Model 5200 High-Level Orderpicker

Battery Indicator Messages

The battery indicator has five LEDs used in three prioritized modes of operation (3 is the highest priority). See Table6-2.

Table 6-2.Battery Indicator Messages

Status Mode Priority Display

Fault Code3 (highest) Series of blinks for each digit (all 5 blink together); see “Operator Display Fault Codes” on page6-41.

Info Display

Battery State-ofCharge

2Blinks a single LED to indicate a particular condition; see Table6-3, “Info Display Messages,” on page6-3

1 (lowest) Steady LEDs represent the current state-of-charge.

The battery indicator always shows the mode with the highest priority that is active. For example, an Info Display message overrides a Battery State-of-Charge message.

Fault Codes

All five LEDs flash in series to identify the fault code. Each series (code) has two digits. If more

Table 6-3.Info Display Messages

Display

Cause

Section 6.Messages, Codes, and Tests

Operator Display Messages

than one code is present (“stacked codes”), there are rapid flashes between codes.

There is no limit to the number of stacked codes, but only the highest priority codes are displayed. When these codes are resolved, the next highest codes are displayed until they are resolved.

Each code is explained later in this section. See “Operator Display Fault Codes” on page6-41.

Info Display

Each LED represents a different condition. See Figure6-2.

Table6-3 shows the cause and how to clear each display.

How To Clear

Top LED blinkingThe EPO is depressed.Pull out the EPO switch and reset the key switch.

2nd LED from top blinking The Deadman pedal must be depressed before you request motion.

1. Return controls to neutral. (Release throttle)

2. Step on the deadman pedal. (If optional sidegate with interlocks is attached) 3rd LED from top blinking

4th LED from top blinking

The sidegate is up when requesting travel or lift/lower. Lower the sidegate.

The carriage reached lift-limit (if equipped).Press lift-limit bypass switch to continue lifting.

Bottom LED blinkingThe battery charge is too low. Lift cutout is initiated. Install a fully-charged battery.

Publication Number: 1043922B, Revised: 2 Sept 2015

6-3

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

Operator Display Messages

Battery State-of-Charge (BSOC)

On the Battery Indicator display, each LED represents a different level. See Figure6-3.

6-4Publication Number: 1043922B, Revised: 2 Sept 2015

Maintenance Mode

Maintenance Mode allows you to test individual circuits of switches and inputs while the lift truck is stationary or under normal operation.

For example, if you suspect the deadman switch is bad, you can verify the switch circuit input to the Steer/Tractor Manager.

Enter the Maintenance Mode. See “Enter”.

To Enter Maintenance Mode

There are two methods for entering Maintenance Mode, using the deadman pedal or using the horn button. After you enter Maintenance Mode, follow the instructions in “General Testing.”

Deadman Pedal Method

1.Turn the key switch ON. The horn beeps three (3) times after SelfTest is complete.

2.Within 10 seconds after the three (3) horn beeps, step on and off the deadman pedal 3-6 times. The horn starts chirping when the lift truck is in Maintenance Mode.

NOTE: The deadman circuit must be transitioned 12 times to enter Maintenance Mode. If both switches (S2 and S23) are working correctly, you only need to step on and off the pedal 3 times. If one is not working, you need to step on and off 6 times.

Horn Button Method

1.Turn the key switch OFF.

2.Hold the horn button and turn the key switch ON. Do not release the horn button.

3.When the BSOC display clears, release the horn button.

4.While the BSOC display is clear, press and release the horn button one time. Each time you press the horn button, one BSOC LED lights.

5.Wait for the BSOC display to clear. A clear display indicates the first digit was accepted.

NOTE: You must enter the second digit within 3 seconds of entering the first digit.

6.Press and release the horn button one more time.

7.Wait a few seconds for the BSOC display to clear again. All the BSOC LEDs flash to indicate the password was accepted and the lift truck is in Maintenance Mode.

General Testing

1.Enter maintenance mode. See “To Enter Maintenance Mode” on page6-5.

2.Request an operation. For example—travel, lift, and so forth. When the switch turns ON or OFF, or an analog input crosses a threshold, the lift truck determines whether the circuit is good or bad.

If the circuit is good , the horn chirps and the heartbeat LEDs on the Steer/Tractor Manager and Carriage Manager and the steer indicator LEDs on the operator display blink during the operator request. If the circuit is bad , the horn does not chirp and the LEDs do not blink during the operator request.

The following standard switches can be tested in Maintenance Mode:

•Steer Home Switch (S8)

•Deadman (S2 and S23)

•Horn (S3)

•24" Limit (S6); see Note below

•60" Height (S7); see Note below

•120/150" Height (S29); see Note below

•Emergency power off (S21)

NOTE: To test S6, S7, and S29, step on the deadman pedal and lift the operator platform. Each switch is tested as it passes its activation rail.

The following optional switches can also be tested in Maintenance Mode:

Publication Number: 1043922B, Revised: 2 Sept 2015