Crown Forklift SC 5200 Service Manual – PDF DOWNLOAD

Crown Forklift SC 5200 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift SC 5200 Service Manual – PDF DOWNLOAD

Language : English
Pages :822
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift SC 5200 Service Manual – PDF DOWNLOAD

General Maintenance Instructions 4
Cleaning of Material Handling Equipment 6
Control of Hazardous Energy 8
Lockout/Tagout 8
Battery 8
Capacitance (H2) 10
Hydraulic System 12
Releasing the Brakes 13
Towing the Truck 16
Lifting and Blocking 18
Mast 21
Counterweight Removal 23
Hose Reel 24
Lubrication and Adjustment 0
Operator’s Daily Checklist 31
Lubricants, Aerosols, and Service Supplies 0
Metric Torque Values 65
Grade 65
Componentry 69
Introduction 69
Access 1 70
Access 2 (AC Hydraulic System Only) 70
Access 3™ 70
Access 7 (EPV Only) 72
ACS 72
ALM1 72
ALM2 72
AXS1 (Manual Valve Only – Optional) 74
AXS2 (Manual Valve Only – Optional) 74
AXS3 (Optional – Manual Valve Shown) 74
Breather 74
BRES (Optional) 76
BRK1 76
BRK2 76
BRKS1 78
BRKS2 (Optional) 78
Carriage Cylinder 78
Carriage Relief Manifold – First Accessory (Not Shown) 78
Carriage Relief Manifold – Second Accessory (Not Shown) 78
CBVE 80
CBVR 80
CLS (Optional – EPV Valve Only, Not Shown) 80
CR1 82
CR2 82
CR3 82
CR4 (DC Hydraulic System Only) 82
CR5 (Not Shown) 82
CR6 (Not Shown) 84
CR7 (DC Hydraulic System Only – Not Shown) 84
CVLSA1 (EPV Only) 84
CVLSA2 (EPV Only) 84
CVLSI (EPV – Two Accessories Only) 84
CVLST (EPV Only) 86
CVR (EPV Only) 86
Directional Control Valve (Manual Valve Only) 86
DR1 86
DR2 (Not Shown) 88
DS20 (Optional) 88
ECR1 88
ECR2 88
ECR3 (AC Hydraulic System Only) 90
ECR4 (AC Hydraulic System Only) 90
EPV Manifold (EPV Only) 90
FAN1 92
FAN2 (AC “EE” Lift Trucks Only) 92
FAN3 (Optional) 92
FAN4 (Optional) 94
Filter 94
Flow Regulator 94
FNS (Optional) 94
FS 94
FU1 96
FU2 96
FU3 (DC Hydraulic System Only) 96
FU4 96
FU5 98
FU6 98
FU7 (Option – Not Shown) 98
FU8 (Not Shown) 98
FU9 (Optional – EE Lift Trucks Only – Not Shown) 98
FU10 (Optional – EE Lift Trucks Only – Not Shown)100
FU11 (Optional)100
FU12 (Optional)100
HGTS1100
HGTS2 (Optional – AC Hydraulic System Only – Not Shown)102
HGTS3 (Optional – Not Shown)102
HN1102
HNS1102
HNS2 (Not Shown)104
HNS3 (Not Shown)104
HNS4 (EPV Only)104
HR1 (Optional – Not Shown)104
HR2 (Optional – Not Shown)104
Impact Sensor106
InfoLink® (Optional)106
K1106
K2 (Manual Valve Only)108
K3 (EPV Only)108
K11 (Optional)108
K12 (Optional)110
KYS110
L110
LGS1 (Optional)112
LGS2 (Optional)112
LGT1 (Optional)112
LGT2 (Optional)112
LGT3 (Optional)114
LGT4 (Optional)114
LGT5 (Optional)114
LGT6 (Optional)114
Lift, Tilt, and Accessory Pump116
Load Sense Priority Flow Divider (AC Hydraulic System Only)116
LOS (DC Hydraulic System Only – Not Shown)116
Lowering Flow Control Manifold (Manual Valve Only)116
M1118
M2118
M3120
M4 (DC Hydraulic System Only)120
Mast Cylinder120
MLV122
MPCE (Manual Valve Only)122
Operator Presence Manifold (Manual Valve Only)122
ORF1 (EPV Only)122
ORF2 (EPV Only)124
ORF3 (EPV Only)124
ORF4 (EPV Only)124
ORF5 (EPV Only)124
ORF6 (EPV Only)124
ORF7 (EPV Only)126
ORS (EPV Only – Not Shown)126
ORS1 (Manual Valve Only – Not Shown)126
ORS2 (Manual Valve Only – Not Shown)126
ORS3 (Manual Valve Only – Not Shown)126
P (DC Hydraulic System Only)128
PCA (EPV Only)128
PCA1 (EPV Only)128
PCA2 (EPV Only)128
PCL (EPV Only)130
PCT (EPV Only)130
POT1130
POT2130
POT3132
POT4 (AC Hydraulic System Only)132
POT5 (EPV Only)132
POT6 (EPV Only)132
POT7 (EPV Only – shown on previous page)134
PT1134
Emergency Disconnect134
RAS (DC Hydraulic System Only)134
RES1 (Optional)136
RES2 (Optional)136
RES3 (Optional)136
RES4 (Optional – Not Shown)136
RES5 (Optional – Not Shown)136
RES6 (Optional – 48 V Lift Trucks Only – Not Shown)138
RES7 (Optional – 48 V Lift Trucks Only – Not Shown)138
RES50 (Optional – Not Shown)138
Reservoir138
RS138
RV1 (Manual Valve Only)140
RV2 (Manual Valve Only)140
RVA (EPV Only)140
RVM (EPV Only)140
S (DC Hydraulic System Only)140
SB80 (Optional – Not Shown)142
SBS (Optional)142
SES142
Sideshift Cylinder142
SPA1 (EPV Only – Optional)144
SPA2 (EPV Only – Optional)144
SPL (EPV Only)144
SPT (EPV Only)146
Steer Actuator146
Steer Pump (DC Hydraulic System Only)146
Steer Unit146
Suction Strainer146
SV1 (Manual Valve Only)148
SV3 (Manual Valve Only)148
SVBy (EPV Only)148
SVL (EPV Only)150
SVLSD (EPV Only – Optional)150
SVOP (Manual Valve Only)150
SVX (Manual Valve Only, Optional – Not Shown)150
TBS (Manual Valve Only)152
THS1 (Optional)152
THS2 (Optional)152
Tilt Cylinder152
TILT INTERLOCK MODULE (DC Hydraulic System Only)152
Tilt Manifold (Manual Valve Only)154
TLMS154
TLT (Manual Valve Only)154
TPAS (Optional)154
TR1156
TS1156
TS2156
TS3 (AC Hydraulic System Only)156
Two Accessories Manifold (EPV Only)156
Velocity Fuse158
VR1 (DC Hydraulic System Only – Not Shown)158
VTS158
SAE Torque Values161
Grade161
Hydraulic Lines and Fittings258
Reservoir and Filters258
Drift Test259
Cylinder and Circuit Bleeding259
AC Pump and Motor Replacement260
Manual Steering 0
DC Hydraulics – No Demand for Steering 0
AC Hydraulics – No Demand for Steering 0
DC Hydraulics – Steer Left 0
AC Hydraulics – Steer Left 0
DC Hydraulics – Steer Right 0
AC Hydraulics – Steer Right 0
DC Hydraulics – Lift 0
AC Hydraulics – Lift 0
Lower Circuit 0
DC Hydraulics – Tilt Back Circuit 0
AC Hydraulics – Tilt Back Circuit 0
DC Hydraulics – Tilt Forward Circuit 0
AC Hydraulics – Tilt Forward Circuit 0
DC Hydraulics – Sideshift Left Circuit 0
AC Hydraulics – Sideshift Left Circuit 0
DC Hydraulics – Sideshift Right Circuit 0
AC Hydraulics – Sideshift Right Circuit 0
Pump – Gear 0
Oil Seal Removal 0
Oil Seal Replacement 0
Pump Disassembly 0
Parts Inspection 0
Pump Reassembly 0
Start Up Procedure 0
Hydraulic Schematic Symbols307
Steer Pump311
Directional Control Valve – Manual315
Disassembling the Directional Control Valve316
Inspecting and Repairing the Directional Control Valve316
Assembling the Directional Control Valve316
Control Valve Troubleshooting318
Relief Valves (RV1, RV2)320
Checking the Relief Valve (RV1, RV2) Pressure320
Adjusting the Relief Valve (RV1)321
Adjusting the Relief Valve (RV2)321
Drive Unit Repair343
Encoders353
Operation353
Wire designations353
Testing the encoders353
Channel feedback overview353
Index voltage overview354
Wiring Color Codes 0
Power Cables 0
Switches 0
Event Code Introduction560
Checking Brake Wear 0
Brake Disassembly 0
Brake Assembly 0
Steering Column Assembly 0
Steer Axle Assembly 0
Circuit Bleeding 0
Steering Column Assembly 0
Steer Axle Assembly 0
Circuit Bleeding 0
Steering – 3 Wheel602
Steer Control Unit602
Steering Column Assembly602
Steer Axle Assembly607
Steer Unit614
Steering Control Unit Disassembly614
Steering Control Unit Assembly617
Mast622
Torque requirements622
TT lift chain adjustment622
TT mast inspection622
TT mast disassembly623
Mast removal from the power unit629
TT mast assembly-lying horizontal633
Quad mast inspection645
Replacing the wear pads on TT mast647
Fork Inspection 0
Cylinders661
Lift Cylinder661
Disassembly661
Seals661
Seal Removal661
Seal Installation – General662
Rod U-Cup Installation662
Small U-Cup662
Large U-Cup662
Cylinder U-cup Installation663
Cylinder Assembly663
Cylinder Bleeding and Flushing664
Bleeding – Free Lift Cylinder664
Bleeding – Stage Lift Cylinders664
Flushing – Stage and Free Lift Cylinders664
Drift Test664
Glossary675
Index 0
Schematic – DC Hydraulics 0
Truck Rear – DC Hydraulics 0
Truck Splices – DC Hydraulics 0
ACCESS 3 – DC Hydraulics 0
ACCESS 1 – DC Hydraulics 0
Truck Front, Upper – DC Hydraulics 0
Truck Front, Lower – DC Hydraulics 0
Hydraulics – DC Hydraulics 0
Overhead Guard with Incandescent Work Lights 0
Overhead Guard with LED Work Lights 0
Overhead Guard with Mast Mounted Work Lights 0
Freezer Conditioning 0
InfoLink 0
Power Cables – DC Hydraulics 0
Wire Harnesses – DC Hydraulics 0
Schematic – AC Hydraulics 0
Truck Rear – AC Hydraulics 0
Truck Splices – AC Hydraulics 0
ACCESS 3 – AC Hydraulics 0
ACCESS 2 – AC Hydraulics 0
ACCESS 1 – AC Hydraulics 0
Truck Front, Upper – AC Hydraulics 0
Truck Front, Lower – AC Hydraulics 0
Hydraulics – AC Hydraulics 0
Overhead Guard with Incandescent Work Lights 0
Overhead Guard with LED Work Lights 0
Overhead Guard with Mast Mounted Work Lights 0
Freezer Conditioning 0
InfoLink 0
Power Cables – AC Hydraulics 0
Wire Harnesses – AC Hydraulics 0
Index 0
Schematic – DC Hydraulics 0
Lift Truck Rear – DC Hydraulics 0
Lift Truck Splices – DC Hydraulics 0
Access 3™ – DC Hydraulics 0
Access 1 – DC Hydraulics 0
Lift Truck Front, Upper – DC Hydraulics 0
Lift Truck Front, Lower – DC Hydraulics 0
Hydraulics – DC Hydraulics 0
Overhead Guard with Incandescent Work Lights 0
Overhead Guard with LED Work Lights 0
Overhead Guard with Mast Mounted Work Lights 0
Freezer Conditioning 0
InfoLink® 0
Power Cables – DC Hydraulics 0
Wiring Harnesses – DC Hydraulics 0
Schematic – AC Hydraulics 0
Schematic – AC Hydraulics with EPV 0
Lift Truck Rear – AC Hydraulics 0
Lift Truck Rear – AC Hydraulics with EPV 0
Lift Truck Splices – AC Hydraulics 0
Lift Truck Splices – AC Hydraulics with EPV 0
Access 3™ – AC Hydraulics 0
Access 3™ – AC Hydraulics with EPV 0
Access 2 – AC Hydraulics 0
Access 2 – AC Hydraulics with EPV 0
Access 1 – AC Hydraulics 0
Access 1 – AC Hydraulics with EPV 0
Lift Truck Front, Upper – AC Hydraulics 0
Lift Truck Front, Upper – AC Hydraulics with EPV 0
Lift Truck Front, Lower – AC Hydraulics 0
Lift Truck Front, Lower – AC Hydraulics with EPV 0
Hydraulics – AC Hydraulics 0
Hydraulics – AC Hydraulics with EPV 0
Access 7 – AC Hydraulics with EPV 0
Overhead Guard with Incandescent Work Lights 0
Overhead Guard with LED Work Lights 0
Overhead Guard with Mast Mounted Work Lights 0
Freezer Conditioning 0
InfoLink® 0
Power Cables – AC Hydraulics 0
Wiring Harnesses – AC Hydraulics 0
Wiring Harnesses – AC Hydraulics with EPV 0

IMAGES PREVIEW OF THE MANUAL: