Crown SP3400 Series Four-Point Maintenance Manual – PDF DOWNLOAD

Description

Crown SP3400 Series Four-Point Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Crown SP3400 Series Four-Point Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :368
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown SP3400 Series Four-Point Maintenance Manual – PDF DOWNLOAD

SP 3400 SERIES Four-Point 1
Safety 17
Symbols Used in the Manual 19
Safety Symbols 19
General Symbols 19
Fork direction 19
General Safety Instructions 20
Maintenance and Repair Instructions 20
Maintenance and Repair 20
Before Parking the Truck 20
Before Working on the Truck 20
Before Starting the Truck 20
Warning and Instruction Decals on the Truck 21
Control of Hazardous Energy 22
Battery 22
Safety Rules 22
Battery Removal 23
Battery Installation 23
Lockout – Tagout 24
Brake 24
Capacitance 25
Hydraulic System 26
Depressurising the hydraulic system 26
Accumulator 27
Lifting and Blocking 28
Required tools 28
Raising the Side 28
Raising the Drive Wheel 29
Blocking Mast Stages 30
Cleaning Methods 31
Introduction 33
General 35
Operating Instructions 35
Service Training 35
Ordering Spare Parts 35
Using the Manual 35
Data Plate 36
Lubrication & Adjustment 39
Lubricants 41
Maintenance 45
General 45
Component Accessibility 45
Componentry 57
Accumulator 58
ALM1 58
BRES1, BRES2 58
BRK1 58
BRS1 58
CHS1, CHS2 60
CHS3, CHS4 60
CV1 60
CV2 60
CV3 60
Free Lift Cylinder 60
Mast Cylinders 60
DCM 62
DPS 62
DTS1 62
ECR1 62
ECR2 62
ECR3 62
ECR4 62
ED1 64
ED2 64
EDS 64
Fan 64
Filter 64
FNS 64
FS 64
FU1 66
FU2 66
FU3 66
FU4 66
FU5 66
FU6 66
FU8 66
FU9 66
FU10 68
FU11 68
FU12 68
FU13 68
GCM 68
GTS1, GTS2 68
GTS5, GTS6 68
GUS 68
HN1 70
HN2 70
HNS1 70
HSLCS 70
K1 72
K2 72
K5 72
K11 72
K12 72
KYS 74
LCS1 74
LGS1 74
LGS2 74
LGS3 74
LGT1 74
LGT2, 5 74
LGT3, 6 76
LGT4, 7 76
LOS1 76
LOS2 76
M1 76
M2 76
M3 76
M4 76
MRC1 78
MVL 78
ORS1 78
P1 78
P1 Pump 78
P2 78
P2 Pump 78
POT1 80
PS1 80
PS2 80
PVL 80
RAS1 80
RAS2 80
RCS1, RCS2 80
RES1 82
RES2, RES3 82
RES4, RES5 82
RES6, RES7 82
RES8, RES9 82
RES10 82
RES11 82
RES12 84
RES13 84
RES14 84
RES15, RES19 84
RES16 84
RES20, RES21 86
RES23 86
RESERVOIR 86
RGS1, RGS2 86
RS 86
RV1 86
SB10 88
SB11 88
SB21 88
SB30 88
SCM 88
Sensor bar Loadwheel 90
Sensor Bar Steered Wheel 90
Strainer 90
Test Port 90
THS2 90
THS3 90
ZSS 90
Truck Installation 92
Caster Assembly 94
Adjustment 94
Torque Values 95
Hydraulic System 97
Hydraulic Symbols 99
General103
Reservoir103
Hydraulic Lines and Fittings104
Filter104
Freezer Preparation105
Drift Test106
Lift Drift Test106
Circuit Descriptions107
Lift Circuit – Two Speed Lift107
Low Speed Lift107
High Speed Lift107
Relief Valve Operation107
Accumulator Operation107
Lower Circuit – One Speed/Two Speed Lower108
Lower108
Manual Lower -Two Speed Lift/Lower109
Pump Repair110
Pump – Gear110
Oil Seal Removal110
Oil Seal Replacement111
Pump Disassembly111
Parts Inspection111
Body111
Composite Bushings111
Gears112
End Cover112
Mounting Flange112
Pump Reassembly113
Start Up Procedure114
Accumulator115
Precharging115
Hydraulic Troubleshooting117
Drive Unit121
Drive Tire123
Replacement123
Lubrication124
Oil Pump125
Disassembly125
Assembly125
Removal & Installation126
Electrical System127
Relays129
K1129
Power Up Relay129
K2129
Module Power129
K5129
Steer Motor Relay129
K11 & K12130
Freezer/Condition Relays130
Encoders131
Electrical Wiring133
Wiring Color Codes133
Color133
Number133
Power Cables133
Basic Symbols135
Motor Monitoring System (MMS)137
Overtemperature Sensors137
Brushwear Sensors138
Tune Up141
Service Terminal141
Description141
Service Terminal Operation141
Keyboard Commands142
Main Menu143
Calibration – Truck Setup Menu145
Calibration – Lift Cutouts or Zone Menus146
Calibration – Truck Options Menu147
Calibration – PM Interval Setup Menu148
Calibration – Hourmeter Reset Menu149
Calibration – Wire Guidance Menu150
Calibration – Traction Setup Menu151
Calibration – Traction Setup/Features Menus152
Calibration – Traction Setups/Performance Menus154
Calibration – Traction Setups/Performance Menus (Cont’d)155
Display158
Erase159
Show160
Show – System Information Menus161
Show – View Enable Config Menus162
Show – Truck Monitors Menus/View Encoder Counts Menus163
Show – View Switch Status Menus/View System Constants Menus164
Show – View Hardware Outputs Menus166
Show – View Hourmeter Data Menus/View Wire Guide Sensors Menus167
Show – Traction Analyzer Menus168
Show – Status Analyzer Menus169
Show – Traction Inputs Menus170
Show – View Switches Menus171
Show – Traction Outputs Menus173
Traction Setup Performance Values174
Motors176
Display and Steering Modules179
Message Display179
Power “ON” LED’s (green)180
Service LED’s (amber)180
Torque Requirements for Steering Module Terminations181
Contactor183
Inspection183
Contacts183
Coil183
Component Replacement184
Contact Replacement184
Coil Replacement184
Steering Feedback185
Gear Assembly185
Battery187
Safety Rules187
Checking187
Battery Care188
Charging189
Battery Removal191
Battery Installation192
Battery Cleaning193
Troubleshooting193
Event Codes194
Some Troubleshooting Basics194
Check the Event Code Listing194
No Event Code?194
To Locate Malfunctioning Components194
Test Points194
Event Codes194
Event Code 201 – 202195
Event Code 201 – 202195
Event Code 202195
Event Code 204196
Event Code 208197
Event Code 209 – 210199
Event Code 209199
Event Code 210199
Event Code 211 – 212200
Event Code 211200
Event Code 212200
Event Code 213201
Event Code 215202
Event Code 216203
Event Code 217204
Event Code 218205
Event Code 219 & 221206
Event Code 219206
Event Code 221206
Event Code 222 – 223207
Event Code 222207
Event Code 223207
Event Code 224 & 227208
Event Code 224208
Event Code 227208
Event Code 228, 311 – 314209
Event Code 228209
Event Code 311209
Even Code 312209
Event Code 313209
Event Code 314209
Event Code 315210
Event Code 316 – 317211
Event Code 316211
Event Code 317211
Event Code 318212
Event Code 319 & 321213
Event Code 319213
Event Code 321213
Event Code 322 – 323214
Event Code 322214
Event Code 323214
Event Code 324 & 326215
Event Code 326215
Event Code 327216
Event Code 328217
Event Code 331218
Event Code 332219
Event Code 333220
Event Code 334 – 336221
Event Code 334221
Event Code 335221
Event Code 336221
Event Code 337 & 339222
Event Code 337222
Event Code 339222
Event Code 341 – 343223
Event Code 341223
Event Code 342223
Event Code 343223
Event Code 344224
Event Code 345225
Event Code 346226
Event Code 347 – 348227
Event Code 347227
Event Code 348227
Event Code 349 & 351228
Event Code 349228
Event Code 351228
Event Code 352229
Event Code 353 – 354230
Event Code 353230
Event Code 354230
Event Code 355 – 358 & 362231
Event Code 355231
Event Code 356231
Event Code 357231
Event Code 358231
Event Code 362231
Event Code 363 – 364232
Event Code 363232
Event Code 364232
Event Code 365 – 367233
Event Code 365233
Event Code 366233
Event Code 367233
Event Code 368 – 369, 371 – 373234
Event Code 368234
Event Code 369234
Event Code 371234
Event Code 372234
Event Code 373234
Event Code 374 – 377235
Event Code 374235
Event Code 375235
Event Code 376235
Event Code 377235
Event Code 378 – 379236
Event Code 378236
Event Code 379236
Event Code 381 – 383237
Event Code 382237
Event Code 383237
Event Code 384238
Event Code 385 – 388239
Event Code 385239
Event Code 386239
Event Code 387239
Event Code 388239
Event Code 391 – 394240
Event Code 391240
Event Code 392240
Event Code 393240
Event Code 394240
Event Code 396 – 399241
Event Code 396241
Event Code 397241
Event Code 398241
Event Code 399241
Event Code 411 – 416242
Event Code 411242
Event Code 412242
Event Code 413242
Event Code 414242
Event Code 415242
Event Code 416242
Event Code 417 – 418243
Event Code 417243
Event Code 418243
Event Code 419244
Event Code 421245
Event Code 422247
Event Code 423248
Event Code 424249
Event Code 425250
Event Code 426251
Event Code 427252
Event Code 428 – 429253
Event Code 428253
Event Code 429253
Event Code 431 – 435254
Event Code 431254
Event Code 432254
Event Code 433254
Event Code 434254
Event Code 435254
Event Code 436 – 438255
Event Code 436255
Event Code 437255
Event Code 438255
Event Code 439256
Event Code 441 – 442257
Event Code 441257
Event Code 442257
Event Code 800 – 802258
Event Code 800258
Event Code 801258
Event Code 802258
Event Code 803 – 804259
Event Code 803259
Event Code 804259
Event Code 805 – 806260
Event Code 805260
Event Code 806260
Event Code 807261
Event Code 808262
Event Code 809263
Event Code 810 – 814264
Event Code 810264
Event Code 811264
Event Code 812264
Event Code 813264
Event Code 814264
Event Code 827265
Event Code 828266
Event Code 829267
Event Code 831268
Event Code 832 – 834269
Event Code 83269
Event Code 833269
Event Code 834269
Event Code 835 – 838270
Event Code 835270
Event Code 836270
Event Code 837270
Event Code 838270
Brake System271
Brake273
General273
Brake Force Adjustment273
Brake Adjustment274
Air Gap Adjustment274
Torque Gap Adjustment275
Rotor and Brake Pad Replacement276
Brake Disassembly276
Brake Assembly276
Brake Troubleshooting278
Steering279
System Description281
Steering Direction281
Steering Wheel Direction Indicator281
Steering Wheel Adjustment282
Steering Motor Gearbox283
Lifting Mechanism285
General287
TT Mast287
Shim Basics287
Mast Column Roller289
Removal289
Shim Measurements291
Mast Testing (Assembled)292
Flaking293
Shim Removal293
Top Column Rollers293
Bottom Column Rollers293
Mast294
Removal294
Assembly295
Lift Chains296
Inspection296
Cleaning296
Wear296
Freedom of Movement of Chain Links297
Chain Tension297
Chain Anchor and Pulleys298
Worn Connection Plates298
Protruding or Turned Chain Pins298
Corrosion298
Chain Lateral Wear299
Uneven Chain Tension299
Misaligned Lift Components299
Lift Chain Lubrication300
Separating Lift Chains301
Tools and Equipment Required301
Separation301
FEM / ISO Forks302
General302
Terms302
Fork Identification302
FEM / ISO Fork Inspection302
Repair302
Inspection Intervals302
Crack Inspection303
Fork Blade Warping303
Fork Tip Straightness Test304
Measuring the Fork Tip Height304
Fork Tine Height Difference304
Fork Stop305
Fork Blade Abrasion Check305
Platform Fork Blades306
General306
Table Standard Fork Thickness and Wear Limit306
Fork Inspection306
Fork Blade Abrasion Check306
Overloading307
Fatigue308
Bent or Twisted Forks308
Hanger308
Cylinders309
Safety311
For your personal protection311
General Instructions for Repairing Hydraulic Components311
Rod Seal Assembly312
General312
Large Rod Seal Assembly312
Small Seal Rod Assembly313
Rod Seal Assembly, Sealing Lip First314
General315
Inspection315
Disassembly315
Rod Packing316
Accessing Mast Cylinder Rod Packing316
Accessing Free Lift Cylinder Rod Packing316
Rod Packing Replacement (Mast and Free Lift Cylinder)316
Mast Cylinder Removal318
Free Lift Cylinder Removal319
Mast And Free Lift Cylinder Assembly320
Mast And Free Lift Cylinder Installation320
Bleeding320
Platform321
Platform323
Floor Mat Replacement323
Safety Shield323
Forks324
Fork Inspection324
Fork Replacement325
Fork Height Adjustment325
Pallet Grab (Option)326
Release Handle Adjustment326
Pedal Adjustment326
Pallet Grab Removal327
Operator Compartment Gates328
Spring Replacement328
Removal328
Installation329
Operator Egress System330
Platform Removal & Shimming331
Basics331
Platform Removal & Shimming331
Height Sensor Assembly334
Removal334
Installation335
Encoder (ECR4)336
Removal336
Installation336
Bearing Replacement337
Removal337
Installation337
Cable Replacement338
Removal338
Installation338
Schematic Diagrams341
Diagram Usage343
Schematic343
Pictorials343
Index344
Block Diagram345
Schematic with Options346
Schematic without Options347
Schematic – SAA348
Platform349
Platform – SAA350
Distribution Panel351
Motor Monitoring System MMS352
Display Module353
Traction Module354
Steering Module355
Contactor Panel356
Guidance Traction357
Guidance Module358
Lights and Fan359
Freezer Conditioning360
Freezer Conditioning – SAA361
Power Cables362
Wire Harnesses363
Platform363
Power Unit364
Hydraulic Schematic365
Two Speed Lift367

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