Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Inner Telescopic

Installation

1.Line up the bottom roller bearings in the outer telescopic channel and lower into the main frame. See Figure7-197.

5.Install the chains and secure in the chain anchors. See Figure7-199.

2.Install the upper roller bearings on the outer telescopic.

3.Remove the block from the outer telescopic and lower both telescopics.

4.Apply thread-locking compound (P/N1013829) to the bolts and install the chain pulleys.

6.Install the center cylinder. See “Center Lift Cylinder” on page7-93.

7.Install the over-the-mast hose and cable pulleys to the outer telescopic.

8.Install the hoist on the outer telescopic and lift until the inner telescopic raises enough to expose the cable bracket.

9.Install the cables and hoses. Attach cable ties to the bracket on the inner telescopic cable bracket.

10.Install the carriage. See “Carriage with Three-Stage Mast” on page7-98.

Publication Number: 1043922A, Revised: 2 Sept 2015 7-103

Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Outer Telescopic Mast Section

Outer Telescopic

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.Remove the operator platform. See “Carriage with Three-Stage Mast” on page7-98.

2.Remove the inner telescopic. See “Inner Telescopic” on page7-102.

3.Remove the bolt from the top of each piston.

4.Remove the stops from the outside, top of the main frame. See Figure7-200.

5.Remove the top bearing on the main frame.

6.With a suitable hoist, remove the outer telescopic. See Figure7-200.

Installation

1.With a suitable hoist, lower the outer telescopic into the main frame.

2.Install the top roller bearings.

3.Install the stops to the outside, top of the main frame.

4.Install the bolts in the top of the pistons.

5.Install the pulleys.

6.Install the inner telescopic. See “Inner Telescopic” on page7-102.

7.Install the operator platform. See “Carriage with Three-Stage Mast” on page7-98.

8.Before returning the lift truck to service, check the telescopic movement and adjust as necessary. See “Adjustment” on page7-104.

Adjustment

Anytime you replace the outer telescopic, you must adjust the mast stop to make sure the telescopic hits the stops evenly. See Figure7-201.

Publication Number: 1043922A, Revised: 2 Sept 2015