Crown Forklift LP3010/3020 Series Maintenance Manual 812521-006

Description

Crown Forklift LP3010/3020 Series Maintenance Manual 812521-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift LP3010/3020 Series Maintenance Manual 812521-006 – PDF DOWNLOAD

Language : English
Pages :192
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift LP3010/3020 Series Maintenance Manual 812521-006 – PDF DOWNLOAD

LP3010/3020 1
REVISION 3
Overview of Revisions 3
TABLE OF CONTENT 7
TABLE OF CONTENT 2 8
TABLE OF CONTENT 3 9
TABLE OF CONTENT 4 10
TABLE OF CONTENT 5 11
TABLE OF CONTENT 6 12
TABLE OF CONTENT 7 13
SAFETY 17
Safety Symbols used in the Manual 17
General Maintenance and Repair Safety Notes 17
Maintenance and Repair 17
Before Leaving the Truck 18
Before Carrying out Work on the Truck 18
Before Operating the Truck 18
Warnings and Labels on the Truck 18
INTRODUCTION 21
General 21
Operating Instructions 21
Service Training 21
Ordering Spare Parts 21
Using the Manual 21
Model-Number 22
LUBRICATION AND ADJUSTMENT 25
Jacking up the Truck 25
Lifting the Vehicle with a Crane 26
Lifting the Vehicle with a Fork-Lift Truck 26
Towing the vehicle away 26
Access to Components 27
LP3010 Overview 27
LP3020 Overview 28
LP 3010 Overview – High Version 29
LP 3020 Overview – High Version 30
Main components under the motor panel 31
Access to Drive Unit, Hydraulic System and Electrical Components DANGER! 32
Maintenance 33
Operator Involvement 33
Daily Maintenance Record 33
Inspection and Maintenance Schedule 33
Daily or Every 8 Operating Hours, Part 1 34
Daily or Every 8 Operating Hours, Part 2 35
Monthly or Every 100 Operating Hours 36
Monthly or Every 100 Operating Hours, Page2 37
Scheduled Replacement of High Pressure Hoses 36
Every 3 Months or 250 Operating Hours 38
Every 3 Months or 250 Operating Hours 39
Every 6 Months or 500 Operating Hours 40
Every 6 Months or 500 Operating Hours 41
Anually or Every 1000 Operating Hours 42
Annually or Every 1,000 Operating Hours 43
Recommended Lubricants 45
Lubricants 45
Lubrication points / intervals 46
Lubrication Points, Overview 47
Torques 48
Standard Srews and Nuts 48
HYDRAULICS 51
Changing Hydraulic Oil 51
Hydraulic Pipes and Accessories 51
Removing the Hydraulic Unit 52
Replacing the Hydraulic Pump 53
Removal 53
Installation 53
Commissioning 53
Pump Motor 54
Replacing the Hydraulic Filter 54
Oil Change 55
Valve Block 56
Pressure Relief Valves 56
Operation 56
Platform Lift Pressure Relief Valve Setting 56
Aux Lift Pressure Relief Valve Setting 57
Non-Return Valve 57
Functional Test 57
Compensation Valve 57
Functional Test 57
Line Break Safety Device 58
Tools Required 58
Line Break Safety Device Functional Test 58
Emergency Lowering Valve 59
Tools Required 59
Emergency Lowering Valve Functional Test 59
DRIVE UNIT 63
Preparation 63
Material Required 63
Drive Unit Removal 63
Gear Unit Repair 65
General 65
Drive Unit Removal 65
Gear Unit Assembly 67
Installing the Drive Unit 68
ELECTRICS 71
Electrical Components 71
AV Alarm 71
CX Horn 71
F1, F2, FA, FA4 Fuses 71
F3, FA3 Fuses 71
F01 Aisle Recognition Sensor 71
F02 Aisle Recognition Sensor 71
FE Brake 71
HN3 Alarm 71
K1, K2 Travel Direction Contactors 71
K4 Main Contactor 71
K6 Steering Contactor 72
M1 Traction Motor 72
M2 Pump Motor 72
M3 Steering Motor 72
MAC Chain Slack Switch 72
MBC 72
MF Steering Limit Switch 72
MFC Lift Limit Switch (Cabin) 72
MFF Lift Limit Switch (Forks) 72
MFT Overhead Guard Monitor 72
MLS Lift Interruption Switch 72
MMI, MMA, PT Transmitter 72
MPR Door Switch 73
MP1, MP3 Pallet Recognition Switch 73
MR Lower Brake Switch 73
MS1, MS2 Steering: Tachogenerator 73
MSC, MDC, PTP Cabin Lift / Lower 73
MV2, MV3 Lift Height Dependent Speed Reduction 73
PE Emergency Disconnect Switch 73
PCE, PCEglf Brake Switch 74
PCS, PCD Fork Lift / Lower 74
PCS, PCSD, MCSDead Man Switch 74
PCT, MCT Aisle Guidance Two-Hand Switch 74
PCX, PCXglf Horn Switch 74
PEA Chain Slack Bypass Switch 74
PFA Work Lights Switch 74
PLS Bypass Switch 74
PS Pressure Switch 74
PTR Steering Angle Potentiometer 75
QC Key Switch 75
RL1 Trip Relay 75
MK3N Traction Controller 76
General 76
Precautionary Measures 76
Maintenance 76
Replacing the Traction Controller 76
Settings after Replacing the Traction Controller 77
MK3N Lift Controller 78
General 78
Precautionary Measures 78
Maintenance 78
Replacing the Lift Controller 78
Settings after Replacing the Lift Controller 79
EPS-DC Steering Controller 80
General 80
Precautionary Measures 80
Maintenance 80
Replacing the Traction Controller 80
Settings after Replacing the Steering Controller 81
Replacing Fuses 81
Graphic Display 82
General 82
Precautionary Measures 82
Maintenance 82
Replacing the Graphic Display 83
Settings after Replacing the Graphic Display 83
Programmer 85
General 85
Connecting the programmer and the adapter 86
Data Connection to the Pump Controller: 86
Data connection to the Traction Controller: 86
Data Connection to the Graphical Display 87
Description of Keys 88
Operating Menu 88
General 88
Menu Functions 88
Graphic Display, Menu Structure 89
Graphic Display 90
Parameter Change Menu 90
Maximum Speed Setting 91
TESTER Menu 92
TESTER Menu 92
TESTER Menu, Continued 93
SAVE PARAMETER Menu 93
ALARMS Menu 94
ALARMS Menu 94
ALARMS Menu, Continued 95
ALARMS Menu, Continued2 96
ALARMS Menu, Continued 3 97
Lanuage Reference List for the ALARM Menu 98
SET OPTIONS Menu 99
ADJUSTMENTS Menu100
Traction Control System, Menu Structure101
Traction Control System102
PARAMETER CHANGE Menu102
TESTER Menu103
ALARMS Menu104
ALARMS Menu, Continued105
SET MODEL Menu105
Lift Control System107
Menu Structure106
PARAMETER CHANGE Menu107
TESTER Menu108
ALARMS Menu109
Steering Control System110
Menu Structure110
PARAMETER CHANGE Menu111
TESTER menu112
SET OPTIONS menu113
ADJUSTMENTS menu114
ALARM115
Audible Alarm115
Programmer, ALARMS menu115
ALARMS menu115
Remot Control for Platform116
Traction Control System Safety Test117
Electric Motors119
General Maintenance Instructions119
Preparation119
Important Maintenance Instructions119
Drive Motor Maintenance120
Access to Brushes120
Maintenance120
Armature120
Bearings120
Pump Motor Maintenance121
Access to Brushes121
Maintenance121
Armature121
Bearings121
Steering Motor Maintenance122
Access to Brushes122
Maintenance122
Battery123
General123
Operation123
Replacing the Battery123
BRAKE127
General Functional Description127
Removal127
Assembly128
Air Gap Setting128
Brake Moment Setting128
Brake Test128
Braking Distances Series LP129
STEERING133
Operation133
Steering Chain Adjustment133
Steering Pod Removal / Installation134
Steering Motor Removal / Assembly134
Steering Transmission Removal / Assembly135
Potentiometer (PTR) Installation136
Functional Test136
Steering Limit Switch (MF)136
Replacing the Steering Limit Switches136
Limit Switch Test137
Limit Switch Adjustment137
MAST141
Torques141
Fork Settings141
Mast Control (Fitted)141
Flaking141
Mast Stop Buffer141
Fork Carriage Stop Screws141
Removing the Platform without Aux Lift (1200 mm lift height)142
Removing the Platform with Aux Lift (1200 mm lift height)144
Removing Platform without Aux Lift (1800 mm lift height)147
Removing Platform with Aux Lift (1800 mm lift height)150
Mast Rollers153
Removing the Mast Rollers153
Fitting the Mast Rollers153
Guide Rollers153
Guide Roller Removal153
Guide Roller Installation154
Platform Installation (all variants)155
Fork Carriage (Aux Lift Only)156
Fork Carriage Removal156
Removing the Fork Carriage Rollers157
Fork Carriage Roller Installation157
Fork Carriage Installation158
Tensioning the Lift Chain158
Lift Chains160
General160
INSPECTION160
Cleaning160
Wear160
Freedom of Movement161
Chain Anchor and Pulleys161
Worn or Missing Plates161
Protruding or Turned Chain Pins161
Corrosion162
Chain Lateral Wear162
Misalignment of Lift Components162
LIFT CHAIN LUBRICATION163
Fork Tine Test164
General164
Fork Identification164
Repairs164
Crack Inspection164
Fork Blade Warping165
Verticality Test165
Measuring the Fork Tip Width166
Fork Tine Height Difference166
Fork Stop166
Wear167
CYLINDER171
Cylinders171
General171
Plunger Cylinders (single-acting)171
Single-Acting Cylinder173
Piston Cylinder (Double-Acting Cylinder)172
Double-Acting Cylinder173
Maintenance174
Inspection174
Seal Installation175
General175
Aux Lift Cylinder175
Removal – Preparation175
Aux Lift Cylinder Removal175
Repairing the Aux Lift Cylinder176
Disassembly176
Inspection176
Assembly177
Aux Lift Cylinder Assembly177
Lift Cylinder177
Removal – Preparation177
Lift Cylinder Removal178
Repairing the Lift Cylinder178
Disassembly178
Inspection179
Assembly179
Lift Cylinder Assembly179
DIAGRAMS183
Electrical Circuit183
HYDRAULIC SCHEMATIC187
Hydraulic System187
Operation187
LP3010, 1025 mm lift height, without aux lift188
LP3020, 1845 mm lift height, with aux lift189
LP3010, 1620 mm lift height, without aux lift190
LP3020, 2440 mm lift height, with aux lift191

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