Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Brake Drive and Brake

Brake Removal

1.Turn the key switch OFF and disconnect battery.

2.Remove tractor covers.

Use extreme care whenever the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Keep hands and feet clear from vehicle while jacking the lift truck. After the lift truck is jacked, place solid blocks beneath it to support it. Do not rely on the jack alone to support the lift truck. See “Jacking Safety” on page2-8.

3.Jack and block the lift truck under the tractor frame. See “Jacking Lift Truck” on page2-8.

4.Disconnect the electrical cable (PH5) to the brake assembly.

5.Cut cable ties and pull cables from the bracket. See Figure7-107.

6.Remove the brake (3 screws). See Figure7-107.

NOTE: Note the location of the shims.

7.Remove the brake release screws from the tractor (near the steer motor) and install them in the brake.Tighten screws until the brake releases completely.

Installation

1.Install the brake assembly on the traction motor.

2.Align the cable bracket on the brake assembly and install the bolts (3).

3.Connect PH5 and place the cables in the cable bracket. Secure cable ties around the cables.

4.Remove the blocks.

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

Brake Air Gap Adjustment

During normal use, the friction plate wears (gets thinner). This causes the air gap to increase.

With the brake energized, measure the total air gap with a feeler gauge. The total air gap should be 0.010 to 0.015 in. (0.25 to 0.38 mm) and uniform all the way around the armature disc. A total gap greater than 0.015 in. (0.38 mm) indicates brake wear.

If the air gap is too large, the brake may not work correctly; this is especially true when the brake is hot or the battery charge level is low.

If the air gap is too small, the brake friction plate may drag.

Publication Number: 1043922B, Revised: 2 Sept 2015