Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Mast Disassembly and Shimming

Mast Disassembly and Shimming

This section describes procedures for:

•Disassembling the three-stage mast

•Shimming the main frame to the outer telescopic

•Shimming the outer telescopic to the inner telescopic

•Shimming the inner telescopic to the carriage

NOTE: Two-stage masts require similar procedures with the references to the center lift cylinder and inner telescopic not applying.

Mast Disassembly

1.Remove the forks and mast guard.

2.Fully lower the carriage and make sure the pressure is out of the cylinders.

3.Turn the key switch OFF and disconnect the battery connector. Remove the battery.

4.Disconnect the over-the-mast cables and hoses inside the tractor compartment and plug the hoses. Disconnect the lift hose to the side cylinders inside the tractor compartment and plug. Disconnect all other cables that run from the tractor to the mast.

5.Secure the main carriage and telescopics so they cannot move.

6.Remove the tractor from the mast and block each securely.

7.Disconnect and remove the lift chains from the center lift cylinder. Remove the over-the-mast pulley cables and hoses. Remove the center cylinder end cap assembly.

Mast assembly may swing free when lowering. Use extreme caution.

8.With a suitable hoist, carefully lay the mast assembly down and block securely in place. Remove the carriage stops from the inner telescopic.

9.Remove the main carriage by sliding it out the top of the inner telescopic. Set it aside for later reassembly.

10.Disconnect and remo ve the lift cylinders from the telescopics.

11.Attach the hoist to the inner telescopic.

12.Remove the upper roller bearing bosses and roller bearings from the outer telescopic.

13.Remove the telescopics and main frame stops.

Failure to correctly balance load may result in personal injury. Use extreme caution.

14.Slide the inner telescopic out the top of the outer telescopic. Attach the hoist to the outer telescopic.

15.Remove the upper roller bearing bosses and roller bearings from the main frame.

Failure to correctly balance load may result in personal injury. Use extreme caution.

16.Slide the outer telescopic out the top of the main frame.

Shimming Main Frame to Outer Telescopic

1.Install the mast roller bearings at the bottom of the outer telescopic.

Publication Number: 1043922A, Revised: 2 Sept 2015

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