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Crown SC3018 Forklift Service Repair Manual

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Crown SC3018 Forklift Service Repair Manual

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

  2. TABLE OF CONTENT Printed in Germany

  3. TABLE OF CONTENT Table of content Table of content ........................................................................................................................................ IDX-2230-001 MA – SAFETY Safety Symbols used in the Manual.........................................................................................................MA-2230-001 General Maintenance and Repair Safety Notes.......................................................................................MA-2230-001 Maintenance and Repair ......................................................................................................................MA-2230-001 Before Leaving the Truck.....................................................................................................................MA-2230-002 Before Carrying out Work on the Truck..............................................................................................MA-2230-002 Before Operating the Truck .................................................................................................................MA-2230-002 Warnings and Labels on the Truck ..........................................................................................................MA-2230-002 ITD – INTRODUCTION Introduction ...............................................................................................................................................ITD-2230-001 General ..................................................................................................................................................ITD-2230-001 Using the Manual..................................................................................................................................ITD-2230-001 Page Numbers ......................................................................................................................................ITD-2230-003 Operating instruction ...........................................................................................................................ITD-2230-003 Service training ....................................................................................................................................ITD-2230-003 Replacement parts orders ...................................................................................................................ITD-2230-003 Truck Data Numbering Sheet ..............................................................................................................ITD-2230-004 Battery Options ....................................................................................................................................ITD-2230-005 M1 – LUBRICATION AND ADJUSTMENT Lubrication and Adjustment .................................................................................................................. M1.0-2230-001 Access to Components..................................................................................................................... M1.0-2230-001 Jacking up the Truck......................................................................................................................... M1.0-2230-004 Recommended Lubricants and Oils ................................................................................................ M1.1-1710-001 Lubricants....................................................................................................................................... M1.1-1710-001 Cold Store Trucks........................................................................................................................... M1.1-1710-001 Driver Participation ........................................................................................................................... M1.1-1710-001 Daily Maintenance Log...................................................................................................................... M1.1-1710-001 Inspection and Maintenance Schedule............................................................................................ M1.2-2230-001 Torques .............................................................................................................................................. M1.9-2230-001 M2 – HYDRAULICS Hydraulic Symbols ................................................................................................................................. M2.0-0000-001 Hydraulic System ................................................................................................................................... M2.1-2230-001 General ............................................................................................................................................... M2.1-2230-001 Operational Description.................................................................................................................... M2.1-2230-003 Idle Mode ....................................................................................................................................... M2.1-2230-003 Priority Valve .................................................................................................................................. M2.1-2230-003 Steering.......................................................................................................................................... M2.1-2230-003 Lifting.............................................................................................................................................. M2.1-2230-003 Tilting.............................................................................................................................................. M2.1-2230-003 Control Valve ..................................................................................................................................... M2.4-2230-001 Main Relief Valve Setting................................................................................................................ M2.4-2230-001 Maintenance and Repairs............................................................................................................... M2.4-2230-001 Pump Motor ....................................................................................................................................... M2.6-2230-001 Hydraulic Pump ................................................................................................................................. M2.6-2230-001 Commissioning............................................................................................................................... M2.6-2230-001 Bleeding ......................................................................................................................................... M2.6-2230-001 Oil Change ......................................................................................................................................... M2.6-2230-001 M3 – DRIVE UNIT Truck Drive System ................................................................................................................................ M3.0-2230-001 Gear Unit ............................................................................................................................................ M3.0-2230-001 Removal ......................................................................................................................................... M3.0-2230-001 Printed in Germany 01/99 IDX-2230-001

  4. TABLE OF CONTENT Drive Motor ........................................................................................................................................ M3.0-2230-001 Removal ......................................................................................................................................... M3.0-2230-001 Design ................................................................................................................................................ M3.1-2230-001 Spur wheel bevel gear assembly ..................................................................................................... M3.1-2230-001 Pre-assembly of the housing with flange shaft ............................................................................... M3.1-2230-001 Bevel gear spur wheel pinion shaft pre-assembly........................................................................... M3.1-2230-001 Spur wheel flange shaft assembly .................................................................................................. M3.1-2230-001 Bevel gear assembly ...................................................................................................................... M3.1-2230-002 Bevel pinion assembly.................................................................................................................... M3.1-2230-002 Flank tooth bearing ........................................................................................................................... M3.1-2230-003 Correcting the flank tooth bearing................................................................................................... M3.1-2230-003 Reducing the installation path of the conical pinion ........................................................................ M3.1-2230-003 Increasing the installation path of the conical pinion ....................................................................... M3.1-2230-003 Maintenance....................................................................................................................................... M3.1-2230-004 Adding oil........................................................................................................................................ M3.1-2230-004 Types of oil ..................................................................................................................................... M3.1-2230-004 Oil level .......................................................................................................................................... M3.1-2230-004 Oil change ...................................................................................................................................... M3.1-2230-004 M4 – ELECTRICS Electrical System.................................................................................................................................... M4.0-2230-001 Wire Colour Codes ............................................................................................................................ M4.0-2230-001 Abbreviations .................................................................................................................................... M4.0-2230-002 Electrical Symbols ............................................................................................................................ M4.0-2230-004 Electrical Components........................................................................................................................... M4.2-2230-001 Switch Functions............................................................................................................................... M4.2-2230-001 Brake Switch (BRS) ....................................................................................................................... M4.2-2230-001 Encoder (ENC), Encoder Module (EM) .......................................................................................... M4.2-2230-001 Accelerator Pedal Switch (ACS, POT1) ......................................................................................... M4.2-2230-001 Direction Indicator Switch (DIS)...................................................................................................... M4.2-2230-001 Handbrake Switch (HBS) ............................................................................................................... M4.2-2230-001 Raise Potentiometer (POT2) .......................................................................................................... M4.2-2230-001 Steering Axle Potentiometer (POT3) .............................................................................................. M4.2-2230-001 Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS).......................................................................... M4.2-2230-001 Emergency Disconnect .................................................................................................................. M4.2-2230-001 Key Switch (KYS)........................................................................................................................... M4.2-2230-001 Fuses (FU) ..................................................................................................................................... M4.2-2230-001 Seat Switch (SES).......................................................................................................................... M4.2-2230-002 Horn Switch (HNS) ......................................................................................................................... M4.2-2230-002 Electrical Components - Overview................................................................................................... M4.2-2230-002 Zapimos B1S 48/700 Controller ............................................................................................................. M4.3-2230-001 General ............................................................................................................................................... M4.3-2230-001 Main Features .................................................................................................................................... M4.3-2230-001 Protective Devices............................................................................................................................. M4.3-2230-001 Polarity Protection .......................................................................................................................... M4.3-2230-001 Wiring Errors .................................................................................................................................. M4.3-2230-001 Overheating.................................................................................................................................... M4.3-2230-001 Protection ....................................................................................................................................... M4.3-2230-001 Key Terms .......................................................................................................................................... M4.3-2230-001 Shunt or Shunt Resistor (+SH/-SH)................................................................................................ M4.3-2230-001 Volt Motor Negative (VMN)............................................................................................................. M4.3-2230-001 Functional Description...................................................................................................................... M4.3-2230-002 Acceleration / Delay Rate ............................................................................................................... M4.3-2230-002 Travel Switch.................................................................................................................................. M4.3-2230-002 Travel Switch Signal Response ...................................................................................................... M4.3-2230-002 Fault Log ........................................................................................................................................ M4.3-2230-002 Fault Identification .......................................................................................................................... M4.3-2230-002 Sparkless Contactors ..................................................................................................................... M4.3-2230-002 Printed in Germany 01/99 IDX-2230-002

  5. TABLE OF CONTENT Inversion Braking............................................................................................................................ M4.3-2230-002 Creep Mode.................................................................................................................................... M4.3-2230-002 Slow Travel..................................................................................................................................... M4.3-2230-002 Steering Controller ......................................................................................................................... M4.3-2230-002 45° Steering Angle.......................................................................................................................... M4.3-2230-003 MOSFET ........................................................................................................................................ M4.3-2230-003 Pedal Braking (Inversion Braking with Battery Supply Regeneration)............................................. M4.3-2230-003 Pulse Width Modulation (PWM)...................................................................................................... M4.3-2230-003 Ramp Start ..................................................................................................................................... M4.3-2230-003 Key Switch ..................................................................................................................................... M4.3-2230-003 Self Test ......................................................................................................................................... M4.3-2230-003 Inverse Travel Alarm....................................................................................................................... M4.3-2230-003 Seat Switch .................................................................................................................................... M4.3-2230-003 Current Limit................................................................................................................................... M4.3-2230-003 Overvoltage.................................................................................................................................... M4.3-2230-003 Overheating.................................................................................................................................... M4.3-2230-003 Low Voltage Reduction................................................................................................................... M4.3-2230-003 ZAPIMOS B1S 48/700 Traction Controller Connections................................................................. M4.3-2230-004 Programmer Connection "B" .......................................................................................................... M4.3-2230-005 Status LED "A" ............................................................................................................................... M4.3-2230-005 Status LED Diagnosis .................................................................................................................... M4.3-2230-005 Control Line Connections................................................................................................................. M4.3-2230-006 Traction Controller .......................................................................................................................... M4.3-2230-006 ZAPIMOS B1S 48/700 Pin Layout ..................................................................................................... M4.3-2230-007 Maintenance....................................................................................................................................... M4.3-2230-008 Cleaning the Traction Controller ..................................................................................................... M4.3-2230-008 Removing / Installing the Traction Controller ................................................................................. M4.3-2230-008 To remove ...................................................................................................................................... M4.3-2230-008 Installing the Traction Controller ..................................................................................................... M4.3-2230-009 Zapimos HP 350A Pump Controller ...................................................................................................... M4.3-2230-200 General ............................................................................................................................................... M4.3-2230-200 Protective Devices............................................................................................................................. M4.3-2230-200 Polarity Protection .......................................................................................................................... M4.3-2230-200 Wiring Errors .................................................................................................................................. M4.3-2230-200 Overheating.................................................................................................................................... M4.3-2230-200 Protection ....................................................................................................................................... M4.3-2230-200 Key Terms .......................................................................................................................................... M4.3-2230-200 Shunt or Shunt Resistor (+SH/-SH)................................................................................................ M4.3-2230-200 Volt Motor Negative (VMN)............................................................................................................. M4.3-2230-200 Functional Description...................................................................................................................... M4.3-2230-201 Acceleration / Delay Rate ............................................................................................................... M4.3-2230-201 Current Limit................................................................................................................................... M4.3-2230-201 Fault Identification .......................................................................................................................... M4.3-2230-201 Fault Log ........................................................................................................................................ M4.3-2230-201 Hydraulic Function Switch .............................................................................................................. M4.3-2230-201 Key Switch ..................................................................................................................................... M4.3-2230-201 Lift Cut-Out ..................................................................................................................................... M4.3-2230-201 Lift Potentiometer ........................................................................................................................... M4.3-2230-201 Lift Potentiometer Response .......................................................................................................... M4.3-2230-201 Low Voltage Reduction................................................................................................................... M4.3-2230-201 MOSFET ........................................................................................................................................ M4.3-2230-201 Overheating.................................................................................................................................... M4.3-2230-201 Overvoltage.................................................................................................................................... M4.3-2230-201 Pulse Width Modulation (PWM)...................................................................................................... M4.3-2230-201 Seat Switch .................................................................................................................................... M4.3-2230-202 Self Test ......................................................................................................................................... M4.3-2230-202 Steer Support ................................................................................................................................. M4.3-2230-202 Printed in Germany 01/99 IDX-2230-003

  6. TABLE OF CONTENT ZAPIMOS HP 350 A Pump Controller Connections ....................................................................... M4.3-2230-202 Programmer Connection "B" .......................................................................................................... M4.3-2230-203 Status LED "A" ............................................................................................................................... M4.3-2230-203 Status LED Diagnosis .................................................................................................................... M4.3-2230-203 ZAPIMOS HP 350 A Pin Layout........................................................................................................ M4.3-2230-204 Maintenance....................................................................................................................................... M4.3-2230-204 Cleaning the Pump Controller......................................................................................................... M4.3-2230-204 Removing / Installing the Pump Controller ..................................................................................... M4.3-2230-205 To remove ...................................................................................................................................... M4.3-2230-205 Installing the Pump Controller......................................................................................................... M4.3-2230-205 Programmer ............................................................................................................................................ M4.4-2230-001 General ............................................................................................................................................... M4.4-2230-001 Connecting the Programmer ............................................................................................................ M4.4-2230-003 Operating Menu ................................................................................................................................. M4.4-2230-003 General .......................................................................................................................................... M4.4-2230-003 Traction Controller Operating Menu ................................................................................................ M4.5-2230-001 Programmer Start Routine................................................................................................................ M4.5-2230-002 Traction Controller Menu Functions ..................................................................................................... M4.5-2230-003 PROGRAM Menu ............................................................................................................................... M4.5-2230-004 TESTER Menu.................................................................................................................................... M4.5-2230-005 ALARMS Menu................................................................................................................................... M4.5-2230-006 PROGRAM PEDAL Menu .................................................................................................................. M4.5-2230-007 CONFIG Menu .................................................................................................................................... M4.5-2230-008 Pump Controller Operating Menu .................................................................................................... M4.5-2230-009 Menu Functions Pump Controller ......................................................................................................... M4.5-2230-010 PROGRAM Menu ................................................................................................................................M4.5-2230-011 TESTER Menu.................................................................................................................................... M4.5-2230-012 ALARMS Menu................................................................................................................................... M4.5-2230-013 PROGRAM VACC Menu .................................................................................................................... M4.5-2230-014 CONFIG Menu .................................................................................................................................... M4.5-2230-015 Traction Controller Safety Test............................................................................................................ M4.20-2230-001 Pulse Monitor Trip Test (PMT) ........................................................................................................ M4.20-2230-001 Equipment .................................................................................................................................... M4.20-2230-001 Test .............................................................................................................................................. M4.20-2230-001 PMT Safety Test Wiring................................................................................................................... M4.20-2230-002 Battery ................................................................................................................................................... M4.25-2230-001 General ............................................................................................................................................. M4.25-2230-001 Operation ......................................................................................................................................... M4.25-2230-001 Reading the Electrolyte Level......................................................................................................... M4.25-2230-001 Replacing the Battery...................................................................................................................... M4.25-2230-001 Removing the Battery ..................................................................................................................... M4.25-2230-001 Charging the Battery ....................................................................................................................... M4.25-2230-001 Battery Discharge Indicator (BDI) ....................................................................................................... M4.30-2230-001 General ............................................................................................................................................. M4.30-2230-001 Adjusting the Battery Discharge Indicator .................................................................................... M4.30-2230-001 Traction / Pump Motor Maintenance ................................................................................................... M4.35-2230-001 Access.............................................................................................................................................. M4.35-2230-001 M5 – BRAKE Brake System.......................................................................................................................................... M5.0-2230-001 General ............................................................................................................................................... M5.0-2230-001 Operation ........................................................................................................................................... M5.0-2230-001 Replacing the Brake Disks and Linings........................................................................................... M5.0-2230-002 Preparation..................................................................................................................................... M5.0-2230-002 Brake Disk and Lining Dimensions ................................................................................................. M5.0-2230-003 Removing the Brake Disks and the Friction Plates (Fig. M0362).................................................... M5.0-2230-004 Installation ...................................................................................................................................... M5.0-2230-004 Removing the Handbrake Cable (Fig.M0366)................................................................................. M5.0-2230-006 Installation ...................................................................................................................................... M5.0-2230-006 Printed in Germany 01/99 IDX-2230-004

  7. TABLE OF CONTENT Adjusting the Operating Brake and Handbrake .............................................................................. M5.0-2230-006 Preparation..................................................................................................................................... M5.0-2230-006 Adjusting the Operating Brake Air Gap ........................................................................................... M5.0-2230-006 Operating Brake Test ........................................................................................................................ M5.0-2230-007 Handbrake Adjustment ..................................................................................................................... M5.0-2230-007 M6 – STEERING Steering ................................................................................................................................................... M6.0-2230-001 Hydraulic System .............................................................................................................................. M6.0-2230-001 Components ...................................................................................................................................... M6.0-2230-001 Removing the Steering Motor .......................................................................................................... M6.0-2230-002 Steering System Hydraulic Diagram................................................................................................ M6.0-2230-002 Steering Axle........................................................................................................................................... M6.1-2230-001 Design ................................................................................................................................................ M6.1-2230-001 Steering Drive Assembly .................................................................................................................. M6.1-2230-001 Wheel hub pre-assembly................................................................................................................ M6.1-2230-001 Steering knuckle pre-assembly ...................................................................................................... M6.1-2230-001 Steering knuckle and wheel hub assembly..................................................................................... M6.1-2230-001 Spur pinion wheel shaft pre-assembly ............................................................................................ M6.1-2230-002 Housing Pre-Assembly................................................................................................................... M6.1-2230-002 Setting the Bearing Play ................................................................................................................. M6.1-2230-003 Cylinder Pre-Assembly................................................................................................................... M6.1-2230-006 Fitting the Cylinders........................................................................................................................ M6.1-2230-006 Assembling the Axle Bracket to the Steering Drive......................................................................... M6.1-2230-006 Operational and Leak Test.............................................................................................................. M6.1-2230-006 Maintenance....................................................................................................................................... M6.1-2230-007 General .......................................................................................................................................... M6.1-2230-007 Gear Lubricant................................................................................................................................ M6.1-2230-007 Seals .............................................................................................................................................. M6.1-2230-007 M7 – MAST Mast ......................................................................................................................................................... M7.0-2230-001 Disassembly ...................................................................................................................................... M7.0-2230-001 Mast Roller Adjustment .................................................................................................................... M7.0-2230-001 Fork Carriage Roller Adjustment...................................................................................................... M7.0-2230-003 Mast Roller Adjustment .................................................................................................................... M7.0-2230-004 Checking the Mast Play .................................................................................................................... M7.0-2230-004 Lift Chain Test......................................................................................................................................... M7.5-2230-001 General ............................................................................................................................................... M7.5-2230-001 Maintenance....................................................................................................................................... M7.5-2230-001 Detailed Chain Testing ...................................................................................................................... M7.5-2230-002 Worn or Missing Plates................................................................................................................... M7.5-2230-002 Pitting and Corrosion ...................................................................................................................... M7.5-2230-002 Protruding or Turned Chain Pins .................................................................................................... M7.5-2230-002 Freedom of Movement and Worn Edges ........................................................................................ M7.5-2230-002 Measuring the Chain Elongation..................................................................................................... M7.5-2230-003 Chain Tension................................................................................................................................. M7.5-2230-003 Chain Anchor and Pulleys .............................................................................................................. M7.5-2230-003 Fork Tine Test .................................................................................................................................... M7.6-2230-001 General .......................................................................................................................................... M7.6-2230-001 Fork Identification ........................................................................................................................... M7.6-2230-001 Repairs........................................................................................................................................... M7.6-2230-001 Crack Inspection............................................................................................................................. M7.6-2230-001 Verticality Test ................................................................................................................................ M7.6-2230-002 Fork Blade Warping........................................................................................................................ M7.6-2230-002 Measuring the Fork Tip Width......................................................................................................... M7.6-2230-003 Fork Tine Height Difference ............................................................................................................ M7.6-2230-003 Fork Stop........................................................................................................................................ M7.6-2230-003 Wear............................................................................................................................................... M7.6-2230-004 Printed in Germany 01/99 IDX-2230-005

  8. TABLE OF CONTENT M8 – CYLINDERS Cylinders ................................................................................................................................................. M8.0-2230-001 General ............................................................................................................................................... M8.0-2230-001 Plunger Cylinders (Single-Acting Cylinders) .................................................................................. M8.0-2230-001 Piston Cylinder (Double-Acting Cylinder) ....................................................................................... M8.0-2230-002 Maintenance....................................................................................................................................... M8.0-2230-004 Inspection .......................................................................................................................................... M8.0-2230-004 Installing the Piston Seal .................................................................................................................. M8.0-2230-005 General .......................................................................................................................................... M8.0-2230-005 Rod Seal Disassembly Tool ............................................................................................................ M8.0-2230-005 Assembly of Small Rod Seals ........................................................................................................ M8.0-2230-005 Assembly of Large Rod Seals ........................................................................................................ M8.0-2230-005 DIA – ELECTRICAL DIAGRAMS Key............................................................................................................................................................. DIA-2230-001 Connectors .......................................................................................................................................... DIA-2230-001 Contactors ........................................................................................................................................... DIA-2230-001 Abbreviations ...................................................................................................................................... DIA-2230-001 Control Circuit .......................................................................................................................................... DIA-2230-002 Power Circuit ............................................................................................................................................ DIA-2230-003 Connectors ............................................................................................................................................... DIA-2230-004 Traction Controller .............................................................................................................................. DIA-2230-004 Pump Controller .................................................................................................................................. DIA-2230-005 Seat Switch and Steer Pot .................................................................................................................. DIA-2230-006 Control Levers ..................................................................................................................................... DIA-2230-007 B.D.I., Horn and Brake Switches ........................................................................................................ DIA-2230-008 Steer Column ....................................................................................................................................... DIA-2230-009 Star Points ................................................................................................................................................ DIA-2230-010 Panel Wiring.............................................................................................................................................. DIA-2230-011 Power Cables ............................................................................................................................................ DIA-2230-012 Part Numbers for Connectors and Looms ............................................................................................. DIA-2230-013 ZAPI Connectors ................................................................................................................................. DIA-2230-013 MOLEX Connectors............................................................................................................................. DIA-2230-013 DEUTSCH Connectors ........................................................................................................................ DIA-2230-013 Looms .................................................................................................................................................. DIA-2230-013 HYD – HYDRAULIC SCHEMATIC Hydraulic Schematic ...............................................................................................................................HYD-2230-001 Printed in Germany 01/99 IDX-2230-006

  9. SAFETY Printed in Germany

  10. SAFETY Safety Symbols used in the Manual General Maintenance and Repair Safety Notes To help guide you through the manual and to highlight particular danger areas, we have used graphic illustra- tions: DANGER Read the safety notices in the truck Maintenance and Operator's Manuals. DANGER Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. ? This symbol indicates life-threatening risks Failure to comply with this notice may result in severe or fatal injuries to yourself or other people. ? Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines. WARNING This symbol indicates the risk of serious injury and/or serious material damage. Maintenance and Repair 1. Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices. Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. ? 2. Only qualified and authorised personnel may carry out work on the truck. 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. CAUTION This symbol indicates the risk of minor injury and/or minor material damage. 4. To clean, use a non flammable, non combustable cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness. Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. ? 5. Keep the service area clean, dry and well-ventilated. 6. Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed. INFORMATION Contains additional information with supplementary notes and hints. 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. OPTION 8. Keep the truck clean. This will facilitate the location of loose or faulty components. These items relate to optional features not supplied with the standard version. OPTION 9. Make sure that capacity and data plates, warnings and labels are legible at all times. Printed in Germany REV.1 10/99 MA-2230-001 1

  11. SAFETY Warnings and Labels on the Truck 10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. During regular maintenance check that the warnings and labels on the truck are complete and legible. ? 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck. Clean any illegible labels. ? Before Leaving the Truck Replace any faulty or missing labels. ? Stop the truck. ? The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual. Lower the fork carriage fully. ? Apply the parking brake. ? Turn off the travel switch and remove the key. ? Block all wheels when parking on an uneven surface. ? Before Carrying out Work on the Truck Raise the truck to free the drive wheel. Press the Emergency Stop button and disconnect the battery. ? Prevent the truck from rolling away. ? Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping. ? Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others. ? Before Operating the Truck Check the safety devices. ? Get into the driver's seat. ? Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes. ? Printed in Germany 01/99 2 MA-2230-002

  12. INTRODUCTION Printed in Germany

  13. INTRODUCTION Introduction INFORMATION THIS BOOK IS NOT AN OPERATING MANU- AL. IT IS DESIGNED FOR SPECIALIST PERSONNEL WHO HAVE BEEN TRAINED AND AUTHORISED BY CROWN FOR THE WORK DESCRIBED HEREIN. This manual therefore contains fewer and less detailed danger warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all. General The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. It also contains troubleshooting sections which can be used to identify and remedy truck faults. Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French. Each language block in turn is divided into chapters and sections. The page numbers in the Maintenance Section are preceeded by an M. The table on the following page shows how the manual is structured. Printed in Germany 01/99 ITD-2230-001 1

  14. INTRODUCTION o i t c e S n s n i a M e t n a n c e S o i t c e n D e s p i r c o i t n I D X e l b a T f o C e t n o t n M A y t e f a S T I D o r t n I d o i t c u n M 1 L c i r b u o i t a n a n d u j d A t s m t n e M 2 H a r d y c i l u s M 3 v i r D e t i n U M 4 e l E c i r t c l a M 5 a r B k e M 6 n i r e e t S g M 7 M t s a M 8 n i l y C r e d D I A e l E c i r t c l a a r g a i D m s H Y D H a r d y c i l u S c h e c i t a m ITD001B-gb Printed in Germany 01/99 2 ITD-2230-002

  15. INTRODUCTION Page Numbers The page numbers are located on the lower left and right hand margins of each page and have the following form: M1.1-2230-001 X Identical for each language Section is only once in the manual M = Maintenance Chapter Page number Section Truck code z. B. 1.2 = Inspection and Maintenance Plan Operating instruction This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle. Service training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request. Replacement parts orders When ordering spare parts from this manual please always give the full description of the vehicle model as well as the order number. These details enable us to process your orders in an accurate, quick and reliable way. Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this series. Brochures can be obtained from your CROWN dealer or from the following address: CROWN Gabelstapler GmbH Moosacher Str. 52 D-80809 München Tel.: 089/93 00 20 Fax: 089/93 00 2-175 Printed in Germany 01/99 ITD-2230-003 3

  16. INTRODUCTION Truck Data Numbering Sheet 1.3 SC T L – 2 – 2 Capacity 1.3 = 1250 kg 1.6 = 1600 kg 1.8 = 1800 kg F o k r L e n g h t D a s h m m 1 9 0 0 2 1 0 0 0 3 1 1 5 0 Model designation SC = Sitdown Rider Counterbalance 4 1 2 0 0 5 1 2 2 0 6 6 0 0 7 8 0 0 T = Telescopic 8 1 3 7 0 L = Double, part free lift F = Double, full free lift T = Triple, full free lift 9 1 0 6 7 ITD002-gb a l l o C n i t f i L p s e g d g i e H g i e H h t t m ( m m ( m ) ) / h D a s h S C T L / S C T F 1 1 7 5 0 / 2 4 6 0 2 1 9 7 0 / 2 8 8 0 3 2 1 6 5 / 3 2 7 0 4 2 3 1 5 / 3 5 7 0 5 2 4 6 5 / 3 8 7 0 6 2 6 6 5 / 4 2 7 0 7 2 8 4 0 / 4 6 2 0 8 3 0 3 5 / 5 0 1 0 NOTE 9 3 3 4 0 / 5 6 2 0 FOR SPECIALS USE THE ACTUAL FIGURES FOR COLLAPSED / LIFT HEIGHT AND FORK LENGTH (SEE TABLES ITD002-GB AND ITD.003-GB). 1 0 3 4 8 5 / 5 9 1 0 D a s h S C T T 1 1 7 6 0 / 3 6 7 0 Example: 2 1 9 7 0 / 4 3 0 0 Truck with data 1.3SCTL-2-2 designates 3 2 1 6 5 / 4 8 8 5 4 2 3 1 5 / 5 3 3 5 Capacity 1250 kg ? 5 2 4 6 5 / 5 7 8 5 Sitdown Rider Counterbalance ? 6 2 6 6 5 / 6 3 8 5 7 2 8 4 0 / 6 9 1 0 Telescopic double part free lift mast ? 8 3 0 3 5 / 7 4 9 5 Collapsed height 1970 mm ? 9 1 9 9 3 / 4 3 6 8 1 0 2 0 4 4 / 4 5 2 1 Lift height 2880 mm ? 1 1 2 1 4 5 / 4 8 2 6 Fork length 1000 mm ? 1 2 2 5 6 9 / 6 0 9 1 3 ITD003-gb Printed in Germany 01/99 4 ITD-2230-004

  17. INTRODUCTION e t t a B r y O o i t p n s M o l e d o i t p O n A h T y p e ( m m ) D I N 4 3 5 3 1 A ( m m ) 3 3 0 6 0 0 4 4 1 1 8 8 x x 8 8 3 3 5 5 x x 6 6 2 2 7 7 S H S D o i t p O n 1 D 1 1 8 7 3 4 6 6 0 5 4 4 1 1 8 8 x x 8 8 3 3 5 5 x x 7 7 8 8 4 4 S H S D o i t p O n 1 h D S C 3 0 1 3 4 4 0 8 0 0 5 5 2 2 6 6 x x 8 8 3 3 5 5 x x 6 6 2 2 7 7 S H S D o i t p O n 2 D 1 2 9 5 4 6 8 2 0 0 5 5 2 2 6 6 x x 8 8 3 3 5 5 x x 7 7 8 8 4 4 S H S D o i t p O n 2 h D 4 4 0 8 0 0 5 5 2 2 6 6 x x 8 8 3 3 5 5 x x 6 6 2 2 7 7 S H S D o i t p O n 2 D 1 2 9 5 4 6 8 2 0 0 5 5 2 2 6 6 x x 8 8 3 3 5 5 x x 7 7 8 8 4 4 S H S D o i t p O n 2 h D S C 3 0 1 6 5 6 0 0 0 0 6 6 3 3 4 4 x x 8 8 3 3 5 5 x x 6 6 2 2 7 7 S H S D o i t p O n 3 D 1 4 0 3 6 7 0 7 0 5 6 6 3 3 4 4 x x 8 8 3 3 5 5 x x 7 7 8 8 4 4 S H S D o i t p O n 3 h D 5 6 0 0 0 0 6 6 3 3 4 4 x x 8 8 3 3 5 5 x x 6 6 2 2 7 7 S H S D o i t p O n 3 D S C 3 0 1 8 1 4 0 3 6 7 0 7 0 5 6 6 3 3 4 4 x x 8 8 3 3 5 5 x x 7 7 8 8 4 4 S H S D o i t p O n 3 h D ITD004-gb NOTE ALWAYS SPECIFY MODEL NO. WHEN ORDERING SPARE PARTS. Spare parts for model SC3013 option 2/2h correspond to model SC3016 option 2/2h. Spare parts for model SC3016 option 3/3h correspond to model SC3018 option 3/3h. Printed in Germany 01/99 ITD-2230-005 5

  18. LUBRICATION AND ADJUSTMENT Printed in Germany

  19. MAINTENANCE Lubrication and Adjustment Access to Components In the course of regular maintenance the contactor panel, drive unit, hydraulic system and electrical components in the chassis can be reached by removing or opening the panels. Fig. C: LH and RH panels (LH illustrated) Lift the side panel out of the attachment ? Fig. D: Steering column front panel Fig. B: Battery compartment lid Provides access to: Provides access to: Key switch ? Battery ? Direction switches ? Contactor panel including impulse controls ? Encoder ? Steering axle and potentiometer ? Wiring ? Hydraulic motor and pump ? Steering unit and distributor block ? CAUTION Hydraulic lines ? WHEN THE BATTERY COMPARTMENT LID IS OPENED IT CAN TIP OVER IF THE LID CENTRE OF GRAVITY MOVES OVER THE PIVOT POINT / ATTACHMENT POINT OF THE LID. To remove: Loosen two hex. socket screws ? Lift panel slightly and lever out at the bottom ? Access: Pull the handle on the front of the lid and open the battery compartment lid. Fig. E: Inner dashboard Provides access to: Handbrake ? Figs. B1 and B2 Battery display ? Provides access to: Wiring ? Hydraulic lines (Fig. B1) on the right hand side of the battery compartment. ? Hydraulic lines ? Cable duct (Fig. B2) on the left hand side of the battery compartment. To remove: ? Loosen 6 hex. socket screws ? Access: Remove panel ? Lift off the side panel ? Remove the battery ? Printed in Germany 01/99 M1.0-2230-001 1

  20. MAINTENANCE Fig. F: Valve and Control Handle Panel Fig. G: LH and RH base plate (RH illustrated) Provides access to: Provides access to: Valve block Brake pedal and mechanism ? ? Switch, potentiometer Brake ? ? Control handle mechanism Accelerator pedal / travel switch and potentiometer ? ? To remove: Tilt cylinder attachment (frame) ? Remove the base plate ? Valve block hydraulic lines ? Loosen the two hex. socket screws at the rear ? upper section. Wiring ? Remove the single hex. socket screw at the front below the base plate LH and RH drive motor ? ? To remove: Lift up the panel ? Loosen the single hex. socket screw on the RH base plate ? Lift out the LH and RH base plates. ? Printed in Germany 01/99 2 M1.0-2230-002

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  22. MAINTENANCE B1 M0258 B M0251 B2 M0252 D M0257 E M0254b A M0116 G F C M0253 M0256 M0259 Printed in Germany 01/99 M1.0-2230-003 3

  23. MAINTENANCE Jacking up the Truck WARNING ALWAYS SUPPORT A RAISED TRUCK WITH WOODEN BLOCKS OR OTHER APPROPRIATE EQUIPMENT TO RELIEVE THE JACK. Apply the jack as shown in Fig. M0262. The same procedure is used for raising the front section of the truck. M0262 Jack Wooden blocks Printed in Germany 01/99 4 M1.0-2230-004

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