Crown Forklift SP 3500 Wheel Service Manual – PDF DOWNLOAD

Crown Forklift SP 3500 Wheel Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift SP 3500 Wheel Service Manual – PDF DOWNLOAD

Language : English
Pages :768
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift SP 3500 Wheel Service Manual – PDF DOWNLOAD

Introduction 1
Operator instructions 1
Operator training 1
Service training 1
Replacement parts 1
Manual structure 1
Data plate 2
Introduction 7
Operator Instructions 7
Operator Training 7
Service Training 7
Replacement Parts 7
Manual Structure 7
Truck Specifications and Speeds 11
Heading 1 – Introduction 0
Heading 2 – Operator Instructions 0
Heading 2 – Operator Training 48
Heading 2 – Service Training 0
Heading 2 – Replacement Parts 0
Lubrication and Adjustment 0
Electrical Diagrams Index 0
Schematic – Power Unit w/Options 0
Schematic – Platform w/Options 0
Schematic – Power Unit 0
Schematic – Platform 0
Platform Distribution Panel 0
Platform Distribution Panel Forks First SAA 0
Power Unit Distribution Panel 0
Platform Modules Access 1 & 4 0
Platform Modules Access 1 & 4 Forks First SAA 0
Control Pod and Light Switches 0
Overhead Guard Lights/Fans 0
Traction Control Module Access 3 0
Steering Control Module Access 5 0
Hydraulics & Optional MMS 0
Guidance Control Module Access 6 (Optional) 0
Freezer Conditioning (Optional) 0
Freezer Conditioning SAA (Optional) 0
Power Cables 0
Wire Harnesses 0
Cleaning of Material Handling Equipment 48
Control of Hazardous Energy 0
Operator’s Daily Checklist 64
Lubricants, Aerosols, and Service Supplies 0
Planned Maintenance 72
Overview 72
Planned maintenance information 72
Lubrication 72
Component access 74
Access 1 90
Access 3 (TCM) 90
Access 4 (VCM) 90
Access 5 (SCM) 91
Access 6 (GCM) 91
ACCUMULATOR 91
ALM1 92
BRES1, BRES2 92
CHS1, CHS2 93
CHS3, CHS4 93
CYLINDER 95
CYLINDER 95
RGS1 and RGS2 (Optional) 0
SENSOR BAR LOAD WHEEL 0
SENSOR BAR STEER WHEEL 0
Componentry169
Introduction169
Access 1170
Access 3™172
Access 4172
Access 5174
Access 6174
Accumulator174
ALM1176
AUX176
BATT176
BRES1 and BRES2176
BRK178
BRS178
CHS1 and CHS2178
CHS3 and CHS4178
CS1180
CV1180
CV2180
CV3180
DB1180
DMS1182
DTS1182
EACA1182
EACA2182
EACB1182
EACB2184
ECR1184
ECR2184
ECR3184
ECR4186
ECR5186
ECR6186
ED1188
ED2188
EDS188
FAN1188
FAN2190
FIL1190
FILTER190
FNS1190
FS192
FU1192
FU2192
FU3192
FU4194
FU5194
FU6194
FU7194
FU8194
FU9196
FU10196
FU11196
FU12196
FU13196
FU14198
FU15198
FU16198
FU17198
GS1200
GS2200
GTS1 and GTS2200
GTS5 and GTS6200
GUS202
HGTRS202
HN1202
HN2202
HNS204
InfoLink® Control Module (HD2500) (Optional)204
InfoLink® Control Module (HD2000) (Optional)204
Parts Breakdown: 100-7335-003 (1) (732)204
InfoLink® Control Module (HD1000) (Optional)204
LGT2 and LGT5210
LGT3 and LGT6210
LGT4 and LGT7210
LGT8 and LGT9210
LMS1210
LOS1 and LOS2212
LOS3 and LOS4212
M1214
M2214
M3214
M4214
M5214
MVL216
ORS1216
P1218
P1218
P2218
P2218
PCL218
PCLF218
PGS1220
PGLS1 and PGLS2220
POT1220
PS1222
PS2222
PVL222
PVLF222
RAS1222
RAS2222
RAS3 and RAS4224
RES1224
RES2 and RES3224
RES5 and RES6224
RES7 and RES8226
RES9 and RES10226
RES11 and RES12226
RES13226
RES14226
RES15228
RES16228
RES17228
RES18228
RES19 and RES20228
RES21 and RES22230
RES25230
RES33, RES34, RES35, and RES36 (not shown)230
RES40 and RES41 (not shown)230
RGSL and RGSR230
RS230
RV1232
RV2232
SB1232
SB30232
Impact Sensor232
SVL232
SV1234
SENSOR BAR LOAD WHEEL234
SENSOR BAR STEER WHEEL234
TB502234
THS2234
THS3236
TS1236
ZSS236
Hydraulic Circuits 0
Lift Circuit – One Speed Lift 0
Relief Valve Operation 0
Accumulator Operation 0
Lift Circuit – Two Speed Lift 0
Relief Valve Operation 0
Accumulator Operation 0
Lower Circuit – One Speed/Two Speed Lower 0
Manual Lower Circuit 0
Reservoir 0
Hydraulic Lines and Fittings 0
Filter 0
Drift Test 0
Lift Drift Test 0
Freezer Preparation 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 Troubleshooting263
Drive Unit268
Drive Tire Replacement268
Change the Oil270
Oil Pump Disassembly and Assembly271
Traction Motor Removal and Installation272
Drive Unit Removal and Installation272
Encoders274
Operation274
Wire designations274
Testing the encoders274
Channel feedback overview274
Index voltage overview275
Wiring Color Codes 0
Power Cables 0
Switches 0
Testing Motor Monitoring System (MMS)303
Wire Guidance 0
Operation Modes 0
Sensors 0
Calibration 0
Access 0
Troubleshooting 0
Adjustments 0
Component Replacement 0
RAS1, RAS2, LOS1, LOS2, HNS, EDS 0
Safety Rules 0
Checking 0
Battery Care 0
Charging 0
Battery Stop Adjustment 0
Battery Removal 0
Battery Installation 0
Battery Cleaning 0
Troubleshooting 0
Event Codes 0
Event Code 101 0
Event Code 103 0
Event Code Repair or replace104 0
Event Code 105 0
Event Code 106 0
Event Code 111 0
Event Code 113 0
Event Code 114 0
Event Code 115 0
Event Code 116 0
Event Code 123 0
Event Code 124 0
Event Code 125 0
Event Code 126 0
Event Code 131 0
Event Code 133 0
Event Code 134 0
Event Code 160 0
Event Code 161 0
Event Code 162 0
Event Code 163 0
Event Code 164 0
Event Code 165 0
Event Code 166 0
Event Code 167 0
Event Code 168 0
Event Code 169 0
Event Code 301 0
Event Code 302 0
Event Code 303 0
Event Code 304 0
Event Code 305 0
Event Code 306 0
Event Code 307 0
Event Code 309 0
Event Code 310 0
Event Code 312 0
Event Code 313 0
Event Code 315 0
Event Code 316 0
Event Code 318 0
Event Code 319 0
Event Code 320 0
Event Code 322 0
Event Code 323 0
Event Code 324 0
Event Code 325 0
Event Code 326 0
Event Code 327 0
Event Code 328 0
Event Code 329 0
Event Code 330 0
Event Code 332 0
Event Code 334 0
Event Code 336 0
Event Code 337 0
Event Code 338 0
Event Code 339 0
Event Code 340 0
Event Code 341 0
Event Code 342 0
Event Code 343 0
Event Code 344 0
Event Code 345 0
Event Code 346 0
Event Code 348 0
Event Code 349 0
Event Code 350 0
Event Code 351 0
Event Code 352 0
Event Code 353 0
Event Code 354 0
Event Code 355 0
Event Code 356 0
Event Code 357 0
Event Code 358 0
Event Code 359 0
Event Code 360 0
Event Code 361 0
Event Code 362 0
Event Code 363 0
Event Code 364 0
Event Code 365 0
Event Code 366 0
Event Code 367 0
Event Code 368 0
Event Code 369 0
Event Code 370 0
Event Code 371 0
Event Code 372 0
Event Code 373 0
Event Code 374 0
Event Code 375 0
Event Code 378 0
Event Code 379 0
Event Code 380 0
Event Code 381 0
Event Code 382 0
Event Code 383 0
Event Code 384 0
Event Code 385 0
Event Code 386 0
Event Code 387 0
Event Code 389 0
Event Code 390 0
Event Code 392 0
Event Code 393 0
Event Code 395 0
Event Code 396 0
Event Code 397 0
Event Code 398 0
Event Code 401 0
Event Code 405 0
Event Code 411 0
Event Code 413 0
Event Code 415 0
Event Code 416 0
Event Code 421 0
Event Code 422 0
Event Code 423 0
Event Code 424 0
Event Code 425 0
Event Code 426 0
Event Code 427 0
Event Code 429 0
Event Code 430 0
Event Code 431 0
Event Code 432 0
Event Code 433 0
Event Code 435 0
Event Code 440 0
Event Code 441 0
Event Code 442 0
Event Code 443 0
Event Code 445 0
Event Code 446 0
Event Code 447 0
Event Code 448 0
Event Code 449 0
Event Code 452 0
Event Code 453 0
Event Code 460 0
Event Code 462 0
Event Code 463 0
Event Code 465 0
Event Code 466 0
Event Code 469 0
Event Code 470 0
Event Code 473 0
Event Code 501 0
Event Code 503 0
Event Code 504 0
Event Code 505 0
Event Code 506 0
Event Code 511 0
Event Code 512 0
Event Code 513 0
Event Code 514 0
Event Code 515 0
Event Code 521 0
Event Code 522 0
Event Code 523 0
Event Code 526 0
Event Code 527 0
Event Code 528 0
Event Code 529 0
Event Code 530 0
Event Code 531 0
Event Code 532 0
Event Code 533 0
Event Code 534 0
Event Code 535 0
Event Code 536 0
Event Code 537 0
Event Code 538 0
Event Code 539 0
Event Code 540 0
Event Code 541 0
Event Code 542 0
Event Code 544 0
Event Code 545 0
Event Code 546 0
Event Code 548 0
Event Code 549 0
Event Code 551 0
Event Code 552 0
Event Code 553 0
Event Code 554 0
Event Code 555 0
Event Code 556 0
Event Code 557 0
Event Code 558 0
Event Code 561 0
Event Code 562 0
Event Code 563 0
Event Code 564 0
Event Code 565 0
Event Code 566 0
Event Code 567 0
Event Code 568 0
Event Code 569 0
Event Code 570 0
Event Code 571 0
Event Code 572 0
Event Code 573 0
Event Code 574 0
Event Code 576 0
Event Code 581 0
Event Code 582 0
Event Code 585 0
Event Code 586 0
Event Code 587 0
Event Code 588 0
Event Code 589 0
Event Code 590 0
Event Code 591 0
Event Code 592 0
Event Code 593 0
Event Code 594 0
Event Code 595 0
Event Code 596 0
Event Code 597 0
Event Code 601 0
Event Code 603 0
Event Code 604 0
Event Code 605 0
Event Code 611 0
Event Code 612 0
Event Code 621 0
Event Code 628 0
Event Code 631 0
Event Code 632 0
Event Code 633 0
Event Code 636 0
Event Code 637 0
Event Code 638 0
Event Code 639 0
Event Code 652 0
Event Code 659 0
Event Code 660 0
Event Code 663 0
Event Code 664 0
Event Code 667 0
Event Code 668 0
Event Code 671 0
Event Code 672 0
Event Code Introduction540
Braking Force 0
Brake Force Adjustment 0
Brake Adjustment 0
Steering Direction 0
Steering Wheel Direction Indicator 0
Steering Wheel Adjustment 0
Steering Motor Gearbox 0
Mast553
TL Mast553
TT Mast553
Shim Basics553
General Repair and Safety Instructions555
Mast Testing (Assembled)555
Mast Column Rollers and Shims557
Shim Removal (Mast Assembled)562
Mast Removal562
Mast Installation564
Fork Inspection 0
Lift Cylinder Operation577
General Repair and Safety Instructions579
Disassembling the Cylinders579
Assembling the Cylinders579
Inspection580
Accessing the Rod Packing in the Mast Cylinder582
Accessing the Rod Packing in the Free Lift Cylinder582
Rod Packing Replacement582
Mast Cylinder Removal585
Mast Cylinder Installation585
Free Lift Cylinder Removal587
Free Lift Cylinder Installation588
Mast and Free Lift Cylinders589
Lift cylinder operation589
General repair and safety instructions591
Cylinder Repair Tools592
Rod Packing Access and Replacement592
Replacing the rod packing593
Mast Cylinder Removal and Installation596
Platform615
Safety Notices615
Mat Replacement615
Shield Removal and Installation616
Fork Removal and Installation617
Fork Height Adjustment618
Pallet Grab619
Side Gates623
Full Body Harness and Lanyard624
Shim Installation on TL Masts, Platform Removal, and Platform Installation625
Shim Installation on TT Masts, Platform Removal, and Platform Installation626
Height Sensor Encoder Replacement (ECR4) 0
Cable Replacement 0
Glossary 0
Single Speed Lift 0
Two Speed Lift 0
Single Speed Lift (With Lifting Fork) 0
Two Speed Lift (With Lifting Fork) 0
Mast Cylinders 0
Electrical Diagrams Index 0
Schematic – Power Unit w/Options 0
Schematic – Platform w/Options 0
Schematic – Power Unit w/Pallet Grab 0
Schematic – Platform w/Pallet Grab 0
Schematic – Power Unit 0
Schematic – Platform 0
Platform Distribution Panel 0
Platform Distribution Panel Forks First SAA 0
Power Unit Distribution Panel 0
Platform Modules ACCESS 1 & 4 0
Platform Modules ACCESS 1 & 4 Forks First SAA 0
Control Pod and Light Switches 0
Overhead Guard Lights/Fans 0
Overhead Guard Spotlights (Optional) 0
Traction Control Module ACCESS 3 0
Steering Control Module ACCESS 5 0
Hydraulics & Optional MMS 0
Guidance Control Module ACCESS 6 (Optional) 0
Travel Alarm & Freezer Conditioning (Optional) 0
Travel Alarm & Pallet Grab 0
Forks First/Lifting Forks (Optional) 0
Power Cables 0
Electrical Diagrams Index 0
Schematic – Power Unit w/Options 0
Schematic – Platform w/Options 0
Schematic – Power Unit w/Pallet Grab 0
Schematic – Platform w/Pallet Grab 0
Schematic – Power Unit 0
Schematic – Platform 0
Platform Distribution Panel 0
Platform Distribution Panel Forks First SAA 0
Power Unit Distribution Panel 0
Platform Modules ACCESS 1 & 4 0
Platform Modules ACCESS 1 & 4 Forks First SAA 0
Control Pod and Light Switches 0
Overhead Guard Lights/Fans 0
Overhead Guard Spotlights (Optional) 0
Traction Control Module ACCESS 3 0
Steering Control Module ACCESS 5 0
Hydraulics & Optional MMS 0
Guidance Control Module ACCESS 6 (Optional) 0
Travel Alarm & Freezer Conditioning (Optional) 0
Travel Alarm & Pallet Grab 0
Forks First/Lifting Forks (Optional) 0
Power Cables 0
Wire Harnesses 0
Electrical Diagrams Index 0
Schematic – Power Unit w/Options 0
Schematic – Platform w/Options 0
Schematic – Power Unit w/Pallet Grab 0
Schematic – Platform w/Pallet Grab 0
Schematic – Power Unit 0
Schematic – Platform 0
Platform Distribution Panel 0
Platform Distribution Panel Forks First SAA 0
Power Unit Distribution Panel 0
Platform Modules ACCESS 1 & 4 0
Platform Modules ACCESS 1 & 4 Forks First SAA 0
Control Pod and Light Switches 0
Overhead Guard Lights/Fans 0
Overhead Guard Spotlights (Optional) 0
Traction Control Module ACCESS 3 0
Steering Control Module ACCESS 5 0
Hydraulics & Optional MMS 0
Guidance Control Module ACCESS 6 (Optional) 0
Travel Alarm & Freezer Conditioning (Optional) 0
Travel Alarm & Pallet Grab 0
Forks First/Lifting Forks (Optional) 0
Power Cables 0
Wire Harnesses 0
Index729
Schematic – Power Unit w/Options729
Schematic – Platform w/Options730
Schematic – Power Unit w/Pallet Grab732
Schematic – Platform w/Pallet Grab733
Schematic – Power Unit733
Schematic – Platform734
Platform Distribution Panel736
Platform Distribution Panel Forks First SAA737
Power Unit Distribution Panel738
Platform Modules ACCESS 1 & 4738
Platform Modules ACCESS 1 & 4 Forks First SAA739
Control Pod and Light Switches741
Overhead Guard Lights/Fans742
Traction Control Module ACCESS 3743
Steering Control Module ACCESS 5744
Hydraulics & Optional MMS746
Guidance Control Module ACCESS 6 (Optional)747
Travel Alarm & Freezer Conditioning (Optional)747
Travel Alarm & Pallet Grab748
Forks First Option w/Heaters750
Power Cables751
Wire Harnesses752
Single Speed Lift782
Two Speed Lift783
Single Speed Lift (With Lifting Fork)784
Two Speed Lift (With Lifting Fork)785
Mast Cylinders786

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