Model 5200 High-Level Orderpicker

Setting Battery State-of-Charge Cutout

1.Fill, charge, and install a battery that is typical of the batteries normally used in this application.

2.Have a customer operator use the lift truck in the normal application until cutout occurs.

3.Allow the battery to cool and stabilize for at least two hours.

4.Before filling the battery, either take specific gravity readings or measure open circuit voltage of the battery cells.

5.Compare the measurements with the battery manufacturer’s recommendations for maximum discharge.

6.Adjust the cutout value as needed and repeat the previous steps until battery cutout occurs at the desired discharge level.

NOTE: Additional BSOC adjustment is available using FlashWare.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 5.Troubleshooting

Troubleshooting Wiring Problems

Troubleshooting Wiring Problems

Visually inspect all wiring and electrical components for:

•Loose connections or connectors

•Loose or broken terminals

•Damaged terminals, blocks, or strips

•Exposed wire at terminations, excessive strip gap

•Abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage

•Broken wire strands and shorted conditions (especially those that are close to metal edges or surfaces)

Power Cables Inspection

Power cables should be checked for damage, including:

•Evidence of overheating

•Burned spots in the cable

•Nicks or cracks in the insulation

•Damaged or overheated terminal lugs

•Damaged mounting hardware or brackets

Repair or replace the damaged cables or mounting hardware as necessary.

Power cables are marked on the terminal lug with the location where they belong. If the marking is missing or is not readable, remark the cable with the correct information.

The terminal lugs should be crimped tightly and securely on the wire. Replace the lug if overheating is evident. Repair or replace the faulty connectors as necessary.

Guidelines

During troubleshooting and repairs, it is sometimes necessary to unplug a connector,

Model 5200 High-Level Orderpicker

move a harness, cut a cable tie, or remove the wire from a bracket. Note carefully the location of the wire and all of the protective or securing attachments before moving the harness.

After repair, return or replace all of the protective and/or securing hardware to its original condition. Pr otective materials are necessary for the interconnect system to perform reliably.

Examine and maintain any added materials used to dress or protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, and so forth

Do not attach cable ties tight enough to pinch or deform the cable harnesses. Avoid fastening to hydraulic hoses that expand with pressure to hinder extra pinching of secured electrical cables.

Use a digital ohmmeter to check for wiring continuity.

Wiring Harness Terminology

The term “connector JPCx” or “connector JPTx” means a mated connector consisting of two connector halves. One half contains male connectors, or pins (P); the other half contains female connectors, or jacks (J). The third character references the relative location of the connection. Connections on the Carriage Manager are designated by a (C). Connections on the Steer/Tractor Manager are designated by (T). Hanging connections are designated by (H).

When you disconnect a mated JP connector, you have two connector halves. The individual connector halves are designated by “Jx” and “Px.”

For example, connector JPT3 is the mated connector for steer po sition feedback. J3 represents the jack connections, P3 represents the pin connections and T designates the Steer/Tractor Manager.

Publication Number: 1043922B, Revised: 2 Sept 2015