Crown Forklift SC3000 Series Service Manual

Service Manual Wartungshandbuch Manuel de maintenance UF.p65

1

SC3000 Series 06.04.99, 10:59

TABLE OF CONTENT

Printed in Germany

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Printed in Germany

TABLE OF CONTENT Table of content Table of content ........................................................................................................................................ IDX-2230-001

MA – SAFETY Safety Symbols used in the Manual ......................................................................................................... MA-2230-001 General Maintenance and Repair Safety Notes ....................................................................................... MA-2230-001 Maintenance and Repair ...................................................................................................................... MA-2230-001 Before Leaving the Truck ..................................................................................................................... MA-2230-002 Before Carrying out Work on the Truck .............................................................................................. MA-2230-002 Before Operating the Truck ................................................................................................................. MA-2230-002 Warnings and Labels on the Truck .......................................................................................................... MA-2230-002

ITD – INTRODUCTION Introduction ............................................................................................................................................... ITD-2230-001 General .................................................................................................................................................. ITD-2230-001 Using the Manual .................................................................................................................................. ITD-2230-001 Page Numbers ...................................................................................................................................... ITD-2230-003 Operating instruction ........................................................................................................................... ITD-2230-003 Service training .................................................................................................................................... ITD-2230-003 Replacement parts orders ................................................................................................................... ITD-2230-003 Truck Data Numbering Sheet .............................................................................................................. ITD-2230-004 Battery Options .................................................................................................................................... ITD-2230-005

M1 – LUBRICATION AND ADJUSTMENT Lubrication and Adjustment .................................................................................................................. M1.0-2230-001 Access to Components ..................................................................................................................... M1.0-2230-001 Jacking up the Truck ......................................................................................................................... M1.0-2230-004 Recommended Lubricants and Oils ................................................................................................ M1.1-1710-001 Lubricants ....................................................................................................................................... M1.1-1710-001 Cold Store Trucks ........................................................................................................................... M1.1-1710-001 Driver Participation ........................................................................................................................... M1.1-1710-001 Daily Maintenance Log ...................................................................................................................... M1.1-1710-001 Inspection and Maintenance Schedule ............................................................................................ M1.2-2230-001 Torques .............................................................................................................................................. M1.9-2230-001

M2 – HYDRAULICS Hydraulic Symbols ................................................................................................................................. M2.0-0000-001 Hydraulic System ................................................................................................................................... M2.1-2230-001 General ............................................................................................................................................... M2.1-2230-001 Operational Description .................................................................................................................... M2.1-2230-003 Idle Mode ....................................................................................................................................... M2.1-2230-003 Priority Valve .................................................................................................................................. M2.1-2230-003 Steering .......................................................................................................................................... M2.1-2230-003 Lifting .............................................................................................................................................. M2.1-2230-003 Tilting .............................................................................................................................................. M2.1-2230-003 Control Valve ..................................................................................................................................... M2.4-2230-001 Main Relief Valve Setting ................................................................................................................ M2.4-2230-001 Maintenance and Repairs ............................................................................................................... M2.4-2230-001 Pump Motor ....................................................................................................................................... M2.6-2230-001 Hydraulic Pump ................................................................................................................................. M2.6-2230-001 Commissioning ............................................................................................................................... M2.6-2230-001 Bleeding ......................................................................................................................................... M2.6-2230-001 Oil Change ......................................................................................................................................... M2.6-2230-001

M3 – DRIVE UNIT Truck Drive System ................................................................................................................................ M3.0-2230-001 Gear Unit ............................................................................................................................................ M3.0-2230-001 Removal ......................................................................................................................................... M3.0-2230-001 Printed in Germany

01/99 IDX-2230-001

TABLE OF CONTENT Drive Motor ........................................................................................................................................ M3.0-2230-001 Removal ......................................................................................................................................... M3.0-2230-001 Design ................................................................................................................................................ M3.1-2230-001 Spur wheel bevel gear assembly ..................................................................................................... M3.1-2230-001 Pre-assembly of the housing with flange shaft ............................................................................... M3.1-2230-001 Bevel gear spur wheel pinion shaft pre-assembly ........................................................................... M3.1-2230-001 Spur wheel flange shaft assembly .................................................................................................. M3.1-2230-001 Bevel gear assembly ...................................................................................................................... M3.1-2230-002 Bevel pinion assembly .................................................................................................................... M3.1-2230-002 Flank tooth bearing ........................................................................................................................... M3.1-2230-003 Correcting the flank tooth bearing ................................................................................................... M3.1-2230-003 Reducing the installation path of the conical pinion ........................................................................ M3.1-2230-003 Increasing the installation path of the conical pinion ....................................................................... M3.1-2230-003 Maintenance ....................................................................................................................................... M3.1-2230-004 Adding oil ........................................................................................................................................ M3.1-2230-004 Types of oil ..................................................................................................................................... M3.1-2230-004 Oil level .......................................................................................................................................... M3.1-2230-004 Oil change ...................................................................................................................................... M3.1-2230-004

M4 – ELECTRICS Electrical System .................................................................................................................................... M4.0-2230-001 Wire Colour Codes ............................................................................................................................ M4.0-2230-001 Abbreviations .................................................................................................................................... M4.0-2230-002 Electrical Symbols ............................................................................................................................ M4.0-2230-004 Electrical Components ........................................................................................................................... M4.2-2230-001 Switch Functions ............................................................................................................................... M4.2-2230-001 Brake Switch (BRS) ....................................................................................................................... M4.2-2230-001 Encoder (ENC), Encoder Module (EM) .......................................................................................... M4.2-2230-001 Accelerator Pedal Switch (ACS, POT1) ......................................................................................... M4.2-2230-001 Direction Indicator Switch (DIS) ...................................................................................................... M4.2-2230-001 Handbrake Switch (HBS) ............................................................................................................... M4.2-2230-001 Raise Potentiometer (POT2) .......................................................................................................... M4.2-2230-001 Steering Axle Potentiometer (POT3) .............................................................................................. M4.2-2230-001 Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) .......................................................................... M4.2-2230-001 Emergency Disconnect .................................................................................................................. M4.2-2230-001 Key Switch (KYS) ........................................................................................................................... M4.2-2230-001 Fuses (FU) ..................................................................................................................................... M4.2-2230-001 Seat Switch (SES) .......................................................................................................................... M4.2-2230-002 Horn Switch (HNS) ......................................................................................................................... M4.2-2230-002 Electrical Components - Overview ................................................................................................... M4.2-2230-002 Zapimos B1S 48/700 Controller ............................................................................................................. M4.3-2230-001 General ............................................................................................................................................... M4.3-2230-001 Main Features .................................................................................................................................... M4.3-2230-001 Protective Devices ............................................................................................................................. M4.3-2230-001 Polarity Protection .......................................................................................................................... M4.3-2230-001 Wiring Errors .................................................................................................................................. M4.3-2230-001 Overheating .................................................................................................................................... M4.3-2230-001 Protection ....................................................................................................................................... M4.3-2230-001 Key Terms .......................................................................................................................................... M4.3-2230-001 Shunt or Shunt Resistor (+SH/-SH) ................................................................................................ M4.3-2230-001 Volt Motor Negative (VMN) ............................................................................................................. M4.3-2230-001 Functional Description ...................................................................................................................... M4.3-2230-002 Acceleration / Delay Rate ............................................................................................................... M4.3-2230-002 Travel Switch .................................................................................................................................. M4.3-2230-002 Travel Switch Signal Response ...................................................................................................... M4.3-2230-002 Fault Log ........................................................................................................................................ M4.3-2230-002 Fault Identification .......................................................................................................................... M4.3-2230-002 Sparkless Contactors ..................................................................................................................... M4.3-2230-002

Printed in Germany

01/99 IDX-2230-002

TABLE OF CONTENT Inversion Braking ............................................................................................................................ M4.3-2230-002 Creep Mode.................................................................................................................................... M4.3-2230-002 Slow Travel ..................................................................................................................................... M4.3-2230-002 Steering Controller ......................................................................................................................... M4.3-2230-002 45° Steering Angle .......................................................................................................................... M4.3-2230-003 MOSFET ........................................................................................................................................ M4.3-2230-003 Pedal Braking (Inversion Braking with Battery Supply Regeneration) ............................................. M4.3-2230-003 Pulse Width Modulation (PWM) ...................................................................................................... M4.3-2230-003 Ramp Start ..................................................................................................................................... M4.3-2230-003 Key Switch ..................................................................................................................................... M4.3-2230-003 Self Test ......................................................................................................................................... M4.3-2230-003 Inverse Travel Alarm ....................................................................................................................... M4.3-2230-003 Seat Switch .................................................................................................................................... M4.3-2230-003 Current Limit ................................................................................................................................... M4.3-2230-003 Overvoltage .................................................................................................................................... M4.3-2230-003 Overheating .................................................................................................................................... M4.3-2230-003 Low Voltage Reduction ................................................................................................................... M4.3-2230-003 ZAPIMOS B1S 48/700 Traction Controller Connections ................................................................. M4.3-2230-004 Programmer Connection "B" .......................................................................................................... M4.3-2230-005 Status LED "A" ............................................................................................................................... M4.3-2230-005 Status LED Diagnosis .................................................................................................................... M4.3-2230-005 Control Line Connections ................................................................................................................. M4.3-2230-006 Traction Controller .......................................................................................................................... M4.3-2230-006 ZAPIMOS B1S 48/700 Pin Layout ..................................................................................................... M4.3-2230-007 Maintenance ....................................................................................................................................... M4.3-2230-008 Cleaning the Traction Controller ..................................................................................................... M4.3-2230-008 Removing / Installing the Traction Controller ................................................................................. M4.3-2230-008 To remove ...................................................................................................................................... M4.3-2230-008 Installing the Traction Controller ..................................................................................................... M4.3-2230-009 Zapimos HP 350A Pump Controller ...................................................................................................... M4.3-2230-200 General ............................................................................................................................................... M4.3-2230-200 Protective Devices ............................................................................................................................. M4.3-2230-200 Polarity Protection .......................................................................................................................... M4.3-2230-200 Wiring Errors .................................................................................................................................. M4.3-2230-200 Overheating .................................................................................................................................... M4.3-2230-200 Protection ....................................................................................................................................... M4.3-2230-200 Key Terms .......................................................................................................................................... M4.3-2230-200 Shunt or Shunt Resistor (+SH/-SH) ................................................................................................ M4.3-2230-200 Volt Motor Negative (VMN) ............................................................................................................. M4.3-2230-200 Functional Description ...................................................................................................................... M4.3-2230-201 Acceleration / Delay Rate ............................................................................................................... M4.3-2230-201 Current Limit ................................................................................................................................... M4.3-2230-201 Fault Identification .......................................................................................................................... M4.3-2230-201 Fault Log ........................................................................................................................................ M4.3-2230-201 Hydraulic Function Switch .............................................................................................................. M4.3-2230-201 Key Switch ..................................................................................................................................... M4.3-2230-201 Lift Cut-Out ..................................................................................................................................... M4.3-2230-201 Lift Potentiometer ........................................................................................................................... M4.3-2230-201 Lift Potentiometer Response .......................................................................................................... M4.3-2230-201 Low Voltage Reduction ................................................................................................................... M4.3-2230-201 MOSFET ........................................................................................................................................ M4.3-2230-201 Overheating .................................................................................................................................... M4.3-2230-201 Overvoltage .................................................................................................................................... M4.3-2230-201 Pulse Width Modulation (PWM) ...................................................................................................... M4.3-2230-201 Seat Switch .................................................................................................................................... M4.3-2230-202 Self Test ......................................................................................................................................... M4.3-2230-202 Steer Support ................................................................................................................................. M4.3-2230-202

Printed in Germany

01/99 IDX-2230-003

TABLE OF CONTENT ZAPIMOS HP 350 A Pump Controller Connections ....................................................................... M4.3-2230-202 Programmer Connection "B" .......................................................................................................... M4.3-2230-203 Status LED "A" ............................................................................................................................... M4.3-2230-203 Status LED Diagnosis .................................................................................................................... M4.3-2230-203 ZAPIMOS HP 350 A Pin Layout ........................................................................................................ M4.3-2230-204 Maintenance ....................................................................................................................................... M4.3-2230-204 Cleaning the Pump Controller ......................................................................................................... M4.3-2230-204 Removing / Installing the Pump Controller ..................................................................................... M4.3-2230-205 To remove ...................................................................................................................................... M4.3-2230-205 Installing the Pump Controller ......................................................................................................... M4.3-2230-205 Programmer ............................................................................................................................................ M4.4-2230-001 General ............................................................................................................................................... M4.4-2230-001 Connecting the Programmer ............................................................................................................ M4.4-2230-003 Operating Menu ................................................................................................................................. M4.4-2230-003 General .......................................................................................................................................... M4.4-2230-003 Traction Controller Operating Menu ................................................................................................ M4.5-2230-001 Programmer Start Routine ................................................................................................................ M4.5-2230-002 Traction Controller Menu Functions ..................................................................................................... M4.5-2230-003 PROGRAM Menu ............................................................................................................................... M4.5-2230-004 TESTER Menu .................................................................................................................................... M4.5-2230-005 ALARMS Menu ................................................................................................................................... M4.5-2230-006 PROGRAM PEDAL Menu .................................................................................................................. M4.5-2230-007 CONFIG Menu .................................................................................................................................... M4.5-2230-008 Pump Controller Operating Menu .................................................................................................... M4.5-2230-009 Menu Functions Pump Controller ......................................................................................................... M4.5-2230-010 PROGRAM Menu ................................................................................................................................ M4.5-2230-011 TESTER Menu .................................................................................................................................... M4.5-2230-012 ALARMS Menu ................................................................................................................................... M4.5-2230-013 PROGRAM VACC Menu .................................................................................................................... M4.5-2230-014 CONFIG Menu .................................................................................................................................... M4.5-2230-015 Traction Controller Safety Test ............................................................................................................ M4.20-2230-001 Pulse Monitor Trip Test (PMT) ........................................................................................................ M4.20-2230-001 Equipment .................................................................................................................................... M4.20-2230-001 Test .............................................................................................................................................. M4.20-2230-001 PMT Safety Test Wiring ................................................................................................................... M4.20-2230-002 Battery ................................................................................................................................................... M4.25-2230-001 General ............................................................................................................................................. M4.25-2230-001 Operation ......................................................................................................................................... M4.25-2230-001 Reading the Electrolyte Level ......................................................................................................... M4.25-2230-001 Replacing the Battery ...................................................................................................................... M4.25-2230-001 Removing the Battery ..................................................................................................................... M4.25-2230-001 Charging the Battery ....................................................................................................................... M4.25-2230-001 Battery Discharge Indicator (BDI) ....................................................................................................... M4.30-2230-001 General ............................................................................................................................................. M4.30-2230-001 Adjusting the Battery Discharge Indicator .................................................................................... M4.30-2230-001 Traction / Pump Motor Maintenance ................................................................................................... M4.35-2230-001 Access .............................................................................................................................................. M4.35-2230-001

M5 – BRAKE Brake System .......................................................................................................................................... M5.0-2230-001 General ............................................................................................................................................... M5.0-2230-001 Operation ........................................................................................................................................... M5.0-2230-001 Replacing the Brake Disks and Linings ........................................................................................... M5.0-2230-002 Preparation ..................................................................................................................................... M5.0-2230-002 Brake Disk and Lining Dimensions ................................................................................................. M5.0-2230-003 Removing the Brake Disks and the Friction Plates (Fig. M0362) .................................................... M5.0-2230-004 Installation ...................................................................................................................................... M5.0-2230-004 Removing the Handbrake Cable (Fig.M0366) ................................................................................. M5.0-2230-006 Installation ...................................................................................................................................... M5.0-2230-006 Printed in Germany

01/99 IDX-2230-004

TABLE OF CONTENT Adjusting the Operating Brake and Handbrake .............................................................................. M5.0-2230-006 Preparation ..................................................................................................................................... M5.0-2230-006 Adjusting the Operating Brake Air Gap ........................................................................................... M5.0-2230-006 Operating Brake Test ........................................................................................................................ M5.0-2230-007 Handbrake Adjustment ..................................................................................................................... M5.0-2230-007

M6 – STEERING Steering ................................................................................................................................................... M6.0-2230-001 Hydraulic System .............................................................................................................................. M6.0-2230-001 Components ...................................................................................................................................... M6.0-2230-001 Removing the Steering Motor .......................................................................................................... M6.0-2230-002 Steering System Hydraulic Diagram ................................................................................................ M6.0-2230-002 Steering Axle ........................................................................................................................................... M6.1-2230-001 Design ................................................................................................................................................ M6.1-2230-001 Steering Drive Assembly .................................................................................................................. M6.1-2230-001 Wheel hub pre-assembly ................................................................................................................ M6.1-2230-001 Steering knuckle pre-assembly ...................................................................................................... M6.1-2230-001 Steering knuckle and wheel hub assembly ..................................................................................... M6.1-2230-001 Spur pinion wheel shaft pre-assembly ............................................................................................ M6.1-2230-002 Housing Pre-Assembly ................................................................................................................... M6.1-2230-002 Setting the Bearing Play ................................................................................................................. M6.1-2230-003 Cylinder Pre-Assembly ................................................................................................................... M6.1-2230-006 Fitting the Cylinders ........................................................................................................................ M6.1-2230-006 Assembling the Axle Bracket to the Steering Drive ......................................................................... M6.1-2230-006 Operational and Leak Test .............................................................................................................. M6.1-2230-006 Maintenance ....................................................................................................................................... M6.1-2230-007 General .......................................................................................................................................... M6.1-2230-007 Gear Lubricant ................................................................................................................................ M6.1-2230-007 Seals .............................................................................................................................................. M6.1-2230-007

M7 – MAST Mast ......................................................................................................................................................... M7.0-2230-001 Disassembly ...................................................................................................................................... M7.0-2230-001 Mast Roller Adjustment .................................................................................................................... M7.0-2230-001 Fork Carriage Roller Adjustment...................................................................................................... M7.0-2230-003 Mast Roller Adjustment .................................................................................................................... M7.0-2230-004 Checking the Mast Play .................................................................................................................... M7.0-2230-004 Lift Chain Test ......................................................................................................................................... M7.5-2230-001 General ............................................................................................................................................... M7.5-2230-001 Maintenance ....................................................................................................................................... M7.5-2230-001 Detailed Chain Testing ...................................................................................................................... M7.5-2230-002 Worn or Missing Plates ................................................................................................................... M7.5-2230-002 Pitting and Corrosion ...................................................................................................................... M7.5-2230-002 Protruding or Turned Chain Pins .................................................................................................... M7.5-2230-002 Freedom of Movement and Worn Edges ........................................................................................ M7.5-2230-002 Measuring the Chain Elongation ..................................................................................................... M7.5-2230-003 Chain Tension ................................................................................................................................. M7.5-2230-003 Chain Anchor and Pulleys .............................................................................................................. M7.5-2230-003 Fork Tine Test .................................................................................................................................... M7.6-2230-001 General .......................................................................................................................................... M7.6-2230-001 Fork Identification ........................................................................................................................... M7.6-2230-001 Repairs ........................................................................................................................................... M7.6-2230-001 Crack Inspection ............................................................................................................................. M7.6-2230-001 Verticality Test ................................................................................................................................ M7.6-2230-002 Fork Blade Warping ........................................................................................................................ M7.6-2230-002 Measuring the Fork Tip Width ......................................................................................................... M7.6-2230-003 Fork Tine Height Difference ............................................................................................................ M7.6-2230-003 Fork Stop ........................................................................................................................................ M7.6-2230-003 Wear ............................................................................................................................................... M7.6-2230-004 Printed in Germany

01/99 IDX-2230-005

TABLE OF CONTENT M8 – CYLINDERS Cylinders ................................................................................................................................................. M8.0-2230-001 General ............................................................................................................................................... M8.0-2230-001 Plunger Cylinders (Single-Acting Cylinders) .................................................................................. M8.0-2230-001 Piston Cylinder (Double-Acting Cylinder) ....................................................................................... M8.0-2230-002 Maintenance ....................................................................................................................................... M8.0-2230-004 Inspection .......................................................................................................................................... M8.0-2230-004 Installing the Piston Seal .................................................................................................................. M8.0-2230-005 General .......................................................................................................................................... M8.0-2230-005 Rod Seal Disassembly Tool ............................................................................................................ M8.0-2230-005 Assembly of Small Rod Seals ........................................................................................................ M8.0-2230-005 Assembly of Large Rod Seals ........................................................................................................ M8.0-2230-005

DIA – ELECTRICAL DIAGRAMS Key ............................................................................................................................................................. DIA-2230-001 Connectors .......................................................................................................................................... DIA-2230-001 Contactors ........................................................................................................................................... DIA-2230-001 Abbreviations ...................................................................................................................................... DIA-2230-001 Control Circuit .......................................................................................................................................... DIA-2230-002 Power Circuit ............................................................................................................................................ DIA-2230-003 Connectors ............................................................................................................................................... DIA-2230-004 Traction Controller .............................................................................................................................. DIA-2230-004 Pump Controller .................................................................................................................................. DIA-2230-005 Seat Switch and Steer Pot .................................................................................................................. DIA-2230-006 Control Levers ..................................................................................................................................... DIA-2230-007 B.D.I., Horn and Brake Switches ........................................................................................................ DIA-2230-008 Steer Column ....................................................................................................................................... DIA-2230-009 Star Points ................................................................................................................................................ DIA-2230-010 Panel Wiring .............................................................................................................................................. DIA-2230-011 Power Cables ............................................................................................................................................ DIA-2230-012 Part Numbers for Connectors and Looms ............................................................................................. DIA-2230-013 ZAPI Connectors ................................................................................................................................. DIA-2230-013 MOLEX Connectors ............................................................................................................................. DIA-2230-013 DEUTSCH Connectors ........................................................................................................................ DIA-2230-013 Looms .................................................................................................................................................. DIA-2230-013

HYD – HYDRAULIC SCHEMATIC Hydraulic Schematic ............................................................................................................................... HYD-2230-001

Printed in Germany

01/99 IDX-2230-006

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

l

This symbol indicates life-threatening risks

l

Failure to comply with this notice may result in severe or fatal injuries to yourself or other people.

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

l

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.

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.

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.

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

l

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

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 combustable 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.

INFORMATION Contains additional information with supplementary notes and hints.

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.

OPTION OPTION

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

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.

Printed in Germany

REV.1 10/99 MA-2230-001 1

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

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

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

l l

Before Leaving the Truck

l

Stop the truck.

l

Lower the fork carriage fully.

l

Apply the parking brake.

l l

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.

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

l l l

l

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

l

Check the safety devices.

l

Get into the driver's seat.

l

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

Printed in Germany

01/99 MA-2230-002 2

INTRODUCTION

Printed in Germany

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Printed in Germany

INTRODUCTION Introduction INFORMATION THIS BOOK IS NOT AN OPERATING MANUAL. IT IS DESIGNED FOR SPECIALIST PERSONNEL WHO HAVE BEEN TRAINED AND AUTHORISED BY CROWN FOR THE WORK DESCRIBED HEREIN. This manual therefore contains fewer and less detailed danger warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.

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.

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 page numbers in the Maintenance Section are preceeded by an M. The table on the following page shows how the manual is structured.

Printed in Germany

01/99 1 ITD-2230-001

INTRODUCTION 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

M6

Steering

M7

Mast

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic ITD001B-gb

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01/99 2 ITD-2230-002

INTRODUCTION Page Numbers The page numbers are located on the lower left and right hand margins of each page and have the following form:

M1.1-2230-001 X Identical for each language

M = Maintenance

Section is only once in the manual

Chapter

Page number

Section

Truck code

z. B. 1.2 = Inspection and Maintenance Plan

Operating instruction 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.

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

Replacement parts orders When ordering spare parts from this manual please always give the full description of the vehicle model as well as the order number. These details enable us to process your orders in an accurate, quick and reliable way.

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

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

CROWN Gabelstapler GmbH Moosacher Str. 52 D-80809 München Tel.: 089/93 00 20 Fax: 089/93 00 2-175

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01/99 3 ITD-2230-003

INTRODUCTION Truck Data Numbering Sheet 1.3

SC

T

L

–

Capacity 1.3 = 1250 kg 1.6 = 1600 kg 1.8 = 1800 kg

2

–

2

Fork Length Dash

mm

1

900

2

1000

Model designation SC = Sitdown Rider Counterbalance T = Telescopic L = Double, part free lift F = Double, full free lift T = Triple, full free lift

3

1150

4

1200

5

1220

6

600

7

800

8

1370

9

1067 ITD002-gb

Collapsed Height (mm) / Lifting Height (mm)

NOTE FOR SPECIALS USE THE ACTUAL FIGURES FOR COLLAPSED / LIFT HEIGHT AND FORK LENGTH (SEE TABLES ITD002-GB AND ITD.003-GB).

Example: Truck with data 1.3SCTL-2-2 designates

l l l

Capacity 1250 kg Sitdown Rider Counterbalance Telescopic double part free lift mast

l

Collapsed height 1970 mm

l

Lift height 2880 mm

l

Fork length 1000 mm

Dash

SC TL / SC TF

1

1750 / 2460

2

1970 / 2880

3

2165 / 3270

4

2315 / 3570

5

2465 / 3870

6

2665 / 4270

7

2840 / 4620

8

3035 / 5010

9

3340 / 5620

10

3485 / 5910

Dash

SC TT

1

1760 / 3670

2

1970 / 4300

3

2165 / 4885

4

2315 / 5335

5

2465 / 5785

6

2665 / 6385

7

2840 / 6910

8

3035 / 7495

9

1993 / 4368

10

2044 / 4521

11

2145 / 4826

12

2569 / 60913 ITD003-gb Printed in Germany

01/99 4 ITD-2230-004

INTRODUCTION Battery Options Model

Option

Ah

Option 1

300 360

(mm)

DIN 43531 A (mm)

Type

418 x 835 x 627 418 x 835 x 627

SD SHD

Option 1h

360 465

418 x 835 x 784 418 x 835 x 784

SD SHD

Option 2

400 480

526 x 835 x 627 526 x 835 x 627

SD SHD

Option 2h

480 620

526 x 835 x 784 526 x 835 x 784

SD SHD

Option 2

400 480

526 x 835 x 627 526 x 835 x 627

SD SHD

Option 2h

480 620

526 x 835 x 784 526 x 835 x 784

SD SHD

Option 3

500 600

634 x 835 x 627 634 x 835 x 627

SD SHD

Option 3h

600 775

634 x 835 x 784 634 x 835 x 784

SD SHD

Option 3

500 600

634 x 835 x 627 634 x 835 x 627

SD SHD

Option 3h

600 775

634 x 835 x 784 634 x 835 x 784

SD SHD

1187

SC3013 1295

1295

SC3016 1403

SC3018

1403

ITD004-gb

NOTE ALWAYS SPECIFY MODEL NO. WHEN ORDERING SPARE PARTS. Spare parts for model SC3013 option 2/2h correspond to model SC3016 option 2/2h.

Spare parts for model SC3016 option 3/3h correspond to model SC3018 option 3/3h.

Printed in Germany

01/99 5 ITD-2230-005

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Printed in Germany

LUBRICATION AND ADJUSTMENT

Printed in Germany

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany

MAINTENANCE Lubrication and Adjustment Access to Components In the course of regular maintenance the contactor panel, drive unit, hydraulic system and electrical components in the chassis can be reached by removing or opening the panels.

Fig. C: LH and RH panels (LH illustrated)

l

Lift the side panel out of the attachment

Fig. D: Steering column front panel Fig. B: Battery compartment lid Provides access to: Provides access to:

l l l l

l

Battery

l l

Contactor panel including impulse controls Steering axle and potentiometer Hydraulic motor and pump

CAUTION WHEN THE BATTERY COMPARTMENT LID IS OPENED IT CAN TIP OVER IF THE LID CENTRE OF GRAVITY MOVES OVER THE PIVOT POINT / ATTACHMENT POINT OF THE LID.

Key switch Direction switches Encoder

l

Wiring

l

Steering unit and distributor block

l

Hydraulic lines

To remove:

l

Loosen two hex. socket screws

l

Lift panel slightly and lever out at the bottom

Access: Pull the handle on the front of the lid and open the battery compartment lid.

Fig. E: Inner dashboard Provides access to:

Figs. B1 and B2 Provides access to:

l l

Hydraulic lines (Fig. B1) on the right hand side of the battery compartment.

Cable duct (Fig. B2) on the left hand side of the battery compartment.

Lift off the side panel

l

Remove the battery

Handbrake

l

Battery display

l

Wiring

l

Hydraulic lines

To remove:

Access:

l

l

l

Loosen 6 hex. socket screws

l

Remove panel

Printed in Germany

01/99 1 M1.0-2230-001

MAINTENANCE Fig. F: Valve and Control Handle Panel

Fig. G: LH and RH base plate (RH illustrated)

Provides access to:

Provides access to:

l l l

l

Valve block

l l

Switch, potentiometer Control handle mechanism

To remove:

l

Remove the base plate

l

Loosen the two hex. socket screws at the rear upper section.

l l

Remove the single hex. socket screw at the front below the base plate

Brake pedal and mechanism Brake Accelerator pedal / travel switch and potentiometer

l

Tilt cylinder attachment (frame)

l

Valve block hydraulic lines

l

Wiring

l

LH and RH drive motor

To remove: Lift up the panel

l l

Loosen the single hex. socket screw on the RH base plate Lift out the LH and RH base plates.

Printed in Germany

01/99 2 M1.0-2230-002

MAINTENANCE

B1

M0258

B

M0251

B2

M0252

D

E A

G

M0257

M0254b

M0116

M0253

F

M0256

C

M0259

Printed in Germany

01/99 3 M1.0-2230-003

MAINTENANCE Jacking up the Truck WARNING ALWAYS SUPPORT A RAISED TRUCK WITH WOODEN BLOCKS OR OTHER APPROPRIATE EQUIPMENT TO RELIEVE THE JACK. Apply the jack as shown in Fig. M0262. The same procedure is used for raising the front section of the truck.

M0262

Jack

Wooden blocks

Printed in Germany

01/99 4 M1.0-2230-004

MAINTENANCE Recommended Lubricants and Oils Lubricants Only high grade lubricants and oils should be used. These can be obtained from any oil manufacturer. Those listed on the following page 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 M1.1-1710-002). 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.

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 M1.2-2230-002.

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

Printed in Germany

01/99 5 M1.1-1710-001

MAINTENANCE Lubricants and Oil Recommendations Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Type

Grease (multi purpose)

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

SEA40

Dow Corning

063002-022

M

C

W01-gb

Printed in Germany

01/99 6 M1.1-1710-002

MAINTENANCE Inspection and Maintenance Schedule The following inspection and maintenance schedule assumes single-shift operation under normal operating conditions. The length of maintenance intervals will however depend on the particular operating conditions.

In dusty or otherwise extreme environments, including cold stores, the specified maintenance intervals should be reduced. The exact periods should be established after consultation with Crown service personnel.

When performing maintenance work always check for wear, corrosion and damage and ensure that the parts are operating correctly and are secure. If in doubt, replace the component.

Larger maintenance schedule should always include the work of the next smallest maintenance schedule.

Printed in Germany

01/99 7 M1.2-2230-001

MAINTENANCE Daily or every 8 service hours Item

Component

Action

1

Battery

Re-charge discharged batteries. Check electrolyte level and replenish if necessary.

2

Battery plug

Check operation.

3

Seat belt

Check operation; check suppor t and belt for wear, replace if necessary.

4

Horn

Check operation.

5

Accelerator pedal

Check operation.

6

Direction switch

Check operation.

7

Handbrake

Check operation.

8

Hydraulic system control handle

Check operation.

9

Hydraulic lines and screws

Check for leakage, tighten screws if necessary.

10

Brake pedal

Check operation.

11

Steering wheel

Check operation.

12

Wheels

Check tyres for wear, nails, metal splints etc.

13

Hoist frame chain

Check for wear, even chain tension on left and right hand sides.

14

Free lift cylinder chain

Check operation.

15

Chain attachment

Inspect condition.

16

Forks, fork carriage

Check for visible signs of cracks, wear and damage.

Load guard

Ensure it is secure.

Labels and stickers (see section 10.9 of par ts manual)

Check that they are all present, clean and legible. Clean or replace if necessary.

WARTUNG02gb Printed in Germany

01/99 8 M1.2-2230-002

MAINTENANCE

6

7

4

13

5

11 15 15

M0323

10

8 9 M0322

14

3

2 1 15

16 M0324

M0321

4

12

Printed in Germany

01/99 9 M1.2-2230-003

MAINTENANCE Monthly or ever 100 service hours Item

Maintenance Manual Page

Component

Action

1

Battery

Check acid density, if necessary replenish with destilled water; check voltage of each cell, if necessary compensate; clean and grease battery terminals.

2

Contactors

Clean, check, replace if necessary.

3

Electrical wiring and equipment

Check wiring, switches and connections are secure, check insulation for damage.

4

Lift cylinder

Check for leaks; check piston rod for damage.

5

Lift chains and chain supports

Check for wear.

6

Hydraulic reservoir

Check oil level, replenish if necessary. Mast and fork must be lowered. Clean bleed cap.

7

Wheels

Check wheel nuts are correctly torqued.

8

Accelerator pedal

Check for wear; grease pivot point.

9

Brake pedal and brake mechanism

Check for wear; grease pivot point.

10

Relief valve

Check operation.

M7.5-2230-001

WARTUNG03gb

Printed in Germany

01/99 10 M1.2-2230-004

MAINTENANCE

5

4

2, 3 1

M0321

7

9 8 3

3

6 10

M0326

Printed in Germany

01/99 11 M1.2-2230-005

MAINTENANCE + Every three months or 250 service hours ++ Every six months or 500 service hours Item

Maintenance Manual Page

Component

Action

+1

Battery connector

Clean contacts, check contact springs.

+2

Pump and drive motor carbon brushes

Clean, apply pressurised air, check for wear and freedom of movement, replace if necessary.

+3

Mast end stops

Check for wear.

+4

Hoist column

Clean bearings and contact surfaces, check for wear, replace if necessary, grease.

+5

Battery compartment lid hinge

Check operation, lubricate

+6

Gear unit

First oil change; subsequent changes after every 2000 service hours.

Ensure bolts are tight.

++ 7

Hydraulic cylinder

Ensure it is securely fitted.

++ 8

Brakes

Blast off abrasion with pressurised air, check brake lining M5.0-2230-001 and brake springs.

++ 9

Battery

Check truck and battery insulation resistance.

WARTUNG04gb

Printed in Germany

01/99 12 M1.2-2230-006

MAINTENANCE

3

5

7 1 9

4

2 6

M0321

8

M0326

8

2

Printed in Germany

01/99 13 M1.2-2230-007

MAINTENANCE + Annually or every 1000 service hours ++ Every two years or every 2000 service hours Item

Maintenance Manual Page

Component

Action

+1

Battery connector

Clean contacts, check contact springs

+2

Pump and drive motor carbon brushes

Clean, apply pressurised air, check for wear and freedom of movement, replace if necessary.

+3

Mast end stops

Check for wear.

+4

Mast column

Clean bearings and contact surfaces, check for wear, replace if necessary, grease.

+5

Battery compartment lid hinge

Check operation, lubricate.

+6

Steer unit

Check steering column teeth on steer unit for wear.

+7

Forks, fork carriage

Check for visible cracks, damage and wear.

+8

Hydraulic cylinder

Ensure it is securely attached.

+9

Brakes

Blast out abrasion with pressurised air, check brake lining and brake springs.

++ 10

Battery

Check truck and battery insulation resistance.

++ 11

Seat runners

Check for wear, grease.

++ 12

Gear unit

Change oil (first oil change after 250 service hours).

Check bolts are tight.

++ 13

Steering axle

Check bolts are tight.

UVV testing

Carry out UVV testing at prescribed intervals.

PMT test

Check fuse circuitry and traction control (see page M4.20-2230-001).

M7.8-2230-001

WARTUNG05gb

Printed in Germany

01/99 14 M1.2-2230-008

MAINTENANCE

3

5

8 11

13 10

6

1

4 7

2

12

M0321

9

M0326

9

2

Printed in Germany

01/99 15 M1.2-2230-009

MAINTENANCE Lubrication Points / Intervals Pos.

Component

Type

QTY

100 Hours

250 Hours

500 Hours

1000 Hours

2000 Hours

1

Fork locking pin

B

A/R

X

2

Hydraulic reservoir check

D

A/R

X

3

Hydraulic oil change

D

A/R

4

Accelerator pedal pivot

B

A/ R

X

5

Accelerator linkage

B

A/R

X

6

Potentiometer pivot

B

A/R

X

7

Handbrake cable

C

A/ R

X

8

Handbrake pivot

B

A/ R

X

9

Handbrake ratchet

B

A/R

X

10

Battery comp. lid hinge

C

A/ R

X

11

Battery latch

C

A/R

X

12

Locking ramp pivot point

C

A/ R

X

13

Steer column adjustment

C

A/R

X

14

Tilt pivots

B

A/ R

X

15

Mast pivot

B

A/ R

X

16

Mast channels

B

A/ R

X

17

Mast column and fork carriage rollers

B

A/ R

X

18

Chain main lift, Chain freelift cylinder

G

A/R

X

19

Column pulleys (Nylon)

H

A/ R

X

20

Fork slide

B

A/ R

X

21

Brake main pivot

B

A/ R

X

22

Brake pedal pivot

B

A/R

X

23

Motor to gearbox spline

M

A/R

X

24

Pump motor to pump spline

M

A/R

X

25

Orbital steer unit spline

B

A/ R

X

26

Seat runners

B

A/ R

X

27

Gearbox oil change

A

A/R

X

first change after 250 hours of operation

X W06-gb

Printed in Germany

01/99 16 M1.3-2230-001

MAINTENANCE 19

25

13

14 M0101

15

26

11 M0115 M0107

16

24

M0109

8

M0251

9

7

10

M0113

12

17

18

20

21

M0116 M0103

2, 3

M0114

1 M0104

5

6

21

23 4 14

22 M0111

M0112

27

M0108

Printed in Germany

01/99 17 M1.3-2230-002

MAINTENANCE Torques The screw and nut grades shown below are used in the manufacture of Crown trucks. The information on the page is designed to help determine the correct torque for maintenance work.

NOTE THE TORQUES LISTED IN THE MAINTENANCE SECTION ALWAYS SUPERSEDE THOSE SHOWN ON THIS PAGE.

Screw Grade Marking

Nut Grade Marking

8 .8 8 .8 8

1 2 .9

1 2 .9 WARTUNG 07gb

Printed in Germany

01/99 18 M1.9-2230-001

MAINTENANCE Standard Screws and Nuts Strength

8 and 8.8

10 and 10.9

Thread Size

12 and 12.9

Torque (Nm)

M5 x 0.8

5-6

7-8

8 - 10

M6 x 1

8 - 10

12 - 14

14 - 16

M8 x 1.25

20 - 25

30 - 35

34 - 40

M10 x 1.5

40 - 45

60 - 65

70 - 75

M12 x 1.75

70 - 80

100 - 110

115 - 130

M16 x 2

170 - 190

240 - 270

280 - 320

M20 x 2.5

340 - 380

450 - 500

550 - 600

M24 x 3

580 - 650

800 - 900

900 - 1050

M30 x 3.5

1150 - 1300

1600 - 1800

1850 - 2100 WARTUNG 08gb

Umbrako Screws and Nuts Grade

10 and 10.8

Thread Size

12 and 12.9

Torque (Nm)

M5 x 0.8

8

11

M6 x 1

14

19

M8 x 1.25

33

45

M10 x 1.5

63

86

M12 x 1.75

111

152

M16 x 2

270

372

M20 x 2.5

521

717 WARTUNG 09gb

Printed in Germany

01/99 19 M1.9-2230-002

MAINTENANCE Torques Assembly

Torque (Nm)

Page / Item

Accelerator pedal assembly attachment to chassis

20 - 25

4.6-2230-025, item 2

Brake activation locknut

30

5.6-2230-025, item 29

Brake assembly locknut

40 - 45

5.6-2230-025, item 12

Chassis counterweight attachment

580 - 650

1.0-2230-027, item 3

8 - 10

6.7-2230-029, item 50

60

3.3-2230-001, item 29

Steering column direction switch assembly

Traction motor - gear unit attachment

Storage compar tment - driver seat attachment

8 - 10

Not present

Brake pedal assembly - chassis attachment

40 - 4 5

5.5-2230-025, item 2

330

3.1-2230-025, item 44

Brake setting counternut

40 - 4 5

5.6-2230-025, item 24

Bearing block / mast locknuts

550 - 600

3.1-2230-025, item 43

Transmission - chassis attachment

Hydraulic reser voir - chassis attachment

6

2.3-2230-025, not present

Pump motor - chassis retaining plate

46

2.13-2230-025, item 5

Steering axle - chassis attachment

330

6.6-2230-025, item 36

Steering sensor - steering column attachment

40 - 45

6.7-2230-029, item 27

Steering wheel attachment

40 - 45

6.7-2230-025,not present

Tilt cylinder - mast/chassis attachment

13

7.5-2230-025, item 31 1.0-2230-025, item 29

Wheel nuts

135

1.5-2230-001contd.

WARTUNG 10gb Printed in Germany

01/99 20 M1.9-2230-003

MAINTENANCE Torques (contd.)

Torque (Nm)

Page / Item

Overhead guard - chassis attachment, front

86

1.0-2230-025, item 23

Overhead guard - chassis attachment, rear

152

1.0-2230-025, item 22

Nuts for contactor cable connections

20

4.4-2230-001 contd.

Traction motor cable connections

13

3.3-2230-001, item 10

Pump motor cable connections

13

2.13-2230-001, item 10

Potentiometer attachment

1

2.2-2230-125, item 12

Microswitch attachment

0.5

-

Assembly

WARTUNG 11gb

Printed in Germany

01/99 21 M1.9-2230-004

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Printed in Germany

HYDRAULICS

Printed in Germany

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Printed in Germany

MAINTENANCE Hydraulic Symbols

Vented reservoir with lines above the fluid level

M

Electric motor with unidirectional turn and speed

M

Electric motor with unidirectional turn and variable speed

Vented reservoir with lines below the fluid level

Filter or strainer

Hydraulic pump with fixed displacement and single direction of turn

Hydraulic line with full flow (tubing or hose)

Pilot or drain line or drainage with limited flow

Hydraulic motor, bi-directional

Lines crossing; not connected

Pressure guage

Lines crossing and connected

Thermometer Plugged port (test port)

Accumulator gas charged diaphragm type Flow meter

M3559

Printed in Germany

01/99 1 M2.0-0000-001

MAINTENANCE

Pressure switch

Manual actuator

Double-acting cylinder; unequal area

Spring, (bias to normal de-energised position)

Double-acting cylinder; equal area Solenoid single coil or winding

Single-acting cylinder with spring returned (rod end vented) Hydraulic pilot operated

Single-acting cylinder ram type Solenoid valve, pilot operated

Single-acting cylinder, with cushion

Dual solenoid

Assembly housing, manifold block Proportional solenoid

Manual lever actuator

Pilot check valve (pilot to open)

M3560 Printed in Germany

01/99 2 M2.0-0000-002

MAINTENANCE

Throttle, fixed

Shuttle valve

Throttle, adjustable

Single counterbalance valve assembly in manifold Pressure-compensated flow control, fixed

Pressure-compensated flow control with reverse flow bypass; fixed.

Flow divider/combiner

Velocity fuse Bypass flow control with controlled flow, pressure-regulated

Relief valve, fixed setting

Shut-off valve, manual

P T

Relief valve, adjustable

T P

Check valve

Torque generator

L R

Hydraulic steer unit

M3561 Printed in Germany

01/99 3 M2.0-0000-003

MAINTENANCE

2/2 way valve (two way, two switch positions)

Valve block with 3 operating units

3/2 way valve (three way, two switch positions)

4/2 way valve (four way, two switch positions)

4/3 way valve (four way, two switch positions)

4/3 way valve (four way, two switch positions); manual activation and spring centered

3/2 way valve (three way, two switch positions); Spring bias solenoid control

M3562

Printed in Germany

01/99 4 M2.0-0000-004

MAINTENANCE Hydraulic System General A low emission motor pump assembly supplies oil from a 37 litre oil tank via an exchangable suction filter (126 µ).

The speed of the 10.5 kW motor is governed by a MOSFET controller. This controller is pre-programmed with set speed ranges which are used depending on the respective hydraulic operation. If two or more operations are being performed at the same time, the higher controller setting has priority over the lower setting.

The single motor pump assembly can operate up to five functions (lifting, reach, tilt, sideshift and an auxiliary function) and, if necessary, supply the hydrostatic steering system with the required flow.

The directional control valve has either three (standard) or four functions and is manually operated from the operator platform via a control lever and actuating linkage. A main relief valve in the input section limits system pressure to 210 bar.

The input section also contains a priority valve which diverts the oil flow in favour of the steering function when the steering and other lifting functions are activated simultaneously.

All system oil is filtered through an oil filter (10 µ) with an diffuser integrated in the tank return line.

Printed in Germany

01/99 5 M2.1-2230-001

6 M2.1-2230-002

R A C K A N D P IN IO N C Y L .

M A IN L IF T C Y L .

T IL T C Y L .

R L

H O S E B U R S T V A L V E

7 9 3 6 8 9 P R E S S U R E R E G U L A T O R S e t to 1 6 0 b a r

F L O W C O N T R O L V A L V E L O W E R IN G

O R B IT A L S T E E R IN G U N IT D Y N A M IC L S C L O S E D C E N T R E N O N R E A C T IO N

S ID E S H IF T L S

01/99 P

C F

1 A

P R IO R IT Y V A L V E D Y N A M IC L S

L IF T

L S T

2 A

1 B

2 B

3 A

3 B

S T E E R R V 7 0 B A R

O P T O E N C O D E R T

M A IN R V 2 1 0 B A R

M O T O R F IL T E R 792341_c_gb

Printed in Germany

P U M P S T R A IN E R

T IL T

A U X I

MAINTENANCE

P

MAINTENANCE Lifting

Operational Description Idle Mode If the operator is seated and the key switch is on, the pump motor will run at idle speed. Oil flows from the tank via a suction filter to the hydraulic pump and from there into the control valve.

Provided no travel or lifting operation is being performed, the priority valve will allow flow through. The oil can flow through the flow channel into the tank channel and from there via a return filter back to the tank.

Priority Valve For safety reasons the priority valve can give priority to steering over other hydraulic functions in the event of several functions being activated simultaneously.

Steering When the steering wheel is applied the steer requirement optical sensor is activated and sends a signal to the controller via the interface module. The controller in turn activates the pump motor at a set pump speed. The steering unit also rotates and supplies oil to the steering motor which simultaneously allows oil on the low pressure side to return to the tank.

The steering unit load pressure controls the priority valve.

The steering function always has priority irrespective of the number of hydraulic operations being performed.

When the rear wheels are turned as far as the mechanical end stops, the oil in the LS line can flow down via the pressure relief valve which is set to 70 bar. This repositions the priority valve to allow for lifting.

If the operator is seated and the key switch is on, the pump motor will run at idle speed. Oil flows from the tank via a suction filter to the hydraulic pump and from there into the control valve.

If no load pressure from the steering unit is applied to the priority valve the pump pressure will move the priority valve to the lifting, tilt and auxiliary functions position.

For lifting the oil flows through a lowering brake valve which is activated by the pump pressure and into the lift cylinder.

If the required lift height is not obtained, the lowering brake valve returns to its resting position. The oil then stays at the slide rod in the spool valve and thus prevents the lift cylinder from lowering.

For lowering the slide rod moves in the opposite direction.

To achieve better control of the lowering speed the oil returns to the reservoir via a choke in the lowering brake valve.

Tilting When the mast is tilted forward the oil flows on the piston side directly into the tilt cylinders. On the return side a load holding valve set to 160 bar must be activated to ensure that the oil can return to the reservoir via the spool valve.

When the mast is tilted backward the oil flows via a nonreturn valve in the load holding valve to the piston side of the tilt cylinders. On the return side the oil flow directly to the spool valve and back to the reservoir.

The load holding valve prevents the mast from tilting forward when laden.

If the pump is not operational, the steering unit can be manually rotated to drive the steering motor in an emergency.

Printed in Germany

01/99 7 M2.1-2230-003

MAINTENANCE Maintenance and Repairs

Control Valve The control valve consists of an input unit, three (standard) or four operating units and an end unit.

The input unit comprises the main relief valve for limiting the system pressure (set to 210 bar), the priority valve for preferential supply to the steering system when several hydraulic functions are activated and the relief valve for the steering (set to 70 bar).

Operational faults with the control valve are often due to contamination or other foreign bodies on the moving parts of the valves.

WARNING

Main Relief Valve Setting

l

De-pressurise all components before carrying out maintenance work on the hydraulic system.

l High pressure hydraulic oil can cause

Fit the pressure gauge in pressure return line.

serious injuries.

l

l Whenever a high pressure fluid enters the

l

l Secure all connections before re-applying

l

l Use absorbent paper to track leaks, never

Remove the domed cap nut from the main relief valve and loosen the counter nut from the pressure adjusting screw.

Slowly apply the hydraulic function until it reaches the stop position.To exceed this position, set the required system pressure with the adjusting screw.

Refit the counter nut and check the system pressure again. Adjust if necessary.

l

skin it must be treated as an emergency, even if the skin initially shows no reaction.

Physically effects will set in later. system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge. use your hands!

Refit and tighten the domed cap nut.

Pilot Valve Troubleshooting Problem

Possible Cause

Action

No build up of pressure

- Valve mechanism jammed - Contamination under the valve seat

Remove the valve and check for contamination. Ensure components' free play.

Incorrect pressure reading

- Valve cone seat damaged - Valve mechanism jammed

- Replace valve.

- Clean and ensure valve mechanism's free play.

Pressure cannot be set correctly.

- Adjusting screw or counter nut loose - Valve wear

- Set pressure to correct reading (see description) and tighten counter nut.

- Replace valve.

Leakage

- Valve seat damaged - O rings damaged or worn - Dirt particles clogging valve

- Replace valve.

- Replace O rings.

- Remove and clean valve.

WARTUNG20gb

Printed in Germany

01/99 8 M2.4-2230-001

MAINTENANCE For service and inspection purposes the valve cartridges can be unscrewed and checked for damage, leakage etc.

Proceed as follows:

l

Thoroughly clean the operating area, remove any contamination and oil.

l

Unscrew the valve cartridge and inspect for signs of foreign bodies, scratches or other damage.

l

Remove any valve housing and check for foreign bodies and damage.

l

Check all moving parts of the valve mechanism. Friction should only occur on the sealing areas.

l

Finally, clean parts thoroughly and lubricate before assembly.

Table WARTUNG20gb describes some of the most common faults.

Printed in Germany

01/99 9 M2.4-2230-002

MAINTENANCE Bleeding

Pump Motor

l

The pump motor carbon brushes and attachment must be checked in accordance with the maintenance schedule intervals.

To ensure maximum operating safety and minimum wear it is advisable to fill the pump housing with oil before starting.

l

l

Remove the strap retainer in the upper motor section.

If necessary, remove the foaming oil at zero pressure circulation by carefully opening the pressure flange (taking care to protect yourself against spray).

When bubble-free oil flows out refit the flange.

l

Apply pressurised air to the carbon brushes and check individually for wear. Replace if less than 15 mm.

l

Check attachment. An evenly distributed layer on the brush surfaces is normal.

Oil Change The hydraulic tank (capacity 37 litres) does not contain a drain plug. When changing the oil, the used oil must therefore be suctioned off via a suction pump.

Hydraulic Pump NOTE THE HYDRAULIC PUMP SHOULD NOT BE REPAIRED ON SITE. FOR THIS REASON IT IS SUPPLIED AS A COMPLETE ASSEMBLY ONLY. When commissioning a new or repaired hydraulic pump proceed as follows:

Commissioning

l

Check that the assembly is clean and correctly assembled.

l

When adding hydraulic oil, you must use a filter with the prescribed minimum retention rate (10 µ).

l

Note the arrow direction.

l

Start the pump unladen and leave it to operate for a few seconds without pressure to allow for sufficient lubrication.

l

Never run a pump without oil.

l

If after 20 seconds the oil is still not free of bubbles, check the unit again.

l

When operating temperature has been reached check the pipes are not leaking.

Printed in Germany

01/99 10 M2.6-2230-001

DRIVE UNIT

Printed in Germany

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Printed in Germany

MAINTENANCE l

Lift out the gear unit from the side. This will also faciliate re-assembly.

Truck Drive System Gear Unit

Drive Motor

NOTE

The drive motor carbon brushes and attachment must be checked at intervals specified in the maintenance schedule.

THE DRIVE TRANSMISSION UNIT MUST ONLY BE SERVICED BY AUTHORISED AND TRAINED PERSONNEL.

l

Remove the strap retainer in the upper motor section.

THE MANUFACTURER'S WARRANTY IS INVALIDATED IF INCORRECT MAINTENANCE IS PERFORMED ON THE TRANSMISSION SYSTEM.

l

Apply pressurised air to the carbon brushes and check individually for wear. Replace if less than 20 mm.

Removal

l

Check attachment. An evenly distributed layer on the brush surfaces is normal.

Prior to removal prepare the work area and make sure any oil spillage can be suitably collected.

Removal

l

Unscrew the two pressure lines and the pressure hose from the distributor block.

NOTE

l

DO NOT TEST THE DISASSEMBLED MOTOR ON THE TEST BENCH AS THE MOTOR COULD BE DAMAGED WITHOUT THE LOWER SUPPORT.

Secure the upper section of the mast with suitable support equipment.

l l

Disassemble the tilt cylinder from the mast.

To remove the drive motor:

Remove the bearing blocks in the lower section of the mast from the gear unit.

l

l

l

Disconnect the power cable.

Remove the four mounting screws in the lower section.

Lift up the mast.

l

Lift out the motor from the top.

l

When re-fitting, lubricate the spline between the motor and gear unit with grease (Crown-P/N 063002-022).

M0040

l

Remove the stabiliser between the drive units.

Remove the brake linkage (Fig. M0040).

l

Remove the wheel.

l

Support the gear unit with a wooden block.

Loosen the mounting screws.

l

Push the gear unit towards the centre of the truck and loosen the two mounting studs.

Printed in Germany

01/99 M3.0-2230-001 1

MAINTENANCE Design Each of the drive wheels of the SC3000 has its own drive transmission system, designed as a spur wheel bevel gear.

Bevel gear spur wheel pinion shaft preassembly

l

Before placing the spur wheel (item 15) on the flange shaft, space must be created in the housing for the conical roller bearing (item 23).

Assemble the spur wheel pinion shaft and the conical roller bearing pair (items 23, 27) in the housing and set the vacuum resistance using the shims (item 22, 29) to 0.4 - 0.6 Nm.

Power transmission from the motor is via a pinion shaft and a bevel gear which transmits the velocity to a spur wheel via a spur wheel pinion shaft and thus to the flange shaft which is fixed to the spur wheel.

l

The reference numbers contained in the following assembly instructions refer to the exploded diagram in section 3.1 of the parts manual.

Now assemble the bevel gear (item 10) together with the spur wheel pinion shaft (item 26).

Spur wheel flange shaft assembly

Spur wheel bevel gear assembly Pre-assembly of the housing with flange shaft

l

Heat the spur wheel (item 15) to approx. 135°C and place it on the flange shaft (item 1) (fig. M1272).

l

Thorougly clean the housing (item 3) with a cold cleaning solution. Assemble the conical roller bearing (item 14) and the rotary shaft seal (item 13) in the housing neck (Fig. M1268).

l

Press the wheel nuts (item 2) into the holes in the shaft flange using a hydraulic tool.

M1272

l

Now assemble the previously cleaned housing lid (item 3), fitted with shim (item 12), the outer ring of the conical roller bearing (item 11) and the hex. socket screws (items 35, 36) with the lock washers (item 34) positioned underneath.

M1268

l

Now press the flange shaft into the housing transmission neck.

Printed in Germany

01/99 2 M3.1-2230-001

MAINTENANCE l

Centre both housing halves using the cylinder pins (item 37).

Bevel pinion assembly

l

To complete the assembly of the spur wheel flange shaft, assemble the following components in the following order:

l

Press the conical roller bearings (items 9, 11) onto the bevel pinion (item 10) (Figs. M1270, M1271).

l

The ground supporting ring (item 16), the conical roller bearing (item 17), the washer (item 18) and the hex. socket screws (item 19, 45 Nm torque, secure with Euro-Lock A-24-20 or similar) for securing the flange shaft tensioned on the block.

l

The bearing pre-tension of the flange shaft should be 5.0 - 6.5 Nm and can be adjusted using the shim (item 16).

l

Insert the snap ring (item 20) in the housing groove and seal the transmission in this area via the filler cap (item 21).

Bevel gear assembly

l

To complete the assembly of the bevel gear insert the outer ring of the conical roller bearing (item 27) in the respective lid section.

l

Now place the bearing race (item 28, secure with Euro-Lock A-24-20 or similar) followed by the shims (items 22, 29) previously obtained when setting the bearing pre-tensioning on the spur wheel pinion shaft.

l

Now insert the shaft seal ring (item 30) in the section provided in the brake backplate (item 38) and screw the backplate onto the housing lid (item 3) using the hex. socket screws (item 4) and the lock washers (item 5) underneath (23 Nm torque).

M1271

l

Adjust the bearing pre-tension to 0.2 - 0.4 Nm using the shims (items 8, 12).

l

To obtain the ideal flank tooth bearing of the bevel gear coat with paste and then manually apply the transmission. If necessary, use the imprints to adjust the tooth bearing with the shims (items 8, 12) (Fig. M1269).

Proceed as follows:

l

Remove all grease from the screw threads in the transmission housing (item 3) with solvent.

NOTE ALL RESIDUAL GREASE AND SOLVENT MUST BE REMOVED WITH PRESSURISED AIR.

l

Remove all grease from the six screws (item 4).

l

Apply LOCTITE No. 577 (CROWN P/N 053050-019) to screws. Fit brake bracket and torque screws to 23 Nm. M1269

Printed in Germany

01/99 M3.1-2230-002 3

MAINTENANCE l

Insert the conical nipple (item 6) in the upper part o fthe transmission lid (item 7). Finally, screw the transmission lid to the pre-assembled transmission halves (23 Nm torque) using the screws (item 4) and the lock washers.

l

Finally, assemble the bleed valve (item 25) with its conical nipple (item 24) and the oil filler caps (items 32, 33) with their respective conical nipples (item 31).

Flank tooth bearing The following diagram shows the ideal flank tooth bearing for the bevel gear pairing.

Centre tooth bearing at inner tooth end on the upper side of the tooth

Centre tooth bearing at inner tooth end on the lower side of the tooth Centre tooth bearing at inner tooth end on the lower side of the tooth

Centre tooth bearing at inner tooth end on the upper side of the tooth

M1275

Correcting the flank tooth bearing If the flank system differs from the example illustrated, the shims (items 8, 12) must be used to correct the tooth bearing.

Increasing the installation path of the conical pinion

Reducing the installation path of the conical pinion

Conversely, if the tooth bearing on the bevel gear is too low, or if the tooth bearing on the conical pinion is too high, the flank tooth bearing must be adjusted by increasing the installation path of the conical pinion.

In the flank tooth shown in Fig. M1276 the installation path of the conical pinion must be reduced.

Low tooth bearing at outer tooth end on the upper side of the tooth

High tooth bearing at inner tooth end on the lower side of the tooth

Low tooth bearing at inner tooth end on the lower side of the tooth High tooth bearing at outer tooth end on the upper side of the tooth M1276

Printed in Germany

01/99 4 M3.1-2230-003

MAINTENANCE Maintenance Adding oil Before use, check that the level of the gear oil is correct.

The level should read 0.9 litres.

Types of oil For standard conditions of use, grade SAE 80-90 (CROWN P/N 053002-004) should be used (temperatures between -22°C and +80°C).

Alternatively, grade SAE 80W may be used in temperatures of between -32°C and +80°C (CROWN P/ N 053002-006).

See also the „Lubricants and Recommended Oil“ table on page M1.1-1710-002 of the present manual.

For use in more extreme conditions and temperatures please contact CROWN service department.

Oil level Fill gear oil to the lower mark of the dipstick (item 33).

The capacity is 0.9 litres.

Oil change Perform the first oil change after 250 operating hours.

Further oil changes every 2000 operating hours, and at least annually.

CAUTION THE MAXIMUM PERMISSIBLE PERMANENT OPERATING TEMPERATURE OF THE GEAR OIL IS MAX. 80°C.

Printed in Germany

01/99 M3.1-2230-004 5

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Printed in Germany

ELECTRICS

Printed in Germany

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Printed in Germany

MAINTENANCE Electrical System Wire Colour Codes The wires used in the truck are colour-coded and numbered according to their function. The first digit or first two digits indicate the wire colour while the last two digits are counter numbers.

ABBREVIATION COLOUR

NUMBER

FUNCTION

BLK

Black

0 **

Digital signal

BRN

Brown

1 **

Analog signal

RED

Red

2 **

Positive not connected

ORG

Orange

3 **

+12 V DC converter

YEL

Yellow

4 **

Third DC converter

GRE

Green

5 **

Negative not connected

BLU

Blue

6 **

Insulated negative

VIO

Violet

7 **

+5 V DC converter

GREY

Grey

8 **

Fourth DC converter

WHT

White

9 **

Various

R/W

Red/White

29 **

Positive connected

G/W

Green/White

59 **

Negative connected ELEKTRIK 01 gb

** Numbers 01 to 99

Printed in Germany

01/99 M1.0-0000-0001 M4.0-2230-001

MAINTENANCE Switch Symbol Abbreviation List * Abbreviation

Component

Abbreviation

Component

K*

Relay

LMS

Limit switch

ACS

Accelerator pedal switch

LOS

Lower switch

AXS

Auxiliary function switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Directional switch

RA

Raise potentiometer

DRS

Door switch

RAS

Raise switch

EDS

Emergency Disconnect Switch

REA

Reach potentiometer

EM

Encoder module

RS

Reverse switch

ENC

Encoder

SAS

Reverse protection switch

FS

Forward switch

SDS

Start switch

HBS

Handbrake switch

SES

Seat switch

HNS

Horn switch

SSS

Sideshifter switch

KYS

Key switch

THS

Thermo switch

LGS

Light switch

TLT

Tilt switch

* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2etc.

ELEKTRIK 02 gb

Printed in Germany

01/99 M4.0-2230-002 M1.0-0000-0002

MAINTENANCE Sundry Abbreviations * Abbreviation

Description

Abbreviation

Description

BDI

Battery discharge indicator

OHGD

Overhead guard display

BR

Brake

P

Pump

BWI

Brush wear indicator

PC

Plug connection

CA

Cable connection

PCB

Printed circuit board

F

Forward

R

Reverse

FAN

Fan

SF

Shunt field

FU

Fuse

STI

Steering wheel indicator

HN

Horn

SV

Solenoid valve

IFD

Information display

TB

Terminal board

M1 (TM)

Traction motor

TMM

Truck management module

M2 (PM)

Pump motor

TT

Hourmeter

MRC

Controller

* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2etc.

ELEKTRIK 03 gb

Printed in Germany

01/99 M4.0-2230-003 M1.0-0000-0003

MAINTENANCE Electrical Symbols EUROPE

1 2 3 4 5 6

USA

1 2 3 4 5 6

DESCRIPTION

EUROPE

DESCRIPTION

Wires joining

Hand operated maintained contact

Wires crossing

Solenoid valve

Wire connection

Inductor

Plug / socket

Resistor

Wire strap

Capacitor

Terminal board

Potentiometer

Fuse

Varistor

U

Assembled unit

NO

USA

J

T

Thermal protector

Contact, normally open

Lamp

Contact, normally closed

Horn

Contact double throw

Battery

Operating device

Diode

Operating devices, slow releasing Operating device, slow operating Hand operated push button

Breakdown diode LED Transistor

c

Mechanically actuated

MOSFET

c

Hydraulically actuated

Thyristor

Emergency disconnect

Comparator

c

Motor armature

.

M0056-gb

Printed in Germany

01/99 M1.0-0000-0004 M4.0-2230-004

MAINTENANCE Raise Potentiometer (POT2)

Electrical Components DANGER

The key movement of the "Raise" operating lever is converted into a control signal by potentiometer POT2 and at C1 is fed into the pump controller. The controller in turn governs the pump motor speed.

THE TRUCK MUST BE JACKED UP PRIOR TO CARRYING OUT REPAIR WORK OR TROUBLESHOOTING THE ELECTRICAL SYSTEM.

Steering Axle Potentiometer (POT3)

Switch Functions The pin references relate to the drive and pump control inputs (see pages 4.3-2230-006 and 4.3-2230-205); all other abbreviations are described in Tables Electric02 and Electric03 (page 4.0-2230-002f).

The steering axle potentiometer POT3 is mounted on the steering axle input shaft and gives the following control signals to the traction controller:

Brake Switch (BRS) The brake switch switches the power supply to pin G6 of the traction controller. This amplifies inversion braking via the traction controller.

l

Travel direction;

l

Steering wheel angle of turn.

This signal enables the traction controller to steer the traction motors accordingly.

Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS)

Encoder (ENC), Encoder Module (EM) Impulses are generated via the steering wheel, the steering column and the connected encoder ENC. These impulses are digitalised in the encoder module EM and transfered to the pump controller via pin E8.

The switches for tilting, sideshift and auxiliary function switch the battery supply to connections E2, E3 and E5 of the pump controller.

The impulse controller governs the pump motor speed via preset voltages.

Accelerator Pedal Switch (ACS, POT1) The accelerator pedal key movement is converted into a control signal via potentiometer POT1 and transfered to pin G1.

The accelerator pedal switch ACS cuts off the electric circuit from the direction indicator switch DIS.

Direction Indicator Switch (DIS) The direction indicator switch has three switch positions: forward, neutral and reverse. When the forward or reverse positions are selected, power is supplied to the traction controller on pin G8 (F) or G7 (R). This causes the controller to activate the respective direction contactors.

Emergency Disconnect The power supply to the truck is disconnected by pulling the battery connector.

Key Switch (KYS) The key switch energises the traction and pump controller via pins E1 and D1 as well as the battery discharge indicator BDI.

Fuses (FU) The main drive motor circuit is protected by fuse FU1 and the lift motor circuit by fuse FU2.

Handbrake Switch (HBS) The handbrake switch sends battery supply to pin F1 of the traction controller. This causes the control system to disconnect the traction current. It is also possible to travel for 5 seconds with the handbrake applied (starting on an incline) before the controller interrupts the traction current.

The controller circuit is protected by fuse FU3 and the horn by fuse FU4.

Printed in Germany

01/99 M1.0-0000-0005 M4.2-2230-001

MAINTENANCE Seat Switch (SES)

Horn Switch (HNS)

When the operator is seated, the seat switch SES is closed and the traction controller on Pin L7 is energised, enabling the truck to travel.

The horn switch HNS is located in the centre of the steering wheel. The horn HN sounds when the horn switch is pressed.

If the operator leaves the seat, the seat switch opens and after an interval of 1.5 seconds travelling is inhibited by the controller.

Electrical Components - Overview

DIS KYS ENC / EM SES ED POT 3

M0369

PM

HNS

BDI / TT M0367

HBS

ACS / POT 1 BRS

1 2

3

4 +

AXS

SSS

M0368

TM

TLT POT 2 Printed in Germany

01/99 M1.0-0000-0006 M4.2-2230-002

MAINTENANCE Protective Devices

Zapimos B1S 48/700 Controller

Polarity Protection

General The programmable impulse controller provides effective control over the truck's travel behaviour.

Wiring must be laid out in accordance with the wiring diagram to avoid damaging the transistors and capacitors.

The logic system itself is internally protected against incorrect polarity.

Wiring Errors The driver outputs for the contactors tolerate only a max. charge of 3A, even though they are protected against overload and short-circuiting.

Overheating When the temperature exceeds 80°C, the maximum current is reduced in proportion to the rise in temperature.

If the temperature exceeds 85°C the traction controller cuts out.

M0201

Protection The traction controller is protected against dust and spray water (IP54) and is contained within a sealed housing.

ZAPIMOS B1S 48/700 Traction Controller

Key Terms Shunt or Shunt Resistor (+SH/-SH)

Main Features

l

The controller logic can measure the current flowing through the motor using a pre-defined resistance (shunt) in series with the motor and thus control the MOSFETs.

Stepless control and inversion braking.

l

High level of efficiency, silent operation through MOSFETs and high level of sampling frequency.

l l

Overvoltage, low voltage protection.

The circuits and software identify errors in the traction circuit, the MOSFET driver circuit, the MOSFETs, the contactor drivers and the contactors.

l

Volt Motor Negative (VMN) The measurement point for the controller logic. The voltage range on the terminal is measured and tests carried out to determine whether the controller power part is faulty.

Switch order monitoring.

l

De-energised switching of contactors through microprocessor controlled contactor drivers.

l

Ramp start function ensures full power start-

up.

Printed in Germany

01/99 M1.0-0000-0007 M4.3-2230-001

MAINTENANCE Functional Description

l

Acceleration / Delay Rate

l

Controller temperature above 80°C.

Contactors do not close or Volt Motor Negative is too high when idle.

The acceleration rate is the time taken for the voltage applied to the motor to rise incrementally to 100 % of the battery supply. The acceleration rate can be changed by the programmer.

Travel Switch The travel switch stroke is 0 - 100% proportional to the controller output.

l

Contactors welded.

Sparkless Contactors If a direction switch is switched off, the output voltage rapidly falls to zero. This causes the current to fall to zero before the direction contactor drops.

Inversion Braking Checking the travel switch signal on the control input prevents the truck from starting without the driver.

Travel Switch Signal Response The controller responds to the incoming travel potentiometer signal in accordance with the programmed acceleration rate. Changes in the travel potentiometer signal are converted linearly.

Fault Log

Creep Mode

The last 5 faults are stored in the controller memory along with the relevant number of service hours, the control temperature and the fault frequency.

The internal microprocessor monitors the controller. When a fault is identified, the controller status LED flashes a fault code. For critical faults the controller cuts out. For intermittent faults, e.g. low voltage, the error message automatically fades out after a while.

Automatic Fault Identification covers: Both travel directions operated simultaneously.

l

Logic error.

In slow travel the maximum speed is reduced. However, the travel switch is still fully extended.

Steering Controller

l

Incorrect start sequency; travel switch operated.

When travelling around corners with the steering wheel at an angle of less than 65° the motors are controlled so that the inside motor is slower and the outside motor correspondingly faster.

Volt Motor Negative Test (VMN) error.

High acceleration potentiometer resistance level when idle.

When the steering angle is between approx. 65° and 73° the inside motor runs at idle speed. If the steering angle is greater than 73° the inside motor will turn in the opposite direction.

Current measurement error: – Travel: Maximum level exceeded; – Idle: Current ≠ zero.

l

Slow Travel

The maximum speed setting can only be adjusted by the programmer.

l

l

Creep speed is applied when the travel potentiometer is activated. Creep speed can be adjusted between 0 and 25 % of the output voltage.

The setting can be adjusted via the potentiometer or the programmer.

Fault Identification

l l

With inversion braking the motor is electrically driven in the opposite direction to which it is mechanically turning.

The controller governs the field current in order to achieve a controlled braking moment. During inversion braking the current is automatically restricted and the armature current is greater than the field current. The inverse current limit for fast travel can be adjusted using the programmer.

Contactor drivers faulty.

This function is dependant on the steering angle measured by the potentiometer on the steering axle, the axle base and the track.

The ratio of the two motor speeds corresponds to the ratio of the radii of the two load wheels.

Printed in Germany

01/99 M1.0-0000-0008 M4.3-2230-002

MAINTENANCE 45° Steering Angle

Seat Switch

Beyond a steering angle of 45° the controller automatically switches to creep speed.

MOSFET A MOSFET (Metal Oxide Semiconductor Field Effect Transistor) is a transistor with high switching speeds and very little power loss.

Pedal Braking (Inversion Braking with Battery Supply Regeneration) In pedal braking the energy from the motor coil is not transfered into heat as in inversion braking but a part is fed back to the battery by the controller via the brake contactor.

Pedal braking is activated when the operator's foot is taken off the accelerator pedal, the travel direction changed or the operating brakes are applied.

If the voltage generated falls to a preset value – (VgenVbat) < 0.7 V – pedal braking is cut out (brake contactor re-opens) and the truck is stopped by the operating brakes (brake pedal).

Pulse Width Modulation (PWM) In pulse width modulation the battery voltage is switched off and on to control the motor speed.

The seat switch circuit contains a time delay relay which interrupts the truck circuit when the operator has left the truck for a period of time. This prevents the truck from switching off caused by the operator moving or jolts received from the truck.

Current Limit The current limit function reduces the PWM signal to the controller power part until the motor current falls below the value of the current limit.

Overvoltage In the event of overvoltage the PWM cuts out and opens the contactors. When the permissable voltage has been reached the controller resumes operation.

Overheating At a temperature of 80°C the current limit is linearly reduced. At 85°C the controller cuts out.

Low Voltage Reduction The controller reduces the speed when the batteries are discharged to less than the minimum charge level. If the motor current is so high that the battery voltage falls below the low voltage level, the controller reduces the speed until the voltage exceeds above the level.

Ramp Start Here the truck is started with a higher inverse braking current which prevents the truck from rolling backwards when it starts. Ramp start increases the current limit in the direction which has just been applied. Switching to the opposite travel direction ends the ramp start function.

Key Switch The key switch switches the voltage to the logic section of the impulse controller.

Self Test The controller is monitored by means of internal self tests.

If an error occurs the controller is cut out. Switching the key switch off and on will cause it to re-start.

Reverse Travel Alarm The traction controller sends a signal via Pin H2 to the lighting module and from there to the horn to activate the alarm when reversing.

Printed in Germany

01/99 M1.0-0000-0009 M4.3-2230-003

MAINTENANCE ZAPIMOS B1S 48/700 Traction Controller Connections Contactor Coils / KYS

Vacant

Programmer c onnection

LED

E

D

B C

A

-B

+ B

V M N L

V M N R

Steering Axle, Drive Motor, Seat

Line Contactor

Vacant

L J

H

Handbrake

F G

-S H L

Potentiometer and Switch

-S H R

+ S H L

+ S H R

M0087

Printed in Germany

01/99 M1.0-0000-00010 M4.3-2230-004

MAINTENANCE Programmer Connection "B"

Status LED Diagnosis

A socket is provided to connect the programmer. The cable is supplied with the programmer.

When the truck is powered up the Status LED flashes briefly to indicate that the test program is being booted up by the controller.

Status LED "A" In normal start up the Status LED is off.

In the event of a fault the LED indicates the fault via a flashing code. The fault can be identified more closely via the programmer (see table, LED Codes).

When a fault occurs the Status LED flashes the respective code (see table, LED Codes) until the fault is rectified.

LED Code

Display

Explanation

LED off

m

Traction controller operating normally

Continually on

l

Both travel directions simultaneously applied

1

H

Logic error

2

HH

Star t order incorrect (travel direction confirmed)

3

HHH

VMN (Volt Motor Negative)Test Error

4

HHHH

High potentiometer voltage in accelerator pedal potentiometer when idle (accelerator pedal potentiometer incorrectly aligned).

5

HHHHH

Motor current measurement error Travel: 0 V measured constantly Idle: current ¹ 0 V

6

HHHHHH

Contactor drivers faulty

7

HHHHHHH

Temperature above 80°C

8

HHHHHHHH

Contactors do not close or VMN (Volt Motor Negativ) is too high at idle speed

9

HHHHHHHHH

Contactors welded

ELEKTRIK 04 gb

Printed in Germany

01/99 M1.0-0000-00011 M4.3-2230-005

MAINTENANCE Control Line Connections Traction Controller

PIN-No.

PIN-No.

E 9 E 8 E 7 E 6 E 5 E 4 E 3 E 2 E 1

L 9 L 8 L 7 L 6 L 5 L 4 L 3 L 2 L 1

D 2 D 1

J 2 J 1

C 3 C 2 C 1

H 3 H 2 H 1

B 8 B 7 B 6 B 5 B 4 B 3 B 2 B 1

G 8 G 7 G 6 G 5 G 4 G 3 G 2 G 1

A 2 A 1

F 2 F 1

Truck LHS

Truck RHS

Printed in Germany

01/99 M1.0-0000-00012 M4.3-2230-006

MAINTENANCE ZAPIMOS B1S 48/700 Pin Layout Pin A1 A2

Function - LED + LED

B1 B2 B3 B4 B5 B6 B7 B8

+ Serial Interface Receiver - Serial Interface Receiver + Serial Interface Sender - Serial Interface Sender - Programmer Power Supply + Programmer Power Supply Pin free Pin free

E1 E2 E3 E4 E5 E6 E7 E8 E9

+ Key Switch + Travel Direction Contactor Coil Pin free - Travel Direction Contactor Coil - Travel Direction Contactor Coil - Travel Direction Contactor Coil - Travel Direction Contactor Coil + Pedal brake contactor - Pedal brake contactor

F1 F2

+ HBS Input Pin free

G1 G2 G3 G4 G5 G6 G7 G8

- Accelerator Pedal Potentiometer Loop, Accelerator Pedal Potentiometer + Accelerator Pedal Potentiometer Pin free Common Output, Travel and Brake Switch BRS Input Reverse Switch Input Forward Switch Input

H1 H2 H3

Pin free Pin free + Line Contactor

J1 J2 L1 L2 L3 L4 L5 L6 L7 L8 L9

Additional Information Alarm Alarm, Output Current 12 mA, for standard LED

12 V

Input

RH drive motor RH drive motor LH drive motor LH drive motor

0 Volt Speed min., 10 V Speed. max.

12 V Output

Travel Direction Switch Travel Direction Switch

Pin free Pin free - B – Input Loop, Steering Axle Potentiometer - Steering Axle Potentiometer + Steering Axle Potentiometer - For Options - For Options - Seat Switch Input - For Options - For Options

+7 V Connected to Battery Negative via L1 Connected to Battery Negative via L1 Connected to Battery Negative via L1 Connected to Battery Negative via L1

Note: + = Positive Potential - = Negative Potential

Printed in Germany

01/99 M1.0-0000-00013 M4.3-2230-007

MAINTENANCE Maintenance Maintenance of the ZAPIMOS B1S 48/700 controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.

Removing / Installing the Traction Controller DANGER BEFORE CARRYING OUT ELECTRICAL WORK OR TROUBLESHOOTING, JACK UP THE TRUCK.

WARNING THE ZAPIMOS B1S 48/700 CONTROLLER OPERATES WITH HIGH THROUGHPUTS. SPECIAL SAFETY MEASURES ARE THEREFORE REQUIRED.

To remove

l

Only properly trained personnel must carry out maintenance work.

l

l l l l

l l

Use non-wearying eye protection.

Do not wear loose clothing.

l l

Do not wear jewelry.

l

Use insulated tools only.

Lift the truck until the drive wheel is free to

Open the battery compartment lid.

l

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

Unplug the battery connector.

Secure the truck to prevent it from rolling away.

Lift the truck until the drive wheel is free to move.

l

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

l

Prevent the truck from rolling away.

move.

Cleaning the Traction Controller

l

Remove the battery connector.

l l

Unplug connector.

Remove the eight power cables.

l

Unscrew the six mounting screws and remove the traction controller

Remove cables.

l

Remove contamination and corrosion from the contact surfaces.

l

Wipe the traction controller with a clean, damp

l

Connect cables.

cloth.

l

Before connecting the battery make sure that the traction controller is completely dry.

M0189

Printed in Germany

01/99 M1.0-0000-00014 M4.3-2230-008

MAINTENANCE CAUTION THE TRACTION CONTROLLER MUST ONLY BE SUPPLIED WITH BATTERY CURRENT. DO NOT USE RECTIFIERS OR POWER UNITS. DO NOT CONNECT THE CONTROLLER TO A BATTERY WITH A DIFFERENT RATED VOLTAGE TO THE VOLTAGE SPECIFIED ON THE CONTROLLER DATA PLATE.

Installing the Traction Controller Installation is the reverse procedure of removal.

l

Coat the rear of the traction controller with heat conductor paste (Crown P/N 053051-008) and install the controller.

l

Test operation of traction controller.

Printed in Germany

REV.1 10/99 M4.3-2230-009 M1.0-0000-00015

MAINTENANCE Zapimos HP 350A Pump Controller Protective Devices Polarity Protection

General

Wiring must be laid out in accordance with the wiring diagram to avoid damaging the transistors and capacitors.

The logic system itself is internally protected against incorrect polarity.

Wiring Errors The driver outputs for the contactors tolerate only a max. charge of 3A, even though they are protected against overload and short-circuiting.

Overheating When the temperature exceeds 80°C, the maximum current is reduced in proportion to the rise in temperature.

If the temperature exceeds 85°C the traction controller cuts out.

Protection M0202

The programmable impulse controller provides effective control over all hydraulic functions.

Key Terms

The main features are as follows:

l

Shunt or Shunt Resistor (+SH/-SH) Stepless control of the lifting function.

l

High level of efficiency, silent operation through MOSFETs and high level of sampling frequency.

l

Overvoltage, low voltage protection.

l

The controller logic can measure the current flowing through the motor using a pre-defined resistance (shunt) in series with the motor and thus control the MOSFETs.

Volt Motor Negative (VMN)

The circuits and software identify errors in the pump circuit, the MOSFET driver circuit and the MOSFET transistors.

l

The traction controller is protected against dust and spray water (IP54) and is contained within a sealed housing.

The measurement point for the controller logic. The voltage range on the terminal is measured and tests carried out to determine whether the controller power part is faulty.

Switch order monitoring.

Printed in Germany

01/99 M4.3-2230-200 M1.0-0000-00016

MAINTENANCE Key Switch

Functional Description

The key switch switches the voltage to the logic section of the impulse controller.

Acceleration / Delay Rate The acceleration rate is the time taken for the voltage applied to the motor to rise incrementally to 100 % of the battery supply. The acceleration rate can be altered using the programmer.

Current Limit The current limit function red uces the PWM signal to the controller power part until the motor current falls below the value of the current limit.

Lift Cut-Out If the battery capacity falls below 20%, the battery discharge indicator sends a signal to the controller and interrupts lifting.

Lift Potentiometer The operating lever stroke is 0 - 100% proportional to the controller output.

Fault Identification Lift Potentiometer Response The internal microprocessor monitors the controller. When a fault is identified, the controller status LED flashes a fault code. For critical faults the controller cuts out. For intermittant faults, e.g. low voltage, the error message automatically fades out after a while.

Automatic fault identification covers:

l

Low Voltage Reduction

Logic error.

l

Incorrect start sequency; travel switch operated.

l

Volt Motor Negative Test (VMN) error.

l

High lift potentiometer resistance level when

l

Current measurement error:

The controller reduces the speed when the batteries are discharged to less than the minimum charge level. If the motor current is so high that the battery voltage falls below the low voltage level, the controller reduces the speed until the voltage rises above the level.

MOSFET A MOSFET (Metal Oxide Semiconductor Field Effect Transistor) is a transistor with high switching speeds and very little power loss.

idle.

– Idle: Current ≠ zero.

l

The controller responds to the incoming lift potentiometer signal in accordance with the programmed acceleration rate. Changes in the lift potentiometer signal are converted linearly.

Overheating At a temperature of 80°C the current limit is linearly reduced. At 85°C the controller cuts out.

Temperature above 80°C.

Fault Log Overvoltage The last 5 faults are stored in the controller memory along with the relevant number of service hours, the control temperature and the fault frequency.

In the event of overvoltage the PWM cuts out and opens the contactors. When the permissable voltage has been reached the controller resumes operation.

Hydraulic Function Switch Pulse Width Modulation (PWM) The sideshift, tilt and aux. hydraulic functions are governed by switches. If the switch is closed via the operating lever the pump motor operates initially at a speed set by the programmer.

In pulse width modulation the battery voltage is switched off and on to control the motor speed.

Steering has priority over lifting. This is controlled by a priority valve in the valve block.

Printed in Germany

01/99 M4.3-2230-201 M1.0-0000-00017

MAINTENANCE Steer Support

Seat Switch

A sensor generates signals which are digitalised in the sensor module and sent to the pump controller. The pump controller then governs the pump motor at a speed determined by the programmer.

The seat switch circuit contains a time delay relay which interrupts the truck circuit when the operator has left the truck for a period of time. This prevents the truck from switching off caused by the operator moving or jolts received from the truck.

Self Test The controller is monitored by means of internal self tests.

If an error occurs the controller is cut out. Switching the key switch off and on will cause it to re-start.

ZAPIMOS HP 350A Pump Controller Connections

Hydraulic functions, sensor

Key switch

Programmer connection

Lift potentiometer

LED

E 9 8 7 6 5 4 3 2 1

+ B

D

2 1

C

3 2 1

+ M

B

8 7 6 5 4 3 2 1

A

2 1

-B

- M

M0264

Printed in Germany

01/99 M1.0-0000-00018 M4.3-2230-202

MAINTENANCE Programmer Connection "B"

Status LED Diagnosis

A socket is provided to connect the programmer. The cable is supplied with the programmer.

When the truck is powered up the Status LED flashes briefly to indicate that the test program is being booted up by the controller.

Status LED "A" In normal start up the Status LED is off.

In the event of a fault the LED indicates the fault via a flashing code. The fault can be identified more closely via the programmer.

When a fault occurs the Status LED flashes the respective code (see table, LED Codes) until the fault is rectified.

LED Code

Display

Explanation

LED off

m

Pump controller operating normally

1

H

Logic error

2

HH

Star t order incorrect (travel direction confirmed)

3

HHH

VMN (Volt Motor Negative)Test Error

4

HHHH

High potentiometer voltage in accelerator pedal potentiometer when idle.

5

HHHHH

Motor current measurement error Travel: 0 V measured constantly Idle: current ¹ 0 V

6

HHHHHH

Contactor drivers faulty

7

HHHHHHH

Temperature above 80°C

ELEKTRIK 06 gb

Printed in Germany

01/99 M1.0-0000-00019 M4.3-2230-203

MAINTENANCE ZAPIMOS HP 350 A Pin Layout Pin A1 A2

Function - LED + LED

Additional Information Alarm Alarm, Output Current 12 mA, for standard LED

B1 B2 B3 B4 B5 B6 B7 B8

+ Serial Interface Receiver - Serial Interface Receiver + Serial Interface Sender - Serial Interface Sender - Programmer Power Supply + Programmer Power Supply Pin free Pin free

C1 C2 C3

Lift potentiometer loop - Lift potentiometer + Lift potentiometer

0 volt speed min., 10 volt speed max.

D1 D2

+ Key switch input + Connected

Connection to D2 via diode

EE1 E2 E3 E4 E5 E6 E7 E8 E9

Pin free Aux. function switch input Sideshift switch input Pin free Tilt switch input Lift cut-out input Pin free Sensor input Pin free

Note:

+ = Positive potential – = Negative potential

12 V

14 volt output

Active when B+ applied Active when B+ applied Active when B+ applied Active when B+ applied

Maintenance Maintenance of the ZAPIMOS HP 350A controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.

Cleaning the Pump Controller

WARNING THE ZAPIMOS HP 350A CONTROLLER OPERATES WITH HIGH THROUGHPUTS. SPECIAL SAFETY MEASURES ARE THEREFORE REQUIRED.

Unplug the battery connector.

Secure the truck to prevent it from rolling away.

l

Lift the truck until the drive wheel is free to move.

l

Remove wire.

l

Remove contamination and corrosion from the contact surfaces.

l

Only properly trained personnel must carry out maintenance work.

l l l l

l l

l

Wipe the pump controller with a clean, damp

Use non-wearying eye protection.

cloth.

Do not wear loose clothing.

l

Connect wire.

Do not wear jewelry.

l

Before connecting the battery make sure that the pump controller is completely dry.

Use insulated tools only.

Printed in Germany

01/99 M1.0-0000-00020 M4.3-2230-204

MAINTENANCE CAUTION

Removing / Installing the Pump Controller

THE PUMP CONTROLLER MUST ONLY BE SUPPLIED WITH BATTERY CURRENT. DO NOT USE RECTIFIERS OR POWER UNITS.

DANGER

DO NOT CONNECT THE CONTROLLER TO A BATTERY WITH A DIFFERENT RATED VOLTAGE TO THE VOLTAGE SPECIFIED ON THE CONTROLLER DATA PLATE.

BEFORE CARRYING OUT ELECTRICAL WORK OR TROUBLESHOOTING, JACK UP THE TRUCK

To remove

l

Remove the battery connector.

l

Prevent the truck from rolling away.

l l

Installing the Pump Controller Installation is the reverse procedure of removal.

l

Lift the truck until the drive wheel is free to move.

Coat the rear of the traction controller with heat conductor paste (Crown P/N 053051-008) and install the controller.

Open the battery compartment lid.

l

l

Unplug connector.

l

Remove the eight power cables.

Test operation of pump controller.

l

Unscrew the six mounting screws and remove the pump controller

M0189

Printed in Germany

REV.1 10/99 M4.3-2230-205 M1.0-0000-00021

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany

MAINTENANCE Programmer General The optional ZAPI programmer, Crown P/N 793548, is used to program, test and perform diagnostic functions on the traction controller.

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

M0271-a

Printed in Germany

REV.1 10/99 M4.4-2230-001 1

MAINTENANCE Description of Keys Key

Designation

Explanation

Key 1

ROLL up

Selects the next sub-menu or an option.

Key 2

ROLL down

Selects the previous sub-menu or an option.

Key 3

ENTER

Enters the main menu. Stores the pin configuration.

Key 4

OUT *

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

Key 5

PARAM up

Increases setting values or selects configuration.

Key 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.

ELEKTRIK 07gb

Display Window

l l

1

3

5

R OL L R OL L

EN TER OU T

PA R A M SET

2

4

6

Alphanumeric LCD Display 2 lines @ 16 characters

Operating Keys

M0274-a

Printed in Germany

REV.1 10/99 2 M4.4-2230-002

MAINTENANCE Connecting the Programmer The programmer can be connected to the traction or pump controller via a plug. The controller acts as a power supply source for the programmer.

CAUTION ONLY CONNECT AND DISCONNECT THE PROGRAMMER TO THE CONTROLLER WHEN THE TRUCK IS SWITCHED OFF.

E

D

B

C

A

M0272

Operating Menu General When the programmer has been connected a self test start routine is performed (see page M4.5-2230-002). When it is complete, use the ROLL up/down and ENTER to select the required menu.

The following two pages show a menu structure for traction and pump control with an explanation of the individual menu functions.

Printed in Germany

01/99 M4.4-2230-003 3

MAINTENANCE Traction Controller Operating Menu

START ROUTINE

PROGRAM

TESTER

ACCELERATION INVERSE BRAKING RELEASE BRAKING PEDAL BRAKING TRACTION BRAKING TRACTION I MAX (2) SPEED CUTBACK I CREEP SPEED (1) SPEED LIMIT

L VMN R L MOTOR R BATTERY VOLTAGE STEER ANGLE ACCELERATION SEAT SWITCH FORWARD SWITCH BACKWARD SWITCH TEMPERATURE BRAKE SWITCH CUTBACK SWITCH 1 CUTBACK SWITCH 2

ALARMS

PROGRAM PEDAL

VIEW ALARM(S)

PROGRAM VACC

CONFIG

CLEAR ALARM(S)

SET MODEL

SET OPTIONS

ADJUSTMENTS

STEER TABLE SC3013 SC3016 SC3018

HOURS RUNNING / KEY ON BATTERY CHECK ON/OFF RELEASE BRAKING ON/OFF ANTIROLL BACK ON/OFF AUTO BRAKE LIGHT ON/OFF

STEER POT

(1) Read only, cannot be overwritten (2) Not available in version B1SHA1.05

Printed in Germany

01/99 4 M4.5-2230-001

MAINTENANCE Programmer Start Routine Connect programmer

Connect truck Internal check routine

Control logic start

C h e c k

C h e c k

No display

C h e c k

No error

No power supply, switch off truck and check wiring

YES

C h e c k

W A IT C O N N E C T N O C O N N E C T

C h e c k

Switch off truck; check programmer - controller connection

YES

C h e c k

C H O P P E R N O T O K

C h e c k

C h e c k

W A IT C O N N E C T

Switch off truck; programmer and controller are incompatible

YES

Information Display Traction Controller YES

C R O W N R E G E N E R

B 1

V .1 .0 3 5

Information Display Pump Controller

NO YES

Error during travel

C R O W N P U M P S T D

H 2

V .1 .0 3 5

Current error *** A L A R M *** S T E E R S E N S O R

K O

M0288d

Printed in Germany

01/99 M4.5-2230-002 5

MAINTENANCE Traction Controller Menu Functions PROGRAM In the PROGRAM menu the listed truck parameters can be read and set in real time.

TESTER In the TESTER menu the listed truck parameters can be read in real time.

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

PROGRAM PEDAL In the PROGRAM PEDAL 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 adapt the programmer to the respective truck model.

In addition, auxiliary functions can be activated or deactivated. The steering potentiometer is calibrated in the "Adjustments" sub-menu.

Printed in Germany

01/99 6 M4.5-2230-003

MAINTENANCE PROGRAM Menu The following table describes the various truck parameters which can be set in the PROGRAM menu.

Traction Control System Setting Values Menu Item

ACC. DELAY

INVERSE BRAKING

RELEASE BRAKING

PEDAL BRAKING

TRACTION I MAX

SPEED CUTBACK 1

CREEP SPEED

Setting Range

0-9

0-9

0-9

0-9

0-6

0-9

0-9

Recommended Description Setting 4

Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100%.

5

Inversion braking. Activated when the directional switch is reversed. The brake force is dependant on the accelerator pedal position and the maximum traction current setting.

3

Release braking. Activated when the accelerator pedal is released or when it returns to neutral. The brake effect is dependant on the maximum traction current setting.

9

Pedal braking. Activated when the accelerator pedal is released, when the directional switch returns to neutral or when it is set to the opposite direction. The brake effect is dependant on the maximum traction current setting.

6

Traction current limit. This value determines the maximum supply to the drive motors during all traction and braking operations.

9

Adjustable speed reduction, e.g. in relation to the lift height or the steer angle. In order to program this parameter cable no. 5933 on Pin L5 must first be disconnected.

2

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

ELEKTRIK 08gb

Printed in Germany

01/99 M4.5-2230-004 7

MAINTENANCE 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

L VMN R

Displays in real time the output voltage from the drive motors applied to the Volt Motor Negative.

An important reading which provides information on the status of the MOSFETs.

L i MOTOR R

Displays in real time the current flowing through the resistors. Displayed during travel as well as braking.

BATTERY VOLTAGE

Displays in real time the voltage applied to the traction controller.

STEER ANGLE

Displays in real time the steer angle. The display ranges from +90° to -90° and is measured with reference to the forward position (=0°) of the steering wheels.

ACCELERATOR

Displays the input voltage applied to the traction potentiometer up to 10V. Also displays the accelerator pedal stroke as a percentage which can be used to check whether the traction potentiometer is calibrated correctly.

SEAT SWITCH

Tests the operation of the seat switch and wiring.

FORWARD SWITCH

Tests the operation of the "Forward" switch and its wiring.

BACKWARD SWITCH

Tests the operation of the "Reverse" switch and its wiring.

TEMPERATURE

Displays in real time the temperature of the MOSFET heat dissipators in the traction controller.

BRAKE SWITCH

Tests the operation of the foot brake switch and its wiring.

CUTBACK SWITCH 1 & 2

Tests the operation of the speed cutback switch and its wiring

ELEKTRIK 09gb

Printed in Germany

01/99 8 M4.5-2230-005

MAINTENANCE ALARMS Menu The traction controller can collect and store operational faults during operation. The ALARMS menu can be used to call up and read the respective fault codes.

The programmer can display 5 different types of fault codes up to 99 times together with the applicable number of service hours.

ALARMS Menu Fault Code

Description

Possibe Cause

BRAKE CON CLOSED

The test is performed during operation or at the start of inverse braking. The alarm is activated when the supply to the VMN exceeds 2/3 of the battery voltage.

- Pedal braking contactor jammed - Logic error

R DIR. CONT. OPEN, L DIR. CONT. OPEN

Tests the operation of the direction contactors by measuring the VMN voltage.

- Direction contactor does not close - Motor wiring faulty - Direction contactor faulty

BRAKE CONT. OPEN

The test is performed when the brake contactor has closed. Tests whether the VMN is rising from < 1/3 to > 2/3 of the battery voltage.

- Brake contactor faulty - Magnetic coil or wiring faulty

R DIR. CON. CLOSED, L DIR. CON. CLOSED

Tests the operation of the direction contactors at idle speed or braking.

- Direction contactor jammed - Logic error

R VMN LOW, L VMN LOW

The test is performed in standby mode or during operation at up to 80% of the PWM signal. The alarm is activated when the VMN falls below 1/3 of the battery voltage.

- Direction contactors faulty - Motor insulation between armature and field faulty - Brake contactors closed - Logic error

R VMN HIGH L VMN HIGH

The test is performed in standby mode. The alarm - Short circuit between battery + and is activated when the VMN exceeds 2/3 of the VMN battery voltage.

- Logic error

R i = 0 EVER L i = 0 EVER

The test is performed during operation. The alarm is activated when the minimum supply level is exceeded and travelling is inhibited.

EEPROM DATA KO

Displays a fault in the hourmeter memory.

Followed by reset to zero, traction controller continues to operate however.

STEER SENSOR KO

Steer sensor faulty. Input signal at L2 >4.8 V or < 0.2 V.

- Steer potentiometer wiring faulty - Steer potentiometer incorrectly calibrated

WATCH DOG

Microprocessor self test. Performed during standby mode and operation.

- Faulty logic

- Current sensor faulty - Power supply fault

ELEKTRIK 10agb

Printed in Germany

01/99 M4.5-2230-006 9

MAINTENANCE ALARMS Menu (contd.)

Fault Code

Description

Possible Cause

COIL SHORTED

Detects the short circuit current when the contactor coils are activated.

- Short circuit or more than 6A constant current in one of the contactor coils.

- Negative connection from one of the contactor tips to battery positive short-circuited

DRIVER SHORTED

Tests the voltage applied to the contactor drivers.

Performed when contactor drivers are not activated.

- Logic error - Faulty contactor drivers due to excessive voltage input.

CHOPPER RUNNING

Informs the operator that the required function cannot be selected while the traction controller is operating.

HANDBRAKE ERROR

Informs the operator that a travel function has been performed with the handbrake on for more than 5 seconds.

- Handbrake on while travel function activated.

- Handbrake switch faulty.

SEAT SWITCH OPEN

Informs the operator that a travel function has been performed with the seat switch open.

- Driver seat unoccupied.

- Seat switch wiring faulty - Seat switch faulty ELEKTRIK 10bgb

PROGRAM PEDAL 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.

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

01/99 10 M4.5-2230-007

MAINTENANCE CONFIG Menu The CONFIG menu provides access to the SET MODEL, SET OPTIONS and ADJUSTMENTS sub-menus.

CONFIG Menu Sub-Menu

Option

Description

SET MODEL

Used to select the correct wheel base. The following options are available: SC3013, SC3016, SC3018.

SET OPTIONS

Hours running / key on

Determines the mode of the hourmeter in the traction control system. The following options are available: - RUNNING: Counts the hours while the traction motor is activated - KEY ON: Counts the hours while the truck is switched on

Battery check on / off

Activates battery monitoring system in the traction controller. If the battery voltage falls to below 10% and this function is performed (ON): - the traction controller restricts the max. current to 50 %; - the respective Service LED on the display starts to flash.

Release braking on / off

Activates the release braking function. When set to OFF the truck does not brake when the travel switch is released or returns to zero, but continues to coast.

Antiroll back on / off

When set to ON the traction controller can power the drive motor in the opposite sense to its direction of turn up to the programmed maximum value.

Autobrake light on / off1

- OFF position: Traction controller sets a pin to 0V when the brake pedal is applied.

- ON position: Traction controller sets a pin to 0V during release braking and inversion braking.

ADJUSTMENTS

Used to calibrate the steer potentiometer by reading and storing the minimum and maximum output voltages of the steer potentiometer.

Based on these minimum/maximum values the traction controller calculates the respective steer angle within a range of +90° to 90°.

ELEKTRIK 11gb

Printed in Germany

01/99 M4.5-2230-008 11

MAINTENANCE Pump Controller Operating Menu

START ROUTINE

PROGRAM

TESTER

ACCELERATION DECELERATION CURRENT LIMIT HYDRO SPEED COARSE HYDRO SPEED FINE HYDRO SPEED COMP. CREEP SPEED HYDRO TIME 1ST SPEED FINE 1ST SPEED COMP. 2ND SPEED COARSE 2ND SPEED FINE 2ND SPEED COMP. 3RD SPEED COARSE 3RD SPEED FINE 3RD SPEED COMP. 4TH SPEED COARSE 4TH SPEED FINE 4TH SPEED COMP.

VMN MOTOR VOLTAGE MOTOR CURRENT BATTERY VOLTAGE TEMPERATURE LIFTING CONTROL (1) LIFTING SWITCH (1) DESCENT SWITCH 1ST SPEED SWITCH 2ND SPEED SWITCH 3RD SPEED SWITCH 4TH SPEED SWITCH HYDRO SPEED REQ.

ALARMS

PROGRAM

VIEW ALARM(S)

PROGRAM VACC

CONFIG

CLEAR ALARM(S)

SET MODEL

SET OPTIONS

ADJUSTMENTS

(1) PUMP (1) PUMP + HYDRO

(1) BYPYSS BATTERY CHECK HOUR COUNTER (1) MAIN CONTACTOR (1) AUX. FUNCTIONS

(1) SET BATTERY TYPE

(1) SET BATTERY VOLTAGE (1) No longer available with version HPHA1.73

Printed in Germany

01/99 12 M4.5-2230-009

MAINTENANCE Menu Functions Pump Controller PROGRAM In the PROGRAM menu the listed truck parameters can be read and set in real time.

TESTER In the TESTER menu item the listed truck parameters can be read in real time.

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

PROGRAM VACC In the PROGRAM VACC menu the lift potentiometer is calibrated. The pump controller reads and records the potentiometer's minimum and maximum output voltages.

CONFIG The Configuration menu is used to activate or de-activate various auxiliary functions.

Printed in Germany

01/99 M4.5-2230-010 13

MAINTENANCE PROGRAM Menu The following table describes the various parameters which can be set in the PROGRAM menu for the pump controller.

Pump Control System Settings Menu Item

Setting Range

ACCELERATION DELAY

0-9

3

Acceleration. The time taken for the pump controller to increase the pump speed from 0 to 100% if necessary.

DECELERATION DELAY

0-9

0

Delay. The time taken for the pump controller to reduce the pump speed from 100 to 0% when the lift potentiometer is reset.

CURRENT LIMIT

0-9

9

Restricts the maximum current of the pump motor.

HYDRO SPEED* COARSE / FINE

0-9

coarse: 1 fine: 4

Parameter for pump speed setting during steering.

See also SPEED COARSE and SPEED FINE.

HYDRO SPEED COMPENSATION

Recommended Description Setting

0-9

2

With this function the pump control system varies the pump speed via the output voltage within a small range and can therefore compensate for any change in load.

This function is only active for hydraulic functions with a fixed pump speed.

CREEP SPEED

0-9

4

Creep speed setting for lifting. When this parameter is increased the time taken to reach the maximum pump speed automatically reduces.

HYDRO TIME

0-9

1

Pump motor delay period: time taken for the pump motor to cut out after a steering function.

0-9

1st 2nd 3rd 4th

0 1 0 0

Coarse setting of the respective pump speed in increments of approx. 11%. The actual pump speed is the result of coarse and fine settings (SPEED COARSE and SPEED FINE).

0-9

1st 2nd 3rd 4th

0 1 0 (5) 0

Fine adjustment of the respective pump speed through repeated sub-division of the 11% levels set in SPEED COARSE by increments of 1.2 %.

1ST, 2ND, 3RD & 4TH** SPEED COARSE

1ST, 2ND, 3RD & 4TH SPEED FINE

* HYDRO SPEED: Steering ** 1ST SPEED: Not used 2ND SPEED: Tilt (2nd lever) 3RD SPEED: Sideshift (3rd lever) 4TH SPEED: Aux. function (4th lever)

ELEKTRIK 12gb

Printed in Germany

01/99 14 M4.5-2230-011

MAINTENANCE TESTER Menu The following table shows the various truck parameters which can be selected and tested in the TESTER menu.

TESTER Menu Menu Item

Description

VMN

Displays in real time the output voltage for the pump motor applied to the Volt Motor Negative.

MOTOR VOLTAGE

Displays in real time the voltage applied to the pump motor.

MOTOR CURRENT

Displays in real time the motor current flowing through the pre-resistor (SH) in the pump controller.

BATTERY VOLTAGE

Displays in real time the battery voltage applied to the pump controller.

TEMPERATURE

Displays in real time the MOSFET heat dissipator temperature in the pump controller.

LIFTING CONTROL

Displays the input voltage applied to the lift potentiometer.

1ST SPEED SWITCH

Displays the signal status for the 5th hydraulic function.

2ND SPEED SWITCH

Displays the signal status for the 2nd hydraulic function.

3RD SPEED SWITCH

Displays the signal status for the 3rd hydraulic function.

4TH SPEED SWITCH

Displays the signal status for the 4th hydraulic function.

HYDRO SPEED REQUEST

Displays the signal status for the steering function.

ELEKTRIK 13gb

Printed in Germany

01/99 M4.5-2230-012 15

MAINTENANCE ALARMS Menu The pump controller can detect and store any faults which occur during operation. The ALARMS menu can be used to call up and read the respective fault codes.

The programmer can display 5 different types of fault codes up to 99 times together with the applicable number of service hours.

ALARMS Menu Fault Code

Description

Possible Cause

VMN LOW

The test is performed in standby mode. The alarm - Faulty motor wiring sounds when the VMN falls to below 1/3 of the - Pump controller faulty battery voltage.

NO FULL COND.

The test is performed in operational mode. When the VMN falls to below 1/3 of the battery voltage the pump motor power supply is disconnected.

TH. PROTECTION

For cold MOSFETs: Indicates that the temperature of the MOSFETs is - Heat sensor wiring faulty - Heat sensor faulty greater than 80°C. The maximum current is gradually reduced and is zero at 85°C. - Error in logic connector - Logic faulty

BATTERY

Low battery voltage. Alarm displayed only when BATTERY CHECK option is active. All hydraulic functions interrupted except for steering.

- Diagnostic circuit in controller faulty

INCORRECT START

Truck functions when key switch pressed.

- Operating error: lever applied when key switch activated.

- Microswitch faulty - Wiring faulty

I HIGH AT STAND

Checks motor current in standby mode. For a value other than 0V an error message is displayed and controller is interrupted.

- Current sensor faulty.

- Logic faulty

I = 0 EVER

Checks motor current during operation. When the minimum current is exceeded controller is interrupted.

- Current sensor faulty.

EEPROM PAR. KO

Error message interrupts pump controller operation.

- Error in truck parameter memory range; replace controller.

EEPROM CONF. KO

Error message interrupts pump controller operation.

- Error in configuration data memory range; replace controller.

ELEKTRIK 14agb Printed in Germany

01/99 16 M4.5-2230-013

MAINTENANCE ALARMS Menu (cont.)

Fault Code

Description

Possible Cause

EEPROM DATA KO

Displays fault in hourmeter memory range.

Hourmeter is reset to zero, but controller continues to operate.

EEPROM OFF LINE

Fault in hourmeter data, error message and truck parameter memory range

If alarm persists, replace controller.

CHOP. NO CONF.

Configuration data do not match the controller used.

Incorrect controller

WATCH DOG

Microprocessor self test: performed during standby and travel modes.

Logic faulty

ELEKTRIK 14bgb

PROGRAM VACC Menu The PROGRAM VACC sub-menu is used to calibrate the lift potentiometer. The maximum potentiometer voltage corresponds to the full lever displacement. The minimum voltage is always 0V. 14V is supplied to the lift potentiometer via the pump controller logic. The signal range used by the potentiometer is between 0V (minimum speed) and 10V (max. speed) as signals above 10V are reduced to 10V by the internal logic system.

Printed in Germany

01/99 M4.5-2230-014 17

MAINTENANCE CONFIG Menu The CONFIG menu provides access to the SET OPTIONS sub-menu.

CONFIG Menu Sub-Menu

SET OPTIONS

Option

Description

Hours running / key on

Determines the mode of the hourmeter in the pump controller. The following options are available: - RUNNING: Counts the hours while the drive motor is activated - KEY ON: Counts the hours while the truck is switched on

Battery check on / off

Activates battery monitoring system in the pump controller. If the battery voltage falls to below 10% and this function is activated (ON): - the traction controller restricts the max. current to 50 %; - the respective Service LED on the display starts to flash.

ELEKTRIK 15gb

Printed in Germany

01/99 18 M4.5-2230-015

MAINTENANCE l

Traction Controller Safety Test

Lower the front wheels.

The truck is now operational.

Pulse Monitor Trip Test (PMT) CAUTION IN COMPLIANCE WITH EU NORM PREN1175-1 THE FOLLOWING TEST MUST BE CARRIED OUT TO MONITOR THE TRACTION CONTROLLER FUSE CIRCUIT.

Equipment A test cable with a 10A fuse and an insulated crocodile clip at each end.

Test

l

Switch off the truck.

l

Jack up the front wheels of the truck.

l

Connect the test cable between - B and VMN L.

l

Connect the programmer to the controller.

l l l

Press the seat switch.

Switch on the truck.

LED code (lights up three times) and following message displayed: "ALARM L VMN LOW".

l l

Select truck forward or reverse.

Depress accelerator pedal:

1. Travel mode does not start.

Test performed successfully 2. No LED display, travel mode starts.

Replace traction controller.

l

Switch off the truck.

l

Connect the test cable between - B and VMN R.

l

Repeat the test for VMN R.

l

Disconnect the test cable between - B and VMN R.

Printed in Germany

01/99 M4.20-2230-001 19

MAINTENANCE PMT Safety Test Wiring

+ S H L

+ S H R

S H

S H R D 2

L D 2

L D 1

-S H L

-S H R

V M N L

V M N R

R D 1

B 1 S 4 8 V / 3 5 0 + 3 5 0 L O G IC

1 0 A F U

- B

1 0 A F U

M0341

Test Cable

Printed in Germany

01/99 20 M4.20-2230-002

MAINTENANCE Replacing the Battery

Battery

WARNING

General

ONLY USE BATTERIES WHICH COMPLY WITH THE DIMENSION, WEIGHT AND CAPACITY REQUIREMENTS FOR THIS TRUCK.

The condition of the battery considerably affects the output and behaviour of the truck. Proper maintenance enhances the performance and service life of the battery.

An incorrect tbattery can damage the truck.

Incorrect weight and dimensions alter the truck centre of gravity. This can result in accidents and will invalidate the warranty.

Only service the battery in accordance with the manufacturer's instructions.

The respective manufacturer's maintenance manual is provided with all batteries supplied by Crown.

Operation During discharge the battery connector is connected to the truck circuit. During charging, it is connected to the charger.

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

Removing the Battery

Make sure that the battery connector is not disconnected when the truck is in use and that there is a fixed connection between the connector halves during truck operation and when the battery is being charged. A poor connection will cause the contacts to burn and damage the operation and charging capacity of the battery.

Apply the handbrake.

l

Switch off the truck and remove the key.

l

Open the battery compartment lid.

l

Remove the battery connection and put the battery cable in a safe place.

l l

Reading the Electrolyte Level

Securely fit the appropriate lifting equipment.

Using an appropriate lifting mechanism lift the battery out of the truck and rest it securely.

Check the electrolyte level on the surface of the battery fluid before adding destilled water.

The electrolyte density is the most reliable indicator of the battery's condition. When checking it, make sure that sufficient electrolyte is suctionned into the glass tube so that the floating body can swim freely when the acid tester is held vertically.

l

l

Install the charged battery in the reverse order.

Charging the Battery DANGER

To compensate for loss of electrolyte use destilled water only. Replenish at regular intervals irrespective of the ambient temperature (see maintenance schedule in Section M1.0).

The battery plates must be covered. Never overfill the battery as wet and dirty cell lids lead to leak current and can thus reduce battery power. Overfilling can also lead to corrosion of the battery terminals and damage to the battery housing.

HYDROGEN IS RELEASED DURING CHARGING WHICH CAN IGNITE AND EXPLODE. IT IS A LIFE-THREATENING DANGER!

l Always keep the battery compartment lid open when charging a fixed battery. l

Make sure the charging area is well ventilated.

l

The charging area must be free from naked flames and sparks.

Excessive loss of electrolyte indicates a faulty battery, e.g. due to over-charging, total discharge, leak current from individual battery cells etc.

Printed in Germany

01/99 M4.25-2230-001 21

MAINTENANCE CAUTION BEFORE COMMISSIONING THE CHARGER MAKE SURE THAT IT IS SUITABLE FOR THE BATTERY VOLTAGE AND SIZE. READ THE INSTRUCTIONS OF THE CHARGER MANUFACTURER. Connect the battery to the charger. Make sure that the connection is secure.

After charging, make sure that all insulators between the cell connections and the battery lid are correctly positioned before using the truck again.

DANGER NEVER TRAVEL WITHOUT A SIDE BATTERY COMPARTMENT PANEL OR WITH AN OPEN BATTERY COMPARTMENT LID. THIS CAN RESULT IN ACCIDENTS.

Printed in Germany

01/99 22 M4.25-2230-002

MAINTENANCE Battery Discharge Indicator (BDI) General A battery from the factory requires between 5 - 10 discharge cycles before it reaches its full capacity.

A battery is considered to be discharged when it has a residual capacity of 20 %. For example, a battery with a capacity of 500 Ah has an actual available output of 400 Ah. In addition the usable output depends on the discharge rate which in turn is governed by the particular truck application. For this reason the battery discharge indicator must be set in accordance with the conditions of use of the truck. An incorrectly set battery discharge indicator can result in total discharge or complete failure of the battery.

NOTE FOR NEW TRUCKS, ADJUST THE BATTERY DISCHARGE INDICATOR AFTER TEN DISCHARGE AND CHARGE CYCLES AT THE LATEST.

Adjusting Indicator

the

Battery

Discharge

The standard factory setting for the battery discharge indicator is "N" (selector at the back of the BDI module).

To adjust this setting proceed as follows:

l

Measure the electrolyte density on the fully charged battery.

The density should be measured on three different battery cells and should be at least 1.27 - 1.28 or 1.29 - 1.30 for high density batteries (consult battery manufacturer for exact values).

l

Measure the acid density again as soon as two red LEDs on the battery discharge indicator flash and lifting is automatically interrupted. Take the reading as before. The reading should not be less than 1.12- 1.13.

l

For higher readings change the battery discharge indicator setting to "K", for lower readings change to "U".

l

Make a test measurement with the battery charged and discharged.

Printed in Germany

01/99 M4.30-2230-001 23

MAINTENANCE Traction / Pump Motor Maintenance Access

l

Remove the battery connector.

l

Remove the left hand floorboard (no screws, Fig. M0023).

M0077

l

Remove all carbon brushes and check each one for wear. Replace if brush length is less than 20 mm (traction motor) respectively 15 mm (pump motor) (Fig. M0076). Apply pressurised air to the motor.

M0023

l

On the right hand floorboard loosen one hex. socket screw and lift up the floorboard (Fig. M0024).

M0076

l

Check the anchor for evenness and make sure it is not damaged in any way. An evenly distributed layer on the brush surfaces is normal.

M0024

l

Remove the strap retainer from the upper motor section (Fig. M0077).

l

Make sure that all brushes apply a uniform pressure to the anchor.

l

Re-fit the strap retainer.

Printed in Germany

01/99 24 M4.35-2230-001

BRAKE

Printed in Germany

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Printed in Germany

MAINTENANCE Brake System General The left and right hand gear units each contain a drive wheel brake unit (Fig. M0361) which acts as an operating and parking brake.

The operating brake is activated via a brake pedal linkage.

The parking brake is activated by a handbrake lever and a handbrake cable which is connected to the brake linkage.

The brakes are spring-released.

Operation When the brake pedal is applied the two friction plates act on the brake disk via the clamping plate to brake.

Base plate

Friction plate

Handbrake cable

Brake pedal linkage

Brake disk

Spring

M0361

RH brake unit

Spacer

Clamping plate

LH brake unit

Printed in Germany

01/99 M5.0-2230-001 1

MAINTENANCE Replacing the Brake Disks and Linings Preparation To assemble new brake lining disks:

l

Raise the mast and secure it with square wedges (Fig. M0342);

l

Remove the floorboards and internal panelling (Fig. M0253b, M0254b).

Secure inside mast with square wedges

M0342

M0253b

Fig. M0253b: Removing the left and right-hand floorboards):

Fig. M0254b: Removing the dashboard panel:

l

Remove the Allen screw from the RH floorboard.

l

Move the floorboards away from each other and lift them out.

l

Remove the 6 Allen screws.

l

Remove the panelling.

M0254b

Printed in Germany

01/99 2 M5.0-2230-002

MAINTENANCE Brake Disk and Lining Dimensions Always replace the LH and RH brake disks and brake lining plates (as a set) at the same time.

l

Replace the friction plate if the lining is 2.8mm thick or less (lining thickness ≤ 2.8mm).

l

Replace the brake disk if the thickness is 5.6mm thick or less (thickness ≤ 5.6mm).

l

When the brake is applied the overall thickness of the LH and RH friction plates and brake disks should be no less than 11.2 mm (overall thickness ≥ 11.2mm).

Printed in Germany

01/99 M5.0-2230-003 3

MAINTENANCE Removing the Brake Disks and the Friction Plates (Fig. M0362)

l

Disconnect the battery;

l

Secure the truck to prevent it from rolling away;

l l

Remove the 2 splints (1);

Remove both bolts (2) from the base plate and clamping plate (4) and press the linkage (3) down;

l

Remove the clamping plate (4);

l

Loosen the mounting screw (5);

l l

Remove the mounting pad (6) and spacer (7);

Unscrew the 4 nuts (8) and remove the 4 washers (9);

l

Remove the front friction plate (10);

l

Remove springs (12, 13);

l

Remove the brake disk (14) from the pinion

l

Remove the pinion (15) from the transmission

(15);

shaft;

l

Unscrew the 4 studs (16) and remove the back friction plate (17).

Installation

l

Installation is the reverse of removal.

NOTE BEFORE INSTALLING THE FRONT FRICTION PLATE (10) INSERT TWO PINS (11) TO FIX THE SPACER (7).

l l

Adjust the operating and hand-brake; Test the brake.

Printed in Germany

01/99 4 M5.0-2230-004

MAINTENANCE

Printed in Germany

01/99 M5.0-2230-005 5

MAINTENANCE l

l

Remove the 4 nuts (1);

Measure the air gap at three points between the brake disk and the friction plate using a feeler gauge (Fig. M0364). The nominal value is 0.5 - 0.7mm;

l

Remove the pin (2);

l

Removing the Handbrake Cable (Fig.M0366)

Unscrew the counternut (Fig. M0343);

l

l

l

l

Measure the air gap again at three points;

l

Fix the counternut;

To reduce the air gap turn the threaded rod clockwise, to increase it anticlockwise;

Remove the bolt (3) from the handbrake lever and cable; Remove the upper end of the handbrake cable (6) from the handbrake lever;

l

Remove the pin (4);

l

Remove the bolt (5);

l

Remove the handbrake cable (6) from the truck;

l

Make sure that the brake disk is free to move on the toothing;

l

Adjust the handbrake cable.

Installation

l

Installation is the reverse procedure.

l

Adjust the handbrake.

0.5 - 0.7 mm

M0364

Jam nut Reduce air gap

Increase air gap

Adjusting the Operating Brake and Handbrake Preparation

Threaded rod

To adjust the operating and handbrake, remove the floorboards (Fig. M0253b) and inside panelling (Fig. M0254b).

M0343

Adjusting the Operating Brake Air Gap

l

Push the floating brake disk towards the left or right-hand friction plate;

Printed in Germany

01/99 6 M5.0-2230-006

MAINTENANCE Operating Brake Test

l

On a level, dry surface accelerate the empty truck at operating temperature to maximum speed.

l

Record the braking distance from the point where the brakes were applied to the point where the truck stops. The braking distance should not exceed 3.10m.

Handbrake Adjustment Adjust the handbrake lever so that the lever is in the 5th notch when applied.

l l l

Remove the nut (1); Screw the nut (2) to adjust; Tighten the nut (1);

l

Pull the handbrake cable ten times in the applied position (5th notch);

l

If the lever exceeds the 5th notch position, readjust the handbrake.

CAUTION IF THE BRAKE CABLE IS TO BE REPLACED IN FULL, THE HANDBRAKE MUST BE SET TO THE THIRD NOTCH POSITION TO ALLOW FOR THE CABLE EXTENSION.

2

1

M0363 Printed in Germany

01/99 M5.0-2230-007 7

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Printed in Germany

STEERING

Printed in Germany

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Printed in Germany

MAINTENANCE Steering Hydraulic System The input section of the pilot valve contains a so-called priority valve (Fig. M0117) which distributes the oil flow between the steering and the other hydraulic functions of the truck. Priority is always given to steering.

When the steering wheel is turned, oil flows from the oil tank to the pilot valve and from there to the steering unit via the priority valve. Any oil not required for steering at a given moment is also directed via the priority valve to the in-line lifting functions.

When the oil is distributed, the composition is determined by the LS signal transmitted by the steering unit to the priority valve. When the load pressure increases a proportionally greater amount of oil enters the steering unit. An overload valve limits the operating pressure in the steering unit to 70 bar.

M0115B

Figure M0118 shows a lateral view of the complete steering system motor. The following components can be seen:

l l l l

Steering potentiometer and connection 3 point mounting flange Wheel hub and wheel pickup Steering cylinder and hydraulic connection.

M0117

Components The following components can be accessed by removing the steering shaft cover (Fig. M0115B):

l

Steering shaft and toothing

l

Steer sensor (records steering shaft motion to activate the pump via the pump controller)

l

Sensor module

l

Distributor system with 5 connections (pressure, return flow, LS to priority valve and 2 outputs to the steering drive cylinders).

The hydraulic steering unit is behind the distributor system.

M0118

Printed in Germany

01/99 M6.0-2230-001 1

MAINTENANCE l

Disconnect the steering potentiometer and remove the potentiometer;

Removing the Steering Motor

l

Jack up and secure the truck;

l

Disassemble both wheels;

l

Attach a rope to the top of the drive unit to prevent it from falling;

l

l

l

l

Remove the 3 screws of the mounting flange;

l

Lower the drive motor.

Prepare the area for the collection of spilled hydraulic oil; Disassemble the two hydraulic lines from the steering cylinders;

Secure the lower section of the drive unit with wooden blocks;

Steering System Hydraulic Diagram R A C K A N D P IN IO N C Y L .

R L

O R B IT A L S T E E R IN G U N IT D Y N A M IC L S C L O S E D C E N T R E N O N R E A C T IO N L S

P

C F

1 A

P R IO R IT Y V A L V E D Y N A M IC L S

L IF T

L S T

1 B

S T E E R R V 7 0 B A R

O P T O E N C O D E R T

M A IN R V 2 1 0 B A R

P

M O T O R F IL T E R

T IL T

P U M P S T R A IN E R

792341lenk-gb Printed in Germany

01/99 2 M6.0-2230-002

MAINTENANCE Steering Drive Assembly

Steering Axle

Wheel hub pre-assembly

Design

l

Insert the wheel bolts (item 34) using a hydraulic device (Fig. M1248).

The steering axle comprises the steering drive and the axle bracket. The steering drive comprises a hydraulically activated spur gear tooth rod drive connected to the axle bracket via a flange.

l

Fit the bearing halves of the conical roller bearings (item 28) into position and grease the bearing half of the inner conical roller bearing with Crown P/N 053002-001.

NOTE WHEN ORDERING SPARE PARTS BEAR IN MIND THAT THE AXLE BRACKET IS ONLY AVAILABLE AS A COMPLETE ASSEMBLY, I.E. WITH PRE-ASSEMBLED AXLE.

Steering knuckle pre-assembly

l

Push the seal (item 27) up the steering knuckle filled with grease (Crown P/N 053002-001).

The reference numbers contained in the following assembly instructions refer to the exploded diagram in chapter 6 of the spare parts section in the second part of this manual.

l

Heat the inner conical roller bearing (item 28) and fit it in position. Finally, grease with Crown P/N 053002-001.

Steering knuckle and wheel hub assembly As mentioned at the beginning, the steering knuckle is supplied with the pre-assembled axle as a complete assembly (item 25).

For the remaining assembly, proceed as follows:

l

Fit the wheel hub (item 29) on the steering knuckle (item 25).

l

Fill the space between the wheel hub and the steering knuckle with Crown P/N 053002-001 grease.

l

Grease the outer conical roller bearing (item 28) with Crown P/N 053002-001 and insert it in the wheel hub.

l

Position the U-shaped washer (item 30) and firmly screw in the castellated nut (item 32).

l

To check the bearing play, turn the wheel hub.

The vacuum resistance should be 2 - 6 Nm. If necessary adjust using the torque of the castellated nut.

M1248

l

When the bearing play has been correctly set, secure the castellated nut using the splint (item 31).

l

Drive in the cover (item 33) filled with Crown P/ N 053002-001 grease, thereby sealing the assembly from external influences.

Printed in Germany

01/99 M6.1-2230-001 3

MAINTENANCE l

Spur pinion wheel shaft pre-assembly

l

Fill the seal (item 23) with Crown P/N 053002001 grease and place it in position.

l

Press the conical roller bearing (item 22) on top.

Position the shim and the bevelled washer (item 6). Place another shim above the bevelled washer.

l

Fit the bearing half of the conical roller bearing (item 5) into position (Figs. M1251, M1252).

l

Heat the bearing race (item 21) to approx. 120°C and seal with LOCTITE 620, Crown P/N 794102 (Fig. M1249).

M1251

M1249

Housing Pre-Assembly

l

Clean the housing (item 9) using a cold cleaning solution and blast out with pressurised air.

l

Insert the retaining ring (item 7) for the top conical roller bearing (Fig. M1250).

M1252

l

Turn the housing and fit the bearing half of the conical roller bearing (item 22) into position (Fig. M1253).

l

Fit the conical roller bearing (item 5) (Fig. M1254). Now place the wheel shaft in the housing.

M1250

Printed in Germany

01/99 4 M6.1-2230-002

MAINTENANCE When the bearing play has been set, disassemble the spur pinion wheel shaft and proceed as follows to continue preparation of the housing:

l

Gently oil the shaft seals (items 8, 20) and press into position (Figs. M1255-M1258).

M1253

M1256

M1254

Setting the Bearing Play: Place two shims on the bearing.

l

Screw the groove nut (item 1) to medium tightness.

l

After tightening, hammer gently on the top section of the housing using the plastic hammer to position the bearings.

M1255

l

Check the bearing play manually. It is better for the bearing to be slow to move rather than too free (vacuum resistance 2 - 5 Nm). If the bearing is too free, replace the bevelled shim (gauge, item 6).

Printed in Germany

01/99 M6.1-2230-003 5

MAINTENANCE

M1260 M1258

M1257

M1259

l

l

Thoroughly grease the bearing halves of the conical roller bearing (item 22) using GRESALIT LZ2 (Fig. M1260).

l

Grease the conical roller bearing (item 22) and the spur pinion wheel shaft with GRESALIT LZ2 (Fig. M1259).

Place the tooth rod (item 36) in the housing, while ensuring that the threaded groove rests in the middle of the housing.

2 teeth on the spur pinion wheel shaft are marked with a bevel. The housing must be positioned so that the tooth rod groove lies between the bevelled teeth (Fig. M1261).

Printed in Germany

01/99 6 M6.1-2230-004

MAINTENANCE Tooth bevelment

Tooth rod

M1263

l

Fill the seal (item 4) with grease (use residual grease from previous step) and place in position.

M1261

Threaded groove

l

Position the shim (item 3) and the retaining plate (item 2) (Fig. M1264).

Drive shaft

l

Fill the bearing half of the top conical roller bearing (item 5) with Crown P/N 053002-001 so that grease emerges when the bearing is re-positioned (Figs. M1262, M1263).

M1262

l

Tighten the groove nut (item 1) and fix in position by placing it over a hub of the retaining plate (item 2) Fig. M1265).

M1264

Printed in Germany

01/99 M6.1-2230-005 7

MAINTENANCE l

Manually screw in the cylinder (item 17) using screw locking device (LOCTITE 242 Crown P/N 053050-006) and tighten (medium tight) in a clamp using the wrench.

Assembling the Axle Bracket to the Steering Drive

l

Drive the clamping sleeve (item 19) into the top treated surface of the axle bracket (Fig. M1267).

M1265

Cylinder Pre-Assembly

l

Place the pistons (item 13) complete with piston guide rings (item 12) and the compact seal (item 14) into the cylinder (item 17) without tilting. Ensure that the cylinder contact surfaces are totally clean.

M1267

l

Place the axle bracket on the transmission housing.

l

l

Finally, fill each cylinder with G00F (to DIN 51502) gear lubricant. Capacity per cylinder:125 cm3.

Fit the tensile lock screws (item 26) and torque to prescribed moment (320 Nm).

l

Fitting the Cylinders

Final check: move cylinder in both directions with air and check operation.

l

Drive the bushing (item 5) into the housing.

Gently oil the tooth rod (item 36) (Fig. M1266).

l

Place gently greased O-rings (item 16) in their respective housing grooves. Check correct position.

The final assembly of the steering axle is complete when the lock screw (item 10) is assembled with the seal ring (item 11) placed underneath it.

Operational and Leak Test Finally, an operational and leak test should be carried out if possible.

l

Steer in both directions two or three times until you reach the stop.

l

Remove the cylinder again and carry out a visual inspection. Above all, check for any damage, leaks, grooves in the cylinder surfaces etc.

M1266

Printed in Germany

01/99 8 M6.1-2230-006

MAINTENANCE Maintenance General To protect cylinders and seals the machine-specific oil checks and change schedules must be observed (see page M1.3-2230-001 in the present manual).

In addition the steering axle must be checked in the course of daily service and maintenance for any leakages, corrosion or other types of damage as well as for general operation and safety. If in doubt, replace the parts.

In particular, the seals must be aligned with the wheel bearings (item 27) and the wheel shaft bearing (item 4), as the bearings could run dry if damage occurs.

Gear Lubricant The gear lubricant used is G00F (to DIN 51502) and is suitable for use in temperatures of between -20°C and +80°C. For colder ambient temperatures contact your Crown dealer.

Seals The seal material used is designed for temperatures between -40°C and +100°C.

Printed in Germany

01/99 M6.1-2230-007 9

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Printed in Germany

MAST

Printed in Germany

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Printed in Germany

MAINTENANCE Mast Disassembly To disassemble the lift mast proceed as follows:

l

Mast roller

Prepare the area for the collection of spilled

oil.

l

Remove the 2 pressure lines and 1 pressure hose from the storage housing (Fig. M0234).

Washers 0.4 - 1.52 mm

M0380

The following washer dimensions are available: 0.4mm, 0.76mm and 1.52mm. Ideally, the same number of washers should be used on all mast rollers. Although this is not always possible, it is important to ensure at least an even distribution of washers on each side.

An example of this would be 2 washers on each roller on the left-hand side of the mast and 1 washer on each roller on the right-hand side of the mast (Fig. M0381). Uneven distribution of the mast rollers will cause the mast to tilt (Fig. M0382).

M0234

l l l l

Secure the upper section of the mast with suitable equipment.

Disassemble the tilt cylinder from the mast.

Remove the bearing halves in the lower mast section from drive.

Lift out the mast from the top.

Mast Roller Adjustment The play of the mast sections is greatest when they are retracted and least when they are extended. Accordingly, the mast rollers can move freely when the mast is retracted and provide maximum stability when the mast is extended. The mast sections' play should therefore only be checked when the mast is extended.

The washers used for adjusting the mast roller play are placed underneath the mast rollers (Fig. M0380). To do this, the mast rollers must first be disassembled.

Printed in Germany

01/99 M7.0-2230-001 1

MAINTENANCE

Non-Adjustable

1 washer (fork carriage)

2 washers (mast)

2 washers (fork carriage)

2 washers (fork carriage)

1 washer (fork carriage)

1 washer (fork carriage)

2 washers (fork carriage)

2 washers (mast)

1 washer (mast)

1 washer (mast)

2 washers (mast)

1 washer (mast)

M0381

M0382

Printed in Germany

01/99 2 M7.0-2230-002

MAINTENANCE Fork Carriage Roller Adjustment 6 rollers are attached to the fork carriage in total (Fig. M0383). The highest roller extends above the mast section when the mast is lifted. It is secured by a retaining ring and does not require any adjustment.

Sideshift roller, adjustable

Mast rollers, fixed

M0384

Crow bar

Caliper

Mast rollers, adjustable Sideshift roller, adjustable

To adjust the other 4 rollers, proceed as follows:

l

Extend the fork carriage as far as the stop and lower slightly.

M0385

Add washer if play > 0.76mm

l

To check the play of the fork carriage rollers push the fork carriage on its side using a crow bar.

This will keep the opposite side held firmly against the mast section, enabling the mast section to be measured exactly (Fig. M0384).

l

After moving the fork carriage maintain a slight pressure to keep the fork carriage in position.

l

Record the play between the roller and the mast section at a distance of 10mm from the front of the section (Fig. M0384). If the rollers are slightly skew, always measure the lesser play.

l

The play should be between 0mm and 0.76mm.

If it exceeds 0.76mm fit another washer behind the roller (Fig. M0385).

Printed in Germany

01/99 M7.0-2230-003 3

MAINTENANCE Mast Roller Adjustment

Checking the Mast Play

6 rollers are attached to the TT mast in total, 4 on the TL and TF masts respectively. To adjust the mast rollers, proceed as follows:

When the mast roller play has been adjusted by adding or removing washers, the operation of the mast rollers must be checked as follows.

l

l

l

l

Extend the mast as far as the stop and lower slightly. This prevents the mast from twisting.

To check the play of the mast rollers push the mast section on its side using a crow bar. This will keep the opposite side held firmly against the mast section, enabling the mast section to be measured exactly.

l

After moving the mast section maintain a slight pressure to keep the mast section in position.

l

Record the play between the mast roller and the mast section at a distance of appr. 10 mm from the front of the section (Fig. M0386). If the rollers are slightly skew, always measure the lesser play.

Remove grease from the mast sections with a solvant and wipe with a cloth.

Spay the mast sections with a thin layer of paint. The grooves provide a guide to the mast rollers' operation. There should only be wear on the contact surfaces of the mast rollers.

l

There should be no grooves or other damage to the mast sections. Grooves normally form on the roller side approx. 10 mm from the front of the section.

If this occurs, a washer should be removed and the mast re-aligned.

l

The play should be between 0mm and 0.76mm.

If it exceeds 0.76mm place another washer behind the roller (Fig. M0385).

M0386

Crow bar

Caliper

Printed in Germany

01/99 4 M7.0-2230-004

MAINTENANCE service hours for maintenance should be halved. The lift chains should be cleaned with paraffin or a derivative prior to inspection.

Lift Chain Test General

NOTE

Lift chains are a major component of a fork lift truck and are subject to considerable stress.

DO NOT USE CHEMICAL SOLVANTS OR STEAM TO CLEAN THE CHAINS AS THE LUBRICANT APPLIED AT THE FACTORY WILL BE REMOVED FROM THE INNER PLATE SURFACES.

The present maintenance instructions will contribute to ensuring maximum operational life and prevent premature failure of the lift chains.

The lift chain with its numerous connection plates is designed to provide a better flow of oil to the individual chain pins (Fig. 2777si).

Look out for the following damage and wear:

l

Worn or missing connection plates

l

Pitting due to rust or corrosion, in particular on the outer surfaces of the connection plates;

Lubricant film

l

Pins turning in or extruding from the outside plates;

l

Loss of freedom of movement, worn connection plate edges;

l l

Wear and corrosion to the anchor bolt and anchor;

2777si

l

Wear between the bolts and the connection plates;

A sufficient lubricant film guarantees:

l l l

l

Less joint wear as well as less chain elongation;

IF ONE OF THE ABOVE PROBLEMS OCCURS IMMEDIATELY REPLACE THE CHAINS, CHAIN ANCHORS OR BOLTS IN PAIRS.

Less distortion of the pins; The joints are free to move;

l

Smooth and even chain flow;

l

Less tension due to reduced internal friction.

Chain elongation.

DANGER

Less corrosion;

l

Damage to the anchor bolt attachment;

NEVER ATTEMPT TO REPAIR DAMAGED CHAINS. THIS CAN RESULT IN FATAL ACCIDENTS.

Maintenance The chain must be inspected every 100 hours for any signs of faults or damage. If this cannot be performed on the truck, the lift chains must be removed.

Irrespective of the result of the inspection, the lift chains, detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first.

In severe operating conditions (e.g. cold store) the maintenance interval or the recommended number of Printed in Germany

01/99 M7.5-2230-001 5

MAINTENANCE DANGER

Detailed Chain Testing

NEVER ATTEMPT TO REPAIR THE CHAIN BY DRIVING PINS BACK INTO THE CHAIN. THIS CAN RESULT IN ACCIDENTS WITH SEVERE OR EVEN FATAL INJURIES.

Worn or Missing Plates Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (Fig. 2774si) can crack after a large number of lifting cycles with heavy loads.

2774si

Replace both chains immediately if cracking shows or plates are missing.

Pitting and Corrosion Pitting and corrosion occur as a result of poor maintenance or storage. The layer of grease applied at the factory is an excellent protection and should never be removed by steam jet cleaning or chemical solvants.

Pitting and corrosion contribute to wear of the outside plates in particular, in the form of cracking (Fig. 2773si).

If rust is visible during inspection, immediately disassemble the chains and inspect for any damaged or worn plates.

2776si

Freedom of Movement and Worn Edges Each individual chain link must flex freely. Tight joints (Fig. 2775si) increase friction and the chain tension during lifting.

Excessive chain tension in turn accelerates material wear.

Possible causes of stiff joints are as follows:

2773si

Immediately replace the chains if damage or cracking is visible.

l

Bent pins or plates;

l

Rusty joints;

l

Peened plate edges.

Chains which are bent or whose edges are worn must be replaced immediately.

Possible causes of worn edges are as follows:

Protruding or Turned Chain Pins Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existant film of oil. In extreme cases the frictional torque in the joints can be such that the pins turn and gradually work out of the chain (Fig. 2776si). This can result in chain failure.

l

Worn pulleys;

l

Lifting too heavy loads;

l

Chain chafed at another part of the mast.

Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction.

Chains with twisted or protruding pins must be replaced immediately.

2775si

Printed in Germany

01/99 6 M7.5-2230-002

MAINTENANCE Measuring the Chain Elongation Before testing the chain elongation it is important to tension the lift chain if necessary. For non-detachable lift chains the weight of the fork carriage or mast is sufficient. If the lift chain is detached it must be kept taut during measurement.

First mark the most heavily worn section of the lift chain which regularly runs over the pulley. The measurement must now be recorded within the marked area and must cover at least ten links over at least three different points.

This can be carried out using a scale (Crown No. 106440, Fig. 2771) or a steel tape.

2771

If an elongation of more than 3% over the nominal length is recorded, the chain must be replaced in pairs.

Stencil with 2 measurement scales: Measurement scale A: Scale division 19 mm Measurement scale B: Scale division 25 mm and 16 mm

Chain Tension When installed, both lift chains should have the same chain tension to ensure even distribution of the load over the two chains when lifting.

When replacing the forks make sure that both forks lie evenly on the surface. If they are not even, compensate the chain length via the chain anchor so that both chains have the same chain tension.

After adjusting the counternuts tighten the chain anchor again.

Chain Anchor and Pulleys In the course of checking the chain system, the chain anchors, chain bolts and pulleys must be checked for wear.

On the chain anchor watch out for wear and cracking of the individual fingers. If one of the above problems occurs replace the chain anchor.

Pulleys with heavily worn flanges and contact surfaces must be replaced. Worn flanges are due to misalignment.

The chain tension and mast roller setting must be checked.

Printed in Germany

01/99 M7.5-2230-003 7

MAINTENANCE DANGER

Fork Tine Test

FORKS SHOWING SIGNS OF CRACKING, DISTORTION OR WEAR MUST BE DECOMMISSIONED. THEY ENDANGER THE LIFE OF THE OPERATOR AND OTHER PEOPLE AS WELL AS THE GENERAL OPERATION OF THE TRUCK.

General The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see M1.22230-009) for cracks, damage and wear.

If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.

Repairs Fork repairs must only be carried out by the manufacturer / qualified personnel. When repairing supporting members always carry out a load test and check for signs of cracking.

Crack Inspection

Fork blade Fork hanger

Inspect all fork tine surfaces for signs of cracks (Fig. M0346) and if necessary carry out a non-rupturing crack test (magnetic particle cracking test in accordance with DIN 4113). For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam.

Fork shank

M0344

Curve section

Fork Identification The data plate is on the side of the fork back (Fig. 0345) and comprises the following data:

l

Capacity

l

Load Centre of Gravity

l l l

Cracks

Manufacturing Data (Month / Year) M0346

Company Logo Manufacturing SIte 1

2 900 x 600 304 ... ../..

5

4

3

M0347

Check fork hanger welding seams for any signs of cracking

M0345

Printed in Germany

01/99 8 M7.6-2230-001

MAINTENANCE If any cracking is discovered which could affect safety remove the relevant fork.

DANGER NEVER CARRY OUT REPAIR WELDING TO SURFACE CRACKS, DAMAGED OR WORN PARTS AROUND THE HEEL OF THE FORK.

Verticality Test Check verticality of fork shank (Fig. M0349) and fork tip (Fig.M0350/0351). If the readings illustrated below are exceeded the fork must be taken out of service.

Linear

≤ 6.0 mm

M0351

500 mm

≤ 2.5 mm

Fork Blade Warping Measure the angle deflection between the top of the fork blade and the front of the fork shank. If it is more than 91° or less than 88° (Fig. M0352) the fork must be re-aligned and checked before it can be used again. For measuring procedure see Fig. M0353.

M0349

Min. 88° Max. 91°

Fork tip

2 mm M0352

250 mm M0350

500 mm x - 17.0 mm x + 8.5 mm

x

M0353

Printed in Germany

01/99 M7.6-2230-002 9

MAINTENANCE Measuring the Fork Tip Width

Fork Stop

If the fork tip width S is less than a + 6 mm (a = fork back width) do not use the fork (Fig. 0355).

Check the stop mechanism (Fig. M0356) on both fork tines.

If faults or damage are discovered do not use the fork.

S ≥ a + 6 mm

Stop mechanism

M0355

Fork Tine Height Difference Check the height of the fork tines in relation to each other (Fig. M0354) if the fork is fixed to the fork carriage. If the difference is greater than 3 % of the fork blade length the fork tines must be correctly aligned.

M0356

Example: If the length of the fork blade is 1150mm the maximum permissable deviation is approx. 35mm.

It is however generally advisable to align the forks if the deviation is max. 10mm.

L

3 % of L

Left Fork

M0354

Right Fork

Printed in Germany

01/99 10 M7.6-2230-003

MAINTENANCE Wear Check for fork blade wear, in particular at the heel. If the width is 90 % or less than the original value, the fork must be taken out of service. Use a caliper (Crown No. 107330) to check for wear (Fig. 0357).

Fork Blade Cross Section

Outside jaws 100% (Fork Shank)

Inside jaws 90 % (Fork Blade) M0360

M0357

l

First caliper the outer opening 100% in the central area "a" (Figs. M0358, M0359) of the fork shank.

Caliper here the outer opening

M0358

Fork Back Section

M0359

l

Using the caliper, scan the fork blade between the taper and the curved area.

l

If the inner scan point fits 90% over the fork blade (Fig. M0360), the fork must not be used.

Printed in Germany

01/99 M7.6-2230-004 11

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Printed in Germany

CYLINDERS

Printed in Germany

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Printed in Germany

MAINTENANCE Cylinders General There are two types of hydraulic cylinder

l l

Plunger cylinders Piston cylinders (double-acting cylinders)

The two types differ in their action as well as their sealing material.

Plunger Cylinders (single-acting cylinders) The plunger cylinder has a single pressurised piston surface which generally equates to the piston rod diameter (see Fig. M0823).

The piston rod enters the cylinder through one or more guide rings. The inside of the cylinder and the piston rod are sealed from the outside by a rod seal contained in the cylinder head and a contamination scraper ring.

The piston rod retracts either through its own weight or through the force of the load acting on the piston rod.

The lift cylinders on the SC3000 are single-acting.

Guide Ring

Oil

Cylinder Tube

Oil

Rod Seal

CylinderHead

O Ring

Piston rod

Scraper M0823

Printed in Germany

01/99 M8.0-2230-001 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.

The tilt cylinders are examples of double-acting cylinders on the SC3000.

Printed in Germany

01/99 2 M8.0-2230-002

MAINTENANCE Single-Acting Cylinder

Piston Seal

Piston

Guide Ring

CylinderHead

Piston Rod Oil

Cylinder Tube

Rod Seal Scraper Ring

Return Flow to Tank

M0822

Double-Acting Cylinder

Piston Seal

Piston

Oil

Cylinder Tube

Guide Ring

Oil

Rod Seal

O Ring

Scraper Ring

Cylinder Head

Piston Rod

M0824

Printed in Germany

01/99 M8.0-2230-003 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.

l

High-pressure fluids can penetrate the skin and cause severe injuries. Reduce the pressure before disconnecting the hydraulic lines.

l

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

l

Use paper or cardboard to trace leaks.

Do not use your hands.

l

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.

l

Check the piston rod for scratches, nicks and other surface damage.

l

Check scraper rings and the entire cylinder head area for individual component wear and abnormal leakage.

l

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.

l

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.

l

Minor irregularities on the cylinder tube surface or on the piston rod can be removed with an aluminium oxide cloth or a honing tool.

l

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

01/99 4 M8.0-2230-004

MAINTENANCE Installing the Piston Seal Connecting Rod

General NOTE

Critical Seal Position

CHECK THE SEAL GROOVE AND THE PISTON ROD (CRITICAL SEAL POSITION) FOR DAMAGE BEFORE FITTING A NEW SEAL. OTHERWISE, LEAKAGE WILL RE-OCCUR AFTER THE NEW SEAL HAS BEEN FITTED.

Groove Aligning Arbor

M0041B

When fitting rod seals use assembly equipment and tools made of soft metal or plastic without sharp edges. Do not use a screwdriver or similar tools as these will damage the seal edges.

Assembly of Large Rod Seals Equipment:

If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate protective mechanisms.

l l

Rod Seal Disassembly Tool

Tool body Three pins nos. 1, 2 and 3; pin no. 1 is fixed;

Assembly:

l

Apply a thin layer of hydraulic oil to the rod seal and seal position;

l

Place the rod seal over fixed pin no. 1 and wrap it around pin no. 2 (Fig. M0042); 127 mm Pin no. 3

Tool body

M0040B

Pin no. 1

Assembly of Small Rod Seals

Pin no. 2

Equipment:

M0042

l

Groove aligning arbor to lock with the cylinder union groove

l

l

Keep bending the rod seal until pin no. 3 can fit in the loop created (Fig. M0054);

Connecting rod

Assembly:

l

Apply a thin layer of hydraulic oil to the rod seal and fitting groove; Pin no. 3

l

Gently squeeze the seal together and place it in the hole;

Pin no. 1

l

Pin no. 2

Using the connecting rod push the seal into the groove (Fig. M0041B).

M0054

Printed in Germany

01/99 M8.0-2230-005 5

MAINTENANCE l

Fit the tool body and rod seal into the cylinder

union.

l

Remove pin no. 3 so that the rod seal loop can spring into the groove (Fig. M0043);

Pin no. 3

M0043

l

Remove pin no. 2 so that the rod seal is positioned fully in the groove (Fig. M0044);

Pin no. 2 M0044

l

Remove the tool body from the cylinder union.

Printed in Germany

01/99 6 M8.0-2230-006

ELECTRICAL DIAGRAMS

Printed in Germany

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Printed in Germany

ELECTRICAL DIAGRAMS Key Connectors

Contactors

Traction Controller Connectors

FA

Left Motor Forward Contactor

CA 201

E

RA

Left Motor Reverse Contactor

CA 202

D

FB

Right Motor Forward Contactor

CA 203

C

RB

Right Motor Reverse Contactor

CA 204

B

LC

Line Contactor

CA 205

A

RGB

Regenerative Braking Contactor

CA 206

F

CA 207

G

CA 208

H

CA 209

J

Abbreviations

Pump Controller Connectors CA 210

L

CA 211

E

CA 212

D

CA 213

C

CA 214

B

CA 215

A

CA 216

Panel

CA 217

Seat Switch

CA 218

Steering Feedback Potentiometer

CA 401

Accelerator Potentiometer

CA 402

Accelerator Switch

CA 403

Lift Potentiometer

CA 404

Tilt Switch

CA 405

Side Shift Switch

CA 406

Auxiliary Switch

CA 407

Pedal Brake Switch

CA 408

Handbrake Switch

CA 409

Horn

CA 410

BDI Supply

CA 411

BDI

CA 412

Steering Column

CA 601

Horn Switch

CA 602

Steering Encoder Module

ACS

Accelerator Switch

AXS

Auxiliary Function Switch

BDI

Battery Discharge Interrupt

BRS

Brake Switch

DIS

Direction Switch

EM

Encoder Module

ENC

Encoder

HBS

Handbrake Switch

HF

Hash Filter

HN

Horn

HNS

Horn Switch

KYS

Key Switch

POT 1

Accelerator Potentiometer

POT 2

Lift Potentiometer

POT 3

Steer Potentiometer

SES

Seat Switch

SH

Shunt

SSS

Side Shift Switch

TLT

Tilt Switch

TT

Hour Meter

NOTE: CA Connectors are a combination of the JC -XXX jack and the PC -XXX plug components (example CA 601 is a combination of PC 601 and JC 601).

Printed in Germany

01/99 DIA-2230-001 1

2 DIA-2230-002

01/99

B-

LC

B + SW

B+

H3 E1

KYS

FU3 10A

E2

E4

RB

D1

C1

POT2

E5

C3

E8

E2

E6

RA

E7

FA

E8

E3

D2

RGB

-

DIS

G7

B+ BDI

G5 F1

HBS

G8

G2

G3

+ POT1 -

G1

ACS

10A

Curtis 803 1 5 BDI + TT BBDI

FU5

8

2

L5 L6 L1 L8 L9

E6

4

3+

TRACTION CONTROL

L7

SES

E9

E5

AXS SSS TLT

ENC

PUMP CONTROL

FB

C2

-

+

EM

L2

L

R

L3

L4

+ POT3 -

HN

FU4 10A

G6

HF

BRS

HNS

ELECTRICAL DIAGRAMS

Control Circuit

793574_1a

Printed in Germany

BBDI

48V

BDI B+

+

LC

LD1

LD2

RGB

FU1 500A

VMNL

-SHL

SH

+SHL

RA

LA1 A

LA2 FB

RA1 A

-SHR VMNR

SH

+SHR

RB

RA2

RIGHT MOTOR (B)

TRACTION CONTROLLER

FA

LEFT MOTOR (A)

RD1

RD2 PUMP CONTROLLER

SH

B-

M-

M+

B+

FU2 350A

A

B-

B + SW

B+

ELECTRICAL DIAGRAMS

Power Circuit

793574_2

Printed in Germany

01/99

3 DIA-2230-003

ELECTRICAL DIAGRAMS Traction Controller CA 201

CA 206

ZAPI R 9

9 9

1

1

2930 - STAR D

ZAPI R 8

8 8

2

2

not used

ZAPI R 7

7 7

ZAPI R 6

6 6

1

1

524 - PC 401 - 3

ZAPI R 5

5 5

2

2

123 - PC 401 - 2

ZAPI R 4

4 4

3

3

722 - PC 401 - 1

not used

3 3

4

4

not used

ZAPI R 2

2 2

5

5

2927 - STAR B

ZAPI A 3 / L

1 1

6

6

2929 - PC 407 - C

7

7

2906 - PC 412 - 6

8

8

2905 - PC 412 - 5

1

1

not used

CA 207

CA 202 not used

2

not used

1

CA 208 CA 203

not used

3

2

2

not used

not used

2

3

3

ZAPI S 3

not used

1 1

1

not used

2

2

not used

1

1

5932 - STAR C

2

2

120 - PC 218 - 2

3

3

521 - PC 218 - 3

4

4

719 - PC 218 - 1

5

5

5933 - STAR C

6

6

5934 - STAR C

7

7

5931 - STAR C

8

8

5957 - STAR C

9

9

5958 - STAR C

CA 209 CA 204

7 6 5 4 3 2

HANDSET CONNECTOR

8 CA 210

1 CA 205 2 LED 1

793881-1 Printed in Germany

01/99 DIA-2230-004 4

ELECTRICAL DIAGRAMS Pump Controller CA 211 not used

9 9

5908 PC 601 - 8

8 8

not used

7 7

2937 PC 411 - 4

6 6

2915 PC 404 - C

5 5

not used

4 4

2914 PC 405 - C

3 3

2913 PC 406 - C

2 2

not used

1 1 CA 212

ZAPI A 10 JC 216 - 10

2

2

ZAPI L CA 201 - 1

1

1 CA 213

716 PC 403 - 1

3

3

518 PC 403 - 3

2

2

117 PC 403 - 2

1

1 CA 214

7 6 5 4 3 2

HANDSET CONNECTOR

8

1 CA 215 2 LED

1

793881-2 Printed in Germany

01/99 5 DIA-2230-005

ELECTRICAL DIAGRAMS Seat Switch and Steer Pot

JC 216

PC 216 201 PC 412 - 1

1

1

ZAPI A 1 Fu 3

202 PC 412 - 2

2

2

ZAPI A 2 Fu 4

2903 PC 412 - 3

3

3

ZAPI A 3 PC 201 - 1

not used

4

4

not used

5

5

not used

6

6

562 PC 409 - 2

7

7

ZAPI A 7 ( B - )

509 PC 601 - 9

8

8

ZAPI A 8 ( B - )

not used

9

9

2935 STAR A

10 10

not used

11 11

not used

12 12

PC 217

ZAPI A 10 PC 212 - 2

JC 217

5938 STAR E

1

1

5945 STAR C

2

2

SES

JC 218

PC 218 719 PC 210 - 4

1

1

120 PC 210 - 2

2

2

521 PC 210 - 3

3

3

not used

4

4

POT 3 STEERING FEEDBACK

793881-3 Printed in Germany

01/99 6DIA-2230-006

ELECTRICAL DIAGRAMS Control Levers JC 401

PC 401 722 PC 207 - 3

1

1

POT 1

123 PC 207 - 2

2

2

ACCEL.

524 PC 207 - 1

3

3

not used

4

4

JC 402

PC 402

2925 STAR B

A A

not used

B B

2904 PC 412 - 4

C C

ACS

JC 403

PC 403 716 PC 213 - 3

1

1

POT 2

117 PC 213 - 1

2

2

LIFT

518 PC 213 - 2

3

3

not used

4

4

JC 404

PC 404

2959 STAR A

A A

not used

B B

2915 PC 211 - 5

C C

TLT

JC 405

PC 405

2960 STAR A

A A

not used

B B

2914 PC 211 - 3

C C

SSS

JC 406

PC 406

2961 STAR A

A A

not used

B B

2913 PC 211 - 2

C C

AXS

793881-4 Printed in Germany

01/99 7 DIA-2230-007

ELECTRICAL DIAGRAMS B.D.I., Horn and Brake Switches

JC 407

PC 407 2928

STAR D

A A

not used

B B

2929 PC 207 - 6

C C

JC 408

PC 408 2926

A A

STAR B

not used 2950

BRS

HBS

B B C C

STAR D

JC 409

PC 409 2907 PC 412 - 7

1 1

562 JC 216 - 7

2 2

HN

JC 410

PC 410

244 PC 411 - 8

Fu 5 543 PC 411 - 5

253

1 1

to Battery Connector ( B + BDI )

2 2

to Battery Connector ( B - BDI )

PC 411

JC 411

5939 STAR E

1 1

2910 PC 412 - 10

2 2

2936 STAR A

3 3

2937 PC 211 - 6

4 4

543 PC 410 - 2

5 5

not used

6 6

not used

7 7

244 PC 410 - 1

8 8

BDI + TT

+ 48 V

793881-5 Printed in Germany

01/99

DIA-2230-008 8

ELECTRICAL DIAGRAMS Steer Column

PC 412

JC 412

201 JC 216 - 1

1

1

202 JC 216 - 2

2

2

2903 JC 216 - 3

3

3

2904 PC 402 - C

4

4

2905 PC 207 - 8

5

5

202 PC 601 - C

KYS

F R

2906 PC 207 - 7

6

6

2907 PC 409 - 1

7

7

2907 PC 601 - A

5908 PC 211 - 8

8

8

5908 PC 602 - 2

509 JC 216 - 8

9

9

509 PC 602 - 1

2910 PC 411 - 2

10 10

not used

11 11

not used

12 12

DIRECTIONAL SWITCHES

2951 PC 602 - 3

JC 601

PC 601 2907 JC 412 - 7

A A

not used

B B

202 JC 412 - 2

C C

HNS

JC 602

PC 602

ENCODER 509 JC 412 - 9

1

1

5908 JC 412 - 8

2

2

2951 JC 412 - 3

3

3

4

4

not used

MODULE

STEER ENCODER

793881-6 Printed in Germany

01/99 9 DIA-2230-009

Star Points

STAR A

2961 PC 406 - A 2960 PC 405 - A 2935 JC 216 - 10 2959 PC 404 - A 2936 PC 411 - 3

STAR B

2925 PC 402 - A 2927 PC 207 - 5 2926 PC 408 - A

STAR C

5933 PC 210 - 5 5934 PC 210 - 6 5932 PC 210 - 1

5945 JC 217 - 2 5957 PC 210 - 8 5958 PC 210 - 9

STAR D

2928 PC 407 - A 2930 PC 206 - 1 2950 PC 408 - C

STAR E

5938 JC 217 - 1 5931 PC 210 - 7 5939 PC 411 - 1

793881-7 Printed in Germany

01/99 10 DIA-2230-010

ELECTRICAL DIAGRAMS Panel Wiring

Fu 3 ZAPI A 1 PC 216 - 1

Fu 4

B+

(LINE CONTACTOR)

B-

(BUSBAR)

ZAPI A 2 PC 216 - 2 ZAPI A 3 PC 216 - 3 ZAPI A 7 PC 216 - 7 ZAPI A 8 PC 216 - 8

ZAPI A10 PC 216 -10

ZAPI R 9 PC 201 - 9

RGB

ZAPI R 8 PC 201 - 8 ZAPI R 7 PC 201 - 7

FA RA

ZAPI R 6 PC 201 - 6 ZAPI R 5 PC 201 - 5

FB RB

ZAPI R 4 PC 201 - 4 ZAPI R 2 PC 201 - 2 ZAPI A3/L PC 201 - 1

ZAPI S 3 PC 208 - 3

ZAPI A10 PC 212 - 2

ZAPI L

PC 212 - 1

LC

ZAPI A 10 ZAPI L

793881-8 Printed in Germany

01/99 11 DIA-2230-011

ELECTRICAL DIAGRAMS Power Cables LINE + CONTACTOR

794042 *

+ 48 V

Fu 2

Fu 1

794042

794045 *

BC 50-003 BC 50-002 BC 50-001 794038

A A

RGB

+

CONTACTOR

794036

LA2

A1

LTM D D1 LD1

794037

D

LA1

RA1

L/H

R/H

F/R CONTACTOR

F/R

PC16-022 -006 -014

A2

CONTROLLER

D

M-

B-

794039 *

PC16-023 -007 -015

LA1

PUMP

PM 794044 *

B+

M+

PC16-019 -003 -011 RA2

CONTACTOR

794040 *

794039 *

PC16-020 -004 -012

RA1 A1

LA2

RA2

LD2

D 2 RTM D1 RD2

2

PC16-022 -006 -014

(+) + SHL LD2 - SHL

B+ TRACTION

A2

PC16-018 -002 -010 - SHR RD2

+ SHR

RD1

CONTROLLER PC16-021 -005 -013

LD1 VMN/L

B-

VMN/R RD1

(-) 794041 *

PC16-017 -001 -009

793882

KEY: * = Control Panel Copper Link

BC 50 = Battery cable assy PC 16 = Power cable assy

794897-XXX 792878-XXX

BC / PC XX- XXX = SC 3018 - XXX = SC 3016 - XXX = SC 3013 Printed in Germany

01/99 DIA-2230-012 12

ELECTRICAL DIAGRAMS Part Numbers for Connectors and Looms ZAPI connectors: Female Socket Housing 2way 3way 8way 9way Socket Crimp Standard Spade (1/4 inch = 6.25 mm; insulated)

Looms 793240-001 -002 -003 -004 793241 062007-021

Truck Main Loom Steering Column Loom Seat Deck Loom (not on Suspension Seat) Flashing Beacon Cable Assy Flashing Beacon Cable Assy Reverse Alarm Cable Assy Reverse Module to JC 216 Cable Assy L/H Work Light Cable Assy R/H Work Light Cable Assy If R/H Work Light is rear mounted, Cable Assy

794929 793207 795289 793789 793839 793803 794314 793790 793791 793796

MOLEX Connectors: MOLEX Free Plug 8way (BDI Connector) MOLEX Socket

803450-008 116858

DEUTSCH Connectors: Male Pin Housing 2way 3way 4way 6way 8way 12way Anti Back Out 2way 3way 4way 6way 8way 12way Pin Crimp

792880-001 -002 -003 -004 -005 -006 793090-001 -002 -003 -004 -005 -006 792882

Female Socket Housing 2way 3way 4way 6way 8way 12way Anti Back Out 2way 3way 4way 6way 8way 12way Socket Crimp

792881-001 -002 -003 -004 -005 -006 793091-001 -002 -003 -004 -005 -006 792883

Sealing pin (for use with 792880-xxx and 792881-xxx)

793222

Printed in Germany

01/99 DIA-2230-0013 13

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Printed in Germany

HYDRAULIC SCHEMATIC

Printed in Germany

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany

O P T O E N C O D E R

C L O S E D C E N T R E N O N R E A C T IO N

O R B IT A L S T E E R IN G U N IT D Y N A M IC L S

L

P

T

R A C K A N D P IN IO N C Y L .

R

L S

P U M P

M O T O R

S T R A IN E R

H O S E B U R S T V A L V E

M A IN L IF T C Y L .

F IL T E R

T

P

M A IN R V 2 1 0 B A R

C F

P R IO R IT Y V A L V E D Y N A M IC L S

S T E E R R V 7 0 B A R

L S

F L O W C O N T R O L V A L V E L O W E R IN G

L IF T

1 A

1 B

T IL T

2 A

T IL T C Y L .

2 B

A U X I

3 A

3 B

S ID E S H IF T

7 9 3 6 8 9 P R E S S U R E R E G U L A T O R S e t to 1 6 0 b a r

HYDRAULIC SCHEMATIC

792341_c-gb

Printed in Germany

01/99

1 HYD-2230-001

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

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 B Order Number: 812544-999