Model 5200 High-Level Orderpicker

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

Section 4.Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

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

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.

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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.

Horn Check that the horn sounds correctly when activated. Check mounting bracket insulators.

Hydraulic HosesInspect 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 TankCheck fluid level.

Lift Chains Check adjustment. Inspect center cylinder chain anchors and springs. Inspect for excessive stretch or wear (tool P/N939-10606).

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.

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).

Publication Number: 1043922B, Revised: 2 Sept 2015

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Section 4.Scheduled Maintenance

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

Motors Visually inspect brushes for excessive heat (discoloration of the pigtails). If excessive heat is evident, inspect the armature circuit for loose connections. Check the condition of the commutator. See Table5-1 on page5-10. Find the shortest brush in the holder. Remove the brush and check overall dimension per the table on page7-62. Inspect the brush for even wear over the full surface of the brush. If the brush is not contacting the complete surface, replace the brushes. Inspect the brush rigging for damage or loose brush holders. Make sure the connections on the brush leads are tight. Check the brush spring tension. Blow out the inside of the motor with compressed air. Blow out the impeller and cooling fins. Make sure cable lugs are tight to the terminal studs. The inside and outside nuts should be torqued to the value listed on page7-63. Replace any cable that shows signs of excessive heat. Check sensor wires for sound connection and condition.

Overhead GuardInspect guard for physical damage. If structurally damaged, replace the carriage.

Pallet ClampCheck operation of the pallet clamp.

Safety Belt or Harness

Check for signs of wear, fraying, or damage.

Shorts to FrameCheck for electrical shorts to frame.

Skid Pads

To check floor clearance, park the lift truck on a level and flat floor surface. Measure the clearance between each skid pad and the floor. Correct clearance is 0.31 to 0.56 inches (8 to 14 mm). If clearance exceeds 0.75 in. (19 mm), the skid pads must be replaced.

Static StrapsMake sure static straps are not worn or broken. Clean debris from straps. Check resistance of resistor in standoff. Resistance must measure >200K and <250K. EE lift trucks require a phosphor bronze static strap; do not use steel braided cable on EE lift trucks.

Steering Check that the steering system function is smooth and responsive, without binding and excess play. Inspect the teeth on the steer gear and drive unit for wear.

Switches Check all switches for correct operation and adjust as needed.

Ventilation SlotsMake sure ventilation slots in the tractor frame are clear of obstructions and debris.

Warning DecalsReplace any illegible or damaged decals.

Warning LightCheck for correct operation.

Wheels and TiresExamine for bond failure, chunking, and excessive or uneven wear. Inspect load wheel bearings for binding or excessive play. Inspect drive axle for excessive play.

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Publication Number: 1043922B, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

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

Section 4.Scheduled Maintenance

Every 180 Days or 500 Deadman Hours (HD)

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

Wire GuidanceCheck sensor assemblies for damage and mounting hardware for tightness. Verify that the lift truck acquires and tracks the guide wire correctly. Verify that the brake is applied when the lift truck loses the wire.

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Publication Number: 1043922B, Revised: 2 Sept 2015

Section 4.Scheduled Maintenance

Every 360 Days or 2000 Deadman Hours (HD)

Every 360 Days or 2000 Deadman Hours (HD)

Model 5200 High-Level Orderpicker

Perform the following maintenance tasks every 360 days or 2000 HD, whichever comes first.

Hydraulic ReservoirChange fluid and filter.

Lift PumpSeparate lift pump and motor. Apply molybdenum anti-seize compound (P/N 990-638) to the splines.

Publication Number: 1043922B, Revised: 2 Sept 2015