Section 7.Component Procedures

Mast Disassembly and Shimming

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

5.Move the carriage to the top of the inner telescopic and repeat the process for the top set of bearings.

6.Remove the carriage from the inner telescopic.

7.Install half of the total shim thickness required to each roller boss.

8.Reinstall the roller bearings.

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

10.Use a pry bar to check for bearing tightness. If a thin shim can be inserted between the bearing and the inner telescopic, remove the carriage and install the shim between the bearing and the roller boss. Do not apply excessive pressure to the bearings with the pry bar.

11.Use a suitable lifting device and reinstall the carriage, checking for tightness. Make sure the carriage can be moved in and out by hand.

12.When the correct fit is obtained, measure the gap between the top of the platform and the inner telescopic on both sides. If the gap between the platform and the inner telescopic is not within 1/16 in. (1.59 mm) of each other, remove the platform.

13.Take shims from the top roller on the side that is farthest away and install them on the opposite side. Repeat this procedure until 1/16 in. (1.59 mm) is obtained. If all shims are on one side of the top rollers, remove shims from the bottom roller on the side that is farthest away and install them on the opposite side.

14.Repeat this procedure until the required clearance at the top of the platform is obtained.

15.Install the carriage and the carriage stops.

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Mast Section

16.Install the pulleys for the over-the-mast hoses and cables.

17.Secure the main carriage and telescopics in place so that they do not move while standing the assembly back up.

18.Install all the other items removed during the disassembly process after laying the assembly down.

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

19.Attach the hoist to the mast assembly and stand the mast back up. Install all the other items removed during the disassembly process prior to laying the assembly down.

20.Attach the tractor to the mast.

21.Install the remaining components.

22.Connect the hoses and cables inside the tractor compartment. Set spring tension so the cables just stay on the pulleys. Higher tension causes premature failure. Maximum spring tension is 5 to 7 in. lb. (0.57 to 0.79 Nm).

Make sure all mast stops are installed and securely tightened before operating the lift truck.

23.Reinstall the battery.

24.Reconnect the battery connector and turn the key switch ON.

25.Adjust the lift chains.

26.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.

27.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.

28.Install the forks and mast guard.

Publication Number: 1043922A, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Mast Disassembly and Shimming

29.Check for correct operation.

30.Grease the channels.

31.Bleed the lift cylinders. See “Bleeding the Hydraulic System” on page7-88 .

Publication Number: 1043922A, Revised: 2 Sept 2015

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Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Lift Chains, Three-Stage

Lift Chains, Three-Stage

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.

Center Cylinder Chain Replace

1.Turn the key switch OFF and disconnect the battery connector.

2.Inspect the lift chain for wear or broken links. See “Lift Chain” on page7-123.

3.Attach a suitable hoist and lift the carriage approximately 3 feet (0.9 m) and block.

4.Disconnect the chain from the chain anchor and feed out the lift truck.

5.Replace the chain as necessary.

6.Feed the chain over the pulley and connect in the chain anchor.

7.Remove the block and hoist.

8.Reconnect the battery connector and test lift function before returning the lift truck to service.

Side Cylinder Chains Replace

1.Inspect the lift chain for wear or broken links. See “Lift Chain” on page7-123.

2.Lift the carriage enough to block between the carriage and inner telescopic.

3.Place blocking between the carriage and the inner telescopic.

4.Turn the key switch OFF and disconnect the battery cinnector.

5.Disconnect the chain from chain anchors. Feed the chain off the pulley. See Figure7-210 and Figure7-211.

6.Replace the chain as necessary. See Figure7-212.

7.Feed chain over pulley and connect in chain anchors. See Figure7-210 and Figure7-211

Publication Number: 1043922A, Revised: 2 Sept 2015

Mast Section 7-116

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Section 7.Component Procedures

Mast Section Lift Chains, Three-Stage

8.Remove block and hoist.

9.Reconnect the battery connector and test lift function before returning the lift truck to service.

Publication Number: 1043922A, Revised: 2 Sept 2015

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Section 7.Component Procedures

Lift Chains, Two-Stage

Lift Chains, Two-Stage

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.

1.Attach a suitable hoist and block the carriage just enough to gain slack on the chains.

2.Disconnect the chain anchors from both sides. See Figure7-213 and Figure7-214.

Model 5200 High-Level Orderpicker

Mast Section

3.Inspect the lift chain for wear or broken links. See “Lift Chain” on page7-123.

4.Replace the chains as necessary.

5.Connect the outside chain anchor. See Figure7-214.

6.Feed the chain over the pulley.

7.Connect the chain to the inside anchor. See Figure7-213.

8.Remove the block and hoist.

9.Reconnect the batter y connector and test the lift function before returning the lift truck to service.

Publication Number: 1043922A, Revised: 2 Sept 2015