Crown Forklift FC4000 Series Service Manual – PDF DOWNLOAD

Crown Forklift FC4000 Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift FC4000 Series Service Manual – PDF DOWNLOAD

Language : English
Pages :646
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift FC4000 Series Service Manual – PDF DOWNLOAD

Index108
Electrical Schematic, Contactor Lift, Standard Display110
Electrical Schematic, SCR Lift, Enhanced Display111
Electrical Schematic, Contactor Lift, Enhanced Display112
Electrical Schematic, InfoLink113
Distribution Panel114
Distribution Panel, InfoLink115
Traction Control116
Hydraulic Lift Control – Contactor117
Hydraulic Lift Control – SCR118
Steer Column, Seat, Horn, Park Brake119
Steer Column, Seat, Horn, Park Brake, InfoLink120
Steer Column, FODC121
Brake Cutout122
Accelerator, Brake, FAN2 & FAN4123
Accelerator, Brake, FAN2 & FAN4, InfoLink124
Hydraulic Harness125
Hydraulic Harness, Contactor Lift, InfoLink126
Hydraulic Harness, SCR Lift, InfoLink127
Hydraulic Harness, Tilt Assist128
Hydraulic Harness, Contactor Lift, Tilt Assist, InfoLink129
Hydraulic Harness, SCR Lift, Tilt Assist, InfoLink130
BRES, Worklight Switches, FAN3131
BRES, Worklight Switches, FAN3, InfoLink132
Lights133
Standard Display134
Enhanced Display, Contactor Lift135
Enhanced Display, SCR Lift136
Freezer/Corrosion137
Power Cables, Contactor Lift138
Power Cables, SCR Lift139
Electrical Schematic EE140
Electrical Schematic EE, Field Weakening141
Pump Control EE142
Traction Control EE143
Traction Control EE, Field Weakening144
Power Cables EE145
Power Cables EE, Field Weakening146
Wire Harnesses147
Main Wire Harness150
Freezer/Corrosion Wire Harness154
EE Wire Harness155
Lubrication and Adjustment161
Planned Maintenance167
Component Access167
Lubrication168
Planned Maintenance186
Component Access186
Lubrication187
1A, ACC1, ACS, Accumulator205
ALM1, 2, AXS1, 2, BRES206
Breather, BRS1, CBV, Cylinder (parking brake)207
Cylinder (carriage), (lift), (steer), (tilt)208
Display, Dipstick, Distribution Panel, DPS1, 2, 3209
F, FAN1, 3, 4210
FIL, Filter (return), FNS, FS211
FU1, 2, 3, 4212
FU5, 6, 7, 11213
FU12, FW, Hand Pump, HGTS1214
HN, HNS, HSS, K1215
K2, 3, 11, 12216
KYS, LGS1, 2, LGT1, 2, 3217
LGT4, 5, 6, Lift/Tilt Module, M1218
M2, 3, Manual Release Valve, MPCE219
MRC1, 2, P1, 2220
Pressure Check Point, PRKA, B, PS, PS1221
Pump, R, RAS222
RB, RES1, 2, 3223
RS, RV1, 2, 3224
S, SB60, 80, SCU225
Sensor1, 2, 3, SES1, 2226
Strainer, SV1, 2, TBS227
THS1, 2, TLMS, TLT228
TMM, ULV, Valve229
Metric Torque Values255
Grade255
SAE Torque Values259
Grade259
Lines, Fittings, Reservoir261
Drift Test262
Bleeding262
General265
Steering and Brake267
Steer Left269
Steer Right270
Service Brake Applied271
Service Brake Released272
Lift273
Lower274
Tilt Back275
Tilt Forward276
Sideshift – Left277
Sideshift – Right278
Hydraulic Circuitry279
Steer & Brake Circuit281
Steer Left Circuit283
Steer Right Circuit284
Service Brake Applied Circuit285
Service Brake Released Circuit286
Lift Circuit287
Lower Circuit288
Tilt Back Circuit289
Tilt Forward Circuit290
Sideshift – Left Circuit291
Sideshift – Right Circuit292
Hydraulic Schematic Symbols293
Drive Unit Disassembly319
Remove the traction motor319
Disassemble320
Remove and disassemble axles and hubs320
Remove brake assemblies321
Disassemble housings322
Assemble the Drive Unit324
Assemble the 1st Reduction Pinion Assembly324
Install the 2nd Axle Pin Assembly324
Install the Bearing and the 2nd Axle Gear Assembly325
Install the Differential Assembly326
Assemble the Housing Halves326
Adjusting the Differential327
Install Axle Housings328
Install Service Brakes331
Hub Installation332
Axle Installation334
Traction Motor Installation334
Breather Vent and Plug Installation335
Drive Unit Inspection335
AXS1, AXS2, TLT339
RAS340
TBS341
HSS342
ACS343
HGST1344
SES1, SES2344
TLMS344
Wiring Color Codes358
Power Cables358
Switches362
Handset388
Enhanced Display390
Chart Selection391
Location 473
Jumper Configurations473
Reverse Travel Alarm474
Forward Travel Alarm475
Travel Alarm476
Switch Controlled Rear Worklight477
Relay Controlled Rear Worklight478
Inspection487
Component Replacement488
Safety Rules492
Checking Battery492
Battery Care493
Charging Battery493
Battery Removal494
Battery Installation495
Seat Deck Cover Adjustment495
Seat Deck Latch Adjustment496
Seat Deck Cylinders497
Battery Cleaning499
Troubleshooting499
Operation501
Brake Pedal502
Shimming the Brake Pedal503
Brake Assembly Removal504
Disassembly of Brake504
Lining/Rotor Inner And Outer Stator505
Piston, Wiper and Seal Removal505
Wiper, Seal & Piston Installation506
Service Brake Assembly506
Service Brake Installation506
Service Brake Bleeding507
Drive Tire Installation507
Service Brake Adjustments507
Service Brake Valve507
Operation508
Shoe Replacement508
Brake Hub509
Adj when replacing Shoes or Hub509
Park Brake Release Manifold509
Hydrostatic Steering Unit511
Steering Column511
Column, Gas Cylinder512
Directional Control, Steering Wheel Removal513
Steering Wheel514
Final Assembly515
Steer Axle515
Tire515
Torque Requirements515
Positioning517
Steer Unit519
Steering Control Unit Disassembly519
Steering Control Unit Assembly522
Bearing Cap Torque Requirements527
Shim Basics528
Shim Removal530
Carriage Side Thrust Roller Adjustments532
Mast Column Roller Removal – TT Mast (Third Stage)533
Mast Column Rollers Removal – TL Mast534
Mast Assembly534
Lift Cylinder Removal – TT & TL534
Carriage Removal – TT Mast534
Carriage Removal – TL Mast535
Mast Removal535
Mast Assembly537
Tilt Cylinder Adjustments539
Mast Flaking540
Mast Testing (Assembled)541
Fork Inspection553
Cylinders557
Lift Cylinder557
Disassembly557
Seals557
Seal Removal557
Seal Installation – General558
Rod U-Cup Installation558
Small U-Cup558
Large U-Cup558
Cylinder U-cup Installation559
Cylinder Assembly559
Cylinder Bleeding and Flushing560
Bleeding – Free Lift Cylinder560
Bleeding – Stage Lift Cylinders560
Flushing – Stage and Free Lift Cylinders560
Drift Test560
Cylinder Disassembly563
Rod Disassembly563
Seal Replacement564
Cylinder Reassembly564
Tilt Cylinder Flushing and Bleeding Procedures564
Tilt Drift Test565
Tilt Cylinder Installation and Adjustments565
Cylinder Removal568
Cylinder Disassembly568
Cylinder Assembly570
Cylinder Installation570
Removal571
Disassembly572
Assembly573
Installation573
Audible Indicators609
Battery (36/48 Volt)609
Cards & Controllers610
Connections611
Contactors616
Displays617
Fans618
Fuses618
Lights620
Miscellaneous620
Motors621
Rectifiers622
Potentiometers623
Relays623
Resistors623
Sensors624
Solenoids624
Switches625
Thermostats629
General Maintenance Instructions630
Cleaning of Material Handling Equipment632
Lockout/Tagout634
Battery634
Capacitance636
Hydraulic637
Towing Truck638
Lifting and Blocking641
Mast642
Disconnect Tilt Cylinder644
Removing Mast645
Removing Counterweight646

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