Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Hydraulic Components Center Lift Cylinder

Center Lift Cylinder Removal

1.Remove the carriage. See “Carriage with Thr ee-Stage Mast” on page7-98.

2.Remove the snap ring and washer from the bottom of the center cylinder. Se e Figure7-177 .

Service of Cylinder with Cushions

Cushion Replacement

Refer to Figure7-180 on page7-94 for the following steps.

1.Remove the snap ring for older production cylinders. See Figure7-178

2.Remove the threaded end cap with Raymond tool (P/N 1090761/002) for current production. See Figure7-179

3.Remove and cap the hydraulic hoses.

4.Remove the U-shaped bracket.

5.Remove the center cylinder.

Installation

1.Install the center cylinder. Make su re the bushing is on the mounting bolt.

2.Install the washer and snap ring to the bolt under the center cylinder. See Figure7-177 .

3.Install the U-shaped bracket.

4.Install the carriage. See “Carriage with Thr ee-Stage Mast” on page7-98.

5.Install the end cap and hydraulic hoses on the center cylinder.

6.Reconnect the battery connector and tur n the key switch ON.

7. Bleed the hydraulic system after reas sembly. See “Bleeding the Hydraulic Syst em” on page7-88. Check for leaks.

8.Test the lift truck operation before returning to service.

3.Remove the top bearing.

NOTE: When the snap ring or end cap is removed, a spring behind the top bearing may push the bearing out of the housing.

4.Remove the spring and pressure ring.

Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Center Lift Cylinder Hydraulic Components

5.Remove the three staging screws located about 6 in. from the top of the housing.

6.Remove the piston from the cylinder housing.

7.Remove the cushion assembly.

8.Coat the threads of the new cushion assembly with thread-locking compound primer (P/N 990-666 ). Allow the primer to cure for a minimum of 1 minute.

9.Apply thread-locking compound (P/N990-575) on the internal threads of the piston rod.

10.Start threading the cushion assembly into the piston.

11.Apply thread-locking compound (P/N990-575) on external threads of the cushion assembly.

12.Continue installing the assembly into the piston.

NOTE: Assemble components within 30 seconds of application as the thread locking compound begins to cure immediately.

13.Allow the assembly to cure a minimum of 10 minutes.

14.Re-install the piston assembly in the cylinder housing.

15.Re-install the three staging screws. Refer to “Component Specific Service/Torque Chart” on pageA-4

16.Lightly oil a new seal and install it in the pressure ring. Check to make sure the small orifice in the pressure ring is not obstructed.

17.Install the spring.

18.Remove the bad parts from the top bearing.

19.Lightly oil the new seal, O-ring, backup ring, and wiper and install into the top bearing.

20.Install the top bearing.

21.Install the snap ring for older model cylinders or threaded end-cap for current production. Refer to “Component Specific Service/Torque Chart” on pageA-4 .