Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Mast Disassembly and Shimming shims between the bearing and inner telescopic, determine the number of shims required to remove side play.

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

5.Remove the inner telescopic from the outer telescopic.

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

7.Install half the total shim thickness required to each roller boss at the bottom of the inner telescopic.

8.Reinstall the roller bearings. Torque the bolts. (See Table7-6 on page7-110.)

9.Use a suitable lifting device and reinstall the inner telescopic into the outer telescopic. Check for tightness while moving the inner telescopic to the bottom of the outer telescopic.

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

10.With the inner telesc opic fully nested, use a pry bar to check for bearing tightness. If a thin shim can be inserted between the bearing and the outer telescopic, remove the inner telescopic and install the shim between the bearing and the roller boss. Torque the bearing stud retaining bolt (refer to Table7-6 on page7-110). Leave the lifting device connected to the outer telescopic. Do not apply excessive pressure to the bearings with the pry bar.

11.Assemble the two roller bearings and bosses for the top inner telescopic without shims.

12.Insert the bearing/boss assemblies and attach with the retaining bolts. Draw the bearing bosses up snug to the outer telescopic.

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

13.Use a pry bar and carefully move the inner telescopic to the other side. Using spare

14.Remove the bearing/boss assemblies.

15.Install half the total shim thickness to each bearing/boss assembly.

16.Install the bearing/boss assemblies into the outer telescopic/inner telescopic. Attach with a mounting bolt and tighten.

17.With the inner telescopic fully nested, use a pry bar to check for bearing tightness. If more shims can be inserted between the bearing and the inner telescopic, remove the bearing/boss assembly and install the shim(s). Reinstall the bearing/boss assembly. Torque the bearing stud retaining bolt. (See Table7-6 on page7-110.)

18.Check for correct shimming by pulling the inner telescopic out and then pushing it in all the way. The inner telescopic should not hang up while moving it in and out.

19.Install the outer lift cylinders.

20.Install the chain rollers and lift chains.

21.Adjust the main lift chain so the top of the inner telescopic is even with the outer telescopic +/- 0.125 in. (3.2 mm) And both chains have equal tension.

22.Adjust the free lift chains so the top of the fork just in front of the platform is at a minimum of 2.75 in. (70 mm) from the floor and the tips are at a maximum of 3.5 in. (89 mm) from the floor.

23.Install the center lift cylinders

Shimming Inner Telescopic to Carriage

1.Install the mast roller bearings on the carriage roller bosses.

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

NOTE: The carriage may have to be removed several times to obtain the correct fit.

3.Using a pry bar, move the bottom carriage bearings to one side.

Publication Number: 1043922A, Revised: 2 Sept 2015 7-113