Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Hydraulic Components Center Lift Cylinder

Seal Replacement

Refer to Figure7-180 for the following steps.

1.Remove the snap ring or threaded end-cap, for your style cylinder, and 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.

2.Remove the spring and pressure ring.

3.Check to make sure the small orifice in the pressure ring is not obstructed.

4.Lightly oil a new seal and install in the pressure ring.

5.Remove the bad parts from the top bearing.

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

7.Install the top bearing.

8.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

Installation

1.Reverse the removal procedure.

2.Install cylinder. See “Side Cylinder” on page7-89.

3.Reconnect the battery connector and turn the key switch ON.

4.Bleed the hydraulic system after reassembly. See “Bleeding the Hydraulic System” on page7-88. Check for leaks.

5.Test all vehicle functions.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Flow Control Valve

Flow Control Valve Replace

1.Lift and block the carriage enough to reach the valve housing block.

2.Turn the key switch OFF and disconnect the battery.

3.Remove the hydraulic tubing. See Figure7-181.

4.Remove the fitting. See Figure7-181.

Model 5200 High-Level Orderpicker

Hydraulic Components

7

5.Pull out the flow control valve.

6.Place the new valve in the housing.

NOTE: Follow the directional arrow on the flow control valve to install it correctly. It should be pointing out of the housing in the direction of regulated flow. See Figure7-182.

7.Place the hydraulic fitting in the valve housing block (with the O-ring end first) and tighten.

8.Install the hydraulic tubing.

9.Reconnect the battery connector and turn the key switch ON.

10.Bleed the hydraulic system after reassembly. See “Bleeding the Hydraulic System” on page7-88. Check for leaks.

11.Test all vehicle functions.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Carriage with Three-Stage Mast

Carriage with Three-Stage Mast

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 the 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.

Removal

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

2.Remove the operator console cover.

3.Remove the electrical over-the-mast cable from the bottom pulley on the carriage. See Figure7-183.

4.Disconnect the cable tension spring from the carriage. See Figure7-183.

Model 5200 High-Level Orderpicker

Mast Section

Do not place hands between the masts before blocking the carriage.

6.Feed the cable through the carriage to the tractor.

7.Use 90° snap ring pliers to remove the snap ring holding the chain rocker assembly to the center cylinder. See Figure7-184.

5.Disconnect JPC8 and JPC9 from the Carriage Manager and cut the cable tie from the tractor side.

8.Attach a suitable hoist to the carriage and lift approximately 1 ft. (30.5 cm).

9.Remove the rocker assembly, its associated hardware, and chain from the center cylinder. Place the chain on the operator platform.

10.Remove the end cap from the center cylinder.

11.Remove the carriage stops (2) from the inner telescopic. See Figure7-185.

12.Pound in the locator pins until the carriage can clear the telescopic. See Figure7-186.

13.Remove the operator platform. 7

Publication Number: 1043922A, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Carriage with Three-Stage Mast

Installation

1.With a suitable hoist, lower the bottom bearings on the carriage into the channel on the inner telescopic.

2.Make sure there are sufficient shims to prevent side play. See “Mast Shimming” on page7-108.

3.Make sure the two switches (S6 and S7) at the bottom of the carriage are riding on their switch rail correctly. See Figure7-187.

Switch Rail

4.Position the operator platform 3 ft. (0.9 m) from the floor.

5.Install the rocker assembly, its associated hardware, and the chain on the center cylinder. See Figure7-188.

6.Install the end cap pulley on the center cylinder.

7.Feed the chains for the center cylinder and over-the-mast cable.

8.Feed the over-the-mast cable through the back of the carriage to the Carriage Manager. Connect to JPC8 and JPC9.

Publication Number: 1043922A, Revised: 2 Sept 2015

7-99

Section 7.Component Procedures

Carriage with Three-Stage Mast

9.Use cable ties to secure the electric cables to the platform.

10.Install the carriage stops at the top of the inner telescopic. See Figure7-189.

Model 5200 High-Level Orderpicker

Mast Section center, left side, and right side into the mast. See Figure7-191.

11.Lower the carriage and install the cable on the bottom pulley of the carriage. Install the cable retainer spring. See Figure7-190.

NOTE: There is 5 1/2 in. (140 mm) from the top of the spring on the carriage to the center of the bolt in the cable clamp.

14.Torque the hex head bolts. Refer to “Component Specific Service/Torque Chart” on pageA-4

15.Install the console cover.

16.Install the mast guard.

17.Install the battery and connect the battery connector. Turn the key switch ON.

18.Lift and lower the platform fully, and check the functions of the lift system. Look for:

•Oil leaks

•Cables on pulleys

•Switch actuation

12.Mate the tractor to the mast, engaging the locating pins in the tractor with the holes in the mast frame.

13.From the battery compartment, thread twelve hex head bolts and five socket flat head bolts through the tractor frame in the

7-100

•Unusual bearing noise

Center Cylinder Ride Spring Chain Anchors

Inspection of the chain anchors and pivot rocker should be done any time that the chains are lubricated and adjusted.

Publication Number: 1043922A, Revised: 2 Sept 2015