Symptom Tables: Hydraulic Functions

NOTE: If you determine that a component failed as a result of hydraulic fluid contamination, replace the failed component and flush, fill, and bleed the hydraulic system.

Lift/Lower System

No Lift - Motor Runs, No Codes

Possible Cause Action

Binding in lift mechanism or low system pressure

No Lift - Motor Does Not Run, No Codes

Check the lift pressure, if in bypass, inspect the mast, rollers, and rails. If lift pressure is low:

1.Measure the voltage to lift/lower solenoid.

2.Inspect the L/L solenoid for binding.

3.Replace the pressure relief.

4.Replace the lift pump.

Possible Cause Action

Open in cables to lift motor or bad motorTest for B+ to the D terminal at the lift motor with the the lift contactor closed. Test for B- to the A terminal at the lift motor. If voltage is present, replace the motor. If voltage is not present, inspect cables and contactor tips.

Slow Lift or No Lift - Empty, Motor Runs

Possible Cause Action

Binding in lift mechanism or low system pressure

Check the lift pressure, if in bypass, inspect the mast, rollers, and rails. If lift pressure is low:

1.Measure voltage to lift/lower solenoid.

2.Inspect L/L solenoid for binding.

3.Replace the pressure relief.

4.Replace the lift pump.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 5.Troubleshooting

Symptom Tables: Hydraulic Functions

Model 5200 High-Level Orderpicker

Unable to Pick Up a Load; Lift Pump Runs; Travel OK

Possible Cause Action

Low battery voltageMeasure the battery voltage during lift. If low, check cutout adjustment:

1.Allow the battery to set unused for two hours. Check SG and compare the reading to the battery manufacturer’s recommendations.

2.Adjust cutout in CONFIG until the correct discharge is obtained.

Binding in lift mechanism or low system pressure Check the lift pressure, if in bypass, inspect the mast, rollers, and rails. If pressure is low:

1.Measure the voltage to lift/lower solenoid.

2.Inspect L/L solenoid for binding.

3.Replace the pressure relief valve.

4.Replace the lift pump.

No Lower, Lift and Travel OK

NOTE: Display shows code.

Possible Cause Action

Load holding solenoid not openingInspect for binding of valve by opening emergency knob. Measure voltage to the valve.

Binding mast or plugged flow controlBack out pressure relief, REL-1. If the mast does not lower, inspect flow controls for blockage or mast for binding.

Load Drifting/Settling

Possible Cause Action

Load too large for lift truck capacityCheck load weight.

Incorrect lift pressure adjustmentCheck and adjust lift pressure setting.

Contaminated or bad relief valve REL1 Replace the relief valve REL1. If contamination is present, flush, fill, and bleed the hydraulic system.

Leaking or contaminated load holding solenoid SOL1 Replace SOL1.

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Publication Number: 1043922B, Revised: 2 Sept 2015