Crown Forklift DualMode™ R Series Service Manual – PDF DOWNLOAD

Crown Forklift DualMode™ R Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift DualMode™ R Series Service Manual – PDF DOWNLOAD

Language : English
Pages :883
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift DualMode™ R Series Service Manual – PDF DOWNLOAD

Introduction 3
Overview 4
General Information 4
Operator Information 4
How to Use This Manual 4
Data Plate Information 8
Model Number Information 9
Data Number Information 10
Capacity Plate Information 15
Serial Number Information 16
Global Contact Information 17
Safety 19
General Safety 20
Introduction 20
Safety Messages 20
Standards and Regulations 21
Environmental Protection 22
Organizational Requirements 22
General Maintenance 22
General Hot Work Instructions 23
Personal Protective Equipment (PPE) 23
Hazards From Stored Energy 24
Returning the Lift Truck to Service 24
Lift Truck Cleaning 24
Safe Battery Handling 24
Hydraulic System Safety 25
Safety Labels on the Lift Truck 25
Lifting Equipment 25
Cleaning the Lift Truck 26
Cleaning the Lift Truck 26
Preparing for Cleaning 26
General Cleaning 26
Returning to Operation 27
General Maintenance 28
Standard Torque Values 29
Introduction 29
Special Torque Values 33
Introduction 33
Hydraulic Fitting Torque Values 34
Introduction 34
Manifold Component Torque Values 36
Introduction 36
Lubricants 38
Handling of Static Sensitive Components 42
Planned Maintenance 43
Introduction 43
Lubricants 43
Icons 44
Visual Inspection 44
Operational Check and Test Drive 45
Preparing the Lift Truck for Maintenance 45
Inspection and Lubrication 46
Preparing the Lift Truck for Operation136
Final Operational Check and Test Drive136
Planned Maintenance Completion136
Power Source137
General Information138
Componentry139
A21 Fan143
A31 Fan144
Access 11145
Access 12146
Access 13147
Access 15148
Access 16149
Access 21150
Access 22151
Access 31152
Access 41153
Access 51154
Access 71155
Accessory Potentiometer156
Accessory Pump Motor157
Accessory Solenoid Valve158
Battery Retainer Switch 1 (Optional)159
Battery Retainer Switch 2160
Brake Switch 1161
Camera162
Card Reader163
Direction Selector Sensor164
Distribution Panel165
Dome Light166
Dome Light Switch167
Emergency Disconnect Switch 1168
Emergency Disconnect Switch 2169
Emergency Disconnect Switch 3170
Emergency Disconnect Switch 4171
Emergency Disconnect Switch 5172
Entry Bar Switch173
Floor Line Light 1174
Floor Line Light 2175
Floor Line Light 3176
Forks First Switch177
Fuse 1178
Fuse 2179
Fuse 3180
Fuse 4181
Fuse 5182
Fuse 6183
Fuse 8184
Fuse 9185
Fuse 10186
Fuse 12187
Fuse 15188
Fuse 16189
Fuse 17190
Fuse 18191
Fuse 19192
Fuse 22193
Height Encoder 1194
Height Encoder 2195
Height Reset Sensor 1196
Height Reset Sensor 2197
Hoist Potentiometer198
Horn199
Horn Switch200
Impact Sensor201
Line Contactor202
Load Sensor203
Lower Solenoid Valve204
M21 Sensor205
M21 Thermal Sensor206
M22 Sensor207
M22 Thermal Sensor208
M31 Fan209
M31 Sensor 1210
M31 Sensor 2211
M31 Thermal Sensor212
M31 Traction Brake213
M51 Sensor 1214
M51 Sensor 2215
M51 Thermal Sensor216
Main Pump217
Main Pump Motor218
Manual Lowering Valve219
Mode Select Switch220
Operator Alarm221
Operator Presence Switch 1222
Power Unit First Switch223
Reach Position Sensor224
Reach Solenoid Valve225
Relay 1226
Relay 2227
Relay 3228
Relay 4229
Relay 5230
Relay 6231
Relay 10232
Relay 13233
Resistor 2234
Sideshift Solenoid Valve235
Sideshift Switch236
Speaker237
Steer Motor238
Steer Sensor239
Steering Sensor240
Straight Ahead Sensor241
Test Point242
Tilt Down Switch243
Tilt Position Sensor244
Tilt Solenoid Valve245
Tilt Up Switch246
Traction Motor247
Traction Potentiometer248
Travel Alarm249
Worklight 1250
Xpress Lower Proportional Valve 1251
Xpress Lower Proportional Valve 2252
Electrical253
Multi-Task Control Handle254
Technician Tips254
Technician Tips254
Theory of Operation254
Theory of Operation254
Tools and Equipment254
Recommended Tools and Equipment254
Additional Tools and Equipment255
Multi-Task Control Handle255
Disassembly255
Preparing the Lift Truck for Maintenance255
Removing the Multi-Task Control Handle255
Assembly259
Installing the Multi-Task Control Handle259
Preparing the Lift Truck for Operation263
Direction Selector Sensor264
Disassembly264
Preparing the Lift Truck for Maintenance264
Removing the Direction Selector Sensor264
Inspecting the Direction Selector Sensor265
Assembly266
Installing the Direction Selector Sensor266
Preparing the Lift Truck for Operation266
Potentiometers267
Disassembly267
Preparing the Lift Truck for Maintenance267
Removing the Potentiometers267
Inspecting the Potentiometers269
Assembly270
Installing the Potentiometers270
Preparing the Lift Truck for Operation272
Accessory Thumb Wheel Harness272
Disassembly272
Preparing the Lift Truck for Maintenance272
Removing the Accessory Thumb Wheel Harness272
Inspecting the Accessory Thumb Wheel Harness274
Assembly274
Installing the Accessory Thumb Wheel Harness274
Preparing the Lift Truck for Operation276
Troubleshooting276
Troubleshooting276
Contactor277
Theory of Operation277
Theory of Operation277
Tools and Equipment277
Recommended Tools and Equipment277
Disassembly277
Preparing the Lift Truck for Maintenance277
Removing the Line Contactor278
Inspecting the Line Contactor279
Assembly280
Installing the Line Contactor280
Preparing the Lift Truck for Operation281
Troubleshooting281
Troubleshooting281
Distribution Panel282
Technician Tips282
Technician Tips282
Theory of Operation282
Theory of Operation282
Tools and Equipment282
Recommended Tools and Equipment282
Disassembly283
Preparing the Lift Truck for Maintenance283
Removing the Distribution Panel283
Disassembling the Distribution Panel284
Inspecting the Distribution Panel285
Assembly287
Assembling the Distribution Panel287
Installing the Distribution Panel288
Preparing the Lift Truck for Operation290
Event Codes291
Introduction292
Event Codes294
Hydraulic497
Theory of Operation498
Motor – M21500
Theory of Operation500
Theory of Operation500
Tools and Equipment500
Recommended Tools and Equipment500
Additional Tools and Equipment500
Disassembly501
Preparing the Lift Truck for Maintenance501
Removing the Main Pump Motor501
Inspecting the Main Pump Motor508
Assembly509
Installing the Main Pump Motor509
Preparing the Lift Truck for Operation516
Motor – M22518
Theory of Operation518
Theory of Operation518
Tools and Equipment518
Recommended Tools and Equipment518
Disassembly518
Preparing the Lift Truck for Maintenance518
Removing the Accessory Pump Motor519
Inspecting the Accessory Pump Motor521
Assembly521
Installing the Accessory Pump Motor521
Preparing the Lift Truck for Operation523
Troubleshooting523
Troubleshooting523
Pumps524
Tools and Equipment524
Recommended Tools and Equipment524
Additional Tools and Equipment524
Priming the Pumps524
Main Pump525
Preparing the Lift Truck for Maintenance525
Preparing the Lift Truck for Priming the Main Pump525
Removing Air from the Circuit for the Main Pump525
Checking for Hydraulic Oil Leaks for the Main Pump526
Preparing the Lift Truck for Operation526
Accessory Pump526
Preparing the Lift Truck for Maintenance526
Preparing the Lift Truck for Priming the Accessory Pump527
Removing Air From the Circuit for the Accessory Pump527
Checking for Hydraulic Oil Leaks for the Accessory Pump528
Preparing the Lift Truck for Operation528
System529
Raising529
Lowering530
Extending the Reach Mechanism531
Retracting the Reach Mechanism533
Sideshift Left534
Sideshift Right536
Tilting the Fork Up537
Tilting the Fork Down539
Lifting Mechanism541
Theory of Operation542
Control Cable544
Tools and Equipment544
Recommended Tools and Equipment544
Assembly544
Preparing the Lift Truck for Maintenance544
Installing the Control Cable544
Adjusting the Control Cable Tension545
Preparing the Lift Truck for Operation547
Cylinder – Primary548
Technician Tips548
Technician Tips548
Theory of Operation548
Theory of Operation548
Tools and Equipment548
Recommended Tools and Equipment548
Additional Tools and Equipment549
Creating the Packing Removal Tool549
Disassembly549
Preparing the Lift Truck for Maintenance549
Preparing for Removing the Primary Cylinder550
Removing the Primary Cylinder551
Disassembling the Cylinder554
Inspecting the Primary Cylinder555
Assembly557
Assembling the Cylinder557
Installing the Primary Cylinder559
After Installing the Primary Cylinder562
Testing the Cylinder Seal for Leaks563
Bleeding the Cylinder564
Preparing the Lift Truck for Operation564
Cylinder – Reach566
Technician Tips566
Technician Tips566
Theory of Operation566
Theory of Operation566
Tools and Equipment566
Recommended Tools and Equipment566
Additional Tools and Equipment566
Disassembly567
Preparing the Lift Truck for Maintenance567
Removing the Reach Cylinder567
Disassembling the Reach Cylinder569
Inspecting the Reach Cylinder572
Assembly573
Assembling the Reach Cylinder573
Installing the Reach Cylinder576
Adjusting the Reach Cylinder579
Preparing the Lift Truck for Operation580
Troubleshooting580
Troubleshooting580
Cylinder – Secondary581
Tools and Equipment581
Recommended Tools and Equipment581
Additional Tools and Equipment581
Disassembly581
Preparing the Lift Truck for Maintenance581
Removing the Secondary Cylinder582
Disassembling the Secondary Cylinder582
Assembly582
Assembling the Secondary Cylinder582
Installing the Secondary Cylinder582
Preparing the Lift Truck for Operation582
Cylinder – Sideshift583
Tools and Equipment583
Recommended Tools and Equipment583
Additional Tools and Equipment583
Disassembly583
Preparing the Lift Truck for Maintenance583
Removing the Sideshift Cylinder584
Disassembling the Sideshift Cylinder584
Inspecting the Sideshift Cylinder589
Assembly591
Assembling the Sideshift Cylinder591
Installing the Sideshift Cylinder596
Preparing the Lift Truck for Operation596
Troubleshooting597
Troubleshooting597
Cylinder – Tilt598
Theory of Operation598
Theory of Operation598
Tools and Equipment598
Recommended Tools and Equipment598
Disassembly598
Preparing the Lift Truck for Maintenance598
Removing the Tilt Cylinder599
Inspecting the Tilt Cylinder599
Disassembling the Tilt Cylinder600
Assembly604
Assembling the Tilt Cylinder604
Installing the Tilt Cylinder609
Preparing the Lift Truck for Operation609
Troubleshooting610
Troubleshooting610
Fork Inspection611
Tools and Equipment611
Recommended Tools and Equipment611
Additional Tools and Equipment611
Inspection611
Preparing the Lift Truck for Maintenance611
Introduction612
Identification613
Measuring the Fork Blade for Wear613
Checking for Fatigue Cracks615
Bent or Twisted Forks615
Checking the Fork Tip for Straightness616
Checking the Fork Locking Pin617
Preparing the Lift Truck for Operation617
Height Encoder 1619
Tools and Equipment619
Recommended Tools and Equipment619
Disassembly619
Preparing the Lift Truck for Maintenance619
Removing Height Encoder 1619
Assembly621
Installing Height Encoder 1621
Preparing the Lift Truck for Operation622
Height Encoder 2624
Tools and Equipment624
Recommended Tools and Equipment624
Disassembly624
Preparing the Lift Truck for Maintenance624
Removing Height Encoder 2624
Assembly625
Installing Height Encoder 2625
Preparing the Lift Truck for Operation626
Hydraulic Lines628
Technician Tips628
Technician Tips628
Tools and Equipment628
Recommended Tools and Equipment628
Primary Lift Hose629
Disassembly629
Preparing the Lift Truck for Maintenance629
Removing the Primary Lift Hose629
Assembly631
Installing the Primary Lift Hose631
Preparing the Lift Truck for Operation634
Accessory Mast Hose634
Disassembly634
Preparing the Lift Truck for Maintenance634
Removing the Accessory Mast Hose635
Assembly636
Installing the Accessory Mast Hose636
Preparing the Lift Truck for Operation637
Lift Chains639
Tools and Equipment639
Recommended Tools and Equipment639
Additional Tools and Equipment639
Lift Chains – Primary Cylinder640
Disassembly640
Preparing the Lift Truck for Maintenance640
Removing the Lift Chains From the Primary Cylinder640
Inspecting the Lift Chains642
Checking the Lift Chains for Wear644
Assembly645
Installing the Lift Chains on the Primary Cylinder645
Inspecting the Fork Height649
Preparing the Lift Truck for Operation649
Lift Chains – Secondary Cylinder649
Disassembly649
Preparing the Lift Truck for Maintenance649
Removing the Lift Chains From the Secondary Cylinder650
Inspecting the Lift Chains657
Checking the Lift Chains for Wear659
Assembly660
Installing the Lift Chains on the Secondary Cylinder660
Inspecting the Fork Height669
Preparing the Lift Truck for Operation669
Mono-Mast670
Tools and Equipment670
Recommended Tools and Equipment670
Additional Tools and Equipment670
Mast Torque Requirements671
Mast Torque Sequence672
Inspecting and Lubricating the Mast672
Mast Flaking679
Mast Bumper679
Disassembly679
Preparing the Lift Truck for Maintenance679
Removing the Mast Bumpers680
Inspecting the Mast Bumpers681
Assembly681
Installing the Mast Bumpers681
Preparing the Lift Truck for Operation682
Mono-Mast683
Disassembly683
Preparing the Lift Truck for Maintenance683
Removing the Mast683
Disassembling the Mast Columns687
Removing the Thrust Rollers and Shims688
Removing the Column Rollers689
Removing the Mast Guides690
Assembly692
Installing the Mast Guides692
Installing the Column Rollers693
Installing the Thrust Rollers and Shims694
Assembling the Mast Columns695
Installing the Mast696
Preparing the Lift Truck for Operation700
Power Unit701
Caster702
Technician Tips702
Technician Tips702
Tools and Equipment702
Recommended Tools and Equipment702
Additional Tools and Equipment702
Disassembly703
Preparing the Lift Truck for Maintenance703
Removing the Caster703
Disassembling the Caster706
Inspecting the Caster707
Assembly708
Assembling the Caster708
Installing the Caster709
Preparing the Lift Truck for Operation712
Undercarriage714
Technician Tips714
Technician Tips714
Theory of Operation714
Theory of Operation714
Tools and Equipment714
Recommended Tools and Equipment714
Additional Tools and Equipment714
Disassembly715
Preparing the Lift Truck for Maintenance715
Removing the Undercarriage715
Disassembling the Undercarriage715
Inspecting the Undercarriage717
Assembly717
Assembling the Undercarriage717
Installing the Undercarriage719
Preparing the Lift Truck for Operation719
Adjusting the Undercarriage720
Troubleshooting722
Troubleshooting722
Steering723
System Overview724
Theory of Operation724
Theory of Operation724
Motor – M51 and Gearbox Assembly725
Tools and Equipment725
Recommended Tools and Equipment725
Additional Tools and Equipment725
Disassembly725
Preparing the Lift Truck for Maintenance725
Removing the Steer Motor and the Gearbox Assembly726
Removing M51 Sensor 1 and M51 Sensor 2727
Disassembling the Steer Motor and the Gearbox Assembly728
Inspecting the Steer Motor and the Gearbox Assembly729
Assembly729
Assembling the Steer Motor and the Gearbox Assembly729
Installing M51 Sensor 1 and M51 Sensor 2729
Installing the Steer Motor and the Gearbox Assembly730
Preparing the Lift Truck for Operation732
Troubleshooting732
Troubleshooting732
Straight Ahead Sensor733
Theory of Operation733
Theory of Operation733
Tools and Equipment733
Recommended Tools and Equipment733
Additional Tools and Equipment733
Disassembly734
Preparing the Lift Truck for Maintenance734
Removing the Straight Ahead Sensor734
Assembly736
Installing the Straight Ahead Sensor736
Adjusting the Straight Ahead Sensor739
Preparing the Lift Truck for Operation740
Tiller741
Technician Tips741
Technician Tips741
Theory of Operation741
Theory of Operation741
Tools and Equipment741
Recommended Tools and Equipment741
Additional Tools and Equipment742
Disassembly742
Preparing the Lift Truck for Maintenance742
Removing the Tiller742
Disassembling the Tiller745
Inspecting the Tiller749
Assembly750
Assembling the Tiller750
Installing the Tiller754
Preparing the Lift Truck for Operation757
Troubleshooting757
Troubleshooting757
User Interface758
Theory of Operation759
Theory of Operation759
Camera760
Introduction760
Keyboard760
System Interaction761
Standby Mode761
Horizontal Bars761
Locking the Keyboard762
Language Settings763
Default Settings764
Display Overview766
Touchscreen766
Dashboard766
Turning on the Lift Truck767
System Interaction767
InfoLink® or Login Required is Enabled767
InfoLink® or Login Required Is Disabled768
Main Menu Overview770
Main Menu Overview770
Menu Structure773
Introduction773
Adjusting the Settings775
Menus775
Auto Height Select782
Theory of Operation782
Theory of Operation782
System Interaction782
System Interaction782
Raise and Lower Cutouts788
Speed Reduction791
Software Installation794
Preparing For Software Installation794
Preparing for Software Installation794
Software Installation – Serial Number Search795
Software Installation – Serial Number Search795
Software Installation – Manual Software Selection797
Software Installation – Manual Software Selection797
After Software Installation799
After Software Installation799
Traction and Brake801
Theory of Operation802
Theory of Operation802
Brake – M31803
Theory of Operation803
Theory of Operation803
Tools and Equipment803
Recommended Tools and Equipment803
Disassembly803
Preparing the Lift Truck for Maintenance803
Disassembling the M31 Traction Brake804
Inspecting the M31 Traction Brake810
Assembly810
Assembling the M31 Traction Brake810
Preparing the Lift Truck for Operation816
Troubleshooting816
Troubleshooting816
Drive Tire818
Tools and Equipment818
Recommended Tools and Equipment818
Disassembly818
Preparing the Lift Truck for Maintenance818
Removing the Drive Tire818
Inspecting the Drive Tire819
Assembly820
Installing the Drive Tire820
Preparing the Lift Truck for Operation820
Drive Unit821
Technician Tips821
Technician Tips821
Tools and Equipment821
Recommended Tools and Equipment821
Additional Tools and Equipment821
Disassembly822
Preparing the Lift Truck for Maintenance822
Removing the Drive Unit822
Disassembling the Drive Unit825
Assembly829
Assembling the Drive Unit829
Installing the Drive Unit834
Preparing the Lift Truck for Operation836
Troubleshooting837
Troubleshooting837
Motor – M31838
Theory of Operation838
Theory of Operation838
Tools and Equipment838
Recommended Tools and Equipment838
Disassembly838
Preparing the Lift Truck for Maintenance838
Removing the Traction Motor839
Inspecting the Traction Motor840
Assembly840
Installing the Traction Motor840
Preparing the Lift Truck for Operation842
Troubleshooting842
Troubleshooting842
Diagrams843
Introduction844
Introduction844
Schematics844
Pictorials844
Components844
Connectors844
Wiring844
Wire Numbers and Colors845
Reference Designators845
Diagram Key856
Pictorials – Electrical859
Pictorials – Electrical859
Schematics – Hydraulic879
Schematics – Hydraulic879

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