Crown SC3200 Series Forklift Service Repair Manual

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

REVISION Overview of Revisions: Page 3.... Rev.1 04/00..........General corrections and additions to the text. ..............................................Reference to authorised service personnel added. Chap. MA Rev. 01/99 ............now Rev. 03/04 1. DANGER box, ..............................................warning: Failure to comply with this notice may ..............................................result in severe or fatal injuries to yourself or other people. SC3200 03/2004 • Printed in Germany MS-REV-2232 A

TABLE OF CONTENT Printed in Germany I

TABLE OF CONTENT Table of Content MA – SAFETY Safety Symbols used in the Manual...................................... 3 ...........................N/A ................................ 03/04 PAGE SER-NO. CUT REV. ITD – INTRODUCTION General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair ................................................ 3 Before Leaving the Truck ................................................ 4 Before Carrying out Work on the Truck.......................... 4 Before Operating the Truck............................................. 4 Warnings and Labels on the Truck ........................................ 4 General..................................................................................... 7 Operating Instructions .................................................... 7 Service Training .............................................................. 7 Ordering Spare Parts...................................................... 7 Using the Manual ............................................................ 7 Model-Number ......................................................................... 8 PAGE SER-N0. CUT REV. M1 – LUBRICATION AND ADJUSTMENT Lifting the Truck....................................................................... 11 Lifting by Crane............................................................... 11 Lifting by another truck ................................................... 11 Towing the Truck ..................................................................... 12 Jacking up the Truck............................................................... 12 Counterweight......................................................................... 13 Disassembly .................................................................... 13 Assembly .................................................................... 14 Lubrication and Adjustment .................................................. 15 Component Access......................................................... 15 Recommended Lubricants and Oils .............................. 18 Lubricants ................................................................... 18 Cold Store Truck Lubricants........................................ 18 Taking the truck out of service ....................................... 18 Bringing the truck back into service............................ 18 Lubricant Points and Intervals............................................... 20 Inspection and Maintenance Schedule................................. 21 Daily Maintenance (or every 8 service hours) .............. 22 Monthly Maintenance or every 100 service hours ........ 24 3-Monthly Maintenance (or every 250 service hours) .. 26 6-Monthly Maintenance (or every 500 service hours) .. 28 Annual Maintenance (or every 1000 service hours)..... 28 2-Yearly Maintenance (or every 2000 service hours)... 28 Torque Requirements ............................................................. 30 Standard Torque Tables .................................................. 30 Special Torque Tables..................................................... 34 PAGE SER-N0. CUT REV. M2 – HYDRAULICS Hydraulic Symbols.................................................................. 41 Valve Block ...................................................................... 45 Pump motor..................................................................... 45 Hydraulic pump ............................................................... 45 Commissioning ........................................................... 45 Bleeding ...................................................................... 45 Oil Change ...................................................................... 45 Bleeding the hydraulic system .............................................. 46 Bleeding the tilt cylinders ............................................... 46 Bleeding the free lift cylinder.......................................... 46 PAGE SER-N0. CUT REV. SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232 III

TABLE OF CONTENT M2 – HYDRAULICS Bleeding the lift cylinders ............................................... 46 Flushing the cylinders..................................................... 47 Drift Tests................................................................................. 47 Lift cylinder drift test ....................................................... 47 Tilt cylinder drift test ....................................................... 47 Steer unit drift test .......................................................... 47 Overload Valves (RV) .............................................................. 48 PAGE SER-N0. CUT REV. M3 – DRIVE UNIT Drive Unit ................................................................................. 51 Gear Unit ......................................................................... 51 Disassembly ............................................................... 51 Disassembly ............................................................... 51 Assembly .................................................................... 51 General............................................................................ 53 Dismantling the Gear Unit...................................................... 53 Gear Unit Assembly ................................................................ 53 Pre-assembly of the housing with flange shaft ........... 53 Bevel gear spur wheel pinion shaft pre-assembly ...... 53 Spur wheel flange shaft assembly .............................. 53 Bevel gear assembly................................................... 54 Bevel pinion assembly ................................................ 54 Flank tooth bearing ..................................................... 55 Correcting the flank tooth bearing .............................. 55 Reducing the installation path of the conical pinion . 55 Maintenance.................................................................... 55 Adding oil .................................................................... 55 Types of oil .................................................................. 55 Oil level ....................................................................... 55 Oil change................................................................... 55 PAGE SER-N0. CUT REV. M4 – ELEKTRICS Electrics - General .................................................................. 59 Wire Colour Codes ......................................................... 59 Abbreviations .................................................................. 60 Electrical Symbols .......................................................... 61 Electrical Components ........................................................... 63 Switch Functions............................................................. 63 Brake Switch (BRS) .................................................... 63 Encoder (ENC), Encoder Module (EM) ...................... 63 Accelerator Pedal Switch (ACS, POT1) ...................... 63 Direction Indicator Switch (DIS).................................. 63 Handbrake Switch (HBS) ............................................ 63 Raise Potentiometer (POT2)....................................... 63 Steering Axle Potentiometer (POT3) .......................... 63 Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) ..... 63 Emergency Disconnect............................................... 63 Key Switch (KYS)........................................................ 63 Fuses (FU) .................................................................. 63 Seat Switch (SES) ...................................................... 64 Electrical Components - Overview ............................. 64 Horn Switch (HNS) ..................................................... 64 Electrical Board............................................................... 65 Zapimos B1S 48/700 Controller ............................................. 67 General............................................................................ 67 Protective Devices .......................................................... 67 Polarity Protection....................................................... 67 PAGE SER-N0. CUT REV. MS-IDX-2232 SC3200 03/2004 • Printed in Germany IV

TABLE OF CONTENT M4 – ELEKTRICS Wiring Errors............................................................... 67 Overheating ................................................................ 67 Protection.................................................................... 67 Key Terms........................................................................ 67 Shunt or Shunt Resistor (+SH/-SH)............................ 67 Volt Motor Negative (VMN) ......................................... 67 Functional Description.................................................... 67 Acceleration / Delay Rate ........................................... 67 Travel Switch ............................................................... 67 Travel Switch Signal Response .................................. 67 Fault Log ..................................................................... 67 Fault Identification....................................................... 67 Sparkless Contactors ................................................. 68 Inversion Braking ........................................................ 68 Creep Mode ................................................................ 68 Slow Travel .................................................................. 68 Steering Controller...................................................... 68 45° Steering Angle...................................................... 68 Pedal Braking (Inversion Braking with Battery Supply Regeneration) 68 Ramp Start.................................................................. 68 Key Switch .................................................................. 68 Self Test ...................................................................... 68 Reverse Travel Alarm ........................................ 68 Seat Switch ................................................................. 69 Current Limit ............................................................... 69 Overvoltage ................................................................ 69 Overheating ................................................................ 69 Low Voltage Reduction ............................................... 69 ZAPIMOS B1S 48/700 Traction Controller Connections70 ZAPIMOS B1S 48/700 Pin Layout .............................. 71 Programmer Connection "B"....................................... 73 Status LED "A"............................................................ 73 Status LED Diagnosis................................................. 73 ZAPIMOS HP 350A Pump Controller ..................................... 74 General............................................................................ 74 Protective Devices .......................................................... 74 Polarity Protection....................................................... 74 Wiring Errors............................................................... 74 Overheating ................................................................ 74 Protection.................................................................... 74 Key Terms........................................................................ 74 Shunt or Shunt Resistor (+SH/-SH)............................ 74 Volt Motor Negative (VMN) ......................................... 74 Functional Description.................................................... 75 Acceleration / Delay Rate ........................................... 75 Hydraulic Switches ..................................................... 75 Lift Cutout ................................................................... 75 Lift potentiometer ........................................................ 75 Lift Potentiometer Response ...................................... 75 Fault Log ..................................................................... 75 Fault Identification....................................................... 75 Steering Support......................................................... 75 Key Switch .................................................................. 75 Self Test ...................................................................... 75 Current Limit ............................................................... 75 Overvoltage ................................................................ 75 Overtemperature......................................................... 75 PAGE SER-N0. CUT REV. SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232 V

TABLE OF CONTENT M4 – ELEKTRICS Low Voltage Reduction ............................................... 75 ZAPIMOS HP 350A Pump Controller Connections ...... 76 ZAPIMOS HP 350 A Pin Layout..................................... 77 Pump Controller, LED error code................................... 78 Programmer Connection "B"....................................... 78 Status LED "A"............................................................ 78 Status LED Diagnosis................................................. 78 Pump Controller Removal........................................... 79 Pump Controller Assembly ......................................... 79 Traction Controller Removal ....................................... 79 Traction Controller Assembly ...................................... 80 Programmer............................................................................. 81 General............................................................................ 81 Display Window........................................................... 82 Operating Keys ........................................................... 82 Connecting the Programmer .......................................... 83 Operating Menu .............................................................. 83 General ....................................................................... 83 Traction Controller Operating Menu............................... 84 Programmer Start Routine ............................................. 85 Traction Controller Menu Functions ..................................... 86 PROGRAM ...................................................................... 86 TESTER........................................................................... 86 ALARMS .......................................................................... 86 PROGRAM PEDAL ......................................................... 86 CONFIG........................................................................... 86 PROGRAM Menu............................................................ 87 TESTER Menu ................................................................ 88 ALARMS Menu................................................................ 89 PROGRAM PEDAL Menu............................................... 91 CONFIG Menu ................................................................ 92 Pump Controller Operating Menu .................................. 93 Menu Functions Pump Controller ......................................... 94 PROGRAM ...................................................................... 94 TESTER........................................................................... 94 ALARMS .......................................................................... 94 PROGRAM VACC ........................................................... 94 CONFIG........................................................................... 94 PROGRAM Menu............................................................ 95 TESTER Menu ................................................................ 99 ALARMS Menu................................................................ 100 PROGRAM VACC Menu ................................................. 102 CONFIG Menu ................................................................ 103 Calibrating the Steering Potentiometer ................................ 104 Preparation...................................................................... 104 Calibration ....................................................................... 104 Calibrating the Lift Potentiometer ......................................... 105 Preparation...................................................................... 105 Calibration ....................................................................... 105 Calibrating the Accelerator Potentiometer........................... 106 Preparation...................................................................... 106 Calibration ....................................................................... 106 Traction Controller Safety Test .............................................. 108 Pulse Monitor Trip Test (PMT) ........................................ 108 Equipment................................................................... 108 Test ............................................................................. 108 PMT Safety Test Wiring .................................................. 109 PAGE SER-N0. CUT REV. MS-IDX-2232 SC3200 03/2004 • Printed in Germany VI

TABLE OF CONTENT M4 – ELEKTRICS Battery...................................................................................... 110 General............................................................................ 110 Replacing the battery ..................................................... 110 Battery Discharge Indicator (BDI) ......................................... 110 General............................................................................ 110 Battery Discharge Indicator Setting (BDI) ..................... 111 Calibration ....................................................................... 111 Electric Motors ........................................................................ 112 General Maintenance Instructions................................. 112 Preparation ................................................................. 112 Important Maintenance Instructions ........................... 112 Traction Motor Maintenance .................................................. 113 Access to Brushes .......................................................... 113 Maintenance.................................................................... 113 Armature ..................................................................... 113 Bearings...................................................................... 113 Pump Motor Maintenance ...................................................... 114 Access to brushes .......................................................... 114 Maintenance.................................................................... 114 Armature ..................................................................... 114 PAGE SER-N0. CUT REV. M5 – BRAKE Brakes ...................................................................................... 117 General............................................................................ 117 Brake Lining Wear Limits................................................ 117 Brake Removal................................................................ 117 Brake Assembly .............................................................. 119 Before Assembling...................................................... 119 Assembly .................................................................... 119 Foot Brake ....................................................................... 120 Foot Brake Adjustment ............................................... 120 Checking the braking distance ................................... 120 Handbrake Adjustment ............................................... 121 PAGE SER-N0. CUT REV. M6 – STEERING Steering.................................................................................... 125 Hydraulics........................................................................ 125 Function ...................................................................... 125 Steering Components..................................................... 126 Steering wheel......................................................................... 127 Disassembly .................................................................... 127 Assembly ......................................................................... 127 Direction Control Switches .................................................... 128 Switch Removal .............................................................. 128 Switch Assembly ............................................................. 128 Steer Sensor Module .............................................................. 130 Disassembly .................................................................... 130 Assembly ......................................................................... 130 Steering Sensor ...................................................................... 130 Disassembly .................................................................... 130 Assembly ......................................................................... 130 Steering Column Adjustment ................................................ 131 Gas Pressure Cylinder Removal.................................... 131 Gas Pressure Cylinder Assembly and Adjustment..... 131 Steering column ...................................................................... 132 Disassembly .................................................................... 132 Steering Column Removal.......................................... 132 PAGE SER-N0. CUT REV. SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232 VII

TABLE OF CONTENT M6 – STEERING Removing the steering shaft from the steering column .......................................... 132 Replacing the slip rings ............................................ 132 Steering Gear Removal .................................................. 134 Steering axle............................................................................ 135 Design ............................................................................. 135 Steering Gear Assembly ................................................ 135 Wheel hub pre-assembly ............................................ 135 Steering knuckle pre-assembly................................... 135 Steering Knuckle and Wheel Hub Assembly .............. 135 Spur pinion flange shaft pre-assembly ....................... 136 Housing pre-assembly ................................................ 136 Adjusting the bearing clearance ................................. 137 Cylinder Pre-Assembly ............................................... 140 Inserting the cylinder .................................................. 140 Assembling the Axle Bracket to the Steering Gear..... 140 Operational and Leakage Test .................................... 141 Steering axle 2.12.01.1............................................................ 142 Steering axle 2.12.09.0............................................................ 143 PAGE SER-N0. CUT REV. M7 – MAST Mast (TT Series) ...................................................................... 147 General............................................................................ 147 Torques ....................................................................... 147 Mast bearing mounting screws................................. 147 Mast Stoppers........................................................... 147 Lifting Gear Minimum Capacity................................... 147 Mast Testing (Assembled) .............................................. 147 Flaking ............................................................................. 147 Mast Disassembly................................................................... 149 Dismantling the Mast (Attached).................................... 149 General ....................................................................... 149 Fork Carriage Removal............................................... 151 Free Lift Cylinder Removal ......................................... 151 Removing the individual mast stages ......................... 153 Replacing the Mast Rollers on the Mast Stages and the Fork Carriage................. 153 Mast Stage Rollers ................................................... 153 Fork Carriage Mast Rollers....................................... 155 Lift Cylinder Removal.................................................. 155 Removing the Mast from the Truck ................................ 156 Mast Assembly................................................................ 157 Lift Chains ............................................................................... 158 General............................................................................ 158 Inspection ........................................................................ 158 Cleaning...................................................................... 158 Wear ........................................................................... 158 Freedom of Movement of Chain Links ........................ 159 Chain Tension ............................................................. 159 Chain Anchor and Pulleys .......................................... 160 Worn Connection Plates ............................................. 160 Protruding or Turned Chain Pins................................. 160 Corrosion .................................................................... 160 Chain Lateral Wear ..................................................... 161 Uneven Chain Tension .............................................. 161 Misalignment of Lift Components ............................. 161 Lift Chain Lubrication...................................................... 162 Detaching Lift Chains ..................................................... 163 PAGE SER-N0. CUT REV. MS-IDX-2232 SC3200 03/2004 • Printed in Germany VIII

TABLE OF CONTENT M7 – MAST Tools and Equipment Required...................................... 163 Detachment ..................................................................... 163 Fork Tines ................................................................................ 164 General............................................................................ 164 Terms .......................................................................... 164 Fork Identification ....................................................... 164 Repairs ............................................................................ 164 Checking the Fork........................................................... 164 Crack Inspection ......................................................... 164 Verticality Test ............................................................. 165 Fork Blade Warping .................................................... 165 Measuring the Fork Tip Width ........................................ 165 Fork Tine Height Difference ........................................... 165 Stop Mechanism ............................................................. 166 Fork Blade Wear ............................................................. 166 Sideshifter ............................................................................... 167 General............................................................................ 167 Integrated Sideshifter ..................................................... 169 Removal, Repair and Assembly ................................. 169 Hook-on Sideshifter................................................................ 171 Removal, Repair and Assembly..................................... 171 PAGE SER-N0. CUT REV. M8 – CYLINDERS Cylinders.................................................................................. 175 General............................................................................ 175 Safety when working on hydraulic systems ................ 175 General Instructions for Repairing Hydraulic Components............................... 175 Rod Seal Assembly................................................................. 176 General............................................................................ 176 Large Rod Seal Assembly .............................................. 176 Small Seal Rod Assembly .............................................. 177 Rod Seal Assembly, Sealing Lip First............................ 178 Tilt Cylinders ........................................................................... 179 General............................................................................ 179 Removal .......................................................................... 179 Tilt Cylinder Sectional Drawing ...................................... 180 Dismantling ..................................................................... 182 Component Inspection................................................ 182 Assembly .................................................................... 182 Assembly ......................................................................... 184 Lift Cylinders ........................................................................... 187 General............................................................................ 187 Removal and Assembly .................................................. 187 Dismantling ..................................................................... 187 Rod Seal Removal .......................................................... 187 Piston Rod Removal ................................................... 189 Assembly ......................................................................... 189 Piston Rod Assembly.................................................. 189 Installing the Rod seal ................................................ 189 Free-Lift Cylinder .................................................................... 191 General............................................................................ 191 Removal and Assembly .................................................. 191 Dismantling ..................................................................... 191 Rod Seal Removal ...................................................... 191 Piston Rod Removal ................................................... 191 Assembly ......................................................................... 191 Piston Rod Assembly.................................................. 191 PAGE SER-N0. CUT REV. SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232 IX

TABLE OF CONTENT M8 – CYLINDERS Installing the Rod Seal................................................ 191 Hook-on Sideshifter, Cylinder................................................ 195 Integrated Sideshifter, Cylinder ............................................. 197 PAGE SER-N0. CUT REV. DIA – ELECTRICAL DIAGRAMS Key............................................................................................ 201 Connectors ...................................................................... 201 Contactors ....................................................................... 201 Abbreviations .................................................................. 201 Control Circuit ......................................................................... 203 Power Circuit ........................................................................... 204 Option Brush Wear & Over Temperature Indicator Circuit Diagram.................................................................................... 205 Option Lighting Diagram ........................................................ 206 Seat Switch and Steer Pot...................................................... 208 Steer Column........................................................................... 208 BDI, Horn and Brake Switches............................................... 209 Control Levers......................................................................... 209 Star Points ............................................................................... 210 Panel Wiring............................................................................. 210 Traction Controller .................................................................. 211 Pump Controller ...................................................................... 211 Power Cable Diagram ............................................................. 212 Main Loom, Part 1 ................................................................... 213 Main Loom, Part 2 ................................................................... 214 Steer Column Loom ................................................................ 215 Fan Standard ........................................................................... 216 Option: Main Harness, Middle East Fan............................... 217 Option Lights, Main Loom Lights .......................................... 218 Option Lights, Panel to Switch .............................................. 219 Option Lights, Module to Panel ............................................. 220 Option Lights, Panel to Main Loom Lights ........................... 221 Option Lights, Reverse Alarm to Module.............................. 222 Option, Brush Wear and Overtemperature Display Loom... 223 Option, 5th Hydraulic Function.............................................. 224 Option, Cold Store Model Additional Loom, Part 1 of 2 ...... 225 Option, Cold Store Model Additional Loom, Part 2 of 2 ...... 226 Option, Cold Store Model Additional Loom, Heating Control Module.......................................................... 227 PAGE SER-N0. CUT REV. HYD – HYDRAULIC SCHEMATICS Hydraulic Schematic............................................................... 231 PAGE SER-N0. CUT REV. MS-IDX-2232 SC3200 03/2004 • Printed in Germany X

SAFETY Printed in Germany 1

SAFETY Safety Symbols used in the Manual General Maintenance and Repair Safety Notes To help guide you through the manual and to highlight parti- cular danger areas, we have used graphic illustrations: DANGER DANGER Read the safety notices in the truck Maintenance and Operator's Manuals. This symbol indicates life-threatening risks Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. ● Failure to comply with this notice may result in fatal injuries to yourself or other people. ● Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guide- lines. WARNING This symbol indicates the risk of serious injury and/or serious material damage. Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. ● DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels. CAUTION Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. ● This symbol indicates the risk of minor injury and/or minor material damage. Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. ● 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. INFORMATION 2. Only qualified and authorised personnel may carry out work on the truck. Contains additional information with supplementary notes and hints. 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. OPTION 4. To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness. These items relate to optional features not supplied with the standard version. 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. 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. 8. Keep the truck clean. This will facilitate the location of loose or faulty components. SC3200 03/2004 • Printed in Germany MS-MA-0000 Rev. 03/04 Rev. 01/03 3

SAFETY Warnings and Labels on the Truck 9. Make sure that capacity and data plates, warnings and labels are legible at all times. During regular maintenance check that the warnings and labels on the truck are complete and legible. 10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. Clean any illegible labels. ● Replace any faulty or missing labels. 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck. Before Leaving the Truck ● The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual. Stop the truck. ● Lower the fork carriage fully. ● Apply the parking brake. ● Turn off the truck and remove the key. ● Block all wheels when parking on an uneven surface. 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. ● MS-MA-0000 SC3200 03/2004 • Printed in Germany Rev. 03/04 4

INTRODUCTION Printed in Germany 5

INTRODUCTION General Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address: The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133 It also contains troubleshooting sections which can be used to identify and remedy truck faults. INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual. Using the Manual The manual is divided into sections. The following table shows how the manual is structured. S o i t c e n s n i a M e t n a n c e This manual therefore contains fewer and less detailed warnings than the Operator’s Manual, as the latter is aimed at persons who have very little or no prior experi- ence at all. Operating Instructions 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 This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. M A y t e f a S T I D o r t n I d o i t c u n 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 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 CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request. Ordering Spare Parts M 3 v i r D e t i n U M 4 e l E c i r t c l a The maintenance manual does not cover spare parts. These are listed in a separate manual. M 5 a r B k e Spare parts can be ordered by quoting: M 6 n i r e e t S g The truck specification number ● The truck model number M 7 M / t s a n i t f i L g M e c h s i n a m ● The truck serial number ● M 8 n i l y C r e d This information can be found on the truck’s data plate. Only if this information is provided can the order be proc- essed quickly, correctly and reliably. 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 A01M-gb SC3200 03/2004 • PRINTED IN GERMANY MS-ITD-2232 7

INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions: T T ( t h g i e H t f i L ) t s a M 4 3 7 0 m m 4 8 2 5 m m e t t a B z i S r y C o m p t r a m e n t 5 2 8 5 m m e 5 7 4 0 m m 4 1 8 m m 6 1 2 0 m m 5 2 6 m m 6 3 7 5 m m 6 3 4 m m 6 9 1 0 m m T I D 0 - 4 7 4 9 5 m m C d l o S t o r e V e o i s r n T I D 0 - 3 - N o n e M t s a F W h t i d l o c e r o t s o i s r e v n - N o m t s a T I D 0 - 5 e r h T e l e t e c a t s c i p o , e g m T T T y r e s s t s a T I D 0 - 1 S a t S n d r a d O o i t p O n T y p e T I D 0 - 6 - a t S n d r a d H y d r a c i l u A . x u F u o i t c n n C C o t s u m r e s p c i f i c e - N o S S p l a i c e d g i s e n S t s 1 a u f . x u o i t c n n T I D 0 - 2 D 2 n d a u f . x u o i t c n n T I D 0 - 7 C TT 4370 526 - S S H CA 1 - d i S e s e t f i h r - N o d i s e r e t f i h s A a l m r o i t p O n s H H o o - k o n d i s e r e t f i h s - N o e r s r e v e a r t l e v r a l a m I e t n I e t a r g d d i s e r e t f i h s 1 R e s r e v e a r t l e v r a l a m T I D 0 - 8 T I D 1 - 0 d i S e s e t f i h r M o l e d e t t a B r y D s i c h a r g e n I c i d t a o r - - N o d i s e r e t f i h s C A C a s c a d e 1 a t S n d r a d K A K a u p 2 o i t p O n T I D 0 - 9 T I D 1 - 1 MS-ITD-2232 SC3200 03/2004 • Printed in Germany 8

LUBRIFICATION AND ADJUSTMENT Printed in Germany 9

LUBRICATION AND ADJUSTMENT Lifting the Truck Lifting by another truck The SC 3200 can be lifted by another truck from the side. CAUTION Calculate the minimum capacity requirement based on the weight of the truck. This information can be found on the truck data plate. Scalding hazard! Spilled battery acid can cause injuries and damage the truck. Position the forks of the truck which is doing the lifting as shown by the diagram below. ● You must remove the battery before transporting the truck. Secure the SC 3200 firmly to the forks of the truck which is doing the lifting (e.g. with appropriate straps). ● DANGER Falling loads are hazardous! Accidents can result from lifting gear with insufficient capacity and unsecured loads. Always use lifting gear with sufficient capacity and prevent the load slings from sliding. 0,51 m Lifting by Crane Calculate the minimum capacity requirement based on the weight of the truck. This information can be found on the truck data plate. Attach the 3 straps to the hitch points as shown. G_SC32-Heben-seitl Centre of Gravity of the Truck Between Chassis and Drive Wheel Tow coupling G_SC32-Heben-Kran Printed in Germany MS-1.0-2232 11

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LUBRICATION AND ADJUSTMENT Towing the Truck First jack up the rear section of the truck: ● Support one side with a wooden block. ● If the truck is out of order it can only be towed if the handbrake is released. Then jack up the truck at the opposite side until the steered wheels are free (see figure). ● WARNING Support the raised side. ● Towing is only allowed with a tow bar. Then lift the opposite side and support it. ● To jack up the front section of the truck, place the jack under the chassis frame behind one of the front wheels. ● The brakes of the towing vehicle must be capable of braking the towed vehicle. Jacking up the Truck ● As soon as this drive wheel is free, support the outer part of the mast on this side. ● DANGER Repeat this process to lift and support the opposite side. ● Always support a raised truck with wooden blocks or other appropriate equipment to relieve the jack. Never reach your hands or other parts of your body under the truck before it has been supported, or while jacking the truck up! Improper handling of the truck or of the auxiliary equipment can result in fatal accidents. ● To jack up the truck, the forks must be completely low- ered (with no load on them) and the parking brake applied. Required capacity of the jack = 0.5 × overall truck weight. Do not forget to include the battery weight. Steered wheel Jack Wooden blocks MO-2232-035 MS-1.0-2232 Printed in Germany 12

LUBRICATION AND ADJUSTMENT Counterweight WARNING Trapping hazard! The counterweight weighs at least 800 kg. Hands and feet can be trapped. Only use levers and suitable tools when assembling and disassembling. Never use hands or feet. WARNING Falling load hazard! A falling counterweight can result in serious trapping. Prevent the counterweight from falling. To do this, use a load sling suspended to a crane. The load sling must be pulled through the hole for the tow pin. The crane must have a minimum capacity of 1000 kg. Disassembly Remove the mounting screw of the electrical base plate from the counterweight. Tools required: ● 1. For disassembly you will need a crane or forklift (minimum capacity 200 kg at 2.5m elevation) to support the overhead guard. Remove the mounting screws of the overhead guard from the counterweight. ● Raise the back of the overhead guard 1 – 2 cm and pull a load sling through the hole for the tow pin in the counterweight. 2. A second crane or forklift (minimum capacity 1000 kg at 2m elevation) to prevent the counterweight from tipping. ● Insert the load sling into a crane hook (crane minimum capacity 1000 kg). If you are using a forklift instead of a crane, prevent the load sling on the fork of the truck from sliding. 3. A pallet truck (minimum capacity 1000 kg) with forks that will lower to fit under the counterweight. ● 4. Hard wooden blocks to fit under the outer mast stages. Tighten the load sling slightly. ● Drive the truck into a secure maintenance area. ● Drive a pallet truck (minimum capacity 1000 kg) underneath the counterweight. The forks must be positioned under the flat surfaces of the counterweight. ● Tilt the mast back as far as it will go (in the direction of the driver). ● Lower the mast and fork carriage fully. ● Raise the forks of the pallet truck until they are touching the counterweight. Place two wooden blocks, one on the left and one on the right hand side underneath the outer mast stage. This will prevent the truck from tilting onto the fork tips. ● ● Remove the mounting screws of the counterweight. ● Remove the battery. ● Pull the counterweight approx. 10 cm away from the forklift, using the pallet truck. ● Attach a load sling to the rear of the overhead guard. This will secure the overhead guard when you loosen the attachment. Alternatively, you can support the overhead guard from the side using a forklift. ● Raise the counterweight off the pallet truck using the crane, and place it of a flat surface. ● Remove the tow pin from the counterweight. ● Printed in Germany MS-1.0-2232 13

Crown SC3200 Series Forklift Service Repair Manual