Crown Forklift TSP6000 Series Maintenance Manual – PDF DOWNLOAD

Description

Crown Forklift TSP6000 Series Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift TSP6000 Series Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :638
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift TSP6000 Series Maintenance Manual – PDF DOWNLOAD

Safety 23
Symbols Used in the Manual 25
Safety Symbols 25
General Symbols 25
Fork direction 25
General Safety Instructions 26
Maintenance and Repair Instructions 26
Maintenance and Repair 26
Before Parking the Truck 26
Before Working on the Truck 26
Before Starting the Truck 26
Warning and Instruction Decals on the Truck 27
Control of Hazardous Energy 28
Battery 28
Safety Rules 28
Battery Care 28
Charging 28
Battery Removal 28
Battery Installation 29
Lockout – Tagout 29
Brake 30
Capacitance 30
Hydraulic 31
Depressurizing the Hydraulic System 31
Lifting and Blocking 32
Lifting one Side 32
Lifting the Steered Wheel 33
Masts 33
Blocking Main Mast 33
Blocking Auxiliary Mast 34
Height Sensor 35
Spring Removal 35
Spring Installation 36
Lifting Auxiliary Mast and Platform 37
Auxiliary Mast 37
Platform 37
Service Platform 38
Cleaning Methods 39
Introduction 41
General 43
Operating Instructions 43
Service Training 43
Ordering Spare Parts 43
Using the Manual 43
Truck Data Number 44
Table Lift Heights 45
Table Guide Wheel Spreads 45
Lubrication & Adjustment 47
General 49
Lube Identification 49
Alternate Lube Identification 51
General 53
Safety 53
Maintenance Intervalls 53
Component Accessibility 53
Maintenance Intervalls 54
Charts Part 1 55
Charts Part 2 56
Charts Part 3 59
Charts Part 4 61
Componentry 62
ACM (Access 7) 62
ALM1 62
ALM2 (Optional) 62
BRK 62
BRS1, BRS2, BRS3, BRS4 62
CHS1, CHS2 62
CHS3, CHS4 64
CS1 64
CTS (TF Mast Only) 66
DCM (Access 1) 66
DTS 66
EACA1 66
EACA2 66
EACB1 66
EACB2 66
ECR1 68
ECR2 68
ECR3 68
ECR4 68
ECR5 68
ECR6 68
ECR7 68
ECR8 68
ED1, ED2 70
EDS 70
EML 70
EMS1 70
FAN1 70
FAN3 (Option) 70
FHSL, FHSR 70
FNS 70
FPS1, FPS2, FPS3, FPS4, FPS5, FPS6, FPS7, FPS8, FPS9 72
FS 72
FSB1 72
FSB2 72
FU1 72
FU2 72
FU3 74
FU4 74
FU5 74
FU6 76
FU7 76
FU8 76
FU9 76
FU10 76
FU11 76
FU12 76
FU13 76
FU14 78
FU15 78
FU16 78
FU17 78
FU18 78
FU19 78
FU20 78
FU21 78
FU22 80
FU23 80
GCM (Access 6) (Optional) 80
GS1 80
GS2 80
GTSL, GTSR 80
GUS 80
HCM (Access 2) 82
HCS 84
HGTRS1 84
HGTRS2 84
HN 84
HNS 84
HPSL 84
HPSR 84
K1 86
K2 86
KYS 86
LGS1 86
LGS2 86
LGS3 86
LGT1 86
LGT2, 3 86
LGT4, 5 88
LGT6, 7 88
LGT8, 9 88
LS 88
M1 88
M2 88
M3 88
MVL 88
OCM (Access 8) 90
ORS1 90
P1 90
PCML 90
PLS 90
POT1 90
POT2 90
Main Hoist Raise/LowerPOT3 90
Pot3 90
POT4 92
POT5 92
PRS 92
PS1 92
PS2 92
PVAL 92
PVAR 92
PVF – S1 94
PVF – S2 94
PVLH 96
PVMR 96
PVP 96
PVT 96
RES1, RES2 96
RES3 96
RES4 96
RES5 96
Reservoir 98
RGSL, RGSR (Optional) 98
RS 98
RSS 98
SB11 98
SB31 98
SCM (Access 5) 98
SES 98
SLS100
SP1100
SPS100
SVAL100
SVML100
TBS (Optional)100
TCM (Access 3)100
TDS (Optional)100
TS1102
TS2102
TS3102
TS4102
TVRS102
VCM (Access 4)102
ZSS102
Hydraulic System105
Hydraulic Symbols107
General111
Hydraulic Lines and Fittings111
Freezer Preparation111
Reservoir & Filter112
General112
Drift Test112
Main Lift Circuit113
Main Lower Circuit114
Main Lower Circuit (MVL)115
Load Handler Circuit through Main Frame Manifold116
Auxiliary Lift Circuit118
Auxiliary Lower Circuit120
Traverse Left Circuit121
Traverse Right Circuit123
Fork Extend Circuit125
Fork Retract Circuit127
Pivot Right Circuit129
Pivot Left Circuit131
Hydraulic Pump133
Pump Removal133
Initial Start Up Procedure134
Valves135
Relief Valve (RV1)135
Adjustment135
Proportional Valves135
Manifold Block136
O-Ring Replacement136
Valve Torque Charts137
Main Frame Manifold137
Load Handler Manifold140
Hydraulic Motor143
Preparation Before Disassembly143
Tools and Materials Required for Servicing143
Disassembly and Inspection146
Reassembly151
Final Checks157
Trouble Shooting Table158
Drive Unit159
Drive Tyre161
Replacement161
Lathe Cutting162
Lubrication163
Removal / Installation164
Removal164
Installation164
Motor Removal / Installation165
Removal165
Installation165
Electrical System167
Tune Up169
Display (Access 1)169
When a Malfunction Occurs169
Accessing Event History169
Power Cable Connections169
Access Modules170
Main Menu172
A – Analyzer Menu173
A11 – Status Menu174
A2 – Inputs175
A21 – Load Handler176
A21 – Load Handler177
A22 – Platform Menu178
A23 – Seat Controls Menu179
A24 – Power Unit Menu180
A24 – Power Unit Menu181
A24 – Power Unit Menu182
A3 – Outputs183
A31 – Load Handler184
A31 – Load Handler185
A31 – Load Handler186
A31 – Load Handler187
A31 – Load Handler188
A32 – Platform Menu189
A33 – Seat Controls Menu190
A34 – Power Unit Menu191
A34 – Power Unit Menu192
A34 – Power Unit Menu193
A34 – Power Unit Menu194
A34 – Power Unit Menu195
A4 – Test Outputs Menu196
A41 – Load Handler Menu197
A41 – Load Handler Menu198
A42 – Platform Menu199
A43 – Seat Controls Menu200
A44 – Power Unit Menu201
A44 – Power Unit Menu202
A45 – Power Unit Menu203
C – Calibrations Menu204
C1 – Handles Menu205
C1 – Handles Menu206
C2 – Hydraulics Menu207
C21 – Traverse Sense208
C22 – Pivot Sense209
C23 – Main R Valve210
C24 – Main L Valve211
C25 – Main Height Sense212
C26 – Aux Flow Valve213
C27 – Traverse Valve214
C28 – Pivot Valve215
C29 – Extend Valve216
C210 – Aux R Valve217
C211 – Weight Sense218
C212 – Aux L Valve219
C213 – Aux Height Sense220
C214 – Tilt Valve221
C3 – Height Cutouts222
C4 – Steer Encoder223
C5 – Wire Guide224
C51 – Calibrate225
C51 – Calibrate226
C51 – Calibrate227
C51 – Calibrate228
C52 – Ajust X-Offset229
C52 – Ajust X-Offset230
F – Features Menu231
F1 – Truck Model232
F2 – Mast Type232
F3 – Measurement233
F4 – F6 Collapsed Height, Height & Traverse Menus234
F7 – Fork Type235
F7 – Fork Type236
F8, F10, F11: Fork Length, Pallet Width, Pallet Length237
F12 – Battery Compartment238
F13 – F14 Truck Weight, Max Load239
F15 – Lift Motor240
F16 – Capacity Data Monitor242
F17 – Wire Guidance244
F18 – Manual Wire Sense245
F19 – End Aisle Sense246
F20 – Battery Retainer SW247
F21 – Travel Alarm248
F23 – Language249
F24 – User Performance250
F25 – User Codes251
F26 – Cold Condition252
F27 – Options253
F27 – Options254
F28 – Front Rail255
F29 – Zone Switch255
F30 – Aux Mast256
F31 – Screen Setup256
F99 – Save257
H – Hour Meter Menu258
H1 – H12 Hour Meters258
L – Event Codes Menu259
L1 – L3 Event Codes259
P – Performance Menu260
P1 – Setup P1261
P1 – Setup P1262
P1 – Setup P1263
P2 – Setup P2264
P2 – Setup P2265
P3 – Setup P3266
P3 – Setup P3267
P4 – Plug268
P5 – Coast268
P6 – Braking269
P7 – Free Range Speeds270
P8 – Guided Speeds271
P9 – BDI271
P10 – EAC Setup272
P10 – EAC Setup273
P11- Main Hoist R/L274
P11- Main Hoist R/L275
P12- Aux Hoist R/L276
P13- PDS Setup277
P13- PDS Setup278
U – Utilities Menu279
U1 – Part Numbers280
U2 – Tow Mode281
U3 – Shipping Mode281
U4 – Truck Lockout281
U5 – Traverse Valve283
Wire Guidance System285
Operation Modes286
Manual286
Automatic286
Sensors287
Line Driver Output288
Calibration289
End of Aisle Control (EAC)290
Wire Guidance Calibration Speed291
Peak sensor wire guidance calibration291
Offset wire guidance calibration291
EAC Zones291
Troubleshooting291
Termination Point Locations292
Contactors293
General293
ED1 Contactor293
Inspection293
Contacts293
Coil293
Component Replacement293
Contact Replacement293
Coil Replacement293
Contactor K2294
Battery295
Location295
General Safety Rules295
Maintenance and Repair295
Replacing the Battery295
Charging296
General Charging Safety Rules296
Motors298
Event Codes, General299
Troubleshooting Basics299
When a Malfunction Occurs299
No Event Code?299
To Locate Malfunctioning Components299
Test Points299
Power Cable Connections299
Access Modules300
Eventcode 101301
Eventcode 104302
Eventcode 105303
Event Code 106304
Event Code 107305
Event Code 108306
Event Code 112 – 118307
Event Code 112307
Event Code 113307
Event Code 114307
Event Code 115307
Event Code 116307
Event Code 117307
Event Code 118307
Event Code 212 – 214308
Event Code 212308
Event Code 213308
Event Code 214308
Event Code 215 – 217309
Event Code 215309
Event Code 216309
Event Code 218, 221- 222310
Event Code 218310
Event Code 221310
Event Code 222310
Event Code 223 – 224311
Event Code 224311
Event Code 225, 228312
Event Code 225312
Event Code 229, 231313
Event Code 229313
Event Code 231313
Event Code 232315
Event Code 233317
Event Code 234319
Event Code 235320
Event Code 236, 237, 246, 247322
Event Code 236322
Event Code 237322
Event Code 246322
Event Code 247322
Event Code 249, 251, 268 – 269323
Event Code 249323
Event Code 250323
Event Code 268323
Event Code 269323
Event Code 272324
Event Code 273, 278325
Event Code 273325
Event Code 278325
Event Code 300, 312 – 313, 315326
Event Code 300326
Event Code 312326
Event Code 313326
Event Code 315326
Event Code 317 or 318327
Event Code 321, 322328
Event Code 321328
Event Code 322328
Event Code 323 or 324329
Event Code 325330
Event Code 326 and 327331
Event Code 326331
Event Code 327331
Event Code 328 – 329332
Event Code 328332
Event Code 329332
Event Code 331 – 332333
Event Code 331333
Event Code 332333
Event Code 333334
Eventc Code 334335
Event Code 336336
Event Code 337, 346, 347, 349, 351, 368337
Event Code 337337
Event Code 346337
Event Code 347337
Event Code 349337
Event Code 351337
Event Code 368337
Event Code 369338
Event Code 372339
Event Code 373, 378340
Event Code 378340
Event Code 400341
Event Code 402343
Event Code 403345
Event Code 407346
Event Code 408 & 409347
Event Code 411 – 430, 436348
Event Code 411 – 430348
Event Code 436348
Event Code 437 – 438349
Event Code 437349
Event Code 438349
Event Code 439 – 440350
Event Code 439350
Event Code 440350
Event Code 441351
Event Code 442 – 443352
Event Code 442352
Event Code 443352
Event Code 444353
Event Code 445354
Event Code 446355
Event Code 447, 491 – 499356
Event Code 447356
Event Code 491 – 499356
Event Code 501357
Event Code 502 – 503359
Event Code 502359
Event Code 503359
Event Code 504 – 505360
Event Code 504360
Event Code 505360
Event Code 507361
Event Code 508362
Event Code 509 & 510, 511 – 521363
Event Code 509 & 510363
Event Code 511 – 521363
Event Code 522 & 523364
Event Code 524 – 527365
Event Code 526 & 527365
Event Code 528 & 529366
Event Code 530 & 531367
Event Code 532 & 533368
Event Code 534 & 535, 536369
Event Code 534 & 535369
Event Code 536369
Event Code 537 – 539370
Event Code 538 & 539370
Event Code 540371
Event Code 541372
Event Code 542 – 545374
Event Code 542374
Event Code 544374
Event Code 545374
Event Code 546 – 550375
Event Code 551 – 554376
Event Code 551376
Event Code 552 & 553376
Event Code 554376
Event Code 555 & 556377
Event Code 557378
Event Code 558 – 561379
Event Code 562 – 564380
Event Code 562380
Event Code 563380
Event Code 564380
Event Code 565381
Event Code 566, 567 – 570382
Event Code 566382
Event Code 567 – 570382
Event Code 571 & 572, 573 – 581384
Event Code 571 & 572384
Event Code 573 – 581384
Event Code 582 – 585385
Event Code 586 & 587386
Event Code 588 & 589387
Event Code 590 – 593388
Event Code 590 & 591388
Event Code 592 & 593388
Event Code 594, 595389
Event Code 595389
Event Code 596390
Event Code 597391
Event Code 605, 611 & 612, 621 – 628, 631392
Event Code 605392
Event Code 611 & 612, 621 – 628392
Event Code 631392
Event Code 632393
Event Code 633394
Event Code 636, 637395
Event Code 636395
Event Code 637395
Event Code 638 & 639396
Event Code 652 – 659397
Event Code 660 – 667398
Event Code 660 – 663398
Event Code 664 – 667398
Event Code 668 – 672399
Event Code 668 – 671399
Event Code 672399
Event Code 700400
Event Code 701401
Event Code 702402
Event Code 707404
Event Code 708 & 709405
Event Code 711 – 720, 736406
Event Code 711 – 720406
Event Code 736406
Event Code 737407
Event Code 738 – 739408
Event Code 738408
Event Code 739408
Event Code 740409
Event Code 741 – 742410
Event Code 741410
Event Code 742410
Event Code 743411
Event Code 744 – 745412
Event Code 744412
Event Code 745412
Event Code 746413
Event Code 747 – 749, 750414
Event Code 747 – 749414
Event Code 750414
Event Code 751416
Event Code 752417
Event Code 753418
Event Code 754419
Event Code 755420
Event Code 756421
Event Code 757 – 759422
Event Code 757422
Event Code 759422
Event Code 760424
Event Code 761425
Event Code 762 & 763426
Event Code 762426
Event Code 764427
Event Code 765428
Event Code 767429
Event Code 768430
Event Code 769 & 770431
Event Code 769431
Event Code 770431
Event Code 771 & 772432
Event Code 771432
Event Code 772432
Event Code 773 & 774433
Event Code 773433
Event Code 774433
Event Code 775434
Event Code 776435
Event Code 777436
Event Code 778 & 779437
Event Code 778437
Event Code 779437
Event Code 780438
Event Code 781439
Event Code 782440
Event Code 783441
Event Code 784442
Event Code 785, 790 & 799443
Event Code 790 & 799443
Event Codes 800444
Event Code 801445
Event Code 802446
Event Code 803448
Event Code 804449
Event Code 805450
Event Code 806452
Event Code 807453
Event Code 816, 821 & 822454
Event Code 816454
Event Code 821454
Event Code 822454
Event Code 823455
Event Code 824456
Event Code 825457
Event Code 836 – 837458
Event Code 836458
Event Code 837458
Event Code 838459
Event Code 839460
Event Code 840461
Event Code 841, 842462
Event Code 841462
Event Code 842462
Event Code 843463
Event Code 844464
Event Code 845, 846465
Event Code 845465
Event Code 846465
Event Code 847466
Event Coder 848468
Event Code 849470
Event Code 850 – 852472
Event Code 853 – 855473
Event Code 856 – 859474
Event Code 860 – 863475
Event Code 864 – 867476
Event Code 868 & 869477
Event Code 870 & 871478
Event Code 872 – 874479
Event Code 875 – 877481
Event Code 878 – 880483
Brake System485
General487
Function487
Stopping Distance487
Brake Adjustment488
Air Gap Adjustment488
Torque Gap Adjustment489
Rotor and Brake Pad Replacement490
Disassembly490
Assembly491
Troubleshooting492
Steering493
Steering Feedback495
Replacing Steering Feedback Assembly Encoder495
Replacing Steering Feedback Assembly Gears496
Steering Encoder Alignment497
Motor498
Minimum Brush Lengh498
Replacing the Brushes498
Replacing Steering Motor499
Replacing Steering Gearbox501
Lifting Mechanism503
Mast Types505
TN – Mast505
TF – Mast505
Second Stage Mast Removal506
Removing Second Stage Mast506
Removing Without Sufficient Overhead Clearance506
Removing With Sufficient Overhead Clearance510
Roller Adjustment510
Column Rollers510
Side Thrust Rollers510
Installing Second Stage Mast Without Sufficient Overhead Clearance511
Installing Second Stage Mast With Sufficient Overhead Clearance512
Hose Take-Up Cable513
Cable Removal513
Cable Installation515
Load Wheels516
Load Wheel Removal516
Tire Replacement516
Lathe Cutting517
Lift Chains518
Inspection518
Cleaning518
Wear518
Freedom of Movement of Chain Links519
Chain Tension519
Chain Anchor and Pulleys520
Worn Connection Plates520
Protruding or Turned Chain Pins520
Corrosion520
Chain Lateral Wear521
Uneven Chain Tension521
Misaligned Lift Components521
Lift Chain Lubrication522
Separating Lift Chains523
Tools and Equipment Required523
Separation523
Fork Inspection524
Inspection Intervals524
Fork Blade Abrasion Check524
Measurement524
Hanger Bore Measurement525
Overloading525
Fatigue526
Bent or Twisted Forks526
Hanger527
Cylinders529
TF Lift Cylinders531
General531
Pivoting The Tip-Out Assembly531
Primary Lift Cylinder Repair534
Cylinder Packing Installation536
Installation of Tip-Out Assembly536
Primary Lift Cylinder Removal537
Secondary Lift Cylinder Removal538
Primary Lift Cylinder Installation539
Secondary Lift Cylinder Installation539
Lift Cylinder Bleeding540
TN Lift Cylinder541
Pivoting The Tip-Out Assembly541
Lift Cylinder Repair543
Cylinder Packing Installation545
Installing the Tip-Out Assembly545
Lift Cylinder Removal546
Lift Cylinder Installation547
Lift Cylinder Bleeding548
Auxiliary Lift Cylinder549
Repair549
Rod Packing Installation551
Auxiliary Lift Cylinder Bleeding551
Fork Cylinders552
Cylinder Disassembly552
Piston Rod Disassembly553
Reassembly554
Pivot Cylinders556
Cylinder Removal556
Cylinder Disassembly557
Cylinder Reassembly558
Cylinder Installation559
Pivot Cylinder Bleeding559
Platform561
Inspection and Adjustment563
Column Roller Area563
Overhead Guard Area563
Operator Controls563
Lower Platform Area563
Lubrication565
Mast Shield Removal566
Gates567
Gate Switches GTSL & GTSR568
Adjustments569
Chain Anchors and Platform Height569
Side Thrust Roller Adjustment – Platform569
Traverse Hose Replacement571
Removal573
Assembly575
Seat576
Seat Pivot Bearing Assembly576
Seat Position Switch Adjustment576
Seat Coil Cord Installation577
Seat Up/Down Switch Adjustment578
Mirror580
Installation580
Adjustment582
Height Sensing System583
Height Sensor Assembly Removal and Installation583
Removal583
Height Cable Broken Switch (HCS)584
Replacement of components584
Height Sensor Assembly585
Cable Replacement586
Glossary589
Index591
Schematic Diagrams607
Platform609
Power Unit610
Platform Distribution Panel611
Power Unit Distribution Panel612
Lights and Fans613
Operator Display614
Platform Chain Switches615
Vehicle Control Module616
Platform Seat Area617
Platform Floor Area618
Traction Control Module619
Steering Control Module620
Contactor Panel621
Traction Motor, FSB1 & Brake622
Hydraulic Control Module623
Hydraulic Motor624
Operator Control Module625
Left Armrest – Platform626
EAC & Guidance Control Module627
Traction Motor, FSB1,FSB2 & Brake628
Accessory Control Module629
Power Cables630
Wire Harness631
Hydraulic Schematic633
Manifold Block Main Frame & Lift Cylinders635
Manifold Block Load Handler, with extending Forks636
Manifold Block Load Handler, with tilting Forks637

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S.M 08/24