Crown SC3200 Series Forklift Service Repair Factory Manual INSTANT

Service Manual Wartungshandbuch Manuel de maintenance SC3000 Series UF.p65 06.04.99, 10:59 1

Printed in Germany TABLE OF CONTENT

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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

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Crown SC3200 Series Forklift Service Repair Factory Manual INSTANT

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