Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Carriage With Two-Stage Mast

Carriage With Two-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. See “Operator Console Co ver” on page7-11.

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

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

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

5.Lift the carriage high enough to create slack on the chains. Block the carriage.

6.Remove the finger guard. See Figure7-202.

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7.Disconnect the inside chain anchors at the bottom of the carriage. See Figure7-203.

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8.Place the disconnected end of the chains over the top of the mast, toward the tractor. See Figure7-204.

Publication Number: 1043922A, Revised: 2 Sept 2015

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Section 7.Component Procedures

Carriage With Two-Stage Mast

9.Remove both chain pulleys from the top of the cylinder. See Figure7-204.

Model 5200 High-Level Orderpicker

Mast Section

4.Install the stop at the top of the telescopic. See Figure7-205.

5.Install the chain pulleys to the top of the piston. See Figure7-204.

6.Feed chains over the pulleys and connect the chain anchors. See Figure7-203.

7.Feed the over-the-mast cable through the mast and into the operator console. Connect cable ties where necessary.

8.Install the finger guard.

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

10.Install the operator console cover.

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

10.Remove the stop from the top of the telescopic. See Figure7-205.

•Oil leaks

•Cables on pulleys

•Switch actuation

•Unusual bearing noise

11.Attach a suitable hoist and remove the operator platform.

Installation

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

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

3.Make sure the two switches at the bottom of the carriage are riding their switch rail correctly. See Figure7-187.

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Publication Number: 1043922A, Revised: 2 Sept 2015