Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Mast Section Forks

Forks Remove

1.Raise the operator platform high enough to reach the bottom of the forks.

2.Block the operator platform.

3.Secure the fork to the hoist using a suitable strap or chain.See Figure7-215.

4.Remove the socket head cap screw from underneath the fork at the tractor end. See Figure7-215.

6.Drive out the pivot pin. The fork, washers, or shim drops. See Figure7-216.

7.Replace the damaged fork.

Install

1.Hold the new fork in place underneath the operator platform.

2.Install the pivot pin through the fork. NOTE: Always use a new snap rings when assembling components.

3.Install a new snap ring in the pivot pin.

4.Install the correct amount of washers or shim at the back side of the fork to maintain a level fork. See Figure7-217.

5.Install

6.Remove the block from the operator platform.

7.Lower the operator platform to the floor and make sure the forks are level. The top surface of the forks should be within 0.25 in. (6.3 mm) of each other (31 in. and longer) or 0.125 in. (3.2 mm) of each other (under 31 in.) at the tips. If the forks are not level, add more shims to the fork.

8.Check the fork up tilt. It must be between level and 0.5 inch (12.7 mm) maximum.

Publication Number: 1043922A, Revised: 2 Sept 2015

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Section 7.Component Procedures

Pallet Clamp

Pallet Clamp Install

1.Install the pallet clamp assembly on the platform front plate. Secure it with four (4) M10 x 20 screws. Torque to 30 ft. lbs. (41Nm).

2.Install the pedal assembly to the platform main support plate. Secure it with two (2) M8 x 20 screws. Torque to 15 ft. lbs. (20 Nm).

3.Hook the tension spring into the 1/4-inch holes in the pivot bracket and pedal weld in the pedal assembly. See Figure7-218.

Model 5200 High-Level Orderpicker

Mast Section

8.Adjust the hex nut closest to the pedal mounting until there is a 90° angle between the pallet clamp and the left-hand pallet support. Torque the remaining hex nut to 21 ft. lbs. (29 Nm).

4.To extend the spring so you can connect the cable assembly, slide a two inch-wide block between the left-hand pallet support and the pallet clamp on the pallet clamp assembly.

5.Install the cable bracket on the pedal assembly. Secure it with the M8 x 10 shoulder bolt and M8 hex nut. Torque to 15 ft. lbs. (20 Nm).

6.Place the cable assembly in the cable bracket and secure with the M6 hex nuts. Finger-tighten the hex nut closest to the pedal mounting and leave the other nut loose.

7.Remove the two inch block you used in Step 4.

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Publication Number: 1043922A, Revised: 2 Sept 2015