 Sept 2015