Crown Forklift SC3200 Series Maintenance Manual 812548-006

Maintenance Manual

SC3200 Series Printed in Germany ● Status 2, Revision Level A Order Number: 812548-006

This master manual is subject to continual updates.

It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.

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

All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2004 CROWN Equipment Corporation

REVISION Overview of Revisions: Page 3 .... Rev.1 04/00 .......... General corrections and additions to the text. .............................................. Reference to authorised service personnel added.

Chap. MA Rev. 01/99 ............ now Rev. 03/04 1. DANGER box, .............................................. warning: Failure to comply with this notice may .............................................. result in severe or fatal injuries to yourself or other people.

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TABLE OF CONTENT Table of Content MA – SAFETY

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Safety Symbols used in the Manual ...................................... 3 ........................... N/A ................................ 03/04

ITD – INTRODUCTION

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General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair ................................................ 3 Before Leaving the Truck ................................................ 4 Before Carrying out Work on the Truck .......................... 4 Before Operating the Truck............................................. 4 Warnings and Labels on the Truck ........................................ 4 General ..................................................................................... 7 Operating Instructions .................................................... 7 Service Training .............................................................. 7 Ordering Spare Parts ...................................................... 7 Using the Manual ............................................................ 7 Model-Number ......................................................................... 8

M1 – LUBRICATION AND ADJUSTMENT

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Lifting the Truck ....................................................................... 11 Lifting by Crane ............................................................... 11 Lifting by another truck ................................................... 11 Towing the Truck ..................................................................... 12 Jacking up the Truck ............................................................... 12 Counterweight ......................................................................... 13 Disassembly .................................................................... 13 Assembly .................................................................... 14 Lubrication and Adjustment .................................................. 15 Component Access ......................................................... 15 Recommended Lubricants and Oils .............................. 18 Lubricants ................................................................... 18 Cold Store Truck Lubricants ........................................ 18 Taking the truck out of service ....................................... 18 Bringing the truck back into service ............................ 18 Lubricant Points and Intervals ............................................... 20 Inspection and Maintenance Schedule ................................. 21 Daily Maintenance (or every 8 service hours) .............. 22 Monthly Maintenance or every 100 service hours ........ 24 3-Monthly Maintenance (or every 250 service hours) .. 26 6-Monthly Maintenance (or every 500 service hours) .. 28 Annual Maintenance (or every 1000 service hours) ..... 28 2-Yearly Maintenance (or every 2000 service hours) ... 28 Torque Requirements ............................................................. 30 Standard Torque Tables .................................................. 30 Special Torque Tables ..................................................... 34

M2 – HYDRAULICS

PAGE

Hydraulic Symbols .................................................................. 41 Valve Block ...................................................................... 45 Pump motor ..................................................................... 45 Hydraulic pump ............................................................... 45 Commissioning ........................................................... 45 Bleeding ...................................................................... 45 Oil Change ...................................................................... 45 Bleeding the hydraulic system .............................................. 46 Bleeding the tilt cylinders ............................................... 46 Bleeding the free lift cylinder .......................................... 46 SC3200 03/2004 • PRINTED IN GERMANY

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TABLE OF CONTENT M2 – HYDRAULICS

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Bleeding the lift cylinders ............................................... 46 Flushing the cylinders ..................................................... 47 Drift Tests ................................................................................. 47 Lift cylinder drift test ....................................................... 47 Tilt cylinder drift test ....................................................... 47 Steer unit drift test .......................................................... 47 Overload Valves (RV) .............................................................. 48

M3 – DRIVE UNIT

PAGE

Drive Unit ................................................................................. 51 Gear Unit ......................................................................... 51 Disassembly ............................................................... 51 Disassembly ............................................................... 51 Assembly .................................................................... 51 General ............................................................................ 53 Dismantling the Gear Unit ...................................................... 53 Gear Unit Assembly ................................................................ 53 Pre-assembly of the housing with flange shaft ........... 53 Bevel gear spur wheel pinion shaft pre-assembly ...... 53 Spur wheel flange shaft assembly .............................. 53 Bevel gear assembly ................................................... 54 Bevel pinion assembly ................................................ 54 Flank tooth bearing ..................................................... 55 Correcting the flank tooth bearing .............................. 55 Reducing the installation path of the conical pinion . 55 Maintenance .................................................................... 55 Adding oil .................................................................... 55 Types of oil .................................................................. 55 Oil level ....................................................................... 55 Oil change ................................................................... 55

M4 – ELEKTRICS

PAGE

Electrics - General .................................................................. 59 Wire Colour Codes ......................................................... 59 Abbreviations .................................................................. 60 Electrical Symbols .......................................................... 61 Electrical Components ........................................................... 63 Switch Functions ............................................................. 63 Brake Switch (BRS) .................................................... 63 Encoder (ENC), Encoder Module (EM) ...................... 63 Accelerator Pedal Switch (ACS, POT1) ...................... 63 Direction Indicator Switch (DIS) .................................. 63 Handbrake Switch (HBS) ............................................ 63 Raise Potentiometer (POT2) ....................................... 63 Steering Axle Potentiometer (POT3) .......................... 63 Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) ..... 63 Emergency Disconnect ............................................... 63 Key Switch (KYS) ........................................................ 63 Fuses (FU) .................................................................. 63 Seat Switch (SES) ...................................................... 64 Electrical Components - Overview ............................. 64 Horn Switch (HNS) ..................................................... 64 Electrical Board ............................................................... 65 Zapimos B1S 48/700 Controller ............................................. 67 General ............................................................................ 67 Protective Devices .......................................................... 67 Polarity Protection ....................................................... 67

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TABLE OF CONTENT M4 – ELEKTRICS

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Wiring Errors ............................................................... 67 Overheating ................................................................ 67 Protection .................................................................... 67 Key Terms ........................................................................ 67 Shunt or Shunt Resistor (+SH/-SH) ............................ 67 Volt Motor Negative (VMN) ......................................... 67 Functional Description .................................................... 67 Acceleration / Delay Rate ........................................... 67 Travel Switch ............................................................... 67 Travel Switch Signal Response .................................. 67 Fault Log ..................................................................... 67 Fault Identification ....................................................... 67 Sparkless Contactors ................................................. 68 Inversion Braking ........................................................ 68 Creep Mode ................................................................ 68 Slow Travel .................................................................. 68 Steering Controller ...................................................... 68 45° Steering Angle ...................................................... 68 Pedal Braking (Inversion Braking with Battery Supply Regeneration) 68 Ramp Start .................................................................. 68 Key Switch .................................................................. 68 Self Test ...................................................................... 68 Reverse Travel Alarm ........................................ 68 Seat Switch ................................................................. 69 Current Limit ............................................................... 69 Overvoltage ................................................................ 69 Overheating ................................................................ 69 Low Voltage Reduction ............................................... 69 ZAPIMOS B1S 48/700 Traction Controller Connections 70 ZAPIMOS B1S 48/700 Pin Layout .............................. 71 Programmer Connection "B" ....................................... 73 Status LED "A" ............................................................ 73 Status LED Diagnosis ................................................. 73 ZAPIMOS HP 350A Pump Controller ..................................... 74 General ............................................................................ 74 Protective Devices .......................................................... 74 Polarity Protection ....................................................... 74 Wiring Errors ............................................................... 74 Overheating ................................................................ 74 Protection .................................................................... 74 Key Terms ........................................................................ 74 Shunt or Shunt Resistor (+SH/-SH) ............................ 74 Volt Motor Negative (VMN) ......................................... 74 Functional Description .................................................... 75 Acceleration / Delay Rate ........................................... 75 Hydraulic Switches ..................................................... 75 Lift Cutout ................................................................... 75 Lift potentiometer ........................................................ 75 Lift Potentiometer Response ...................................... 75 Fault Log ..................................................................... 75 Fault Identification ....................................................... 75 Steering Support ......................................................... 75 Key Switch .................................................................. 75 Self Test ...................................................................... 75 Current Limit ............................................................... 75 Overvoltage ................................................................ 75 Overtemperature ......................................................... 75 SC3200 03/2004 • PRINTED IN GERMANY

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TABLE OF CONTENT M4 – ELEKTRICS

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Low Voltage Reduction ............................................... 75 ZAPIMOS HP 350A Pump Controller Connections ...... 76 ZAPIMOS HP 350 A Pin Layout ..................................... 77 Pump Controller, LED error code ................................... 78 Programmer Connection "B" ....................................... 78 Status LED "A" ............................................................ 78 Status LED Diagnosis ................................................. 78 Pump Controller Removal ........................................... 79 Pump Controller Assembly ......................................... 79 Traction Controller Removal ....................................... 79 Traction Controller Assembly ...................................... 80 Programmer ............................................................................. 81 General ............................................................................ 81 Display Window ........................................................... 82 Operating Keys ........................................................... 82 Connecting the Programmer .......................................... 83 Operating Menu .............................................................. 83 General ....................................................................... 83 Traction Controller Operating Menu ............................... 84 Programmer Start Routine ............................................. 85 Traction Controller Menu Functions ..................................... 86 PROGRAM ...................................................................... 86 TESTER ........................................................................... 86 ALARMS .......................................................................... 86 PROGRAM PEDAL ......................................................... 86 CONFIG ........................................................................... 86 PROGRAM Menu ............................................................ 87 TESTER Menu ................................................................ 88 ALARMS Menu ................................................................ 89 PROGRAM PEDAL Menu ............................................... 91 CONFIG Menu ................................................................ 92 Pump Controller Operating Menu .................................. 93 Menu Functions Pump Controller ......................................... 94 PROGRAM ...................................................................... 94 TESTER ........................................................................... 94 ALARMS .......................................................................... 94 PROGRAM VACC ........................................................... 94 CONFIG ........................................................................... 94 PROGRAM Menu ............................................................ 95 TESTER Menu ................................................................ 99 ALARMS Menu ................................................................ 100 PROGRAM VACC Menu ................................................. 102 CONFIG Menu ................................................................ 103 Calibrating the Steering Potentiometer ................................ 104 Preparation ...................................................................... 104 Calibration ....................................................................... 104 Calibrating the Lift Potentiometer ......................................... 105 Preparation ...................................................................... 105 Calibration ....................................................................... 105 Calibrating the Accelerator Potentiometer ........................... 106 Preparation ...................................................................... 106 Calibration ....................................................................... 106 Traction Controller Safety Test .............................................. 108 Pulse Monitor Trip Test (PMT) ........................................ 108 Equipment ................................................................... 108 Test ............................................................................. 108 PMT Safety Test Wiring .................................................. 109

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TABLE OF CONTENT M4 – ELEKTRICS

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Battery ...................................................................................... 110 General ............................................................................ 110 Replacing the battery ..................................................... 110 Battery Discharge Indicator (BDI) ......................................... 110 General ............................................................................ 110 Battery Discharge Indicator Setting (BDI) ..................... 111 Calibration ....................................................................... 111 Electric Motors ........................................................................ 112 General Maintenance Instructions ................................. 112 Preparation ................................................................. 112 Important Maintenance Instructions ........................... 112 Traction Motor Maintenance .................................................. 113 Access to Brushes .......................................................... 113 Maintenance .................................................................... 113 Armature ..................................................................... 113 Bearings ...................................................................... 113 Pump Motor Maintenance ...................................................... 114 Access to brushes .......................................................... 114 Maintenance .................................................................... 114 Armature ..................................................................... 114

M5 – BRAKE

PAGE

Brakes ...................................................................................... 117 General ............................................................................ 117 Brake Lining Wear Limits ................................................ 117 Brake Removal ................................................................ 117 Brake Assembly .............................................................. 119 Before Assembling ...................................................... 119 Assembly .................................................................... 119 Foot Brake ....................................................................... 120 Foot Brake Adjustment ............................................... 120 Checking the braking distance ................................... 120 Handbrake Adjustment ............................................... 121

M6 – STEERING

PAGE

Steering .................................................................................... 125 Hydraulics ........................................................................ 125 Function ...................................................................... 125 Steering Components ..................................................... 126 Steering wheel ......................................................................... 127 Disassembly .................................................................... 127 Assembly ......................................................................... 127 Direction Control Switches .................................................... 128 Switch Removal .............................................................. 128 Switch Assembly ............................................................. 128 Steer Sensor Module .............................................................. 130 Disassembly .................................................................... 130 Assembly ......................................................................... 130 Steering Sensor ...................................................................... 130 Disassembly .................................................................... 130 Assembly ......................................................................... 130 Steering Column Adjustment ................................................ 131 Gas Pressure Cylinder Removal .................................... 131 Gas Pressure Cylinder Assembly and Adjustment ..... 131 Steering column ...................................................................... 132 Disassembly .................................................................... 132 Steering Column Removal .......................................... 132

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TABLE OF CONTENT M6 – STEERING

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Removing the steering shaft from the steering column .......................................... 132 Replacing the slip rings ............................................ 132 Steering Gear Removal .................................................. 134 Steering axle ............................................................................ 135 Design ............................................................................. 135 Steering Gear Assembly ................................................ 135 Wheel hub pre-assembly ............................................ 135 Steering knuckle pre-assembly ................................... 135 Steering Knuckle and Wheel Hub Assembly .............. 135 Spur pinion flange shaft pre-assembly ....................... 136 Housing pre-assembly ................................................ 136 Adjusting the bearing clearance ................................. 137 Cylinder Pre-Assembly ............................................... 140 Inserting the cylinder .................................................. 140 Assembling the Axle Bracket to the Steering Gear ..... 140 Operational and Leakage Test .................................... 141 Steering axle 2.12.01.1............................................................ 142 Steering axle 2.12.09.0............................................................ 143

M7 – MAST

PAGE

Mast (TT Series) ...................................................................... 147 General ............................................................................ 147 Torques ....................................................................... 147 Mast bearing mounting screws ................................. 147 Mast Stoppers ........................................................... 147 Lifting Gear Minimum Capacity ................................... 147 Mast Testing (Assembled) .............................................. 147 Flaking ............................................................................. 147 Mast Disassembly ................................................................... 149 Dismantling the Mast (Attached) .................................... 149 General ....................................................................... 149 Fork Carriage Removal ............................................... 151 Free Lift Cylinder Removal ......................................... 151 Removing the individual mast stages ......................... 153 Replacing the Mast Rollers on the Mast Stages and the Fork Carriage ................. 153 Mast Stage Rollers ................................................... 153 Fork Carriage Mast Rollers ....................................... 155 Lift Cylinder Removal .................................................. 155 Removing the Mast from the Truck ................................ 156 Mast Assembly ................................................................ 157 Lift Chains ............................................................................... 158 General ............................................................................ 158 Inspection ........................................................................ 158 Cleaning ...................................................................... 158 Wear ........................................................................... 158 Freedom of Movement of Chain Links ........................ 159 Chain Tension ............................................................. 159 Chain Anchor and Pulleys .......................................... 160 Worn Connection Plates ............................................. 160 Protruding or Turned Chain Pins................................. 160 Corrosion .................................................................... 160 Chain Lateral Wear ..................................................... 161 Uneven Chain Tension .............................................. 161 Misalignment of Lift Components ............................. 161 Lift Chain Lubrication ...................................................... 162 Detaching Lift Chains ..................................................... 163 MS-IDX-2232

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TABLE OF CONTENT M7 – MAST

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Tools and Equipment Required ...................................... 163 Detachment ..................................................................... 163 Fork Tines ................................................................................ 164 General ............................................................................ 164 Terms .......................................................................... 164 Fork Identification ....................................................... 164 Repairs ............................................................................ 164 Checking the Fork ........................................................... 164 Crack Inspection ......................................................... 164 Verticality Test ............................................................. 165 Fork Blade Warping .................................................... 165 Measuring the Fork Tip Width ........................................ 165 Fork Tine Height Difference ........................................... 165 Stop Mechanism ............................................................. 166 Fork Blade Wear ............................................................. 166 Sideshifter ............................................................................... 167 General ............................................................................ 167 Integrated Sideshifter ..................................................... 169 Removal, Repair and Assembly ................................. 169 Hook-on Sideshifter ................................................................ 171 Removal, Repair and Assembly ..................................... 171

M8 – CYLINDERS

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Cylinders .................................................................................. 175 General ............................................................................ 175 Safety when working on hydraulic systems ................ 175 General Instructions for Repairing Hydraulic Components ............................... 175 Rod Seal Assembly ................................................................. 176 General ............................................................................ 176 Large Rod Seal Assembly .............................................. 176 Small Seal Rod Assembly .............................................. 177 Rod Seal Assembly, Sealing Lip First ............................ 178 Tilt Cylinders ........................................................................... 179 General ............................................................................ 179 Removal .......................................................................... 179 Tilt Cylinder Sectional Drawing ...................................... 180 Dismantling ..................................................................... 182 Component Inspection ................................................ 182 Assembly .................................................................... 182 Assembly ......................................................................... 184 Lift Cylinders ........................................................................... 187 General ............................................................................ 187 Removal and Assembly .................................................. 187 Dismantling ..................................................................... 187 Rod Seal Removal .......................................................... 187 Piston Rod Removal ................................................... 189 Assembly ......................................................................... 189 Piston Rod Assembly .................................................. 189 Installing the Rod seal ................................................ 189 Free-Lift Cylinder .................................................................... 191 General ............................................................................ 191 Removal and Assembly .................................................. 191 Dismantling ..................................................................... 191 Rod Seal Removal ...................................................... 191 Piston Rod Removal ................................................... 191 Assembly ......................................................................... 191 Piston Rod Assembly .................................................. 191 SC3200 03/2004 • PRINTED IN GERMANY

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TABLE OF CONTENT M8 – CYLINDERS

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Installing the Rod Seal ................................................ 191 Hook-on Sideshifter, Cylinder ................................................ 195 Integrated Sideshifter, Cylinder ............................................. 197

DIA – ELECTRICAL DIAGRAMS

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Key ............................................................................................ 201 Connectors ...................................................................... 201 Contactors ....................................................................... 201 Abbreviations .................................................................. 201 Control Circuit ......................................................................... 203 Power Circuit ........................................................................... 204 Option Brush Wear & Over Temperature Indicator Circuit Diagram .................................................................................... 205 Option Lighting Diagram ........................................................ 206 Seat Switch and Steer Pot ...................................................... 208 Steer Column ........................................................................... 208 BDI, Horn and Brake Switches ............................................... 209 Control Levers ......................................................................... 209 Star Points ............................................................................... 210 Panel Wiring ............................................................................. 210 Traction Controller .................................................................. 211 Pump Controller ...................................................................... 211 Power Cable Diagram ............................................................. 212 Main Loom, Part 1 ................................................................... 213 Main Loom, Part 2 ................................................................... 214 Steer Column Loom ................................................................ 215 Fan Standard ........................................................................... 216 Option: Main Harness, Middle East Fan ............................... 217 Option Lights, Main Loom Lights .......................................... 218 Option Lights, Panel to Switch .............................................. 219 Option Lights, Module to Panel ............................................. 220 Option Lights, Panel to Main Loom Lights ........................... 221 Option Lights, Reverse Alarm to Module .............................. 222 Option, Brush Wear and Overtemperature Display Loom ... 223 Option, 5th Hydraulic Function .............................................. 224 Option, Cold Store Model Additional Loom, Part 1 of 2 ...... 225 Option, Cold Store Model Additional Loom, Part 2 of 2 ...... 226 Option, Cold Store Model Additional Loom, Heating Control Module .......................................................... 227

HYD – HYDRAULIC SCHEMATICS

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Hydraulic Schematic ............................................................... 231

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SAFETY

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

General Maintenance and Repair Safety Notes DANGER

DANGER

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

This symbol indicates life-threatening risks ●

●

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

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

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

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

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

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

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

1.

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

2.

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

3.

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

4.

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

Only carry out cleaning with an oil separator.

Protect the electrical system from dampness.

5.

Keep the service area clean, dry and wellventilated.

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.

8.

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

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

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

Maintenance and Repair

INFORMATION Contains additional information with supplementary notes and hints.

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

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SAFETY 9.

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

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

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

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the truck and remove the key.

●

Block all wheels when parking on an uneven surface.

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

Clean any illegible labels.

●

Replace any faulty or missing labels.

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

Before Carrying out Work on the Truck ●

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

●

Prevent the truck from rolling away.

●

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

●

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

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

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

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INTRODUCTION

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

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

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

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

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

Additional copies can be ordered as required.

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

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

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

These are listed in a separate manual.

Spare parts can be ordered by quoting: ●

The truck specification number

●

The truck model number

●

The truck serial number

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

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

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address: CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

Using the Manual The manual is divided into sections. The following table shows how the manual is structured.

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 / Lifting Mechanism

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic A01M-gb

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INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions:

Lift Height (TT Mast) 4370 mm 4825 mm

Battery Compartment Size

5285 mm 5740 mm

418 mm

6120 mm

526 mm

6375 mm

634 mm

6910 mm

ITD-04

7495 mm ITD-03

Mast -

No mast

TT

Three stage, telescopic mast

Cold Store Version -

N one

F

With cold store version ITD-05

Tyres ITD-01

S

Standard

O

Option

T yp e

ITD-06

-

Standard

C

Customer specific

S

S p e ci a l d e si g n

Hydraulic Aux. Function

ITD-02

-

No

S

1st aux. function

D

2nd aux. function ITD-07

C

TT 4370 526 - S S H CA 1 -

Sideshifter -

No sideshifter

H

Hook-on sideshifter

I

Integrated sideshifter

Alarm Options -

No reverse travel alarm

1

Reverse travel alarm

ITD-08

ITD-10

Sideshifter Model Battery Discharge Indicator

--

No sideshifter

CA

C a sca d e

1

Standard

KA

K aup

2

Option

ITD-09 MS-ITD-2232

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ITD-11

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LUBRIFICATION AND ADJUSTMENT

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LUBRICATION AND ADJUSTMENT Lifting by another truck

Lifting the Truck

The SC 3200 can be lifted by another truck from the side.

CAUTION Scalding hazard!

Spilled battery acid can cause injuries and damage the truck.

You must remove the battery before transporting the truck.

DANGER

Calculate the minimum capacity requirement based on the weight of the truck. This information can be found on the truck data plate. ●

Position the forks of the truck which is doing the lifting as shown by the diagram below.

●

Secure the SC 3200 firmly to the forks of the truck which is doing the lifting (e.g. with appropriate straps).

Falling loads are hazardous!

Accidents can result from lifting gear with insufficient capacity and unsecured loads.

Always use lifting gear with sufficient capacity and prevent the load slings from sliding.

0,51 m

Lifting by Crane Calculate the minimum capacity requirement based on the weight of the truck. This information can be found on the truck data plate.

Attach the 3 straps to the hitch points as shown.

G_SC32-Heben-seitl

Centre of Gravity of the Truck

Tow coupling

Between Chassis and Drive Wheel

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LUBRICATION AND ADJUSTMENT Towing the Truck If the truck is out of order it can only be towed if the handbrake is released.

WARNING Towing is only allowed with a tow bar.

●

●

First jack up the rear section of the truck:

●

Support one side with a wooden block.

●

Then jack up the truck at the opposite side until the steered wheels are free (see figure).

●

Support the raised side.

●

Then lift the opposite side and support it.

●

To jack up the front section of the truck, place the jack under the chassis frame behind one of the front wheels.

●

As soon as this drive wheel is free, support the outer part of the mast on this side.

●

Repeat this process to lift and support the opposite side.

The brakes of the towing vehicle must be capable of braking the towed vehicle.

Jacking up the Truck DANGER Always support a raised truck with wooden blocks or other appropriate equipment to relieve the jack.

Never reach your hands or other parts of your body under the truck before it has been supported, or while jacking the truck up! ●

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

To jack up the truck, the forks must be completely lowered (with no load on them) and the parking brake applied.

Required capacity of the jack = 0.5 × overall truck weight.

Do not forget to include the battery weight.

Steered wheel

Jack

Wooden blocks MO-2232-035

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LUBRICATION AND ADJUSTMENT Counterweight WARNING Trapping hazard!

The counterweight weighs at least 800 kg.

Hands and feet can be trapped.

Only use levers and suitable tools when assembling and disassembling. Never use hands or feet.

WARNING Falling load hazard!

A falling counterweight can result in serious trapping.

Prevent the counterweight from falling.

To do this, use a load sling suspended to a crane. The load sling must be pulled through the hole for the tow pin. The crane must have a minimum capacity of 1000 kg.

Disassembly Tools required: 1.

For disassembly you will need a crane or forklift (minimum capacity 200 kg at 2.5m elevation) to support the overhead guard.

●

Remove the mounting screw of the electrical base plate from the counterweight.

●

Remove the mounting screws of the overhead guard from the counterweight.

2.

A second crane or forklift (minimum capacity 1000 kg at 2m elevation) to prevent the counterweight from tipping.

●

Raise the back of the overhead guard 1 – 2 cm and pull a load sling through the hole for the tow pin in the counterweight.

3.

A pallet truck (minimum capacity 1000 kg) with forks that will lower to fit under the counterweight.

●

4.

Hard wooden blocks to fit under the outer mast stages.

Insert the load sling into a crane hook (crane minimum capacity 1000 kg). If you are using a forklift instead of a crane, prevent the load sling on the fork of the truck from sliding.

●

Drive the truck into a secure maintenance area.

●

Tighten the load sling slightly.

●

Tilt the mast back as far as it will go (in the direction of the driver).

●

●

Lower the mast and fork carriage fully.

Drive a pallet truck (minimum capacity 1000 kg) underneath the counterweight. The forks must be positioned under the flat surfaces of the counterweight.

●

Place two wooden blocks, one on the left and one on the right hand side underneath the outer mast stage. This will prevent the truck from tilting onto the fork tips.

●

Raise the forks of the pallet truck until they are touching the counterweight.

●

Remove the mounting screws of the counterweight.

●

Pull the counterweight approx. 10 cm away from the forklift, using the pallet truck.

●

Raise the counterweight off the pallet truck using the crane, and place it of a flat surface.

●

Remove the battery.

●

Attach a load sling to the rear of the overhead guard. This will secure the overhead guard when you loosen the attachment. Alternatively, you can support the overhead guard from the side using a forklift.

●

Remove the tow pin from the counterweight.

Printed in Germany

MS-1.0-2232

13

LUBRICATION AND ADJUSTMENT Assembly ●

Assemble the counterweight in the reverse order of disassembly.

MS-1.0-2232

14

Printed in Germany

LUBRICATION AND ADJUSTMENT Lubrication and Adjustment Component Access 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.

MO-2232-037

MO-2232-038

Printed in Germany

MS-1.0-2232

15

LUBRICATION AND ADJUSTMENT

MS-2232-043

B MS-2232-040

A MS-2232-039

C

MS-2232-038

MS-2232-042

E D MS-2232-041 MS-1.0-2232

16

Printed in Germany

LUBRICATION AND ADJUSTMENT Fig. A: Battery compartment lid

●

Wiring

Provides access to:

●

Steer unit

●

Battery

To remove:

●

Contactor panel including impulse controls

●

Loosen 6 hex. socket screws

●

Steering axle and potentiometer

●

Remove panel

●

Hydraulic motor and pump

Fig. C: Valve and Control Handle Panel

●

Seat switch and plug connector

Provides access to:

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.

●

Valve Block

●

Switch, potentiometer

●

Control handle mechanism

To remove: ●

Remove the base plate

●

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

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

●

Remove the single hex. socket screw at the front below the floor board

When you have removed the battery and the side panels you will have access to:

●

Lift up the panel

●

the hydraulic lines on the right hand side of the battery compartment.

When you have lifted out the floor boards you will have access to:

●

the cable duct on the left hand side of the battery compartment.

Access:

●

Brake pedal and mechanism

●

Brake

●

Accelerator pedal / travel switch and potentiometer

●

Tilt cylinder attachment (frame)

Fig. B: Steering column front panel

●

Valve block hydraulic lines

Provides access to:

●

Wiring

●

Key switch

●

LH and RH drive motor

●

Direction control switch

To remove the floor boards:

●

Encoder

●

●

Wiring

●

Steering unit and distributor block

●

Hydraulic lines

●

the flow controller on the right hand side (only for lift heights above 5000 mm)

Move the floor boards away from each other and lift them out.

To remove: ●

Loosen two hex. socket screws

●

Lift panel slightly and lever out at the bottom

Fig. E: Inner dashboard Provides access to: ●

Handbrake

●

Battery display

Printed in Germany

MS-1.0-2232

17

LUBRICATION AND ADJUSTMENT Recommended Lubricants and Oils Lubricants The next page shows typical lubricants used by Crown itself in its factories. However, you can use any lubricants provided they meet the same technical criteria.

Cold Store Truck Lubricants Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table on following page). An anticorrosion fluid (Crown no. 805236-004) must be applied to all screws, washers, nuts, pins, retaining rings etc. Carefully protect all electrical connections and components against corrosion. For detailed information, refer to chapter 4.

Service intervals must be adapted to the conditions of use. This means they must be reduced as far as possible to prevent excessive wear.

Bringing the truck back into service If you wish to bring the truck back into service, proceed as follows: ●

Remove any anti-corrosion agents which have been additionally applied (apart from the cold store agents)*.

●

Jack up the truck, remove the wooden blocks and lower the truck.

●

Charge the battery or fit a charged battery.

●

Connect the battery.

●

Carry out the daily inspection.

* Do not apply high pressure cleaning agents and/ or solvents to the truck. Do not use metallic brushes.

Do not wet clean the electrical system and do not use flammable solvents.

Taking the truck out of service If you wish to take the truck out of service for more than 3 months, proceed as follows: ●

Disconnect the battery from the truck.

●

Decommission the battery in accordance with the manufacturer’s instructions.

●

Clean the truck*). Lubricate in accordance with the maintenance manual.

●

If the truck is to be stored in harsh conditions (e.g. saline atmosphere) treat the surface of the truck with a suitable preservative to prevent corrosion.

●

Do not park the truck in the open air or in a humid environment. The ideal place is a dry room where the temperature and air humidity are as constant as possible. If the truck has to be covered, use an air-permeable material. Do not use plastic sheets.

Otherwise, condensation may form.

●

Jack up the truck. Lower the chassis onto suitable wooden blocks so that the wheels clear the ground (prevents the wheels from flattening from constant pressure).

●

Every 3 months connect the battery, carry out a daily inspection and activate all the truck functions. Now disconnect the battery again.

MS-1.0-2232

18

Printed in Germany

LUBRICATION AND ADJUSTMENT Lubricant Type

Product Description

Manufacturer

CROWN Part No.

Type

Grease (multi purpose)

Aralube HLP-2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe E2 Retinax LX LGWM1

Aral Castrol Century Esso Maxol Mobil Shell SKF

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

Lubrication oil (chain)

Kowal 40 Essolube HD + 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 B110

Aral Castrol Esso Mobil Shell Fuchs Mineralölwerke GmbH

053001-003

D

Low temperature hydraulic oil

Univis J 13 Aero HFA

Esso 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-LS75W-90

Mobil

053002-006

AA

Rubber and vinyl dressing

H

Special grease

MOS2 Lithium

Universal lubrication oil

SEA40

Anti-corrosion agent

Tectyl

Dow Corning

063002-022

M

C Corrosion agent for cold store trucks

805236-004

L62-GB

Printed in Germany

MS-1.0-2232

19

LUBRICATION AND ADJUSTMENT Lubricant Points and Intervals Lubricant Points / Intervals Item Component

Type

Qty.

100 hrs

250 hrs

500 hrs

1000 2000 hrs hrs

1

Batter y compar tment lid lock and batter y compar tment lid hinges

C

A/R

X

2

Brake pedal pivots & brake main pivot

B

A/R

X

3

Accelerator pedal pivots, resetter rollers

B

A/R

X

4

Fork lock & fork carriage tines

B

A/R

X

5

Handbrake pivot

B

A/R

X

6

Handbrake cable

C

A/R

X

7

Handbrake ratchet

B

A/R

X

8

Mast channels

B

A/ R

X

9

Check hydraulic oil, replenish if necessar y

D

A/R

X

10

All lift chains

B

A/R

X

11 Mast pivots

B

A/R

X

12

Potentiometer pivots; lift, traction and steer potentiometers

C

A/R

X

13

Rollers: Mast column and fork carriage rollers

B

A/R

X

14

Plastic guide pulleys, mast

H

A/R

X

15

Batter y compar tment lid bearing journals for the hydraulic levers and the respective hook on the batter y compar tment lid.

C

A/R

X

16

Tilt cylinder pivots

B

A/R

X

17

Steering axle pivot

B

A/R

X

18

Steer column adjustment

C

A/R

X

19

Motor : Drive motor to gearbox spline

M

A/R

X

20

Motor : Pump motor to pump spline

M

A/R

X

21 Replace transmission oil

A

A/R

X

22

Replace hydraulic oil

D

A/R

X

23

Seat runners

B

A/R

X

24

Steering column: Orbital steer unit spline

B

A/R

X L63-GB

MS-1.0-2232

20

Printed in Germany

LUBRICATION AND ADJUSTMENT Inspection and Maintenance Schedule The following pages show the inspection and maintenance schedule for this truck.

The service intervals are based on single shift operation under normal conditions.

They should be reduced accordingly if the truck is to be operated in dusty or extreme conditions such as a cold store. Exact details should be discussed with a Crown service engineer.

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

The lubrication work for longer service intervals must also include the items covered under the shorter intervals.

Printed in Germany

MS-1.0-2232

21

LUBRICATION AND ADJUSTMENT Daily Maintenance (or every 8 service hours) Daily or every 8 service hours Item Component

Action

1

Truck

Clean if necessary.

2

Seat

Make sure that the seat is properly engaged and attached.

3

Seat belt

Check operation. Check support and belt for wear.

4

Battery

Make sure battery connector is secure and check for any damage, check contacts for signs of burning.

Check battery compar tment for any spilled acid.

Check / service battery as required in accordance with battery manufacturer's service manual

5

Gear unit

Check for leaks (oil on the ground by the drive wheels?).

6

Hydraulic lines and screws Check for leaks. If leakage is found, take the truck out of service.

7

Forks, fork carriage

Check for possible damage, cracks and excessive wear.

The forks should be firmly engaged.

8

Load guard, any accessories

Ensure it is securely fitted and check for damage

9

Lift chains, chain anchor

Check for possible distor tion, cracks and any other damage.

The forks should be firmly engaged.

10

Wheels

Check for damage and foreign bodies. Remove any foreign bodies

11 Labels and stickers

Check they are all present and legible (2-10, 2-11).

12

Key switch

Turn key switch ON (green) and test operation of battery discharge indicator and the hourmeter (+ any optional displays).

13

Emergency Disconnect

Check operation.

14

Seat switch

Check operation.

15

Horn

Check operation.

16

Hydraulics

Test all functions.

Check freedom of movement of control handle.

Check the mast, chains, hoses and rollers while the forks are being raised and lowered to ensure they work correctly.

17

Steering

Check operation and safety

18

Travel, regenerative braking

Move the truck in both directions, first slowly and then at full speed.

Test brakes: While the truck is moving set the travel selection lever to the opposite direction

19

Brake pedal

Apply the brake pedal: Has the braking distance changed since the last inspection?

20

Parking brake

Apply the parking brake lever: Check operation.

Does the traction motor cut out after 5 seconds?

21

if applicable: lights

Check operation L70-GB

MS-1.0-2232

22

Printed in Germany

LUBRICATION AND ADJUSTMENT

21

9

20 12 12

8

9

16 13 14 MS-2232-044

10

MS-2232-045

9

2

3

9

M0324

4

7

MS-2232-038

5 Printed in Germany

MS-1.0-2232

23

LUBRICATION AND ADJUSTMENT Monthly Maintenance or every 100 service hours Monthly or every 100 service hours Item Component

Action

1

Battery

Service in accordance with the battery manufacturer's instructions

2

Mast column cylinder

Check for leaks; check piston rods for damage

3

Wheels

Torque wheel nuts to correct level (141Nm)

4

Mast column and freelift cylinder chains and chain anchor

Check for wear, corrosion and damage

5

Guide pulley yoke

Check for damage L71-GB

2

4 2

MS-2232-046

MS-1.0-2232

24

Printed in Germany

LUBRICATION AND ADJUSTMENT

4

8

4 1

MS-2232-044

3

5

4

4

2 M0324

Printed in Germany

MS-1.0-2232

25

LUBRICATION AND ADJUSTMENT 3-Monthly Maintenance (or every 250 service hours) Every 3 months or 250 service hours Item Component

Action

1

Contactors

Clean, check, replace if necessary.

2

Mast end stops

Check for wear, grease if necessary

3

Mast column

Clean bearings and contact surfaces, check for wear, if necessary replace, check mast column itself for wear, lubricate

4

Battery compar tment lid lock & battery compar tment lid pivot

Check operation, lubricate

5

Gear unit

Check gear unit for leaks, first oil change after 250 service hours,otherwise after 2000 service hours. Ensure bolts are tight.

6

Accelerator pedal / accelerator pedal linkage

Check for wear, lubricate pivots, linkage

7

Brake pedal, brake linkage and brake pivots

Check for wear; grease pivot points.

8

Guide pulleys

Check for wear; lubricate

9

Fork lock and fork carriage slide

Check / lubricate

10

Handbrake cable

Check / lubricate

11

Handbrake ratchet and pivot

Check / lubricate

12

Hydraulic oil level

Check hydraulic oil, replenish if necessary

13

Lift Chains

Check and lubricate

14

Mast bearings

Check and lubricate

15

Lift, traction and steer potentiometer Check for freedom of movement and lubricate pivots

16

Mast Rollers

Check for freedom of movement and lubricate

17

Battery compar tment lid lock

Check operation of the bearing journals of the battery compar tment lid for the hydraulic levers and the respective hook on the battery compar tment lid, and lubricate.

18

Tilt cylinder pivots

Check / lubricate L72-GB

MS-1.0-2232

26

Printed in Germany

LUBRICATION AND ADJUSTMENT

17

12

MS-223 2-039 MS-2232-047

5

2, 3, 8, 13, 16

17

1

10, 11

14

7 6

MS-2232-038

18

Printed in Germany

MS-1.0-2232

27

LUBRICATION AND ADJUSTMENT 6-Monthly Maintenance (or every 500 service hours) Every 6 months or 500 service hours Item Component

Action

19

Battery connector

Clean contacts, check contact springs.

20

Hydraulic cylinder

Ensure it is securely fitted.

21

Brakes

Blast off abrasion with pressurised air, check brake lining and brake springs for wear.

22

Steering axle pivot

Check / lubricate

23

Steer column adjustment

Check / lubricate

24

Pump motor to pump spline and traction motor to gear unit spline

Check / lubricate L73-GB

Annual Maintenance (or every 1000 service hours) Annually or every 1000 service hours Item Component

Action

1

Pump and drive motor carbon brushes

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

2

Electrical cables & connections

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

3

Steer unit

Check steering column teeth on steer unit for wear.

4

UVV testing

Carry out UVV testing at prescribed intervals.

5

PMT test

Check traction controller safety circuit L74-GB

2-Yearly Maintenance (or every 2000 service hours) Every 2 years or 2000 service hours Item Component

Action

1

Seat runners

Check for wear, grease.

2

Gear unit

First oil change after 250 service hours, thereafter every 2000 service hours. Ensure bolts are tight.

3

Steering axle

Ensure bolts are tight.

4

Hydraulic reservoir

Replace ventilation and pressure filters. Replace hydraulic oil

5

Orbital steer unit spline

Check and lubricate L75-GB

MS-1.0-2232

28

Printed in Germany

LUBRICATION AND ADJUSTMENT

17

4

5, 6 2 11

9

MS-2232-047

1

MS-2232-039

8

7,12

3, 10

5, 6

MS-2232-038

Printed in Germany

MS-1.0-2232

29

LUBRICATION AND ADJUSTMENT Torque Requirements The information on the following pages can be used to determine the correct torque. Torques deviating from the standard ratings are summarised in tables.

Always use the standard torque unless otherwise indicated in the maintenance manual.

Festigkeitsmarkierung für Schrauben

Festigkeitsmarkierung für Muttern

8 .8

8 .8 8

1 2 .9

1 2 .9

WARTUNG 07

Standard Torque Tables Standard Allen screws and hex. bolts Grade

8.8 Thread size

30

12.9

Torque (Nm)

M5 x 0.8

5-8

7-8

8 - 10

M6 x 1

8 - 10

12 - 14

15 - 16

M8 x 1,25

20 - 25

28 - 31

34 - 37

M10 x 1.5

39 - 43

56 - 61

68 - 75

M12 x 1.75

71 - 76

100 - 107

119 - 127

M14 x 2

113 - 122

159 - 171

190 - 205

M16 x 2

175 - 190

247 - 267

296 - 320

M20 x 2.5

340 - 357

479 - 518

574 - 621

M24 x 3

587 - 635

824 - 892

990 - 1071

M30 x 3.5

1175 - 1274

1654 - 1792

1985 - 2150

Torque wrench tolerance ± 25%

MS-1.0-2232

10.9

T58-GB

Printed in Germany

LUBRICATION AND ADJUSTMENT Hex. countersunk screws Grade

8.8 Thread size

10.9

12.9

Torque (Nm)

M5 x 0.8

4-7

5-8

7 - 10

M6 x 1

7 - 10

9 - 12

11 - 14

M8 x 1.25

16 - 19

23 - 26

27 - 30

M10 x 1.5

31 - 34

45 - 49

54 - 58

M12 x 1.75

56 - 60

79 - 84

94 - 102

M14 x 2

-

-

-

M16 x 2

124 - 146

190 - 206

228 - 247

M20 x 2.5

259 - 281

363 - 395

437 - 473

M24 x 3

416 - 451

586 - 635

702 - 762

M30 x 3.5

-

-

-

Torque wrench tolerance ± 25%

Printed in Germany

T59-GB

MS-1.0-2232

31

LUBRICATION AND ADJUSTMENT Hex. head cap screws Grade

8.8 Thread size

12.9

Torque (Nm)

M5 x 0.8

6-8

7-9

8 - 11

M6 x 1

9 - 12

12 - 15

15 - 18

M8 x 1.25

22 - 24

30 - 33

35 - 38

M10 x 1.5

42 - 45

58 - 64

71 - 76

M12 x 1.75

72 - 77

102 -110

122 - 132

M14 x 2

115 - 125

161 - 175

194 - 210

M16 x 2

179 - 194

251 - 273

301 - 327

M20 x 2.5

348 - 377

489 - 530

588 - 637

M24 x 3

601 - 651

846 - 915

1014 - 1098

M30 x 3.5

1196 - 1296

1681 - 1822

2017 - 2187

Torque wrench tolerance ± 25%

MS-1.0-2232

32

10.9

T60-GB

Printed in Germany

LUBRICATION AND ADJUSTMENT Umbrako screws and nuts Grade

8.8 Thread size

10.9

12.9

Torque (Nm)

M5 x 0.8

-

8 - 11

9 - 12

M6 x 1

-

14 - 16

16 - 19

M8 x 1.25

-

31 - 34

38 - 41

M10 x 1.5

-

62 - 68

75 - 81

M12 x 1.75

-

108 - 117

130 - 141

M14 x 2

-

174 - 187

209 - 225

M16 x 2

-

273 - 294

327 - 354

M20 x 2.5

-

-

-

Torque wrench tolerance ± 25%

Printed in Germany

T61-GB

MS-1.0-2232

33

LUBRICATION AND ADJUSTMENT Special Torque Tables Torque Settings MECHANICAL Location

Size / Fittings

Maximum Torque

Accelerator Assembly to Chassis

M8

20-25nm

Brake Actuator Arms Retaining Nuts

M10 All Metal Prevailing Torque Nuts

30nm

Brake Disc Assembly Retaining Nuts

M10 All Metal Prevailing Torque Nuts

40-45nm

Counterweight to Chassis

M20

380 Nm

Drive Motor to Gearbox

M10 Durlock

60nm

M10

40-45nm

Durlock M16 Bolts & Nuts

330nm

M10

39-43nm

M20 Bolts

574-621nm

Oil Tank to Chassis

M10 Nuts & Special Washer

6nm

Steer Axle to Chassis

Durlock M16 X 45

327-354nm

Steering Wheel Center Nut

3/4

37nm

Tilt Eye Fixing Pins

M8

20-25nm

M14 Nuts

141nm

Footbrake Pedal Assembly to Chassis Gearbox to Chassis Lower Brake Adjuster Locknuts Mast Pivots

Wheel Nuts

T56_1-GB

MS-1.0-2232

34

Printed in Germany

LUBRICATION AND ADJUSTMENT Torque Settings HYDRAULIC Location

Size / Fittings

Maximum Torque

Control Valve to Chassis

M10

40-45 Nm

Steering Column to Steering Valve

M10

39-43nm

Oil Tank Suction Flange

M6

4nm

Pump Inlet Adapter

M6

8-10nm

M10 (Clamp)

to be evaluated

M6

8-10nm

Pump to Motor (Steel Motor Only)

M10 Durlock

63nm

Return Filter Head (Plastic) to Tank

M8

Hand Tight

Pump Motor to Rear Bulkhead Pump Outlet Elbow

T56_2-GB

Torque Settings ELECTRICAL Location

Size / Fittings

Maximum Torque

Nut Connections on Contactors

10mm Steel Nut

20nm

Drive Motor Cable Connections

M8 Hex Head

13nm

Control Unit Heatsink to Chassis

M10 Nut

40-45nm

Handbrake Assembly to Chassis

M5

7nm

Microswitch to Metal

0.5nm

Potentiometer to Metal

1nm

Pump Motor Cables to Motor

M8 Hex Head

13nm

Overhead Load Guard to Chassis (Front)

M12

76nm

Overhead Load Guard to Chassis (Rear)

M20

380 Nm

Front Scuttle Console

M6

16-19nm T56_3-GB

Printed in Germany

MS-1.0-2232

35

LUBRICATION AND ADJUSTMENT Specific Fastener Torque Requirements Location

Fastener Size

Grade

Torque Nm

M8 Hx Socket Button Hd, Black Oxide

8.8

22

Counterweight to Chassis

M20 Hx Hd, Black Oxide

8.8

359

Drive Motor to Gearbox

M10 FI Hd, Durlock Nut, Black chr

12.9

62

Footbrake Pedal Assembly to Chassis

M10 Plow bolt / nut, Zinc pl

8.8

37

Drive Unit to Chassis

M16 FI Hd Durlock, Black chr

12.9

339

Steer Axle to Chassis

M16 FI Hd, Durlock Nut, Black chr

12.9

339

Mast Lower Pivot Mount

M20 Hx Socket, Black oxide

12.9

569

Tilt Cylinder Pin Keeper

M8 Hx Hd, Zinc pl

8.8

22

Tilt Cylinder Clevis

M12 Hx Hd, Zinc pl

8.8

102

Pump Motor Mount To Chassis

M10 Fl Csk Sq Neck, Zink pl

8.8

37

Contactor Panel to Chassis

M10 Fl Csk Sq Neck, Zinc pl

8.8

37

Steering Wheel Center Nut

3/4" Hx Nut, Black Oxide

SAE Gr 8

37

Drive Wheel Nuts

M14 spherical nut, Zinc pl

CI 10

141

M8 Csk Screw, Zinc pl

8.8

18

Accelerator Assembly to Cowl

Control Valve to Chassis Tool accuracy required ± 25%

MS-1.0-2232

36

T57_1-GB

Printed in Germany

LUBRICATION AND ADJUSTMENT Specific Fastener Torque Requirements Location

Fastener Size

Grade

Torque Nm

Lift Lever Bracket to Chassis

M10 Plow Bolt / nut, Zinc pl

8.8

37

Steering Control Unit Mounting to Cowl

M10 Hx Socket Hd, Zinc pl

8.8

42

Steering Column Mounting to Cowl

M10 Hx Socket Hd, Zinc pl

8.8

42

Parking Brake Mounting to Cowl

M5 Hx Hd Screw, Zinc pl

8.8

7

Overhead Guard Front Mount To Chassis

M12 Hx Hd Screw, Zinc pl

8.8

76

Overhead Guard Rear Mount To Chassis

M20 Hx Hd, Zinc pl

8.8

359

M10 Plow bolt, M10 Flanged Nut

8.8

37

M10 Flanged Nut

8.8

42

1/2" Hex Head bolt, Zinc pl

SAE Gr 5

102

Seat Deck Latch Bar to Chassis Seat Deck Gas Strut Load Backrest Tool accuracy required ± 25%

T57_2-GB

Printed in Germany

MS-1.0-2232

37

Blank Page

Printed in Germany

HYDRAULICS

Printed in Germany

39

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Printed in Germany

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HYDRAULICS 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 line with full flow (tubing or hose)

Pilot or drain line or drainage with limited flow

Hydraulic pump with fixed displacement and single direction of turn

Hydraulic motor, bi-directional

Lines crossing; not connected Pressure gauge

Lines crossing and connected Thermometer

Plugged port (test port)

Accumulator gas charged diaphragm type Flow meter

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HYDRAULICS

Pressure switch

Manual actuator

Double-acting cylinder;unequal area

Spring, (bias to normal deenergised position)

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

Single-acting cylinderwith 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)

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HYDRAULICS

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

Relief valve, adjustable

Check valve

Shut-off valve, manual

Torque generator

P T

T P

L R

Hydraulic steer unit

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HYDRAULICS

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

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HYDRAULICS Valve Block The valve block 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 235 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).

The pressure relief valve settings must not be changed.

In the event of a fault, always replace the pressure relief valves. New valves are pre-set to the correct pressure.

●

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.

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.

Pump motor Refer to Chapter 4 for pump motor maintenance and repair instructions.

Hydraulic pump INFORMATION 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 ●

Check that the assembly is clean and correctly assembled.

●

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

●

Note the arrow direction.

●

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

●

Never run a pump without oil.

●

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

●

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

Bleeding ●

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

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HYDRAULICS Bleeding the hydraulic system WARNING Risk of serious injury from pressurized hydraulic oil.

Pressurized hydraulic oil can penetrate the skin. This is a serious medical emergency which requires immediate medical attention.

●

Slowly open the vent screw on one of the tilt cylinders.

●

Tighten the vent screw as soon as bubble-free oil emerges.

●

Repeat the previous stages on the second tilt cylinder.

Bleeding the free lift cylinder ●

Prepare the work area to collect spilled oil.

●

Cover the brake disks with a plastic sheet to prevent the brake linings becoming contaminated with oil.

●

Raise the fork carriage to approx. 1,200 mm.

Always take the following precautions:

●

Depressurise the hydraulic system before starting assembly work on the hydraulic system.

Wear protective clothing, safety glasses and gloves before carrying out the next step.

●

Slowly open the vent screw on the free lift cylinder.

●

Tighten the vent screw as soon as bubble-free oil emerges.

●

Clean any oily components on the truck.

The skin will not show any obvious initial damage and the physical effects will not be manifested immediately. Seek medical assistance if your skin has been affected by pressurized hydraulic oil.

After carrying out assembly work carefully check to see that all ports are tightened before re-pressurising the system.

Wear protective clothing, safety glasses and safety gloves when tracing leaks or bleeding the system.

Use a piece of absorbent paper to trace leaks, never use your hands.

Follow the hydraulic oil manufacturer’s safety instructions when handling these oils.

Bleed the system after carrying out repairs to the free lift, lift and tilt cylinders.

CAUTION Possible damage!

On hydraulic connections with O ring seals the O rings will be damaged if opened under pressure.

Do not open connections with O ring seals for ventilation. Use only the vent screws provided on the assemblies.

Bleeding the lift cylinders ●

Prepare the work area to collect spilled oil.

●

Cover the brake disks with a plastic sheet to prevent the brake linings becoming contaminated with oil.

●

Raise the fork carriage to approx. 1,200 mm.

●

Wear protective clothing, safety glasses and gloves before carrying out the next step.

●

Slowly open the vent screw on one of the lift cylinders.

●

Tighten the vent screw as soon as bubble-free oil emerges.

●

Repeat the previous stages on the other lift cylinder.

●

Clean any oily components on the truck.

Bleeding the tilt cylinders ●

Prepare the work area to collect spilled oil.

●

Cover the brake disks with a plastic sheet to prevent the brake linings becoming contaminated with oil.

●

Raise the fork carriage to approx. 1,200 mm.

●

Wear protective clothing, safety glasses and gloves before carrying out the next step.

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HYDRAULICS Flushing the cylinders After bleeding the cylinders: ●

Extend the mast fully.

●

Check the cylinders for leaks.

●

Fully extend and retract the mast at least 10 times at max. speed to flush the system.

If this distance is exceeded, this could indicate internal leakage in one of the lift cylinders. It may also be caused by a foreign body in one of the valve seats. Flush the system again (extend and retract the mast at least 10 times). Now carry out the test again.

Tilt cylinder drift test ●

Fully extend and retract the mast several times from one end to the other to flush the hydraulic system.

●

Collect the maximum permissible load for a lift height of 2500 mm (see capacity plate on truck).

●

Tilt the mast backwards (towards the driver) up to the limit.

●

Raise the test load so that one of the fork tips is 2500 mm above the ground.

●

Switch off the truck and disconnect the battery.

Measure the temperature in the hydraulic reservoir before carrying out the tests.

●

Remove one of the floorboards to provide access to one of the tilt cylinders.

The test load must correspond to the maximum capacity at the respective lift height (see capacity plate on truck).

●

Measure the distance from the front of the cylinder gland to the clevis. Note down the reading.

●

Wait for 5 minutes.

●

Measure again the distance from the front of the cylinder gland to the clevis.

●

The difference should be max. + 16 mm.

Drift Tests After carrying out repairs to the hydraulic system perform a drift test. This is the only way of identifying internal leakage.

INFORMATION Whenever you carry out a drift test the hydraulic oil temperature must be 30 40 °C.

DANGER Falling loads are hazardous!

You could be fatally injured by a falling load.

Never stand underneath a raised load.

The test load must be evenly distributed.

The load centre of gravity must be centrally located and must not exceed the capacity plate specification. Secure the test load to prevent it from slipping and falling.

Lift cylinder drift test ●

Fully extend and retract the mast several times to flush the hydraulic system.

●

Collect the maximum permissible load for the highest lift height (see capacity plate on truck).

●

Attach a measuring tape to one of the fork tips.

●

Extend the mast fully.

●

Switch off the truck and disconnect the battery.

●

Measure the distance from the fork tip to the ground.

●

Wait for 10 minutes.

●

Measure again the distance from the fork tip to the ground.

●

The load should lower max. 100 mm.

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If this distance is exceeded, this could indicate internal leakage in one of the tilt cylinders. It may also be caused by a foreign body in one of the valve seats. Flush the system again (tilt the mast from one end to the other at least 10 times). Now carry out the test again.

Steer unit drift test ●

Turn the steering wheel as far as it will go.

●

Keep holding the steering wheel against the stop, applying gentle pressure. The steering wheel should continue to turn max. 1 revolution within 60 seconds.

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HYDRAULICS Overload Valves (RV) The main overload valve and the steering overload valve are pre-set. In the event of a fault, replace the valves. It is not necessary to adjust them after replacement.

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DRIVE UNIT

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DRIVE UNIT Disassembly

Drive Unit The drive unit of the truck consists of the drive motor and the gear unit. For drive motor maintenance and repair details, see Chapter 4.

WARNING Do not test the disassembled motor on the test bench as the motor could be damaged without the lower support.

Gear Unit NOTE The drive transmission unit must only be serviced by authorised and trained personnel.

The manufacturer’s warranty is invalidated if incorrect maintenance is performed on the transmission system.

Disassembly ●

Assembly Assemble the gear unit in the reverse order of disassembly. ●

When re-assembling, lubricate the spline shaft connection between the motor and the gear unit with grease, part no. 063002-022.

●

Torque the mounting screws to 60 Nm.

●

Torque the drive motor power cable to 13 Nm.

Remove the mast (see Chapter 7).

To remove the drive motor: ●

Remove the electrical connections.

●

Remove the 4 mounting screws from the lower section.

●

Lift the motor out from the top.

MS-2232-100

●

Remove the stabiliser between the drive units.

●

Remove the brake linkage (Fig. MS-2232-100).

●

Remove the wheel.

●

Support the gear unit with a wooden block. Loosen the mounting screws.

●

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

●

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

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DRIVE UNIT

0

23 Nm 4 5

6

7 1 339 Nm

339 Nm

0

0

13

24

25

8 9

3

2

10 14

11

40

45

12

43

22

10

41 26 23

42

15 34 0

35 42 - 45 Nm 37 3

27

28 29 30

32 31

16 33

34

39

17 18

5

36 21

0

19 45 Nm

44

20 38

4

MP-2232-016

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

Bevel gear spur wheel pinion shaft pre-assembly ●

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.

●

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

Dismantling the Gear Unit Clean the gear unit thoroughly before dismantling it.

Note that the gear unit cover (item 5) and the two transmission housing halves (item 3) are fixed with parallel pins.

Make sure the raised and flat faces are not damaged during disassembly.

Dismantle the gear unit in accordance with diagram MP2232-016.

Spur wheel flange shaft assembly ●

Gear Unit Assembly

Heat the spur wheel (item 15) to approx. 135°C and place it on the flange shaft (item 1) (fig. MS2232-102).

Replace all bearings and seals.

Pre-assembly of the housing with flange shaft ●

Thoroughly 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. MS-2232-101).

MS-2232-102

●

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.

MS-2232-101 ●

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

●

Now press the flange shaft into the housing transmission neck.

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DRIVE UNIT ●

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

●

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

●

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 Loctite Crown No. 053050-019) for securing the flange shaft tensioned on the block.

●

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

●

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

Bevel pinion assembly ●

Press the conical roller bearings (items 9, 11) onto the bevel pinion (item 10) (Fig MS-2232-103).

●

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

Bevel gear assembly ●

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

●

Now place the bearing race (item 28, secure with Loctite Crown No. 053050-019) followed by the shims (items 22, 29) previously obtained when setting the bearing pre-tensioning on the spur wheel pinion shaft.

●

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).

MS-2232-103 ●

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. MS-2232-104).

Proceed as follows: ●

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. ●

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

●

Apply LOCTITE No. 577 (CROWN P/N 053050019) to screws. Fit brake bracket and torque screws to 23 Nm.

MS-2232-104

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DRIVE UNIT ●

●

Insert the conical nipple (item 6) in the upper part of the 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 (item 5).

Finally, assemble the bleed valve (item 45) with its conical nipple (item 24) and the oil filler caps (items 32, 33) with their respective conical nipples (item 31).

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 See lubricant table in Chapter 1.

Oil level

Flank tooth bearing The following diagram shows the flank tooth bearing tolerances.

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.

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.

Correct flank system for inner conical pinion High

Low

High

Correct flank system for inner bevel gear

Low

M1565-1

Reducing the installation path of the conical pinion If the flank system on the conical pinion is too high, the installation path of the conical pinion must be reduced. If the flank system is too low, increase the installation path.

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ELECTRICS

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ELECTRICS Electrics - General Wire Colour Codes The wires used in the truck are colour-coded and numbered according to their function. The first digit or the 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 conver ter

YEL

Yellow

4 **

Third DC conver ter

GRN

Green

5 **

Negative not connected

BLU

Blue

6 **

Insulated negative

VIO

Violet

7 **

+5 V DC conver ter

GREY

Grey

8 **

Four th DC conver ter

WHT

White

9 **

Various

RED/WHT

Red/White

29 **

Positive connected

GRN/WHT

Green/White

59 **

Negative connected

** Numbers 01 to 99

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ELECTRICS Abbreviations 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

Direction control 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 safety switch

FS

Forward switch

SDS

Star t switch

HBS

Handbrake switch

SES

Seat switch

HSS

Fast / Slow Travel switch

SSS

Sideshifter switch

HNS

Horn switch

THS

Thermo switch

KYS

Key switch

TLT

Tilt switch

LGS

Light switch

WAS

Walk along switch

* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2 etc.

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E02-gb

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ELECTRICS 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 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

.

Varistor

U

Assembled unit

NO

USA

Motor armature

.

M0056-gb

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ELECTRICS Electrical Components DANGER The truck must be jacked up prior to carrying out repair work or troubleshooting the electrical system.

Switch Functions The pin references relate to the drive and pump control inputs.

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.

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.

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.

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.

SC3200 03/2004 • Printed in Germany

Raise Potentiometer (POT2) 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.

Steering Axle Potentiometer (POT3) The steering axle potentiometer POT3 is mounted on the steering axle input shaft and gives the following control signals to the traction controller: ●

Travel direction;

●

Steering wheel angle of turn.

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

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

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.

The controller circuit is protected by fuse FU3 and the horn by fuse FU4. FU5 protects the supply voltage to the BDI.

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ELECTRICS 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 Emerg.

Disconnect POT 3 Electrical board

M0369

PM

HNS

BDI / TT M0367

HBS

ACS / POT 1 BRS

1

2

3

4 +

AXS

FU5

SSS

M0368

TM

TLT POT 2

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ELECTRICS Electrical Board

Back wall

10 A control fuses FU4 FU3

Pump controller

FU2 (Hydraulic circuit, 350 A) FU3 (Traction circuit, 500 A)

RGB contactor

Main contactor (LC)

Diode module

Resistor

Traction controller

LH travel contactor (LHS)

RH travel contactor (RHS)

CAUTION Risk of damage to the controllers and contactors.

WARNING Risk of personal injury.

Incorrect polarity between the control lines and the contactors will short-circuit the existing freewheel diodes.

Swapping the control lines leading to the travel contactors (left connected to right) will cause the truck to steer unpredictably at a given steering angle.

Mark the position of the control lines relative to the contactors before removal.

Check the connections again to ensure correct polarity before powering up the truck.

Mark the position of the control lines relative to the contactors before removal.

Check the connections again to ensure correct polarity before powering up the truck.

After working on the travel contactors test the steering over the full steering range in a secure environment.

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ELECTRICS Zapimos B1S 48/700 Controller

Key Terms

General

Shunt or Shunt Resistor (+SH/-SH) 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 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

Functional Description M0201

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 changed by the programmer.

Travel Switch ZAPIMOS B1S 48/700 Traction Controller

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

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

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 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.

Fault Identification 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.

●

Logic error.

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ELECTRICS ●

Incorrect start sequency; travel switch operated.

●

Volt Motor Negative Test (VMN) error.

●

High acceleration potentiometer resistance level when idle.

●

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

●

Contactor drivers faulty.

●

Controller temperature above 80°C.

●

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

●

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 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.

Creep Mode 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.

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

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

Steering Controller 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.

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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.

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.

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

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).

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.

SC3200 03/2004 • Printed in Germany

ELECTRICS Seat Switch 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.

SC3200 03/2004 • Printed in Germany

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

Vacant

Programmer connection

LED

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

C 3 2 1

+B

B 8 7 6 5 4 3 2 1

-B

VMN R

Steering Axle, Drive Motor, Seat

VMN L

Line Contactor

- SHL

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Potentiometer and Switch

Handbrake

Vacant

L 9 8 7 6 5 4 3 2 1

+ SHL

A 2 1

J 2 1

H 3 2 1

G 8 7 6 5 4 3 2 1

F 2 1

- SHR

+ SHR

SC3200 03/2004 • Printed in Germany

ELECTRICS ZAPIMOS B1S 48/700 Pin Layout Pin

Function

Additional Info

A1 -

LED

Alarm

A2 +

LED

Alarm, output current 12 mA, for standard LED

B1 +

Serial interface receiver

B2 -

Serial interface receiver

B3 +

Serial interface sender

B4 -

Serial interface sender

B5 -

Programmer power supply

B6 +

Programmer power supply

B7

Pin free

B8

Pin free

E1 +

Key switch input

E2 +

Travel direction contactor coil

E3

Pin free

E4 -

Travel direction contactor coil

RH drive motor

E5 -

Travel direction contactor coil

RH drive motor

E6 -

Travel direction contactor coil

LH drive motor

E7 -

Travel direction contactor coil

LH drive motor

E8 +

Pedal braking contactor

E9 -

Pedal braking contactor

F1 +

Input HBS

F2

Pin free

G1 -

Accelerator pedal potentiometer

G2

Accelerator pedal potentiometer loop

O volt min. speed, 10 V max. speed

G3 +

Accelerator pedal potentiometer

12 volt output

G4

Pin free

G5

Common output for travel and brake switches

G6

Input BRS

G7

Input for reverse switch

Travel direction switch

G8

Input for forward switch

Travel direction switch

H1

Pin free

H2

Pin free

H3 +

Battery contactor

SC3200 03/2004 • Printed in Germany

12 volts

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ELECTRICS Pin

Function

Additional Info

J1

Pin free

J2

Pin free

L1 -

Output B

L2

Steering axle potentiometer loop

L3 -

Steering axle potentiometer

L4 +

Steering axle potentiometer

+7 V

L5 -

For options

Connected to battery negative terminal via L1

L6 -

For options

Connected to battery negative terminal via L1

L7 -

Seat switch input

L8 -

For options

Connected to battery negative terminal via L1

L9 -

For options

Connected to battery negative terminal via L1

Note: +

= Positive potential

-

= Negative potential

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ELECTRICS 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.

LE D C ode

Display

Explanation

LED off

❍

Traction controller operates error-free.

Permanently on

●

Both travel directions selected simultaneously

1

★

Error in electronics (EEPROM KO, WATCH DOG)

2

★★

On power up a travel direction is selected or the start sequence is not maintained (INCORRECT START, SEAT SWITCH OPEN)

3

★★★

VMN not ok (R VMN LOW, L VMN LOW, R NO FULL COND., BRAKE CONTACTOR OPEN)

4

★★★★

Error in potentiometer signal (VACC NOT OK) or in signal from steering angle sensor (STEER SENSOR KO, BAD S TE E R )

5

★★★★★

Current flow in main circuit not ok (R STBY I HIGH, L STBY I HIGH, R I=0 EVER, L I=0 EVER)

6

★★★★★★

Contactor driver error (DRIVER SHORTED, COIL SHORTED)

7

★★★★★★★

Temperature > 70°C (TH PROTECTION); Motor temperature option (THERMIC LEVEL 2)

8

★★★★★★★★

Contactors do not close or VMN high when truck is idle (R DIR. CONT. OPEN, L DIR. CONT. OPEN, R VMN HIGH, L VMN HIGH)

9

★★★★★★★★★

Contactors do not open (BRAKE CONT. CLOSED, R DIR. CONT. CLOSED, L DIR. CONT. CLOSED) E55-GB

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ELECTRICS ZAPIMOS HP 350A Pump Controller Key Terms General The key features are: ●

Infinitely variable lift control.

●

Overvoltage / Low voltage protection.

●

Circuits and software recognise errors in the pump circuit, driver circuit and the power part.

●

Power up sequence monitoring.

Protective Devices

Shunt or Shunt Resistor (+SH/-SH) The controller logic can measure the current flowing through the motor using a pre-defined resistance (shunt) in series with the motor. This controls the output current of the power part.

Volt Motor Negative (VMN) The measurement point for the controller logic. The voltage range on the power part is measured. The result obtained is used to check the power part for faults.

Polarity Protection 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 If the temperature on the heat dissipator of the power part exceeds 80°C, the output current is reduced in proportion to the rise in temperature. At 85°C the pump controller cuts out.

Protection The pump controller is protected against dust and spray water (IP54).

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ELECTRICS Functional Description 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 changed by the programmer.

Hydraulic Switches The sideshift, tilt and aux. hydraulic functions are driven by switches. If applying an operating lever causes the switch to close, the pump motor operates at a preset speed controlled by the programmer.

Steering has priority over lifting. Priority control is governed by a priority valve in the valve block.

Lift Cutout If the battery capacity falls below 20%, the battery discharge indicator sends a signal to the controller. The controller cuts out lifting.

Lift potentiometer The travel switch stroke is 0 - 100% proportional to the controller output.

Lift Potentiometer 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 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.

Fault Identification

Steering Support Signals are generated via an encoder. These are digitalized in the encoder module and sent to the pump controller. The pump controller then drives the pump motor at a speed which is preset by the programmer. Steering has priority over lifting. This is controlled by a priority valve in the valve block.

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.

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 controller range limit cuts out and opens the contactors. When the permissible voltage has been reached the controller resumes operation.

Overtemperature At a temperature of 80°C the output current 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.

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: ●

Logic error.

●

Incorrect start sequence.

●

Volt Motor Negative Test (VMN) error.

●

High resistance level on the lift potentiometer when truck is idle.

●

Current when truck is idle. Current > 0 A

●

Temperature above 80°C

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ELECTRICS

ZAPIMOS HP 350A Pump Controller Connections Lift potentiometer Hydraulic functions, encoder

Programmer connection

Key Switch

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

+B

C 3 2 1

+M

B 8 7 6 5 4 3 2 1

A 2 1

LED

-B

-M

MS-2232-051

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SC3200 03/2004 • Printed in Germany

ELECTRICS ZAPIMOS HP 350 A Pin Layout Pin

Function

Additional Info

A1 -

LED Alarm

A2 +

LED Alarm

B1 +

Serial interface receiver

B2 -

Serial interface receiver

B3 +

Serial interface sender

B4 -

Serial interface sender

B5 -

Programmer power supply

B6 +

Programmer power supply

B7

Pin free

B8

Pin free

C1

Lift potentiometer loop

C2

- Lift potentiometer

C3

+ Lift potentiometer

14 volt output

D1

+ Key switch input

Connection to D2 via diode

D2

+ connected

E1

Pin free

E2

Aux. function switch input

E3

Sideshift switch input

E4

Pin free

E5

Tilt switch input

Active when B + is applied

E6

Lift cutout input

Active when B + is applied

E7

Pin free

E8

Encoder input

E9

Pin free

Note:

+ = Positive potential

Output current 12 mA, for standard LED

12 volts

0 volt min. speed, 10 volt max. speed

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

– = Negative potential

SC3200 03/2004 • Printed in Germany

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ELECTRICS Pump Controller, LED error code Programmer Connection "B" A socket is provided to connect the programmer. The cable is supplied with the programmer.

Status LED "A" 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).

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

In normal start up the Status LED is off.

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

LE D C ode

Display

Explanation

LED off

❍

Lift controller operates error-free.

1

★

Error in electronics (EEPROM KO, WATCH DOG)

2

★★

On power up a hydraulic switch function is activated (INCORRECT START)

3

★★★

VMN not okay (NO FULL COND)

4

★★★★

Error in potentiometer signal VAC C > 1

5

★★★★★

Current flow in main circuit not ok (I HIGH AT STAND)

6

★★★★★★

Contactor driver error (DRIVER SHORTED, COIL SHORTED)

7

★★★★★★★

Temperature > 80°C (TH PROTECTION) E67-GB

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SC3200 03/2004 • Printed in Germany

ELECTRICS Pump Controller Assembly WARNING

●

Thoroughly clean the back of the pump controller and the contact surface in the truck. The surfaces must be free of grease and foreign bodies. Apply a thin layer of heat conducting past (Crown P/N 053051-008) to the back of the traction controller.

The amount applied correct if the heat conducting paste covers the entire surface and the structure of the metal surface can still be seen through the heat conducting paste. Too much or too little paste will adversely affect the transfer of heat.

●

Reposition the pump controller exactly in its mounting plate and screw it tight. Torque: 5.5 – 6 Nm.

Risk of injury through burning.

●

Screw the power cables back on.

Short circuits can form an arc with high currents!

●

Reconnect the control lines.

●

The controller capacitors have a high capacity and can store energy for a long time.

Re-fit the ventilator.

●

Jack up the truck until the drive wheels are free.

●

Connect the programmer and check the settings of the new controller. Make any necessary adjustments.

●

Re-fit the side panel.

Incorrect wiring when carrying out repairs can cause the truck to start accidentally.

Jack up the truck until the drive wheel is free and no longer touches the ground.

Always disconnect the battery from the truck when working on the electrical system.

Prevent the truck from being switched on again.

WARNING

Use only insulated tools.

Wear eye protection.

Do not wear jewelry.

●

Connectors, wire bundles and lines are normally labelled. If the writing is illegible or missing, mark the connections prior to removal.

●

Disconnect the battery.

●

Prevent the truck from rolling away and being switched on again.

●

Open the battery compartment lid.

●

Remove the retaining screws from the left hand side panel.

●

Lift out the left hand side panel.

●

Unscrew the ventilator panel and the ventilator.

●

Remove the internal capacitors. Briefly bypass connections -B und +B with a resistance of 10 to 100 ohms (min. 5 watts).

●

Remove the connectors from the pump controller.

●

Unscrew the power cables.

●

Remove the 4 mounting screws from the pump controller and remove the pump controller.

SC3200 03/2004 • Printed in Germany

0

Pump Controller Removal

5.5 - 6 Nm M0189

Traction Controller Removal Connectors, wire bundles and lines are normally labelled.

If the writing is illegible or missing, mark the connections prior to removal.

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ELECTRICS ●

Remove the counterweight (see Chapter 1).

●

Remove the retaining screws from the left hand side panel.

●

Lift out the left hand side panel.

●

Unscrew the ventilator panel and the ventilator.

●

Remove the internal capacitors of the traction controller. Briefly bypass connections -B and +B with a resistance of 10 to 100 ohms (min. 5 watts).

●

Remove the connectors from the traction controller.

●

Unscrew the power cables.

●

Remove the 6 mounting screws from the traction controller and remove the traction controller.

Traction Controller Assembly ●

Thoroughly clean the back of the traction controller and the contact surface in the truck. The surfaces must be free of grease and foreign bodies.

●

Apply a thin layer of heat conducting past (Crown P/N 053051-008) to the back of the traction controller. The amount applied correct if the heat conducting paste covers the entire surface and the structure of the metal surface can still be seen through the heat conducting paste. Too much or too little paste will adversely affect the transfer of heat.

●

Reposition the pump controller exactly in its mounting plate and screw it tight. Torque: 5.5 – 6 Nm.

●

Screw the power cables back on.

●

Reconnect the control lines.

●

Re-fit the ventilator.

●

Re-install the counterweight and the battery (see chapter 1).

●

Jack up the truck until the drive wheels are free.

●

Connect the programmer and check the settings of the new controller. Make any necessary adjustments.

●

Carry out the PMT test.

●

Re-fit the side panel.

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ELECTRICS 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-neu

MS-2232-034

SC3200 03/2004 • Printed in Germany

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ELECTRICS Key Description K ey

Description

Explanation

K ey 1

ROLL up

Selects the next sub-menu or an option.

K ey 2

ROLL down

Selects the previous sub-menu or an option.

K ey 3

E N TE R

Enters the main menu. Stores the pin configuration.

K ey 4

OUT *

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

K ey 5

P A R A M up

Increases setting values or selects configuration.

K ey 6

S E T dow n

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.

E54-GB

Display Window ● Alpha-numeric LCD display ● 2 lines @ 16 characters

B.REVERSE I MAX BREAKING COMPENS: R.BRAKE ACCEL. SPEED I MAX SP. SPEED II S.P.I SPEED III S.P.II FIELD WEAK..

BYPASS

2 TESTER 3 SAVE 4 RESTORE 5 ALARMS 6 ACCELERATOR 7 MOTOR DATA

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

Operating Keys

MS-2232-023

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ELECTRICS 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.

Operating Menu

M0272

General When the programmer has been connected a self test start routine is performed. 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.

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ELECTRICS 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

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ELECTRICS 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 power supply, switch off truck and check wiring

YES

Switch off truck; check programmer - controller connection

YES

Switch off truck; programmer and controller are incompatible

C h e c k

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

No error

YES

C h e c k

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

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

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

H 2

V .1 .0 3 5

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

SC3200 03/2004 • Printed in Germany

K O

M0288d MS-4.5-2232

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ELECTRICS 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.

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

Traction Controller Settings Recommended Explanation Setting

Menu item

Setting range

A C C . D E LA Y

0-9

4

Acceleration delay. Minimum time required for the motor current to rise from the minimum to the maximum level.

INVERSE BREAKING

0-9

5

Braking intensity for inversion braking by changing travel direction. The brake force is dependant on the accelerator pedal position and the maximum traction current setting.

R E LE A S E BREAKING

0-9

3

Braking intensity during release braking (accelerator pedal in neutral). The brake force is dependant on the maximum traction current setting.

PED AL BREAKING

0-9

9

Braking intensity when the brake pedal is applied. The brake force is dependant on the maximum traction current setting.

6

Defines the maximum motor current. All current settings are expressed as a percentage of the I max value which is set here. The setting range is from 50% (level 0) to 100% (level 9) of the maximum current of the controller.

5

Reduced travel speed. Active when potential B- is applied to input Cutback 1. If this input is not used for reduced travel speed, the CUT BACK SPEED 1 value must be set to level 9.

2

Defines the minimum value for the motor current when the travel switch has just been closed. When the travel switch is activated voltage is applied to the motor; this provokes a rapid response to the travel command.

TRACTION I MAX

C U TB A C K SPEED 1

C R EEP SPEED

0-6

0-9

0-9

E53-GB

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

TESTER menu (traction controller) Menu item

Explanation

L VMN R

Displays in real time the output voltage for the traction motors applied to the Volt Motor Negative. An important reading which provides information on the status of the MOSFETs.

L IMOTOR R

Displays in real time the current flowing through the pre-resistors (SH). Displayed during travel as well as braking.

BATTERY VOLTS

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 of the steering wheels.

ACCELLEATOR

Displays the output voltage from the traction potentiometer applied to the traction controller up to a value of 10 V. 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 ""Forward"" switch and its wiring.

TEMPERATURE

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

BRAKE SWITCH

Tests the operation of the brake switch and its wiring.

CUTBACK SWITCH 1 & 2

Tests the operation of the speed cutback switch and its wiring E52-GB

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ELECTRICS 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 (traction controller) Error code

Description

Possible cause

BRAKE CON CLOSED

The test is performed during operation or - Regenerative brake contactor jammed at the start of inverse braking. The alarm is - External connection from E9 to Bactivated when the supply to the VMN - Logic error exceeds 2/3 of the battery voltage.

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 - Faulty motor wiring - Direction contactor faulty

BRAKE CONT OPEN

The test is performed when the regenerative brake contactor has closed.

Tests whether the VMN is rising from 1/3 to 2/3 of the battery voltage.

- Regenerative brake contactor faulty - Magnetic coil or wiring faulty

R DIR CONT CLOSED L DIR CONT 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 100% to 80% of the PWM signal. The alarm sounds when the VMN falls to below 1/3 of the battery voltage.

- Direction contactor 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 is activated when the VMN exceeds 2/3 of the battery voltage.

- Short circuit between battery + and VMN - Logic error

R I=0 EVER L I=0 EVER

The test is performed in operational mode. The alarm is activated when the minimum supply level is exceeded and travelling is inhibited.

- Current sensor faulty.

- Power supply fault

EEPROM DATA KO

Displays fault in hourmeter memory range. Followed by reset to zero, traction controller continues to operate however.

- Logic section error (not permanent)

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 - Steer potentiometer faulty E50_1-GB

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ELECTRICS ALARMS menu (traction controller) Contd. 1 Error code

Description

Possible cause

WATCH DOG

Microprocessor self test: performed during standby and travel modes.

- Logic faulty

COIL SHORTED

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

Detects the shor t circuit current when the - Negative connection from one of the contactor coils are activated. contactor tips to battery positive shor tcircuited.

- Coils incorrectly connected with recovery diode

DRIVER SHORTED

Tests the voltage applied to the contactor drivers. Performed when contactor drivers - Traction controller faulty are not activated.

CHOPPER RUNNING

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

(Communication only between the programmer and the controller).

HANDBRAKE ERROR

- Driver's seat not occupied while Informs the operator that a travel function travel function activated has been performed with the handbrake - Seat switch faulty on for more than 5 seconds.

- Seat switch wiring faulty

SEAT SWITCH OPEN

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

HIGH TEMPERATURE

Indicates that the heat dissipator temperature has reached 70°C. At 85°C the maximum current is reduced to 0.

BATTERY LOW

Can only appear if Battery Check is activated in the Config Menu.

- Disable function

INCORRECT START

Incorrect star ting sequence.

- Incorrect operating sequence.

- Wiring error.

- Direction and/or travel switch jammed

- Handbrake on while travel function activated.

- Handbrake switch faulty.

- Handbrake switch wiring faulty.

E50_2-GB

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ELECTRICS ALARMS menu (traction controller) Contd. 2 Error code

Description

Possible cause

FORW-BACK

The test is performed permanently and - Wiring error checks if both travel directions are applied - Direction contactors faulty simultaneously.

VACC NOT OK

The test is performed in standby mode.

The alarm indicates that the potentiometer loop voltage is more than 1 V higher than the stored minimum.

R STBY HIGH L STBY HIGH

- Current control circuit error in the The test is performed in standby mode. controller.

The alarm indicates that the motor current - Problem with the battery or the power is not 0. circuit

THERMIC LEVEL 2

Motor temperature too high. For temperature control option only.

- Negative connection to potentiometer interrupted.

- Potentiometer incorrectly calibrated.

- Potentiometer faulty

- Motor temperature too high.

- Wiring error.

- Temperature sensor faulty E50_3-GB

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).

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ELECTRICS 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 wheelbase. The display 3013 corresponds to model 3210, 3016 to model 3220 and 3018 to model 3240.

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 activated (ON): - the traction controller restricts the max. current to 50 %; - the respective Service LED on the display star ts 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.

Steerpot

Used to calibrate the steering potentiometer. The minimum and maximum output voltages of the steering potentiometer are recorded and stored. Based on these minimum/maximum values the traction controller calculates the respective steer angle within a range of +90° to -90° -> see instructions.

ADJUSTMENTS

E69-GB

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ELECTRICS 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

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ELECTRICS 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.

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

Traction Controller Settings Recommended Explanation Setting

Menu item

Setting Range

A C C . D E LA Y

0-9

4

Acceleration delay: Time required for the motor current to rise from the minimum to the maximum level.

DECELERATION D E LA Y

0-9

0

Coast delay: Time required for the motor current to fall from the maximum to the minimum level.

9

Defines the maximum current of the pump motor. All current settings are expressed as a percentage of the MAXIMUM CURRENT value which is set here. The setting range is from 50% (level 0) to 100% (level 9) of the maximum current of the controller.

1

Approximate setting for the maximum pump motor speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values.

This value is based on the steering function.

4

Fine setting for the maximum pump motor speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the steering function.

MAXIMUM C U R R EN T

H YD R O SPEED COARSE

H YD R O SPEED FINE

0-9

0-9

0-6

HYDRO COMPEN

0-9

2

Speed compensation for load peaks. With this function the pump controller varies the pump speed, thereby compensating for speed reductions caused by peak demand. This value is related to the steering function.

C R EEP SPEED

0-9

4

Defines the minimum voltage applied to the pump motor

HYDRO TIME

0-9

1

Hydraulic pump delay period when no steering input signal is applied to the controller E68_1-GB

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ELECTRICS Traction Controller Settings (Contd. 1) Menu item 1 st SPEED COARSE

1st SPEED FINE

1 st S P E E D COMP

2nd S P E E D COARSE

2nd S P E E D FINE

Setting Range

0-9

0-9

0-9

0-9

0-9

Recommended Explanation Setting

2

Approximate setting for the maximum pump motor speed.

The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the second hydraulic function, tilt.

2

Fine setting for the maximum pump motor speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the second hydraulic function, tilt.

2

Speed compensation for load peaks. With this function the pump controller varies the pump speed, thereby compensating for any speed reduction caused by peak demand. This value relates to the second hydraulic function, tilt.

0 (2)

Approximate setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the first auxiliary function (=third hydraulic function), normally the sideshifter.

Values without brackets if the function is not used (standard).

Values in brackets for optional sideshifter, for all other accessories the values must be individually selected.

0 (0)

Fine setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the first auxiliary function (= third hydraulic function), normally the sideshifter. Values without brackets if the function is not used (standard). Values in brackets for optional sideshifter, for all other accessories the values must be individually selected.

E68_2-GB

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ELECTRICS Traction Controller Settings (Contd. 2) Menu item

2nd S P E E D COMP

3rd SPEED COARSE

3rd SPEED FINE

3rd SPEED COMP

Setting Range

0-9

0-9

0-9

0-9

Recommended Explanation Setting

0 (2)

Speed compensation (motor voltage) dependent on the current when traveling at reduced speed. With this function the pump controller varies the pump speed via the output voltage and can thereby compensate for any load changes.

This value relates to the first auxiliary function (=third hydraulic function), normally the sideshifter. Values without brackets if the function is not used (standard). Values in brackets for optional sideshifter, for all other accessories the values must be individually selected.

0

Approximate setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the second auxiliary function (=third hydraulic function), for example the paper roll clamp. Values in the event the function is not filled (standard), for all accessories the values must be selected individually.

0

Fine setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the second auxiliary function (=fourth hydraulic function), for example the paper roll clamp. Values in the event the function is not used (standard), for all accessories the values must be selected individually.

0

Fine setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to the second auxiliary function (=fourth hydraulic function), for example the paper roll clamp. Values in the event the function is not used (standard), for all accessories the values must be selected individually.

E68_3-GB

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ELECTRICS Traction Controller Settings (Contd. 3) Menu item

4th SPEED COARSE

4th SPEED FINE

Setting Range

0-9

0-9

Recommended Explanation Setting

0

Approximate setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to input E1, reserved for later applications and not used here.

0

Fine setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to input E1, reserved for later applications and not used here.

4th SPEED COMP

0-9

0

Fine setting for the maximum pump motor voltage, this has a direct influence on the pump speed. The actual pump speed is based on the respective SPEED COARSE and SPEED FINE values. This value relates to input E1, reserved for later applications and not used here.

AUXILLIARY TIME

0-9

0

Sets the time delay for auxiliary functions, not used E68_4-GB

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

TESTER menu (pump controller) Menu item

Explanation

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 VOLTS

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 output voltage from the lift potentiometer applied to the pump controller up to a value of 10 V.

1ST SPEED SWITCH

Displays the signal status for the 2nd hydraulic function.

2ND SPEED SWITCH

Displays the signal status for the 3rd hydraulic function.

3RD SPEED SWITCH

Displays the signal status for the 4th hydraulic function.

4TH SPEED SWITCH

Not used.

BRAKE SWITCH

Tests the operation of the brake switch and its wiring.

HYDRO SPEED REGULATION

Displays the signal status for the steering function.

E51-GB

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ELECTRICS 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 (Pump controller) Error code

Description

Possible cause

STAND BY VMN LOW

The test is performed in standby mode or during operation at 100% to 80% of the PWM signal. The alarm sounds when the VMN falls to below 1/3 of the battery voltage.

- Motor wiring faulty - Motor insulation between armature and field faulty - Logic error

No FULL COND

The test is performed in standby mode.

The alarm is activated when the VMN exceeds 2/3 of the battery voltage.

- Short circuit between battery + and VMN - Logic error

I=0 EVER

The test is performed in operational mode. The alarm is activated when the minimum supply level is exceeded and travelling is inhibited.

- Current sensor faulty.

- Power supply fault

EEPROM DATA KO

Displays fault in hourmeter memory range. Followed by reset to zero, traction controller continues to operate however.

- Logic section error (not permanent)

EEPROM KO

Shows fault in controller memory range

- Logic section error E64-GB

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ELECTRICS ALARMS Menu (Pump controller) Contd. 1 Error code

Description

Possible cause

WATCH DOG

Microprocessor self test: performed during standby and travel modes.

- Logic faulty

COIL SHORTED

Detects the shor t circuit current when the contactor coils are activated.

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

- Negative connection from one of the contactor tips to batter y positive shor tcircuited.

- Coils incorrectly connected with recover y diode

DRIVER SHORTED

Tests the voltage applied to the contactor drivers. Performed when contactor drivers - Traction controller faulty are not activated.

CHOPPER RUNNING

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

(Communication only between the programmer and the controller).

TH. PROTECTION

Indicates that the heat dissipator temperature has reached 80°C. Maximum current is reduced to 0 at 85°C.

BATTERY

Can only appear if Batter y Check is activated in Config Menu.

- Disable function

INCORRECT START

Incorrect star ting sequence.

- Incorrect operating sequence.

- Wiring error - Direction and/or travel switch jammed

- Handbrake on while travel function activated.

- Handbrake switch faulty.

- Handbrake switch wiring faulty

E65-GB

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ELECTRICS ALARMS Menu (Pump controller) Contd. 2 Error code

Description

Possible cause

VACC NOT OK VACC > 1 V

The test is performed in standby mode.

The alarm indicates that the potentiometer loop voltage is more than 1 V higher than the stored minimum.

- Negative connection to potentiometer interrupted - Potentiometer incorrectly calibrated - Potentiometer faulty

I HIGH AT STAND

- Current control circuit error in the The test is performed in standby mode. controller The alarm indicates that the motor current - Problem with the battery or the power is not 0. circuit

EEPROM PAR. KO

- If the error persists after resetting Error in memory range. The settings have (key switch OFF/ON) -> replace the been reset to default values. controller

EEPROM CONF. KO CHOP. NO CONF.

Error in configuration range. The configuration data have been reset to default values.

- If the error persists after resetting (key switch OFF/ON) -> replace the controller

EEPROM OFF lINE

Error in memory range of the error memory, hourmeter and settings

- If the error persists after resetting (key switch OFF/ON) -> replace the controller E66-GB

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.

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

CONFIG Menu Sub Menu

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.

MAIN CONTACTOR

RUNNING STATUS

Must not be changed

AUX. FUNCTION

RUNNING STATUS

Must not be changed

BYPASS CONTACTOR

BYPASS

Must not be changed

BATTERY CHECK

OFF

Must not be changed

Set Model

Model Type Standard Pump

Must not be changed

Adjustments

Set Battery Type 48 V

Must not be changed

Adjust Battery

Brings the battery display in line with the battery voltage.

SET OPTIONS

E76-GB

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ELECTRICS Calibrating the Steering Potentiometer

Crown B1S V1.0 48V 320A 0

The steering transmitter potentiometer must always be calibrated if: ●

The steering potentiometer has been replaced.

●

The traction controller has been replaced.

MAIN MENU PARAMETER CHANGE

Preparation ●

Power down the truck and jack it up so that the drive wheel is free (see chapter 1).

●

Connect the programmer to the traction controller (connector B, via diagnostic LED).

●

Switch on the truck.

Calibration ●

Using the ROLL UP or ROLL DOWN keys scroll through to the CONFIG MENU, ADJUSTMENTS menu.

●

Press ENTER.

●

The display shows SET STEER MIN and the stored minimum level of the potentiometer.

●

Press ENTER.

●

Turn the steering wheel to the left until the level displayed does not change.

●

Using ROLL UP or ROLL DOWN select the SET STEER MAX menu item.

●

The display shows SET STEER MAX and the stored maximum level of the potentiometer.

●

Press ENTER.

●

Turn the steering wheel to the right until the level displayed does not change.

●

Now press OUT

●

The display will ask “Are you sure?” If you want to save the new levels, press ENTER. Otherwise, press OUT.

●

Press OUT to quit the VACC menu.

MAIN MENU CONFIG. MENU

CONFIG MENU SET MODEL

CONFIG MENU ADJUSTMENTS

SET STEER MIN 0.5 V

SET STEER MIN 0.4 V

SET STEER MAX 4.4 V

SET STEER MAX 4.4 V

ARE YOU SURE? YES=ENTER NO=OUT

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ELECTRICS Calibrating the Lift Potentiometer

HP PUMP STD V.1.7 48V 320A 0

The lift potentiometer must always be calibrated if:

MAIN MENU PARAMETER CHANGE

●

The lift potentiometer has been replaced.

(After replacement adjust the potentiometer before calibrating it, see chapter 1)

●

The pump controller has been replaced.

Preparation

MAIN MENU PROGRAM VACC

●

Park the truck in such a way that accidental lift movements will not cause damage.

●

Connect the programmer to the lift controller (connector B, via diagnostic LED).

●

Switch on the truck.

Calibration VACC SETTING 1.3

MIN 1.3

MIN 1.3

10.0

VACC -

VACC

MAX 1.3

MAX 10.0

●

Press ENTER.

●

Using the ROLL UP or ROLL DOWN keys scroll through to the PROGRAM VACC menu.

●

Press ENTER.

●

The display shows the stored minimum and maximum levels of the potentiometer.

●

Press ENTER to delete the stored levels.

●

Slowly activate lifting until you reach the stop.

The display now shows the minimum level and the maximum level.

●

Now press OUT

●

The display will ask “Are you sure?” . If you wish to save the new levels, press ENTER. Otherwise, press OUT.

●

Press OUT to quit the VACC menu.

ARE YOU SURE? YES=ENTER NO=OUT

MS-2232-056

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ELECTRICS Calibrating the Accelerator Potentiometer

Crown B1S V1.0 48V 320A 0

The accelerator potentiometer must always be calibrated if: ●

The accelerator potentiometer has been replaced.

(After replacement adjust the potentiometer before calibrating it, see chapter 1).

●

The traction controller has been replaced.

MAIN MENU PARAMETER CHANGE

Preparation

MAIN MENU PROGRAM VACC

VACC SETTING 1.5

●

Power down the truck and jack it up so that the drive wheel is free (see chapter 1).

●

Connect the programmer to the traction controller (connector B, via diagnostic LED).

●

Switch on the truck.

10.0

Calibration

MIN 1.5

MIN 1.5

VACC -

VACC -

●

Press ENTER.

●

Using the ROLL UP or ROLL DOWN keys scroll through to the PROGRAM VACC menu.

●

Press ENTER.

●

The display shows the stored minimum and maximum levels of the potentiometer.

●

Press ENTER to delete the stored levels.

●

Slowly depress the accelerator pedal until you reach the stop. The display now shows the minimum level and the maximum level. An arrow is also indicated. The arrow shows the travel direction currently selected*.

●

Now press OUT

●

The display will ask “Are you sure?” . If you wish to save the new levels, press ENTER. Otherwise, press OUT.

●

Press OUT to quit the VACC menu.

MAX 1.5

MAX 10.0

ARE YOU SURE? YES=ENTER NO=OUT

MS-2232-055

* It is sufficient to calibrate for just one travel direction.

The value for the opposite direction will be set automatically.

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ELECTRICS Traction Controller Safety Test 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 ●

Switch off the truck.

●

Jack up the front wheels of the truck.

●

Connect the test cable between - B and VMN L.

●

Connect the programmer to the controller.

●

Press the seat switch.

●

Switch on the truck.

●

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

●

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.

●

Switch off the truck.

●

Connect the test cable between - B and VMN R.

●

Repeat the test for VMN R.

●

Disconnect the test cable between - B and VMN R.

●

Lower the front wheels.

The truck is now operational.

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ELECTRICS 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

Test Cable

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1 0 A F U

M0341

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ELECTRICS Battery General

Battery Discharge Indicator (BDI) WARNING The following setting and calibration instructions for the BDI apply only to wet batteries.

The battery condition has a considerable impact on the performance of the truck. Effective maintenance will maintain the performance levels and lifespan of the battery. ●

WARNING The battery must be serviced solely in accordance with the battery manufacturer's instructions. ●

Incorrect or inadequate maintenance will initially reduce the performance of the truck and ultimately result in premature failure of the battery.

It is essential to adjust the battery discharge indicator (BDI) correctly to ensure on the one hand that the battery is not fully discharged and on the other that there is maximum battery capacity available for the task in hand.

Replacing the battery WARNING Only use batteries of the permitted size, weight and specifications for this truck. ●

An incorrect battery type can cause damage to the truck.

●

An incorrect weight and size will alter the centre of gravity of the truck, potentially resulting in accidents.

There are several different battery compartment versions.

Refer to the truck operator manual to battery replacement instructions.

The operator manual contains the latest safety instructions and information.

For maintenance-free batteries follow the manufacturer's instructions regarding the discharge terminal voltage.

General A battery from the factory will require approx. 5 - 10 charge and discharge cycles to reach its full capacity.

A battery is considered to be technically discharged when it has reached 20% residual capacity. For example, a battery with a 500 amp hour capacity has an actual available output of 400 amp hours.

In addition, the effective output will depend on the discharge speed, which in turn is affected by the particular truck application.

The battery discharge indicator must therefore be set in accordance with the truck's particular application conditions.

The battery discharge indicator controls the lift cutout system. The lift cutout system is designed to prevent the battery from being operated to the point where is fully discharged.

If the battery is constantly discharged to below 20% of residual capacity it will be damaged.

If the lift cutout system is activated above 20% of the battery's residual capacity the battery will not be damaged, but the truck's maximum operating time under a single battery charge will not be attained.

The lift cutout system should therefore be activated as close to 20% of the battery's residual capacity as possible.

If at all, it may be slightly above 20%, but never below.

NOTE For new trucks the battery discharge indicator should be set at the latest after ten discharge and charge cycles.

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ELECTRICS battery manufacturer's maintenance instructions to check if the battery is actually 100% charged.

Faulty battery cells will make calibration impossible.

Battery Discharge Indicator Setting (BDI) The acid density is a very reliable indicator of the charge status of a lead acid battery. However, since it is unrealistic to continually measure the acid density of a truck battery to an industrial standard, the battery voltage is used to determine the charge status over longer journeys.

To adapt the BDI to the battery used and the truck's specific application profile, you need the battery manufacturer's data sheet. The values you require are the density of the electrolyte for an 80% discharged battery (20% battery residual capacity) and for a fully charged battery (100% battery capacity).

Finally, via the potentiometer on the back of the BDI the display is set to the actual discharge terminal voltage of the battery at 20% residual capacity.

●

Operate the truck as usual under normal operating conditions until the battery is empty: both LEDs of the BDI will flash and the lift cutout system will be triggered.

●

Leave the battery for at least 10 to12 hours (one hour at the very minimum!).

●

After this interval measure the acid density on at least three different battery cells. The smallest recorded value is the one you need.

●

Compare the recorded density with the density specified by the manufacturer for an 80% discharged battery (20% residual capacity).

●

If the battery is more than 80% discharged (less than 20% residual capacity), set the potentiometer on the back of the BDI to direction K.

●

If the battery is less than 80% discharged (more than 20% residual capacity), set the potentiometer on the back of the BDI to direction U.

●

Charge the battery again and then check the calibration.

The factory default setting of the battery discharge indicator is "M" (any setting from K to U is possible).

Calibration ●

Fully charge the battery as indicated by the battery manufacturer in the operating instructions. Measure the acid density in accordance with the

Discharge Terminal Voltage Setting in Volts/Cell K

L

M

N

O

P

Q

R

S

T

U

1.57

1.63

1.68

1.73

1.78

1.82

1.84

1.86

1.89

1.91

1.93 E77-GB

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MS-4.25-2232

111

ELECTRICS Electric Motors

●

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

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

●

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

●

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

●

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

●

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

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

Preparation ●

Disconnect the battery (= EMERGENCY DISCONNECT).

●

Secure the truck from rolling away.

Important Maintenance Instructions ●

Remove all carbon brushes and check for wear.

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

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

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

●

Blast the motor with dry compressed air only.

●

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

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

●

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

●

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

In this case replace all brushes as they will probably have been thermally overloaded. Thermal overloading (temperatures >160 ºC) causes the brushes to swell up.

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

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112

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ELECTRICS Traction Motor Maintenance

MS-2232-053

Maintenance ●

Apply dry compressed air to the motor.

●

Remove all carbon brushes and check them with the armature in accordance with the instructions in "Key Maintenance Instructions".

●

A new carbon brush is 28 mm long

●

Carbon brush wear limit: 15 mm

●

Refit the tensioning belt

Armature

MS-2232-039

Access to Brushes ●

Disconnect the battery

●

Prevent the truck from rolling away.

●

Remove the tensioning belt from the motor.

●

A new armature has a max. diameter of 64.5 mm.

●

The armature can be overwound provided the remaining diameter is no less than 61.5mm.

●

The armature must be replaced if the diameter is 60.5 mm or less.

●

After overwinding cut the mica down to a depth of 0.5 mm without changing the gap width between the multi-plates.

●

The multi-plate edges must be carefully de-burred.

Bearings ●

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The ball bearings are maintenance-free. They must always be replaced if removed for repair work.

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113

ELECTRICS Pump Motor Maintenance

M0076

Maintenance ●

Apply dry compressed air to the motor.

●

Remove all carbon brushes and check them with the armature in accordance with the instructions in "Key Maintenance Instructions".

●

A new carbon brush is 20 mm long

●

Carbon brush wear limit: 10 mm

Armature ●

A new armature has a diameter of 40 mm.

The wear limit is 38.3 mm.

●

The armature must not be overwound. Instead it must be replaced when the wear limit is reached.

Refit the hydraulic unit as described in Chapter 2.

MS-2232-052

Access to brushes ●

Disconnect the battery

●

Prevent the truck from rolling away.

●

Remove the hydraulic unit as described in Chapter 2.

●

Unscrew the commutator bearing lid and remove the insulating protective cap.

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BRAKE

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116

BRAKE On the brake linings which contact the rotor (brake applied), measure the distance between the two fixed plates (see Fig. MS-2232-010). The brake linings are worn if the distance is 11.8 mm or less.

Brakes General DANGER A falling mast section can have fatal consequences.

When carrying out work which requires the mast sections to be raised: secure the raised mast stages to prevent them from suddenly falling (hard wooden blocks underneath the raised sections and if necessary chains around the cross arms of the mast stages)!

Brake Removal ●

Secure the truck with blocks under the wheels to prevent it from rolling away. Raise the inner mast until you can access the brakes through the mast.

Lower the inner mast onto suitable square hard wooden blocks and secure it. De-pressurise the hydraulic system (see Chapter 2). Disconnect the battery.

●

If necessary, with the hydraulic system depressurised, remove the hydraulic lines and hoses in order to access the brakes.

●

Remove the floor boards. Remove the lower instrument panel cover. Undo the jam nut from the handbrake cable and discharge the brake cable (A, Fig. MS-2237-004).

A

MS-2232-002

NOTE To remove the brakes, replace the brake disks and the linings, you may need to disconnect the hydraulic connections, depending on the type of mast. Cover the brakes with a plastic sheet beforehand. This will prevent the brake linings from being contaminated with oil.

MS-2232-004 ●

If you have difficulty reaching the brakes, remove the drive motors (see Chapter 4). Although this is not strictly necessary, it can save considerable time.

●

Unscrew the cross strut which connects the two brake units (Fig. MS-2232-006 on following page).

●

Remove the bolts (16, Fig. MP-2232-007 on following page) from the clamping plate (15).

●

Remove the nut and washer (10) from the lever (18). Remove the lever from the pin (A) on the base plate (1). The connecting rod (19 to 21) can remain attached to the lever (18).

Brake Lining Wear Limits

MS-2232-010

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Rev. 01/03

117

BRAKE Right brake 1

A

2 3 4 5 6 7 8 9

B

4 10

10 22

A

21 19

19 24

18

20

16 21

11 12

23

13

14 16

17

Left brake 16 16

17

21

15

20 17 17

C

10

24 19

22 11

21

4 9

14 23 D 13

17

15

17

B

18

8 7

17

6 12

5 4

10

3 2 1 C

D MS-2232-007

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BRAKE

●

●

Fit the hub (8) to the rotor (7): align the hub and the rotor so that you bring both ends of the torsional springs (9) into the notches. Now pretension the torsional springs with a half turn of the hub and push the hub into the brake disk.

●

Push the rotor with the pre-assembled hub onto the drive shaft.

●

Place the second fixed plate (4) onto the stud bolts (5) of the base plate.

MS-2232-006

●

Tilt the spherical head of the connecting rod out of the clamping plate (15) and remove the clamping plate.

Fit the washers and nuts (10) onto the stud bolts.

Tighten the nuts crosswise and evenly.

●

Insert the supporting plate (13) and fix the supporting plate with a new washer (23) and the screw (14). Bend a bracket of the washer (23) over a flat side of the screw (14) to secure the screw.

●

Using the pin (16) re-attach the clamping plate (15) to the base plate (1). Push the washer (17) up and secure the pin with the retaining spring (17).

●

Insert the spherical head of the connecting rod (19-21) into the clamping plate (15). Attach it with the pin (16). Push up the washer (17) again and secure the pin with the retaining spring (17).

●

Re-connect any previously dismantled hydraulic lines and bleed the hydraulic system (see Chapter 2).

●

Remove the screw (14), the lock washer (23) and the supporting plate (13) from the drive shaft.

●

Remove the four nuts and washers (10) from the stud bolts (5). At the same time counter-fix the stud bolts with a pin to prevent them from coming undone on the transmission side.

●

Remove the first fixed plate (4) from the stud bolts.

●

Remove the torsional spring (9). Remove the hub (8) and the rotor (7) from the drive shaft.

●

Remove the 4 pressure springs from the stud bolts and then take off the second fixed plate.

Brake Assembly Before Assembling ●

Clean all parts with a brake cleaning agent or any other oil and silicon-free agent.

●

Check all parts of the brakes for damage and wear. Replace any faulty or worn parts. The fixed plates (with the brake lining) must always be replaced in pairs.

●

Now carry out the following adjustments and inspections: ●

Adjust the foot brake

●

Adjust the handbrake

●

Check the braking distance

See the following pages for instructions.

Replace any brake linings which have become oily over a long period of time. These will soak up too much oil. Cleaning is generally superficial and the oil will seep back to the surface during operation.

Only when the oil has a short effect - e.g. when you have removed the brakes - can the it be removed with a brake cleaning agent and the brake lining re-used .

Assembly ●

Place the first fixed plate (4) on the stud bolts (5) of the base plate.

●

Push the pressure springs (6) onto the four stud bolts.

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119

BRAKE Foot Brake

●

Turn the linkage clockwise to increase the distance between the pedal base and the floor. Turn anticlockwise to reduce the distance. Adjust the linkage so that the brake pedal free travel is 15 to 23 mm.

●

Temporarily replace the right floorboard and check the distance between the pedal base and the floor (> / = 20 mm).

●

If both measurements are within the tolerance range, remove the floorboard again.

●

Fasten the linkage again using the jam nut (A, Fig. MS-2232-009).

●

Adjust the brake switch so that it engages after 2 to 3 mm pedal travel.

●

Adjust the handbrake.

●

Check the truck‘s braking distance.

DANGER Before carrying out work on the brake system block the drive wheels to prevent the truck from moving in any direction.

Foot Brake Adjustment 4.5 kg

Brake pedal

20 mm Floor

Checking the braking distance WARNING Always check the brakes in a secure area to avoid endangering other people.

MS-2232-008

The ground for the brake test must be level, dry, clean and afford some grip (concrete ground).

Adjustment is necessary whenever: At a pedal pressure of approx. 4.5 kg the distance between the bottom of the pedal and the floor is 20 mm or less. However, before adjusting the brake, make sure that the linings have not reached the wear limit (see first page of this chapter). If they have reached the wear limit, replace the linings and then adjust the brake.

The brake pedal free travel until contacting the brake lining is less than 15 mm or more than 23 mm. ●

Remove the floorboards.

●

Release the handbrake.

●

Undo the jam nut from the linkage (A, Fig. MS2232-009).

●

With the truck unladen and at operating temperature, accelerate to maximum speed.

●

Brake the truck and measure the stopping distance. The braking distance from the time of applying the brakes to the truck coming to rest should be approx. 3100 mm.

A

MS-2232-009

MS-M5-2232

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BRAKE Handbrake Adjustment The handbrake is correctly set when: The brake linings just touch the rotor when the pawl (A) is in the first tooth of the ratchet (B).

The handbrake switch [HBS] (D) engages before the pawl is in the first tooth of the ratchet.

If the handbrake requires more than one tooth until the brake linings are contacted: ●

Undo the jam nuts (E) from the brake cable holder.

●

Pull the cable sheath down suddenly and turn the lower jam nut until it contacts the retaining plate.

●

Use the top nut to jam the brake cable.

●

Check the setting and adjust if necessary.

●

Check the point of application of the handbrake application point. Adjust the handbrake switch if the switching point is not before the first tooth reaches the ratchet.

A

MS-2232-003

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MS-M5-2232

121

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122

STEERING

Printed in Germany

123

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124

STEERING When the steering wheel is applied, oil flows from the oil tank to the spool valve via the hydraulic pump. The priority valve (2) distributes the flow of oil: the amount currently required for steering is routed to the steer unit (3).

The rest is routed to the downstream hydraulic functions.

Steering Hydraulics Function The input unit of the spool valve (1) contains a priority valve (2). If the steering and at least one other hydraulic function are activated at the same time, the priority valve controls the distribution of the oil between the required functions. Steering always takes priority over the other function.

2 1

The proportions are determined by the LS signal (4) sent from the steer unit to the priority valve. As the load pressure increases, so the amount of oil flowing to the steer unit rises. A pressure relief valve restricts the operating pressure in the steer unit to 70 bar.

Refer to the HYD chapter for a illustration of the steering hydraulic system.

3

4

MS-2232-058

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MS-6-2232

125

STEERING Steering Components

●

Wheel hub and receptacle

●

Steering cylinder and hydraulic port

Key switch Steering wheel

Gas pressure cylinder

Steering column

Bracket Steer unit

MS-2232-059

Remove the top and bottom panel, the instrument cover and the steering column covers to open up the following: ●

Steering column

●

Steering sensor (detects the movement of the steering shaft to activate the pump via the pump controller).

●

Encoder module

●

Direction control switch

●

Key switch

●

Slip ring contacts from the horn to the steering shaft

●

Steer unit (5 ports: pump, LS signal, LH steering cylinder, RH steering cylinder, return flow)

●

Gas pressure cylinder for the steering column adjustment

After removing the counterweight (see Chapter 1) you have access to: ●

Steering potentiometer and plug connection

●

Steering gear

MS-6-2232

126

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STEERING Steering wheel

●

Disassembly ●

Jack up the truck until the drive wheels are free (see Chapter 1).

●

Prevent the truck from rolling away.

●

Disconnect the battery.

●

Lift off the horn button.

●

Undo the horn cable connections from the contact ring.

●

Pull the horn cables through a 1 1/4“ wrench.

Place the wrench on the steering wheel nuts. Push back the horn wires into the wrench so that the square in the wrench is available for the extension shaft. Attach a ratchet with an extension and undo the steering wheel nuts. Remove the tool and manually unscrew the steering wheel nuts.

●

Attach the steering wheel extractor (part no.

129256) with 2 off M8 x 70 screws (see illustration). Guide the horn cables into the recess in the tool to avoid trapping the cables.

M8 x 70 129256

Tighten both screws alternately and evenly to pull the steering wheel from the shaft. If the steering wheel is too tight, use a rubber hammer to tap on the inner ring of the steering wheel until the steering wheel can be removed with the screws.

Assembly ●

Apply a small amount of anti-adhesive (part no.

065005-003) to the cone of the steering shaft. Do not apply the anti-adhesive to the thread!

●

Fit the steering wheel in position, turn it slightly until the steering wheel fits into the spline of the steering shaft. Press the steering wheel down onto the cone of the steering shaft.

●

Manually fit the steering wheel nuts.

●

Pull the horn cables through a 1 1/4“ wrench.

Place the wrench on the steering wheel nuts. Push back the horn wires into the wrench so that the square in the wrench is available for the extension shaft. Attach a torque wrench with an extension.

Torque the steering wheel nuts to 36 Nm. Do not over-tighten!

●

Screw the horn cables back onto the contact rings.

●

Refit the horn button. Press it down until it engages.

●

Re-connect the battery.

●

Test the horn.

●

Jack down the truck.

MS-2232-060 SC3200 03/2004 • Printed in Germany

MS-6-2232

127

STEERING Direction Control Switches INFORMATION The illustration shows the direction control switch in the position for left-handed application. For right-handed application, apply the lever at an angle of 180°.

Forward switch

Reverse switch

1 2

MS-2232-061

Switch Removal ●

Disconnect the battery.

●

Remove the covers from the steering column.

●

Remove the cables from the travel switches.

●

Pull the retaining clips (2) off the pins (1).

●

Pull out the pins. Be careful not to lose any parts.

Switch Assembly ●

Replace any faulty components. Assemble the switches in the reverse order of disassembly. Use the new retaining clips (2) for the pins (1).

●

Now test the direction control switches.

MS-6-2232

128

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Blank page

Printed in Germany

129

STEERING Steer Sensor Module

Steering Sensor

Disassembly

Disassembly

●

Disconnect the battery.

●

Disconnect the battery.

●

Remove the covers from the steering column.

●

Remove the covers from the steering column.

●

Remove the cables from the sensor module (21).

●

Remove the steering sensor module (21).

●

Loosen the mounting screws (23).

●

Remove the cable from the steering sensor (16).

●

Remove the sensor module.

●

Remove the adhesive from the gearwheel (17) and remove the gearwheel.

●

Undo the locknut of the steering sensor (16).

●

Remove the steering sensor.

Assembly ●

Assemble the sensor module in the reverse order of disassembly.

●

Now test the sensor module.

Assembly ●

Assemble the steering sensor in the reverse order of disassembly.

●

Apply adhesive (part no. 061001-007) to the pinion (17).

●

Now test the steering sensor.

23 22

18 19

21 16

20 15 24 14 17

MP-2232-010

9

MS-6-2232

130

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STEERING Steering Column Adjustment Gas Pressure Cylinder Removal Retaining Ring ●

Disconnect the battery.

●

Remove the bottom covers.

●

Fold up the steering column completely. This will relieve the gas pressure cylinder.

●

Loosen the bottom attachment from the gas pressure cylinder to the truck chassis and the top retaining ring. Lift out the gas pressure cylinder unit.

●

Undo the counternuts from the piston rod.

●

Unscrew the piston rod from out of the head of the unlocking lever.

Gas Pressure Cylinder Assembly and Adjustment ●

Screw the counternut (1) onto the piston rod (2) of the cylinder.

●

Screw the piston rod into the head (4) of the unlocking lever until the stud (3) of the piston rod contacts the bottom corner of the lever (5).

●

Now continue to turn the piston rod. The unlocking lever will move up. Keep turning until the lever reaches the stop and there is no more clearance.

●

Turn the piston rod a further ¼ turn and tighten the counternut.

●

Put the gas pressure cylinder back in the truck.

●

Attach the cylinder again and test it.

Unlocking lever

Unlocking head Gas pressure cylinder Part of chassis

Counternut

Part of steering column

MS-2232-063

5 2 1 4

3

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MS-2232-064

MS-6-2232

131

STEERING Steering column Disassembly

Removing the steering shaft from the steering column First disassemble the steering column.

WARNING

Steering Column Removal ●

Disconnect the battery.

●

Remove all the covers.

●

Remove the steering wheel (see previous section).

●

Remove all the wires from the steering column (1, Figure MP-2232-008).

●

Fold up the steering column completely. This will relieve the gas pressure cylinder. Loosen the bottom attachment from the gas pressure cylinder to the truck chassis and the top retaining ring. Lift out the gas pressure cylinder unit.

●

Remove the 4 mounting screws from the steer unit to the steering column.

●

Remove the mounting screws from the steer unit to the chassis.

●

Pull the steering column up out of the toothing in the steer unit.

●

Place the steering column on a clean workbench.

Risk of damage.

Removing the steering shaft with the brushes and brush holder still in place will damage them.

Remove the brush holder (3, Fig. MP-2232008) and the brushes (2) before removing the steering shaft. ●

Remove the brush holder and the brushes (3 and 2, Fig. MP-2232-008) from the steering column.

●

Remove the retaining ring (1, Fig. MP-2232-008).

●

Pull the steering shaft (7, Fig. MP-2232-008) from out of the base of the steering column.

Replacing the slip rings The steering shaft has 2 slip ring contacts for the horn’s electrical power supply.

Refer to figure MS-2232-062 when assembling. The insulating tape must cover the soldering joint and the keep the connecting wire flat against the shaft.

17 mm

Insulating tape

Slip ring

MS-6-2232

132

Soldering joint max. 2 mm

Insulator

MS-2232-062

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STEERING

1

MP-2232-008

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MS-6-2232

133

STEERING Steering Gear Removal ●

Jack-up and secure the truck

●

Dismantle both steering wheels;

●

Prepare to collect any spilled hydraulic oil.

●

Dismantle the two hydraulic lines from the steering cylinders;

●

Loosen the steering potentiometer plug connection and remove the potentiometer.

●

Secure the gear unit from the top with a rope to prevent it from falling.

●

Support the gear unit below with wooden blocks.

●

Undo the 3 screws from the mounting flange;

●

Lower the gear unit.

M0118

792341lenk

MS-6-2232

134

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STEERING Steering axle

Steering Gear Assembly

Design

Wheel hub pre-assembly

The steering axle consists of the steering gear and the axle bracket. The steering gear consists of a hydraulically actuated spur wheel steering rack transmission which connects to the axle bracket via a flange.

●

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

●

Drive the bearing shells of the conical roller bearings (item 28) into their seat and grease the bearing shell of the inner conical roller bearing (grease = Crown part no. 053002-001).

NOTE For spare parts it should be noted that the axle bracket is only available as a whole assembly, i.e. with the axle already preassembled.

Important: There are 2 different steering axle types. They differ in the type of seal used in the steering knuckle.

The data plate indicates which type is used (2.12.01.1 or 2.12.09.0)

Steering knuckle pre-assembly ●

For 2.12.01.1 push the Nilos ring (item 27), for 2.12.09.0 push the guard ring (item 37) and shaft seal (item 27) filled with grease (Crown part no.

053002-001) onto the steering knuckle.

●

Heat up the inner conical roller bearing (item 28 for 2.12.01.1, item 36 for 2.12.09.0) and drive it into its seat. Now lubricate with Crown part no. 053002001.

The reference numbers contained in the following assembly instructions refer to the exploded diagrams at the end of this chapter.

Steering Knuckle and Wheel Hub Assembly As mentioned at the beginning, the steering knuckles is supplied as a complete assembly (item 25) with the axle already assembled.

For further assembly proceed as follows:

M1248

SC3200 03/2004 • Printed in Germany

●

Push the wheel hub (item 29) onto the steering knuckle (item 25).

●

Fill the space between the wheel hub and the steering knuckle with Crown part no. 053002-001.

●

Lubricate the outer conical roller bearing (item 28) with Crown part no. 053002-001 and insert it into the wheel hub.

●

Fit the U washer (item 30) and fix the castle nut (item 32).

●

Turn the wheel hub to check the bearing clearance.

The torque should be 2 – 6 Nm. If necessary, adjust via the torque of the castle nut.

●

After correct adjustment of the bearing clearance secure the castellated nuts with the splint (item 31).

●

Strike in the protective cover (item 33) filled with Crown part no. 053002-001 to protect the assembly from external influences.

MS-6-2232

135

STEERING Spur pinion flange shaft pre-assembly ●

Fill the Nilosring (item 22) with grease (Crown part no. 053002-001) and place it in position.

●

Press on the conical roller bearing (item 23).

●

Heat up the bearing race (item 21) to approx.

120°C and secure with LOCTITE 620, Crown part no. 794102, (Fig. M1249).

●

Fit the shim and the ground washers (item 6). Fit another shim over the ground washers.

●

Drive the bearing shell of the conical roller bearing (item 5) into its seat (Figs. M1251, M1252).

M1251

M1249

Housing pre-assembly ●

Thoroughly clean the housing (item 9) with a cold cleaning solution and apply compressed air to it.

●

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

M1252

●

Turn the housing and drive the bearing shell of the conical roller bearing (item 23) into its seat (Fig. M1253).

●

Insert the conical roller bearing (item 5) (Fig. M1254). Now fit the flange shaft into the housing.

M1250 MS-6-2232

136

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STEERING ring slightly and fit new shims. Re-tighten the bearing and check the clearance as described above.

After setting the bearing clearance dismantle the spur pinion flange shaft again to prepare the housing, and proceed as follows: ●

Gently lubricate the shaft seals (items 8, 20) and drive them into their seats (Figs. M1255 - M1258).

M1253

M1256

M1254

Adjusting the bearing clearance Place two shims onto the bearing. ●

Apply a medium torque to the groove nut (item 1).

●

After tightening, gently tap on the upper section of the housing with the plastic hammer to position the bearings.

●

Manually check the bearing clearance. The bearing should be more stiff than free (torque 2 – 5 Nm). If the bearing is too free, replace the ground shim (bore hole gauge, item 6). Estimate how many washers are needed. To repalce, remove the retaining ring (item 7). Turn out the bearing inner

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M1255

MS-6-2232

137

STEERING

M1258

M1257 M1259 M1260

●

Generously lubricate the bearing shell of the conical roller bearing (item 23) with Crown part no.

053002-001 (Fig. M1260).

●

●

Lubricate the conical roller bearing (item 23) and the spur pinion flange shaft with Crown part no.

053002-001 (Fig. M1259).

On the spur pinion flange shaft 2 teeth are marked with a bevel. The housing must be positioned so that the groove of the steering rack lies between the marked teeth (Fig. M1261).

MS-6-2232

138

Insert the steering rack (item 36) in the housing.

Make sure that the groove is positioned centrally in the housing.

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STEERING Tooth bevelment

Steering rack

M1263

M1261

Groove ●

Flange shaft

Fill the bearing shell of the upper conical roller bearing (item 5) with grease (Crown part no.

053002-001) so that grease emerges when the bearing is inserted (Figs. M1262, M1263).

M1262

SC3200 03/2004 • Printed in Germany

●

Fill the Nilos ring (item 4) with grease (use surplus grease from the previous step) and fit it in place.

●

Put the shim (item 3) and the safety plate (item 2) in position (Fig. M1264).

●

Tighten the groove nut (item 1) and fix it by rotating a tappet of the safety plate (item 2) (Fig. M1265).

M1264

MS-6-2232

139

STEERING ●

Insert the slightly greased O rings (item 16) into the housing groove provided for them. Make sure they are seated correctly.

●

Manually screw in the cylinder (item 17) with Loctite 242, Crown part no. 053050-006 and using the wrench tighten it to a medium degree in a clamping device.

Assembling the Axle Bracket to the Steering Gear ●

Strike the clamping sleeve (item 19) in the upper prepared area of the axle bracket.

●

Place the axle bracket on the transmission housing.

●

Insert the Tensilock screws (item 26) and using a torque wrench apply the prescribed torque (320 Nm).

●

Final check: Use compressed air to move the cylinder from one side to the other and test the operation.

M1265

Cylinder Pre-Assembly ●

Insert the pistons (item 13) with the piston guide rings (item 12) and the compact seal (item 14) into the cylinder (item 17) without twisting. Make sure the cylinder contact surfaces are totally clean.

●

Now fill each cylinder with gear liquid grease G00F (to DIN 51502 The level for each cylinder should be 125 cm3.

M1267

Inserting the cylinder ●

Strike the sleeve (item 15) into the housing. To do this, apply a thin film of oil to the steering rack (item 35) (Fig. M1266).

To complete the assembly of the steering axle, fit the seal screw (item 10) with the packing washer underneath (item 11).

M1266

MS-6-2232

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STEERING Operational and Leakage Test Finally, an operational and leakage test should be performed where possible. ●

To do this, turn the steering wheel two or three times in either direction until it reaches the stop.

●

Remove the cylinder again and perform a visual inspection. Look out for any damage, leaks, grooves on the cylinder contact surfaces etc.

After re-installing in the truck: ●

The steering gear should reach the stop after 5.5 turns of the steering wheel. There may be air in the system if the stop is not reached after 5.5 turns.

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STEERING Steering axle 2.12.01.1

MP-2232-006 MS-6-2232

142

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STEERING Steering axle 2.12.09.0

36

37 36

37

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SAFETY

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MAST

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146

MAST Lifting Gear Minimum Capacity

Mast (TT Series) DANGER Risk of trapping and severing limbs!

When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally moving.

Make sure the wooden blocks and lifting gear used have sufficient capacity.

General Torques Mast bearing mounting screws Torque the 4 mounting screws on the mast bearing blocks to 550 – 600 Nm.

Note the minimum capacity for the lifting gear whenever carrying out work on the mast. The required minimum capacity is as follows: Complete mast: 1,200 kg Attachments:

100 kg

Mast Testing (Assembled) Clean the mast channels and test the tracking paths of the rollers in the mast channels. There should only be wear in the rear section of the I beam where the rollers slide. There should not be any grooving or cutting in the I beam caused by the mast rollers. If grooving or cutting is evident, it will normally take place at the side of the roller; 10 mm from the channel face. In this case the mast rollers will have to be adjusted. Remove a shim from underneath the affected mast roller.

A recheck of the mast channel will be required. De-grease the running area of the roller in the mast channel and spray on a thin layer of paint. Extend and retract the mast, and then check the tracking path of the roller (the paint will show up the tracking path).

If the contact pattern matches requirements, apply grease to the contact surfaces (see lubrication table, chapter 1).

0

When the mast is raised and nearly fully extended, it should not tilt to the right or left but should be even and straight. All mast stages should be aligned. If a tilting condition exists, it is a sign that the shimming is too loose or unbalanced and will need to be adjusted.

550 - 600 Nm

All hose guide pulleys should move freely, check hoses for chafing.

Flaking It is not uncommon for a new mast to appear as if it is flaking or peeling. This appearance indicates that the rollers are seating on the mast channel and this is considered normal. Eventually, this condition will disappear.

The grease applied to the channel will retain these particles.

MS-2232-011

Mast Stoppers Torque the mast stoppers to 122 – 149 Nm. Apply the standard torque to all the other screws (see table in Chapter 1).

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MAST 31 A 34 32

35 36 37

42 40 41 35

38 39

36

43

33

68

69

44 53

50 52

12 14

51 13

49

9

70

48

71 A 30

9 19

9 18

4 5 6 7 8

18

18

30

20 21 22

59 61

18 12 13

63

17

10 1

62 60

2

15 18

64

9

45 46

47 46

18

3

57

58

67

A

54

66 14

55

65 9

67

16

56 21

22 9

17

29

9 18

18 28 25

26

11

27 24 24

29

23

28 25

MS-7-2232

148

9

26

MP-2232-028

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MAST Mast Disassembly DANGER All assembly work on the mast is hazardous.

Unsecured stage masts and attachments can sever limbs or even cause fatal injuries. Always block and secure the respective components properly prior to starting assembly.

Pressurised hydraulic systems can cause serious injury when the opened.

Dismantling the Mast (Attached) General For the complete mast you required lifting gear with a minimum capacity of 1,200 kg. For attachments (fork carriage etc.) the minimum capacity of the lifting gear is 100 kg. ●

Remove the load backrest and fully lower the mast.

●

Disconnect the battery.

●

Reduce the system hydraulic pressure: To do this move the sideshift lever and if applicable the auxiliary function lever a few times backward and forward.

●

Place a flat tray underneath the mast area and collect any spilled hydraulic oil.

●

Cover the brakes with a plastic sheet. This will prevent the brake lining from being contaminated with oil.

●

Immediately seal any open hydraulic ports with filler plugs.

●

Item numbers in brackets refer to Figure MP2232-028.

Pressurised hydraulic oil can result in serious injury.

Any fluid which penetrates the skin at high pressure must be considered as a serious medical emergency even if the skin does not initially show any unusual signs.

The pain may take time to set in.

Tighten all connections before pressuring the system again. Keep your hands and body away from holes as hydraulic oil could emerge at high pressure.

Always use a piece of absorbent paper to trace leaks, never use your hands.

The mast can be dismantled while attached to the truck, provided there is sufficient height and the crane used has the necessary lift height. Alternatively, dismantle the mast from the chassis, turn it over and dismantle it in a horizontal position.

DANGER Note the minimum capacity for the lifting gear required.

Falling assemblies can sever limbs and cause fatal injuries.

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MAST 31 A 34 32

35 36 37

42 40 41 35

38 39

36

43

33

68

69

44 53

50 52

12 14

51 13

49

9

70

48

71 A 30

9 19

9 18

4 5 6 7 8

18

18

30

20 21 22

59 61

18 12 13

63

17

10 1

62 60

2

15 18

64

9

45 46

47 46

18

3

57

58

67

A

54

66 14

55

65 9

67

16

56 21

22 9

17

29

9 18

18 28 25

26

11

27 24 24

29

23

28 25

MS-7-2232

150

9

26

MP-2232-028

27

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MAST Fork Carriage Removal

●

Remove the screw of the lower cylinder attachment (56). Take care not to lose the locking mechanism (55).

●

Remove the clamp (57) from the cylinder pipe.

●

Lift the cylinder out.

4

3

1

5 6

2 7

8

MP-2232-027 ●

Using a crane raise the fork carriage until the lift chain becomes slack.

●

Remove the upper pulleys and their corresponding hoses from the yoke (64).

●

Unscrew the yoke from the free lift cylinder (54).

●

Loosen the chain and the hydraulic lines from the fork carriage.

●

Unscrew the hose guide from beneath the free lift cylinder.

●

Now lower the fork carriage to the ground using the crane.

●

Attach a load sling to the cross member of the third mast stage.

●

Raise the third mast stage with the crane until the fork carriage can be taken out of the mast from the front.

Free Lift Cylinder Removal ●

Undo the hydraulic connection to the free lift cylinder.

●

Attach a load sling directly below the chain anchor block to the cylinder pipe and the crane hook in order to secure the cylinder on disassembly (risk of tipping on removal).

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MAST 31 A 34 32

35 36 37

42 40 41 35

38 39

36

43

33

68

69

44 53

50 52

12 14

51 13

49

9

70

48

71 A 30

9 19

9 18

4 5 6 7 8

18

18

30

20 21 22

59 61

18 12 13

63

17

10 1

62 60

2

15 18

64

9

45 46

47 46

18

3

57

58

67

A

54

66 14

55

65 9

67

16

56 21

22 9

17

29

9 18

18 28 25

26

11

27 24 24

29

23

28 25

MS-7-2232

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9

26

MP-2232-028

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MAST Replacing the Mast Rollers on the Mast To replace the mast rollers you need to remove the mast Stages and the Fork Carriage

Removing the individual mast stages stages.

First remove the fork carriage and the individual mast stages as described in the previous section. If it is impossible to remove the mast stages with the mast attached (height), completely detach the mast from the truck (see Removing the Mast from the Truck) and dismantle the mast in a horizontal position.

●

Attach a load sling to the cross member of the third mast stage.

●

Raise the third mast stages until the lift chains become slack.

●

Remove the lift cylinder attachments (15, 16, 17)

●

Disconnect all the hydraulic connections to the third mast stage so that it can be freely lifted out.

The mast rollers are available in three diameters: standard (part no. 074668-001), with 0.635 mm oversize (part no. 124321-025) and with 1.27 mm oversize (part no. 124321-050).

●

At the top of the second mast stage remove the lift chain, the pulleys and the hydraulic hoses.

A maximum of 6 shims may be placed under a roller.

●

Remove the cover (38) and the screws (42) from the top of the left-hand side of the second mast stage. Replace the cover (38) back on the pulley assembly.

Mast Stage Rollers 1.

First determine the roller diameter required for each mast stage. Use the roller with the diameter which just runs over the entire running area in the mast channel without jamming.

2.

Push the appropriate rollers onto the mast stage bolts until they come to rest on the shoulder.

●

Now remove the screw (33) and take off the pulley assembly with the hydraulic hoses.

●

Remove the pulley (50) and the lift chain from the top right hand side of the second mast stage.

3.

Lift the second mast stage into the first stage.

●

Remove the lift chains and the hoses from the bottom of the third mast stage.

4.

Lower the second mast stage into the first stage to leave an overlap of 455mm.

●

Check again if there are any connections which could be damaged when the third mast stage is lifted out.

5.

Using a crowbar press against the upper mast rollers of the second mast stage until it rests against the opposite roller in the mast channel.

●

Using the crane pull the third mast stage out from the top. Place the third mast stage on the ground.

6.

●

Attach a load sling to the cross member of the second mast stage.

Keep holding the crowbar under pressure and using a feeler gauge measure the distance between the edge of the roller and the mast channel.

●

Slightly raise the second mast stage. Remove the screw (30) in order to loosen the lift cylinder piston rod.

7.

●

Raise the second mast stage until the stop block at the top of the first mast stage can be accessed via the lower hole in the second mast stage.

●

Remove the stop block (4 to 8, 66).

●

Check again if there are connections which could be damaged when the second mast stage is lifted out.

Divide the reading by 2. The figure now obtained is the play that needs to be compensated for on each side of the mast by placing shims underneath a roller. Divide the measurement previously obtained by 0.76 to give you the number of shims needed to place under the mast rollers (the shims are 0.76mm thick). After inserting the shims the maximum residual play can be 0.76 mm.

8.

Repeat stages 5 to 7 on the lower mast roller.

9.

Lift the second mast stage out again and place the number of shims calculated in stages 7 and 8 underneath the mast rollers. It is important to use the same number of shims on either side.

●

Using the crane pull the second mast stage out from the top. Place the second mast stage on the ground.

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MAST 31 A 34 32

35 36 37

42 40 41 35

38 39

36

43

33

68

69

44 53

50 52

12 14

51 13

49

9

70

48

71 A 30

9 19

9 18

4 5 6 7 8

18

18

30

20 21 22

59 61

18 12 13

63

17

10 1

62 60

2

15 18

64

9

45 46

47 46

18

3

57

58

67

A

54

66 14

55

65 9

67

16

56 21

22 9

17

29

9 18

18 28 25

26

11

27 24 24

29

23

28 25

MS-7-2232

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9

26

MP-2232-028

27

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MAST 10. Lift the second mast stage into the first stage.

11. Now move the second mast stage carefully over the entire running area in the first stage. The rollers should not jam.

12. Repeat stages 1 to 9 with the third mast stage in the second mast stage.

Finally, generously lubricate all the running tracks (see Lubricant table in Chapter 1).

Finally, generously lubricate all the running tracks (see Lubricant table in Chapter 1).

Lift Cylinder Removal The lift cylinder should only be removed if it needs to be repaired. ●

Prepare the working area to collect any spilled hydraulic oil (see General section).

●

Detach the hydraulic line from the lift cylinder and the distributor block.

●

Remove all the clamps (15, 16, 17, 18).

●

Attach a load sling directly below the upper attachment block on the cylinder pipe and the crane hook in order to secure the cylinder on disassembly (risk of tipping on removal).

●

Remove the split pin (14) and the bolt (12) and washer (13).

●

Remove the retaining ring (23) from the bottom of the cylinder.

●

Check again if there are any connections which could be damaged when the cylinder is lifted out.

●

Lift the cylinder out.

Fork Carriage Mast Rollers 1.

2.

First determine the roller diameter required.

Use the roller with the diameter which just runs over the entire running area in the mast channel without jamming.

Push the appropriate rollers onto the fork carriage bolts until they come to rest on the shoulder.

3.

Using the crane lift the third mast stage until the fork carriage can be pushed underneath it.

4.

Lower the third mast stage over the fork carriage.

5.

Suspend the fork carriage on the crane and pull it up to its maximum lift height in the third mast stage.

6.

Now use a crowbar to press against one of the upper mast rollers of the fork carriage until the opposite roller in the mast channel makes contact with it.

7.

Keep holding the crowbar under pressure and using a feeler gauge measure the distance between the edge of the roller and the mast channel.

8.

Divide the reading by 2. The figure now obtained is the play that needs to be compensated for on each side of the fork carriage by placing shims underneath a roller. Divide the measurement previously obtained by 0.76 to give you the number of shims needed to place under the mast rollers (the shims are 0.76mm thick). After inserting the shims the maximum residual play can be 0.76 mm.

9.

Repeat stages 5 to 7 on one of the lower mast rollers of the fork carriage.

For cylinder repair work, see Chapter M8.

10. Remove the fork carriage from the mast and place the required number of shims under the mast rollers. It is important to use the same number of shims on either side.

11. Re-fit the fork carriage (items 3 to 4) 12. Now move the fork carriage carefully over the entire running area in the third mast stage. The rollers should not jam.

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MAST ●

Place a load sling around the cross member of the first mast stage. Note the minimum capacity of the crane and the sling (see Mast Weight table in this chapter). Lift with the crane so that the sling is slightly tensioned. This will secure the mast when it is unscrewed.

●

Undo the connections of both tilt cylinders to the mast (Fig. MS-2232-012). Unscrew the safety plate (1) of the bolts and drive bolt (2) out.

0

Removing the Mast from the Truck

550 - 600 Nm 2

1

MS-2232-012 ●

Unscrew the left and right mast bearings (Fig. MS-2232-011).

●

With the crane, extend the mast far enough out at the front.

●

When you pull off the mast bearings, it is essential to mark the side of the mast on which the bearing was fitted. Keep the removed bearing and the corresponding shims together. Otherwise the mast will not be centred on re-assembly.

●

Place the mast with its back (the side normally facing the driver) on the ground.

MS-2232-011 ●

Remove the load backrest and fully lower the mast.

●

Disconnect the battery.

●

Reduce the system hydraulic pressure: To do this move the sideshift lever and if applicable the auxiliary function lever a few times backward and forward.

●

Place a flat tray underneath the mast area and collect any spilled hydraulic oil.

●

Cover the brakes with a plastic sheet. This will prevent the brake lining from being contaminated with oil.

●

Immediately seal any open hydraulic ports with filler plugs.

●

Item numbers in brackets refer to Figure MP2232-028.

●

Disconnect all electrical connections between the mast and the truck chassis and secure the cable ends in the mast area with an adhesive tape.

●

Disconnect the hydraulic lines between the mast and the truck chassis.

MS-7-2232

156

If the mast has to be further dismantled, refer to Dismantling the Mast (Attached).

CAUTION Risk of injury from falling components.

Using the crane, hold the cylinder and the mast assemblies at their centre of gravity and prevent the load slings from sliding off.

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MAST The procedure is practically identical to removing the mast components with the mast assembled. Only the crane movements are horizontal. You will therefore need a portal or gantry crane.

Mast Assembly Assemble the mast in the reverse order of the procedure in Mast Removal.

Refit the mast bearings (Fig. MS-2232-011) and the corresponding number of shims on their original side.

Torque the mast bearing mounting screws to 550 600 Nm. Apply liquid sealant part no. 060015-016 to the mast stopper (66) screws and torque to 122 - 149 Nm. Apply liquid sealant part no. 060017-014 to the lift cylinder mounting studs prior to assembly.

Apply a thin layer of grease to the tilt cylinder bearing studs (2, Fig. MS-2232-012). For grease type see Lubricant table in Chapter 1.

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MAST Inspection

Lift Chains General Lift chains are a major component of a fork lift truck. The chain system on this mast is designed to transmit the lift force from the hydraulic cylinder to the fork reliably and efficiently. Safe, uninterrupted truck operation depends on careful servicing and maintenance of the lift chains.

Most complaints about the chain performance are due to lack of maintenance. Highly stressed precision chains require regular maintenance to ensure a long useful life.

The chain must be inspected every 100 hours for any signs of faults or damage. If used in a corrosive or dusty environment, this interval must be reduced to 50 hours.

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.

The inspection should include the following: ●

Chain wear and elongation.

●

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

●

Pins turning in or extruding from the outside plates.

●

Loss of freedom of movement.

●

Damage to the anchor bolt attachment

●

Wear and corrosion to the anchor bolt and anchor.

●

Wear between the bolts and the connection plates.

The following sections cover the above items in detail.

Cleaning WARNING Never use chemical solvents or steam to clean the chains.

The lubricant applied at the factory will be removed from the inner plate surfaces.

The chain surface should be cleaned with paraffin, a hard bristle brush and lint-free cloth.

After inspection apply another film of chain spray. The oil acts both as a lubricant and as an anti-corrosive protection.

Wear The chain bends as it passes over the chain rollers. This leads to a gradual wearing of the joints.

Any slack a chain undergoes during its lifetime is due to wear to the links and the chain plate eyelet.

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MAST DANGER

Freedom of Movement of Chain Links

When checking for chain wear be sure to measure a part of the chain which passes over the guide pulleys. Never repair chains by cutting out the worn section and replacing it with a new section. If a chain is worn, always replace both lift chains.

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.

Chain wear can be measured with a wear gauge (Crown No. 106440) or a steel tape measure (see Fig. 2271).

Before testing the chain slack 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.

The chain slack test must cover at least ten links, over at least three different points in a section of the chain which always passes over a pulley during operation.

2775si

Possible causes of stiff joints are as follows: ●

Bent pins or plates

●

Rusty joints.

●

Peened plate edges.

Plate edge distortion is caused by: ●

Ruptured chain pinion.

●

Constant overloading of the chain.

●

Chain striking the mast components.

Immediately replace any chains with stiff joints.

Chain Tension

Centre Chain Dimensions (Dimension C in Fig. 2271).

New:

10 links = 254 mm

Wear limit:

10 links = 262 mm

Outer Chain Dimensions New:

10 links = 190.5 mm

Wear limit:

10 links = 196 mm

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, tighten the counternuts of the chain anchor again (for correct torques see Chapter 1, Torque table).

DANGER If just one of the faults mentioned in this chapter is detected, both chains together with their chain anchors or bolts must be immediately replaced.

Never repair damaged chains!

This can result in fatal accidents!

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MAST Chain Anchor and Pulleys

Protruding or Turned Chain Pins DANGER

2774si

Never attempt to repair the chain by driving pins back into the chain. This can result in accidents with severe or even fatal injuries if the chain tears. Fit new chains.

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.

Detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first.

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.

Worn Connection 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.

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

2776si

Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existent 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.

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.

Corrosion

2773si

The chains used on fork lift trucks are highly stressed precision components. It is particularly important to maintain the original fatigue strength throughout its useful life.

Corrosion considerably reduces the capacity of a lift chain. It results in cracking in the side plates.

Lift chains must therefore be protected from corrosion.

The layer of grease applied in the factory hot dip galvanizing process is an excellent protection and fully penetrates the joints.

MS-7-2232

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MAST Do not remove this layer! After commissioning the chain supplement the factory lubrication through a regular lubrication schedule.

Rust film on lift chains can be removed and neutralised by cleaning with chain oil. Always replace heavily corroded and rusting chains. The risk of cracking as a result of rust is too great.

Chain Lateral Wear Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This can have one of two causes: uneven chain tension or misalignment between the pulleys and the chain anchors.

Uneven Chain Tension When fitting or adjusting the chains make sure that they are evenly charged. If for example the fork heel height or the platform height are changed, the chain anchors must be loosened until both forks touch the ground. Both chains must have equal amounts of air or tension at this point.

The lower chain anchor nuts must be tightened by the same number of turns. When the required height has been reached, fix the setting with the top (chain side) lock nut and its respective lock washer.

Misalignment of Lift Components Misalignment of the chain pinion and the chain due to the wrong number of washers on the mast or a damaged mast or cylinder components can also contribute to wearing of the chain sides.

To test whether this is the case, proceed as follows: Place the truck on a horizontal surface in the service station.

Support the fork carriage and detach both ends of the lift chain from the chain anchor and visually inspect the alignment with the anchor slots.

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MAST Lift Chain Lubrication Lubrication is the most important factor in lift chain maintenance. It considerably affects the chain’s useful life.

Highly stressed chains under constant use cannot last sufficiently long if they are not regularly lubricated within a planned maintenance schedule.

bolt (see Fig. 277si) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty.

In normal operating conditions the chains should be cleaned and immediately lubricated every 100 service hours. In extreme conditions this interval must be reduced accordingly.

As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear.

Maintaining a lubricant film on all the chain surfaces provides the following benefits: ●

Restricts joint wear to a minimum (chain elongation)

●

Avoids corrosion

●

Reduces the risk of chain bolts turning

●

Restricts the danger of chain joints turning in to a minimum

●

Ensures an even movement of the chains and thus reduces noise levels

●

Reduces the chain tension due to less friction in the chain system

Oil film

Key factors when considering which lubricant to use are as follows: ●

High degree of penetration in the narrowest of gaps

●

Maximum tolerance of pressure and shearing forces before the lubricant film comes off.

●

Suitability to the operating temperature range, especially important for cold store trucks.

277si

You will find details of Crown approved chain oils in the Lubricant table in Chapter 1 of this manual.

Lubrication intervals depend on the operating conditions and the environment. Trucks parked outdoors, in cold stores or which are subjected to extreme weather conditions must be lubricated more frequently.

Dust will gather on oiled chains in dusty environments.

However, even in these conditions, regular lubrication can considerably reduce wear.

A paste mixture of oil and dirt will gather on the chain joints, but they will not wear as fast as they would if they were left to dry, leaving a metal to metal contact between the pins and plates.

Note: A lift chain must never be allowed to dry.

In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains.

Multi-plate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain MS-7-2232

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MAST Detaching Lift Chains Lift chains are supplied by the meter and must be cut to the required length.

Tools and Equipment Required ●

A secure working plate with a hole slightly larger than the head diameter of a chain bolt. The hole must be deeper than the chain bolt length.

●

A bearing ring (washer) with a hole slightly larger than the head diameter of a chain bolt. The bearing ring thickness must be slightly larger than the height of the head of a chain bolt.

●

A grinder.

●

A hole with a diameter slightly shorter than the chain bolt and a hammer. Or a press with a suitable mandrel.

Detachment WARNING Wear protective glasses.

●

Carefully grind the head of the chain bolt. The inner plate surface must not be damaged.

●

Place the bearing ring onto the hole in the working plate. The bearing ring prevents the inner plate surface from being damaged when you drive out the chain bolt.

●

Place the head of the chain bolt to be driven out into the bearing ring.

●

Make sure the chain bolt, the bearing ring and the hole are aligned in the working plate and drive the chain bolt out.

Grinder Connecting plate

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Hole in working plate MS-7-2232

163

MAST Repairs

Fork Tines

DANGER

General The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see chapter 1) for cracks, damage and wear.

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

Terms

Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork.

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.

Checking the Fork Fork blade

DANGER Forks showing signs of cracking, distortion or wear beyond the stated tolerance levels must be de-commissioned. They endanger the life of the operator and other people.

Fork hanger

Fork shank

Crack Inspection Inspect all fork tine surfaces for signs of cracks.

Fork heel

M0344

Fatigue cracking tends to occur around the heel of the forks. Check this area with particular care. If necessary carry out a non-rupturing crack test (paint penetration process or Magnaflux).

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

Capacity

●

Load centre of gravity

●

Manufacturing Data (Month / Year)

●

Company logo

●

Manufacturing site

Welding seams

Cracks M0346

M0347

For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam. If any cracking is discovered which could affect safety remove the relevant fork.

Fork identification

M0345

MS-7-2232

164

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MAST Verticality Test

Measuring the Fork Tip Width

Check verticality of fork tip (Fig. M0350). If the tolerance level has been exceeded, de-commission the fork.

Fork stop Ruler

2 mm

M0355

250 mm M0350

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

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.

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

500 mm

L Ruler 3% from L max. 6 mm

1st fork

Fork Blade Warping Measure the angle deflection between the top of the fork blade and the front of the fork shank (Fig. M0353). If dimension x is outside the tolerance range, the fork must be aligned by a specialist and re-checked.

500 mm

2nd fork

M0354

However, this would prevent the fork from working. In practice, forks must be aligned if the deviation is max. 10 mm.

x - 17 mm x + 8.5 mm

x M0353

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MAST Stop Mechanism

Fork Blade Wear

Check the stop mechanism (Fig. M0356) on both fork tines. The mechanism should lock securely, otherwise the fork must be de-commissioned.

Stop mechanism

Check the fork blade for wear, the heel is particularly subject to wear. If the width is 90 % or less than the original value, the fork must be taken out of service. For the inspection, use the calliper with part no. 107330 (see Fig. 0357).

100%

90%

M0357

M0356

This calliper has 2 opposite tappets. The outer tappet is used to determine the original fork blade thickness at a section with no wear. This is the fork shank. This determines the 100% value. The inner tappets correspond to 90% of the value previously obtained. ●

Scan the thickness of the fork shank using the outer tappets (Point a = 100% in Fig. MS-2232-013).

Fix the calliper.

●

Now use the inner tappets (90%) to scan the fork blade between the shank and the start of the curved area. If the calliper fits at any point over the fork blade, then the fork is worn. Take the fork out of service.

a = 100% Scanning area

90% wear limit MS-2232-013

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166

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MAST Sideshifter

DANGER Falling components are hazardous!

DANGER

Note the minimum capacity for the lifting gear required.

All assembly work on the mast is hazardous.

Unsecured stage masts and attachments can sever limbs or even cause fatal injuries. Always block and secure the respective components properly prior to starting assembly.

Pressurised hydraulic systems can cause serious injury when the system is opened.

To assemble the sideshifter you require lifting gear with a minimum capacity of 500 kg. ●

Disconnect the battery.

●

Prevent the truck from being switched on again.

●

Reduce the system hydraulic pressure: To do this move the sideshift lever and if applicable the auxiliary function lever a few times backward and forward.

●

Place a flat tray underneath the mast area and collect any spilled hydraulic oil.

●

Cover the brakes with a plastic sheet. This will prevent the brake lining from being contaminated with oil.

●

Immediately seal any open hydraulic ports with filler plugs.

Pressurised hydraulic oil can result in serious injury.

Any fluid which penetrates the skin at high pressure must be considered as a serious medical emergency even if the skin does not initially show any unusual signs.

Physical effects may take time to set in.

Tighten all connections before pressuring the system again. Keep your hands and body away from holes as hydraulic oil could emerge at high pressure.

Always use a piece of absorbent paper to trace leaks, never use your hands.

General The truck can be fitted with 2 different sideshifters. The standard sideshifter is integrated in the fork carriage. The fork carriage can also be equipped with a hook-on sideshifter as an option.

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167

MAST

5

4 2

5 3

1 5 3

1

MS-7-2232

168

MS-2232-030

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MAST Integrated Sideshifter DANGER Risk of serious, even fatal injuries!

There is a risk of trapping and severing limbs if the mast and the fork carriage are not protected against accidental movement.

Secure the mast stages and the fork carriage to prevent them from lowering whenever you work on them (see Mast section).

For the assembly you will require lifting gear with a minimum capacity of 500 kg.

Removal, Repair and Assembly ●

De-pressurise the hydraulic system and prevent the truck from being switched on again (see General Section, Page 1 of this chapter).

●

Remove the load backrest.

●

Remove the forks.

●

Remove the screws (1) and replace them with eye bolts M12 DIN 850.

●

Remove the screws (3). Remove the bracket (5).

●

Insert a load lifting gear into the eye bolts.

●

Slightly raise the fork carriage (2) with the crane.

Pull out the lower edge approx. 50 mm to the front.

Lift off the fork carriage.

●

Clean the slide pieces (5) and all bearings.

●

Check the slide pieces and replace if worn.

●

Lubricate the slide pieces and the bearings before re-assembling (for greases see lubricant chart in Chapter 1).

●

Re-assemble the fork carriage in the reverse order.

Refer to chapter 8 for instructions on how to repair the integrated cylinder.

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169

MAST

Glands

MS-2232-031

Wear limit mark

min. 46 mm

Lower attachment hook

Fork Carriage

Sideshifter

Fork direction

0

Bearing clearance: Min. 0.8 mm Max. 1.6 mm 165 Nm

MS-7-2232

170

MS-2232-032

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MAST Hook-on Sideshifter

After assembly: ●

Adjust the lower bearings as indicated at the left hand side of figure MS-2232-032. This is the only way of ensuring functionality!

●

Lubricate the bearings with grease (see Lubricant table in Chapter 1).

DANGER Risk of serious, even fatal injuries!

There is a risk of trapping and severing limbs if the mast and the fork carriage are not protected against accidental movement.

Secure the mast stages and the fork carriage to prevent them from lowering whenever you work on them (see Mast section).

For the assembly you will require lifting gear with a minimum capacity of 500 kg.

Removal, Repair and Assembly ●

De-pressurise the hydraulic system and prevent the truck from being switched on again (see General Section, Page 1 of this chapter).

●

Remove the forks.

●

Remove the load backrest.

●

Mark the position of the hydraulic hoses on the sideshifter cylinder for re-assembly purposes.

●

Only if the hydraulic cylinder is to be repaired: Loosen the glands on the hydraulic cylinder. Otherwise ignore this instruction. Refer to chapter 8 for instructions on how to repair the cylinder.

●

Detach the lower attachment hooks. If they are worn, use new hooks on re-assembly.

●

Insert a load lifting gear into the eye at the top of the fork carriage.

●

Lift off the fork carriage with the crane.

Before re-assembling the fork carriage in the reverse order. ●

Clean all components.

●

Inspect all components for wear and cracks.

●

Replace any damaged components.

●

The wear limit for the sliding bearings at the top and bottom is 2.5 mm.

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MAST

Blank page

MS-7-2232

172

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CYLINDERS

Printed in Germany

173

Blank Page

Printed in Germany

174

CYLINDERS applies to the open ports and lines on the truck when you remove any hydraulic components.

Cylinders General

●

Do not refinish any cylinder surfaces! Replace any damaged components.

Safety when working on hydraulic systems

●

When carrying out repairs always replace all the seals in the assembly. Never recycle seals which have already been used.

WARNING Risk of serious injury from pressurized hydraulic oil.

Pressurized hydraulic oil can penetrate the skin. This is a serious medical emergency which requires immediate medical attention.

The skin will not show any obvious initial damage and the physical effects will not be manifested immediately. Seek medical assistance if your skin has been affected by pressurized hydraulic oil.

For your personal protection: Depressurise the hydraulic system before starting assembly work on the hydraulic system.

After carrying out assembly work carefully check to see that all ports are tightened before re-pressurising the system.

Wear protective clothing, safety glasses and safety gloves when tracing leaks or bleeding the system.

Use a piece of absorbent paper to trace leaks, never use your hands.

Follow the hydraulic oil manufacturer’s safety instructions when handling these oils.

General Instructions for Repairing Hydraulic Components Hydraulic systems are sensitive to dirt. ●

Thoroughly clean any hydraulic components you have removed before dismantling them and placing them on a workbench.

●

Always repair hydraulic components in a clean working environment.

●

Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil.

Use the same type as is used in the truck.

●

Protect all components from re-contaminating until they are installed again.

●

Immediately seal any open hydraulic ports on repaired assemblies with filler plugs. This also

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CYLINDERS Large Rod Seal Assembly

Rod Seal Assembly

Tools required:

General All tools and equipment used for rod seals must be burr-free and not have sharp edges. The tools should be made either of soft metal (aluminium, brass) or a suitable plastic.

Do not use hooks to remove seals. The same rule applies: Burr-free, rounded tips and made of soft metal to avoid damaging the seal seat.

Screwdrivers or similar tools will damage the seal seats and the seals. This will result in leaks.

●

Tool body (outer diameter must fit the internal diameter of the gland).

●

Three pins (1, 2 and 3). Pin (1) is fixed; pins (2) and (3) are moveable.

Assembly: ●

Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the gland.

●

Place the rod seal over the fixed pin (1).

●

Bend the rod seal under pin (2) (see Fig. MS2232-019).

1 3 2 MS-2232-013

To remove rod seals from the lift cylinder and the freelift cylinder, you will require 2 specially produced tools (see Figure MS-2232-016).

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

Screwdriver, shaft min . 150 mm long, max. 4mm Ø

MS-2232-019

●

Bend the loop created in this way so far up that pin (3) can be pushed into the loop.

●

Now push the tool body into the gland until the rod seal is aligned with the seal seat (see Fig. MS-2232-020).

4mm self-tapping screw 3

Insulating tape Hard-soldered screw, soldering joint sanded.

1

MS-2232-016

We will now demonstrate 2 processes – depending on the seal rod diameter – for ensuring safe assembly.

2

MS-2232-020

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CYLINDERS ●

Pull back pin (3). A section of the rod seal jumps into the seal seat (Fig. MS-2232-022).

Small Seal Rod Assembly Tools required: Groove aligning arbor. The outer diameter must fit the internal diameter of the gland. The arbor should end at the bottom of the seal seat.

3

Arbor to drive in the seal.

2

●

Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the gland.

●

Place the gland onto the groove aligning arbor.

●

Gently squeeze the rod seal together.

●

Place the rod seal at one point of the seal seat.

MS-2232-022

●

Now pull back pin (2). The rod seal is now fully seated in the seal seat.

MS-2232-024 MS-2232-021

●

Pull the tool body out of the gland.

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●

Press the rod seal and the arbor into the seal seat.

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177

CYLINDERS Rod Seal Assembly, Sealing Lip First The sealing lip is sensitive and must not be damaged.

You therefore require special protective sleeves when pushing the seal over the thread and holes.

Sealing lip assembly direction: Always to the pressure side!

Protective sleeve Seal Tool

Bearing ring

MS-8.0-2232

178

MS-2232-025

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CYLINDERS Tilt Cylinders General

Removal INFORMATION Always leave one tilt cylinder installed!

Make sure the components and the working area are clean. Thoroughly clean the tilt cylinder before dismantling it. Hydraulic systems are sensitive to contamination.

If both tilt cylinders have to be repaired on a truck, first remove one cylinder, repair it and then install it again. Then remove the second cylinder for repair and refit it.

When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly.

Use hydraulic oil according to the temperature range of the area of application (see Lubricant table in Chapter 1).

Various tilt angles are possible depending on the truck model. The key factors in deciding the tilt angle are the spacer bushings (9 and 17, Fig. MP-2232-031). When ordering spare parts refer to the parts table in the spare parts catalog.

If both tilt cylinders were to be removed at the same time, you would need and inclinometer and a horizontal surface to re-adjust the mast tilt angle with a tolerance of 15 angular minutes. ●

Tilt the mast fully forward (the tilt cylinders must be fully extended). The mast must remain at this angle until the tilt cylinder is re-installed.

●

Disconnect the battery and depressurise the hydraulic system (see Chapter 7 Mast).

●

Remove the screw (6, Fig. MP-2232-031) and the safety plate (5, MP-2232-031) from the clevis of one of the tilt cylinders.

●

Remove the screw (6) and pull the retaining pin (27, MP-2232-031) out of the bearing stud (26, MP-2232-031).

CAUTION Possible damage!

Do not drive the bearing studs in or out.

Any knocks will damage the studs and the bearings and will distort the forks on the cylinder tube and the clevis.

Push or pull the studs with a suitable tool.

While doing so, ensure that the tool is supporting the opposite side of the fork.

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●

Press out the stud (4, MP-2232-031).

●

Press out the stud (26).

●

Remove the tilt cylinder from the truck.

●

Remove the bearings (24 and 2, MP-2232-031) from their seats in the frame or the mast.

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179

CYLINDERS Tilt Cylinder Sectional Drawing

Clevis

Counternut Shims Spacer Sleeve O Ring

Deflector Ring Rod Seal

Retaining Ring O Ring Conical Nipple Bearing Ring

Spacer Sleeve

Piston Rod Bearing Ring Rod Seal

Cylinder Tube

MS-2232-014

MS-8.0-2232

180

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CYLINDERS 1 3 4 2

7 6

8 5

9 10

17 11 12 23

13 14

15

22

18 21

16

25

26

19 20

6

27

24

MP-2232-031

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CYLINDERS ●

Clean the bearings and check them for damage and wear. Replace the bearings if necessary.

Component Inspection ●

Scratches, grooves and corrosion on the piston rod will result in leaks. If this has occured replace the piston rod.

●

Burrs on the cylinder tube near the hole for the wire retainer and the connecting threads for the hydraulic ports will also result in leakage on assembly. Deburr these areas if necessary and smooth the edges.

●

Now thoroughly clean any refinished components.

Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a hydraulic oil film (for the oil type refer to the lubricant table in Chapter 1).

Dismantling CAUTION Possible damage!

The cylinder tube can become damaged when you clamp the cylinder in a vice.

Do not overtighten the vice. ●

Clamp the cylinder upright in a vice with the piston rod facing up.

●

Mark the position of the hydraulic ports (23) and unscrew the hydraulic ports from the cylinder tube.

●

Remove the clevis (3).

●

Remove the retaining ring (22).

●

Using a pin wrench (42 mm pin distance, 5 mm pin diameter) turn the gland until the retaining ring (22) is no longer blocking the gland.

●

Pull the piston rod (18) and the gland (14) out of the cylinder tube.

●

Make sure the spacer bushing (17) is refitted in this cylinder, as it determines the mast tilt angle.

CAUTION Possible damage!

Never use a screwdriver or any other sharp-edged tools to remove seals. This could result in irreparable damage to the seal seats. Use a small, burr-free hook. ●

Remove all seals, bearing rings and the deflector ring (11, 12, 13, 15, 16, 19, 20)

●

Thoroughly clean all components with a suitable solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry.

Immediately protect shiny metal surfaces with a hydraulic oil film (for the oil type refer to the lubricant table in Chapter 1).

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182

Assembly CAUTION Possible damage!

Incorrect handling during assembly can result in leaks. Take care not to jam the piston rod and the gland in the cylinder tube during assembly. Otherwise the seals in the hole for the retaining ring (22) could be damaged.

Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter. ●

Pull the conical nipple (20) and the bearing ring (19) onto the piston rod (18).

●

Guide the piston rod into the cylinder tube (21), taking care not to damage the seals.

●

Push the spacer bushing (17) previously removed from this cylinder up onto the piston rod.

(This bushing determines the mast tilt angle).

●

Insert the guide ring (13), the seal (12) and the deflector (11) into the gland.

●

Pull the O ring (15) and the bearing ring (16) up on the outside of the gland.

●

Lubricate the retaining ring (22) with hydraulic oil.

●

Push the gland over the piston rod. At the same time insert the retaining ring (22) and its hook into the hole of the gland. Turn the gland 360 degrees using a pin wrench (42 mm pin distance, 5 mm pin diameter) while at the same time pressing the gland until it is seated in the cylinder tube. The retaining ring (22) should “snap” into the recess in the cylinder tube.

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CYLINDERS

1 3 4 2

0

7 6

8 5

9 10

17 11 12 23

13 14

15

0

22

18 21

16

25

26

19 20

6

27

24

MP-2232-031

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CYLINDERS ●

Insert the O ring (10) into the spacer bushing (9) belonging to this cylinder. Lubricate the hole and the O ring of the spacer bushing with universal grease (see lubricant table in Chapter 1). Push the spacer bushing and the shims (8) over the piston rod.

●

Screw in the counternut onto the piston rod (7) until it comes to rest.

●

Screw on the clevis(3).

●

Refit the hydraulic ports (23). Align the hydraulic ports in accordance with the positions marked prior to dismantling them. Torque them to 23 Nm.

●

Attach filler plugs to the hydraulic ports to protect the cylinder from contamination until it is reconnected in the truck.

Assembly CAUTION

●

Attach the retaining pin (27) and secure it with the screw (6).

●

Now use a fork wrench to turn the piston rod (18) until the holes of the clevis (3) are aligned with the bearing holes (2) on the mast side.

●

Place a bearing stud (4) on the mast side of the tilt cylinder.

●

Align the bearing stud so that after the bearing stud is pressed in, the safety plate (5) will fit into the recess in the bearing stud and the safety plate can be screwed on.

●

Press in the bearing stud and fix it with the safety plate and the screw (6).

●

Counter-fix the nut (7) with a 330 Nm torque.

●

Refit the hydraulic lines and the battery.

●

Bleed the tilt cylinder by tilting several times in both directions.

●

While doing so, check that the cylinder and the ports are sealed (note warnings in Chapter 2, Hydraulics).

●

Tilt the mast back fully.

●

With the cylinder still installed, check whether the spacer sleeve (4) is contacting the gland. It should not be possible to turn it manually.

●

On the previously re-installed cylinder, now check whether the spacer sleeve (4) is contacting the gland. It should not be possible to turn it manually.

Possible damage!

Do not drive the bearing studs in or out.

Any knocks will damage the studs and the bearings and will distort the fork on the cylinder tube and the clevis.

Push the studs using a suitable tool.

While doing so, ensure that the tool is supporting the opposite side of the fork. ●

●

Insert 2 bearings into each receptacle in the chassis and the mast. The outer surfaces of the bearings should lie approx. 1 mm below the receptacle surfaces.

Ensure that the M8 threaded holes for the retaining components on the tilt cylinder are facing the outside of the truck and insert the tilt cylinder.

●

Place a bearing stud (26) on the chassis side of the tilt cylinder, the M16 threaded hole in the bearing stud should face the outside of the truck.

●

Align the cross hole for the retaining pin so that the eye of the retaining pin will lie over the M8 threaded hole when the bearing stud is pressed in.

●

Press in the bearing stud (26).

MS-8.0-2232

184

If the spacer sleeve can still be manually turned: ●

Calculate the clearance with a feeler gauge.

●

Fully tilt the mast forward.

●

Loosen the counternut (7).

●

Using a fork wrench turn the piston rod to compensate for the previously calculated clearance.

●

Counter-fix the nut (7) with a 330 Nm torque.

●

Now check again whether the spacer sleeve (4) is still contacting the gland and can be manually turned.

●

When you have adjusted the setting, check the clearance on the cylinder which has not yet been removed.

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CYLINDERS ●

The spacer sleeves on both cylinders should make contact and it should not be possible to turn them manually.

●

Activate tilting a few times. Now check the cylinder for leaks.

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CYLINDERS

13

15

12

1

11

14

10

12 13

13 1

12 14

11

11

14 10

10 15

15 8

7 1

2

3

5 4 6

7/8 9

2 3

9

4 6 5 6 2 3

4 6 5 6

MP-2232-024

MS-8.0-2232

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CYLINDERS Lift Cylinders

●

Now turn 2 of the prepared seal extractors – at 180 degrees to each other – into the rod seal.

(See General section, Fig. MS-2232-016).

Make sure you don’t damage the piston rod.

●

Pull out the rod seal (11) evenly using the two tools.

●

Remove the bearing ring (10).

●

Thoroughly clean all components with a suitable light solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a thin film of hydraulic oil (for the oil type refer to the lubricant table in Chapter 1).

General Make sure the components and the working area are clean. Thoroughly clean the cylinder before dismantling it. Hydraulic systems are sensitive to contamination.

When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly.

Use hydraulic oil according to the application temperature range (see Lubricant table in Chapter 1).

Removal and Assembly Inspect the piston rod for damage over the full lift height before removing it. Damaged piston rods damage the seals very rapidly. Replace the damaged piston rod whenever you fit new seals. ●

Refer to the Mast chapter for the removal and assembly of the lift cylinders.

Dismantling CAUTION Possible damage!

The cylinder tube can become damaged when you clamp the cylinder. Do not overtighten the devices for holding the cylinder.

Rod Seal Removal ●

Clamp the removed cylinder to prevent it from twisting.

●

Unscrew the gland (12) from the cylinder tube.

●

Remove the deflector ring (13).

12

7/8

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CYLINDERS

13

15

12

1

11

14

10

12 13

13 1

12 14

11

11

14 10

10 15

15 8

7 1

2

3

5 4 6

7/8 9

2 3

9

4 6 5 6 2 3

4 6 5 6

MP-2232-024

MS-8.0-2232

188

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CYLINDERS Piston Rod Removal ●

●

If the piston rod has to be replaced, you should now pull the piston rod out of the cylinder tube.

Otherwise the piston rod could remain in the cylinder tube.

Installing the Rod seal ●

Insert a new guide ring (10) into the cylinder tube (8).

●

Push a suitable guide bushing into the cylinder tube to cover the thread. Otherwise you will damage the sealing lip of the rod seal on assembly. Apply a thin layer of oil to the guide bushing.

●

Push a new rod seal over the piston rod with the sealing lips in front.

●

Using a suitable mandrel (without sharp edges!) drive the rod seal further until it makes uniform contact with the guide bushing.

Remove the inner retaining ring (4). Remove the piston (3) and the spring (2) from the piston rod.

Assembly CAUTION Possible damage!

Incorrect handling during assembly can result in leaks. Take care not to damage the piston rod and the new seals during assembly. Use guide bushing and burrfree tools without sharp edges.

Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter.

Seal seat

Piston Rod Assembly ●

Insert a retaining ring (6) into the upper groove of the piston rod.

●

Push a new, oiled bush (5) onto the piston rod.

●

Fix the bush with the retaining ring (6).

●

●

Push the spring (2) and the piston (3) into the piston rod.

Insert a new deflector ring (13) into the gland (12).

●

Screw the gland back in and tighten it.

●

Refit the lift cylinder (see Mast chapter).

●

Bleed the cylinder (see Hydraulics chapter).

●

Perform a drift test (see Hydraulics chapter).

●

Fix the spring and the piston with the inner retaining ring (4).

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MS-2232-018

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CYLINDERS

10 14 13

14 13 12

4

11 3

3

12 4 11

1

10

1 9 8 6 7 6 9

5

8 6 2 6

7 5 2

MP-2232-025

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CYLINDERS Free-Lift Cylinder

Piston Rod Removal ●

If the piston rod has to be replaced, you should now pull the piston rod out of the cylinder tube.

Otherwise the piston rod could remain in the cylinder tube.

●

Remove the inner retaining ring (5). Remove the piston (8) and the spring (9) from the piston rod.

General Make sure the components and the working area are clean.

Thoroughly clean the cylinder before dismantling it. Hydraulic systems are sensitive to contamination.

When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly.

Use hydraulic oil according to the application temperature range (see Lubricant table in Chapter 1).

Assembly CAUTION Possible damage!

Removal and Assembly

Incorrect handling during assembly can result in leaks. Take care not to damage the piston rod and the new seals during assembly. Use guide bushing and burrfree tools without sharp edges.

Inspect the piston rod for damage over the full lift height before removing it. Damaged piston rods damage the seals very rapidly. Replace the damaged piston rod whenever you fit new seals. ●

Refer to the Mast chapter for the removal and assembly of the free-lift cylinder.

Dismantling CAUTION

Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter.

Piston Rod Assembly ●

Insert a retaining ring (6) into the upper groove of the piston rod.

●

Push a new, oiled bush (7) onto the piston rod.

●

Fix the bush with the lower retaining ring (6).

●

Push the spring (9) and the piston (8) into the piston rod.

●

Fix the spring and the piston with the inner retaining ring (5).

Possible damage!

The cylinder tube can become damaged when you clamp the cylinder. Do not overtighten the devices for holding the cylinder.

Rod Seal Removal ●

Clamp the removed cylinder to prevent it from twisting.

●

Unscrew the gland (13) from the cylinder tube.

●

Remove the deflector ring (14).

●

Now turn 2 of the prepared seal extractors – at 180 degrees to each other – into the rod seal.

Make sure you don’t damage the piston rod.

●

Using the two tools pull the rod seal (12) evenly up off the piston rod.

●

Remove the bearing ring (11).

●

Thoroughly clean all components with a suitable light solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a thin film of hydraulic oil (for the oil type refer to the lubricant table in Chapter 1).

SC3200 03/2004 • Printed in Germany

Installing the Rod Seal ●

Insert a new guide ring (11) into the cylinder tube (1)

●

Push a suitable guide bushing into the cylinder tube to cover the thread. Otherwise you will damage the sealing lip of the rod seal on assembly. Apply a thin layer of oil to the guide bushing.

●

Push a new rod seal over the piston rod with the sealing lips in front.

●

Using a suitable mandrel (without sharp edges!) drive the rod seal further until it makes uniform contact with the guide bushing.

●

Insert a new deflector ring (14) into the gland (13).

●

Screw the gland back in and tighten it.

●

Refit the lift cylinder (see Mast chapter).

●

Bleed the cylinder (see Hydraulics chapter).

●

Perform a drift test (see Hydraulics chapter).

MS-8.0-2232

191

CYLINDERS

10 14 13

14 13 12

4

11 3

3

12 4 11

1

10

1 9 8 6 7 6 9

5

8 6 2 6

7 5 2

MP-2232-025

MS-8.0-2232

192

SC3200 03/2004 • Printed in Germany

CYLINDERS

Blank page

SC3200 03/2004 • Printed in Germany

MS-8.0-2232

193

CYLINDERS

MP-2232-004

Rod seal Deflector Ring

MS-2232-028 MS-8.0-2232

194

SC3200 03/2004 • Printed in Germany

CYLINDERS Hook-on Sideshifter, Cylinder

●

Screw off the glands from both ends of the cylinder.

INFORMATION The sideshifter must be removed from the truck in order to repair the cylinder. For removal instructions see chapter 7.

If there are grooves on the piston rod or if the piston rod is bent, replace the entire cylinder unit. ●

Remove the pins (9, Fig. MP-2232-004).

●

Lift out the cylinder unit.

CAUTION Possible damage!

The cylinder tube can be damaged when you clamp the cylinder.

MS-2232-027

Do not clamp the cylinder tube. Clamp the cylinder unit around the core plate. ●

Clamp the cylinder unit in a vice with protective jaws.

●

Push the piston rod into the central position.

Core plate

●

Remove the seals and the deflector from the gland using the hook tool (see General section).

●

Thoroughly clean the piston rod and the seal seats of the glands with a solvent.

●

Remove any burrs from the piston rod ends.

●

Lubricate the new rod seal with hydraulic oil and place it in the gland. Note the assembly position (Fig. MS-2232-028): Pressure seals are installed with the lip facing the pressure side!

●

Fit the new O ring and the new deflector ring into the gland.

●

Lubricate the piston rods with hydraulic oil. Push the glands carefully onto the piston rod.

●

Hand-tighten the glands.

Gland

The glands should only be fixed once the sideshift has been fitted in the truck. Torque: 165 Nm.

MS-2232-026

SC3200 03/2004 • Printed in Germany

MS-8.0-2232

195

CYLINDERS 21

23 22

27 27 14

15

26

25 9

21 8 24

13 12

5

10 11

6

7 20 4 19 17 16

18

1 2 3 MP-2232-030

MS-8.0-2232

196

SC3200 03/2004 • Printed in Germany

CYLINDERS Integrated Sideshifter, Cylinder INFORMATION The integrated sideshifter (1) must be removed from the truck in order to repair the cylinder. For removal instructions see chapter 7. ●

Make sure that the hydraulic system is de-pressurised (see removal instructions in Chapter 7).

●

Undo the hydraulic connections from the fork carriage.

●

Pull the corresponding piston rod (15) from out of the fork carriage frame.

●

Pull the washer (13) out from the side.

●

Remove the seal (12), the deflector (14) and the bushing (11). No tools are required for this.

●

Dispose of the seal and the deflector.

●

Thoroughly clean all components with a solvent.

●

Examine the piston rod and the bushing for damage. Replace any damaged components.

●

Apply a thin coating of hydraulic oil to all the components.

●

Re-assemble the cylinder in the reverse order.

●

Refit the sideshifter and carry out the necessary tests (see Chapter 7).

SC3200 03/2004 • Printed in Germany

MS-8.0-2232

197

SAFETY

Blank page

Printed in Germany

198

ELECTRICAL DIAGRAMS

Printed in Germany

199

Blank Page

Printed in Germany

200

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

Abbreviations

CA 209

J

ACS

Accelerator Switch

Pump Controller Connectors

AXS

Auxiliary Function Switch

CA 210

L

BDI

Battery Discharge Interrupt

CA 211

E

BRS

Brake Switch

CA 212

D

DIS

Direction Switch

CA 213

C

EM

Encoder Module

CA 214

B

ENC

Encoder

CA 215

A

HBS

Handbrake Switch

CA 216

Panel

HF

Hash Filter

CA 217

Seat Switch

HN

Horn

CA 218

Steering Feedback Potentiometer

HNS

Horn Switch

CA 401

Accelerator Potentiometer

KYS

Key Switch

CA 402

Accelerator Switch

POT 1

Accelerator Potentiometer

CA 403

Lift Potentiometer

POT 2

Lift Potentiometer

CA 404

Tilt Switch

POT 3

Steer Potentiometer

CA 405

Side Shift Switch

SES

Seat Switch

CA 406

Auxiliary Switch

SH

Shunt

CA 407

Pedal Brake Switch

SSS

Side Shift Switch

CA 408

Handbrake Switch

TLT

Tilt Switch

CA 409

Horn

TT

Hour Meter

CA 410

BDI Supply

CA 411

BDI

CA 412

Steering Column

CA 601

Horn Switch

CA 602

Steering Encoder Module

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).

SC3200 03/2004 • Printed in Germany

MS-DIA-2232

Rev. 01/99

201

DIAGRAMS

Blank page

Printed in Germany

202

DIAGRAMS Control Circuit

PCM

DIRC RH

DIRC LH

TCM

796324_2a_1_2

SC3200 03/2004 • Printed in Germany

MS-2.0-2232

203

DIAGRAMS Power Circuit

TM LH

TM RH

PCM

TCM

796324_2a_2_2

MS-DIA-2232

204

SC3200 03/2004 • Printed in Germany

DIAGRAMS Option Brush Wear & Over Temperature Indicator Circuit Diagram

B WAY FROM EXISTING MAIN LOOM STAR POINT

*

STAR POINT

METER

STAR POINT

TM LOW LH

+ STAR POINT

TM LOW RH

TM HIGH LH

switched -

PM LOW

TM HIGH RH

STAR POINT

Existing Main Loom

BWI & TEMP LOOM

Option: Brush Wear and Overtemperature Note: Temperature/Brush wear switches are normally closed, opening at the over temperature/brush worn condition. * HBS: Applied Shown SC3200 03/2004 • Printed in Germany

TCM

STAR POINT

MS-2.0-2232

205

DIAGRAMS Option Lighting Diagram Control Panel

CONNECT TO PANEL WIRE S3 LOCATED ON LINE CONTACTOR COIL switched

after LC

Starpoint A

open

Cable Assy 813071 Starpoint B

Cable Assy switch 8 way plug 793793 module Rev./Brake Light module

supplies from control panel 12 way plug

Cable Assy

Starpoint C switch

Rev. Alarm 115565

Cable Assy

strobe TAIL

BRAKE Cable Assy 813072

BACK UP

worklight rear

TAIL

BRAKE

Cable Assy

BACK UP

PCB Tail 813070_2e_1_1

worklight Front RH MS-DIA-2232

206

worklight Front LH SC3200 03/2004 • Printed in Germany

DIAGRAMS

BRS

DIS

HBS

POT1 ACS

POT2 TLT

SSS AXS

POT3

Cold Store Option

810350_2b_1_1

SC3200 03/2004 • Printed in Germany

MS-2.0-2232

207

DIAGRAMS

Steer Column

Seat Switch and Steer Pot JC 216

PC 216

PC 412

201 PC 412 - 1

1

1

ZAPI A1 FU 3

202 PC 412 - 2

2

2

ZAPI A2 FU 4

2903 PC 412 - 3

3

3

ZAPI A3 PC 201 - 1

NOT USED

4

4

NOT USED

5

5

NOT USED

6

6

562 PC 409 - 2

7

7

ZAPI A7 (B-)

509 PC 412 - 9

8

8

ZAPI A8 (B-)

NOT USED

9

9

A9

2935 STAR A

10

10

ZAPI A 10 PC 212 - 2

NOT USED

11

11

A11 only for lighting option

NOT USED

12

12

A12 only for lighting option

A4

only for lighting option

only for lighting option

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

2906 PC 207 - 7

6

6

2907 PC 409 - 1

7

7

5908 PC 211 - 8

8

8

5908 PC 602 - 2 509 PC 602 - 1

509 JC 216 - 8

9

9

2910 PC 411 - 2

10

10

NOT USED

11

11

NOT USED

12

12

201 PC 603

DIS

F R

HNS

2999 PC 603

PC 217

JC 217

5938 STAR E

1

1

5945 STAR C

2

2

PC 218

SES

JC 218

719 PC 210 - 4

1

1

120 PC 210 - 2

2

2

521 PC 210 - 3

3

3

NOT USED

4

4

208

201 JC 412 - 1

A

A

NOT USED

B

B

2999 JC 412-3

C

C

PC 602

1 2 3 4

POT 3

(Steering Feedback)

814590_2a_1-8

MS-DIA-2232

JC 603

PC 603

KYS

JC 602

1

1

2

2

3

3

4

4

EM

ENC

814590_2a_2-8

SC3200 03/2004 • Printed in Germany

DIAGRAMS

Control Levers

BDI, Horn and Brake Switches JC 407

PC 407 A

2928 STAR D

A

2929 PC 207 - 6

B

B

NOT USED

C

C

BRS

JC 408

PC 408 2926 STAR B

A

A

NOT USED

B

B

2950 STAR D

C

C

HBS

A

A

R

562 JC 216 - 7

B

B

C

543 PC 411 - 5

FU 5

1

123 PC 207 - 2

2

2

524 PC 207 - 1

3

3

NOT USED

4

4

HN

A

A

to Battery Connector (B+ BDI)

B

B

to Battery Connector (B- BDI)

PC 411

2 3 4

POT 1

(Accellerator)

JC 402

2925 STAR B

A

A

NOT USED

B

B

2904 PC 412 - 4

C

C

ACS

JC 403

716 PC 213 - 3

1

1

117 PC 213 - 1

2

2

1 2

518 PC 213 - 2

3

3

NOT USED

4

4

3 4

POT 2

(Lift)

JC 404

PC 404 2915 PC 211 - 5

A

A

NOT USED

B

B

2959 STAR A

C

C

TLT

JC 411

JC 405

PC 405 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

2914 PC 211 - 3

A

A

NOT USED

B

B

2960 STAR A

C

C

SSS

+ TT

JC 406

PC 406 + 48 V

814590_2a_3-8

SC3200 03/2004 • Printed in Germany

1

JC 410

PC 410 263

1

PC 403

2907 PC 412 - 7

244 PC 411 - 8

722 PC 207 - 3

PC 402

JC 409

PC 409

JC 401

PC 401

2913 PC 211 - 2

A

A

NOT USED

B

B

2961 STAR A

C

C

AXS

814590_2a_4-8

MS-2.0-2232

209

DIAGRAMS

Star Points

Panel Wiring

STAR POINT A

2935 JC 216 - 10

FU 3

ZAPI A 1 PC 216 - 1

2961 PC 406 - C

ZAPI A 4 PC 216 - 4

2960 PC 405 - C

ZAPI A 2 PC 216 - 2

2959 PC 404 - C

ZAPI A 5 PC 216 - 5

2936 PC 411 - 3

ZAPI A 3 PC 216 - 3

FU 4

B+ LC

ZAPI A 6 PC 216 - 6 ZAPI A 7 PC 216 - 7 B- (BUSBAR) ZAPI A 8 PC 216 - 8

STAR POINT B 2925 PC 402 - A

2927 PC 207 - 5

2926 PC 408 - A

ZAPI A 9 PC 216 - 9 ZAPI A 10 PC 216 - 10

ZAPI R 9 PC 201 - 9

5933 PC 210 - 5 5934 PC 210 - 6 5945 JC 217 - 2 5957 PC 210 - 8 5958 PC 210 - 9

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 A 3/L PC 201 - 1

LC

ZAPI S3 PC 208 - 3

STAR POINT D

ZAPI A 11 PC 216 - 11

ZAPI A 11 PC 208 - 2

2928 PC 407 - A

2930 PC 206 - 1

RGB

ZAPI R 8 PC 201 - 8

STAR POINT C

5932 PC 210 - 1

ZAPI A 12 PC 216 - 12

ZAPI A 12 PC 201 - 3

2950 PC 408 - C

ZAPI A 10 PC 212 - 2 ZAPI L PC 212 - 1

ZAPI A 10 ZAPI L

814590_2a_6-8

STAR POINT E

5931 PC 210 - 7

5938 JC 217 - 1 5939 PC 411 - 1

814590_2a_5-8

MS-DIA-2232

210

SC3200 03/2004 • Printed in Germany

DIAGRAMS

Traction Controller

Pump Controller

CA 201 9

9

ZAPI R 8

8

8

ZAPI R 7

7

7

ZAPI R 6

6

6

ZAPI R 5

5

5

ZAPI R 4 NOT USED ZAPI R 2 ZAPI A 3 / L

4 3 2 1

F

E

TCM

3

G

2 1 CA 202 2

NOT USED

1

2

1 2

3

NOT USED

2

NOT USED

1

D

C

(Handset Connector)

NOT USED

7

7

2937 PC 411 - 4

6

6

524 PC 401 - 3

2915 PC 404 - A

5

5

2

2

123 PC 401 - 2

NOT USED

4

4

3

3

722 PC 401 - 1

2914 PC 405 - A

3

3

4

4

NOT USED

2913 PC 406 - A

2

2

5

5

2927 STAR B

NOT USED

1

1

6

6

2929 PC 407 - D

7

7

2906 PC 412 - 6

8

8

2905 PC 412 - 5

1

1

NOT USED

2

2

NOT USED

3

3

ZAPI S 3

ZAPI A 10 JC 216 - 10

2

2

ZAPI L CA 201 - 1

1

1

B

716 PC 403 - 1

3

3

518 PC 403 - 3

2

2

117 PC 403 - 2

1

1

NOT USED

8

2

2

NOT USED

7

5

5932 STAR C

2

2

120 PC 218 - 2

2

3

3

521 PC 218 - 3

1

4

4

719 PC 218 - 1

5

5

5933 STAR C

6

6

5934 STAR C

7

7

5931 STAR E

8

8

5957 STAR C

2

9

9

5958 STAR C

1

3

L

1

LED

A

C

6

1

2

D

CA 214

1

CA 205

E

CA 213

1

CA 210

4

PCM

CA 212

1

6 5

8

CA 209

J

7

9

8

CA 208

H

8

9

5908 PC 412 - 8

1

CA 204

814590_2a_7-8

SC3200 03/2004 • Printed in Germany

NOT USED

NOT USED

1

CA 203 NOT USED

2930 STAR D

CA 207

4

NOT USED

1

(Handset Connector)

ZAPI R 9

CA 211

CA 206

B

4 3 2 1

CA 215 LED

A

814590_2a_8-8

MS-2.0-2232

211

DIAGRAMS Power Cable Diagram

808742-00x

792878-019 -003 -011

792878-020 -004 -012

792878-024 -008 -016

792878-023 -007 -015

KEY:

792878-022 -006 -013

792878-021 -005 -013

* = Control Panel Copper Link

792878-018 -002 -010

808742-001 = SC3210-1.3 808742-002 = SC3210-1.3H; SC3220-1.3; SC3220-1.6 808742-003 = SC3220-1.3H; SC3220-1.6H; SC3240-1.8 808742-004 = SC3240-1.6H; SC3240-1.8H

792878-017 -001 -009

792878-009 to -016 = SC3210 792878-001 to -008 = SC3220 792878-017 to -024 = SC3240

813167_2b_1_1

MS-DIA-2232

212

SC3200 03/2004 • Printed in Germany

DIAGRAMS Main Loom, Part 1

CAP INSERT PIN PLUG

Data of terminals and connections see next page!

CAP INSERT PIN PLUG

PLUG

CAP INSERT PIN PLUG

CAP INSERT PIN PLUG

Q (see next page)

PLUG LABEL PLUG

CAP INSERT PIN PLUG

PLUG

CAP INSERT

PLUG

CAP INSERT PIN PLUG doc-794929_f_2_3

SC3200 03/2004 • Printed in Germany

MS-2.0-2232

213

DIAGRAMS Main Loom, Part 2

PLUG CONTACT

PLUG INSERT PIN PLUG

PLUG INSERT

PLUG INSERT PIN PLUG PLUG INSERT PIN PLUG CAP INSERT

(see previous page)

L PLUG INSERT PIN PLUG

CONNECTS

LEAD DATA

LEAD COLOR 1 T O 37 2613 RED/WHT 2 T O 39 2914 RED/WHT 3 T O 41 2915 RED/WHT 4 T O 56 2937 RED/WHT 5 T O 66 5908 GRN/WHT 6 T O 44 117 BRN 7 T O 45 518 GRN 8 T O 43 716 VIO 9 T O 80 5932 GRN/WHT 10 T O 33 120 BRN 11 T O 34 521 GRN 12 T O 32 719 VIO 13 T O 80 5933 GRN/WHT 14 T O 80 5934 GRN/WHT 15 T O 77 5931 GRN/WHT 16 T O 80 5957 GRN/WHT 17 T O 80 5958 GRN/WHT 18 T O 48 524 GRN 19 T O 47 123 BRN 20 T O 46 722 VIO 21 T O 91 2927 RED/WHT 22 T O 76 2929 RED/WHT 23 TO 64 2906 RED/WHT 24 T O 63 2905 RED/WHT 25 TO 94 2930 RED/WHT

LEFT TERMINAL DATA NO. PART # 1 062800-001 2 062800-001 3 062800-001 4 062800-001 5 062800-001 6 062800-001 7 062800-001 8 062800-001 9 062800-001 10 062800-001 11 062800-001 12 062800-001 13 062800-001 14 062800-001 15 062800-001 16 062800-001 17 062800-001 18 062800-001 19 062800-001 20 062800-001 21 062800-001 22 062800-001 23 062800-001 24 062800-001 25 062800-001

RIGHT TERMINAL DATA NO. PART # 37 062704-004 39 062704-004 41 062704-004 56 116858 66 062704-004 44 062704-004 45 062704-004 43 062704-004 80 062007-107 33 062704-004 34 062704-004 32 062704-004 80 TO #80 80 TO #80 77 062007-107 80 TO #80 80 TO #80 48 062704-004 47 062704-004 46 062704-004 91 062007-107 76 062704-004 64 062704-004 63 062704-004 94 TO #94 794929-1_T-GB

MS-DIA-2232

214

CONNECTS

LEAD DATA

LEAD COLOR 26 TO 59 2613 RED 27 TO 60 2914 RED 28 TO 61 2915 RED/WHT 29 TO 70 2937 GRN 30 TO 67 5908 GRN 31 TO 86 117 RED/WHT 35 TO 77 518 GRN/WHT 36 TO 80 716 GRN/WHT 38 TO 86 5932 RED/WHT 40 TO 86 120 RED/WHT 42 TO 86 521 RED/WHT 49 TO 91 719 RED/WHT 50 TO 62 5933 RED/WHT 51 TO 91 5934 RED/WHT 52 TO 94 5931 RED/WHT 53 TO 77 5957 GRN/WHT 54 TO 68 5958 RED/WHT 55 TO 86 524 RED/WHT 57 TO 72 123 GRN 58 TO 74 722 RED 69 TO 65 2927 RED/WHT 71 TO 73 2929 RED 75 TO 94 2906 RED/WHT

LEFT TERMINAL RIGHT TERMINAL DATA DATA NO. PART # NO. PART # 26 062704-003 59 062704-004 27 062704-003 60 062704-004 28 062704-003 61 062704-004 29 062704-003 70 062704-004 30 062704-003 67 062704-004 31 062704-0031 86 062007-107 35 062704-003 77 TO #77 36 062704-003 80 TO #80 38 062704-004 86 TO #86 40 062704-004 86 TO #86 42 062704-004 86 TO #86 49 062704-004 91 TO #91 50 062704-004 62 062704-004 51 062704-004 91 TO #91 52 062704-0041 94 TO #94 53 116858 77 TO #77 54 116858 68 062704-004 55 116858 86 TO #86 57 116858 72 062704-003 58 116858 74 062007-068 69 062704-004 65 062704-004 71 062704-003 73 062007-068 75 062704-004 94 062007-107

PLUG INSERT PIN PLUG

doc-794929_f_3_3

794929-2_T-GB SC3200 03/2004 • Printed in Germany

DIAGRAMS Steer Column Loom

BUTTSPLICE CAP

INSERT

SEALING PLUG PLUG INSERT SEALING PLUG

PLUG INSERT SEALING PLUG

810209_e

CONNECTS 1 TO 15 2 TO 21 3 TO 22 4 TO 12 5 TO 13 6 TO 14 7 TO 20 8 TO 18 9 TO 17 10 TO 22 11 TO 12 16 TO 22 19 TO 22

LEAD DATA LEAD COLOR 201 RED 202 RED 2903 RED/WHT 2904 RED/WHT 2905 RED/WHT 2906 RED/WHT 2907 RED/WHT 5908 GRN/WHT 509 GRN 2910 RED/WHT 2953 RED/WHT 2999 RED/WHT 2951 RED/WHT

LEFT TERMINAL DATA NO. PART # 1 062704-003 2 062704-003 3 062704-003 4 062704-003 5 062704-003 6 062704-003 7 062704-003 8 062704-003 9 062704-003 10 062704-003 11 062007-068 16 062704-004 19 062704-004

RIGHT TERMINAL DATA NO. PART # 15 062704-004 21 062007-032 22 062007-103 12 062007-078 13 062007-068 14 062007-068 20 062007-032 18 062704-004 17 062704-004 22 TO #22 12 TO #12 22 TO #22 22 TO #22 810209_T-GB

SC3200 03/2004 • Printed in Germany

MS-2.0-2232

215

DIAGRAMS Fan Standard

CONNECTS

LEAD DATA LEAD

1 TO 2 3 TO 6 4 TO 5

COLOR RED/WHT RED/WHT GRN

LEFT TERMINAL DATA NO. PART # 1 062007-003 3 TO 062530 4 062007-003

RIGHT TERMINAL DATA NO. PART # 2 062530 6 062007-112 5 062007-112 794878_T-GB

-

+ Fuse Holder 10 A Fuse doc-794878_b

MS-DIA-2232

216

SC3200 03/2004 • Printed in Germany

DIAGRAMS Option: Main Harness, Middle East Fan

CONNECTS 1 TO 2 3 TO 6 4 TO 5

LEAD DATA LEAD COLOR 201 RED/WHT 202 RED/WHT 2903 GRN

LEFT TERMINAL DATA NO. PART # 1 062007-003 3 TO 062530 4 062007-003

RIGHT TERMINAL DATA NO. PART # 2 062530 6 062007-063 5 062007-050 132427_T-GB

-

Fuse Holder 10 A Fuse doc-132427_a

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DIAGRAMS Option Lights, Main Loom Lights CONNECTS 1 TO 11 2 TO 14 3 TO 17 4 TO 16 5 TO 13 7 TO 12 6 TO 12 8 TO 10 9 TO 11 6 TO 15

LEAD DATA LEAD COLOR 283 RED 284 RED 5944 GRN/WHT 5943 GRN/WHT 550 GRN 5942 GRN/WHT 5940 GRN/WHT 286 RED 285 RED 5941 GRN/WHT

LEFT TERMINAL DATA NO. PART # 1 062007-063 2 062007-063 3 062007-063 4 062007-063 5 062007-063 7 062007-050 6 062007-076 8 062007-050 9 062007-050 6 TO #6

RIGHT TERMINAL DATA NO. PART # 11 062007-076 14 062007-050 17 062007-050 16 062007-050 13 062007-050 12 TO #12 12 062007-076 10 062007-050 11 TO #11 15 062007-050

Front RT W/L

813072-t-DE

Front Left W/L

CA817 Tail CA818

reverse Back Up Brake

switched

Rear W/L neg

Rear W/L + BV

doc-813072_a

Option Lights Main Loom Lights

MS-DIA-2232

218

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DIAGRAMS Option Lights, Panel to Switch

LEAD DATA

CONNECTS

LEAD 1 TO 2 3 TO 10 4 TO 6 5 TO 10 6 TO 7 8 TO10 9 TO 10

540 281 541 280 282

COLOR RED RED GRN RED GRN RED RED

LEFT TERMINAL DATA NO. PART # 1 062007-003 3 TO 062530 4 062007-003 5 062007-050 6 TO #6 8 062007-050 9 062007-050

RIGHT TERMINAL DATA NO. PART # 2 062530 10 062007-103 6 062007-076 10 TO #10 7 062007-050 10 TO #10 10 TO #10 813071-T-GB

+ Panel

doc-813071_a

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DIAGRAMS Option Lights, Module to Panel

LEAD DATA CONNECTS 1 TO 5 2 TO 6 3 TO 7 4 TO 8

LEAD COLOR 2613 RED/WHT 2914 GRN/WHT 2915 GRN/WHT 2937 GRN/WHT

LEFT TERMINAL DATA NO. PART # 1 062704-004 2 062704-004 3 062704-004 4 062704-004

RIGHT TERMINAL DATA NO. PART # 5 062704-003 6 062704-003 7 062704-003 8 062704-003 794314_T-GB

Connector Insert Sealing Plug

doc-794314_c

MS-DIA-2232

220

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DIAGRAMS Option Lights, Panel to Main Loom Lights

CONNECTS 1 TO 2 3 TO 4

LEAD DATA LEAD COLOR 5934 GRN/WHT 5933 GRN/WHT

LEFT TERMINAL DATA NO. PART # 1 062007-050 3 062007-050

RIGHT TERMINAL DATA NO. PART # 2 062704-004 4 062704-004 793794_T-GB

P CA 817

CA 818 doc-793794_b

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DIAGRAMS Option Lights, Reverse Alarm to Module

LEAD DATA

CONNECTS 1 TO 3 2 TO 4

LEAD COLOR 5991 GRN/WHT 292 RED

LEFT TERMINAL DATA NO. PART # 1 062007-036 2 062007-036

RIGHT TERMINAL DATA NO. PART # 3 062704-004 4 062704-004 793803_T-GB

I

Reverse Alarm

+ doc-793803_b

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DIAGRAMS CONNECTS

LEAD DATA

LEAD COLOR 1 TO 19 2985 RED/WHT 2 TO 53 591 GRN 3 TO 50 5989 GRN/WHT 4 TO 56 2990 RED/WHT 5 TO 11 5939 GRN/WHT 6 TO 43 2910 RED/WHT 7 TO 13 2936 RED/WHT 8 TO 14 2998 RED/WHT 9 TO 39 543 GRN 10 TO 16 244 RED 12 TO 43 2989 RED/WHT 15 TO 39 575 GRN 17 TO 31 2984 RED/WHT 18 TO 24 2982 RED/WHT 20 TO 50 5988 GRN/WHT 21 TO 47 5977 GRN/WHT 22 TO 47 5976 GRN/WHT 23 TO 43 2981 RED/WHT 25 TO 39 573 GRN 26 TO 30 5987 GRN/WHT 28 TO 53 580 GRN 29 TO 37 5972 GRN/WHT 32 TO 36 2983 RED/WHT 33 TO 47 5978 GRN/WHT 34 TO 27 5979 GRN/WHT 35 TO 56 2992 RED/WHT 38 TO 50 5970 GRN/WHT 39 TO 53 592 GRN 43 TO 56 2963 RED/WHT

LEFT TERMINAL DATA NO. PART # 1 062704-004 2 062704-004 3 062704-004 4 062704-004 5 129761-001 6 129761-001 7 129761-001 8 129761-001 9 129761-001 10 129761-001 12 116858 15 116858 17 116858 18 116858 20 1168584 21 116858 22 062800-001 23 062007-021 25 062007-021 26 062007-021 28 062007-021 29 062007-021 32 062007-021 33 062007-021 34 062007-021 35 062007-021 38 062007-021 39 TO #39 43 TO #43

RIGHT TERMINAL DATA NO. PART # 19 116858 53 062007-103 50 TO #50 56 TO #56 11 116858 43 062007-103 13 116858 14 116858 39 TO #39 16 116858 Connector 43 TO #43 insert seal 39 062007-103 31 062007-021 24 062007-021 50 TO #50 47 062007-103 47 TO #47 43 TO #43 Connector 39 TO #39 30 062007-021 53 TO #53 37 062007-021 36 062007-021 47 TO #47 27 062007-021 56 TO #56 50 062007-103 793896_T-DE 53 TO #53 56 062007-103

Option, Brush Wear and Overtemperature Display Loom

Connector 116851-001

doc-793896_c_2_2

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DIAGRAMS Option, 5th Hydraulic Function

CONNECTS 1 TO 5 2 TO 3 4 TO 6

LEAD DATA LEAD COLOR 29111 RED/WHT 29110 RED/WHT 506 GRN

LEFT TERMINAL DATA NO. PART # 1 2 4 062007-063

RIGHT TERMINAL DATA NO. PART # 5 062704-004 3 062007-063 6 062704-004 127511_T-GB

Inner housing

doc-127511_c

MS-DIA-2232

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DIAGRAMS CONNECTS 1 TO 24 2 TO 20 3 TO 6 4 TO 24 5 TO 20 7 TO 32 8 TO 32 9 TO 28 10 TO 24 11 TO 20 12 TO 36 13 TO 28 14 TO 43 15 TO 39 16 TO 43 17 TO 39 18 TO 43 19 TO 39 20 TO 28 24 TO 32 28 TO 39 32 TO 36 36 TO 43

LEAD DATA LEAD COLOR 501 GRN 2901 RED/WHT 5901 GRN/WHT 502 GRN 2902 RED/WHT 508 GRN 505 GRN 2905 RED/WHT 503 GRN 2903 RED/WHT 506 GRN 2906 RED/WHT 510 GRN 2908 RED/WHT 511 GRN 2909 RED/WHT 512 GRN 2910 RED/WHT 2904 RED/WHT 504 GRN 2907 RED/WHT 507 GRN 509 GRN

LEFT TERMINAL DATA NO. PART # 1 062800-001 2 062800-001 3 062800-001 4 062800-001 5 062800-001 7 062800-001 8 062800-001 9 062800-001 10 062800-001 11 062800-001 12 062800-001 13 062800-001 14 062800-001 15 062800-001 16 062800-001 17 062800-001 18 062800-001 19 062800-001 20 062800-001 24 062800-001 28 062800-001 32 062800-001 36 062800-001

RIGHT TERMINAL DATA NO. PART # 24 062007-103 20 062007-103 6 062007-068 24 TO #24 20 TO #20 32 TO #32 32 TO #32 28 TO #28 24 TO #24 20 TO #20 36 TO #36 28 TO #28 43 TO #43 39 TO #39 43 TO #43 39 TO #39 43 TO #43 39 TO #39 28 062007-103 32 062007-103 39 062007-103 36 062007-103 43 062007-103

Option, Cold Store Model Additional Loom, Part 1 of 2

Connector insert

Connector insert

Connector insert

794588-T-GB

Connector insert

I To following page

doc-794588_e_2_3

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DIAGRAMS CONNECTS 1 TO 24 2 TO 20 3 TO 6 4 TO 24 5 TO 20 7 TO 32 8 TO 32 9 TO 28 10 TO 24 11 TO 20 12 TO 36 13 TO 28 14 TO 43 15 TO 39 16 TO 43 17 TO 39 18 TO 43 19 TO 39 20 TO 28 24 TO 32 28 TO 39 32 TO 36 36 TO 43

LEAD DATA LEAD COLOR 501 GRN 2901 RED/WHT 5901 GRN/WHT 502 GRN 2902 RED/WHT 508 GRN 505 GRN 2905 RED/WHT 503 GRN 2903 RED/WHT 506 GRN 2906 RED/WHT 510 GRN 2908 RED/WHT 511 GRN 2909 RED/WHT 512 GRN 2910 RED/WHT 2904 RED/WHT 504 GRN 2907 RED/WHT 507 GRN 509 GRN

LEFT TERMINAL DATA NO. PART # 1 062800-001 2 062800-001 3 062800-001 4 062800-001 5 062800-001 7 062800-001 8 062800-001 9 062800-001 10 062800-001 11 062800-001 12 062800-001 13 062800-001 14 062800-001 15 062800-001 16 062800-001 17 062800-001 18 062800-001 19 062800-001 20 062800-001 24 062800-001 28 062800-001 32 062800-001 36 062800-001

Option, Cold Store Model Additional Loom, Part 2 of 2

RIGHT TERMINAL DATA NO. PART # 24 062007-103 20 062007-103 6 062007-068 24 TO #24 20 TO #20 32 TO #32 32 TO #32 28 TO #28 24 TO #24 20 TO #20 36 TO #36 28 TO #28 43 TO #43 39 TO #39 43 TO #43 39 TO #39 43 TO #43 39 TO #39 28 062007-103 32 062007-103 39 062007-103 36 062007-103 43 062007-103

Housing insert

794588-T-GB

/ Connector insert Connector insert

To previous page

E Connector insert doc-794588_e_3_3

MS-DIA-2232

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DIAGRAMS Option, Cold Store Model Additional Loom, Heating Control Module

CONNECTS 1 TO 6 2 TO 3 4 TO 13 5 TO 15 7 TO 1 8 TO 12 9 TO 14 1 0 TO 2 11 TO 17 17 TO 15 16 TO 14

LEAD DATA LEAD COLOR 201 RED 501 GRN 2901 RED/WHT 5901 GRN/WHT 202 RED 203 RED 204 RED 514 GRN 5911 GRN/WHT 5912 GRN/WHT 205 RED

LEFT TERMINAL DATA NO. PART # 1 062007-116 2 062007-071 4 062704-004 5 062704-004 7 062007-021 8 062007-021 9 062007-021 10 062007-068 11 062007-068 17 TO #17 16 062007-110

RIGHT TERMINAL DATA NO. PART # 6 062007-021 3 062704-004 13 062007-021 15 TO #15 1 TO #1 12 062007-021 14 062007-048 2 TO #2 17 62007-110 15 62007-048 14 TO #14 810263_t-GB

Connector insert

doc-810263_b

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DIAGRAMS

Blank page

Printed in Germany

228

HYDRAULIC SCHEMATIC

Printed in Germany

229

Blank page

Printed in Germany

230

HYDRAULICS Lowering orifices

Free lift cylinder Tilt cylinder

Steering cylinder Lift cylinder LH

Lift cylinderRH 2

L

R

130 bar

1

3

CBV setting pressure 115 bar

Wire break safety devices C

D

E

Flow controller (Only available for lift heights above 5000 mm)

Orbitrol Dynamic steering signal, no steering signal (LS) without steering movement A

B

LS

1A 1B P

LS

T

2A

2B

Sideshifter

Sideshifter

3A

3A

3B

3B

4A

4B

CF

Steering RV 70 bar

Main RV 235 bar

Opto Encoder

Motor Suction filter

Priority valve dynamic LS

Lift

Tilt

Aux. function 1

Aux. function 1

Aux. function 2

With 2 auxiliary functions Pump Based on: 808819_2d_1_1

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Return filter MS-2.0-0000

231

HYDRAULICS

Blank page

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MS-2.0-0000

232