Crown Forklift FC 4500 Series AC Traction Service & Parts Manual

Description

Crown Forklift FC 4500 Series AC Traction Service & Parts Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift FC 4500 Series AC Traction Service & Parts Manual – PDF DOWNLOAD

Language : English
Pages :764
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift FC 4500 Series AC Traction Service & Parts Manual – PDF DOWNLOAD

FC 4500 AC Traction 1
How to Order Service Parts 2
Safety Page 5
General Maintenance Instructions 3 5
Cleaning of Material Handling Equipment 5 5
Cleaning Methods 5 5
Control of Hazardous Energy 7 5
Lockout/Tagout 7 5
Battery 7 5
Capacitance 9 5
Hydraulic 10 5
Lifting and Blocking 11 5
Mast 12 5
Disconnect Tilt Cylinder 15 5
Removing Mast 16 5
Removing Counterweight 17 5
Introduction Page 5
Introduction 21 5
Operation Instructions 21 5
Operator Training 21 5
Service Training 21 5
Replacement Parts 21 5
Lubrication & Adjustment Page 5
Lubrication and Adjustment 27 5
Lubrication & Adjustment 33 5
Component Access 33 5
Lubrication 34 5
Componentry 53 6
ACC POT1 53 6
ACS 53 6
ACCUMULATOR 53 6
ACCESS 1 54 6
ACCESS 2 54 6
ACCESS 3 54 6
ALM1 55 6
ALM2 55 6
ALM3 (Optional) 55 6
AXS1 56 6
AXS2 56 6
AXS3 56 6
BRES 57 6
BREATHER 57 6
BRKS 57 6
CBV 58 6
CYLINDER 58 6
CYLINDER 58 6
CYLINDER 59 6
CYLINDER 59 6
CYLINDER 59 6
DIPSTICK 60 6
DISTRIBUTION PANEL 60 6
ECR1 60 6
ECR2 61 6
FAN1 & FAN2 61 6
FAN3 (Optional) 61 6
FAN4 62 6
FAN5 62 6
FIL 62 6
FILTER 63 6
FNS (Optional) 63 6
FS 63 6
FU1 64 6
FU2 64 6
FU3 64 6
FU4 65 6
FU5 65 6
FU6 65 6
FU7 66 6
FU8 66 6
FU11 (Optional) 66 6
FU12 (Optional) 67 6
HAND PUMP 67 6
HGTS1 67 6
HN1 68 6
HNS 68 6
HR1 68 6
HR2 69 6
HSS 69 6
INFOLINK MODULE (Optional) 69 6
IMPACT SENSOR (Optional) 70 6
K1 70 6
K2 70 7
K11 (Optional) 71 7
K12 (Optional) 71 7
KYS 71 7
L 72 7
LGS1 (Optional) 72 7
LGS2 (Optional) 72 7
LGT1, 2, 3 (Optional) 73 7
LGT4 73 7
LGT5, 6 73 7
M1 74 7
M2 74 7
M3 74 7
MANUAL RELIEF VALVE 75 7
MPCE 75 7
P 75 7
PRESSURE CHECK POINT 76 7
PRK-A, PRK-B 76 7
12V POWER SUPPLY 76 7
PS1 77 7
Pump 77 7
Pump 77 7
RAS 78 7
RES2 (Optional) 78 7
RES3 (Optional) 78 7
RS 79 7
RV1 79 7
RV2 79 7
RV3 80 7
S 80 7
SB80 (Optional) 80 7
SCU 81 7
SES 81 7
SES1, SES2 81 7
Strainer 82 7
Suction 82 7
SV1 82 7
SV2 82 7
SV3 83 7
TBS 83 7
THS1 (Optional) 83 7
THS2 (Optional) 84 7
TLMS 84 7
TLT 84 7
TMM 85 7
TS1 85 7
TS2 85 7
ULV 86 7
VALVE 86 7
VALVE 86 7
Metric Torque Values 87 7
Grade 87 7
Torque Values 91 7
Grade 91 7
Hydraulic Page 8
Hydraulic System 95 8
Hydraulic Lines and Fittings 95 8
Reservoir 95 8
Drift Test 97 8
Cylinder and Circuit Bleeding 97 8
Hydraulic Circuitry 101 8
Accumulator and Unloading Valve 105 8
Spring Apply/Hydraulic Release Park Brake 106 8
Hydraulic Schematic Symbols 121 8
Lift Pump 125 8
Disassembly 125 8
Mounting Flange And End Cover 126 8
Assembly 126 8
Control Valve 127 8
Relief Valve RV1 Operation 127 8
Relief Valve RV2 Operation 127 8
Main Pressure Compensating Element (MPCE) Operation 129 8
Control Valve Disassembly 130 8
Control Valve Inspection & Repair 131 8
Control Valve Assembly 131 8
Adding 4th Spool Valve Section 132 8
Hydraulic Manifold Blocks 135 8
Manifolds 135 8
Drive Unit Page 8
Drive Unit 139 8
Drive Unit Lubrication 139 8
Drive Unit Mounting Bolts 139 8
Drive Tire Replacement 140 8
Traction Motor (M1) 140 8
Axle Hub and Axle Installation 145 8
Drive Unit Removal 146 8
Electrical Page 9
Electrical 151 9
Access 1 – Display Control Module (DCM) 151 9
Switches 153 9
AXS1, AXS2, TLT 153 9
RAS 154 9
TBS 156 9
HSS 157 9
ACS 158 9
158 9
HGTS1 159 9
SES1, SES2 160 9
TLMS 160 9
Electrical System 163 9
Wiring Color Codes 163 9
Power Cables 163 9
Switches 167 9
Access 123System 175 9
User Main Menu Level 175 9
User Level 175 9
Analyzer 192 9
Calibration 195 9
Features 197 9
Hour/Event/Utilities Menu 200 9
Performance 202 9
Distribution Board 205 9
Components Included On Distribution Board 205 9
Distribution Board Jumper Configurations 206 9
Potentiometers 211 9
Accelerator Potentiometer (POT1) 211 9
Removal/Installation 211 9
Contactors 213 10
140538-001/-002 Contactor (36/48 Volt) S (Steering) 213 10
132084-005/-006 Contactor L (Line) & P (Pump) 213 10
Inspection 213 10
Contacts 213 10
Steering Contactor 214 10
Line and Pump Contactor 216 10
Component Replacement 216 10
“EE” Component Replacement 217 10
Battery 219 10
Safety Rules 219 10
Checking Battery 219 10
Battery Care 220 10
Charging Battery 220 10
Battery Removal 221 10
Battery Installation 221 10
Seat Deck Cover Adjustment 222 10
Seat Deck Latch Adjustment 223 10
Seat Deck Cylinders 224 10
Battery Cleaning 226 10
Troubleshooting 226 10
Dual Voltage Conversion 226 10
Battery Discharge Interrupt Performance (P4) 227 10
Motors 229 10
Event Codes 231 10
Event Code 110 235 10
Event Code 111 237 10
Event Code 112 237 10
Event Code 113 237 10
Event Code 119 238 10
Event Code 123 238 10
Event Code 130 239 10
Event Code 131 239 10
Event Code 133 240 10
Event Code 134 240 10
Event Code 163 241 10
Event Code 164 242 10
Event Code 165 242 10
Event Code 199 243 10
Event Code 200 244 10
Event Code 201 244 11
Event Code 202 244 11
Event Code 203 245 11
Event Code 204 246 11
Event Code 205 246 11
Event Code 206 247 11
Event Code 207 247 11
Event Code 208 248 11
Event Code 209 248 11
Event Code 210 248 11
Event Code 214 249 11
Event Code 215 250 11
Event Code 216 250 11
Event Code 217 250 11
Event Code 219 251 11
Event Code 220 251 11
Event Code 221 251 11
Event Code 222 252 11
Event Code 223 252 11
Event Code 224 253 11
Event Code 225 253 11
Event Code 247 253 11
Event Code 299 253 11
Event Code 300 254 11
Event Code 301 254 11
Event Code 302 255 11
Event Code 303 255 11
Event Code 304 256 11
Event Code 305 256 11
Event Code 306 257 11
Event Code 307 257 11
Event Code 308 257 11
Event Code 309 257 11
Event Code 310 258 11
Event Code 311 258 11
Event Code 312 259 11
Event Code 313 259 11
Event Code 314 260 11
Event Code 315 260 11
Event Code 316 261 11
Event Code 317 261 11
Event Code 319 261 11
Event Code 320 261 11
Event Code 321 262 11
Event Code 322 262 11
Event Code 323 263 11
Event Code 324 263 11
Event Code 325 263 11
Event Code 326 264 11
Event Code 330 264 11
Event Code 399 264 11
FWD/REV 264 11
Creep Speed Only 266 11
No Traction/No Lift/BDI = 0% 266 11
Brake Page 12
Service Brake 269 12
Operation 269 12
Brake Pedal 270 12
Shimming the Brake Pedal 271 12
Brake Assembly Removal 272 12
Disassembly of Brake 272 12
Lining/Rotor Inner And Outer Stator 273 12
Piston, Wiper and Seal Removal 273 12
Wiper, Seal & Piston Installation 274 12
Service Brake Assembly 274 12
Service Brake Installation 274 12
Service Brake Bleeding 275 12
Drive Tire Installation 275 12
Service Brake Adjustments 275 12
Service Brake Valve 275 12
Parking Brake 277 12
Operation 277 12
Inspection 277 12
Adjustment 278 12
Adjustments When Replacing Brake Shoes or Brake Hub 279 12
Traction Motor 279 12
Park Brake Release Manifold 280 12
Manually Releasing the Parking Brake 281 12
Parking Brake Solenoid 281 12
Steering Page 12
Steering 285 12
Hydrostatic Steering Unit 285 12
Steering Column Assembly 286 12
Column 286 12
Gas Cylinder 287 12
Directional Control 288 12
Steering Wheel Removal 289 12
Steering Wheel 290 12
Final Assembly 291 12
Steer Axle Assembly 291 12
Lifting Mechanism Page 13
Mast 299 13
Bearing Cap Torque Requirements 299 13
Shim Basics 300 13
Shim Removal 302 13
Carriage Side Thrust Roller Adjustments (TL & TT Masts) 304 13
Mast Column Roller Removal – TT Mast (Inner Mast) 305 13
Mast Column Rollers Removal – TL Mast 306 13
Mast Assembly 306 13
Lift Cylinder Removal – TL & TT 306 13
Carriage Removal – TT Mast 307 13
Carriage Removal – TL Mast 307 13
Mast Removal (TL & TT Mast) 308 13
Mast Assembly (TL & TT Mast) 309 13
Tilt Cylinder Adjustments 312 13
Quad (Four Stage) Mast 312 13
Mast Flaking 312 13
Mast Testing (Assembled) 313 13
Lift Chains 317 13
Inspection 317 13
Lift Chain Lubrication 320 13
Lift Chain Replacement 320 13
Fork Inspection 323 13
Abrasion 323 13
Overloading 325 13
Fatigue 326 13
Bent or Twisted Forks 326 13
Hanger 327 13
Cylinders Page 14
Cylinders 331 14
Lift Cylinder 331 14
Disassembly 331 14
Seals 331 14
Seal Removal 331 14
Seal Installation – General 332 14
Rod U-Cup Installation 332 14
Cylinder U-cup Installation 333 14
Cylinder Assembly 333 14
Cylinder Bleeding and Flushing 334 14
Bleeding – Free Lift Cylinder 334 14
Bleeding – Stage Lift Cylinders 334 14
Flushing – Stage and Free Lift Cylinders 334 14
Drift Test 334 14
Tilt Cylinder 335 14
Cylinder Disassembly 337 14
Rod Disassembly 337 14
Seal Replacement 338 14
Cylinder Reassembly 338 14
Tilt Cylinder Flushing and Bleeding Procedures 338 14
Tilt Drift Test 339 14
Tilt Cylinder Installation and Adjustments 339 14
Steer Cylinder 341 14
Cylinder Removal 342 14
Cylinder Disassembly 342 14
Cylinder Assembly 344 14
Cylinder Installation 344 14
Parking Brake Cylinder 345 14
Cylinder Removal 346 14
Cylinder Disassembly 347 14
Cylinder Assembly 347 14
Cylinder Installation 348 14
Glossary Page 14
Glossary 351 14
Wiring Diagrams Page 15
Introduction to Diagram Usage 357 15
Schematic 357 15
Pictorials 357 15
Hydraulic Schematic Page 15
Hydraulic Schematic 383 15
Power Unit Parts Page 15
Seat Deck 386 15
Power Unit 390 15
Overhead Guard & Covers 394 15
Battery Spacers & Retainers 398 15
Static Seat 404 15
Suspension Seat 408 15
Hip Restraint 412 15
Hydraulic Parts Page 16
Suction Line Hydraulics 416 16
Lift & Tilt Line Hydraulics 418 16
Steer & Brake Line Hydraulics 420 16
Pressure Line Hydraulics 422 16
Accessory Line Hydraulics – TL/Quad 424 16
Accessory Line Hydraulics – TT 426 16
Steer & Brake Line Hydraulics 428 16
Return Line Hydraulics 430 16
Lift & Return Line Hydraulics – TL Mast 432 16
Lift & Return Line Hydraulics – TT Mast 434 16
Accessory Line Hydraulics – TL Mast 436 16
Accessory Line Hydraulics – TT Mast 438 16
Mast Hydraulics – Quad Mast 440 16
Mast Hydraulics – Quad Mast 442 16
Lift Pump – TT 444 16
Lift Pump – TL/Quad 446 16
Lift Pump Motor 448 16
DC Lift Motor 450 16
Directional Control Valve – 3 Spool 452 16
Directional Control Valve – 4 Spool 454 16
Manifold Crossover Relief 456 16
Tilt Manifold 458 16
Park Brake Release Manifold 460 16
4-Position Pressure Relief Valve 462 16
Lowering Flow Control Valve – TL 464 16
Lowering Control Valve – TT 466 16
Accessory Manifold – TL/Quad 468 16
Accessory Manifold – TL/TT 472 16
Accessory Manifold – Quad 474 16
Control Lever 478 16
Control Valve Linkage – Standard No Accessories 482 16
Control Valve Linkage – One Accessory 486 16
Control Valve Linkage – Two Accessories 490 16
TT Carriage Hydraulics – Single Accessory 494 16
Carriage Hydraulics – TL Single Accessory 498 16
Carriage Hydraulics – Quad Mast 502 16
TT Carriage Hydraulics – Double Accessory 506 16
Carriage Hydraulics – TL Double Accessory 512 16
Drive Unit Parts Page 16
Drive Unit 520 16
AC Traction Motor 524 16
Drive Tire 526 16
Electrical Parts Page 17
Electrical Components – Power Unit 534 17
Controller Panel – DC Lift 538 17
Controller Panel – AC Lift 540 17
Contactor Panel 542 17
Distribution Panel 544 17
Freezer Condition Distribution Board 546 17
Contactor L & P 548 17
Contactor L & P – “EE” 550 17
Steering Contactor 552 17
Steering Contactor “EE” 554 17
Directional Control 556 17
Foot Operated Directional Control 558 17
Accelerator 560 17
Park Brake Switch 562 17
Tilt Limit Switch 564 17
Control Cable – TT 566 17
Control Cable – TL 568 17
Connectors 570 17
Strobe Light 576 17
Overhead Guard – Front Lights & Mirrors 578 17
Overhead Guard – Rear Lights 580 17
Drive Thru Overhead Guard – Front Lights & Mirrors 584 17
Drive Thru Overhead Guard Accessories – Rear 586 17
TL/TT Mast Mounted Work Lights 590 17
Quad Mast Mounted Work Lights 592 17
Brake Parts Page 17
Brake Pedal 596 17
Power Service Brake 598 17
Parking Brake 600 17
Steering Parts Page 17
Steering Column – Part 1 604 17
Steering Column – Part 2 608 17
Steering Axle 610 17
Steering And Service Brake Pump 614 17
Power Steering Pump Motor 616 17
Steer Unit 618 17
Steer Tire 620 17
Lifting Mechanism Parts Page 18
TL Mast Accessories 624 18
Mast – TL 626 18
TT Mast Accessories 636 18
Mast – TT 638 18
Quad Mast 648 18
Fork Carriage – TL 656 18
Fork Carriage – TT 658 18
Fork Carriage – Quad 660 18
Yoke – TT 662 18
Yoke Quad Mast 666 18
Lift Chain – TL 668 18
Lift Chain TT 670 18
Lift Chain Quad 674 18
Load Backrest – TL 678 18
Load Backrest – TT 680 18
Load Backrest – Quad 682 18
Fork 686 18
Cylinder Parts Page 18
Mast Cylinder – TL 696 18
Mast Cylinder – TT 698 18
Quad Mast Cylinder 702 18
Quad Carriage Cylinder 704 18
Carriage Cylinder – TT 706 18
Tilt Cylinder – TL/Quad 708 18
Tilt Cylinder – TT 712 18
Sideshifter Cylinder 716 18
Parking Brake Cylinder 718 18
Steer Cylinder 720 18
Platform Parts Page 18
Sideshifter – TL/TT 724 18
Sideshifter – Quad 726 18
Labels and Decals Page 18
Work Assist Accessories 730 18
InfoLink Accessories 734 18
Labels and Decals 736 18
Safety 19
General Maintenance Instructions 21
Cleaning of Material Handling Equipment 23
Control of Hazardous Energy 25
Introduction 37
Introduction 39
Lubrication & Adjustment 43
Lubrication and Adjustment 45
Lubrication & Adjustment 51
Componentry 71
Metric Torque Values105
Torque Values109
Hydraulic111
Hydraulic System113
Hydraulic Circuitry119
Hydraulic Schematic Symbols139
Lift Pump143
Control Valve145
Hydraulic Manifold Blocks153
Drive Unit155
Drive Unit157
Electrical167
Electrical169
Switches171
Electrical System181
Access 123System193
Distribution Board223
Potentiometers229
Contactors231
Battery237
Motors247
Event Codes249
Event Code 110253
Event Code 111255
Event Code 112255
Event Code 113255
Event Code 119256
Event Code 123256
Event Code 130257
Event Code 131257
Event Code 133258
Event Code 134258
Event Code 163259
Event Code 164260
Event Code 165260
Event Code 199261
Event Code 200262
Event Code 201262
Event Code 202262
Event Code 203263
Event Code 204264
Event Code 205264
Event Code 206265
Event Code 207265
Event Code 208266
Event Code 209266
Event Code 210266
Event Code 214267
Event Code 215268
Event Code 216268
Event Code 217268
Event Code 219269
Event Code 220269
Event Code 221269
Event Code 222270
Event Code 223270
Event Code 224271
Event Code 225271
Event Code 247271
Event Code 299271
Event Code 300272
Event Code 301272
Event Code 302273
Event Code 303273
Event Code 304274
Event Code 305274
Event Code 306275
Event Code 307275
Event Code 308275
Event Code 309275
Event Code 310276
Event Code 311276
Event Code 312277
Event Code 313277
Event Code 314278
Event Code 315278
Event Code 316279
Event Code 317279
Event Code 319279
Event Code 320279
Event Code 321280
Event Code 322280
Event Code 323281
Event Code 324281
Event Code 325281
Event Code 326282
Event Code 330282
Event Code 399282
FWD/REV282
Creep Speed Only284
No Traction/No Lift/BDI = 0%284
Brake285
Service Brake287
Parking Brake295
Steering301
Steering303
Lifting Mechanism315
Mast317
Lift Chains335
Fork Inspection341
Cylinders347
Cylinders349
Tilt Cylinder353
Steer Cylinder359
Parking Brake Cylinder363
Glossary367
Glossary369
Wiring Diagrams373
Introduction to Diagram Usage375
Index377
Electrical Schematic – AC Traction/DC Lift378
Electrical Schematic – AC Traction/AC Lift379
Electrical Schematic – AC Traction/DC Lift With Options380
Distribution Panel381
ACCESS 3 – AC Traction Controller382
ACCESS 2 – AC Lift Controller383
Hydraulic Switch Harness With Tilt Position Assist384
Dashboard with TMM Option385
ACCESS 1 – Display386
Steering387
Foot Operated Direction Control388
Brake and Accelerator Pedals389
Motors and Alarms390
InfoLink391
Overhead Guard392
Freezer Condition393
Freezer Condition – Jumper Harness394
Power Cables – AC Traction/DC Lift395
Power Cables – AC Traction/AC Lift396
Wire Harnesses397
Hydraulic Schematic399
Hydraulic Schematic401
Power Unit Parts403
Seat Deck404
Power Unit408
Overhead Guard & Covers412
Battery Spacers & Retainers416
Static Seat422
Suspension Seat426
Hip Restraint430
Hydraulic Parts433
Suction Line Hydraulics434
Lift & Tilt Line Hydraulics436
Steer & Brake Line Hydraulics438
Pressure Line Hydraulics440
Accessory Line Hydraulics – TL/Quad442
Accessory Line Hydraulics – TT444
Steer & Brake Line Hydraulics446
Return Line Hydraulics448
Lift & Return Line Hydraulics – TL Mast450
Lift & Return Line Hydraulics – TT Mast452
Accessory Line Hydraulics – TL Mast454
Accessory Line Hydraulics – TT Mast456
Mast Hydraulics – Quad Mast458
Mast Hydraulics – Quad Mast460
Lift Pump – TT462
Lift Pump – TL/Quad464
Lift Pump Motor466
DC Lift Motor468
Directional Control Valve – 3 Spool470
Directional Control Valve – 4 Spool472
Manifold Crossover Relief474
Tilt Manifold476
Park Brake Release Manifold478
4-Position Pressure Relief Valve480
Lowering Flow Control Valve – TL482
Lowering Control Valve – TT484
Accessory Manifold – TL/Quad486
Accessory Manifold – TL/TT490
Accessory Manifold – Quad492
Control Lever496
Control Valve Linkage – Standard No Accessories500
Control Valve Linkage – One Accessory504
Control Valve Linkage – Two Accessories508
TT Carriage Hydraulics – Single Accessory512
Carriage Hydraulics – TL Single Accessory516
Carriage Hydraulics – Quad Mast520
TT Carriage Hydraulics – Double Accessory524
Carriage Hydraulics – TL Double Accessory530
Drive Unit Parts537
Drive Unit538
AC Traction Motor542
Drive Tire544
Electrical Parts551
Electrical Components – Power Unit552
Controller Panel – DC Lift556
Controller Panel – AC Lift558
Contactor Panel560
Distribution Panel562
Freezer Condition Distribution Board564
Contactor L & P566
Contactor L & P – “EE”568
Steering Contactor570
Steering Contactor “EE”572
Directional Control574
Foot Operated Directional Control576
Accelerator578
Park Brake Switch580
Tilt Limit Switch582
Control Cable – TT584
Control Cable – TL586
Connectors588
Strobe Light594
Overhead Guard – Front Lights & Mirrors596
Overhead Guard – Rear Lights598
Drive Thru Overhead Guard – Front Lights & Mirrors602
Drive Thru Overhead Guard Accessories – Rear604
TL/TT Mast Mounted Work Lights608
Quad Mast Mounted Work Lights610
Brake Parts613
Brake Pedal614
Power Service Brake616
Parking Brake618
Steering Parts621
Steering Column – Part 1622
Steering Column – Part 2626
Steering Axle628
Steering And Service Brake Pump632
Power Steering Pump Motor634
Steer Unit636
Steer Tire638
Lifting Mechanism Parts641
TL Mast Accessories642
Mast – TL644
TT Mast Accessories654
Mast – TT656
Quad Mast666
Fork Carriage – TL674
Fork Carriage – TT676
Fork Carriage – Quad678
Yoke – TT680
Yoke Quad Mast684
Lift Chain – TL686
Lift Chain TT688
Lift Chain Quad692
Load Backrest – TL696
Load Backrest – TT698
Load Backrest – Quad700
Fork704
Cylinder Parts713
Mast Cylinder – TL714
Mast Cylinder – TT716
Quad Mast Cylinder720
Quad Carriage Cylinder722
Carriage Cylinder – TT724
Tilt Cylinder – TL/Quad726
Tilt Cylinder – TT730
Sideshifter Cylinder734
Parking Brake Cylinder736
Steer Cylinder738
Platform Parts741
Sideshifter – TL/TT742
Sideshifter – Quad744
Labels and Decals747
Work Assist Accessories748
InfoLink Accessories752
Labels and Decals754

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