Crown Forklift SC4200 Series Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Crown Forklift SC4200 Series Maintenance Manual – PDF DOWNLOAD
Language : English
Pages :334
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Crown Forklift SC4200 Series Maintenance Manual – PDF DOWNLOAD
SC 4200 SERIES 1
Table of Contents 3
Safety page serial no cut Rev 5
Introduction page serial no cut Rev 5
Lubrication & Adjustment page serial no cut Rev 5
Hydraulic System page serial no cut Rev 7
Drive Unit page serial no cut Rev 8
Electrical System page serial no cut Rev 8
Brake System page serial no cut Rev 11
Steering page serial no cut Rev 11
Lifting Mechanism page serial no cut Rev 11
Cylinders page serial no cut Rev 12
Glossary page serial no cut Rev 13
Schematic Diagrams page serial no cut Rev 13
Hydraulic Schematic page serial no cut Rev 13
Safety 15
Cleaning of Material Handling Equipment 17
Cleaning Methods 17
Control of Hazardous Energy 18
Battery 18
Safety Rules 18
Battery Care 18
Charging 18
Battery Removal 19
Battery Installation 19
Lockout – Tagout 19
Capacitance 20
Brake 21
Releasing Brakes 21
Releasing Brakes by Switching Connectors & Using an External Power Source 21
Releasing Brakes by Switching Connectors & Using On Board Truck Battery 21
Releasing Brakes by Using the Crown Operator Display and Truck Battery is Present 21
Releasing Brakes Using Screws 22
Hydraulic 22
Towing Truck 24
Lifting and Blocking 25
Mast 27
Blocking Masts 27
Disconnecting Tilt Cylinder 29
Removing Mast 30
Removing Counterweight 31
Hose Reel 33
Introduction 35
General 37
Operator Instructions 37
Driver Training 37
Service Training 37
Replacement Parts 37
Data Plate 38
Truck Data Number 39
Lubrication & Adjustment 41
Lubrication and Adjustment 43
Component Access 43
Battery Cover 43
Left Side Cover 43
Right Side Cover 43
Floorboards 43
Steering Column Covers 43
Dashboard 44
Control Lever Cover 44
Lubrication 44
Lubrication and Adjustment 62
Componentry 67
ACS 67
Accelerator Switch 67
ACCESS 1 67
ACCESS 2 67
ACCESS 3 68
Traction Control Module (TCM) 68
ALM1 68
Status Alarm 68
ALM2 68
Travel Alarm 68
AXS1, AXS2 69
Auxiliary Function Switches 69
AXS3 69
Additional Auxiliary 5th Function Switch 69
BREATHER 69
Reservoir 69
BRK1, BRK2 70
BRKS1 70
Brake Switch 70
BRKS2 70
Brake Switch 70
CBV 71
Counter Balance Valve 71
CYLINDER 71
Carriage 71
CYLINDER 71
Lift 71
CYLINDER 72
Steer 72
CYLINDER 72
Tilt 72
ECR1 72
ECR2 73
Traction Motor Encoder 73
ECR3 73
ECR4 73
FAN1 & FAN2 74
Controller Panel 74
FAN3 74
Floorboard Fan 74
FIL 74
Horn Filter 74
FILTER 75
Hydraulic Fluid Return Filter 75
FS 75
Forward Travel Switch 75
FU1 75
Traction Motor Power Fuse 75
FU2 76
Lift Pump Motor Power Fuse 76
FU3 76
Main Control Fuse 76
FU4 76
Power for Tow Plug & Lights 76
FU5 77
FU11 77
Freezer/Corrosion Fuse 77
FU12 77
Freezer/Corrosion Fuse 77
HGTS1 77
Height Switch 77
HN1 78
Horn 78
HNS 78
Horn Switch 78
INFOLINK MODULE 78
IMPACT SENSOR 79
K1 79
K11 79
Freezer/Corrosion Relay 79
K12 80
KYS 80
Key Switch 80
L 81
Line Contactor 81
LGS1 81
Front Work Light Switch 81
LGS2 81
LGT1 & LGT21 82
Front Work Lights 82
LGT3 82
Rear Work Light 82
LGT4 82
Strobe Light 82
LGT5 & LGT6 83
LOAD SENSE PT1 83
Load Sense Monitor 83
Main Relief Valve 83
M1 & M2 84
Traction Motors 84
M3 84
Hydraulic Pump Motor 84
POT1 STR 84
Steer Wheel Position Potentiometer 84
POT2 BRK 85
Brake Potentiometer 85
POT3 ACC 85
Traction Accelerator Potentiometer 85
POT4 85
Lift 85
Priority Steer Valve 86
Pump 86
Lift/Steer 86
RES2 86
Freezer/Corrosion Heater 86
RES3 87
Freezer/Corrosion Heater 87
RS 87
Reverse Switch 87
SB80 87
5th Function Suppressor Block 87
SCU 88
Steer Control Unit 88
SES 88
Suspension Seat Switch 88
Strainer 88
Suction 88
THS1 89
Freezer/Corrosion Thermostat 89
THS2 89
Freezer/Corrosion Thermostat 89
TLT 90
Tilt Switch 90
TS1 & TS2 90
Traction Motor Temperature Sensor 90
TS3 90
Lift Pump Motor Temperature Sensor 91
Metric Torque Values 92
Grade 92
Torque Values 94
Grade 94
Hydraulic System 97
Hydraulic Schematic Symbols 99
Hydraulic System103
General103
Hydraulic Lines and Fittings103
Tank and Filters103
Tank103
Filters104
Operational Description104
Idle Mode104
Priority Valve104
Steering105
Lifting105
Tilting105
Control Valve105
Main Relief Valve Setting105
Maintenance105
Drift Test106
Tilt Drift Test106
Lift Drift Test106
Cylinder and Circuit Bleeding107
Lift Cylinder Circuit107
Tilt Cylinder Circuit108
Sideshift Cylinder Circuit108
Steer Cylinder Circuit108
Hydraulic Circuitry109
Pump Maintenance122
General122
Pump Disassembly122
Inspection123
Pump Reassembly123
Hydraulic Lines and Fittings123
Reassembly123
Hydraulic Manifold Blocks124
Manifolds124
Tilt Manifold124
Crossover Relief Manifold124
Manifold Block Component Replacement125
Drive Unit127
General129
Drive Motor129
Drive Motor Removal129
Drive Unit Lubrication129
Drive Tire Replacement130
Drive Unit Repair131
Drive Unit131
Drive Motor Removal131
Drive Unit Removal131
Drive Unit Assembly131
Pre-assembly of the housing with wheel shaft:131
Spiral bevel gear helical pinion shaft pre-assembly:133
Wheel flange shaft assembly:133
Spiral bevel gear assembly:134
Spiral bevel pinion assembly:135
Spiral Bevel Pinion136
Spiral Bevel Pinion/Gear Adjustment136
Electrical System139
Switches141
AXS1, AXS2, TLT141
Hydraulic Auxiliary and Tilt Switches141
ACS143
Accelerator Switch143
BRKS1, BRKS2 (Optional)143
Brake Switches143
HGST1144
Height Switch144
SES144
Seat Switch144
General145
Wiring Color Codes145
Power Cables145
Switches149
Type of Switch149
Number of Terminals149
Momentary or Maintained Contact149
How the Switch is Held and Wired149
How the Switch is Activated150
Application150
Switch Symbols (Mechanically activated switches)151
Specialty Switches153
AC Traction Drive156
ACCESS 3 Traction Control Module (TCM)156
Basics of System Operation156
Control Circuit Operation156
Power Circuit Operation156
Access 3 Traction Control Module157
Access 1 2 3158
Access 1158
User Level158
Message Mode159
Timer – Message Mode159
Timer – Start159
Timer – Stop159
Timer – Reset159
Trip – Message Mode159
Trip – Reset159
Bdi – Message Mode159
Hours – Message Mode159
Odometer – Message Mode159
Hour160
Events160
Service160
Performance160
Operator Menus161
Analyzer Menus163
Calibration Menus167
Features Menus168
Performance Menus171
Hour Menus173
Event Menus174
Utilities Menus175
Potentiometers176
Steer Potentiometer POT1 STR176
Removal and Installation176
Brake Potentiometer POT2 BRK177
Removal and Installation177
Accelerator Potentiometer POT3 ACC178
Removal and Installation178
Lift Potentiometer POT4179
Removal and Installation179
Contactor180
132084-003 Contactor L (Line)180
Inspection180
Contacts180
Coil180
Component Replacement181
Contact Replacement181
Coil Replacement181
Battery182
Safety Rules182
Checking Battery182
Battery Care183
Charging Battery183
Placing battery on charge:183
Removing battery from charge:183
Battery Removal184
Battery Installation185
Seat Deck Latch Adjustment185
Battery Cleaning186
Troubleshooting186
AC Motors187
Event Codes188
Access Module Listing188
Some Troubleshooting Basics188
When a Malfunction Occurs188
No Event Code?188
Display Messages189
To Locate Malfunctioning Components190
Power Cable Connections190
Event Code 110191
Communication Between Access 1, Access 2 and Access 3 Not Established at Power Up191
Event Code 111 – 113193
Event Code 111193
Access 3 Periodic Communication Check (PDO) Error193
Event Code 112193
Brake Off Test Error193
Event Code 113193
Access 1 SPI Command Read Back Error193
Event Code 114194
BRK2 Brake Short (Left Hand Brake Coil)194
Event Code 115195
BRK2 Brake Short (Right Hand Brake Coil)195
Event Code 116196
Access 1 Display Brake Test Error196
Event Code 117197
BRK1 Brake Open (Right Hand Brake)197
Event Code 118198
BRK2 Brake Open (Left Hand Brake)198
Event Code 120199
Access 2 Periodic Communication Check (PDO) Error199
Event Code 121200
Seat Switch Mismatch200
Event Code 122201
Staging Switch Mismatch201
Event Code 123202
Brake Switch Mismatch202
Event Code 124203
Steer Encoder (ECR4) Error203
Event Code 162204
Load Sensor Out of Range204
Event Code 199 – 200205
Compatibility Error205
Event Code 200205
Loss of CAN Communication From Access 2 to Access 1205
Event Code 201206
Access 2 Logic Error206
Event Code 202207
Low Voltage on Lift Motor (M3) Terminal Outputs207
Event Code 203 – 204208
Event Code 203208
High Voltage on Motor Terminal Outputs208
Event Code 204208
Hydraulic Motor Current Low While Motor is Running208
Event Code 205209
Hydraulic Motor Current Greater Than 0 in Standby209
Event Code 206210
Access 2 Driver For Optional Traction Motor Compartment Fan Driver Shorted210
Event Code 207211
Optional Traction Motor Compartment Fan (FAN3)211
Event Code 208 – 209212
Event Code 208212
Access 2 Has Detected a Short Circuit in Optional Traction Motor Compartment Fan Circuit212
Event Code 209212
Incorrect Battery Voltage Detected at Access 2212
Event Code 213 – 214, 218213
Event Code 213213
Access 2 Lost CAN Communication213
Event Code 214213
Access 2 Current Transducer Output is Out of Range213
Event Code 218213
ECR3 (Hyd Sensor Bearing) Feedback Error213
Event Code 219214
Access 2 Detects U, V and W Voltage Feedback Circuit Out of Range214
Event Code 220, 223215
Event Code 220215
Access 2 Overload Protection Circuit215
Event Code 223215
Access 2 Capacitor Not Charging After Power Up Sequence215
Event Code 224216
ECR3 (Pump Motor Encoder) Feedback Lost216
Event Code 225217
Lift POT4 Out of Electrical Limit217
Event Codes 226, 299 & 300218
Access 2 has detected an issue in lift potentiometer (POT4) wiring218
Event Code 299218
This event code should never occur If it does, then likely caused by incompatible software218
Event Code 300218
CAN Communication Error From Access 3 to Access 1218
Event Code 301219
Access 3 Overload Protection Circuit219
Event Code 302220
Access 3 Logic Error #2220
Event Code 303221
Access 3 Logic Error #1221
Event Code 304222
Low Voltage on Motor Terminal Outputs222
Event Codes 305, 306, 307224
High Voltage on Motor Terminal Outputs224
Event Code 306224
Voltage Present at Access 3 (B+) Terminal Prior to Power Up Sequence224
Event Code 307224
Voltage Not Present at Access 3 (B+) Terminal After Power Up Sequence224
Event Code 308, 309, 310225
Event Code 308225
Access 3 Incorrect Voltage in Current Sensor Feedback Circuit225
Event Code 309225
Access 3 Capacitor Charge225
Event Code 310225
Access 3 CAN Communication Out of Range225
Event Code 311, 312226
Event Code 311226
Line Contactor Coil Shorted226
Event Code 312226
Line Contactor Driver Open226
Event Codes 313, 314227
Event Code 313227
Line Contactor Coil Open227
Event Code 314227
ECR1 or ECR2 Traction Encoder Issue227
Event Codes 315, 316, 317229
Incorrect Battery Voltage Detected at Access 3229
Event Code 316229
Access 3 Internal Communication Out of Range229
Event Code 317229
Brake Pedal Error229
Event Codes 318, 319, 320231
Event Code 318231
Access 3 EEPROM (Out of Range)231
Event Code 319231
Access 3 EEPROM Error231
Event Code 320231
Access 3 RAM Warning231
Event Code 321232
Access 3 FAN1 and FAN2 Not Operating232
Event Code 322233
Access 3 Temperature Out of Range233
Event Code 323234
M1 or M2 Traction Motor Temperature Out of Range234
Event Code 324, 325, 326235
Event Code 324235
Event Code 325235
Event Code 326235
Access 3 Accelerator Potentiometer (POT3) Error235
Event Code 327237
Access 3 Observes Forward/Reverse Closed at Same Time237
Event Code 331238
Access 3 Steering Potentiometer (POT1) Out of Range238
Event Code 332, 399239
Event Code 332239
Steering potentiometer open or shorted239
Event Code 399239
Compatibility Error239
Brake System241
Brake243
Checking Brake Air Gap243
Brake Assembly Removal243
Brake Disassembly244
Brake Assembly244
Brake Assembly Installation245
Steering247
Steering249
Hydrostatic Steering Unit249
Steering Column Assembly249
Column250
Gas Cylinder251
Directional Control252
Steering Wheel Removal252
Steering Wheel253
Final Assembly254
Steer Axle Assembly254
Steer Tire255
Hub256
Housing and Yoke Shaft256
Housing, Rack, Pistons and Cylinders257
Steer Cylinders Seal Replacement258
Circuit Bleeding260
Lifting Mechanism261
Mast263
Torque Requirements263
Mast Testing (Assemblied)263
Flaking264
Disassembly264
Removal From Power Unit267
Assembly Mast Lying Horizontal267
Mast268
Quad (Four Stage) Mast271
Mast Flaking271
Mast Testing (Assembled)272
Mast Inspection272
Mast Removal273
Carriage Removal274
Carriage Inspection274
Lift Chain Adjustment274
Lift Chains276
Inspection276
Wear276
Roller and Leaf Chain Wear Scale276
Rust and Corrosion277
Corroded Chain (with Stress-Corrosion Cracks)277
Cracked Plates277
Fatigue Cracks277
Tight Joints278
Protruding or Turned Pins278
Chain Side Wear278
Lift Chain Lubrication279
Lubricant279
Lift Chain Replacement279
Chain Anchors and Pulleys280
Leaf Chain Disconnect280
Disconnect Procedures:280
Fork Inspection281
Abrasion281
Wear vs Capacity282
Overloading282
Fatigue283
Bent or Twisted Forks283
Hanger284
Sideshifter285
Sideshifter Inspection285
Sideshifter Removal286
Sideshifter Installation287
Bearings289
Bearing Lubrication289
Bearing Service289
Troubleshooting291
Supply Circuit Test291
Sideshift Circuit Test292
Cylinders293
Cylinders295
Lift Cylinder295
Disassembly295
Seals295
Seal Removal295
Seal Installation – General296
Rod U-Cup Installation296
Small U-Cup296
Large U-Cup297
Cylinder U-cup Installation298
Cylinder Assembly298
Cylinder Bleeding and Flushing298
Bleeding – Free Lift Cylinder298
Bleeding – Stage Lift Cylinders298
Flushing – Stage and Free Lift Cylinders299
Drift Test299
Tilt Cylinder300
Left Hand Tilt Cylinder Shown300
Disassembly301
Rod Disassembly301
Seal Replacement301
Cylinder Reassembly301
Tilt Cylinder Flushing and Bleeding Procedures302
Tilt Drift Test302
Tilt Cylinder Adjustments303
Clevis Adjustments303
Glossary305
Glossary307
Schematic Diagrams311
Electrical Diagrams Index313
Electrical Schematic with Options314
Electrical Schematic with InfoLink™315
Access 3, AC Traction Controller316
Access 2, Hydraulics, Console Switches and Fan317
Floorboard, Contactor Panel and Bus318
Steering, Control Column, Seat, Relays and Horn319
Traction Motor and Brakes320
Pedals and Pots321
Access 1, Display322
Hydraulics, TPA Console Switches, Mast and Operator Fan323
Overhead Guard Lights324
Freezer Corrosion325
Power Cables326
InfoLink™327
Wire Harnesses328
Hydraulic Schematic331
Schematic333
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