Crown Forklift PTH50 SERIES Parts & Maintenance Manual 812752-006

Description

Crown Forklift PTH50 SERIES Parts & Maintenance Manual 812752-006 –  PDF DOWNLOAD

FILE DETAILS:

Crown Forklift PTH50 SERIES Parts & Maintenance Manual 812752-006 –  PDF DOWNLOAD

Language : English
Pages :190
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift PTH50 SERIES Parts & Maintenance Manual 812752-006 –  PDF DOWNLOAD

TABLE OF CONTENTS
INTRODUCTION 1
Important Information 3
Manual structure 3
Text mark-ups in the manual 3
Service personnel qualification 3
Ordering spare parts 3
Ordering documentation 3
SAFETY 5
Safety Notices 7
Basic Safety Notices 8
Organisational measures 8
Personal safety equipment 8
Protecting the hazardous area 8
Hazards from stored energy 8
Repair work 8
Restoring the truck to service after repair work 9
Cleaning work 9
Handling batteries 9
Warning and instruction decals on the truck 9
Lifting gear and slings 9
Environmental protection 10
LUBRICATION & ADJUSTMENT 11
Cleaning the Truck and Components 13
Effects of incorrect cleaning 13
Electrical components 13
Roller and slide bearings 13
Corrosion-protected surfaces 13
Environmental protection 13
Cleaning the entire truck 13
Cleaning removed components 14
Cleaning mechanical components 14
Components 15
Data plate 15
PTH50 PS and S components 15
PTH50 WS components 16
Lubricants and Consumables 17
Cold store application requirements 17
Abbreviations used in the table 17
Regular inspection in accordance with FEM 4004 19
Planned Maintenance – PTH50, PTH50 GLV and PTH50 WS 20
Maintenance Interval 20
Inspection points 21
Lubrication points 21
PTH50 PS and S Planned Maintenance 22
Maintenance Interval 22
Inspection points 22
Lubrication points 23
Troubleshooting 24
IV
PTH50 Series
TABLE OF CONTENTS
All models 24
Troubleshooting (PTH50 PS only) 25
HYDRAULIC SYSTEM 27
Hydraulic Unit 29
Functional Description 29
Lifting 29
Actuating lever in neutral position 29
Lowering 29
Service 32
Approved hydraulic oils 32
Adding hydraulic oil (all models except PTH50 PS and PTH50 S) 32
Adding hydraulic oil (PTH50 PS) 33
Adding hydraulic oil (PTH50 S) 34
Replacing the Hydraulic Unit 35
Replacing the hydraulic unit (all models except PTH50 PS and PTH50 S) 35
Hydraulic unit disassembly 35
Hydraulic unit assembly 35
Replacing the hydraulic unit (PTH50 PS) 35
Hydraulic unit disassembly 35
Hydraulic unit assembly 36
Replacing the hydraulic unit (PTH50 S) 36
Hydraulic unit disassembly 36
Hydraulic unit assembly 36
Repairing the Hydraulic Unit (all models except PTH50 S version 1) 37
Replacing the piston ram and seals 37
Replacing the piston ram and seals 37
Replacing the control piston and seals 38
Replacing the valve cartridge 38
Repairing the Hydraulic Unit (PTH50 S version 2) 39
Replacing the piston ram and seals 39
Replacing the control piston and seals 39
Cleaning and repairing the control valves 40
Relief Valve 43
Checking the operation of the hydraulic unit relief valve 43
Replacing the relief valve on the hydraulic unit (all models except PTH50 S version 2) 43
Repairing and adjusting the relief valve on the hydraulic unit (PTH50 S version 2 only) 43
Testing the relief valve on the hydraulic aggregate (PTH50 PS) 43
Adjusting the relief valve on the hydraulic aggregate (PTH50 PS only) 44
Adjusting the control piston 44
Replacing the Hydraulic Aggregate (PTH50 PS) 45
Disassembly 45
Assembly 45
Replacing the Pump Connecting Plate and Hydraulic Pump (PTH50 PS) 46
Servicing the Hydraulic Aggregate (PTH50 PS) 47
Replacing the hydraulic filter 47
Replacing the pressure filter 47
Replacing the suction and return filters 47
Replacing the hydraulic oil 47
ELECTRICAL SYSTEM 49
On-Board Charger (PTH50 PS) 51
Charging the battery 51
V
Error messages 52
Battery (PTH50 PS) 54
Replacing the battery 54
Miscellaneous Electrical Components and Functions 55
Fuses (PTH50 PS) 55
FU1 55
FU2 55
FU3 55
Emergency Disconnect switch 55
Lift cutout on falling battery voltage 55
PTH50 WS, Electrical Components 56
PTH50 WS – Weigher System 57
General 57
Standardised weighing scales 57
Display resolution 57
Accuracy 57
Calibrating the 2100 Weighing Scale 58
Required tools 58
Calibration stages 58
Calculating the weighing curve 58
Decision factor for 1-point or 3-point calibration 59
1-point calibration of 2100 weighing scale 60
3-point calibration of 2100 weighing scale 61
Calibrating the 4100 Weighing Scale 63
Required tools 63
Calibration stages 63
Calculate the weighing curve 63
Decision factor for 1-point or 3-point calibration 64
1-point calibration of 4100 weighing scale 65
3-point calibration of the 4100 weighing scale 67
PTH50 WS Weighing Scale, Troubleshooting 69
Most common error causes 69
No display 69
No display despite buttons being pressed 69
Unstable display 69
Same weight raised several times shows different readings 70
Weighing scale is inaccurate 71
Load Cell Replacement 72
Load cell removal 72
Load cell assembly 73
Repairing Contactors 74
Wear test 74
Checking the contacts 74
Checking the coils 74
Checking the springs 74
Pump Motor (PTH50 S) 75
Checking the carbon brushes and commutator 75
BRAKE SYSTEM 77
Parking Brake 79
Checking the parking brake setting 79
Adjusting the parking brake 79
VI
STEERING 81
Control Handle 83
Control handle assembly 83
Fitting the control chain and adjusting the control piston 84
LIFTING MECHANISM 87
Forks 89
General 89
Fork inspection 89
Checking forks for cracks 89
CYLINDERS 91
General 93
Safety Notices 93
Hydraulic System Repair Instructions 93
Tools 94
Small hook 94
Extractor 94
Producing extractors 94
Groove aligning arbor for small rod seals 94
Assembly devices for large rod seals 95
Protective mechanisms 95
Rod Seal Removal and Assembly 96
Removing a large rod seal 96
Removing a small rod seal 96
Inserting a large rod seal 96
Fitting a small rod seal 97
Rod seal assembly, sealing lip first 97
SCHEMATIC DIAGRAMS 99
Wire Colour Code 101
General contact symbol abbreviations 102
Electrical wiring diagrams 104
PTH50 PS Wiring Diagram 106
HYDRAULIC SCHEMATIC 107
Hydraulic Symbols 109
PTH50 PS Hydraulic Diagram 113
INTRODUCTION 117
Important Customer Information 119
Ordering spare parts 119
Truck modifications 119
Maintenance, repairs and training 119
Manual structure 119
Abbreviations used 119
HYDRAULIC SYSTEM 121
Hydraulic Unit PTH50 122
PTH50 PS Hydraulic Unit 124
Pump motor and pump PTH50 PS 126
PTH50 PS Hydraulic Unit, Part 1 / 2 128
VII
PTH50 PS Hydraulic Unit, Part 2 / 2 130
PTH50 S Hydraulic Unit, Version 1, Part 1 / 2 132
PTH50 S Hydraulic Unit, Version 1, Part 2 / 2 134
PTH50 S Hydraulic Unit, Version 2 136
PTH50 S Hydraulic Unit, Version 2 138
ELECTRICAL SYSTEM 141
PTH50 WS Electrical System 142
PTH50 PS Electrical System 144
BRAKE SYSTEM 147
Parking Brake 148
LIFTING MECHANISM 151
PTH50 Lifting Mechanism, Part 1 / 2 152
PTH50 Lifting Mechanism, Part 2 / 2 154
PTH50 Lifting Mechanism, Part 2 / 2 156
PTH50 Lifting Mechanism, Part 2 / 2 158
PTH50 Lifting Mechanism, Part 2 / 2 160
Tandem Load Wheel PTH50 162
PTH50 PS Lifting Mechanism 164
PTH50 PS Lifting Mechanism 166
PTH50 S Lifting Mechanism 168
PTH50 S Lifting Mechanism 170
MISCELLANEOUS 173
Decals and Labels PTH50 174
Decals and Labels PTH50 PS 176
Decals and Labels PTH50 S 178

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