UL Label “EE”

Underwriters Laboratories (UL) ratings indicate that specific criteria are met by the manufacturer, and tested and documented by UL. “EE” designated lift trucks are electrically powered units that have, in addition to all of the requirements for “E” and “ES” units, electric components completely enclosed. In certain applications, an “EE” lift truck may be used where an “E” or “ES” lift truck may not be considered suitable.

Model 5200 High-Level Orderpicker

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 4.Scheduled Maintenance

Maintenance Guidelines

Maintenance Guidelines

Following a regularly scheduled maintenance program:

•promotes maximum truck performance

•prolongs truck life

•reduces costly down time

•avoids unnecessary repairs

Scheduled maintenance includes:

•Lubrication

•Cleaning

•Inspection

•Service

Perform all of the scheduled checks and maintenance during the suggested intervals. The time intervals given in this guide are based on Deadman Hours (HD) under normal operating conditions.

Table 4-1.Suggested Maintenance Intervals

Operating Conditions

Light to Moderate

Severe

Model 5200 High-Level Orderpicker

When operating under Severe or Extreme conditions, perform these services more often as indicated in the chart below.

Extreme

Working Environment

An eight hour shift of basic material handling180 days or 500 hours, whichever comes first

•Extended heavy duty operation

•Freezer operation

•Sudden temperature changes such as going from freezer to room temperature.

•All UL Type EE rated lift trucks

•Dusty or sandy conditions such as in cement plants, lumber or flour mills, coal dust, or stone-crushing areas

•High temperature areas such as in steel mills, foundries, enclosed (TypeEE) applications

•Corrosive atmosphere such as chlorine or salt-sea air environments

60 days or 250 hours, whichever comes first

30 days or 100 hours, whichever comes first

Publication Number: 1043922B, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

Initial 90 Day/250

Deadman Hours (HD) Maintenance

Table 4-2.Initial 90 Day/250 HD Maintenance

Section 4.Scheduled Maintenance

Initial 90 Day/250 Deadman Hours (HD) Maintenance

Perform the following maintenance tasks 90 days after the lift truck was put into service or at 250HD, whichever comes first.

Component

What to do

Drive UnitBreak mounting bolts free and reapply thread-locking compound (P/N1013829). Re-torque mounting bolts to 120 ft. lb. (163 Nm). Change fluid.

Hydraulic TankChange hydraulic fluid and filter.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 4.Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

Every 180 Days or 500 Deadman Hours (HD)

Table 4-3.Every 180 Days or 500 HD Hours

Model 5200 High-Level Orderpicker

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component

What to do Refer to

BatteryCheck the weight stamped on the battery in the lift truck against the minimum and maximum allowable weights on the specification tag for the lift truck. Report any lift trucks that are running with batteries under the minimum or over the maximum allowable weight. Check for voltage leaks to frame. If cleaning does not remove voltage to frame, install a new battery. Inspect all battery connectors and leads for damage and cuts in protective coatings. Make sure the battery gates are in place and not damaged. Make sure the battery has no more than 0.5 inch (13 mm) free play in any direction.

Brakes In an open area, measure stopping distance. Traveling at 2 to 3 mph (3.2 to 4.8km/h.) empty, push the EPO switch; the empty lift truck should stop within 2 to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and traveling at top speed, the lift truck should stop within approx. one and one-half truck lengths. Stopping distance depends on the load, floor, and tire condition. Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake, clean rotor, and replace the pads. Check brake gap.

Contactors Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips may prevent the contactor from opening or closing causing unscheduled downtime. With the key switch OFF and the battery disconnected, check the plunger for smooth operation with no binding. If binding occurs, the lift truck may malfunction or exhibit intermittent fault codes.

NOTE: For EE lift trucks, remove cover to inspect tips.

Control HandleVerify travel function is smooth and responsive through full range of motion. Check for play in center position of travel control. Verify all handle switches function correctly.

Deadman PedalCheck for smooth operation with no binding. Check correct activation and deactivation of the deadman switch by the pedal

Drive Unit Inspect for leaks. Check fluid level. Make sure O-ring is present on the dipstick. Examine for radial ring wear. Apply grease to the steer gear on the drive unit. Lubricate all grease points on the drive unit.

Electrical CablesInspect all power cables for nicks or cuts. 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 causes intermittent system shutdowns and/or electronic failures. Check the tension of the over-the-mast pulley cables. Set 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).

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Publication Number: 1043922B, Revised: 2 Sept 2015