Model 5200 High-Level Orderpicker

Steering and Controls

3.Remove the mounting bolt and shims from the steer motor shaft. See Figure7-15.

4.Loosen the set screw and remove the pinion gear and remaining shims. See Figure7-15.

Section 7.Component Procedures

Steer Moor

Spur Gear Orientation

Install the spur gear as shown in Figure7-17

5.Install shims, new pinion gear (with key in keyway), and shims on the steer motor shaft, then secure the motor with mounting bolt and thread-locking compound (P/N 1013829). Tighten the set screw. See Figure7-16.

6.Install the steer motor assembly. See “Steer Moor” on page7-18.

7.Reconnect the battery connector and turn the key switch ON. Test the lift truck operation before returning to service.

Standard Drive Unit

Note: Make sure that the spur gear teeth mesh fully with the teeth of the gear on the drive unit.

Any time the steering motor or gear box is repaired or replaced, make sure the radial rings on the drive unit are not binding. Make sure to rotate the drive unit full left and full right while pumping grease into the radial rings at both grease fittings.

Publication Number: 1043922B, Revised: 2 Sept 2015 7-19

Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Control Handle Steering and Controls

Control Handle Removal

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

2.Disconnect JPC9 and remove the Control Handle from the lift truck.

NOTE: Observe the orientation of switches, potentiometers (pot), and the routing of cables/wires as the handle is disassembled to make reassembly easier.

Make sure to observe correct precautions agains t electrostatic discharge. See “Static Precautions” on page2-7.

Before disassembly, determine what components require replacement:

•Lift/Lower Pot, Spring, and/or Horn Switch

•Travel Pot

•Travel Spring and/or Pinion

•Lift/Lower Knob

Disassembly

1.Remove the two 3/32 socket head nylon set screws in the lif t/lower knob (thumb lever). If stripped, use a small 1/8 in. (3.2mm) blade flat screwdriver and carefully back out the set screw.

2.Loosen the two metal set screws in the lift/lower knob two full turns and remove the lift/lower knob.

NOTE: Carefully slide the two spacer washers, lift/lower spring, and third spacer washer off the lift pot shaft. See Figure7-18.

3.Remove the three 3 mm socket head cap screws from the handle assembly. See Figure7-19 and Figure7-20 . Separate the cover from the handle.

Publication Number: 1043922B, Revised: 2 Sept 2015