Model 5200 High-Level Orderpicker

Programming

You can change certain parameters using the PMT. See Table5-9. All changes occur in “real time”; the parameters can be changed while the lift truck is in operation.

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

2.Remove the tractor cover.

3.Connect the PMT to the traction power amplifier.

4.Connect the battery and turn the key switch ON.

5.Press the program key to enter the Program mode.

6.Press either scroll display key until the parameter you want is the top line of the display.

Table 5-9.Traction Power Amplifier Parameters

M4 RESTRAINT (Plugging)

M3 RESTRAINT6-40 (Amps)6 (Amps)

Section 5.Troubleshooting

Programmable Maintenance Tool

7.Press either change value key until the setting you want is displayed. The parameter is now set at the value you selected.

8.If the display stops changing and you want to go further, press the more info key. If the display shows “Min. Limit” or “Max Limit,” you have reached the factory set limit for that parameter.

NOTE: The parameter may be dependent on another parameter. If so, the display shows this information. Changing the related parameter may allow you to change the setting further.

See “Definitions” on page5-19.

6-40 (Amps)6 (Amps)The plugging force applied to the traction motor by the power amplifier when the throttle is in neutral with the deadman switches closed. With neutral braking set at 0%, the lift truck coasts to a stop when the throttle is in neutral (released). There is no plugging force applied. When set to 100%, the power amplifier applies full plugging force when the throttle is in neutral (released).

M4 ACCEL RATE0-3 seconds0.5 secondTime to reach full output (PWM) from zero. For a fast start, reduce the acceleration time. For a gentler start and a longer acceleration time, increase the acceleration time.

M3 ACCEL RATE0-3 seconds0.5 second

M4 MAX SPEED0-100%100%

M3 MAX SPEED0-96%96%

Maximum speed (PWM duty cycle). There are four settings:

M4 Max Speed Fwd

M4 Max Speed Rev

M3 Max Speed Fwd

M3 Max Speed Rev

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 5.Troubleshooting

Model 5200 High-Level Orderpicker

Drive Unit

Troubleshooting Guide

Table 5-10.Troubleshooting Guide

Symptom Probable Cause

Required Action

Oil leaksDamaged sealing ringsReplace the sealing rings, bearing shims, and drive shaft bearings

Worn or damaged drive shaftReplace the sealing rings, bearing shims, drive shaft bearings, and drive shaft

Housing/cover jointReseal

Worn or damaged housingReplace the drive unit

Drive wheel wobbles

Drive Unit Troubleshooting Guide 5-28

Worn or damaged drive shaft bearingsReplace the sealing rings, bearing shims, and drive shaft bearings

Worn or damaged drive shaftReplace the sealing rings, bearing shims, drive shaft bearings, and drive shaft

Loose wheel mounting hardwareInspect housing and drive shaft for damage; Re-torque the mounting hardware

NoiseWorn or damaged drive shaft bearingReplace the sealing rings, bearing shims, and drive shaft bearings

Worn or damaged pinion bearingsReplace the pinion bearing and pinion shaft nut

Worn or damaged gear set (drive shaft is in good condition)

Worn or damaged gear set (drive shaft is worn or damaged)

Replace the sealing rings, bearing shims, drive shaft bearings, pinion bearings, pinion shaft nut, and gear set

Replace the sealing rings, bearing shims, drive shaft bearings, pinion bearings, pinion shaft nut, gear set, and drive shaft

Worn or damaged helical gear and pinionReplace the helical gear and pinion

Steering binds Inadequate bearing lubricationGrease steering bearing

Worn or damaged steering bearingReplace the radial rings and ball bearings

Publication Number: 1043922B, Revised: 2 Sept 2015

List of Troubleshooting Tables

Section 5.Troubleshooting

5-30

Model 5200 High-Level Orderpicker

Publication Number: 1043922B, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

Section 5.Troubleshooting

Symptom Tables: Hydraulic Functions