Section 7.Component Procedures

Mast Disassembly and Shimming

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

2.Use a suitable lifting device and insert the outer telescopic into the main frame all the way to the bottom.

3.Using a pry bar, move the outer telescopic and roller bearing to one side.

4.Use spare shim(s) as a gauge to determine the amount required to move the roller bearings outward to make contact with the main frame.

5.Remove the outer telescopic from the main frame.

6.Remove the roller bearings from both roller bearing bosses at the bottom of the outer telescopic.

7.Install half of the total shim thickness required to each roller bearing boss at the bottom of the outer telescopic. (Applying one half of the total shim thickness to each side of the telescopic maintains the center line of the mast assembly.)

8.Reinstall the roller bearings. Torque the bolts per Table7-6.

9.Use a suitable lifting device and reinstall the outer telescopic into the main frame. Check for tightness while moving the outer telescopic to the bottom of the main frame. Add/remove shims as necessary to maintain a snug, but free-running, fit.

NOTE: If the outer telescopic hangs up, a pry bar may be used to move the telescopic.

10.Assemble the two top main frame roller bearings and bosses without shims.

11.Install the roller bearing assemblies, attach with a retaining bolt, and snug up to the main frame.

NOTE: Failure to snug the assemblies to the main frame results in the incorrect amount of shims, since the studs are canted.

12.With the outer telesc opic fully nested, use a pry bar and carefully move the outer

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Model 5200 High-Level Orderpicker

Mast Section telescopic to the opposite side. Using spare shims between the bearing and outer telescopic, determine the amount of shims required to remove side play.

13.Remove the roller bearing assemblies.

14.Install half of the total shim thickness to each roller bearing assembly.

15.Install the roller bearing assemblies and attach with the mounting bolts and tighten.

16.With the outer telescopic fully nested, use a pry bar to check for bearing tightness. If more shims can be inserted between the bearing and the outer telescopic, remove the roller bearing assembly and install the shim(s). Reinstall th e bearing assembly.

17.Check for correct shimming by pulling the outer telescopic out and then pushing it in all the way. The outer telescopic should not hang up while moving it in and out. Torque the bearing stud retaining bolts (refer to Table7-6 on page7-110).

18.Install the stops in the main frame.

Shimming Outer Telescopic to Inner Telescopic

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

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

2.Use a suitable lifting device and insert the inner telescopic into the outer telescopic all the way to the bottom.

3.Use a pry bar and carefully move the inner telescopic and bearings to one side.

4.Use spare shim(s) as a gauge to determine the amount required to move the bearings outward to make contact with the outer telescopic.

Publication Number: 1043922A, Revised: 2 Sept 2015