Raymond Forklift 5200 High-Level Orderpicker Lift Truck Maintenance Manual 1043922B – PDF DOWNLOAD

Description

Raymond Forklift 5200 High-Level Orderpicker Lift Truck Maintenance Manual 1043922B – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 5200 High-Level Orderpicker Lift Truck Maintenance Manual 1043922B – PDF DOWNLOAD

Language : English
Pages : 389
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Raymond Forklift 5200 High-Level Orderpicker Lift Truck Maintenance Manual 1043922B – PDF DOWNLOAD

Serial Numbers:
5200 1000 and up

Manual Design:

This Maintenance Manual is designed with the following objectives in mind:
• Provide technical coverage for expected levels of user expertise.
• Anticipate your needs and reduce your decisions regarding maintenance.
• Reduce page flipping through a “one-stop shopping” approach.
The two-line running page header at the top of each page tells you:
• Name of the manual
(Model 5200 High-Level Orderpicker).
• Current Section Title
(for example, this page How to Use This Manual).
• Current topic
(for example, this page Manual Design).

This manual consists of the following sections:

TABLE OF CONTENTS:

Raymond Forklift 5200 High-Level Orderpicker Lift Truck Maintenance Manual 1043922B – PDF DOWNLOAD

Document Revision Historyv
Service Information Listvi
How to Use This Manual 1-1
Manual Design1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations and Symbols1-4
Safety2-1
Definitions 2-2
General Safety 2-3
Battery Safety 2-5
Static Precautions 2-7
Jacking Safety 2-8
Emergency Lower Valve 2-10
Tie-Down for Transport 2-11
Towing 2-12
Welding Safety2-13
Systems Overview3-1
Introduction 3-2
Lift Truck Specifications 3-3
General Information 3-4
Installation3-7
Wire Guidance 3-8
Wire Guidance Setup Procedure 3-9
FlashWare3-12
Cold Storage 3-14
UL Label “EE”3-16
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Initial 90 Day/250 Deadman Hours (HD) Maintenance4-3
Every 180 Days or 500 Deadman Hours (HD) 4-4
Every 360 Days or 2000 Deadman Hours (HD)4-8
Contactor Tip Inspection 4-9
Chain Maintenance 4-10
Troubleshooting 5-1
Electrical Troubleshooting 5-2
Troubleshooting Wiring Problems 5-6
Switches (General) 5-8
Electric Motor Tests5-9
Contactors5-14
Fuses5-14
Wire Guidance Troubleshooting 5-15
Wire Guidance Troubleshooting in FlashWare5-16
Hydraulic Troubleshooting Guidelines5-18
Definitions5-19
Electrical Connector Locator Chart 5-20
Programmable Maintenance Tool 5-22
Drive Unit Troubleshooting Guide5-28
List of Troubleshooting Tables5-29
Symptom Tables: Hydraulic Functions5-31
Table of Contents Model 5200 High-Level Orderpicker
ii Publication Number: 1043922B, Revised: 2 Sept 2015
Symptom Tables: Travel Functions 5-33
Symptom Tables: Electrical Symptoms 5-34
Codes and Tests 6-1
Operator Display Messages6-2
Maintenance Mode6-5
Traction Power Amplifier Fault Codes 6-8
Guidance Manager Operational Codes6-17
Guidance Manager Fault Codes 6-19
Tests 6-39
Operator Display Fault Codes6-41
Component Procedures 7-1
List of Component Procedures 7-2
Component locator Photos7-5
Covers and Finish 7-11
Tractor Covers 7-11
Operator Console Cover 7-11
Special Tools and Decals7-12
Special Tools 7-13
Decals and Tags 7-14
Steering and Controls 7-17
Steer Motor 7-18
Control Handle 7-20
Operator Display 7-26
Proximity Sensor Adjustment7-27
Drive and Brake 7-29
Drive Unit7-30
Drive Wheel 7-50
Brake7-52
Electrical Components 7-55
Battery Procedures 7-56
Power Cables7-58
Motors (General) 7-60
Traction Motor 7-65
Lift Motor7-67
Horn 7-68
Fuses7-69
Circuit Cards (General) 7-70
EPROM/Microprocessor Removal/Replacement 7-71
Switches (General) 7-73
Warning Light7-74
Wiring and Harness Repair 7-75
Hydraulic Components 7-83
Hydraulic Fluid 7-84
Solenoid Valves 7-85
Lift Pump7-86
Lift Pressure Relief Valve Adjustment7-87
Bleeding the Hydraulic System 7-88
Side Cylinder7-89
Center Lift Cylinder 7-93
Flow Control Valve 7-96
Mast Section7-97
Carriage with Three-Stage Mast 7-98
Model 5200 High-Level Orderpicker Table of Contents
Publication Number: 1043922B, Revised: 2 Sept 2015 iii
Inner Telescopic7-102
Outer Telescopic7-104
Carriage With Two-Stage Mast 7-105
Two-Stage Telescopic7-107
Mast Shimming 7-108
Upper Mast Bearing Replacement 7-110
Mast Disassembly and Shimming 7-111
Lift Chains, Three-Stage7-116
Lift Chains, Two-Stage 7-118
Forks7-119
Pallet Clamp7-120
Load Wheels7-121
Skid Pads 7-122
Lift Chain 7-123
Theory of Operation 8-1
Battery Plugged In 8-2
Key Switch (S1) ON8-2
Closing Deadman Switches8-3
Travel 8-5
Steering8-7
Lift/Lower 8-9
Primary Memory 8-13
Wire Guidance System8-14
Pinout Matrix8-17
AppendixA-1
Lubrication Specification ChartA-2
Thread Adhesives, Sealants, and Lubricants A-3
Component Specific Service/Torque Chart A-4
Torque Chart – Hydraulic Fittings A-6
Torque Chart – Straight Thread Face Seal O-Rings A-7
Torque Chart – Standard (Ferrous) A-8
Torque Chart – Metric (Ferrous)A-9
Torque Chart – Standard (Brass) A-10
Torque Chart – Metric (Brass)A-11
Torque Chart – Thread Forming Screws A-12
Decimal Equivalent ChartA-13
Standard/Metric ConversionsA-15
Index I-1

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