Crown Forklift RT3020 Serie Service Manual

Service Manual Wartungshandbuch Manuel de maintenance

RT3020 Serie

TABLE OF CONTENT

Printed in Germany

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Printed in Germany

TABLE OF CONTENT Table of Content MA – SAFETY

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Safety Symbols used in the Manual .................................. M/P-MA-0000-001 General Maintenance and Repair Safety Notes ............... M/P-MA-0000-001 - Maintenance and Repair ................................................. M/P-MA-0000-002 - Before Leaving the Truck ................................................. M/P-MA-0000-002 - Before Carrying out Work on the Truck ............................ M/P-MA-0000-002 - Before Operating the Truck .............................................. M/P-MA-0000-002 Warnings and Labels on the Truck .................................... M/P-MA-0000-002

ITD – INTRODUCTION

PAGE

General ................................................................................. M/P-ITD-2900-001 - Operating instruction ....................................................... M/P-ITD-2900-001 - Service training ............................................................... M/P-ITD-2900-001 - Replacement parts orders ............................................... M/P-ITD-2900-001 - Structure of the Manual .................................................. M/P-ITD-2900-001 - Page Numbers ................................................................ M/P-ITD-2900-002 Truck Data Numbering Sheet ............................................... M/P-ITD-2900-004

M1 – LUBRICATION AND ADJUSTMENT

PAGE

Jacking up the Truck ............................................................ M-1.0-2900-001 Raising the Truck with a Crane ............................................ M-1.0-2900-002 Lifting the Truck with a second Truck ................................. M-1.0-2900-002 Towing the Truck .................................................................. M-1.0-2900-002 Component Access .............................................................. M-1.0-2900-003 Removing the Floorboard .................................................. M-1.0-2900-005 Removing the Side Panel .................................................. M-1.0-2900-005 Access to Drive Unit, Hydraulic System and Electrical Components ............................................... M-1.0-2900-005 Maintenance ......................................................................... M-1.1-2900-001 - Driver Participation ......................................................... M-1.1-2900-001 - Daily Maintenance Log .................................................... M-1.1-2900-001 - Recommended Lubricants and Oils ................................ M-1.1-2900-001 - Lubricants .................................................................. M-1.1-2900-002 Grease items and grease intervals .................................... M-1.2-2900-002 - Inspection and Maintenance Schedule ............................ M-1.2-2900-002 - Daily or every 8 service hours ................................... M-1.2-2900-003 - Monthly or every 100 service hours ........................... M-1.2-2900-005 - Every three months or 250 service hours ................... M-1.2-2900-007 - Every six months or 500 service hours ...................... M-1.2-2900-009 - Annually or every 1.000 service hours ....................... M-1.2-2900-011 - Every 2 years or 2.000 service hours ........................ M-1.2-2900-011 Caster .................................................................................... M-1.5-2900-001 Torques ................................................................................. M-1.9-2900-002

M2 – HYDRAULICS

PAGE

Hydraulic System ................................................................. M/P-M2.1-2900-001 Operation .......................................................................... M/P-M2.1-2900-001 Removing the Hydraulic Unit ............................................. M-2.2-2900-001 Replacing the Hydraulic Pump .......................................... M-2.3-2900-001 - Disassembly .............................................................. M-2.3-2900-001 - Assembly .................................................................. M-2.3-2900-001 - Start-up ..................................................................... M-2.3-2900-001 Replacing the Hydraulic Filter ........................................... M-2.3-2900-001 - Replacing the Suction Filter ....................................... M-2.3-2900-001 - Oil Change ................................................................. M-2.3-2900-002

Printed in Germany

M-IDX-2900-001

TABLE OF CONTENT Valve Setting Control ........................................................ M-2.3-2900-004 Non-return valve control ............................................... M-2.3-2900-004 Safety Valve Control .................................................... M-2.3-2900-004 Safety Valve Setting .................................................... M-2.3-2900-004

M3 – DRIVE UNIT

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Gear Unit ............................................................................... M-3.1-2900-001 Preparation ....................................................................... M-3.1-2900-001 Maintenance ..................................................................... M-3.1-2900-002 - General ...................................................................... M-3.1-2900-002 Drive Unit Disassembly ..................................................... M-3.1-2900-003 Assembly .................................................................... M-3.1-2900-003 Adjusting the Bevel Wheel Set ..................................... M-3.1-2900-004 Final Assembly ............................................................ M-3.1-2900-004 Drive Unit Re-Installation ............................................. M-3.1-2900-005 Live Ring Bearing Replacement ........................................ M-3.1-2900-005 Forcing out the Live Ring Bearing ................................ M-3.1-2900-005 Pressing in the Live Ring Bearing ................................ M-3.1-2900-005 Installation of the Live Ring Bearing in the Drive Unit ... M-3.1-2900-005

M4 – ELECTRICS

PAGE

Electrical Components ........................................................ M-4.2-2900-001 Transmitter (MC,MN,PT) ................................................... M-4.2-2900-001 Fast / Slow Switch (HES) .................................................. M-4.2-2900-001 Safety Pedal (PCT) ........................................................... M-4.2-2900-001 Lift / Lower Switch (PCS, PCD) ......................................... M-4.2-2900-001 Lift Limit Switch (MFF) ...................................................... M-4.2-2900-001 Pressure Switch (PS) ........................................................ M-4.2-2900-001 Horn Switch (PCX) ............................................................ M-4.2-2900-001 Horn (CX) .......................................................................... M-4.2-2900-001 Key Switch (QC) ............................................................... M-4.2-2900-001 Emergency Disconnect Switch (PE) ................................. M-4.2-2900-001 Steering Angle-Dependent Speed Reduction Microswitch . M-4.2-2900-001 Brake (FE) ........................................................................ M-4.2-2900-002 Fuses (F1, F2, FA) ............................................................ M-4.2-2900-002 Traction Motor (M1) ........................................................... M-4.2-2900-002 Pump Motor (M2) .............................................................. M-4.2-2900-002 Pump Contactor (K3) ........................................................ M-4.2-2900-002 Main Contactor (K4) .......................................................... M-4.2-2900-002 Raise Contactor (RLS) and Lower Contactor (RLD) ........... M-4.2-2900-002 Steering Motor (M3) .................................................... M-4.2-2900-002 Encoder (MS) ............................................................. M-4.2-2900-002 Limit Switch (MF) ....................................................... M-4.2-2900-002 Steering-Contactor (K6) .............................................. M-4.2-2900-002 Fuses (F3, FA3) ......................................................... M-4.2-2900-002 Travel Direction Display ..................................................... M-4.2-2900-002 OPTION

OPTION

OPTION

OPTION

OPTION

ES1 Traction Controller ........................................................ M-4.3-2900-001 General ............................................................................. M-4.3-2900-001 - Precautionary Measures ............................................ M-4.3-2900-001 Operational Features ......................................................... M-4.3-2900-001 - Speed Control ............................................................ M-4.3-2900-001 - Reduced Speed Range .............................................. M-4.3-2900-001 - Downhill Speed Control .............................................. M-4.3-2900-001 - Regenerative Braking ................................................. M-4.3-2900-001 - Anti-Roll-Down-Function ............................................. M-4.3-2900-001

Printed in Germany

M-IDX-2900-002

TABLE OF CONTENT - Hourmeter .................................................................. M-4.3-2900-002 Self Test ....................................................................... M-4.3-2900-002 - Monitored Circuits ...................................................... M-4.3-2900-002 Protective Devices ............................................................ M-4.3-2900-003 - Polarity Protection ..................................................... M-4.3-2900-003 - Wiring Errors .............................................................. M-4.3-2900-003 - Temperature ............................................................... M-4.3-2900-003 - Start Sequence ......................................................... M-4.3-2900-003 - Safety Class .............................................................. M-4.3-2900-003 Maintenance ..................................................................... M-4.3-2900-003 ES1 Traction Controller Connections ................................. M-4.3-2900-004 Programmer ......................................................................... M-4.4-2900-001 General ............................................................................. M-4.4-2900-001 Operating Menu ES1 Controller ......................................... M-4.4-2900-002 - General ...................................................................... M-4.4-2900-002 - Menu Functions ......................................................... M-4.4-2900-002 - Operating Menu - Overview ....................................... M-4.4-2900-003 Adjustment ....................................................................... M-4.5-2900-001 - Menu PARAMETER CHANGE ................................... M-4.5-2900-001 - Max. Speed Setting ................................................... M-4.5-2900-002 - TESTER Menu ........................................................... M-4.5-2900-004 - Error Code Display in SAM Hourmeter ....................... M-4.5-2900-006 - ALARMS Menu .......................................................... M-4.5-2900-006 - PROGRAM VACC Menu ............................................ M-4.5-2900-009 CONFIG Menu ............................................................. M-4.5-2900-010 SAM Hourmeter ................................................................ M-4.5-2900-01 Traction Controller Replacement and Transfer of Service Hours into the new Controller: ......................... M-4.5-2900-011 Traction Controller Safety Test ............................................ M-4.20-2900-001 Battery ................................................................................... M-4.25-2900-001 General ............................................................................. M-4.25-2900-001 Operation .......................................................................... M-4.25-2900-001 Battery Replacement ........................................................ M-4.25-2900-001 Battery Removal ............................................................... M-4.25-2900-001 - Replacing the Battery with a Crane ............................ M-4.25-2900-002 - Replacing the Battery with a Battery Trolley ............... M-4.25-2900-003 Charging the Battery .................................................... M-4.25-2900-004 Electric Motors ..................................................................... M-4.35-2900-001 General Maintenance Instructions ..................................... M-4.35-2900-001 Preparation .................................................................. M-4.35-2900-001 Important Maintenance Instructions ............................. M-4.35-2900-001 Traction Motor Maintenance ................................................ M-4.35-2900-002 Access to the Brushes ..................................................... M-4.35-2900-002 Maintenance ..................................................................... M-4.35-2900-002 - Armature .................................................................... M-4.35-2900-002 - Bearings .................................................................... M-4.35-2900-002 Pump Motor Maintenance ................................................... M-4.35-2900-003 Access to the Brushes ..................................................... M-4.35-2900-003 Maintenance ..................................................................... M-4.35-2900-003 Steering Motor Maintenance ......................................... M-4.35-2900-004 Access to the Brushes ..................................................... M-4.35-2900-004 Maintenance ..................................................................... M-4.35-2900-004 OPTION

Printed in Germany

M-IDX-2900-003

TABLE OF CONTENT M-5 – BRAKE

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Brake ..................................................................................... M-5.0-2900-001 - Function ......................................................................... M-5.0-2900-001 - Removal ......................................................................... M-5.0-2900-001 - Assembly ....................................................................... M-5.0-2900-002 - Air Gap Setting ............................................................... M-5.0-2900-002 - Brake Moment Setting .................................................... M-5.0-2900-002 - Brake Test ....................................................................... M-5.0-2900-003

M6 – STEERING

PAGE

Steering ................................................................................ M-6.1-2900-001 Operation .......................................................................... M-6.1-2900-001 Lower Steering Chain Adjustment ..................................... M-6.1-2900-002 Adjusting the Drive Unit Steering Chain ............................ M-6.1-2900-002 Checking the Sliding Clutch .............................................. M-6.1-2900-003 Replacing the Sliding Clutch ............................................. M-6.1-2900-003 Steering Sensor Removal / Installation ...................... M-6.1-2900-004 Steering Motor Removal / Installation ........................ M-6.1-2900-004 Limit Switch Removal / Installation ........................... M-6.1-2900-004 OPTION

OPTION

OPTION

M7 – LIFTING MECHANISM

PAGE

Lifting Mechanism ............................................................... M-7.0-2900-001 Test ................................................................................... M-7.0-2900-001 Adjusting the Stop ............................................................ M-7.0-2900-001

M8 – CYLINDERS

PAGE

Cylinders .............................................................................. M-8.0-0000-001 General ............................................................................. M-8.0-0000-001 Plunger Cylinders (single-acting) .................................. M-8.0-0000-001 Piston Cylinder (Double-Acting Cylinder) ...................... M-8.0-0000-002 Maintenance ..................................................................... M-8.0-0000-004 Inspection ......................................................................... M-8.0-0000-001 Seal Installation ................................................................... M-8.6-2900-001 General ............................................................................. M-8.6-2900-001 Lift Cylinder ....................................................................... M-8.6-2900-001 Removal Preparation ......................................................... M-8.6-2900-001 Removal ........................................................................... M-8.6-2900-001 Repairing the Lift Cylinder ................................................. M-8.6-2900-002 - Disassembly .............................................................. M-8.6-2900-002 - Inspection .................................................................. M-8.6-2900-002 - Assembly .................................................................. M-8.6-2900-002 Assembly ......................................................................... M-8.6-2900-002 Gas Pressure Spring Removal and Assembly ................... M-8.6-2900-003 - Removal Preparation ................................................. M-8.6-2900-003 - Removal .................................................................... M-8.6-2900-003 - Assembly .................................................................. M-8.6-2900-003

DIA – ELECTRICAL DIAGRAMS

PAGE

Standard Version .................................................................. M/P-DIA-2900-001 With electrical steering .................................................. M/P-DIA-2900-002 OPTION

HYD – HYDRAULIC SCHEMATIC

PAGE

Hydraulic Schematic ......................................................... M/P-HYD-2900-001

Printed in Germany

M-IDX-2900-004

SAFETY

Printed in Germany

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Printed in Germany

SAFETY Safety Symbols used in the Manual

General Maintenance and Repair Safety Notes

To help guide you through the manual and to highlight particular danger areas, we have used graphic illustrations:

DANGER Read the safety notices in the truck Maintenance and Operator's Manuals.

DANGER

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.

This symbol indicates life-threatening risks ● Failure to comply with this notice may result in severe or fatal injuries to yourself or other people.

Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines.

WARNING This symbol indicates the risk of serious injury and/or serious material damage.

DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels.

● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/ or other persons.

CAUTION This symbol indicates the risk of minor injury and/or minor material damage.

Maintenance and Repair 1.

Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices.

2.

Only qualified and authorised personnel may carry out work on the truck.

3.

Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame.

4.

To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral.

Only carry out cleaning with an oil separator.

Protect the electrical system from dampness.

5.

Keep the service area clean, dry and well-ventilated.

6.

Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled.

Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.

7.

Neutralise and thoroughly rinse any spilled battery fluid immediately.

● Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage.

INFORMATION Contains additional information with supplementary notes and hints.

OPTION OPTION

These items relate to optional features not supplied with the standard version.

Printed in Germany

REV. 1 4/00 M/P-MA-0000-001 1

SAFETY 8.

Keep the truck clean. This will facilitate the location of loose or faulty components.

9.

Make sure that capacity and data plates, warnings and labels are legible at all times.

10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown.

11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck.

Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. ●

Clean any illegible labels.

●

Replace any faulty or missing labels.

The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual.

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the travel switch and remove the key.

●

Block all wheels when parking on an uneven surface.

Before Carrying out Work on the Truck ●

Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.

●

Prevent the truck from rolling away.

●

Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.

●

Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes.

Printed in Germany

REV. 1 4/00 M/P-MA-0000-002 2

INTRODUCTION

Printed in Germany

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Printed in Germany

INTRODUCTION General The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components.

It also contains troubleshooting sections which can be used to identify and remedy truck faults.

series. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual.

This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.

Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French.

Each language block in turn is divided into chapters and sections.

The table on the following page shows how the manual is structured.

Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle.

Additional copies can be ordered as required.

With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle.

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.

Ordering Spare Parts The maintenance manual does not cover spare parts.

These are listed in a separate manual.

Spare parts can be ordered by quoting: ●

The truck specification number

●

The truck model number

M6

Steering

●

The truck serial number

M7

Mast / Lifting Mechanism

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic

This information can be found on the truck's data plate.

Only if this information is provided can the order be processed quickly, correctly and reliably.

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this

A01M-gb Printed in Germany

M-ITD-2900-001 1

INTRODUCTION Page Numbering in the Manual The page numbers are on the left and right-hand sides of the page footer.

If a page has been modified since the last edition, a revision number will be found in the middle of the footer: 02 REV. 2/99 means the second amendment to this page in February 1999.

The page numbers are not necessarily consecutive!

The back page of the manual contains a print number in the following form: MS-RT3020-GB-D-F 02/00 In this example, 02/00 is the edition date.

A page beginning with M/P- is identical in both the maintenance and spare parts manuals:

M/P-1.2-2900-001 M = Maintenance Manual P = Spare Parts Manual Chapter

Page Number

Section

Truck Code

e.g. 1.2 = Test and Maintenance Schedule

(Pages which are identical for all trucks are given the code 0000 here)

A page beginning with M- is only contained in the maintenance manual:

M-1.2-2900-001 M = Maintenance Manual

Chapter

Page Number

Section

Truck Code

e.g. 1.2 = Test and Maintenance Schedule

(Pages which are identical for all trucks are given the code 0000 here) Printed in Germany

M/P-ITD-2900-002 2

INTRODUCTION A page beginning with P- is only contained in the spare parts manual:

P-1.0-2900-001 P = Spare Parts Manual

Chapter

Page Number

Section

Truck Code

e.g. 1.0 = Panels

(Pages which are identical for all trucks are given the code 0000 here)

Model-Number RT3010 Modeldescription Rider Pallet Truck with 2.000 kg capacity

RT3020 Modeldescription Rider Pallet Truck with 2.200 kg capacity

RT3030 Modeldescription Rider Pallet Truck with 3.300 kg capacity

Printed in Germany

M/P-ITD-2900-003 3

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Printed in Germany

LUBRICATION AND ADJUSTMENT

Printed in Germany

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LUBRICATION AND ADJUSTMENT Jacking up the Truck Apply a jack with sufficient capacity, hard wooden blocks and wedges as shown in Fig. M1883.

DANGER Always support the raised truck on square blocks or other appropriate material to relieve the trolley. Never put your hands or other parts of the body underneath a nonsupported truck.

● Improper handling of the truck or the auxiliary equipment can result in fatal accidents.

●

Lift the forks to maximum height.

●

Secure both loadwheels with a wedge (1).

●

Apply a jack with sufficient capacityat the middle of the chassis frame and raise the truck (2).

●

Slide hard wooden blocks underneath the left and right-hand sides and lower the truck onto them.

●

Place sufficiently sized wooden blocks (hard wood) on both sides underneath the chassis and lower the truck onto the blocks (3).

●

Apply the jack to the forks.

●

Place a wooden block under the forks and lower the truck onto it (4).

1

3 4 2

3 M1883

Printed in Germany

M-1.0-2900-001 1

LUBRICATION AND ADJUSTMENT Raising the Truck with a Crane Attach the straps (ropes, chains) to the hitch point as shown.

DANGER

90

Make sure the crane / fork lift and the lifting equipment have sufficient capacity.

700

350

1000

● If the crane / lift truck crash or a load falls, fatal injuries can result.

Towing the Truck If the truck has been switched off and is idle, it can be towed over short distances without having to release the drive wheel brake. A brokendown truck can be removed from its operating aisle using a fork lift truck with a minimum 1.000 kg capacity.

Lifting the Truck with a second Truck ●

●

●

●

Make sure the drive wheel and the tandem castor wheel of the RT are facing forward; the forks must be in a raised position (maximum height).

●

See illustration for positioning the forks of the truck which is doing the lifting.

Position the forks under the chassis as illustrated in the diagram.

●

Insert a 90 mm thick block between the forks of the RT and the corresponding fork of the lifting truck.

Raise the truck approximately 20 mm off the ground. The drive wheel should not be in contact with the ground.

●

Slowly tow the truck in a forward direction only (black arrow).

Firmly secure the RT to the forks of the truck which is doing the lifting (e.g. with appropriate straps).

M1801

Printed in Germany

M-1.0-2900-002 2

LUBRICATION AND ADJUSTMENT Component Access Access can be gained either by unscrewing the panels or simply by flipping up and lifting the top cover.

WARNING Always remove the battery connector before carrying out maintenance work. This applies especially if the connector and plug connection have to be separate.

Under the Instrument Panel - Switch and electrical connection mechanisms, BDI connections, steering encoder*

Under the panel - Drive unit - Hydraulic pump - Hydraulic tank - Valve block - Brakes - Electronic control system - Fuses - Steering motor*

Under the battery panel - Battery - Battery connector

Under the front panel - Lift cylinder - Lift limit switch - Gas pressure spring

Drive wheel

M1880

Under the Floorboard - Pedal mechanism and switches - Steer motor control system*

Twin caster

* Electrical steering optional feature Printed in Germany

M-1.0-2900-003 3

LUBRICATION AND ADJUSTMENT Component Access Emergency Disconnect Lamps Indicating Travel Direction Forward / Reverse

Multifunction Indicator

Travel Direction Switch

M1881

Travel Speed Switch Fast / Slow

Lift Key Switch

Horn

Lower

Accelerator Pedal

M1882

Dead Man Switch

Printed in Germany

M-1.0-2900-004 4

LUBRICATION AND ADJUSTMENT Removing the Floorboard Unscrew the ball head underneath the pedal. Remove the fastening screws (4 off) from the floorboard. Lift up the floorboard. To assemble, proceed in the reverse order.

Access to Drive Unit, Hydraulic System and Electrical Components Remove the four screws (see Fig. M1808) from the skirting rail and set it to one side.

Removing the Side Panel Remove the four screws (B, Fig. M1883). Pull the panel out at the side and lift it up. Set the panel to one side.

Assembly is the reverse A order of disassembly.

M1808

B

M1883

Printed in Germany

M-1.0-2900-005 5

LUBRICATION AND ADJUSTMENT Maintenance Driver Participation By involving the driver in the maintenance schedule, truck downtimes can be substantially reduced. The driver can also contribute to determining the maintenance schedule, thereby saving costs. Crown therefore recommends that the driver carry out the daily maintenance in accordance with the table on page M-1.2-1720002.

Daily Maintenance Log A maintenance log is provided to keep a record of the extent and time of maintenance performed.

Recommended Lubricants and Oils Lubricants Only high grade lubricants and oils should be used.

These can be obtained from any oil manufacturer. Those listed in table on page M-1.1-1720-002 are typical, and any lubricant of the same grade can be used.

Cold Store Trucks Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table on page M-1.1-1720-002). An anticorrosion fluid (Crown no. 078882-002) must be applied to all screws, washers, nuts, pins, retaining rings etc.

Maintenance schedules should be kept as short as possible to prevent excessive wear of moving components.

Printed in Germany

M-1.1-2900-001 6

LUBRICATION AND ADJUSTMENT Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Type

Grease (multi purpose)

Aralube HLP-2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe E2 Retinax LX

Aral Castrol Century Esso Maxol Mobil Shell

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

Lubrication oil (chain)

Kowal 40 Essolube HDX Plus + 40 Delvac 1240

Aral Esso Mobil

053002-007

G

Low temperature lubrication oil

SHC 626

Mobil

053002-008

GG

Hydraulic oil

Vitam GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32

Aral Castrol Esso Mobil Shell

053001-003

D

Low temperature hydraulic oil

Univis J 13 Aero HFA

Aral Mobil

053001-008

DD

Transmission oil

Hyp 85W90 GX - D 85W90 Mobilube HD85/90 Spirax MB 90

Aral Esso Mobil Shell

053002-004

A

Low temperature transmission oil

Mobilube SHC

Mobil

053002-006

AA

Rubber and vinyl dressing

H

Special grease

MOS2 Lithium

Universal lubrication oil

SAE 40

Dow Corning

063002-022

M

C L01-gb

Printed in Germany

M-1.1-2900-002 7

LUBRICATION AND ADJUSTMENT Grease Points, Overview

L-7,L-8,L-9

M1799

L-7 L-3

M1798

L-11 L-7

L-1,L-2,L-4,L-5,L6,L-10

L-6 M1880

L-10 L-1,L-2 M1796

M1794

Printed in Germany

M-1.2-2900-001 8

LUBRICATION AND ADJUSTMENT Grease Points / Intervals Type

Vol.

100 hours

D

A/R

X

L-2 Replace hydraulic oil and filter

D

A/R

Initially after 500 service hours

L-3 All hinges

C

A/ R

X

L-4 Grease steering linkage

B

A/ R

X

L-5 Grease steering chain

G

A/R

X

L-6 Drive unit live ring bearing

B

A/R

X

L-7 Grease lifting mechanism

B

A/R

X

L-8 Lift cylinder attachment

B

A/R

X

L-9 Piston rod attachment

B

A/R

X

L-10 Change gear oil

A

A/R

L-11 Seat rails

B

A/R

Item Component L-1

Check hydraulic oil level, replenish if necessary

250 hours

500 hours

1000 hours

2000 hours

X

Initially after 250 service hours

X X L08-GB

Inspection and Maintenance Schedule The following inspection and maintenance schedule assumes single-shift operation under normal conditions.

The frequency of maintenance intervals must however be constantly adapted to the prevailing operating conditions.

In dusty or otherwise extreme operating conditions, the maintenance intervals specified must be reduced. Exact details should be discussed with a Crown service engineer.

When carrying out maintenance routinely check for wear, corrosion, damage, component operation and safety. If in doubt, replace components.

Battery Maintenance WARNING The battery must be serviced in accordance with the manufacturer's instructions.

Failing to follow the battery manufacturer instruction could damage the battery.

INFORMATION The next following scheduled maintenance icludes all precious .

Example To carry out the 250 -Servicehours Inspektion, you must include the schedule of the 8-hour and 100-hour schedule.

Printed in Germany

M-1.2-2900-002 9

LUBRICATION AND ADJUSTMENT Daily or every 8 service hours Item

Component

Test Scope

I -1

Battery and battery compar tment

Check / charge battery in accordance with manufacturer's instructions. Check battery compar tment for electrolyte leakage.

I -2

Battery connector

Check for damage. Check contacts for any signs of burning.

I-3

Leaks

- Gear Check for leaks.

- Hydraulic system Check for leaks. If leaks are found, take truck out of service.

I-4

Wheels / load wheels

Check tyres for wear and for any foreign objects. Remove any foreign objects found.

I-5

Forks

Check for damage, cracks and excess wear.

I-6

Labels, decals

Ensure they are complete and legible.

I-7

Key switch and BDI

Turn on the key switch. Check operation of battery discharge indicator and hourmeter.

I-8

Emergency Disconnect Switch

Check operation.

I-9

Horn

Check operation.

I-10

Lifting mechanism

Check for foreign objects.

I-11

Hydraulic functions

Check all functions. The hydraulics must cut out when the lift limit position is reached.

I-12

Steering

Check operation and freedom of movement.

I-13

Travel

I-14

Brake

Check the operation of the travel switch, the deadman pedal, and the speed reduction (which operates as a function of the steering angle).

Check braking in both travel directions: - By releasing the deadman pedal - By reversing the travel direction via the travel switch - By releasing the travel switch to neutral Repeat the above tests for both Tur tle/Rabbit switch positions.

CAUTION: Do not use high pressure cleaners and/or solvents to clean the truck.

Do not use metal brushes.

Lo2-GB

Printed in Germany

M-1.2-2900-003 10

LUBRICATION AND ADJUSTMENT I-13 I-8

I-7

I-13

M1881

I-11

I-13 I-1

I-2

M1882

I-13,I-14

I-13

I-5 M1882

*Note for I-3: It is sufficient to check the floor for fluids. Covers can remain on the truck.

Note for I-6: See the operator manual for the various location of the labels and decals.

M1880

I-4

I-3*

Printed in Germany

M-1.2-2900-004 11

LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours Item

Component

Test Scope

I -1

Hydraulic oil level

Check level, replenish if necessary.

I-2

Lift frame

Clean rollers and contact surfaces. Visually inspect for wear and freedom of movement. Re-grease.

I-3

Brake

Remove any abrasion. Check air gap.

I-4

Lift cylinder

Visually inspect for leaks. Check piston rod for damage. Check cylinder attachment. Check operation of lift limit switch.

I-5

Hydraulic lines

Check hoses and lines for damage, replace if necessary.

Lo3-GB

Printed in Germany

M-1.2-2900-005 12

LUBRICATION AND ADJUSTMENT

I-2

I-4, I-5

M1814

M1880

I-1, I-5

I-3 L02-part3-GB

I-1

M1794 M1815

Printed in Germany

M-1.2-2900-006 13

LUBRICATION AND ADJUSTMENT Every three months or 250 service hours Item

Component

Test Scope

I-6

Battery connector to truck

Clean contacts and check contact springs.

I -7

Lift linkage

Check for wear, damage and ensure it is securely fit.

I -8

Gear system

Carry out first gear oil change. Thereafter every 2000 service hours.

Lo4-GB

Printed in Germany

M-1.2-2900-007 14

LUBRICATION AND ADJUSTMENT

I-6

M1882

M1880

I-8

I-7

M1808

Printed in Germany

M-1.2-2900-008 15

LUBRICATION AND ADJUSTMENT Every six months or 500 service hours Item

Component

Test Scope

I-9

Drive unit fastening screws.

Check torques.

I-10

Pump motor and drive motor Steering motor (if present)

Check carbon brushes for wear and freedom of movement.

I-11

Load wheels and casters

Check bearings for excessive play and wear.

Replace if necessary/ Check torques of fastening screws / nuts.

I-12

Drive wheel

Check wheel screw torque (91 Nm).

I-13

Gear system

Carry out first gear oil change. Thereafter every 2000 service hours or every 2 years.

I-14

Hydraulic system

Carry out first hydraulic oil and filter replacement. Thereafter every 2000 service hours or every 2 years.

I-15

Electrics

Check connections for corrosion, clean if necessary.

I-16

Electrical system

Visually inspect all switches, relays, contactors and wiring.

Remove dust with dry compressed air at low pressure.

Check connections for corrosion, clean if necessary.

I-17

Steering system

Check play, setting and operation of limit switches and the safety clutch setting.

I-18

Brake

Disassemble brake. Check brake lining for wear and damage.

Check anchor disk and friction plate for any signs of overheating and wear. Replace damaged or worn par ts.

Lo5-GB

Printed in Germany

M-1.2-2900-009 16

LUBRICATION AND ADJUSTMENT

I-19

I-15,I-16, I-17, I-18, I-19

I-13 I-20 M1880

I-12, I-14

I-10

M1880

I-11

(6x) M1815

M1808

M1794

Printed in Germany

M-1.2-2900-010 17

LUBRICATION AND ADJUSTMENT Annually or every 1000 service hours Item

Component

Test Scope

I-21

Pump motor and drive motor Steering motor (if present)

Check commutator for wear and damage.

I-22

Gear system

Check oil level, replenish if necessar y.

I-23

Frame and panels.

Check for damage, repaint if necessar y.

I-24

Hydraulic system

Check safety valve operation.

I-25

Carr y out annual UVV test

The UVV test is a requirement in Germany. Different regulations apply in other countries which may differ in the length and scope of the test.

L06-GB

Every 2 years or 2000 service hours Item

Component

Test Scope

I-27

Hydraulic system

Replace hydraulic oil and filter. Clean lines and connections.

Make sure the system is secure and free of leakage.

I-28

Gear system

Change gear oil.

L07-GB

Printed in Germany

M-1.2-2900-011 18

LUBRICATION AND ADJUSTMENT

I-23

I-27

I-24

M1880

I-14, 15,I-16

I-22, I-28 I-21 L03-part2-gb

M1815

24

18

M1808

M1794

23

M1702 M1704

Printed in Germany

M-1.2-2900-012 19

LUBRICATION AND ADJUSTMENT Caster The twin caster is located at the rear right of the truck below the chassis.

The caster is not height-adjustable. Grease the bearing bushing regularly as required (but at a minimum of every 500 service hours or after 6 months).

A lifetime lubrication is applied to the wheel conical bearings. Replace the bearings if there is excessive play or uneven travel.

The wear limit is reached when the diameter of one or both wheels < 120 mm.

Grease Nipple

Printed in Germany

M-1.5-2900-001 20

LUBRICATION AND ADJUSTMENT Torques

NOTE

The information contained on thise page should be used during maintenance work to determine the correct torques for standard screws and nuts.

The torques listed in the maintenance section always take precidence over those listed on this page.

Standard Screws and Nuts Grade

8 and 8.8 Thread Size

10 and 10.9

12 and 12.9

Torque (Nm)

M 5x0.8

6

8

M 6x1

10

14

M 8x1.25

24

35

M 8x1

26

37

M 10x1.5

49

70

M 10x1.25

52

73

M 12x1.75

84

110

M 12x1.5

89

125

M 16x2

200

280

M 16x1.5

215

300

M 20x2.5

390

550

M 20x1.5

430

610

M 24x3

700

980

M 24x2

735

1030

M 30x3.5

1380

1930

M 30x3

1470

2080

10 17 42 44 83 87 143 150 340 360 660 730 1170 1240 2320 2500

T02-GB Printed in Germany

M-1.9-2900-001 21

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Printed in Germany

HYDRAULICS

Printed in Germany

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Printed in Germany

HYDRAULICS Hydraulic System Operation The hydraulic unit comprises the motor, pump, reservoir all filters, valves and the lift cylinder.

Lifting:

The pump delivers oil from the reservoir to the lift cylinder. The lift-valve opens, while the lowering-valve closes.

Lowering: The lowering valve opens, while the lift valve closes. The oil flow returns from the lift cylinder to the reservoir.

M1781 Printed in Germany

M/P-2.1-2900-001 M1.0-0000-0001

HYDRAULICS Removing the Hydraulic Unit WARNING De-pressurise all components before carrying out maintenance work on the hydraulic system.

●

Unplug the battery connector.

●

Secure the truck from rolling away.

●

Before commencing maintenance work place a flat container or (if necessary) a large cardboard box underneath the work surface.

●

Obtain a suitable support on which to rest the hydraulic unit, e.g. a heavy iron ring.

●

Disconnect all wire connections and hoses from the hydraulic unit.

●

Remove the hydraulic unit from the chassis.

● High pressure hydraulic oil can cause serious injuries. ● Whenever a high pressure fluid penetrates the skin it must be treated as an emergency, even if the skin shows no initial reaction. Physical effects set in later. ● Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge. ● Use absorbent paper to track leaks, never use your hands!

.

Pump motor

Hydraulic Block Safety Valve Non-Return Valve Filler Neck

Solenoids

Hydraulic Container

M1825

Printed in Germany

M-2.2-2900-001 M1.0-0000-0002

HYDRAULICS Replacing the Hydraulic Pump

Start-up

NOTE

WARNING The hydraulic pump should not be replaced on site.

The pump should be replaced by a new one.

All seals of dismantled parts and filters must be replaced.

Use approved oils only (see table L02-D, page M-1.1-2900-002)!

●

Check that the assembly is clean and correctly assembled. Above all, the pressure ports must be tight.

●

Initially, fill up to half the container height with hydraulic oil (see lubricant table), via a filter with a minimum retention rate of 10 µm.

●

Never run the pump without oil!

●

All parts, in particular the hydraulic connections, must be completely clean and dry before starting.

Otherwise it is impossible to prevent leaks.

●

Operate the lifting functions for approx. 30 seconds to bleed the system. This will cause heavy frothing of the container oil.

●

Check the pressure port and surrounding hydraulic components for leaks.

●

Park the truck and leave it for approx. 20 minutes.

This will allow time for the air to separate from the oil in the container.

●

When there is no more foam in the container, replenish with oil up to the max. point and repeat bleeding until no more foam is visible.

●

Finally, replenish with hydraulic oil up to the bottom edge of the filler neck.

Disassembly ●

Remove the hydraulic unit as describedin the previous chapter.

●

Drain the oil via the filler neck.

See drawing M1826, page M-2.3-2900-003: ●

Unscrew the 4 nuts (42).

●

Lift out the engine from the top. When doing so, take care to prevent the engine from coming apart.

●

Remove the screws (36) on the container flange, remove the container and the O ring (29).

●

Remove the filter (51) and the suction pipe (50).

●

Loosen the screws (49) and remove the pump.

●

Clean all components (excluding the engine) with a clean de-greasing agent, remove old seals and air-dry all components.

Assembly ●

Fit the new filter element (51) and the suction pipe (50).

●

Apply a thin coat of oil to the new seal (45) and insert it.

●

Fit the carrier (46).

●

Fit the pump (note the alignment) and fix it with the screws (49). Tighten diagonally and evenly.

●

Fit the container with a new, gently greased seal (29) and fix with the screws (36). Tighten the screws diagonally and evenly.

●

●

Pump Motor Pump motor maintenance and repair work is detailled in chapter 4.

Replacing the Hydraulic Filter Replacing the Suction Filter

Place the engine on the support (34) in such a way that the drive shaft fits into the carrier groove.

Align the engine and fix it using the nuts (42) via the stay rods (40).

To re-fit the hydraulic unit, proceed in the reverse order of dis-assembly.

●

To replace the filter (51), loosen the screws (36).

Loosen the return line (2) on the fitting (1).

Remove the container (24) and O ring (29) and dispose of the oil in an environmentally safe manner.

●

Unscrew the filter element (28) and replace it with a new one. Dispose of the old filter in an environmentally safe manner.

Printed in Germany

M1.0-0000-0003 M-2.3-2900-001

HYDRAULICS Fill with suitable hydraulic oil (see lubricant table, chapter 1) and bleed in accordance with the Start-Up section on the previous page.

Oil Change The oil container (approx. 0.75 litre capacity) does not have an oil drain screw. Therefore either suction off the used oil or tilt the oil container.

Disposal must be through approved methods only!

Filling and bleeding are in accordance with the Start-Up section on the previous page.

Printed in Germany

M-2.3-2900-002 M1.0-0000-0004

HYDRAULICS

M1826 Printed in Germany

M1.0-0000-0005 M-2.3-2900-003

HYDRAULICS Valve Setting Control Non-return valve control ●

Remove the hydraulic motor cover so that the collector is visible.

●

Raise the forks.

●

Lower the forks while observing the anchor. The anchor should not move!

If the anchor moves, proceed as follows: ●

Remove the non-return valve (32, Fig. M1770) and replace it with a new valve (available as a kit complete with seals).

Safety Valve Control ●

Assemble a test load with 10% more weight than the maximum admissible load (see data plate).

●

Collect the load with the forks and activate the lift function.

●

The load should not be raised!

Safety Valve Setting WARNING The safety valve setting is very critical. An incorrect setting can cause the truck to be overloaded and result in severe or even fatal injuries! ●

Prepare two test loads, one with 10% more weight than the maximum admissible load (overload) and one with the maximum truck capacity weight (normal load).

●

Unscrew the safety valve cap (33, Fig. M1770) and loosen the set screw jam nut.

●

Collect the excess load and activate the lift function.

●

First set the safety valve so as to prevent the excess load from being lifted.

●

Secondly, collect the normal load and activate the lift function. The load should be raised.

●

Tighten the set screw jam nut and repeat the test.

●

After adjustment, screw the cap back on to the safety valve and seal it.

Printed in Germany

M-2.3-2900-004 M1.0-0000-0006

HYDRAULICS

M1770 Printed in Germany

M1.0-0000-0007 M-2.3-2900-005

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Printed in Germany

DRIVE UNIT

Printed in Germany

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Printed in Germany

DRIVE UNIT Drive Unit Preparation The truck must be raised in order to remove the drive unit. See chapter M1 for instructions.

G

Auxiliary Equipment: ●

Fork lift truck with sufficient capacity, lift height and fork length to raise the truck.

●

Safety device for the forks of the lifting truck to keep the raised truck in position.

●

A hard wooden block (minimum surface area of 250 x 250 mm, 80 mm high) or another suitable support to secure the truck after removing the drive unit.

●

Suitable device to keep the drive assembly vertical when the truck is raised. This device should also be suitable for transporting the assembly.

Removal

F

E A D

Disconnect the battery and remove the key.

Prevent the truck from being switched on again.

B

C

Remove the engine compartment panel and the skirting (C).

Remove the six mounting screws (F) from the drive unit.

Remove the stop screw (D).

Raise the truck until the drive assembly below the chassis is free.

DANGER

Refit the skirting.

NEVER WORK UNDERNEATH A SUSPENDED LOAD. SEVERE INJURIES COULD RESULT IF THE TRUCK IS SUDDENLY LOWERED.

Lower the truck sideways in relation to the drive assembly and place the 80 mm high hard wooden block underneath the skirting (all around).

Lower the drive assembly onto a workbench with the drive wheel facing upwards. Use a suitable retaining device to do this.

Remove the electrical connections to the motor and the brakes (G).

Remove the cam plate (A) and the switch plate (E) if present.

Open the chain tensioner (B) and remove the chain.

Attach the truck to a fork lift and prevent it from sliding away, or use a crane (chapter M1), but do not yet raise.

Fit the device to support the drive assembly.

Printed in Germany

M1.0-0000-0001 M-3.1-2900-001

DRIVE UNIT Maintenance WARNING ONLY AUTHORISED PERSONNEL TRAINED

BY CROWN SHOULD REPAIR THE DRIVE UNIT. FAILURE TO COMPLY WITH THIS NOTICE WILL INVALIDATE THE WARRANTY. Adjusting the flank tooth bearing and tensioning the shaft bearing requires many years' experience with drive units. Inaccurate settings can result in premature drive unit failure. It is therefore generally advisable to replace the drive unit.

Replacement drive units are always supplied without oil!

Before starting the drive unit fill with oil in accordance with the "Lubrication Table".

General ●

Replace all bearings and seals.

●

Before disassembling the drive unit, clean thoroughly with a cold-cleaning solution and blow dry with weak compressed air.

●

Use assembly devices and a clean work station.

All reference numbers, e.g. (06) in the following maintenance instructions relate to drawing M1774 on this page.

M1774

M1558-1 Printed in Germany

M-3.1-2900-002 M1.0-0000-0002

DRIVE UNIT Drive Unit Disassembly ●

●

Loosen the wheel bolts (1) and remove the drive wheel.

Remove the oil drain plug (16) and the filler plug (21) and drain the oil.

●

Remove the screws (18) and lift out the motor.

●

Remove the screws (19), followed by the flange (26) and live ring bearing (24) and finally the O ring (22).

●

Remove the shaft seal (6).

●

Remove the retaining ring (7) and lift out the spacers (11,12).

●

Remove the nut (140) from the flange shaft (36).

●

Fit a removal tool to the flange shaft (36) and pull out the flange shaft.

●

Remove the retaining ring (9) and take the bearing (10) out of the flange shaft.

Assembly CAUTION THOROUGHLY CLEAN ALL BEARINGS AND SEALS, CLEAN ALL COMPONENTS. ●

Fit the outer ring of the upper conical roller bearing (30) in its respective position in the clean housing. Make sure it lies level in the housing. Fit the retaining ring (310).

●

Fit the outer ring of the lower conical roller bearing (30) with spacers 37x47 and an overall width of 0.2 mm in its respective position in the clean housing. Make sure it lies level in the housing.

●

Press the inner ring of the lower bearing (30) onto the conical pinion shaft (38) until it reaches the stop.

●

Place spacers 20x38 mm with an overall width of 1.2 mm and the spacer sleeve (31) onto the conical pinion shaft (38).

●

Push the conical pinion shaft (38) with the thread at the front through the inside of the housing (35) into the previously inserted bearing outer rings (30).

●

While holding the conical pinion shaft (38) by the conical pinion place the inner ring of the upper conical roller bearing (30) onto the conical pinion shaft.

●

Unscrew the self-locking nut (33) from the conical pinion (37).

●

Push the conical pinion (37) down into the housing (35), while ensuring the inner rings of the bearing (39) remain on the shaft.

●

Remove the pinion (32), spacers (38) and spacer sleeve (31).

●

Place a 20 x 28 x 0.5 mm spacer on the upper conical roller bearing.

Pull or push out the outer bearing (30) rings from their seats in the drive unit housing.

●

Position the pinion (32) and temporarily insert a M18 x 1.5 nut. Torque the nut to 310 Nm.

Remove the inner bearing (30) rings from the conical pinion shaft (37).

●

Manually turn the conical pinion several times in both directions and make sure it turns freely.

Thoroughly clean all components and remove all sealant and adhesive residue.

●

Using a dial gauge measure the conical pinion axial play on the roller bearings: Rated = 0 - 0.05 mm.

●

Push the bearing (10) onto the flange shaft (36) and secure with the retaining ring (9).

●

Insert spacers (12) with an overall width of 0.5 mm into the bearing seat of the flange shaft in the housing (35).

●

●

●

Printed in Germany

M1.0-0000-0003 M-3.1-2900-003

DRIVE UNIT Adjusting the Bevel Wheel Set

Correct tooth bearings of the inner tooth end of the conical pinion

CAUTION TAKE CARE WHEN ADJUSTING. THE USEFUL LIFE AND PERFORMANCE OF THE DRIVE UNIT DEPEND LARGELY ON AN ACCURATE SETTING.

The correct setting is obtained from the tooth flank bearing.

High

Low

High

Basic Rules: ●

Always adjust the bevel wheel set to the correct flank position. The tooth ends must not form a straight line.

●

The tooth bearing must always be at the end of the inner tooth.

●

The tooth bearing must range from high (top edge of the tooth) to low (bottom edge of the tooth).

To adjust, add and/or remove spacers (38 and 12).

The following rule applies: However many spacers are removed from one side must be added on the other. This maintains the axial play.

Low

Correct tooth bearings of the inner tooth end of the bevel M1565-1 wheel

Final Assembly ●

Thoroughly clean all components.

●

Replace the nut (33) with a self-locking nut and torque to 310 Nm.

●

Insert the flange shaft (36). Fit a sufficient number of spacers (8) between the retaining ring (7) and the bearing outer ring (10) so that the flange shaft fits tightly in the housing. Secure in the housing with a retaining ring (7).

●

Apply a thin layer of Loctite 574 to the outer circumference of the shaft seal (6). Grease the seat of the shaft seal in the housing. Gently oil the sealing lips and insert the shaft seal using an appropriate tool.

●

Fit a new O ring (22) onto the flange (26).

●

Insert the flange (26) together with a live ring bearing (24) into the housing. Drive in the flange evenly using a rubber hammer. Do not damage the O ring.

Figure M1565-1 shows the tolerances for permissible tooth bearings on the conical pinion and the bevel wheel.

Checking the Flank Bearing ●

Colour the tooth flanks of the flange shaft (36) with contact paste (removable).

●

Carefully fit the flange shaft (36) in the housing and engage it with the conical pinion (37).

●

Temporarily insert the disk (8) and retaining ring (7).

●

Turn the bevel wheel several times in a single direction. The tooth bearing is a bright point (shown black in Fig. 1565-1) on the tooth flanks. ●

●

Disassemble the bevel wheel and check the tooth bearing. By removing and/or adding shims (38 and 12) bring the tooth bearing to within the tolerance range (Fig. M1565-1).

Manually turn the drive unit while checking for freedom of movement and absence of play.

●

Place the drive pinion (27) on the motor. Make sure that the spring (41) is correctly positioned. Fit disks (39) and nut (40). Torque the nut to 50 Nm.

Repeat the process until the tooth bearing lies within the tolerance range.

●

Fit a new O ring (28).

●

Clean the oil drain plug, remove metallic chips from the magnet and re-insert with a new seal (15).

Printed in Germany

M-3.1-2900-004 M1.0-0000-0004

DRIVE UNIT ●

CAUTION LEAVE THE SURFACE AND THREAD SEALANT TO DRY FOR AT LEAST 2 HOURS AT ROOM TEMPERATURE BEFORE FILLING WITH OIL.

●

●

●

●

Add oil at the earliest 2 hours after assembly (approx. 1.9 litres) in accordance with the lubricant table - see Chapter 1.

Fit a new seal (15) to the oil filler plug (21), insert and tighten the plug.

Apply a thin coat of oil to the O ring (28) and carefully fit the drive motor (34) in the housing.

Align with the hole pattern. Apply Loctite 242 to the screws (18) and insert them. Tighten the screws (18) diagonally to 25 Nm. Fit the drive wheel (5) with new lock washers.

Torque the screws to 90 Nm.

Drive Unit Re-Installation

Live Ring Bearing Replacement To replace the live ring bearing remove the drive unit (see page M-3.1-2900-001) and drain the oil. ●

Remove the screws (18) and remove the motor.

●

Remove the oil drain plug (16) and the oil filler plug (21) and drain the oil.

●

Remove the screws (18) and remove the motor.

●

Remove the screws (19).

●

Using a rubber hammer drive the bearing and flange (26) out of the drive unit by gently and evenly tapping the lower part of the live ring bearing (24).

●

Remove the O ring (22).

Forcing out the Live Ring Bearing

●

Assembly is the reverse order of removal. Make sure that the grease nipple (23) is accessible when fitted. Secure the drive unit to the chassis with the screws (25). Torque to 85 Nm.

●

Refit the electrical connections.

●

Attach the steering chain in such a way that the chain tensioner rests as indicated in Fig. M1869-1.

●

Re-fit and adjust the stop screw for the mechanical steering angle limiter.

●

Place the flange and the live ring bearing on a suitable device and using a medium press and a suitable stamp force the flange out of the live ring bearing (see Fig. M1870).

Stamp Device Flange

Tension the steering chain.

Bearing

M1870

●

Chain Tensioner

Carefully clean the flange and its seat in the drive unit. Make sure that no contamination or foreign bodies enter the drive unit.

M1869-1

Printed in Germany

M1.0-0000-0005 M-3.1-2900-005

DRIVE UNIT Pressing in the Live Ring Bearing ●

Degrease the flange and apply a thin and even layer of Loctite 641 to the entire area where the inner ring of the live ring bearing will contact.

●

Position the flange underneath the press and insert a new bearing.

●

Align the bearing with the flange as shown in Fig. M1872.

●

Remove the flange and the live ring bearing from the press. Check the live ring bearing for freedom of movement and even running.

●

Remove the threaded pins and the grease nipple from the old bearing and insert them in the new bearing.

Installation of the Live Ring Bearing in the Drive Unit ● Insert the O ring (22). ●

Degrease the upper section of the flange and its contact surface in the drive unit.

Thread Pins Loctite 574

Grease Nipple Chassis Attachment Holes

M1871

●

Apply Loctite 574 to the contact surfaces of the flange with the drive unit.

●

Fit the flange in the drive unit while observing the hole circle.

●

Using a rubber hammer drive the flange into the drive unit. Take care only to tap the upper area of the flange - not the bearing - and make sure that the O ring (22) remains in its position.

●

Fit screws (19) with washers and screw them in diagonally.

Torque to 50 Nm.

●

Wipe the bearing and turn it until the grease is evenly distributed in the bearing. Use grease as recommended in Chapter M1.

M1872

●

Using a suitable device (see Fig. M1873) press the bearing onto the flange until it is securely positioned. Immediately remove excess Loctite.

CAUTION THE PRESSING DEVICE MUST BE DESIGNED SO THAT PRESSURE IS ONLY EXERTED ON THE BEARING INNER RING.

Device Bearing

Flange

Loctite 641

M1873 Printed in Germany

M-3.1-2900-006 M1.0-0000-0006

ELECTRICS

Printed in Germany

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany

ELECTRICS Electrical Components DANGER Jack up the truck before repairing or troubleshooting the electrical system.

Transmitter (MC,MN,PT) The transmitter is manually activated via a cam switch.

It comprises the commutator (MN) which signals the required travel direction to the control system and a potentiometer (PT) which governs the travel speed.

Fast / Slow Switch (HES) The Fast / Slow switch is activated via a toggle switch (rabbit / tortoise & rabbit symbols) on the instrument panel. High and low speeds can be selected via the switch signal to the traction controller.

Seat Switch (MPD) This safety switch remains opens provided the driver seat is not occupied. Travelling and lifting are inhibited while the switch is open.

Safety Pedal (PCT) The safety pedal (PCT) is energised when the seat switch (MPD)is activated and when pressed applies the brakes via the control system. The brake is released and at the same time power supply is released to the drive motor (M1) via the input (A5) of the traction controller.

When the safety pedal is released the input (A5) of the traction controller is de-energised. The traction controller cuts out the power supply to the drive motor and the spring-loaded brake. The brake magnet is disengaged and the truck brakes.

OPTION

Trucks with Electrical Power Steering: The safety pedal (PCT) applies the brake via the EPSDC steering control system. The brake is released and at the same time power supply is released to the drive motor (M1) via the input (A5) of the traction controller.

When the safety pedal is released the input (A5) of the traction controller is de-energised. The traction controller cuts out the power supply to the drive motor and the spring-loaded brake. The brake magnet is disengaged and the truck brakes.

Lift / Lower Switch (PCS, PCD) The lift (PCS) and lower (PCD) switches are both manually activated via a press button in the instrument panel.

The Lift (PCS) switch activates the auxiliary relay (RLS), the lift limit switch (MFF) as well as the pump contactor (K3) and the “Lift” solenoid via the control system. The pump motor (M2) starts up.

The Lower switch (PCD) activates the “Lower” solenoid via the auxiliary relay (RLD). The pump contactor (K4) simultaneously opens via the control system while the pump motor (M2) is inactive.

Lift Limit Switch (MFF) The limit switch (MFF) interrupts the auxiliary relay (RLS) power circuit when the preset maximum height is reached. Consequently the control system cuts out the pump contactor and the pump motor is inactive.

Pressure Switch (PS) The pressure switch is applied, when the load raised exceeds 500 kg, due to the rise in pressure in the hydraulic system. The second brake level is then made available.

Horn Switch (PCX) The horn sounds when this switch is pressed.

Horn (CX) The horn is located in the truck’s engine compartment.

Key Switch (QC) The key switch activates the traction controller (input A2).

Emergency Disconnect Switch (PE) Pressing the Emergency Disconnect Switch interrupts the voltage supply to input (A2) of the traction controller.

This activates the contactors (K3) and (K4), the traction motor and the lift motor remain inactive, the springloaded brake (FE) is de-energised and brakes the truck.

Steering Angle-Dependent Speed Reduction Microswitch This microswitch senses an angle on the traction motor fitted with rotation bearings. If the steering angle is greater than 10 degrees, the ramp opens the switch.

Input C3 of the traction controller falls to 0 volts and the

Printed in Germany

M1.0-0000-0001 M-4.2-2900-001

ELECTRICS control system reduces the max. travel speed. This is a safety function to avoid excessive curve speeds.

Brake (FE) The two-stage electromagnetic brake is spring-loaded and applies when the truck is de-energised (parking brake). In travel mode the brake only applies when the safety pedal (PCT) opens or the emergency stop switch is pressed.

Raise Contactor (RLS) and Lower Contactor (RLD) These contactors are auxiliary relais to modulate the lift valve (EVS) and the lower valve (EVD).

OPTION

The steering motor is a DC motor. It is governed by the steering controller EPS-DC.

Fuses (F1, F2, FA) OPTION

The entire drive current circuit is protected by fuse F1 while the lift current circuit is controlled by fuse F2. The fine fuse (FA) protects the control circuit.

Traction Motor (M1) The traction motor is a separately excited DC motor and is governed by the traction controlled.

Pump Motor (M2) This is a DC motor. The contactor (K3) applies positive power supply for the pump motor (M2) when a lift request is received.

OPTION

The main contactor governs the entire power supply to the traction and pump motors.

When the key switch (QC) is engaged, positive battery voltage is led from the emergency disconnect switch (PE) to input A2 of the traction controller. The traction controller activates output A7 (after internal tests). The coil of the main contactor is activated, the contacts switch the battery voltage via fuse F1 to the traction motor (M1) and via fuse F2 to the pump contactor.

Steering Limit Switch (MF)

The two limit switches are located on the drive motor.

When the maximum steering angle is reached they interrupt the input signal at pins D1 and D7 of the steering controller respectively. This causes the steering motor to stop. Steering movement is now only possible in the opposite direction until the previously opened switch is closed again.

OPTION

Main Contactor (K4)

Encoder (MS)

The encoder converts the steering movement in impulses which are dependent on the steering movement and deflection. This impulses are sent to the steering controller as input signals.

Pump Contactor (K3) If a lift request is sent to the traction controller via the switch (PCS), output D4 of the traction controller will be positive. The lift valve (EVS) is simultaneously energised. The pump contactor coil is activated and the pump contactor engages the pump motor (M2). The forks raise as far as the maximum lift height which is preset by the lift limit switch (MFF). The limit switch opens and interrupts the voltage supply to the lift switch (PCS). The lift valve (EVS) is de-energised. Output D5 of the control system falls to 0 volts, the pump contactor is activated and the pump motor remains inactive.

Steering Motor (M3)

Steering-Contactor (K6)

This contactor sends positive battery supply to the power part of the steering controller. The coil of the contactor (K6) is directly connected on one side to the battery negative terminal while the other side is fed positive supply from the steering controller EPS-DC via output E4.

OPTION

Fuses (F3, FA3)

The power fuse F3 for the steering motor and power circuit and the control circuit fuse FA3 are located in the controller EPS-DC below the truck floorboard.

Travel Direction Display (STD) These two lights display the travel direction as a function of the switch position (MN).

Printed in Germany

M-4.2-2900-002 M1.0-0000-0002

ELECTRICS

Steering Controller Fuses (F3, FA3) Traction motor (M1) Pump motor (M2) Steering motor (M3) Pressure switch (PS) Electromechanical brake (FE) Hydraulic valves (EVD, EVS) Steering movement limit switch (MF) Steering angle dependent speed reduction microswitch (MV) All contactors (K4, K3,K6) and relais (RLS, RLD) Fuses (F1, F2, FA) Horn (CX)

M1852

OPTION

Battery

M1880

Traction Controller

M1848 M1879 Printed in Germany

M1.0-0000-0003 M-4.2-2900-003

ELECTRICS Emergency Disconnect Switch Multi-Function Display

Travel Direction Display Lights Travel Direction Selector

M1881

Fast / Slow Commutator

Raise Button Lower Button

Key Switch

Accelerator

M1882

Safety Pedal

Printed in Germany

M-4.2-2900-004 M1.0-0000-0004

ELECTRICS ES1 Traction Controller

Operational Features Speed Control

DANGER Jack up the truck before carrying out repair work or troubleshooting the electrical system.

General The programmable ZAPI SEM Zero impulse controller provides effective control over the driving behaviour of the truck.

The truck is powered by a separate excited motor (SEM). This version has two variables for governing the motor output: field and armature current.

Precautionary Measures ●

●

Do not attach the controller to a battery with a different rated voltage to that of the controller (24 - 36 VDC).

A higher battery voltage may destroy the MOSFETs, while a lower power supply will result in system failure.

Only operate the controller with special traction batteries. Do not connect to a rectifier or mains components.

●

When commissioning jack up the truck to prevent it from starting suddenly if there is a wiring error.

●

When the key switch has been turned off the filter capacitors in the controller remain charged for a few minutes. If work is performed on the controller during this time it must be disconnected from the battery (disconnect battery). Finally, to discharge the capacitors short-circuit the positive and negative terminals of the power part together over a resistance (10 - 100 Ohm, min. 5 W) for a few seconds.

Stepless, handset programmable speed control in both directions.

Reduced Speed Range Two travel speed ranges can be chosen using the rabbit/ turtle toggle switch HES. Reduced speeds can be programmed between 30 % and 100 % of normal travel speed by using the handset.

Downhill Speed Control When travelling downhill the controller monitors and compares the motor anchor current with the drive signal from the traction potentiometer. When the motor anchor current decreases, electrical braking with energy retention is introduced.

Regenerative Braking Three forms of regenerative braking are available: ●

Deceleration braking by setting the travel switch to an smaller value, but still > 0, without changing the drive direction.

●

Inversion braking (quick inversion): travel switch set in opposite direction.

●

Release braking: travel switch set to neutral.

Anti - Roll Down Function This function prevents the truck from accidentally rolling down a slope. When the key switch is on the controller monitors anchor current of the traction motor. If the truck starts to roll down the slope without a travel comand, the controller detects the change in the achor current and braking is automatically activated. After this, the monitoring cycle starts over again.

Such, if the brake is not applied manually, the truck will therefore move down the slope very slowly.

Printed in Germany

M1.0-0000-0005 M-4.3-2900-001

ELECTRICS Hourmeter An hourmeter is integrated within the traction controller which can be set via the programmer either to "KEY ON" (hourmeter activated when key switch on) or "RUNNING" (hourmeter activated only during travel).

Self Test The traction controller self-test system lists up to five different error messages which can be called up via the programmer. The type of fault as well as the frequency, number of service hours and the controller temperature at the time of the error are stored and displayed.

In addition, a red LED on the controller flashes a code for the most recent error.

Monitored Circuits See the following diagram for a explanation:

SELF DIGNOSTICS Executed In Four Conditions

ALLWAYS Contin. Test By Key On

KEY ON One Time Test By Key On

STAND BY Contin. As Long As Key Is On

TRACTION Contin. Test During Traction

BATTERY VOLTAGE TEMPERATURE

START UP SEQUENCE

VACC NOT OK

CONTACTOR DRIVER

NO FIELD CURRENT

COIL SHORTED

CAPACITOR CHARGE

I FIELD HIGH

FORW + BACK

I = 0 EVER

WATCHDOG

V FIELD NOT OK

I HIGH AT STAND

VMN NOT OK

INCORRECT START

PEDAL WIRE KO

CONTACTOR DRIVER

Note: Text in the white boxes shows the messages of the programmer.

See table E-13-S-GB for a description of the monitored components.

Printed in Germany

M-4.3-2900-002 M1.0-0000-0006

ELECTRICS Protective Devices Polarity Protection A general protection controlled by the logic system separates the traction controller from the battery and thus protects the power part from incorrect polarity.

Maintenance Maintenance of the ES1 controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.

WARNING

Wiring Errors

The SEM -1 controller operates with high throughputs. Special safety measures are therefore required.

All outputs are protected against wiring errors. The outputs for the general protection and the magnetic brake can be charged with max. 3 A and are fitted with both an overload and a short circuit protection.

● Only properly trained personnel must carry out maintenance work. ● Use non-wearying eye protection.

Temperature

● Do not wear loose clothing.

From a power part temperature of 80°C upwards the maximum current is limited in proportion to the rise in temperature. At 90°C the traction controller automatically cuts out.

At temperatures below -10°C the maximum current is reduced in proportion to the ongoing battery discharge.

● Do not wear jewelry. ● Use insulated tools only.

●

Disconnect the battery (= emergency disconnect).

●

Jack up the truck.

To start the truck there is a specific start sequence which must be observed. Otherwise the line contactor will not be activated and the truck will not function:

●

Discharge the controller capacitors by connecting for a short time BATT- and BATT+ of the controller via a cable including a resistor of about 10 Ohm.

1.

Key "ON"

●

Remove cables.

2.

Press security switch down (= deadman switch). This opens the brake switch (PE)

●

Remove contamination and corrosion from the contact surfaces.

3.

choose your direction and speed

●

Wipe the controller with a clean, damp cloth.

●

Before connecting the cables make sure that the controller is completely dry.

Start Sequence

This means, the usual behavior of some operators leads to an error. This operators normaly choose direction and speed first and then start the truck. This is not possible with this truck.

Safety Class The traction controller is protected against dust and spray water (IP54)

Printed in Germany

M1.0-0000-0007 M-4.3-2900-003

ELECTRICS ES1 Traction Controller Connections

F1 F1

F2 F2

DD 11

88

EE

11

33C C11 66 BB 11 MUSTER

88

AA

11

66

VMN VMN

M1531

Power Connections

Control Connections

BATT+

Positive battery supply

A, B, C, D

BATT-

Negative battery supply

E

VMN

Traction motor driver (negative)

F1, F2

Connections to tractionmotor field coils

Multifunction Instrument SAM and Programmer connection

Printed in Germany

M-4.3-2900-004 M1.0-0000-0008

ELECTRICS The programmer is connected to the controller by a cable, thus powered by the controller.

Programmer General

CAUTION

The optional programmer, Crown P/N 794596, enables programming, testing and diagnostics for the controller.

Only connect / disconnect the programmer to the controller when the truck is switched off.

M0271-neu

Display Window ● ●

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

Alpha-numeric LCD display 2 lines @ 16 characters

Operating Keys

M0274 Printed in Germany

M1.0-0000-0009 M-4.4-2900-001

ELECTRICS Description of Keys Key

Designation

Explanation

1

ROLL up

Selects the next sub-menu or an option.

2

ROLL down

Selects the previous sub-menu or an option.

3

ENTER

Enters the main menu. Stores the pin configuration.

4

OUT *

Quits a sub-menu or an option. Step by step return to the main menu.

5

PARAM up

Increases setting values or selects configuration.

6

SET down

Decreases setting values or selects configuration.

* You can undo a change by switching the truck off and on again. The controller will be reset to the output values.

E05-gb

Operating Menu ZAPI ES1 Controller General When the programmer has been connected a self test start routine is performed. When it is complette, use the ROLL up/down and ENTER keys to select the required menu.

Menu Functions

PROGRAM VACC In the PROGRAM VACC menu item the traction potentiometer is calibrated. The traction controller reads and records the potentiometer's minimum and maximum output voltage.

CONFIG The Configuration menu is used to set the operation of the hourmeter.

PARAMETER CHANGE In the PARAMETER CHANGE menu the listed truck parameters can be read and set in real time.

In addition, the "Adjustments" sub-menu allows for calibration between the battery voltage measured by the controller and the actual battery voltage.

TESTER In the TESTER menu the listed truck parameters can be activated, checked and set in real time.

ALARMS In the ALARMS menu error messages generated and stored during operation can be called up and processed.

Printed in Germany

M-4.4-2900-002 M1.0-0000-00010

ELECTRICS Operating Menu - Overview ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERS. BRAKING SOFT BRAKING SOFT ACCELERATION CUTBACK SPEED 1 CUTBACK SPEED 2 H&S CUTBACK MAX SPEED FORW MAX SP FORW FINE MAX SPEED BACK MAX SP BACK FINE CREEP SPEED

CONSOLE

MAIN MENU PARAMETER CHANGE

MAIN MENU TESTER

MAIN MENU ALARMS

CODE hr, NO.,˚C

HARDWARE SETTING

LOAD HM FROM SAM ON/OFF CHECK UP DOWN ON/OFF CHECK UP TYPE 0-4 ADJUSTMENT #02 0-9 ADJUSTMENT #01 0-9 MAIN MENU PROGRAM VACC

VACC SETTING MIN MAX

MAIN MENU MOTOR DATA

NOT AVAILABLE

0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9

BATTERY VOLTAGE V V MOTOR VOLTAGE MOTOR CURRENT A A FIELD CURRENT V VMN ˚C TEMPERATURE V% ACCELERATOR FORWARD SWITCH ON/OFF BACKWARD SWITCH ON/OFF ON/OFF HANDLE SWITCH QUICK INVERSION ON/OFF LOW PERF. SWITCH ON/OFF CUTBACK SWITCH ON/OFF ON/OFF BRS SWITCH BATTERY CHARGE %

MIN VACC MAX 0.0 UP/DOWN 0.0

MAIN MENU CONFIG. MENU

CONFIG. MENU SET MODEL

CONFIG. MENU SET OPTIONS

CONFIG. MENU ADJUSTMENTS

NOT AVAILABLE

HOUR COUNTER KEY ON/RUNNING QUICK INVERSION BLLY/TIMED QUICK INVERSION ON/OFF

ADJUST BATTERY M1827

Printed in Germany

M1.0-0000-00011 M-4.4-2900-003

ELECTRICS Settings PARAMETER CHANGE Menu Menu item

ACCELER DELAY

Setting range

0-9

Recommended setting

Description

5

Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when transmitter (rocker switch) suddenly set to limit).The greater the value, the longer the delay.

DECELER DELAY

0-9

9

Time taken to reach the new set value when the set value on the transmitter is changed. Corresponds to the braking intensity when the transmitter is returned. The greater the value, the longer the time taken to reach the new value.

RELEASE BRAKING

0-9

7

Release braking. Activated when the accelerator pedal is released or when it returns to neutral. Time taken for the motor current to fall to zero. The greater the value, the shorter the braking distance.

INVERSE BRAKING

0-9

5

Inversion braking. Activated when transmitter (rocker switch) is set to the opposite direction. Time taken for the motor current to fall to zero. The greater the value, the shorter the braking distance.

5

Maximum current for the low speed range selected by the fast / slow speed switch (HSS) (in % of max. current ACC for fast speed (= normal)). Again, the entire mechanical control range of the transmitter is available. Enables more sensitive travelling at reduced speed.The greater the value, the greater the max. speed with the Fast/Slow switch in the "Slow" position.

9

Max. forward speed: this value determines the maximum traction motor current during forward travel.

When the armature voltage has been fully absorbed by the controller, the speed is increased by weakening the field current. If the value is set to 0 the field current will not fall below the nominal value (FCN = field current nominal) when the armature voltage is fully absorbed.

The greater the value, the greater the max. forward speed.

5

Fine adjustment for max. forward speed: This value determines the maximum traction motor current during forward travel.

The greater the value, the greater the max. forward speed.

0

Creep speed. Setting for the minimum voltage applied to the traction motor when the travel switch is closed.This function should be set to one level below the value at which the truck begins to travel.

This ensures that the empty run of the transmitter (rocker switch) is kept to a minimum. The greater the value, the greater the max. creep speed.

H&S CUTBACK

MAX SPEED FRW

MAX SPEED FRW FINE

CREEP SPEED

0-9

0-9

0-9

0-9

E06-1-GB

Printed in Germany

M-4.5-2900-001 M1.0-0000-00012

ELECTRICS Settings PARAMETER CHANGE Menu Menu item

SOFT BRAKING

SOFT ACCELERATION

MAX SPEED BCK W

Setting range

0-9

0-9

0-9

Recommended setting

Description

5

Braking pattern in slow mode.

This value determines the braking pattern when the Fast/Slow switch is set to Slow. The greater the value, the softer the brake application.

0

Acceleration pattern in slow mode.

This value determines the acceleration pattern when the Fast/Slow switch is set to Slow. The lower the value, the softer the acceleration.

9

Max. reverse speed: This value determines the maximum traction motor current during reverse travel. When the armature voltage has been fully absorbed by the controller, the speed is increased by weakening the field current.

If the value is set to 0 the field current will not fall below the nominal value (FCN = field current nominal) when the armature voltage is fully absorbed. The greater the value, the greater the max.reverse speed.

MAX SPEED BCK FINE

0-9

5

Fine adjustment for max. forward speed: This value determines the maximum traction motor current during reverse travel.

The greater the value, the greater the max.reverse speed.

CUTBACK SPEED 1

0-9

6

Speed reduction.

CUTBACK SPEED 2

0-9

6

Speed reduction.

E06-2-GB

DANGER The max. speeds (unladen) of 10 km/h and (laden) of 8 km/h must not be exceeded.

The “MAX SPEED FRW”, “MAX SPEED FRW FINE” and “MAX SPEED BCK W”, “MAX SPEED BCK FINE” determine the maximum speed in both travel directions.

The recommended settings in tables (E06-1GB and E06-2-GB) are approximate. You must always record the actual speed of the truck and adjust the setting so that the truck travels no faster than 10 km/h or 8 km/h.

Max. Speed Setting Preliminary Measures The motor brushes must be run in (at least 10 hours travel time). For new brushes set the recorded value a level lower. This is because the performance improves the more the brushes are run in.

After the brushes have been run in (at least 10 hours travel time), measure the actual truck speed again.

Printed in Germany

M1.0-0000-00013 M-4.5-2900-002

ELECTRICS Speed Measurement In a secure area, mark a length of 10 metres. The route must be even a have a sufficiently long entry area to allow the truck to attain the max. speed beforehand.

Bring the unladen truck at operating temperature to maximum speed and travel along the route.

Using a stopwatch, record the time taken to cover the distance.

Repeat the test twice and obtain the mean time taken.

Example: 3 recordings: Mean value:

(3.6 s) (3.4s) (3.7 s) 3.567 s

Speed Calculation: 10 m : 3,567 * 3.6 = 10,09 km/h Measurement and setting must be carried out separately for each travel direction.

Set the truck so that the max. speed of 10 km/h is not exceeded (unladen).

After any adjustment to a value, repeat the measurement.

Repeat the measurements with full load and adjust the truck so that the max. speed of 8 km/h is not exceeded.

Printed in Germany

M-4.5-2900-003 M1.0-0000-00014

ELECTRICS TESTER Menu The following table describes the various truck parameters which can be selected and checked in the TESTER menu.

TESTER Menu Menu Item

Description

BATTERY VOLTAGE

Battery voltage measured at key switch input.

MOTOR VOLTAGE

Current applied to armature, measured between +BATT and VMN.

MOTOR CURRENT

Current received by motor armature.

FIELD CURRENT

Current received by field coil.

VMN

Measures the current between VMN (Volt Motor Negativ) and -BATT. The reading indicates the potential difference over the controller power part.

TEMPERATURE

Controller temperature, measured at the aluminium base plate next to the MOSFETs.

ACCELERATOR

Displays the nominal signal of the traction potentiometer. The left hand side displays the voltage reading, the right-hand side the percentage relating to the maximum operating signal calibrated via PROGRAM VACC.

FORWARD SWITCH

B6 digital input status.

Displays the open (OFF) and closed (ON) status.

BACKWARD SWITCH

B4 digital input status.

Displays the open (OFF) and closed (ON) status.

HANDLE SWITCH

A5 digital input status.

Displays the open (OFF) and closed (ON) status.

QUICK INVERSION

B5 digital input status.

Displays the open (OFF) and closed (ON) status.

LOW PERF. SWITCH

C2 digital input status.

Control logic input is bridged.

CUTBACK SWITCH

C3 digital input status.

Displays the open (OFF) and closed (ON) status.

BRS SWITCH

A8 digital input status.

Displays the open (OFF) and closed (ON) status.

BATTERY CHARGE

Displays the battery charge status as a percentage.

E07-GB

Printed in Germany

M1.0-0000-00015 M-4.5-2900-004

ELECTRICS ALARMS Menu The traction controller can detect and store operational faults during various operating conditions. The last five error messages are stored together with the following details: ●

Error type

●

Frequency

●

Hourmeter reading

●

Power part temperature

With the ALARMS menus the corresponding error messages can be called up and read.

Error Code Display in SAM Hourmeter The SAM hourmeter has an LCD display to show the error codes. This is an alternative to quickly obtain an overview of the most recent errors.

Printed in Germany

M-4.5-2900-006 M1.0-0000-00016

ELECTRICS

ALARMS Menu SAM Display

Handset Error Message Description

Possible Cause

SAM cannot read data from the control system.

SAM not connected to control system or wire breakage.

Error in auto-diagnostic function performed during truck power-up, when parked and during travel.

Watchdog circuit (hardware) or program (software) faulty. Replace logic system.

EEPROM KO

Error in non-volatile memory area where hourmeter, error message and truck parameter data is stored.

Turn key switch off and on again. If the error persists, replace the logic system. If the error is removed, make sure that all the stored data is deleted and reset to a default value.

15

VFIELD NOT OK

Test performed when truck is idle and main contactor open. The error message appears if approx. 50% of the battery voltage is not applied to the field connections.

- Motor loss to earth - Motor field connections not connected or incorrectly connected to controller - Error in power part field controller range

19

LOGIC FAILURE #1

Main contactor drive test error during autodiagnostic function on truck power-up.

Control logic error.

Replace logic system.

VMN NOT OK

Test performed in idle mode with the main contactor closed and during travel.

The error message appears when VMN - is below the battery voltage when truck is idle - does not comply with power when truck is travelling

- Motor cable wiring error - Motor loss to earth - Power part error

CONTACTOR CLOSED

Test performed during auto-diagnostic function on power-up.

The motor field is energised before the main contactor is applied. The error message appears if the power capacitors do not discharge.

- Main contactor jammed (check contacts, if necessary replace contactor) - Faulty field circuit (check field coil and field cable operation and connections)

Test performed during travelling. The error message appears if the traction current does not exceed a given minimum value.

- Insufficient motor contact (check carbon brushes) - Faulty current sensor (replace controller) - Back coupling, logic system or power part error (replace component or entire controller)

06

08

13

32

37

49

None

WATCH-DOG

I = 0 EVER

E08-GB

Printed in Germany

M1.0-0000-00017 M-4.5-2900-007

ELECTRICS ALARMS Menu SAM Display

53

57 59

60

62

66

75 76

Handset Error Message Description

Possible Cause

Test performed during auto-diagnostic function on power-up and when truck is idle. The error message appears if a current flow is detected.

- Faulty current sensor (replace controller) - Back coupling, logic system or power part error (replace component or entire controller)

HIGH FIELD CURR, NO FIELD CURR

Test performed constantly and checks the field current.

- Field current measuring error (replace controller) - Field cable not connected - Power part error (replace component or entire controller)

CAPACITOR CHARGE

Test during auto-diagnostic function on power-up. If the capacitors have not started to charge 500 metres after turning the key switch, an error message appears and the main contactor does not close.

Power part faulty.

Replace logic system.

TH PROTECTION

- An error message appears if the controller temperatue exceeds 80°C. The maximum current is reduced in proportion to the rise in temperature. At 90°C the system automatically cuts out.

- If the temperature falls below -10°C, the maximum current is reduced to 80%.

- If the error message appears in the normal temperature range, this indicates an error in the controller.

- Temperature sensor faulty (replace controller) - Faulty logic (replace logic system) - Insufficient heat transfer (check mounting bolts and the rest of the system)

BATTERY LOW

An error message appears if thebattery voltage falls below 63% of the nominal value.The ccurrent is reduced in proportion to the potential difference. At 43% of the nominal value the system automatically cuts out.

- If the error message appears at a battery voltage above 63%, this indicates an error in the controller or the wiring.

- Less than 63 % of the battery voltage is applied to input A2 after the key switch is applied.

Wiring problem: poor contact, additional consumer, cable too long, small diameter etc.

- Microprocessor error or battery current measurement error (replace logic system)

Tests the main contactor circuit.

- Contactor coil short-circuited, not connected or incorrectly connected - Contactor drive opened or shortcircuited (replace logic system) - Voltage feedback errorto contactor driver (replace logic system)

STBY I HIGH

CONTACTOR DRIVER; COIL SHORTED

E08-2-GB

Printed in Germany

M-4.5-2900-008 M1.0-0000-00018

ELECTRICS ALARMS Menu SAM Display

Handset Error Message Description

Possible Cause

VACC NOT OK

- Potentiometer cable broken Test performed during auto-diagnostic function on - Wiring error power-up and when truck is idle. The error message - Potentiometer faulty appears if the potentiometer signal deviates by more - PROGRAM VACC not performed or than 2 volts from the stored minimum value. incorrectly performed.

INCORRECT START

Start sequence incorrect. The following sequence must be maintained: Override switch (by moving the multitask handle from idle to travel position), followed by travel switch (by pressing the transmitter (rocker switch)).

- Travel direction switch (FS/RS) or multitask handle switch jammed - Wiring error - Incorrect start sequence entered by user

80

FORW + BACK

Test is performed constantly and checks whether both travel directions are applied simultaneously.

- Wiring error - Travel direction switch jammed - Incorrect start sequence entered by user

86

PEDAL WIRE KO

Test performed constantly and monitors the traction Potentiometer connections not wired potentiometer and its wiring. Error message appears or interrupted. for broken wires.

78

79

99

CHECK UP NEEDED

Scheduled service

Deactivated as standard. If this message is displayed in the SAM, the controller item must be deactivated.

E08-3-GB

PROGRAM VACC Menu The PROGRAM VACC sub-menu enables each traction potentiometer to be calibrated individually for each truck by taking and storing the minimum and maximum output voltages of the traction potentiometer.

The minimum output voltage is read as the travel switch is closed, the maximum output voltage when the travel switch is fully applied (rocket switch at limit). This ensures that the full physical path of the potentiometer is used.

Approx. 14V is applied to the travel switch via the traction controller. The signal range used by the potentiometer is from 0V (minimum speed) to 10V (maximum speed).

Printed in Germany

M1.0-0000-00019 M-4.5-2900-009

ELECTRICS CONFIG Menu The CONFIG menu provides access to the SET OPTIONS and ADJUSTMENTS sub-menus. The SET MODEL sub-menu is blocked (NOT AVAILABLE).

CONFIG Menu Sub-Menu SET MODEL

SET OPTIONS

ADJUSTMENTS

Option

Description ---

Not available

HOUR COUNTER: KEY ON / RUNNING

Determines the operation of the hourmeter in the traction controller. The following options are available: - KEY ON: Counts the hours while the truck is switched on - RUNNING: Counts the hours while the traction motor is applied

QUICK INVERSION: BELLY / TIMED

Not available on this truck.

ADJUST BATTERY

Adjusts the battery current measured by the controller to the actual battery current. This can be necessary for example in the event of a relatively high voltage potential on the key switch.

E11-gb

Printed in Germany

M-4.5-2900-010 M1.0-0000-00020

ELECTRICS SAM Hourmeter When the truck is powered up (key switch ON) the hourmeter reads and displays the previously completed service hours from the traction controller.

Traction Controller Replacement and Transfer of Service Hours into the new Controller: If a traction controller needs to be replaced, the previous number of service hours must be transferred into the new traction controller. ●

Disconnect the battery.

●

Remove the faulty controller.

●

Insert the new controller.

●

Connect the handset (console) to bushing “E” of the new controller.

●

Connect the battery.

●

Set the key switch ON.

●

In the “Hardware Setting” menu of the handset activate item “Load HM from SAM”.

●

Set the key switch OFF and remove the battery plug.

●

Unplug the handset and connect the hourmeter to bushing “E”

●

Re-plug the battery and set the key switch ON.

While the service hours are being transferred from the controller to the hourmeter, the error code 98 is displayed for a minute. The travel function of the controller is inhibited for the duration of the data transfer (1 minute).

Printed in Germany

M1.0-0000-00021 M-4.5-2900-011

ELECTRICS Traction Controller Safety Test

●

Power up the truck.

The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.

●

Switch off the truck and remove the test lead from F1 (the other end remains connected to -BATT).

●

Attach test lead to F2 (item 3).

●

Power up the truck.

The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.

The traction controller safety test takes the form of a Pulse Monitor Trip Test (PMT).

In accordance with EU Norm PREN 1175-1 the following test must be carried out to check the fuse circuit.

The test requires a test lead of approx. 1 mm2 diameter and a 10A fuse. ●

Switch off the truck and jack it up.

●

Connect one end of the test lead to -BATT.

●

Switch off the truck, remove the test lead completely, remove the programmer.

●

Connect the other end of the test lead to VMN (item 1 in Fig. 805980_6).

●

When the truck is switched on again and the transmitter activated, the traction motor should start.

●

If the test proves unsuccessful, replace the traction controller.

●

Connect the programmer to the traction controller.

●

Power up the truck.

The programmer should display CAPACITOR CHARGE. Activating the transmitter should have no effect.

●

Switch off the truck and disconnect the test lead from VMN (the other end remains connected to -BATT).

●

Attach test lead to F1 (item 2).

Test lead 1

FU 10A 2

3

Traction Controller +BATT

F1

VMN F2

A2

F2

-BATT

F1

A1 TM Line +

PM

FU1 125A BD:1

24V BATT.

P

BD:2 805980_6 Printed in Germany

M-4.20-28000-001 M1.0-0000-00022

ELECTRICS Battery General The battery condition considerably affects the truck’s performance and behaviour. A thorough maintenance schedule will help maintain the battery’s performance and working life.

OK

Battery maintenance must only be carried out in accordance with the manufacturer’s instructions.

Operation During battery discharge the battery connector is connected to the truck electrical circuit and during battery charge it is connected to the charger.

Make sure that the battery connector is isolated when the truck is not being used and that when the truck is operational and during charging there is a fixed connection between the two connector halves.

A bad connection will cause the contacts to burn and create faulty charging and operating patterns.

Battery Replacement

Battery Removal ●

Set the wheel straight and lower the fork.

●

If the fork is raised the fork back cover will come into contact the battery lid and prevent it from being opened.

●

Power down the truck and remove the key.

●

Remove the side panel by turning the two quick release mechanisms (see picture) a quarter turn anti-clockwise.

WARNING Only use batteries with the correct dimensions, weight and specifications for this truck. ● An incorrect battery type can damage the truck.

Battery Lid

● Incorrect weight and dimensions alter the truck centre of gravity. This can cause accidents.

To replace the battery either use a battery trolley or a crane with sufficient capacity.

DANGER Risk of Accidents After installing the battery always refit the side panel and fix it securely.

Quick Release Mechanisms

Fork Back Cover

WARNING! Risk of Injury When closing the lid never hold it at the front or side edges.

M1861

Otherwise you may trap your fingers.

Printed in Germany

M1.0-0000-00023 M-4.25-2900-001

ELECTRICS ●

Place the battery cable on the battery and secure it.

●

Make sure that all battery terminals are protected with insulating caps. Attach suitable insulation if this is not the case.

Replacing the Battery with a Crane Lift the battery out of the truck as follows, using a crane with sufficient capacity and suitable lifting gear:

WARNING Risk of short circuit!

Do not touch the top side of the battery with metalic objects. ● A short circuit can result in an electrical arc which can cause severe burning. ● The battery can be damaged. ●

Unscrew the fixing mechanism (see M1859).

Fixing Mechanism

●

RT 3020

Attach a lifting sling (or a chain with a hook) to each diagonally opposite lifting eye of the battery, as indicated in the above diagram by the white arrows. Do not connect the two opposite sides of the battery with just a single lifting sling! The lifting slings must be of equal length in order to keep the battery horizontal during lifting.

M1859

WARNING Do not stand underneath a raised battery/

RT 3020

●

Completely lift the battery out of the truck.

●

Fit the new battery in the truck in the reverse order.

●

Attach the fixing mechanism (see M1859).

Printed in Germany

M-4.25-2900-002 M1.0-0000-00024

ELECTRICS Replacing the Battery with a Battery Trolley The battery is located at a height of 330 mm on the truck. The battery replacement trolley must be the same height. ●

Attach the battery replacement trolley to the fork lift truck (see diagram).

●

Pull the battery onto the battery replacement trolley.

●

Secure the battery against sliding away.

●

Fit the new battery in the truck in the reverse order.

DANGER Risk of accidents.

After fitting the battery always re-fit the side panel and attach the fixing mechanism. ● An unsecured battery can slide off the truck and result in serious damage or fatal injuries.

Attachment opening

Printed in Germany

M1.0-0000-00025 M-4.25-2900-003

ELECTRICS Charging the Battery DANGER Hydrogen is released during charging which can ignite and explode. It is a lifethreatening danger! ● Always keep the battery compartment lid open when charging a fixed battery. ● Make sure the charging area is well ventilated. ● The charging area must be free from naked flames and sparks.

CAUTION Before commissioning the charger make sure that it is suitable for the battery voltage and size.

READ and FOLLOW the instructions of the charger manufacturer and the batterie manufacturer!

The battery must be charged only according to the battery manufacturers maintenance manual!

DANGER Never travel without a side battery compartment panel or with an open battery compartment lid.

This can result in accidents.

Printed in Germany

M-4.25-2900-004 M1.0-0000-00026

ELECTRICS probably have been thermally overloaded. Thermal overloading (temperatures >160 ºC) causes the brushes to swell up.

Brushes which jam in the brush support produce intense sparking and destroy the collector.

Electric Motors General Maintenance Instructions The following instructions apply to all motors. Details relating to specific models and designs are provided in the sub-sections (traction motor, pump motor etc.).

●

The brush edges must not be cracked. Brushes with cracking along the long edge of the surface will have been damaged by a worn collector.

If information is provided in the manual, restore the collector to the specified limits. Otherwise, replace the armature in full.

●

Loose brush connections are a clear sign of motor overload. In this case inspect the collector for burning and repair or replace as necessary.

●

When fitting the brush take care to place the spring gently on the brush. If the contact is too hard the brush will be damaged.

●

Make sure that all brushes contact the armature at the same pressure.

●

New brushes must be run in with a medium load in the first hours. Never fully charge the motor straight away.

Preparation ●

●

Disconnect the battery (= EMERGENCY DISCONNECT).

Secure the truck from rolling away.

Important Maintenance Instructions ●

Remove all carbon brushes and check for wear. If one or more carbon brushes need to be replaced, replace all brushes. In addition to the carbon brushes the pressure springs must also be replaced to ensure the correct pressure.

The length of the shortest brush determines whether the brush set needs to be replaced.

Even if the minimum length has not been reached the brushes should be replaced as the remaining useful life could be much shorter than the time until the next inspection: If a brush is too short the spring will lie on the brush support. The brush sparks during operation and burns the collector with corresponding damage.

●

Blast the motor with dry compressed air only.

●

Check the armature for uneveness, burning, grooves and cracking of the multi-plate edges.

Turn the armature if necessary. A non-oily, evenly distributed layer on the brush surfaces is normal.

●

If oil or grease is found in the motor collector compartment (usually a paste consisting of oil, oil vapour, dust and carbon particles), immediately remove the cause and clean the motor thoroughly: Oil or grease burns in the brush sparks and leaves behind a highly abrasive oil ash which can very quickly destroy the collector and the brushes.

●

The brushes must be able to move freely in the brush support (without spring tension) without tilting. Never modify brushes if one or more brushes cannot move freely.

In this case replace all brushes as they will

Printed in Germany

M1.0-0000-00027 M-4.35-2900-001

ELECTRICS Traction Motor Maintenance Access to the brushes ●

Disconnect the battery

●

Prevent the truck from rolling away

Carbon Brush

Strap retainer M1865

●

Carbon brush wear limit: 13 mm

●

Refit the strap retainer.

Armature ●

The diameter of a new armature is 64 mm.

●

The armature can be oversped, however the diameter must not fall below 62.5 mm.

●

After overspeeding reduce the mica by at least 0.5 mm without changing the gap between the multiplates.

●

Carefully remove any burrs from the multi-plate edges.

Bearings M1815

●

Remove the strap retainer from the upper section of the motor.

●

Apply compressed air to the motor.

●

Remove all carbon brushes (Fig. M1865) and check them together with the armature in accordance with the instructions on page M-4.35-2900001.

●

Both ball bearings are maintenance-free. If the bearings are removed during maintenance they must be replaced. In particular, the seals (shaft seals etc.) must be replaced.

●

The bearings must be replaced after 10,000 service hours

Maintenance ●

Remove all carbon brushes (Fig. M1865) and check them together with the armature in accordance with the instructions on page M-4.35-2900001.

●

Carbon brush length, new: 20 mm

Printed in Germany

M-4.35-2900-002

ELECTRICS Maintenance

Pump Motor Maintenance

●

Remove all carbon brushes (Fig. M1865) and check with the armature in accordance with the instructions on page M4.35-2800-001.

Access to the Brushes ●

Unplug the battery connector.

●

Carbon brush length, new: 25.5 mm

●

Lever out the brush cover from the motor housing using a small screwdriver (see Fig. M1867)

●

Carbon brush wear limit:13 mm

●

Only two brush sets should be replaced in a row.

At the latest after the third brush set the motor should either be repaired or replaced with a new one.

●

Press in and snap shut the covers.

Studs to lift off the cover

M1867

Printed in Germany

M1.0-0000-00029 M-4.35-2900-003

ELECTRICS OPTION

Steering Motor Maintenance

Access to the Brushes ●

Unplug the battery connector.

●

Remove the tensioning belt from the motor.

Maintenance

Insulation

M1866

●

Remove all carbon brushes (Fig. M1866) and check with the armature in accordance with the instructions on page M4.35-2800-001.

●

Carbon brush length, new: 16 mm

●

Carbon brush wear limit:10 mm

●

Check the tensioning belt insulation for damage.

Replace insulation if damaged. Refit the tensioning belt.

Printed in Germany

M-4.35-2900-004 M1.0-0000-00030

BRAKE

Printed in Germany

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Printed in Germany

BRAKE Brake General Functional Description The drive motor contains the drive wheel brake which is in the form of a disk brake.

The assembly is shown on page M-5.0-1720-502.

The brake interlocks with the motor shaft. When the truck is de-energised the brake is applied: If the truck must be moved in this case the brake can be mechanically released by turning the two cheese head (fastening) screws.

Afterwards, always return them to their original position!

Drive motor brake fastening screws (3 off)

Test the brakes before operating the truck again.

●

Remove rotor (16) from hub (15) while taking care not to damage the toothing.

●

Measure the thickness of the rotor (16). Replace the rotor if this thickness is less than 6.0 mm.

A new rotor is 10.0 mm thick.

●

Remove the screws from their nuts.

●

Unscrew the banjo bolts (17) from the magnetic body (3 off).

Removal

●

Remove the anchor disk (14).

CAUTION

●

Thoroughly clean components.

●

Check anchor disk (14) and rotor (16) for even wear, grooves, cracks and burning. Replace worn and damaged components.

The brake is electro-magnetically released. The axial force generated by compression springs acts on the moving anchor disk. The rotor has a friction lining on both sides and also moves axially. The force acting on the anchor disk jams the rotor between the anchor disk and the friction plate. When DC voltage is applied to the coil a magnetic force acts on the anchor disk. The anchor disk is pulled against the compression springs.

The rotor is no longer jammed, i.e. the brake is released.

Do not allow the brake components to come into contact with grease or oil.

M1845

The item numbers in brackets refer to the diagram on the following page. ●

Remove the battery connector (=Emergency Disconnect).

●

Jack up the truck until the drive wheel is free.

Secure the truck to prevent it from rolling away.

●

Remove the panel.

●

Remove any brake dust.

●

Unplug the electric connection from the brake wiring (20).

●

Remove the three Allen screws.

●

Remove the magnetic body (7) from the motor (including everything connected to it).

Printed in Germany

M1.0-0000-0001 M-5.0-2900-001

BRAKE circle. ●

Screw the banjo bolts (17) with a drop of Loctite medium into the magnetic body (7) until they reach the stop.

●

Insert the screws (8) into the anchor plate so that there is a minimum gap of 1 mm between the anchor plate and the magnetic body. Secure screws (8) with nuts (9) in the anchor plate.

●

Push the rotor (16) onto the hub (15) while ensuring that the toothing is not damaged in the process.

●

Attach the pre-assembled magnetic body (7) to the motor using the Allen screws (3).

●

Restore the electrical connection (20).

Air Gap Setting The operating air gap is measured between the magnetic body and the anchor disk when the truck is braked. The air gap should be set to 0.2 mm (see Fig. M1467).

17

●

Unscrew the banjo bolts (3) until they reach the fixed position on the motor flange.

●

Torque the Allen screws (3) evenly to 9.5 Nm.

●

Check the operating air gap at several points along the length using a feeler gauge. The air gap must be even throughout.

●

To increase the air gap slightly unscrew the banjo bolts (17). To reduce the air gap screw the banjo bolts (17) into the magnetic body. Now measure again as described above.

●

When the air gap is correctly set torque the Allen screws (3) again to 9.5 Nm.

17

M0195-1

Assembly Assembly is the reverse order of disassembly. ●

If the thrust pieces (11) and springs (12) have fallen out of the magnetic body (7), insert them in the correct position: First the springs (12), followed by the thrust pieces (11).

●

Insert the spring (10) and bushing (13) in the magnetic body (7).

●

Place the anchor disk (14) in the correct position on the magnetic body: Pay attention to the scribed

Brake Moment Setting Different brake moments can be set for the first and second stages. To increase the moment of the first stage screw the adjusting ring (1) into the magnetic body.The adjustment must be done in stages, ensuring that the threadring can be secured with the lap of the locking plate (2). Start with the basic setting according Table B01-gb, Screw Depth A. To increase the moment of the second stage screw the thread ring (6).

Printed in Germany

M-5.0-2900-002 M1.0-0000-0002

BRAKE Change the brake moment with the adjusting ring (1) to fit the tolerances specified in Table B01-gb.

Brake Test ●

Bring the empty truck (no load on the forks!) to max. speed at operating temperature with a fully charged battery on a level, dry and non-skid concrete surface in a secure area.

●

Release the deadman-pedal to apply the brake.

●

Record the braking distance from the time of application of the brakes to the time the truck comes to a halt.

Secure the adjusting ring (1) with the locking plate (6).

Now repeat the brake test with maximum load. Adjust the brake moment if necessary with the thread ring (6) to the specified range (see Table B01-gb). Secure the thread ring (6) with screw (4) and washer (5) when done.

RT3010 Nominal Braking Distances and Screw Depth Model

RT3010

Capacity

2.000 kg

Screw Depth A

Inner ring = 5.7 mm Outer ring = 5.2 mm

Braking Distance (new brake)

Braking Distance (used brake)

(nominal load)

Unladen

(nominal load)

Unladen

2,00 - 2,10 m

2,00 - 2,10 m

1,90 - 2,00 m

1,90 - 2,00 m B01-GB

Inner ring

Outer ring

Fastening screw Banjo bolt Operating air gap

Tab washer Rotor thickness

M1467

De-energised brake

Printed in Germany

M1.0-0000-0003 M-5.0-2900-003

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Printed in Germany

STEERING

Printed in Germany

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Printed in Germany

STEERING Steering Operation The truck is fitted as standard with a mechanical steering system.

OPTION

Electrical power steering is available as an option.

Here, the steering motion from the steering wheel is mechanically transfered to a sensor. The electrical output signal of the sensor is processed in a control system. The control system converts the input signal from the sensor into an output signal to control the steering motor. The steering motor moves the drive unit in the respective direction via a steering chain.

The steering motion is transfered from the steering wheel via a cardan shaft to a pinion. A steering chain transfers the motion from the pinion to a second pinion and a sliding clutch to the second steering chain which in turn regulates the drive unit.

M1786

M1785 Printed in Germany

M1.0-0000-0001 M-6.1-2900-001

STEERING Lower Steering Chain Adjustment Insufficient chain tension creates play in the steering.

Check the chain for wear and damage before tensioning it and if necessary, replace the chain. To tension the chain, proceed as follows: ●

Disconnect the battery.

●

Remove the floorboard.

●

Loosen the screw (4, Fig. M1785).

● Tension the chain until you can press firmly in the middle of the visible chain section with your thumb without the chain giving way. ●

Tighten the screw (4, Fig. M1785).

Adjusting the Drive Unit Steering Chain Insufficient chain tension creates play in the steering.

Check the chain for wear and damage before tensioning and if in doubt replace the chain. To tension, proceed as follows: ●

Disconnect the battery.

●

Remove the panel.

●

Position the steering so that the chain tensioner is easily accessible.

●

The chain tensioner is on the right-hand side of the drive motor (see Fig. M1836)

●

Loosen the jam nut (A, Fig. M1836).

B

A M1836 Printed in Germany

M-6.1-2900-002 M1.0-0000-0002

STEERING Checking the Sliding Clutch

Replacing the Sliding Clutch

A sliding clutch is fitted to avoid overloading the steering mechanism. The sliding clutch opens in the event of excessive steering forces.

To ensure safety, check the opening moment of the clutch: ●

Disconnect the battery.

●

Turn the steering wheel until it reaches its stop.

●

Fit a dynamometer (measurement range 100 - 200 Nm) to the steering wheel button and pull tangentially in the direction of the stop. Maintain the tangential pulling direction until the sliding clutch opens. At this point measure and record the reading.

●

Remove the floorboard.

●

Loosen the chain tensioner (4, Fig. M1785) and remove the chains from the pinions.

●

Remove the screw (4) and disk (5) as well as disk (33).

●

Remove the retaining ring (38).

●

Lift out the sliding clutch with the pinion facing upwards.

●

Disconnect the sliding clutch from the pinion.

●

Fit the new sliding clutch in the reverse order.

Keep the sliding clutch free of grease.

M1838

●

Repeat the measurement several times in both directions of turn and calculate the mean value.

●

The opening moment should be 127 - 147 Nm.

If you do not obtain this value, replace the sliding clutch.

M1785

Printed in Germany

M1.0-0000-0003 M-6.1-2900-003

STEERING Steering Sensor Removal / Installation OPTION

12

The steering sensor is only available on trucks with electrical power steering and is fitted directly below the steering wheel. ●

Disconnect the battery.

●

Remove the steering column panel and the lower cover of the instrument panel.

●

Unscrew the housing (24, Fig. M1840).

●

Disconnect the electrical connections.

●

Loosen the grub screw (12, Fig. M1840).

●

Remove the nuts (18, Fig. M1840).

(Replace the rubber buffers (16) if they are damaged or porous).

●

Remove the sensor from the bottom.

●

Installation is the reverse order of removal.

OPTION

16

18 Disconnect the battery.

●

Unscrew the panel.

●

Disconnect the electrical connection to the microswitch (42 or 52, Fig. M1786).

●

Loosen the screws (40 or 49, Fig. M1786) and remove the limit switches.

●

Installation is the reverse order of removal.

●

Check that the drive is switched off before the gear reaches the mechanical stop on the chassis (A, Fig. M1844).

Steering Motor Removal / Installation

The steering motor is only available on trucks with electrical power steering. ●

Disconnect the battery.

●

Unscrew the panel.

●

Open the chain tensioner (39, Fig. M1786).

●

Disconnect the electrical connections to the steering motor.

●

Loosen the screw (40, Fig. M1773) and remove the pinion.

●

Remove the four screws (32, Fig. M1773).

●

Lift out the engine, paying attention to the springs (27, Fig. M1773).

●

Installation is the reverse order of removal.

M1840

●

A

M1844

Note: For steering motor maintenance refer to chapter 4.

OPTION

Limit Switch Removal / Installation

The limit switches switch off the steering motor via the steering control system whenever the maximum steering angle is reached.

Printed in Germany

M-6.1-2900-004 M1.0-0000-0004

STEERING

M1786

Printed in Germany

M1.0-0000-0005 M-6.1-2900-005

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Printed in Germany

LIFTING MECHANISM

Printed in Germany

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Printed in Germany

LIFTING MECHANISM Lifting Mechanism The lifting mechanism is self-levelling. Adjust the lifting mechanism and check the self-levelling after replacing the piston rod(s) or a fork head.

If the left and right-hand tension rods or both socket joints were replaced at the same time, check for the level compensation (see diagram M1831): ●

Raise the forks to approximately half the lifting height.

●

Raise the load rollers with a suitable lever so that the distance from ground can be measured. B= 14 mm

WARNING Before carrying out work on or underneath raised forks, make sure that the forks and the truck are wedged with wooden blocks or other sufficiently secure items.

Test All reference numbers relate to Fig. M1769-1, page M7.0-2800-002. ●

Fully lower the unladen fork. The entire lifting mechanism must be free of play and slightly tensioned. To carry out the test move the tension rod (40) longitudinally.

●

Using a feeler gauge measure between the stop nose (A) and the underside of the fork (B). There should be a gap of approx. 1 mm.

M1831

Adjusting the Stop ●

Loosen the jam nut (39) from the tension rod.

●

Loosen the screw (26) and remove the plate (36).

●

Extract the bolt (35) until the socket joint (38) is free.

●

Turn the socket joint (38) to create the required distance between the stop nose (A) and the underside of the fork (B).

●

When the required air gap has been reached, tighten the jam nut (39).

●

Do not forget the disks (37). Re-insert the bolt (35) and secure with the screw (26) and the plate (36).

Printed in Germany

M1.0-0000-0001 M-7.0-2900-001

LIFTING MECHANISM

B

A M1769-1 Printed in Germany

M-7.0-2900-002 M1.0-0000-0002

CYLINDERS

Printed in Germany

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Printed in Germany

MAINTENANCE Cylinders Piston rod

General There are two main types of hydraulic cylinder: ●

Plunger cylinders, and

●

Piston cylinders (double-acting cylinders)

Deflector Guide ring Seal

The main difference between the two types of cylinder lies in their operation as well as the sealing material design.

Guide ring

Plunger Cylinders (single-acting)

Oil

The plunger cylinder (see Fig. M1475) has only one pressurised rod surface.

The piston rod enters the cylinder via a single or several guide rings. A rod seal in the cylinder head and a dirt deflector protect the inside of the cylinder and the piston rod from external contamination.

Cylinder tube

The piston rod return movement is actuated either by the net weight of the rod or by the force acting on the piston rod from the load.

M1475

Printed in Germany

M-8.0-0000-001 1

MAINTENANCE Piston Cylinder (Double-Acting Cylinder) On a piston cylinder both sides of the piston are pressurised. The piston rod can therefore be moved in either direction by the oil flow.

The piston rod can produce different piston areas. This results in different forces and speeds occuring at a constant pressure and flow volume levels.

The rod of the piston cylinder has a piston at one end which enters the cylinder through a guide ring and whose piston seals protect the two oil-filled chambers against each other. The cylinder and piston rod are sealed on the outside by a rod seal in the cylinder head. An additional scraper ring protects the rod seal from external contamination.

When a piston cylinder is used as a single-acting cylinder it offers reduced operating pressure with the same cylinder tube inside diameter compared with the plunger cylinder, thanks to the larger piston surface. However, the operating speed is reduced at the same flow rate. The de-pressurised side of the cylinder must be bled.

Printed in Germany

M-8.0-0000-002 2

MAINTENANCE Single-Acting Cylinder

Piston Seal

Piston

Guide Ring

CylinderHead

Piston Rod Oil

Rod Seal

Cylinder Tube

Deflector Ring

Return Flow to Tank

M0822

Double-Acting Cylinder

Piston Seal

Piston

Oil

Cylinder Tube

Guide Ring

Oil

Rod Seal

O Ring

Deflector Ring

Cylinder Head

Piston Rod

M0824

Printed in Germany

M-8.0-0000-003 3

MAINTENANCE Maintenance WARNING DE-PRESSURISE ALL HYDRAULIC SYSTEM COMPONENTS BEFORE CARRYING OUT MAINTENANCE WORK. IF PRESSURISED HYDRAULIC OIL ESCAPES FROM THE SYSTEM IT CAN RESULT IN SERIOUS INJURIES. High-pressure fluids can penetrate the skin and cause severe injuries. Reduce the pressure before disconnecting the hydraulic lines.

Tighten all connections before re-pressurising the system. Keep ands and feet away from screw holes as high-pressure fluids can emerge at these points.

Use paper or cardboard to trace leaks.

Do not use your hands.

If any high-pressure fluid penetrates the skin it should be treated as an emergency even if there are no markings to the skin at first. Pain will set in later. Damage to the tissue may result.

Inspection Before carrying out maintenance closely inspect the cylinder unit by retracting and inserting the cylinder several times. ● Check the piston rod for scratches, nicks and other surface damage. ● Check deflector rings and the entire cylinder head area for individual component wear and abnormal leakage. ● If excess hydraulic oil emerges from the piston rod from at the cylinder head it may be due to a damaged rod seal. Replace the rod seal and make sure that the seal seat is clean and intact. ● Check the pivot for signs of unusual wear or damage. When servicing the cylinder also check the condition of the other parts. Replace any parts showing signs of premature wear as well as parts which are already worn or damaged. ● Minor irregularities on the cylinder tube surface or on the piston rod can be removed with an aluminium oxide cloth or a honing tool. ● When all the parts have been checked clean the cylinder components in a high-grade solvent and dry with low-pressure pressurised air.

Printed in Germany

M-8.0-0000-004 4

MAINTENANCE Seal Installation General 4

NOTE BEFORE FITTING A NEW SEAL CHECK THE SEAL GROOVE AND PISTON ROD FOR DAMAGE. FAILURE TO DO SO COULD RESULT IN FURTHER LEAKAGE AFTER THE NEW SEAL HAS BEEN FITTED.

2

Use assembly aids and tools made of soft metal or a suitable plastic without burrs or sharp edges to fit rod seals. Do not use a screwdriver or a similar tool as this could damage the seal edges.

If the seal has to be moved over sharp edges, slots or notches, use appropriate protective mechanisms.

Lift Cylinder The lift cylinder is a single acting cylinder. Lowering of the cylinder is supported by a gas pressure spring.

1

Removal Preparation

3

●

Fully lower the forks

●

Power down the truck and disconnect the battery.

●

Prepare a bowl to collect any spilled hydraulic oil.

Removal ●

Unscrew the cover plate

●

Loosen the cylinder pressure port (2, Fig. M1648) and seal the line.

M1829

●

Remove the drainage hose (2, Fig. M1829) from the elbow and seal it.

●

Remove the retaining rings (3 and 4, Fig. M1829).

●

Push the upper and lower bolts to the right until the cylinder is free.

●

Remove the cylinder and seal the hydraulic ports with dummy plugs.

M1828

Printed in Germany

M-8.6-2900-001 5

MAINTENANCE Repairing the Lift Cylinder As with all work on hydraulic components, absolute cleanliness in the operating environment is essential.

All reference numbers relate to diagram M 1768 on page M-8.6-2600-003.

Assembly ●

Assembly is the reverse order of removal.

●

The cylinder is self-bleeding. Carry out the lifting operations a few times. Check for leaks and test operation. If necessary, replenish with hydraulic oil.

Disassembly ●

Loosen the jam nut (12) and remove it together with the articulated joint (13).

●

Remove the cylinder nut (9).

●

Remove the seal (10) and deflector (11) from the cylinder nut (9) and remove the O ring (8).

●

Remove the piston (4), O ring (5) and seal (6) from the piston rod (7).

●

Pull the piston rod (7) out from the cylinder tube (1).

●

Remove the nut (2) and retaining ring (3). Do not tension the piston rod!

●

Remove the piston (4), O ring (5) and seal (6) from the piston rod (7).

Inspection ●

Clean and grease all components with suitable agents.

●

Check all components for wear and damage: - There should be no grooves on the piston rod or cylinder tube.

- Check the articulated joint eye and its new bolt for excessive play. Check the articulated joint for cracks.

If in doubt, replace the component.

Assembly ●

Do not re-use any seals marked with a * in Fig. M1768. These should always be replaced.

●

Assembly is the reverse order of disassembly.

●

Apply a thin coating of hydraulic oil to the seals before inserting them.

●

Apply a thin film of hydraulic oil to all bare metallic components before assembling them, in particular the piston rod and the inside of the cylinder tube.

Printed in Germany

M-8.6-2900-002 6

MAINTENANCE Gas Pressure Spring Removal and Assembly WARNING The gas pressure spring is pre-tensioned.

Wear eye protection and protective clothing. Take care to avoid injuries when removing and installing the spring.

1

Removal Preparation ●

Fully lower the forks

●

Power down the truck and disconnect the battery.

2

M1829 M1828

1

2

Removal ●

Unscrew the cover plate.

●

Loosen and remove the screw (2, Fig. M1829 on this page).

●

Carefully tilt the gas pressure spring out towards the front (2, Fig. M1829 on this page). The spring will expand slightly.

Assembly ●

Assembly is the reverse order of removal.

Printed in Germany

M-8.6-2900-003 7

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Printed in Germany

ELECTRICAL DIAGRAMS

Printed in Germany

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Printed in Germany

BLACK

BLUE/WHITE

RED/WHITE

VIOLET

BLACK

WHITE

BLUE

BROWN/BLACK

BROWN

RED

RED

BLACK

RED

BLUE/BLACK

YELLOW/RED

BLACK

RED/WHITE

BLUE

YELLOW

GREEN

VIOLET

WHITE

BROWN

RED/WHITE

GREY/BLACK

BLUE

BROWN

BROWN/BLACK BLACK

RED/GREEN

RED/GREEN

YELLOW

VIOLET BROWN/YELLOW

BLUE/WHITE

BLUE/BLACK

BLUE

YELLOW YELLOW/BLACK

RED/GREEN

YELLOW/RED

BLUE

BLUE

BROWN

GREY

BLACK

BROWN

BROWN

BLACK

GREY/BLACK

GREY/BLACK

YELLOW/RED

PINK

YELLOW/RED

DIAGRAMS

Control Circut

Printed in Germany

M1818_gb

M/P-DIA-2900-001 3

WHITE

GREY

BROWN/YELLOW BROWN/BLACK

YELLOW

RED/WHITE

VIOLET

BROWN/BLACK

RED

WHITE

BROWN

BLACK

BLUE

BLUE/WHITE

RED

BLACK

RED RED/WHITE

YELLOW/RED

BLACK

BLUE/BLACK

BLUE

RED/BLACK

YELLOW

GREEN

VIOLET

WHITE

BROWN

BROWN/YELLOW BLACK

RED/GREEN

RED/GREEN

GREY/BLACK WHITE/BLACK WHITE/GREEN

PINK/

BLACK

RED/WHITE

BLACK

M/P-DIA-2900-002 4 PINK

GREY/BLACK

VIOLET YELLOW/RED

YELLOW/BLACK

BROWN/YELLOW

BROWN/WHITE

YELLOW YELLOW/BLACK

RED/GREEN

YELLOW/RED

BLUE

BLUE

BROWN

GREY

BLACK

BROWN

BROWN

BLACK

GREY/BLACK

GREY/BLACK

YELLOW/RED

PINK

YELLOW/RED

BLUE/BLACK

BLUE

BLACK

DIAGRAMS

Control Circut/Steering Motor

Printed in Germany

M1856_gb

WHITE

YELLOW

GREY

BROWN

BROWN/BLACK

BLUE

BROWN/BLACK

HYDRAULIC SCHEMATIC

Printed in Germany

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Printed in Germany

HYDRAULIK SCHEMATIC

M1781 Printed in Germany

HYD-2900-001 1

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Printed in Germany

CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Telephone +49 (0)89 93 00 2 - 0 Telefax +49 (0)89 93 00 2 -175 or -133

Printed in Germany • Revision Level Order Number: 812543-999