Raymond Forklift 5200 Orderpicker Schematics Manual SN 1000 and up - PDF DOWNLOAD

Issued: 26 Aug 2015

Publication Number: 1123009B

©2015 The Raymond Corporation.

Serial Numbers 1000 and up

Model

5200

If you need assistance with your lift truck, or to order additional copies of this document, contact your local authorized Raymond Dealer. To locate your local authorized Raymond Dealer, go to www.raymondcorp.com.

This publication applies to the all subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this publication.

Use with Maintenance Manual 1043922B

Schematics

350A

FU3

OPTION ONLY)

TO JPS2-11 PAGE 2 (WIRE GUIDANCE

OPTION ONLY)

TO JPS2-24 PAGE 2 (WIRE GUIDANCE

A

D

TP3

2 FU5 350A OR 500A

MP

2

1

TP4

P

40A

FU4

A2

A1

FU14 2A

-

+ MS

MDE1

MDE2

MD

JPH10-2

TP2

SPL3

HM (OPT)

SPL-6

H

+

-

1

1

X

-

IN

1 2

Y

2

2

JPH5-2

PC

L/L SOL

L/H SOL

JPH10-1

TA

MS2

MDA2 SENSE

12VP HOUR METER ENABLE DGND

-6 -5 -4

GRN

IL8 12VP

BOOST

IL1

RTS/BOOT

DSR

-6

+5V

BOOST-

BOOST+

AGND

DGND

NC

-5

15A

FU1

15A

FU2

B-

GRN RED

IL9 IL10

IN-

K1

B-

B+KEY

B+PCF

B+F

GRN

MAST LIMIT SWITCHS

IL2

IN+

TM POWER SUPPLY

B+PC

B+

+12V GRN

IL6-10

GRN

DMAN1

IL3

RED

HEARTBEAT

B+ESTOP RELAY

+12V

STEERING POWER HEAD

IL4

GRN

+5V

-9

DGND

-4

COMPUTER

-8

DTR/PENDANT2

-3

IL6-6

GRN

HORN

IL6-4

GRN

BRKE

IL6-8

GRN

PC

IL6-7

GRN

L/L

IL6-9

GRN

L/H

IL6-1

GRN

WARN

IL6-2

GRN

SPARE

IL6-5

GRN

PUMP

IL7

RED

STEER LIMIT

TRACTION POWER AMP

-7

TXD RXD/PENDANT1

-2

NC

B+

-12

JT1 -1

PCSENSE

PSENSE

B+PC

B-

-22

B+

B-

-23

-11

B-

-10

-3

-1

HORN CTRL

-19

-2

NC B+HORN

-24

SPARE CTRL

-7

BRAKE CTRL

-15

PC CTRL

L/L SOL CTRL

L/H SOL CTRL

B+ESTOP RELAY

WARNING LIGHT CTRL (OPTION)

-17

-20

-8

-9

-21

-14

IL5

RED

PC DISABLE

TRAVEL ALARM

PUMP CTRL

-18

-16

B+PCF

-13

JPT12

-7

DEADMAN TRAVEL REF

-2

MS1

TRAVEL REQ.

TF/FORWARD

FF/REVERSE

-6

-9

-9 -15 -7

-4

-14

-10

Y

-5

-6

P

-3

-11

-13

-8

-12

B+KEY

PC DRIVE

NC

-10

NC

-1

X

JPT11

NC

J1-4

NC

-14

STEER CURRENT FB

-4

-13

STEER CURRENT LIMIT

-5

-12

BOOST -

-11

BOOST +

-2

-16

+

IL1

STEER DIR2 PWM

-7

-15

STEER DIR2

-10 STEER DIR1 PWM

STEER DIR1

-1

-6

AGND

-9

12VP

H 4

STEER FEEDBACK ENCODER

(OPT)

S16 (OPT)

8/B

1

+

BUS-

BUS+

DGND

DGND

HOME SENSE

12VP

DGND

SPARE IN 5

DGND

SPARE IN 4

DGND

SPARE IN 5

DGND

SPARE IN 4

N/C

CHB

+5V

DGND

-5

-2

-4

-3

GUIDANCE MANAGER

-3

JPT2 -1

0

-1

S8

TO JP4

S17 (OPT)

L/L ALARM

(L/L ALARM OPTION ONLY)

TO S21-2 ZONE H4

+

-

-2

JPT3

-8

-6

-4

-2

-7

-5

-3

-1

PT4

3

K3

-

0

+

-

0

-3

(OPT)

-1

-2

-3

-1

-2

7/A

5

-2

-2

CHA

-1

-3

-4

-3

JPT6 -1

DGND

-3

-1

-1

-4

-4

-4

RECEIVE

-3

-2

-2

DGND TRANSMIT

DEADMAN 2

+12VP

-5

-3

-4

-5

ENC 1

LED 10

-1

JPH7

3A

LED 9

-2

JPC9 -2

LED 8

-3

L/L ALARM

-2

IL3

IL2

RED

+5V DGND

IN+ IN-

CM POWER SUPPLY

GRN

MODEL 5200

+V_P

DGND

-1

JPC4

JPC12 -14

DGND

+12VP

DGND

SLACK CHAIN

-2

11.3VP -1

DGND

TRANSMIT

RECEIVE

DGND

DEADMAN2

+12VP

B-

B+ESTOP

B+KEY

B+F

B-

B+F

B-

B+F

-3

JPC12

-4

-2

-3

JPC10 -1

11.3VP

LED 7

-4

-1

LED 6

-5

L2 L1

LED 4

-8

L3

LED 3

-9

LED 5

LED 2

-10

-6

LED 1

-11

JPC1

-7

JPC8 -6

B-

FU19

MAST CABLE 1

L6

L5 L4

-1

-3

DETAIL A1

L8

L9

L7

L10

DISPLAY CARD

F

JPT9 -6

-4

B+F

JPT10

-3

-1

B+KEY B+ESTOP

B+F

PT7

-15

-2

-3-

-20

-7

-1+

-16

-3-

-8

-2

DGND

SPARE IN 3

12VP

N/C

DGND

LIFT LIMIT SW.

12VP

DGND

-14

-20

-12

SLACK CHAIN 4

HEIGHT 180" SW

12VP

-5

-1+

-3-1+

-11

-13

-20

-9

-3-

-1+

-10

-6

-3-

-3

DGND

-20

-1

-20

-1+

JPT5 -2

-4

12VP

DGND

SLACK CHAIN 3

12VP

DGND

HEIGHT 120"/150"SW

E

ALARM

(Updated from 1043922A)

(OPT)

WL

YEL

FAULT

B

MOTORMHA 4(-)

TRACTION POWER AMP

JPH5-1

B-

S2

S1

M-

B+

A2

A1

MOTOR+

MHA 1(+)

RED

CURRENT LIMIT

DGND 12VP

-8

STEER/TRACTOR MANAGER

D

LIFT/LOWER

Publication Number: 1123009B, Issued: 26 Aug 2015

2

TP1

STEER POWER HEAD

JT8

-3

PS1

C

POWER & DRIVERS

7

6

B-

24V

B+

1

PC

B

S24 (OPT)

5

4

3

2

A

SEE SHEET 2

Section B. Appendix

DGND +V_P

N/C

DGND

LOWER LIMIT

11.3VP

DGND

SPARE

11.3VP

N/C

CHB

SE 5V

DGND

CHA

CHANNEL C

RED

IL1

NC

NC

DGND

11.3VP

DGND

SIDEGATE 1

11.3VP

DGND

HEIGHT 60" SW

11.3VP

DGND

24" LIMIT

11.3VP

DGND

DEADMAN#2

11.3VP

DGND

DEADMAN#1

11.3VP

DGND

LIFT/LOWER LIMIT BYPASS

HORN

DGND

L/L

+5.3V

DGND

TRAVEL

+5.3V

N/C

B+ESTOP

B+KEY

B+KEY

B+F

N/C

N/C

DGND

W/G AUTO MANUAL

HEARTBEAT

CARRIAGE MANAGER

G

ENCODER STEERING

Model 5200 High-level Orderpicker Schematics

ENCODER STEER FEEDBACK

S30 (OPT)

HOME SENSOR

S25 (OPT) SLACK CHAIN

(OPTION) CAN

POWER SPARE DEADMAN/LIMIT SWITCHES

S22 (OPT) KEY,EPO

S29 (OPT) CONTROL HANDLE

DISPLAY

-2 -1

-7 -5

-20 -3-1+ -20 -3-1+ -20 -3-

-6 -4 -8 -7 -9 -11 -12 -10

-8

-15

-7

GND

-3

-2

-

0

+

0 -3 -1

-

+

-VS

+VS

-2

-1

-3-1+

-5

-20

S61 (OPT)

S60 (OPT)

S20 (OPT)

S19 (OPT)

S7

S6

S23

S2

S3 HORN

VR2 LIFT/LOWER

VR1 TRAVEL

CONTROL HANDLE

S21

2

-1

2

2

S51 (OPT)

-3

-6

1

-2

S3 -3

2

1

S1

EPO

-1+

1

1

-1

JPC12

0

-

+

STEER INPUT ENCODER 1

STEER INPUT ENCODER 2

KEYSWITCH

JPC7 -2

-1

-4

-2

JPC5 -3

-3

-4

-6

-5

-7

-9

JPC9 -8

-4

-3

-2

-1

JPC11 -5

-4

-8

-1

-3

-2

-3

JPC3 -6

-2

-1

JPC6 -3

-5

-4

-3

-2

-1

JPC2

-13

-12

JPC12 -11

H

Figure 1. Electrical Schematic, Sheet 1

2

TP4

PC-1

1

JPH12-2

JPH12-1

2

1

10A

FU12

2

JPH11-2

OTM WIRES

JPH11-1

1

1

2

10A

FU11

2

SPL1

JPH13-1

1

JPH14-1

S75

-4

-2

-3

-1

JPC10

-1

-1

-1

-1

6A

FU10

6A

FU9

2A

FU8

-2

-2

-2

FU7 -2

2A

HTR2

TH2

2

HTR4

HTR3

3

2

4

1

(EE ONLY)

TS1

JPH9-1

JPH8-1

RF TERMINAL

(OPTION)

S27

S26

BIN LIGHT

(OPTION)

C

3A

-3

-3

B+F

B+F

-2

-1

-3

-4

-2

JPT10

-2

JPH12 -1

-1

-3

-4

JPC9 -2

-2

JPH11 -1

-2

JPC14 -1

-1

-1

JPT14 -1

-4

-4

DGND

TRANSMIT

-11

-24

JPS2

-5

-6

-3

-4

-1

JPS4

JPC8 -6

-2

-1

JC15 -2

B+ESTOP

B-

BUS-

BUS+

DGND

RES

TERM

-5

MAST CABLE 2

MAST CABLE 1

GND

+12V

-2

FU19

-1

-20

-2

-19

SPEEDFB B

SPEEDFB A

12V

POWER SUPPLY

GUIDANCE CARD

B+ESTOP

SYSTEM

-5

JPT9 -6

-12

-4

JT15 -2

-19

-1

-13

-8 -7

-2

JPS1

JPH6 -3

FILTER CARD

JS1

E

RECEIVE

DGND

DEADMAN 2

+12VP

TRAVEL SPEED ENC2

-13

-15

-15

-8 -14

-8 -14

-7

-7

B-

K1

-5 -6

-5 -6

-3

-3

JPW1 -1 -2

-1 -2

JP1L

-15 -13

-14

-14

-8

-15

-7

-7 -8

-6

-5

-5 -6

-3

B+KEY B+ESTOP

RED

+12V

AGRD

T3

T2

T1

T0

LEFT

JPW2 -2

-1

-3

-2

-1

JP1T

B-

GRN

IL9 IL10

GRN

DETAIL A1

SENSOR

IL2

RIGHT

+12V

AGRD

T3

T2

T1

T0

LEFT

NEAR WIRE

TRACTOR SENSOR

LOAD

RIGHT NEAR WIRE

D WIRE GUIDANCE MANAGER (OPTION)

B+ESTOP RELAY

4

H

(Updated from 1043922A)

JPH9-2

JPH8-2

SPL2

JPH13-2

JPH14-2

BIN LIGHT

DEADMAN

HTR1

CONSOLE

HTR6

CONTROL HANDLE SPL5 2

COLD STORAGE TRACTOR

TH1

1

OPTIONAL POWER W/RF AND BIN LIGHTS SHOWN

TP4

PC-1

10A

FU13

COLD STORAGE CARRIAGE

B

Publication Number: 1123009B, Issued: 26 Aug 2015

7

6

5

4

3

2

A

Model 5200 High-level Orderpicker Schematics

B-

B+ESTOP

B+KEY

B+F

DGND

TRANSMIT

RECEIVE

DGND

DEADMAN2

+12VP

IL3

IL2

RED GRN

F

BALLAST

5 AMP

SLR-2

SLL-2

5 AMP

+

FL-1

FL-2

FAN S41

S43

1

1

1

S90

3

JPC78 -2

JPC78 -1

-1

-3

JPC77 -2

-1

-1

10A

FU16

10A

FU15

-2

-2

TP4

PC-1

-1

-1

10A

FU16

10A

FU15

-2

-2

10A AUX. POWER OPTION

TP4

PC-1

10A AUX. POWER OPTION

TO FU8-2 ZONE B6

TO JPC11-1 ZONE H4 SHEET 1

TO S1-2 ZONE H4 SHEET 1

4

JPT14-2

JPT14-1

4

JPH12-2

JPH12-1

4

6

1

3

2

DA60

K2

JPC14-2

JPC14-1

DETAIL B2

JPH11-2

JPH11-1

DETAIL A2

1

-1

-1

-1

-1

4

1

5

10A

FU8

10A

-2

FU7 -2

10A

FU8

-2

FU7 -2 10A

5 -

6 +

PC5

2

1

TO FU10-2 (TS1-3, EE ONLY)

TO FU9-2 (TS1-2, EE ONLY)

H

Figure 2. Electrical Schematic, Sheet 2

SUPPRESSOR NETWORK

G

2,3,4

WORKING LIGHTS

2

S40

DOME LIGHTS

2

2

SECURITY START SWITCH (OPTION)

SLR-1

SLL-1

FL-1

5 AMP

FAN

BALLAST

-

LIGHTS AND FAN OPTION (SHOWN)

BALLAST

3

F3

2 1 1 1 1 1 2 2 2 2 2 2 2 1 2 2 2 2 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 2 1 2 2 1 2 2 2 2 2 2

FL FU1 FU2 FU3 FU4 FU5 FU7 FU8 FU9 FU10 FU11 FU12 FU13 FU14 FU15 FU16 FU17 FU18 FU19 H HM HTR1 HTR2 HTR3 HTR4 HTR6 IL1(CM) IL1(SPH) IL1(STM) IL2(STM) IL2(CM) IL3(STM) IL3(CM) IL4(STM) IL5(STM) IL6-1 IL6-2 IL6-4 IL6-5 IL6-6 IL6-7 IL6-8 IL6-9 IL6-10 IL7 IL8 IL9 IL10 J1 JPC1 JPC2 JPC3 JPC4 JPC5 JPC6 JPC7 JPC8 JPC9 JPC10 JPC11 JPC12 JPC14 JC15 JPC77 JPC78 JPCH9 JPH5 JPH6 JPH7 JPH8 JPH9 JPH10 JPH11 JPH12 JPH13 JPH14 JP1L JP1T

INTERFACE CABLE CONNECTOR FOR DEADMAN HEATER (OPTION) INTERFACE CABLE CONNECTOR FOR CONTROL HANDLE HEATER (COLD STORAGE OPTION) LOAD ANTENNA CONNECTOR TO FILTER CARD TRACTOR ANTENNA CONNECTOR TO FILTER CARD

SECURITY START SWITCH CONNECTOR CONTROL HANDLE CONNECTOR BRAKE CONNECTOR TRAVEL SPEED ENCODER CONNECTOR STEER FEEDBACK ENCODER CONNECTOR BIN LIGHT CONNECTOR (OPTION) BIN LIGHT CONNECTOR (OPTION) WARNING LIGHT CONNECTOR CARRIAGE CONNECTION FOR CS HEATERS TRACTOR CONNECTION FOR CS HEATERS

CARRIAGE MANAGER CONNECTOR FOR DISPLAY CARD CARRIAGE MANAGER CONNECTOR FOR STEER INPUT ENCODER CARRIAGE MANAGER CONNECTOR LOWER LIMIT & W/G AUTO MANUAL SWITCHES CARRIAGE MANAGER CONNECTOR FOR L/L ALARM CARRIAGE MANAGER CONNECTOR FOR LIFT/LOWER LIMIT BYPASS SWITCH CARRIAGE MANAGER CONNECTOR (SPARE) CARRIAGE MANAGER CONNECTOR FOR DEADMAN/LIMIT SWITCHES CARRIAGE MANAGER CONNECTOR FOR MAST CABLE 1 (SIGNALS) CARRIAGE MANAGER CONNECTOR FOR MAST CABLE 1 (POWER) CARRIAGE MANAGER CONNECTOR FOR SPARE POWER CARRIAGE MANAGER CONNECTOR FOR KEY, EPO SWITCHES CARRIAGE MANAGER CONNECTOR FOR SIDEGATE SWITCHES, STEER INPUT ENCODER 2 CARRIAGE CONNECTION FOR 10A OPTION 2 AVAILABLE OTM CONDUCTORS SECURITY START SWITCH CONNECTOR

TRACTION POWER AMP CONNECTOR

STEER/TRACTOR MANAGER COMMUNICATIONS RECEIVE LED; BLINKING = RECEIVING COMMUNICATIONS

STEER/TRACTOR MANAGER COMMUNICATIONS TRANSMIT LED; BLINKING = TRANMITTING COMMUNICATIONS

STEER/TRACTOR MANAGER BOOST POWER SUPPLY LED; ON = BOOST VOLTAGE PRESENT

STEER/TRACTOR MANAGER STEER CURRENT LIMIT LED; ON = CURRENT LIMIT

STEER/TRACTOR MANAGER DEADMAN 1 SWITCH (S2) LED; ON = SWITCH DEPRESSED

STEER/TRACTOR MANAGER LOAD HOLD SOLENOID CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER POWER CUTOFF CONTACTOR CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

(BRIGHTNESS INDICATES PWM)

STEER/TRACTOR MANAGER LIFT/LOWER SOLENOID CONTROL LED; ON = CONTROL OUTPUT AVTIVATED

STEER/TRACTOR MANAGER HORN CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER PUMP CONTACTOR CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER BRAKE CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER SPARE CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER WARNING LIGHT CONTROL LED; ON = CONTROL OUTPUT ACTIVATED

STEER/TRACTOR MANAGER +5 VOLT POWER SUPPLY LED; ON = +5V PRESENT

CARRIAGE MANAGER COMMUNICATIONS TRANSMIT LED; BLINKING = TRANSMITTING COMMUNICATION

BLINKING CODE = ERROR CONDITION

STEER/TRACTOR MANAGER HEARTBEAT LED; BLINKING SLOW = PROGRAM RUNNING,

CARRIAGE MANAGER COMMUNICATIONS RECEIVE LED; BLINKING = RECEIVING COMMUNICATION

STEER/TRACTOR MANAGER DEADMAN 2 SWITCH (S23) LED; ON = SWITCH DEPRESSED

STEER/TRACTOR MANAGER +12 VOLT POWER SUPPLY LED; ON = +12V PRESENT

STEER POWER HEAD STEER CURRENT LIMIT LED; ON = CURRENT LIMIT

CARRIAGE MANAGER HEARTBEAT LED; STEADY ON = +5V PRESENT, BLINKING SLOW = PROGRAM RUNNING, BLINKING CODE = ERROR CONDITION

HEATER FOR CONTROL HANDLE (COLD STORAGE OPTION)

ELECTRONIC HORN HOUR METER HEATER FOR OPERATOR'S CONSOLE (COLD STORAGE OPTION) HEATER FOR DEADMAN (COLD STORAGE OPTION) HEATER FOR TRACTOR COMPARTMENT (COLD STORAGE OPTION) HEATER FOR TRACTOR COMPARTMENT (COLD STORAGE OPTION)

POWER FUSE FOR AUX. POWER, B+, 10 AMPS POWER FUSE FOR AUX. POWER, B-, 10 AMPS POWER FUSE FOR AUX. POWER, B+, 10 AMPS POWER FUSE FOR AUX. POWER, B-, 10 AMPS POWER FUSE FOR STEER TRACTOR MANAGER, B+KEY, 3 AMPS

CONTROL FUSE FOR RF TERMINAL B+, 2 AMPS CONTROL FUSE FOR RF TERMINAL B-, 2 AMPS CONTROL FUSE FOR LIGHTS & FAN B+, 6 AMPS CONTROL FUSE FOR LIGHTS & FAN B-, 6 AMPS CONTROL FUSE FOR CARRIAGE HEATERS, 10 AMPS (COLD STORAGE OPTION) CONTROL FUSE FOR TRACTOR HEATERS,10 AMPS (COLD STORAGE OPTION) CONTROL FUSE FOR CARRIAGE HEATERS, 10 AMPS (COLD STORAGE OPTION) CONTROL FUSE FOR GUIDANCE MANAGER B+ESTOP, 2A (WIRE GUIDANCE OPTION).

CONTROL FUSE FOR B+PC, 15 AMPS CONTROL FUSE FOR B+, 15 AMPS POWER FUSE FOR TRACTION MOTOR, 350 AMPS POWER FUSE FOR STEER MOTOR, 40 AMPS POWER FUSE FOR LIFT PUMP MOTOR, 350 OR 500 AMPS

CONNECTOR FOR FAN (OPTION)

DIODE MODULE FOR SECURITY START SWITCH

ELECTRICALLY RELEASED BRAKE BATTERY CONNECTOR BATTERY CONNECTOR

DESCRIPTION

(Updated from 1043922A)

B2,B3,D7 B3,C3 B2,B3 D3 D2

F5 G4 B5,C5 D4 E5 B6,C6 B6,C6 B5 A2,A3,E7

F2 G2 G3 F7 G5 G2 G5 F4 F4 F3 G3 G6 E7,G7 E6 F5

C3

D5

D5

D7

D3

D3

D5

D5

D5

D6

D4

D5

D5

D5

D3

D7

G5

D3

G4

D4

D7

C3

G6

B2

C6 C6 B3 B3 B4 B4

F6 F6 H6 H6 E4

B5 B6 B6 B6 B2 B4 A2 B5

D5 D5 A3 B3 B3

G5

2

DA60

C5 A3 A4

ZONE

1 1 1

SHEET

B B+ B-

IDENT.

Publication Number: 1123009B, Issued: 26 Aug 2015

Model 5200 High-level Orderpicker Schematics

1

1 1 1

WL

2

TS1 VR1 VR2

1 1 1 1 2

1

TA

TP1 TP2 TP3 TP4 TP4

2 2 1 2 1

SPL1 SPL2 SPL3 SPL5 SPL6

2 2

2

SLR

TH1 TH2

2

SLL

1 1 1

S6 S7 S8

1 1 1 1 1 1 1 2 2 1 1 2 2 2 1 1 1 2 2

1 1

S1 S2

1 1

1 1 2

PC PC PC-1

S19 S20 S21 S22 S23 S24 S25 S26 S27 S29 S30 S40 S41 S43 S51 S60 S61 S75 S90

1 1

P P

S16 S17

1 1 1

MD MP MS

1 1 1

2

L/H SOL L/L SOL L/L ALARM

1

2 2

JPW1 JPW2

K3

1

JT1

K2

1 2

PS1 JS1

K1

1 1 1 1 1 1 1 1 1 1 1 2 2

JPT2 JPT3 JPT4 JPT5 JPT6 JPT7 JPT8 JPT9 JPT10 JPT11 JPT12 JPT14 JT15

SHEET 2 2 2

IDENT. JPS1 JPS2 JPS4

C5

H4 H4

B5

A3 B3 B3 B4 A3,A5

B2 B4

C5

B3 C3 C5 C2 C5

F3

F3

H6 H6 H4 E2 H5 E3 E3 C6 E2 D2 E3 G3 G3 G2 H5 H3 H3 B2 F4

F5 F5

H5 H6 E6

H3 H5

A3 C5 A2,A4

B3 C4

B4 B4 B3

C5 C5 E6

F6

G4

D4

D3 D2

C7

C2 E2

E7 E6 E5 E2 E5 E3 C2 E4 E4 C3 C4 D7,G7 D6

E4 E6 E5

ZONE

WARNING LIGHT

CONTROL HANDLE TRAVEL REQUEST VARIABLE RESISTOR CONTROL HANDLE LIFT REQUEST VARIABLE RESISTOR

TERMINAL STRIP FOR OPTIONAL POWER (EE OPTION)

TIE POINT FOR TRACTION POWER FUSE (FU3) TIE POINT FOR STEER POWER FUSE (FU4) TIE POINT FOR LIFT PUMP POWER FUSE (FU5) TIE POINT FOR BTIE POINT FOR B-

THERMOSTAT FOR CARRIAGE HEATERS (COLD STORAGE OPTION) THERMOSTAT FOR TRACTOR HEATERS (COLD STORAGE OPTION)

TRAVEL ALARM (OPTIONAL)

SPLICE FOR DEADMAN HEATER (COLD STORAGE OPTION) SPLICE FOR DEADMAN HEATER (COLD STORAGE OPTION) SPLICE FOR POWER TO GUIDANCE MANAGER SPLICE FOR HEATER IN HANDLE (COLD STORAGE OPTION) SPLICE FOR TRAVEL ALARM WITH EE OPTION

CONNECTOR ON BALLAST FOR WORKING LIGHTS

CONNECTOR ON BALLAST FOR WORKING LIGHTS

SIDEGATE SWITCH 1 SIDEGATE SWITCH 2 EPO (EMERGENCY POWER OFF) SWITCH SLACK CHAIN SWITCH 3 DEADMAN 2 SWITCH LIFT LIMIT SWITCH (OPTION) 180" LIMIT SWITCH (LOCATED ON MAST) BIN LIGHT SWITCH (OPTION) BIN LIGHT SWITCH (OPTION) 120"/150" LIMIT SWITCH (LOCATED ON MAST) SLACK CHAIN SWITCH 4 OPTIONAL WORKING LIGHTS SWITCH OPTIONAL DOME LIGHTS SWITCH OPTIONAL FAN SWITCH LIFT/LOWER LIMIT BYPASS SWITCH (OPTION) LOWER LIMIT SWITCH W/G AUTO MANUAL SWITCH THERMOSTAT FOR CONTROL HANDLE HEATER (COLD STORAGE OPTION) SECURITY START SWITCH

SLACK CHAIN SWITCH 1 SLACK CHAIN SWITCH 2

24" LIMIT SWITCH (LOCATED ON CARRIAGE) 60" LIMIT SWITCH 1 (LOCATED ON CARRIAGE) HOME POSITION SWITCH

KEY SWITCH DEADMAN 1 SWITCH

POWER CUTOFF CONTACTOR CONTACTS POWER CUTOFF CONTACTOR COIL COLD STORAGE OPTIONS CONNECTION

PUMP CONTACTOR CONTACTS PUMP CONTACTOR COIL

DRIVE MOTOR LIFT PUMP MOTOR STEER MOTOR

LOAD HOLD SOLENOID LIFT/LOWER PROPORTIONAL SOLENOID LIFT/LOWER ALARM

L/L ALARM RELAY

STEER/TRACTOR MANAGER B+ESTOP RELAY SECURITY START RELAY

FILTER CARD CONNECTOR TO LOAD ANTENNA FILTER CARD CONNECTOR TO TRACTOR ANTENNA

STEER/TRACTOR MANAGER CONNECTOR FOR COMPUTER INTERFACE

STEER/POWER HEAD CONNECTOR FILTER CARD AND GUIDANCE MANAGER INTERFACE

STEER/TRACTOR MANAGER CONNECTOR FOR CAN INTERFACE STEER/TRACTOR MANAGER CONNECTOR FOR HOME SENSOR STEER STEER/TRACTOR MANAGER CONNECTOR (SPARE) STEER/TRACTOR MANAGER CONNECTOR FOR MAST LIMIT SWITCHES, LIFT LIMIT SWITCH STEER/TRACTOR MANAGER CONNECTOR FOR STEER ENCODER FEEDBACK STEER/TRACTOR MANAGER CONNECTOR (SPARE) STEER/TRACTOR MANAGER CONNECTOR FOR STEER POWER HEAD STEER/TRACTOR MANAGER CONNECTOR FOR MAST CABLE 1 (SIGNALS) STEER/TRACTOR MANAGER CONNECTOR FOR MAST CABLE 1 (POWER) STEER/TRACTOR MANAGER CONNECTOR FOR TRACTION POWER AMP STEER/TRACTOR MANAGER CONNECTOR FOR POWER & DRIVERS TRACTOR CONNECTION FOR 10A OPTION 2 AVAILABLE OTM CONDUCTORS

TRAVEL SPEED ENCODER CONNECTION TO GUIDANCE MANAGER POWER TO GUIDANCE MANAGER GUIDANCE MANAGER CONNECTION TO CAN

DESCRIPTION

Figure 3. Electrical Schematic, Legend

4

P

Publication Number: 1123009B, Issued: 26 Aug 2015

GEAR PUMP

M

G1

Model 5200 High-level Orderpicker Schematics

1

1

2

1

2

(Updated from 1043922A)

1

3

5

P R OP VAL VE S OL - 2 L/ L

CV - 1 5 PSI

2

/

H

1

2

LOAD HOLD S OL - 1

L

1

Return Lines

4

2

Pressure Lines

LEGEND

RE L - 1

G2

C2

C1

B

6 GPM FLOW CTRL

SIDE CYLS.

6 GPM FLOW CTRL

9 GPM FLOW CTRL

Figure 4. Hydraulic Schematic

5