Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Steering and Controls Control Handle

13.Tighten the two pan head machine screws on the back of the enclosure while moving the handle to make sure there is no binding. See Figure7-24.

14.Install the handle in the lift truck.

15.Adjust the travel pot. See “Throttle Potentiometer Test” on page6-6. Adjust the travel pot voltages to the values given.

16.Tighten the retaining nut.

17.Install the cover on the travel pot enclosure with the four hex head cap screws. See Figure7-23.

18.Run LEARN. See “Learning Throttle and Lift Potentiometers” on page6-6.

Travel Spring and Pinion

Disassembly

1.Remove the four hex head cap screws from the front of the travel pot enclosure and remove the cover. See Figure7-23.

2.Use a pin removal tool and pull pins 3 thru 6 from JC-9. These wires pass through the shaft to the lift/lower pot and horn switch.

NOTE: The washer and shims can easily slip off the shaft gear. Observe the correct position of these components before disassembling them.

3.Remove the button head screw from the shaft gear and slide the shaft out of the enclosure. See Figure7-25.

4.Carefully rotate the shaft gear assembly to disengage the spring tangs from the pin. Remove the shaft gear assembly from the enclosure.

Assembly

1.Slide the shaft gear assembly back into the enclosure. Engage the travel pot gear with the shaft gear (there is one large tooth that is used to align the gears).

a.Make sure the spring tangs straddle the pin (tangs should be parallel). If the spirol pins were replaced, make sure they are installed such that when the spring is installed, the spring sits on an even edge of the pin and not on the gap. b.Make sure the washer and shims are correctly aligned to allow the handle shaft to slide easily through the enclosure. See Figure7-27.

NOTE: Replace the spring if the tangs are not parallel. Do not bend the spring.

2.Route the lift/lower pot and horn wires through the enclosure. Carefully slide the shaft through the enclosure, passing through the shaft gear assembly, washer, and shims.

3.Align the screw hole in the handle shaft with the hole in the shaft gear. Apply thread-locking compound (P/N 990-412) to the threads in the shaft and on the button head screw. Install the screw and torque. See “Component Specific Service/Torque Chart” on pageA-4.

4.Reinstall the wire pins into the connector.

5.Inspect the tab on the plate ground to make sure that it is in contact with the bronze handle shaft bushing. See Figure7-28.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Model 5200 High-Level Orderpicker

3.Rotate the lift/lower knob fully counterclockwise and tighten the metal set screws to 6 to 8 in. lb. (0.7 to 0.9 Nm).

4.Check the potentiometer for correct operation and for spring return to neutral. Correct any binding.

5.Install and tighten the two nylon set screws on top of the metal set screws.

6.Verify the potentiometer reference voltages. See “Learning Throttle and Lift Potentiometers” on page6-6.

Cleaning and Inspection

6.Install the cover on the travel pot enclosure with the four hex head cap screws. See Figure7-23.

Lift/Lower Knob Installation/Adjustment

1.Rotate the lift/lower potentiometer shaft fully counterclockwise.

2.Install the lift knob on the potentiometer shaft. The pin on the knob must fit between the tangs of the potentiometer return spring.

Table 7-3.Control Handle Checks

When cleaning plastic parts, use a dry rag or a cleaner that is safe on plastics. Most chemicals can damage plastic.

While performing a repair on the Control Handle, clean and inspect the parts listed in Table7-3

Part Check for:

Horn button assemblyCracks or deformation

Lift/lower pot bracketCracks, deformation, loose dowel pin, out-of-round or oversized shaft hole

Travel pot gearCracks, gear deformation, stripped threads

Travel shaft gear assemblyCracks, gear deformation or loose spirol pin

Travel pot enclosureCracks, loose spirol pin, stripped threads, deformation or indents on external stops

Handle halvesCracks, damage or deformation/indents on external stops

Lift/lower knobCracks, deformation, stripped threads, loose dowel pin

Plate groundCheck for continuity between the control handle shaft and the lift truck frame

Other hardwareStripped threads. All screw threads should be cleaned

Publication Number: 1043922B, Revised: 2 Sept 2015

Control Handle Steering and Controls 7-24