Model 5200 High-Level Orderpicker Symptom Tables: Travel Functions

Slow or Sluggish Acceleration

Possible Cause Action

Section 5.Troubleshooting

Symptom Tables: Travel Functions

Dragging brakeAdjust the brake.

Worn wheel bearingsReplace the wheel bearings.

Debris in wheel axleRemove debris.

Binding drive unitCheck amp draw.

Bad traction motor (may test OK with no load, but fail under load)

Test for shorts to frame.

Low battery voltage Measure the battery voltage during acceleration. 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 correct discharge is obtained.

Slow Travel; Lift/Lower OK; No Fault Codes

Possible Cause Action

Incorrect configuration of speed in TPACheck settings with a PMT.

Dragging brakeAdjust the brake.

Worn wheel bearingsReplace the wheel bearings.

Debris in wheel axleRemove debris.

Binding drive unitRemove traction motor and check movement.

Bad traction motor (may test OK with no load, but fails under load)

Test for shorts to frame.

Voltage from throttle pot to CM is not at the learned values Test pot voltages. Run LEARN.

Publication Number: 1043922B, Revised: 2 Sept 2015 5-33

Section 5.Troubleshooting

Model 5200 High-Level Orderpicker

Symptom Tables: Electrical Symptoms

Electrical Motors

Motor Overheating

Possible Cause Action

Application exceeds designed workload -short runs with plugging/acceleration or heavy-duty lifting cycles

Contact Service Manager to correct application.

Incorrect BSOC Cutout valueMeasure battery SG at cutout, after the battery has stabilized. Compare the reading to the battery manufacturer specifications for discharged battery. Adjust BSOC Cutout as needed.

Clogged motor ventsExamine and clear the motor vent openings. Worn, damaged, or bad brushes or springsCheck the motor brushes. Check the brush spring tension.

Cable, terminal, or wiring problems. Look for loose or discolored terminals and loose or damaged crimps

Replace the wiring or cables as needed. Make sure the motor cables are torqued correctly.

High motor current due to binding gearbox, pump, or dragging brake Inspect the gearbox or pump for binding. Check the brake adjustment.

Dead Lift Truck

Display is Dark; Lift Tr uck is not Operational

Symptom Tables: Electrical Symptoms 5-34

Possible Cause Action

Fuse FU2 could be blownRemove the fuse and test the fuse for continuity. If continuity is missing, replace the fuse.

Problem in key switch circuit or with B+ to Vehicle Manager or bad Vehicle Manager

Troubleshoot B+ to B+KEY circuits from the battery to the VM.

Problem with +12V power supplyTroubleshoot +12V supply and wiring.

Bad battery cables or connectorRepair or replace as necessary.

Bad mast cablesRepair or replace the mast cables.

Communication Failure See “Code 4,6” on page6-66.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 6.Messages, Codes, and TestsModel 5200 High-Level Orderpicker

This section contains corrective actions and checks for symptoms indicated on the operator display messages and with a specific fault code.

The information in “Operator Display Messages” has two sections, the Steering Indicator and the Battery Indicator. Th e Steering Indicator displays information on the lift truck’s auto/manual steering functions. The Battery Indicator displays information on fault codes, information display, and battery-state-of-charge (BSOC).

Use the information contained in “Traction Power Amplifier Fault Codes” on page6-8 to identify possible causes of problems that are accompanied by a fault code on the Operator Display.

Use the information contained in “Guidance Manager Operational Codes” on page6-17 for fault codes specific to the optional wire guidance system.

Operator Display Messages

The operator display has two sections, the Steering Indicator and the Battery Indicator. See Figure6-1.

Steering Indicator Messages

The steering indicator has five LEDs and shows the current steering direction based on the position of the drive unit. See Figure6-1.

When the lift truck is in Maintenance Mode, the steering indication is overridden, and the LEDs flash as the horn “chirps”. See “Maintenance Mode” on page6-5.

Each steering indicator message is listed in Table6-1

Display

All LEDs scroll in side-to-side pattern

Lift Truck Condition

Drive unit position is unknown

Red Left LED on steadyDrive unit in left, end-of-travel zone (more than 65° to the left and less than 85° from the center. NOTE: The red LED blinks when it is more than 85° from the center.)

Yellow Mid-Left LED on steady Drive unit in mid-left zone (more than 10° to the left and less than 65° from the center)

Green Center LED on steady Drive unit in center (straight-ahead) zone (within 10° of center)

Yellow Mid-Right LED on steady Drive unit in mid-right zone (more than 10° to the right and less than 65° from the center)

Red Right LED on steady Drive unit in right, end-of-travel zone (more than 65° to the right and less than 85° from the center. NOTE: The red LED blinks when it is more than 85° from the center.)

All LEDs blink in unison as horn beeps

The lift truck is in Maintenance Mode

Operator Display Messages 6-2Publication Number: 1043922B, Revised: 2 Sept 2015