Service Manual
Wartungshandbuch
Manuel de maintenance SC3000 Series
UF.p65 06.04.99, 10:59 1
Printed in Germany
TABLE OF CONTENT
Printed in Germany
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Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-001
Table of content
Table of content ........................................................................................................................................ IDX-2230-001
MA – SAFETY
Safety Symbols used in the Manual ......................................................................................................... MA-2230-001
General Maintenance and Repair Safety Notes ....................................................................................... MA-2230-001
Maintenance and Repair ...................................................................................................................... MA-2230-001
Before Leaving the Truck ..................................................................................................................... MA-2230-002
Before Carrying out Work on the Truck .............................................................................................. MA-2230-002
Before Operating the Truck ................................................................................................................. MA-2230-002
Warnings and Labels on the Truck .......................................................................................................... MA-2230-002
ITD – INTRODUCTION
Introduction ............................................................................................................................................... ITD-2230-001
General .................................................................................................................................................. ITD-2230-001
Using the Manual .................................................................................................................................. ITD-2230-001
Page Numbers ...................................................................................................................................... ITD-2230-003
Operating instruction ........................................................................................................................... ITD-2230-003
Service training .................................................................................................................................... ITD-2230-003
Replacement parts orders ................................................................................................................... ITD-2230-003
Truck Data Numbering Sheet .............................................................................................................. ITD-2230-004
Battery Options .................................................................................................................................... ITD-2230-005
M1 – LUBRICATION AND ADJUSTMENT
Lubrication and Adjustment .................................................................................................................. M1.0-2230-001
Access to Components ..................................................................................................................... M1.0-2230-001
Jacking up the Truck ......................................................................................................................... M1.0-2230-004
Recommended Lubricants and Oils ................................................................................................ M1.1-1710-001
Lubricants ....................................................................................................................................... M1.1-1710-001
Cold Store Trucks ........................................................................................................................... M1.1-1710-001
Driver Participation ........................................................................................................................... M1.1-1710-001
Daily Maintenance Log ...................................................................................................................... M1.1-1710-001
Inspection and Maintenance Schedule ............................................................................................ M1.2-2230-001
Torques .............................................................................................................................................. M1.9-2230-001
M2 – HYDRAULICS
Hydraulic Symbols ................................................................................................................................. M2.0-0000-001
Hydraulic System ................................................................................................................................... M2.1-2230-001
General ............................................................................................................................................... M2.1-2230-001
Operational Description .................................................................................................................... M2.1-2230-003
Idle Mode ....................................................................................................................................... M2.1-2230-003
Priority Valve .................................................................................................................................. M2.1-2230-003
Steering .......................................................................................................................................... M2.1-2230-003
Lifting .............................................................................................................................................. M2.1-2230-003
Tilting .............................................................................................................................................. M2.1-2230-003
Control Valve ..................................................................................................................................... M2.4-2230-001
Main Relief Valve Setting ................................................................................................................ M2.4-2230-001
Maintenance and Repairs ............................................................................................................... M2.4-2230-001
Pump Motor ....................................................................................................................................... M2.6-2230-001
Hydraulic Pump ................................................................................................................................. M2.6-2230-001
Commissioning ............................................................................................................................... M2.6-2230-001
Bleeding ......................................................................................................................................... M2.6-2230-001
Oil Change ......................................................................................................................................... M2.6-2230-001
M3 – DRIVE UNIT
Truck Drive System ................................................................................................................................ M3.0-2230-001
Gear Unit ............................................................................................................................................ M3.0-2230-001
Removal ......................................................................................................................................... M3.0-2230-001
Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-002
Drive Motor ........................................................................................................................................ M3.0-2230-001
Removal ......................................................................................................................................... M3.0-2230-001
Design ................................................................................................................................................ M3.1-2230-001
Spur wheel bevel gear assembly ..................................................................................................... M3.1-2230-001
Pre-assembly of the housing with flange shaft ............................................................................... M3.1-2230-001
Bevel gear spur wheel pinion shaft pre-assembly ........................................................................... M3.1-2230-001
Spur wheel flange shaft assembly .................................................................................................. M3.1-2230-001
Bevel gear assembly ...................................................................................................................... M3.1-2230-002
Bevel pinion assembly .................................................................................................................... M3.1-2230-002
Flank tooth bearing ........................................................................................................................... M3.1-2230-003
Correcting the flank tooth bearing ................................................................................................... M3.1-2230-003
Reducing the installation path of the conical pinion ........................................................................ M3.1-2230-003
Increasing the installation path of the conical pinion ....................................................................... M3.1-2230-003
Maintenance ....................................................................................................................................... M3.1-2230-004
Adding oil ........................................................................................................................................ M3.1-2230-004
Types of oil ..................................................................................................................................... M3.1-2230-004
Oil level .......................................................................................................................................... M3.1-2230-004
Oil change ...................................................................................................................................... M3.1-2230-004
M4 – ELECTRICS
Electrical System .................................................................................................................................... M4.0-2230-001
Wire Colour Codes ............................................................................................................................ M4.0-2230-001
Abbreviations .................................................................................................................................... M4.0-2230-002
Electrical Symbols ............................................................................................................................ M4.0-2230-004
Electrical Components ........................................................................................................................... M4.2-2230-001
Switch Functions ............................................................................................................................... M4.2-2230-001
Brake Switch (BRS) ....................................................................................................................... M4.2-2230-001
Encoder (ENC), Encoder Module (EM) .......................................................................................... M4.2-2230-001
Accelerator Pedal Switch (ACS, POT1) ......................................................................................... M4.2-2230-001
Direction Indicator Switch (DIS) ...................................................................................................... M4.2-2230-001
Handbrake Switch (HBS) ............................................................................................................... M4.2-2230-001
Raise Potentiometer (POT2) .......................................................................................................... M4.2-2230-001
Steering Axle Potentiometer (POT3) .............................................................................................. M4.2-2230-001
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) .......................................................................... M4.2-2230-001
Emergency Disconnect .................................................................................................................. M4.2-2230-001
Key Switch (KYS) ........................................................................................................................... M4.2-2230-001
Fuses (FU) ..................................................................................................................................... M4.2-2230-001
Seat Switch (SES) .......................................................................................................................... M4.2-2230-002
Horn Switch (HNS) ......................................................................................................................... M4.2-2230-002
Electrical Components - Overview ................................................................................................... M4.2-2230-002
Zapimos B1S 48/700 Controller ............................................................................................................. M4.3-2230-001
General ............................................................................................................................................... M4.3-2230-001
Main Features .................................................................................................................................... M4.3-2230-001
Protective Devices ............................................................................................................................. M4.3-2230-001
Polarity Protection .......................................................................................................................... M4.3-2230-001
Wiring Errors .................................................................................................................................. M4.3-2230-001
Overheating .................................................................................................................................... M4.3-2230-001
Protection ....................................................................................................................................... M4.3-2230-001
Key Terms .......................................................................................................................................... M4.3-2230-001
Shunt or Shunt Resistor (+SH/-SH) ................................................................................................ M4.3-2230-001
Volt Motor Negative (VMN) ............................................................................................................. M4.3-2230-001
Functional Description ...................................................................................................................... M4.3-2230-002
Acceleration / Delay Rate ............................................................................................................... M4.3-2230-002
Travel Switch .................................................................................................................................. M4.3-2230-002
Travel Switch Signal Response ...................................................................................................... M4.3-2230-002
Fault Log ........................................................................................................................................ M4.3-2230-002
Fault Identification .......................................................................................................................... M4.3-2230-002
Sparkless Contactors ..................................................................................................................... M4.3-2230-002
Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-003
Inversion Braking ............................................................................................................................ M4.3-2230-002
Creep Mode .................................................................................................................................... M4.3-2230-002
Slow Travel ..................................................................................................................................... M4.3-2230-002
Steering Controller ......................................................................................................................... M4.3-2230-002
45° Steering Angle .......................................................................................................................... M4.3-2230-003
MOSFET ........................................................................................................................................ M4.3-2230-003
Pedal Braking (Inversion Braking with Battery Supply Regeneration) ............................................. M4.3-2230-003
Pulse Width Modulation (PWM) ...................................................................................................... M4.3-2230-003
Ramp Start ..................................................................................................................................... M4.3-2230-003
Key Switch ..................................................................................................................................... M4.3-2230-003
Self Test ......................................................................................................................................... M4.3-2230-003
Inverse Travel Alarm ....................................................................................................................... M4.3-2230-003
Seat Switch .................................................................................................................................... M4.3-2230-003
Current Limit ................................................................................................................................... M4.3-2230-003
Overvoltage .................................................................................................................................... M4.3-2230-003
Overheating .................................................................................................................................... M4.3-2230-003
Low Voltage Reduction ................................................................................................................... M4.3-2230-003
ZAPIMOS B1S 48/700 Traction Controller Connections ................................................................. M4.3-2230-004
Programmer Connection "B" .......................................................................................................... M4.3-2230-005
Status LED "A" ............................................................................................................................... M4.3-2230-005
Status LED Diagnosis .................................................................................................................... M4.3-2230-005
Control Line Connections ................................................................................................................. M4.3-2230-006
Traction Controller .......................................................................................................................... M4.3-2230-006
ZAPIMOS B1S 48/700 Pin Layout ..................................................................................................... M4.3-2230-007
Maintenance ....................................................................................................................................... M4.3-2230-008
Cleaning the Traction Controller ..................................................................................................... M4.3-2230-008
Removing / Installing the Traction Controller ................................................................................. M4.3-2230-008
To remove ...................................................................................................................................... M4.3-2230-008
Installing the Traction Controller ..................................................................................................... M4.3-2230-009
Zapimos HP 350A Pump Controller ...................................................................................................... M4.3-2230-200
General ............................................................................................................................................... M4.3-2230-200
Protective Devices ............................................................................................................................. M4.3-2230-200
Polarity Protection .......................................................................................................................... M4.3-2230-200
Wiring Errors .................................................................................................................................. M4.3-2230-200
Overheating .................................................................................................................................... M4.3-2230-200
Protection ....................................................................................................................................... M4.3-2230-200
Key Terms .......................................................................................................................................... M4.3-2230-200
Shunt or Shunt Resistor (+SH/-SH) ................................................................................................ M4.3-2230-200
Volt Motor Negative (VMN) ............................................................................................................. M4.3-2230-200
Functional Description ...................................................................................................................... M4.3-2230-201
Acceleration / Delay Rate ............................................................................................................... M4.3-2230-201
Current Limit ................................................................................................................................... M4.3-2230-201
Fault Identification .......................................................................................................................... M4.3-2230-201
Fault Log ........................................................................................................................................ M4.3-2230-201
Hydraulic Function Switch .............................................................................................................. M4.3-2230-201
Key Switch ..................................................................................................................................... M4.3-2230-201
Lift Cut-Out ..................................................................................................................................... M4.3-2230-201
Lift Potentiometer ........................................................................................................................... M4.3-2230-201
Lift Potentiometer Response .......................................................................................................... M4.3-2230-201
Low Voltage Reduction ................................................................................................................... M4.3-2230-201
MOSFET ........................................................................................................................................ M4.3-2230-201
Overheating .................................................................................................................................... M4.3-2230-201
Overvoltage .................................................................................................................................... M4.3-2230-201
Pulse Width Modulation (PWM) ...................................................................................................... M4.3-2230-201
Seat Switch .................................................................................................................................... M4.3-2230-202
Self Test ......................................................................................................................................... M4.3-2230-202
Steer Support ................................................................................................................................. M4.3-2230-202
Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-004
ZAPIMOS HP 350 A Pump Controller Connections ....................................................................... M4.3-2230-202
Programmer Connection "B" .......................................................................................................... M4.3-2230-203
Status LED "A" ............................................................................................................................... M4.3-2230-203
Status LED Diagnosis .................................................................................................................... M4.3-2230-203
ZAPIMOS HP 350 A Pin Layout ........................................................................................................ M4.3-2230-204
Maintenance ....................................................................................................................................... M4.3-2230-204
Cleaning the Pump Controller ......................................................................................................... M4.3-2230-204
Removing / Installing the Pump Controller ..................................................................................... M4.3-2230-205
To remove ...................................................................................................................................... M4.3-2230-205
Installing the Pump Controller ......................................................................................................... M4.3-2230-205
Programmer ............................................................................................................................................ M4.4-2230-001
General ............................................................................................................................................... M4.4-2230-001
Connecting the Programmer ............................................................................................................ M4.4-2230-003
Operating Menu ................................................................................................................................. M4.4-2230-003
General .......................................................................................................................................... M4.4-2230-003
Traction Controller Operating Menu ................................................................................................ M4.5-2230-001
Programmer Start Routine ................................................................................................................ M4.5-2230-002
Traction Controller Menu Functions ..................................................................................................... M4.5-2230-003
PROGRAM Menu ............................................................................................................................... M4.5-2230-004
TESTER Menu .................................................................................................................................... M4.5-2230-005
ALARMS Menu ................................................................................................................................... M4.5-2230-006
PROGRAM PEDAL Menu .................................................................................................................. M4.5-2230-007
CONFIG Menu .................................................................................................................................... M4.5-2230-008
Pump Controller Operating Menu .................................................................................................... M4.5-2230-009
Menu Functions Pump Controller ......................................................................................................... M4.5-2230-010
PROGRAM Menu ................................................................................................................................ M4.5-2230-011
TESTER Menu .................................................................................................................................... M4.5-2230-012
ALARMS Menu ................................................................................................................................... M4.5-2230-013
PROGRAM VACC Menu .................................................................................................................... M4.5-2230-014
CONFIG Menu .................................................................................................................................... M4.5-2230-015
Traction Controller Safety Test ............................................................................................................ M4.20-2230-001
Pulse Monitor Trip Test (PMT) ........................................................................................................ M4.20-2230-001
Equipment .................................................................................................................................... M4.20-2230-001
Test .............................................................................................................................................. M4.20-2230-001
PMT Safety Test Wiring ................................................................................................................... M4.20-2230-002
Battery ................................................................................................................................................... M4.25-2230-001
General ............................................................................................................................................. M4.25-2230-001
Operation ......................................................................................................................................... M4.25-2230-001
Reading the Electrolyte Level ......................................................................................................... M4.25-2230-001
Replacing the Battery ...................................................................................................................... M4.25-2230-001
Removing the Battery ..................................................................................................................... M4.25-2230-001
Charging the Battery ....................................................................................................................... M4.25-2230-001
Battery Discharge Indicator (BDI) ....................................................................................................... M4.30-2230-001
General ............................................................................................................................................. M4.30-2230-001
Adjusting the Battery Discharge Indicator .................................................................................... M4.30-2230-001
Traction / Pump Motor Maintenance ................................................................................................... M4.35-2230-001
Access .............................................................................................................................................. M4.35-2230-001
M5 – BRAKE
Brake System .......................................................................................................................................... M5.0-2230-001
General ............................................................................................................................................... M5.0-2230-001
Operation ........................................................................................................................................... M5.0-2230-001
Replacing the Brake Disks and Linings ........................................................................................... M5.0-2230-002
Preparation ..................................................................................................................................... M5.0-2230-002
Brake Disk and Lining Dimensions ................................................................................................. M5.0-2230-003
Removing the Brake Disks and the Friction Plates (Fig. M0362) .................................................... M5.0-2230-004
Installation ...................................................................................................................................... M5.0-2230-004
Removing the Handbrake Cable (Fig.M0366) ................................................................................. M5.0-2230-006
Installation ...................................................................................................................................... M5.0-2230-006
Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-005
Adjusting the Operating Brake and Handbrake .............................................................................. M5.0-2230-006
Preparation ..................................................................................................................................... M5.0-2230-006
Adjusting the Operating Brake Air Gap ........................................................................................... M5.0-2230-006
Operating Brake Test ........................................................................................................................ M5.0-2230-007
Handbrake Adjustment ..................................................................................................................... M5.0-2230-007
M6 – STEERING
Steering ................................................................................................................................................... M6.0-2230-001
Hydraulic System .............................................................................................................................. M6.0-2230-001
Components ...................................................................................................................................... M6.0-2230-001
Removing the Steering Motor .......................................................................................................... M6.0-2230-002
Steering System Hydraulic Diagram ................................................................................................ M6.0-2230-002
Steering Axle ........................................................................................................................................... M6.1-2230-001
Design ................................................................................................................................................ M6.1-2230-001
Steering Drive Assembly .................................................................................................................. M6.1-2230-001
Wheel hub pre-assembly ................................................................................................................ M6.1-2230-001
Steering knuckle pre-assembly ...................................................................................................... M6.1-2230-001
Steering knuckle and wheel hub assembly ..................................................................................... M6.1-2230-001
Spur pinion wheel shaft pre-assembly ............................................................................................ M6.1-2230-002
Housing Pre-Assembly ................................................................................................................... M6.1-2230-002
Setting the Bearing Play ................................................................................................................. M6.1-2230-003
Cylinder Pre-Assembly ................................................................................................................... M6.1-2230-006
Fitting the Cylinders ........................................................................................................................ M6.1-2230-006
Assembling the Axle Bracket to the Steering Drive ......................................................................... M6.1-2230-006
Operational and Leak Test .............................................................................................................. M6.1-2230-006
Maintenance ....................................................................................................................................... M6.1-2230-007
General .......................................................................................................................................... M6.1-2230-007
Gear Lubricant ................................................................................................................................ M6.1-2230-007
Seals .............................................................................................................................................. M6.1-2230-007
M7 – MAST
Mast ......................................................................................................................................................... M7.0-2230-001
Disassembly ...................................................................................................................................... M7.0-2230-001
Mast Roller Adjustment .................................................................................................................... M7.0-2230-001
Fork Carriage Roller Adjustment ...................................................................................................... M7.0-2230-003
Mast Roller Adjustment .................................................................................................................... M7.0-2230-004
Checking the Mast Play .................................................................................................................... M7.0-2230-004
Lift Chain Test ......................................................................................................................................... M7.5-2230-001
General ............................................................................................................................................... M7.5-2230-001
Maintenance ....................................................................................................................................... M7.5-2230-001
Detailed Chain Testing ...................................................................................................................... M7.5-2230-002
Worn or Missing Plates ................................................................................................................... M7.5-2230-002
Pitting and Corrosion ...................................................................................................................... M7.5-2230-002
Protruding or Turned Chain Pins .................................................................................................... M7.5-2230-002
Freedom of Movement and Worn Edges ........................................................................................ M7.5-2230-002
Measuring the Chain Elongation ..................................................................................................... M7.5-2230-003
Chain Tension ................................................................................................................................. M7.5-2230-003
Chain Anchor and Pulleys .............................................................................................................. M7.5-2230-003
Fork Tine Test .................................................................................................................................... M7.6-2230-001
General .......................................................................................................................................... M7.6-2230-001
Fork Identification ........................................................................................................................... M7.6-2230-001
Repairs ........................................................................................................................................... M7.6-2230-001
Crack Inspection ............................................................................................................................. M7.6-2230-001
Verticality Test ................................................................................................................................ M7.6-2230-002
Fork Blade Warping ........................................................................................................................ M7.6-2230-002
Measuring the Fork Tip Width ......................................................................................................... M7.6-2230-003
Fork Tine Height Difference ............................................................................................................ M7.6-2230-003
Fork Stop ........................................................................................................................................ M7.6-2230-003
Wear ............................................................................................................................................... M7.6-2230-004
Printed in Germany
01/99
TABLE OF CONTENT
IDX-2230-006
M8 – CYLINDERS
Cylinders ................................................................................................................................................. M8.0-2230-001
General ............................................................................................................................................... M8.0-2230-001
Plunger Cylinders (Single-Acting Cylinders) .................................................................................. M8.0-2230-001
Piston Cylinder (Double-Acting Cylinder) ....................................................................................... M8.0-2230-002
Maintenance ....................................................................................................................................... M8.0-2230-004
Inspection .......................................................................................................................................... M8.0-2230-004
Installing the Piston Seal .................................................................................................................. M8.0-2230-005
General .......................................................................................................................................... M8.0-2230-005
Rod Seal Disassembly Tool ............................................................................................................ M8.0-2230-005
Assembly of Small Rod Seals ........................................................................................................ M8.0-2230-005
Assembly of Large Rod Seals ........................................................................................................ M8.0-2230-005
DIA – ELECTRICAL DIAGRAMS
Key ............................................................................................................................................................. DIA-2230-001
Connectors .......................................................................................................................................... DIA-2230-001
Contactors ........................................................................................................................................... DIA-2230-001
Abbreviations ...................................................................................................................................... DIA-2230-001
Control Circuit .......................................................................................................................................... DIA-2230-002
Power Circuit ............................................................................................................................................ DIA-2230-003
Connectors ............................................................................................................................................... DIA-2230-004
Traction Controller .............................................................................................................................. DIA-2230-004
Pump Controller .................................................................................................................................. DIA-2230-005
Seat Switch and Steer Pot .................................................................................................................. DIA-2230-006
Control Levers ..................................................................................................................................... DIA-2230-007
B.D.I., Horn and Brake Switches ........................................................................................................ DIA-2230-008
Steer Column ....................................................................................................................................... DIA-2230-009
Star Points ................................................................................................................................................ DIA-2230-010
Panel Wiring .............................................................................................................................................. DIA-2230-011
Power Cables ............................................................................................................................................ DIA-2230-012
Part Numbers for Connectors and Looms ............................................................................................. DIA-2230-013
ZAPI Connectors ................................................................................................................................. DIA-2230-013
MOLEX Connectors ............................................................................................................................. DIA-2230-013
DEUTSCH Connectors ........................................................................................................................ DIA-2230-013
Looms .................................................................................................................................................. DIA-2230-013
HYD – HYDRAULIC SCHEMATIC
Hydraulic Schematic ............................................................................................................................... HYD-2230-001
Printed in Germany
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