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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Crown SC3013 SC3016 SC3018 Forklift Service Repair Manual
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Description
This Service Manual is an essential resource for maintaining and repairing the Crown SC3013 SC3016 SC3018 Forklift. It contains comprehensive technical data, diagrams, and a complete list of parts, making it invaluable for both professional mechanics and DIY enthusiasts.
- Safety
- Introduction
- Lubrication and Adjustment
- Hydraulics
- Drive Unit
- Electrics
- Brake
- Steering
- Mast
- Cylinders
- Electrical Diagrams
- Hydraulic Schematics
This manual is available in PDF format, compatible with all versions of Windows and Mac. It is presented in English and requires Adobe Reader for access. Whether you're working in the garage or looking to save on repair costs, this manual provides step-by-step instructions suitable for all skill levels.
