Crown Forklift TSP 1000 and 1500 Series Service Manual – PDF DOWNLOAD

Crown Forklift TSP 1000 and 1500 Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift TSP 1000 and 1500 Series Service Manual – PDF DOWNLOAD

Language : English
Pages :723
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift TSP 1000 and 1500 Series Service Manual – PDF DOWNLOAD

Introduction 3
Global Contact Information 4
Safety 6
General Safety 8
Introduction 8
Safety Messages 8
Standards and Regulations 9
Environmental Protection 9
Organizational Requirements 10
General Maintenance 10
General Hot Work Instructions 11
Personal Protective Equipment (PPE) 11
Hazards From Stored Energy 12
Returning the Lift Truck to Service 12
Lift Truck Cleaning 12
Safe Battery Handling 12
Hydraulic System Safety 12
Safety Labels on the Lift Truck 13
Lifting Equipment 13
Cleaning the Lift Truck 14
Cleaning the Lift Truck 14
Preparing for Cleaning 14
General Cleaning 14
Steam Cleaning and Power Washing 15
Returning to Operation 15
Control of Hazardous Energy 16
Control of Hazardous Energy (Lockout/Tagout) 16
Lockout/Tagout Procedures 16
Tagout Procedure 17
Lockout Procedure With the Battery Installed 17
Lockout Procedure Without the Battery Installed 17
Preparing the Lift Truck for Maintenance 17
Battery 17
Battery Care 17
Removing the Battery 18
Installing the Battery 18
Discharging the Capacitors 18
Releasing the Hydraulic Pressure 19
Releasing the Pressure in the Hydraulic Circuits 20
Releasing the M31 Traction Brake 21
Releasing the M31 Traction Brake Using Tow Mode 21
Releasing the M31 Traction Brake Using the Drive / Tow Switch 21
Releasing the M31 Traction Brake Mechanically 23
Towing the Lift Truck 24
Preparing for Towing the Lift Truck 24
Towing the Lift Truck by Pulling in the Power Unit First Direction 25
Towing the Lift Truck by Pushing in the Forks First Direction 26
Operating the Service Panel 27
Operating the Manual Lowering Valve 27
Lifting and Blocking 28
Lifting and Blocking the Mainframe 28
Lifting and Blocking the Power Unit 29
Blocking the TF and TN Main Mast 30
Blocking the TT Main Mast 31
Blocking the Third Stage Above the Second Stage Mast 32
Blocking the Auxiliary Mast 34
Blocking the Platform 35
Removing and Installing the Height Encoder 1 Spring 35
Removing the Height Encoder 1 Spring 36
Installing the Height Encoder 1 Spring 39
General Maintenance 42
Standard Torque Values 44
Introduction 44
Special Torque Values 47
Introduction 47
Electrical Assemblies 47
Hydraulic Component Mounting 47
Hydraulic Assemblies 47
Lifting Mechanism Component Mounting 48
Lifting Mechanism Assemblies 49
Power Unit Component Mounting 49
Steering Component Mounting 50
Traction and Brake Component Mounting 50
Traction and Brake Assemblies 50
Automation Component Mounting 50
Hydraulic Fitting Torque Values 52
Introduction 52
Manifold Component Torque Values 54
Introduction 54
Hoist Manifold Torque Values 54
Load Handler Manifold Torque Values 54
Lubricants 56
Handling of Static Sensitive Components 60
Planned Maintenance 61
Introduction 61
Lubricants 61
Icons 61
Visual Inspection 62
Operational Check and Test Drive 63
Preparing the Lift Truck for Maintenance 63
Inspection and Lubrication 64
Preparing the Lift Truck for Operation202
Final Operational Check and Test Drive202
Planned Maintenance Completion202
Power Source203
General Information204
Componentry205
A21 Fan214
Access 11215
Access 21216
Access 31217
Access 41218
Access 51219
Access 61220
Access 64221
Access 65222
Access 71223
Access 72224
Access 73225
Accessory Proportional Valve226
Accessory Switch227
Antenna 1228
Antenna 2229
Auxiliary Hoist Potentiometer230
Auxiliary Hoist Proportional Valve231
Auxiliary Lower Proportional Valve232
Auxiliary Lower Solenoid Valve233
Auxiliary Port Adapter Module234
Auxiliary Power Outlet235
Auxiliary Proportional Valve236
Battery Retainer Switch237
Brake Switch 1238
Brake Switch 2239
Bypass Solenoid Valve240
Cabin Heater241
Cable Tension Switch242
Capacitor 1243
Card Reader244
Chain Slack Switch 1245
Chain Slack Switch 2246
Chain Slack Switch 3247
Chain Slack Switch 4248
Chain Slack Switch 5249
Chain Slack Switch 6250
Chain Slack Switch 7251
Chain Slack Switch 8252
Contactor 1253
Contactor 2254
Contactor 3255
Contactor 3256
Contactor 4257
Control Panel258
Counterbalance Valve 1259
Counterbalance Valve 2260
Counterbalance Valve 3261
Counterbalance Valve 4262
Direction Selector Sensor263
Display Navigation Knob 1264
Distribution Panel 1265
Distribution Panel 2266
Distribution Panel 3267
Dome Light 1268
Dome Light 2269
Dome Light 3270
Dome Light 4271
Dome Light Switch272
Drive/Tow Switch273
Emergency Disconnect Switch 1274
Emergency Disconnect Switch 2275
End Aisle Control Sensor A1276
End Aisle Control Sensor A2277
End Aisle Control Sensor B1278
End Aisle Control Sensor B2279
Feedback Splitter Block 1280
Foot Presence Switch 1281
Foot Presence Switch 2282
Foot Presence Switch 3283
Foot Presence Switch 4284
Foot Presence Switch 5285
Foot Presence Switch 6286
Foot Presence Switch 7287
Foot Presence Switch 8288
Foot Presence Switch 9289
Fork Home Switch 1290
Fork Home Switch 2291
Freezer Cab Door Switch292
Fuse 1293
Fuse 2294
Fuse 3295
Fuse 4296
Fuse 5297
Fuse 6298
Fuse 7299
Fuse 8300
Fuse 9301
Fuse 10302
Fuse 11303
Fuse 12304
Fuse 13305
Fuse 14306
Fuse 15307
Fuse 16308
Fuse 17309
Fuse 18310
Fuse 19311
Fuse 20312
Fuse 21313
Fuse 22314
Fuse 23315
Fuse 24316
Fuse 25317
Fuse 26318
Fuse 27319
Fuse 28320
Fuse 29321
Fuse 30322
Fuse 31323
Fuse 32324
Gate Switch 1325
Gate Switch 2326
Guidance Sensor 1327
Guidance Sensor 2328
Guidance Switch329
Hand Presence Sensor 1330
Hand Presence Sensor 2331
Heater 1332
Heater 2333
Heater 3334
Heater 4335
Height Encoder 1336
Height Encoder 2337
Height Switch 1338
Height Switch 2339
Horn340
Horn Switch341
Impact Sensor 1342
Impact Sensor 2343
Key Switch344
Left Armrest Tilt Switch345
Line Contactor346
Load Sensor347
Load Wheel Sensor348
M21 Encoder349
M21 Thermal Sensor350
M31 Sensor 1351
M31 Sensor 2352
M31 Thermal Sensor353
M31 Traction Brake354
M51 Sensor 1355
M51 Sensor 2356
M51 Thermal Sensor357
Main Hoist Potentiometer358
Main Hoist Solenoid Valve359
Main Lower Solenoid Valve360
Main Pump361
Main Pump Motor362
Manual Lowering Valve363
Mechanical Locking Solenoid364
Oil Temperature Sensor365
Operator Compartment Fan 1366
Operator Compartment Fan 2367
Operator Compartment Fan 3368
Operator Compartment Fan 4369
Operator Compartment Fan 5370
Operator Fan Switch371
Operator Fan Switch372
Override Switch373
Pivot Potentiometer374
Pivot Proportional Valve375
Pivot Switch 1376
Pivot Switch 2377
Power Supply 1378
Power Supply 2379
Power Supply 3380
Power Supply 4381
Power Supply 5382
Power Supply 6383
Pressure Compensator Valve 1384
Pressure Compensator Valve 2385
Pressure Compensator Valve 3386
Pressure Compensator Valve 4387
Pressure Compensator Valve 5388
Pressure Reducing Valve 1389
Pressure Reducing Valve 2390
Proportional Relief Valve391
Rail Guidance Switch 1392
Rail Guidance Switch 2393
Relay 1394
Relay 3395
Relay 4396
Relay 5397
Relay 6398
Relay 7399
Relay 8400
Relay 9401
Relief Valve 1402
Relief Valve 2403
Relief Valve 3404
Resistor 1405
Resistor 2406
Resistor 3407
Resistor 4408
Resistor 5409
Resistor 6410
Resistor 7411
Right Armrest Tilt Switch412
RS422-RS232 Adapter413
Seat Lock Switch414
Seat Position Switch415
Seat Release Switch416
Seat Switch417
Service Platform/Power Unit Switch418
Service Raise/Lower Switch419
Speaker420
Steer Encoder 1421
Steer Encoder 2422
Steering Feedback Encoder423
Steer Motor424
Straight Ahead Sensor425
Thermal Switch 1426
Thermal Switch 2427
Tilt Down Switch428
Tilt Up Switch429
Traction Motor430
Traction Potentiometer431
Travel Alarm432
Traverse Encoder433
Traverse Potentiometer434
Traverse Proportional Valve435
Traverse Override Switch 1436
Traverse Override Switch 2437
Traverse Switch438
USB Receptacle439
Warning Light 1440
Warning Light 2441
Warning Light 3442
Warning Light 4443
Warning Light 5444
Warning Light 6445
Worklight 1446
Worklight 2447
Worklight 3448
Worklight 4449
Worklight 5450
Worklight 6451
Worklight 7452
Worklight 8453
Worklight 9454
Worklight 10455
Worklight Switch 1456
Worklight Switch 2457
Electrical458
Distribution Panel 1459
Tools and Equipment459
Recommended Tools and Equipment459
Disassembly459
Preparing the Lift Truck for Maintenance459
Removing Distribution Panel 1459
Disassembling Distribution Panel 1460
Inspecting Distribution Panel 1461
Assembly462
Assembling Distribution Panel 1462
Installing Distribution Panel 1463
Preparing the Lift Truck for Operation464
Event Codes465
Introduction467
Event Codes469
Hydraulic547
Main Pump548
Tools and Equipment548
Recommended Tools and Equipment548
Additional Tools and Equipment548
Disassembly548
Preparing the Lift Truck for Maintenance548
Removing the Main Pump549
Inspecting the Main Pump554
Assembly554
Installing the Main Pump554
Preparing the Lift Truck for Operation559
Motor – M21561
Theory of Operation561
Theory of Operation561
Tools and Equipment561
Recommended Tools and Equipment561
Additional Tools and Equipment561
Disassembly562
Preparing the Lift Truck for Maintenance562
Removing the Main Pump Motor562
Inspecting the Main Pump Motor565
Assembly565
Installing the Main Pump Motor565
Preparing the Lift Truck for Operation568
Pump570
Tools and Equipment570
Recommended Tools and Equipment570
Additional Tools and Equipment570
570
Preparing the Lift Truck for Maintenance570
Priming the Pump571
Preparing the Lift Truck for Priming the Main Pump571
Removing Air From the Circuit for the Main Pump571
Checking for Hydraulic Oil Leaks for the Main Pump572
Preparing the Lift Truck for Operation572
Lifting Mechanism573
Fork Inspection574
Tools and Equipment574
Recommended Tools and Equipment574
Additional Tools and Equipment574
Inspection574
Preparing the Lift Truck for Maintenance574
Introduction575
Identification576
Measuring the Fork Blade for Wear577
Checking for Fatigue Cracks579
Bent or Twisted Forks581
Checking the Fork Tip for Straightness583
Checking the Fork Locking Pin583
Checking the Slide-On Type Fork Parts584
Measuring the Slide-On Type Fork Bore for Wear584
Preparing the Lift Truck for Operation585
Lift Chains587
Tools and Equipment587
Recommended Tools and Equipment587
Disassembly587
Preparing the Lift Truck for Maintenance587
Inspecting the Lift Chains587
Checking the Lift Chains for Wear590
Assembly591
Preparing the Lift Truck for Operation591
Power Unit592
Steering593
Motor – M51594
Technician Tips594
Technician Tips594
Tools and Equipment594
Recommended Tools and Equipment594
Additional Tools and Equipment594
Disassembly595
Preparing the Lift Truck for Maintenance595
Removing the Steer Motor and Gearbox Assembly595
Removing the M51 Sensor 1 and M51 Sensor 2597
Disassembling the Steer Motor and Gearbox Assembly597
Inspecting the Steer Motor and Gearbox Assembly598
Assembly599
Assembling the Steer Motor and Gearbox Assembly599
Installing the M51 Sensor 1 and M51 Sensor 2600
Installing the Steer Motor and Gearbox Assembly600
Preparing the Lift Truck for Operation603
Straight Ahead Sensor604
Technician Tips604
Theory of Operation604
Tools and Equipment604
Recommended Tools and Equipment604
Disassembly605
Preparing the Lift Truck for Maintenance605
Removing the Straight Ahead Sensor605
Inspecting the Straight Ahead Sensor606
Assembly607
Installing the Straight Ahead Sensor607
Preparing the Lift Truck for Operation608
User Interface609
Theory of Operation610
Traction and Brake611
Brake M31612
Technician Tips612
Technician Tips612
Tools and Equipment612
Recommended Tools and Equipment612
Additional Tools and Equipment612
Disassembly612
Preparing the Lift Truck for Maintenance612
Disassembling the M31 Traction Brake613
Inspecting the M31 Traction Brake618
Assembly618
Assembling the M31 Traction Brake618
Troubleshooting625
Troubleshooting625
Drive Tire627
Tools and Equipment627
Recommended Tools and Equipment627
Additional Tools and Equipment627
Disassembly627
Preparing the Lift Truck for Maintenance627
Removing the Drive Tire628
Inspecting the Drive Tire629
Assembly630
Installing the Drive Tire630
Preparing the Lift Truck for Operation632
Drive Unit633
Technician Tips633
Technician Tips633
Tools and Equipment633
Recommended Tools and Equipment633
Additional Tools and Equipment633
Disassembly634
Preparing the Lift Truck for Maintenance634
Removing the Drive Unit634
Inspecting the Drive Unit636
Assembly638
Installing the Drive Unit638
Preparing the Lift Truck for Operation640
Motor – M31641
Technician Tips641
Technician Tips641
Tools and Equipment641
Recommended Tools and Equipment641
Additional Tools and Equipment641
Disassembly641
Preparing the Lift Truck for Maintenance641
Removing the Traction Motor642
Inspecting the Traction Motor643
Assembly644
Installing the Traction Motor644
Preparing the Lift Truck for Operation645
Troubleshooting646
Troubleshooting646
Automation647
Diagrams648
Pictorials – Electrical649
Pictorials – Electrical – 48 V649
Pictorials – Electrical – 72 / 80 V679
Schematics – Electrical711
Schematics – Electrical – 48 V711
Schematics – Electrical – 72 / 80 V715
Schematics – Hydraulic720
Schematics – Hydraulic720

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