Service Manual: Wartungshandbuch Manuel de Maintenance

Service Manual
Wartungshandbuch
Manuel de maintenance SC3000 Series
UF.p65 1 06.04.99, 10:59
TABLE OF CONTENT
Printed in Germany
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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
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
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
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
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
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
SAFETY
Printed in Germany
Printed in Germany
SAFETY
Safety Symbols used in the General Maintenance and Repair

Manual Safety Notes
To help guide you through the manual and to highlight DANGER
particular danger areas, we have used graphic illustra-
tions: Read the safety notices in the truck
Maintenance and Operator's Manuals.
DANGER
l Failure to do so could result in severe or
This symbol indicates life-threatening risks fatal injuries to maintenance personnel
and/or other persons.
l 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
l Failure to comply with this notice may
1. Maintenance work must only be carried out in
accordance with the test and maintenance program
result in severe injuries to yourself or
contained in the present Maintenance Manual and any
other people and/or serious material
applicable service notices.
damage.
2. Only qualified and authorised personnel may carry
out work on the truck.
3. Always keep fire extinguishers in good working

CAUTION condition. Do not approach fluid levels or leaks with a
This symbol indicates the risk of minor naked flame.
injury and/or minor material damage.
4. To clean, use a non flammable, non combustable
l Failure to comply with this notice may cleaning solution which is groundwater-neutral.
result in minor injuries to yourself or Only carry out cleaning with an oil separator.
other people and/or minor material Protect the electrical system from dampness.
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
INFORMATION and desiccants must be treated as special waste
products. Relevant applicable regulations must be
Contains additional information with followed.
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
OPTION These items relate to optional features not of loose or faulty components.
supplied with the standard version.
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
SAFETY
10. Alterations or modifications by the owner or Warnings and Labels on the Truck
operator are not permitted without the express written
authorisation from Crown. l During regular maintenance check that the
warnings and labels on the truck are
11. Only use original Crown spare parts to ensure the complete and legible.
reliability, safety and suitability of the Crown truck.
l Clean any illegible labels.
Before Leaving the Truck
l Replace any faulty or missing labels.
l Stop the truck.
The order and meaning of the warnings and labels on
l Lower the fork carriage fully. the truck are described in section 10.9 of the parts
manual.
l Apply the parking brake.
l Turn off the travel switch and remove the

key.
l Block all wheels when parking on an uneven

surface.
Before Carrying out Work on the Truck

l Raise the truck to free the drive wheel.
Press the Emergency Stop button and
disconnect the battery.
l Prevent the truck from rolling away.
l 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.
l 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

l Check the safety devices.
l Get into the driver's seat.
l Check the operation of the lifting device,

travel direction switch, speed control,
steering, warning devices and brakes.
Printed in Germany
01/99
MA-2230-002
2
INTRODUCTION
Printed in Germany
Printed in Germany
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
1
ITD-2230-001
INTRODUCTION
Sections Maintenance
Section Description
IDX Table of Content
MA Safety
ITD Introduction
M1 Lubrication and Adjustment
M2 Hydraulics
M3 Drive Unit
M4 Electrical
M5 Brake
M6 Steering
M7 Mast
M8 Cylinder
DIA Electrical Diagrams
HYD Hydraulic Schematic
ITD001B-gb
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ITD-2230-002
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
M = Maintenance Identical for each language

Section is only once in the manual
Chapter Page number
Section
z. B. 1.2 = Inspection and
Truck code
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
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ITD-2230-003
INTRODUCTION
Truck Data Numbering Sheet
1.3 SC T L – 2 – 2
Capacity Fork Length

1.3 = 1250 kg Dash mm
1.6 = 1600 kg
1 900
1.8 = 1800 kg
2 1000
3 1150
Model designation 4 1200
SC = Sitdown Rider 5 1220
Counterbalance
6 600
7 800
T = Telescopic 8 1370
L = Double, part free lift 9 1067
F = Double, full free lift
T = Triple, full free lift ITD002-gb
Collapsed Height (mm) /

Lifting Height (mm)
Dash SC TL / SC TF
1 1750 / 2460
2 1970 / 2880
3 2165 / 3270
4 2315 / 3570
5 2465 / 3870
6 2665 / 4270
7 2840 / 4620
NOTE 8 3035 / 5010
9 3340 / 5620
FOR SPECIALS USE THE ACTUAL FIGURES
10 3485 / 5910
FOR COLLAPSED / LIFT HEIGHT AND FORK
LENGTH (SEE TABLES ITD002-GB AND
ITD.003-GB). Dash SC TT
1 1760 / 3670
Example:
2 1970 / 4300
Truck with data 1.3SCTL-2-2 designates 3 2165 / 4885
l Capacity 1250 kg
4 2315 / 5335
5 2465 / 5785
l Sitdown Rider Counterbalance 6 2665 / 6385
l Telescopic double part free lift mast

7 2840 / 6910
8 3035 / 7495
l Collapsed height 1970 mm 9 1993 / 4368
l Lift height 2880 mm

10 2044 / 4521
11 2145 / 4826
l Fork length 1000 mm 12 2569 / 60913
ITD003-gb
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ITD-2230-004
INTRODUCTION
Battery Options
Model Option Ah Type

(mm) DIN 43531 A (mm)
300 418 x 835 x 627 SD

Option 1
360 418 x 835 x 627 SHD
1187
360 418 x 835 x 784 SD
Option 1h
465 418 x 835 x 784 SHD
SC3013
400 526 x 835 x 627 SD
Option 2
480 526 x 835 x 627 SHD
1295
480 526 x 835 x 784 SD
Option 2h
620 526 x 835 x 784 SHD
400 526 x 835 x 627 SD

Option 2
480 526 x 835 x 627 SHD
1295
480 526 x 835 x 784 SD
Option 2h
620 526 x 835 x 784 SHD
SC3016
500 634 x 835 x 627 SD
Option 3
600 634 x 835 x 627 SHD
1403
600 634 x 835 x 784 SD
Option 3h
775 634 x 835 x 784 SHD
500 634 x 835 x 627 SD

Option 3
600 634 x 835 x 627 SHD
SC3018 1403
600 634 x 835 x 784 SD
Option 3h
775 634 x 835 x 784 SHD
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
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5
ITD-2230-005
Printed in Germany
LUBRICATION AND ADJUSTMENT
Printed in Germany
Printed in Germany
MAINTENANCE
Lubrication and Adjustment
Access to Components
In the course of regular maintenance the contactor panel, Fig. C: LH and RH panels (LH illustrated)
drive unit, hydraulic system and electrical components
in the chassis can be reached by removing or opening l Lift the side panel out of the attachment
the panels.
Fig. D: Steering column front panel

Fig. B: Battery compartment lid
Provides access to:
Provides access to:
l Key switch
l Battery
l Direction switches
l Contactor panel including impulse controls
l Encoder
l Steering axle and potentiometer
l Wiring
l Hydraulic motor and pump
l Steering unit and distributor block
CAUTION
l Hydraulic lines
WHEN THE BATTERY COMPARTMENT LID
IS OPENED IT CAN TIP OVER IF THE LID To remove:
CENTRE OF GRAVITY MOVES OVER THE
PIVOT POINT / ATTACHMENT POINT OF l Loosen two hex. socket screws
THE LID.
l Lift panel slightly and lever out at the bottom
Access:
Pull the handle on the front of the lid and open the Fig. E: Inner dashboard
battery compartment lid.
Provides access to:
l Handbrake
Figs. B1 and B2
l Battery display
Provides access to:
l Wiring
l Hydraulic lines (Fig. B1) on the right hand side
of the battery compartment. l Hydraulic lines
l Cable duct (Fig. B2) on the left hand side To remove:

of the battery compartment.
l Loosen 6 hex. socket screws
Access:
l Remove panel
l Lift off the side panel
l Remove the battery
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M1.0-2230-001
MAINTENANCE
Fig. F: Valve and Control Handle Panel Fig. G: LH and RH base plate (RH illustrated)
Provides access to: Provides access to:
l Valve block l Brake pedal and mechanism
l Switch, potentiometer l Brake
l Control handle mechanism l Accelerator pedal / travel switch and

potentiometer
To remove:
l Tilt cylinder attachment (frame)
l Remove the base plate
l Valve block hydraulic lines
l Loosen the two hex. socket screws at the rear
upper section. l Wiring
l Remove the single hex. socket screw at the l LH and RH drive motor
front below the base plate
To remove:
l Lift up the panel
l Loosen the single hex. socket screw on the
RH base plate
l Lift out the LH and RH base plates.
Printed in Germany
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M1.0-2230-002
MAINTENANCE
B1 M0258
B M0251
B2 M0252
D M0257
E M0254b
A M0116
G M0253 F M0256 C M0259
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M1.0-2230-003
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
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M1.0-2230-004
MAINTENANCE
Recommended Lubricants and Oils
Lubricants
Only high grade lubricants and oils should be used. The-
se can be obtained from any oil manufacturer. Those listed
on the following page are typical, and any lubricant of the
same grade can be used.
Cold Store Trucks

Special hydraulic oil, lubrication oil and grease must be
used for cold store trucks operating in low temperature
conditions (see table on page M1.1-1710-002). An anti-
corrosion fluid (Crown no. 078882-002) must be applied
to all screws, washers, nuts, pins, retaining rings etc.
Maintenance schedules should be kept as short as

possible to prevent excessive wear of moving
components.
Driver Participation
By involving the driver in the maintenance schedule, truck
downtimes can be substantially reduced. The driver can
also contribute to determining the maintenance schedule,
thereby saving costs. Crown therefore recommends that
the driver carry out the daily maintenance in accordance
with the table on page M1.2-2230-002.
Daily Maintenance Log

A maintenance log is provided to keep a record of the
extent and time of maintenance performed.
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M1.1-1710-001
MAINTENANCE
Lubricants and Oil Recommendations
Lubricant Type Product Description Manufacturer CROWN-Part-No. Type
Aralube HLP-2 Aral

LM-Grease Castrol
Regulus A2 Century
Grease (multi purpose) Beacon EP2 Esso 053002-001 B
EP2 Maxol
Mobiluxe E2 Mobil
Rentinax LX Shell
Aralube SKL2 Aral

Low temperature grease 053002-005 BB
Unirex Lotemp EP Mobil
Kowal 40 Aral
Lubrication oil (chain) Essolube HDX Plus + 40 Esso 053002-007 G
Delvac 1240 Mobil
Low temperature
SHC 626 Mobil 053002-008 GG
lubrication oil
Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Hydraulic oil Nuto H32 Esso 053001-003 D
DTE 24 Mobil
Tellus 32 Shell
Low temperature Univis J 13 Aral

053001-008 DD
hydraulic oil Aero HFA Mobil
Hyp 85W90 Aral

GX - D 85W90 Esso
Transmission oil 053002-004 A
Mobilube HD85/90 Mobil
Spirax MB 90 Shell
Low temperature
Mobilube SHC Mobil 053002-006 AA
transmission oil
Rubber and vinyl dressing H
Special grease MOS2 Lithium Dow Corning 063002-022 M
Universal lubrication oil SEA40 C
W01-gb
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M1.1-1710-002
MAINTENANCE
Inspection and Maintenance Schedule
The following inspection and maintenance schedule
assumes single-shift operation under normal operating
conditions. The length of maintenance intervals will
however depend on the particular operating conditions.
In dusty or otherwise extreme environments, including

cold stores, the specified maintenance intervals should
be reduced. The exact periods should be established after
consultation with Crown service personnel.
When performing maintenance work always check for

wear, corrosion and damage and ensure that the parts
are operating correctly and are secure. If in doubt, replace
the component.
Larger maintenance schedule should always include the

work of the next smallest maintenance schedule.
Printed in Germany
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M1.2-2230-001
MAINTENANCE
Daily or every 8 service hours
Item Component Action
Re-charge discharged batteries. Check electrolyte level

1 Battery
and replenish if necessary.
2 Battery plug Check operation.
Check operation; check suppor t and belt for wear,

3 Seat belt
replace if necessary.
4 Horn Check operation.
5 Accelerator pedal Check operation.
6 Direction switch Check operation.
7 Handbrake Check operation.
8 Hydraulic system control handle Check operation.
9 Hydraulic lines and screws Check for leakage, tighten screws if necessary.
10 Brake pedal Check operation.
11 Steering wheel Check operation.
12 Wheels Check tyres for wear, nails, metal splints etc.
Check for wear, even chain tension on left and right hand
13 Hoist frame chain
sides.
14 Free lift cylinder chain Check operation.
15 Chain attachment Inspect condition.
16 Forks, fork carriage Check for visible signs of cracks, wear and damage.
Load guard Ensure it is secure.
Labels and stickers Check that they are all present, clean and legible. Clean or
(see section 10.9 of par ts manual) replace if necessary.
WARTUNG02gb
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8
M1.2-2230-002
MAINTENANCE
6
7
4
13
11
15
15
M0323
10 8
9
M0322
14
3
2
1
15
16
M0324
M0321
4
12
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9
M1.2-2230-003
MAINTENANCE
Monthly or ever 100 service hours
Maintenance
Manual Page
Check acid density, if necessary replenish with destilled

1 Battery water; check voltage of each cell, if necessary
compensate; clean and grease battery terminals.
2 Contactors Clean, check, replace if necessary.
Electrical wiring and Check wiring, switches and connections are secure,
3
equipment check insulation for damage.
4 Lift cylinder Check for leaks; check piston rod for damage.
Lift chains and chain

5 Check for wear. M7.5-2230-001
supports
Check oil level, replenish if necessary. Mast and fork

6 Hydraulic reservoir
must be lowered. Clean bleed cap.
7 Wheels Check wheel nuts are correctly torqued.
8 Accelerator pedal Check for wear; grease pivot point.
Brake pedal and brake

9 Check for wear; grease pivot point.
mechanism
10 Relief valve Check operation.
WARTUNG03gb
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M1.2-2230-004
MAINTENANCE
2, 3
1
M0321
7
9
8
10
M0326
Printed in Germany
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11
M1.2-2230-005
MAINTENANCE
+ Every three months or 250 service hours

++ Every six months or 500 service hours
Maintenance
Manual Page
+1 Battery connector Clean contacts, check contact springs.
Pump and drive motor Clean, apply pressurised air, check for wear and
+2
carbon brushes freedom of movement, replace if necessary.
+3 Mast end stops Check for wear.
Clean bearings and contact surfaces, check for wear,

+4 Hoist column
replace if necessary, grease.
Battery compartment lid

+5 Check operation, lubricate
hinge
First oil change; subsequent changes after every 2000

+6 Gear unit service hours.
Ensure bolts are tight.
++ 7 Hydraulic cylinder Ensure it is securely fitted.
Blast off abrasion with pressurised air, check brake lining

++ 8 Brakes M5.0-2230-001
and brake springs.
++ 9 Battery Check truck and battery insulation resistance.
WARTUNG04gb
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12
M1.2-2230-006
MAINTENANCE
9
4
M0321
8
8
2
M0326
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M1.2-2230-007
MAINTENANCE
+ Annually or every 1000 service hours

++ Every two years or every 2000 service hours
Maintenance
Manual Page
+1 Battery connector Clean contacts, check contact springs
Pump and drive motor Clean, apply pressurised air, check for wear and
+2
carbon brushes freedom of movement, replace if necessary.
+3 Mast end stops Check for wear.
Clean bearings and contact surfaces, check for wear,

+4 Mast column
replace if necessary, grease.
Battery compartment lid

+5 Check operation, lubricate.
hinge
+6 Steer unit Check steering column teeth on steer unit for wear.
+7 Forks, fork carriage Check for visible cracks, damage and wear. M7.8-2230-001
+8 Hydraulic cylinder Ensure it is securely attached.
Blast out abrasion with pressurised air, check brake

+9 Brakes
lining and brake springs.
++ 10 Battery Check truck and battery insulation resistance.
++ 11 Seat runners Check for wear, grease.
Change oil (first oil change after 250 service hours).

++ 12 Gear unit
Check bolts are tight.
++ 13 Steering axle Check bolts are tight.
UVV testing Carry out UVV testing at prescribed intervals.
Check fuse circuitry and traction control (see page

PMT test
M4.20-2230-001).
WARTUNG05gb
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M1.2-2230-008
MAINTENANCE
5 3
11
13 10 6
1
2 7
12
M0321
9
9
M0326
2
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M1.2-2230-009
MAINTENANCE
Lubrication Points / Intervals

100 250 500 1000 2000
Pos. Component Type QTY
Hours Hours Hours Hours Hours
1 Fork locking pin B A/R X
2 Hydraulic reservoir check D A/R X
3 Hydraulic oil change D A/R X
4 Accelerator pedal pivot B A/ R X
5 Accelerator linkage B A/R X
6 Potentiometer pivot B A/R X
7 Handbrake cable C A/ R X
8 Handbrake pivot B A/ R X
9 Handbrake ratchet B A/R X
10 Battery comp. lid hinge C A/ R X
11 Battery latch C A/R X
12 Locking ramp pivot point C A/ R X
13 Steer column adjustment C A/R X
14 Tilt pivots B A/ R X
15 Mast pivot B A/ R X
16 Mast channels B A/ R X
17 Mast column and fork carriage rollers B A/ R X
18 Chain main lift, Chain freelift cylinder G A/R X
19 Column pulleys (Nylon) H A/ R X
20 Fork slide B A/ R X
21 Brake main pivot B A/ R X
22 Brake pedal pivot B A/R X
23 Motor to gearbox spline M A/R X
24 Pump motor to pump spline M A/R X
25 Orbital steer unit spline B A/ R X
26 Seat runners B A/ R X
27 Gearbox oil change A A/R first change after 250 hours of operation X
W06-gb
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M1.3-2230-001
MAINTENANCE
19 25 13
14
M0101 15
26 11
M0115
M0107
24 16
M0109
8 9 7
M0251 10
M0113
12 17 18 20 21
M0116
M0103
2, 3
M0114
1
21
M0104
5 6 23
14
22 M0108
M0111 M0112 27
Printed in Germany
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17
M1.3-2230-002
MAINTENANCE
Torques
The screw and nut grades shown below are used in the
manufacture of Crown trucks. The information on the page
is designed to help determine the correct torque for
maintenance work.
NOTE
THE TORQUES LISTED IN THE

MAINTENANCE SECTION ALWAYS
SUPERSEDE THOSE SHOWN ON
THIS PAGE.
Screw Grade Marking Nut Grade Marking
8 .8
8 .8 8
1 2 .9
1 2 .9
WARTUNG 07gb
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M1.9-2230-001
MAINTENANCE
Standard Screws and Nuts
Strength 8 and 8.8 10 and 10.9 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100
WARTUNG 08gb
Umbrako Screws and Nuts
Grade 10 and 10.8 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717
WARTUNG 09gb
Printed in Germany
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19
M1.9-2230-002
MAINTENANCE
Torques
Torque
Assembly Page / Item
(Nm)
Accelerator pedal assembly attachment to chassis 20 - 25 4.6-2230-025, item 2
Brake activation locknut 30 5.6-2230-025, item 29
Brake assembly locknut 40 - 45 5.6-2230-025, item 12
Chassis counterweight attachment 580 - 650 1.0-2230-027, item 3
Steering column direction switch assembly 8 - 10 6.7-2230-029, item 50
Traction motor - gear unit attachment 60 3.3-2230-001, item 29
Storage compar tment - driver seat attachment 8 - 10 Not present
Brake pedal assembly - chassis attachment 40 - 4 5 5.5-2230-025, item 2
Transmission - chassis attachment 330 3.1-2230-025, item 44
Brake setting counternut 40 - 4 5 5.6-2230-025, item 24
Bearing block / mast locknuts 550 - 600 3.1-2230-025, item 43
Hydraulic reser voir - chassis attachment 6 2.3-2230-025, not present
Pump motor - chassis retaining plate 46 2.13-2230-025, item 5
Steering axle - chassis attachment 330 6.6-2230-025, item 36
Steering sensor - steering column attachment 40 - 45 6.7-2230-029, item 27
Steering wheel attachment 40 - 45 6.7-2230-025,not present
7.5-2230-025, item 31
Tilt cylinder - mast/chassis attachment 13
1.0-2230-025, item 29
Wheel nuts 135 1.5-2230-001contd.
WARTUNG 10gb
Printed in Germany
01/99
20
M1.9-2230-003
MAINTENANCE
Torques (contd.)
Torque
Assembly Page / Item
(Nm)
Overhead guard - chassis attachment, front 86 1.0-2230-025, item 23
Overhead guard - chassis attachment, rear 152 1.0-2230-025, item 22
Nuts for contactor cable connections 20 4.4-2230-001 contd.
Traction motor cable connections 13 3.3-2230-001, item 10
Pump motor cable connections 13 2.13-2230-001, item 10
Potentiometer attachment 1 2.2-2230-125, item 12
Microswitch attachment 0.5 -
WARTUNG 11gb
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21
M1.9-2230-004
Printed in Germany
HYDRAULICS
Printed in Germany
Printed in Germany
MAINTENANCE
Hydraulic Symbols
Vented reservoir with lines above the

fluid level Electric motor with unidirectional turn
M
and speed
Vented reservoir with lines below the

fluid level
M Electric motor with unidirectional turn
and variable speed
Filter or strainer
Hydraulic pump with fixed displace-

Hydraulic line with full flow (tubing or ment and single direction of turn
hose)
Pilot or drain line or drainage with

limited flow Hydraulic motor, bi-directional
Lines crossing; not connected
Pressure guage
Lines crossing and connected
Thermometer
Plugged port (test port)
Accumulator gas charged diaphragm

type
Flow meter
M3559
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M2.0-0000-001
MAINTENANCE
Pressure switch Manual actuator
Double-acting cylinder; Spring, (bias to normal de-energised

unequal area position)
Double-acting cylinder;
equal area
Solenoid single coil or winding
Single-acting cylinder
with spring returned (rod end
vented)
Hydraulic pilot operated
Single-acting cylinder
ram type
Solenoid valve, pilot operated
Single-acting cylinder,
with cushion
Dual solenoid
Assembly housing,
manifold block
Proportional solenoid
Manual lever actuator Pilot check valve (pilot to open)
M3560
Printed in Germany
01/99
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M2.0-0000-002
MAINTENANCE
Throttle, fixed Shuttle valve
Throttle, adjustable
Single counterbalance valve

assembly in manifold
Pressure-compensated flow control,
fixed
Pressure-compensated flow control

with reverse flow bypass; fixed.
Flow divider/combiner
Velocity fuse
Bypass flow control with con-
trolled flow, pressure-regulated
Relief valve, fixed setting Shut-off valve, manual
P
Torque generator
Relief valve, adjustable T
T L Hydraulic steer unit

Check valve
P R
M3561
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M2.0-0000-003
MAINTENANCE
2/2 way valve

(two way, two switch positions) Valve block with 3
operating units
3/2 way valve

(three way, two switch positions)
4/2 way valve

(four way, two switch positions)
4/3 way valve

(four way, two switch positions)
4/3 way valve

(four way, two switch positions); manual
activation and spring centered
3/2 way valve

(three way, two switch positions); Spring
bias solenoid control
M3562
Printed in Germany
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4
M2.0-0000-004
MAINTENANCE
Hydraulic System
General
A low emission motor pump assembly supplies oil from a
37 litre oil tank via an exchangable suction filter (126 µ).
The speed of the 10.5 kW motor is governed by a MOSFET

controller. This controller is pre-programmed with set speed
ranges which are used depending on the respective
hydraulic operation. If two or more operations are being
performed at the same time, the higher controller setting
has priority over the lower setting.
The single motor pump assembly can operate up to five

functions (lifting, reach, tilt, sideshift and an auxiliary
function) and, if necessary, supply the hydrostatic steering
system with the required flow.
The directional control valve has either three (standard) or

four functions and is manually operated from the operator
platform via a control lever and actuating linkage. A main
relief valve in the input section limits system pressure to
210 bar.
The input section also contains a priority valve which

diverts the oil flow in favour of the steering function when
the steering and other lifting functions are activated
simultaneously.
All system oil is filtered through an oil filter (10 µ) with an

diffuser integrated in the tank return line.
Printed in Germany
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5
M2.1-2230-001
M2.1-2230-002
6
R A C K A N D P IN IO N C Y L .
M A IN L IF T
C Y L .
T IL T C Y L .
L R
H O S E B U R S T
V A L V E
7 9 3 6 8 9
F L O W C O N T R O L
P R E S S U R E R E G U L A T O R
O R B IT A L S T E E R IN G V A L V E L O W E R IN G
S e t to 1 6 0 b a r
U N IT D Y N A M IC L S
C L O S E D C E N T R E S ID E S H IF T
N O N R E A C T IO N
L S
01/99
L S C F 1 A 1 B 2 A 2 B 3 A 3 B
P T S T E E R R V
7 0 B A R
O P T O
T
E N C O D E R
M A IN
R V
2 1 0
B A R
MAINTENANCE
M O T O R
P R IO R IT Y V A L V E L IF T T IL T A U X I
F IL T E R D Y N A M IC L S
P U M P
Printed in Germany
792341_c_gb
S T R A IN E R
MAINTENANCE
Operational Description Lifting
Idle Mode If the operator is seated and the key switch is on, the
pump motor will run at idle speed. Oil flows from the tank
If the operator is seated and the key switch is on, the via a suction filter to the hydraulic pump and from there
pump motor will run at idle speed. Oil flows from the tank into the control valve.
via a suction filter to the hydraulic pump and from there
into the control valve. If no load pressure from the steering unit is applied to the
priority valve the pump pressure will move the priority valve
Provided no travel or lifting operation is being performed, to the lifting, tilt and auxiliary functions position.
the priority valve will allow flow through. The oil can flow
through the flow channel into the tank channel and from For lifting the oil flows through a lowering brake valve which
there via a return filter back to the tank. is activated by the pump pressure and into the lift cylinder.
If the required lift height is not obtained, the lowering brake
Priority Valve valve returns to its resting position. The oil then stays at
the slide rod in the spool valve and thus prevents the lift
For safety reasons the priority valve can give priority to cylinder from lowering.
steering over other hydraulic functions in the event of
several functions being activated simultaneously. For lowering the slide rod moves in the opposite direction.
To achieve better control of the lowering speed the oil
Steering returns to the reservoir via a choke in the lowering brake
valve.
When the steering wheel is applied the steer requirement
optical sensor is activated and sends a signal to the Tilting
controller via the interface module. The controller in turn
activates the pump motor at a set pump speed. The steering When the mast is tilted forward the oil flows on the piston
unit also rotates and supplies oil to the steering motor side directly into the tilt cylinders. On the return side a
which simultaneously allows oil on the low pressure side load holding valve set to 160 bar must be activated to
to return to the tank. ensure that the oil can return to the reservoir via the spool
valve.
The steering unit load pressure controls the priority valve.
The steering function always has priority irrespective of When the mast is tilted backward the oil flows via a non-
the number of hydraulic operations being performed. return valve in the load holding valve to the piston side of
the tilt cylinders. On the return side the oil flow directly to
When the rear wheels are turned as far as the mechanical the spool valve and back to the reservoir.
end stops, the oil in the LS line can flow down via the
pressure relief valve which is set to 70 bar. This repositions The load holding valve prevents the mast from tilting
the priority valve to allow for lifting. forward when laden.
If the pump is not operational, the steering unit can be

manually rotated to drive the steering motor in an
emergency.
Printed in Germany
01/99
7
M2.1-2230-003
MAINTENANCE
Control Valve Maintenance and Repairs
The control valve consists of an input unit, three (standard) Operational faults with the control valve are often due to
or four operating units and an end unit. contamination or other foreign bodies on the moving parts
of the valves.
The input unit comprises the main relief valve for limiting
the system pressure (set to 210 bar), the priority valve for WARNING
preferential supply to the steering system when several
hydraulic functions are activated and the relief valve for De-pressurise all components before
the steering (set to 70 bar). carrying out maintenance work on the
hydraulic system.
Main Relief Valve Setting
l High pressure hydraulic oil can cause
l Fit the pressure gauge in pressure return line. serious injuries.
l Remove the domed cap nut from the main relief

l Whenever a high pressure fluid enters the
skin it must be treated as an emergency,
valve and loosen the counter nut from the pressure even if the skin initially shows no reaction.
adjusting screw. Physically effects will set in later.
l Slowly apply the hydraulic function until it l Secure all connections before re-applying
reaches the stop position.To exceed this position, set system pressure. Keep hands and body
the required system pressure with the adjusting screw. away from any ports as high pressure
hydraulic oil can emerge.
l Refit the counter nut and check the system l Use absorbent paper to track leaks, never
pressure again. Adjust if necessary. use your hands!
l Refit and tighten the domed cap nut.
Pilot Valve Troubleshooting
Problem Possible Cause Action
- Valve mechanism jammed Remove the valve and check for

No build up of pressure
- Contamination under the valve seat contamination. Ensure components' free play.
- Replace valve.
Incorrect pressure - Valve cone seat damaged
- Clean and ensure valve mechanism's free
reading - Valve mechanism jammed
play.
- Set pressure to correct reading (see

Pressure cannot be set - Adjusting screw or counter nut loose
description) and tighten counter nut.
correctly. - Valve wear
- Replace valve.
- Valve seat damaged - Replace valve.

Leakage - O rings damaged or worn - Replace O rings.
- Dirt particles clogging valve - Remove and clean valve.
WARTUNG20gb
Printed in Germany
01/99
8
M2.4-2230-001
MAINTENANCE
For service and inspection purposes the valve cartridges
can be unscrewed and checked for damage, leakage etc.
Proceed as follows:
l Thoroughly clean the operating area, remove

any contamination and oil.
l Unscrew the valve cartridge and inspect for

signs of foreign bodies, scratches or other damage.
l Remove any valve housing and check for

foreign bodies and damage.
l Check all moving parts of the valve

mechanism. Friction should only occur on the sealing
areas.
l Finally, clean parts thoroughly and lubricate

before assembly.
Table WARTUNG20gb describes some of the most

common faults.
Printed in Germany
01/99
9
M2.4-2230-002
MAINTENANCE
Pump Motor Bleeding
The pump motor carbon brushes and attachment must be l To ensure maximum operating safety and
checked in accordance with the maintenance schedule minimum wear it is advisable to fill the pump housing
intervals. with oil before starting.
l Remove the strap retainer in the upper motor l If necessary, remove the foaming oil at zero
section. pressure circulation by carefully opening the pressure
flange (taking care to protect yourself against spray).
l Apply pressurised air to the carbon brushes When bubble-free oil flows out refit the flange.
and check individually for wear. Replace if less than
15 mm. Oil Change
l Check attachment. An evenly distributed layer The hydraulic tank (capacity 37 litres) does not contain a
on the brush surfaces is normal. drain plug. When changing the oil, the used oil must
therefore be suctioned off via a suction pump.
Hydraulic Pump
NOTE
THE HYDRAULIC PUMP SHOULD NOT BE

REPAIRED ON SITE. FOR THIS REASON IT IS
SUPPLIED AS A COMPLETE ASSEMBLY
ONLY.
When commissioning a new or repaired hydraulic pump
proceed as follows:
Commissioning
l Check that the assembly is clean and correctly
assembled.
l When adding hydraulic oil, you must use a filter

with the prescribed minimum retention rate (10 µ).
l Note the arrow direction.
l Start the pump unladen and leave it to operate

for a few seconds without pressure to allow for
sufficient lubrication.
l Never run a pump without oil.
l If after 20 seconds the oil is still not free of

bubbles, check the unit again.
l When operating temperature has been reached

check the pipes are not leaking.
Printed in Germany
01/99
10
M2.6-2230-001
DRIVE UNIT
Printed in Germany
Printed in Germany
MAINTENANCE
Truck Drive System l Lift out the gear unit from the side. This will
also faciliate re-assembly.
Gear Unit Drive Motor

NOTE The drive motor carbon brushes and attachment must be
checked at intervals specified in the maintenance
THE DRIVE TRANSMISSION UNIT MUST schedule.
ONLY BE SERVICED BY AUTHORISED AND
TRAINED PERSONNEL. l Remove the strap retainer in the upper motor
section.
THE MANUFACTURER'S WARRANTY IS
INVALIDATED IF INCORRECT l Apply pressurised air to the carbon brushes
MAINTENANCE IS PERFORMED ON THE and check individually for wear. Replace if less than
TRANSMISSION SYSTEM. 20 mm.
Removal
l Check attachment. An evenly distributed layer
Prior to removal prepare the work area and make sure on the brush surfaces is normal.
any oil spillage can be suitably collected.
Removal
l Unscrew the two pressure lines and the
pressure hose from the distributor block. NOTE
l Secure the upper section of the mast with

DO NOT TEST THE DISASSEMBLED MOTOR
ON THE TEST BENCH AS THE MOTOR
suitable support equipment.
COULD BE DAMAGED WITHOUT THE
l Disassemble the tilt cylinder from the mast.
LOWER SUPPORT.
To remove the drive motor:
l Remove the bearing blocks in the lower section
of the mast from the gear unit. l Disconnect the power cable.
l Lift up the mast. l Remove the four mounting screws in the lower
section.
l Lift out the motor from the top.
l When re-fitting, lubricate the spline between

the motor and gear unit with grease (Crown-P/N
063002-022).
M0040
l Remove the stabiliser between the drive units.

Remove the brake linkage (Fig. M0040).
l Remove the wheel.
l Support the gear unit with a wooden block.

Loosen the mounting screws.
l Push the gear unit towards the centre of the

truck and loosen the two mounting studs.
Printed in Germany
01/99
M3.0-2230-001
1
MAINTENANCE
Design Bevel gear spur wheel pinion shaft pre-
assembly
Each of the drive wheels of the SC3000 has its own drive
transmission system, designed as a spur wheel bevel l Before placing the spur wheel (item 15) on
gear. the flange shaft, space must be created in the
housing for the conical roller bearing (item 23).
Power transmission from the motor is via a pinion shaft Assemble the spur wheel pinion shaft and the
and a bevel gear which transmits the velocity to a spur conical roller bearing pair (items 23, 27) in the
wheel via a spur wheel pinion shaft and thus to the flange housing and set the vacuum resistance using the
shaft which is fixed to the spur wheel. shims (item 22, 29) to 0.4 - 0.6 Nm.
The reference numbers contained in the following l Now assemble the bevel gear (item 10)
assembly instructions refer to the exploded diagram in together with the spur wheel pinion shaft (item 26).
section 3.1 of the parts manual.
Spur wheel flange shaft assembly
Spur wheel bevel gear assembly
l Heat the spur wheel (item 15) to approx. 135°C
Pre-assembly of the housing with flange shaft and place it on the flange shaft (item 1) (fig. M1272).
l Thorougly clean the housing (item 3) with a

cold cleaning solution. Assemble the conical roller
bearing (item 14) and the rotary shaft seal (item 13)
in the housing neck (Fig. M1268).
l Press the wheel nuts (item 2) into the holes in

the shaft flange using a hydraulic tool.
M1272
l Now assemble the previously cleaned housing

lid (item 3), fitted with shim (item 12), the outer ring
of the conical roller bearing (item 11) and the hex.
socket screws (items 35, 36) with the lock washers
M1268
(item 34) positioned underneath.
l Now press the flange shaft into the housing

transmission neck.
Printed in Germany
01/99
2
M3.1-2230-001
MAINTENANCE
l Centre both housing halves using the cylinder Bevel pinion assembly
pins (item 37).
l Press the conical roller bearings (items 9, 11)
l To complete the assembly of the spur wheel onto the bevel pinion (item 10) (Figs. M1270, M1271).
flange shaft, assemble the following components in
the following order:
l The ground supporting ring (item 16), the

conical roller bearing (item 17), the washer (item
18) and the hex. socket screws (item 19, 45 Nm
torque, secure with Euro-Lock A-24-20 or similar)
for securing the flange shaft tensioned on the
block.
l The bearing pre-tension of the flange shaft

should be 5.0 - 6.5 Nm and can be adjusted using
the shim (item 16).
l Insert the snap ring (item 20) in the housing

groove and seal the transmission in this area via the
filler cap (item 21).
Bevel gear assembly

l To complete the assembly of the bevel gear
insert the outer ring of the conical roller bearing (item
M1271
27) in the respective lid section.
l Adjust the bearing pre-tension to 0.2 - 0.4 Nm
l Now place the bearing race (item 28, secure using the shims (items 8, 12).
with Euro-Lock A-24-20 or similar) followed by the
shims (items 22, 29) previously obtained when l To obtain the ideal flank tooth bearing of the
setting the bearing pre-tensioning on the spur wheel bevel gear coat with paste and then manually apply
pinion shaft. the transmission. If necessary, use the imprints to
adjust the tooth bearing with the shims (items 8, 12)
l Now insert the shaft seal ring (item 30) in the (Fig. M1269).
section provided in the brake backplate (item 38) and
screw the backplate onto the housing lid (item 3) using
the hex. socket screws (item 4) and the lock washers
(item 5) underneath (23 Nm torque).
Proceed as follows:
l Remove all grease from the screw threads in

the transmission housing (item 3) with solvent.
NOTE
ALL RESIDUAL GREASE AND SOLVENT

MUST BE REMOVED WITH PRESSURISED
AIR.
l Remove all grease from the six screws
(item 4).
l Apply LOCTITE No. 577 (CROWN P/N
053050-019) to screws. Fit brake bracket and torque
screws to 23 Nm.
M1269
Printed in Germany
01/99
M3.1-2230-002
3
MAINTENANCE
l Insert the conical nipple (item 6) in the upper
part o fthe transmission lid (item 7). Finally, screw
the transmission lid to the pre-assembled
transmission halves (23 Nm torque) using the screws
(item 4) and the lock washers.
l Finally, assemble the bleed valve (item 25) with

its conical nipple (item 24) and the oil filler caps (items
32, 33) with their respective conical nipples (item 31).
Flank tooth bearing

The following diagram shows the ideal flank tooth bearing
for the bevel gear pairing.
Centre tooth bearing at

inner tooth end on the
upper side of the tooth
Centre tooth bearing at

lower side of the tooth
Centre tooth bearing at Centre tooth bearing at
inner tooth end on the inner tooth end on the
lower side of the tooth upper side of the tooth M1275
Correcting the flank tooth bearing

If the flank system differs from the example illustrated, Increasing the installation path of the conical
the shims (items 8, 12) must be used to correct the tooth pinion
bearing.
Conversely, if the tooth bearing on the bevel gear is too
Reducing the installation path of the conical low, or if the tooth bearing on the conical pinion is too
pinion high, the flank tooth bearing must be adjusted by
increasing the installation path of the conical pinion.
In the flank tooth shown in Fig. M1276 the installation
path of the conical pinion must be reduced.
Low tooth bearing at

outer tooth end on the
upper side of the tooth
Low tooth bearing at

lower side of the tooth
High tooth bearing at High tooth bearing at
inner tooth end on the outer tooth end on the
lower side of the tooth upper side of the tooth M1276
Printed in Germany
01/99
4
M3.1-2230-003
MAINTENANCE
Maintenance
Adding oil
Before use, check that the level of the gear oil is correct.
The level should read 0.9 litres.
Types of oil
For standard conditions of use, grade SAE 80-90
(CROWN P/N 053002-004) should be used (temperatures
between -22°C and +80°C).
Alternatively, grade SAE 80W may be used in

temperatures of between -32°C and +80°C (CROWN P/
N 053002-006).
See also the „Lubricants and Recommended Oil“ table

on page M1.1-1710-002 of the present manual.
For use in more extreme conditions and temperatures

please contact CROWN service department.
Oil level
Fill gear oil to the lower mark of the dipstick (item 33).
The capacity is 0.9 litres.
Oil change
Perform the first oil change after 250 operating hours.
Further oil changes every 2000 operating hours, and at
least annually.
CAUTION
THE MAXIMUM PERMISSIBLE PERMANENT

OPERATING TEMPERATURE OF THE GEAR
OIL IS MAX. 80°C.
Printed in Germany
01/99
M3.1-2230-004
5
Printed in Germany
ELECTRICS
Printed in Germany
Printed in Germany
MAINTENANCE
Electrical System
Wire Colour Codes

The wires used in the truck are colour-coded and
numbered according to their function. The first digit or
first two digits indicate the wire colour while the last two
digits are counter numbers.
ABBREVIATION COLOUR NUMBER FUNCTION
BLK Black 0 ** Digital signal
BRN Brown 1 ** Analog signal
RED Red 2 ** Positive not connected
ORG Orange 3 ** +12 V DC converter
YEL Yellow 4 ** Third DC converter
GRE Green 5 ** Negative not connected
BLU Blue 6 ** Insulated negative
VIO Violet 7 ** +5 V DC converter
GREY Grey 8 ** Fourth DC converter
WHT White 9 ** Various
R/W Red/White 29 ** Positive connected
G/W Green/White 59 ** Negative connected
ELEKTRIK 01 gb
** Numbers 01 to 99
Printed in Germany
01/99
M1.0-0000-0001
M4.0-2230-001
MAINTENANCE
Switch Symbol Abbreviation List *
Abbreviation Component Abbreviation Component
K* Relay LMS Limit switch
ACS Accelerator pedal switch LOS Lower switch
AXS Auxiliary function switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Directional switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency Disconnect Switch REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Reverse protection switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS Sideshifter switch
KYS Key switch THS Thermo switch
LGS Light switch TLT Tilt switch
* If one of the above abbreviations is used more than once, a number extension
will be used, e.g . SV1, SV2etc.
ELEKTRIK 02 gb
Printed in Germany
01/99
M4.0-2230-002
M1.0-0000-0002
MAINTENANCE
Sundry Abbreviations *
Abbreviation Description Abbreviation Description
BDI Battery discharge indicator OHGD Overhead guard display
BR Brake P Pump
BWI Brush wear indicator PC Plug connection
CA Cable connection PCB Printed circuit board
F Forward R Reverse
FAN Fan SF Shunt field
FU Fuse STI Steering wheel indicator
HN Horn SV Solenoid valve
IFD Information display TB Terminal board
M1 (TM) Traction motor TMM Truck management module
M2 (PM) Pump motor TT Hourmeter
MRC Controller
* If one of the above abbreviations is used more than once, a number extension
will be used, e.g . SV1, SV2etc. ELEKTRIK 03 gb
Printed in Germany
01/99
M4.0-2230-003
M1.0-0000-0003
MAINTENANCE
Electrical Symbols
EUROPE USA DESCRIPTION EUROPE USA DESCRIPTION

Hand operated
Wires joining maintained contact
Wires crossing Solenoid valve
Wire connection Inductor
Plug / socket Resistor
Wire strap Capacitor

1 2 3 4 5 6 1 2 3 4 5 6 Terminal board Potentiometer
Fuse U Varistor
Assembled unit J T Thermal protector
Contact, normally open Lamp
Contact, normally closed Horn
Contact double throw Battery
Operating device Diode

Operating devices,
slow releasing Breakdown diode
Operating device,
slow operating LED
Hand operated
NO push button Transistor
c
Mechanically actuated MOSFET
c Hydraulically actuated Thyristor
c
Emergency disconnect Comparator
Motor armature
.
M0056-gb
Printed in Germany
01/99
M1.0-0000-0004
M4.0-2230-004
MAINTENANCE
Electrical Components Raise Potentiometer (POT2)

DANGER The key movement of the "Raise" operating lever is
converted into a control signal by potentiometer POT2
THE TRUCK MUST BE JACKED UP PRIOR and at C1 is fed into the pump controller. The controller in
TO CARRYING OUT REPAIR WORK OR turn governs the pump motor speed.
TROUBLESHOOTING THE ELECTRICAL
SYSTEM.
Steering Axle Potentiometer (POT3)
Switch Functions
The steering axle potentiometer POT3 is mounted on the
The pin references relate to the drive and pump control steering axle input shaft and gives the following control
inputs (see pages 4.3-2230-006 and 4.3-2230-205); all signals to the traction controller:
other abbreviations are described in Tables Electric02 and
Electric03 (page 4.0-2230-002f). l Travel direction;
Brake Switch (BRS) l Steering wheel angle of turn.
The brake switch switches the power supply to pin G6 of This signal enables the traction controller to steer the
the traction controller. This amplifies inversion braking via traction motors accordingly.
the traction controller.
Tilt (TLT), Sideshift (SSS), Auxiliary Switch
Encoder (ENC), Encoder Module (EM) (AXS)
Impulses are generated via the steering wheel, the The switches for tilting, sideshift and auxiliary function
steering column and the connected encoder ENC. These switch the battery supply to connections E2, E3 and E5
impulses are digitalised in the encoder module EM and of the pump controller.
transfered to the pump controller via pin E8.
The impulse controller governs the pump motor speed
Accelerator Pedal Switch (ACS, POT1) via preset voltages.
The accelerator pedal key movement is converted into a Emergency Disconnect

control signal via potentiometer POT1 and transfered to
pin G1. The power supply to the truck is disconnected by pulling
the battery connector.
The accelerator pedal switch ACS cuts off the electric
circuit from the direction indicator switch DIS. Key Switch (KYS)
Direction Indicator Switch (DIS) The key switch energises the traction and pump controller
via pins E1 and D1 as well as the battery discharge
The direction indicator switch has three switch positions: indicator BDI.
forward, neutral and reverse. When the forward or reverse
positions are selected, power is supplied to the traction Fuses (FU)
controller on pin G8 (F) or G7 (R). This causes the
controller to activate the respective direction contactors. The main drive motor circuit is protected by fuse FU1 and
the lift motor circuit by fuse FU2.
Handbrake Switch (HBS)
The controller circuit is protected by fuse FU3 and the
The handbrake switch sends battery supply to pin F1 of horn by fuse FU4.
the traction controller. This causes the control system to
disconnect the traction current. It is also possible to travel
for 5 seconds with the handbrake applied (starting on an
incline) before the controller interrupts the traction current.
Printed in Germany
01/99
M1.0-0000-0005
M4.2-2230-001
MAINTENANCE
Seat Switch (SES) Horn Switch (HNS)
When the operator is seated, the seat switch SES is The horn switch HNS is located in the centre of the
closed and the traction controller on Pin L7 is energised, steering wheel. The horn HN sounds when the horn switch
enabling the truck to travel. is pressed.
If the operator leaves the seat, the seat switch opens and
after an interval of 1.5 seconds travelling is inhibited by
the controller.
Electrical Components - Overview
DIS
KYS
ENC / EM
SES
ED
POT 3
M0369
PM
HNS BDI / TT
M0367
HBS
ACS / POT 1
BRS 1 2 3 4
+ AXS
M0368 SSS
TM TLT
POT 2
Printed in Germany
01/99
M1.0-0000-0006
M4.2-2230-002
MAINTENANCE
Zapimos B1S 48/700 Controller Protective Devices

Polarity Protection
General
Wiring must be laid out in accordance with the wiring dia-
The programmable impulse controller provides effective gram to avoid damaging the transistors and capacitors.
control over the truck's travel behaviour. The logic system itself is internally protected against
incorrect polarity.
Wiring Errors
The driver outputs for the contactors tolerate only a max.
charge of 3A, even though they are protected against
overload and short-circuiting.
Overheating
When the temperature exceeds 80°C, the maximum
current is reduced in proportion to the rise in temperature.
M0201
If the temperature exceeds 85°C the traction controller
cuts out.
Protection
The traction controller is protected against dust and spray
water (IP54) and is contained within a sealed housing.
ZAPIMOS B1S 48/700 Traction Controller

Key Terms
Shunt or Shunt Resistor (+SH/-SH)
Main Features
The controller logic can measure the current flowing
l Stepless control and inversion braking. through the motor using a pre-defined resistance (shunt)
in series with the motor and thus control the MOSFETs.
l High level of efficiency, silent operation through
MOSFETs and high level of sampling frequency. Volt Motor Negative (VMN)
l Overvoltage, low voltage protection. The measurement point for the controller logic. The
voltage range on the terminal is measured and tests
l The circuits and software identify errors in the carried out to determine whether the controller power part
traction circuit, the MOSFET driver circuit, the is faulty.
MOSFETs, the contactor drivers and the contactors.
l Switch order monitoring.
l De-energised switching of contactors through

microprocessor controlled contactor drivers.
l Ramp start function ensures full power start-

up.
Printed in Germany
01/99
M1.0-0000-0007
M4.3-2230-001
MAINTENANCE
Functional Description l Controller temperature above 80°C.
Acceleration / Delay Rate l Contactors do not close or Volt Motor Negati-

ve is too high when idle.
The acceleration rate is the time taken for the voltage
applied to the motor to rise incrementally to 100 % of the l Contactors welded.
battery supply. The acceleration rate can be changed by
the programmer. Sparkless Contactors
Travel Switch If a direction switch is switched off, the output voltage

rapidly falls to zero. This causes the current to fall to zero
The travel switch stroke is 0 - 100% proportional to the before the direction contactor drops.
controller output.
Inversion Braking
Checking the travel switch signal on the control input
prevents the truck from starting without the driver. With inversion braking the motor is electrically driven in
the opposite direction to which it is mechanically turning.
Travel Switch Signal Response The controller governs the field current in order to achieve
a controlled braking moment. During inversion braking
The controller responds to the incoming travel the current is automatically restricted and the armature
potentiometer signal in accordance with the programmed current is greater than the field current. The inverse current
acceleration rate. Changes in the travel potentiometer limit for fast travel can be adjusted using the programmer.
signal are converted linearly.
Fault Log Creep Mode

The last 5 faults are stored in the controller memory along Creep speed is applied when the travel potentiometer is
with the relevant number of service hours, the control activated. Creep speed can be adjusted between 0 and
temperature and the fault frequency. 25 % of the output voltage.
Fault Identification The setting can be adjusted via the potentiometer or the
programmer.
The internal microprocessor monitors the controller. When
a fault is identified, the controller status LED flashes a Slow Travel
fault code. For critical faults the controller cuts out. For
intermittent faults, e.g. low voltage, the error message In slow travel the maximum speed is reduced. However,
automatically fades out after a while. the travel switch is still fully extended.
Automatic Fault Identification covers: The maximum speed setting can only be adjusted by the
programmer.
l Both travel directions operated simultaneously.
Steering Controller
l Logic error.
When travelling around corners with the steering wheel
l Incorrect start sequency; travel switch at an angle of less than 65° the motors are controlled so
operated. that the inside motor is slower and the outside motor
correspondingly faster.
l Volt Motor Negative Test (VMN) error.
When the steering angle is between approx. 65° and 73°
l High acceleration potentiometer resistance the inside motor runs at idle speed. If the steering angle
level when idle. is greater than 73° the inside motor will turn in the opposite
direction.
l Current measurement error:
This function is dependant on the steering angle measured
– Travel: Maximum level exceeded; by the potentiometer on the steering axle, the axle base
and the track.
– Idle: Current ≠ zero.
The ratio of the two motor speeds corresponds to the
l Contactor drivers faulty. ratio of the radii of the two load wheels.
Printed in Germany
01/99
M1.0-0000-0008
M4.3-2230-002
MAINTENANCE
45° Steering Angle Seat Switch
Beyond a steering angle of 45° the controller automatically The seat switch circuit contains a time delay relay which
switches to creep speed. interrupts the truck circuit when the operator has left the
truck for a period of time. This prevents the truck from
MOSFET switching off caused by the operator moving or jolts
received from the truck.
A MOSFET (Metal Oxide Semiconductor Field Effect Tran-
sistor) is a transistor with high switching speeds and very Current Limit
little power loss.
The current limit function reduces the PWM signal to the
Pedal Braking (Inversion Braking with Battery controller power part until the motor current falls below
Supply Regeneration) the value of the current limit.
In pedal braking the energy from the motor coil is not Overvoltage
transfered into heat as in inversion braking but a part is
fed back to the battery by the controller via the brake In the event of overvoltage the PWM cuts out and opens
contactor. the contactors. When the permissable voltage has been
reached the controller resumes operation.
Pedal braking is activated when the operator's foot is taken
off the accelerator pedal, the travel direction changed or Overheating
the operating brakes are applied.
At a temperature of 80°C the current limit is linearly
If the voltage generated falls to a preset value – (Vgen- reduced. At 85°C the controller cuts out.
Vbat) < 0.7 V – pedal braking is cut out (brake contactor
re-opens) and the truck is stopped by the operating brakes Low Voltage Reduction
(brake pedal).
The controller reduces the speed when the batteries are
Pulse Width Modulation (PWM) discharged to less than the minimum charge level. If the
motor current is so high that the battery voltage falls below
In pulse width modulation the battery voltage is switched the low voltage level, the controller reduces the speed
off and on to control the motor speed. until the voltage exceeds above the level.
Ramp Start
Here the truck is started with a higher inverse braking
current which prevents the truck from rolling backwards
when it starts. Ramp start increases the current limit in
the direction which has just been applied. Switching to
the opposite travel direction ends the ramp start function.
Key Switch
The key switch switches the voltage to the logic section
of the impulse controller.
Self Test
The controller is monitored by means of internal self tests.
If an error occurs the controller is cut out. Switching the
key switch off and on will cause it to re-start.
Reverse Travel Alarm

The traction controller sends a signal via Pin H2 to the
lighting module and from there to the horn to activate the
alarm when reversing.
Printed in Germany
01/99
M1.0-0000-0009
M4.3-2230-003
MAINTENANCE
ZAPIMOS B1S 48/700 Traction Controller Connections
Contactor Coils / Vacant Programmer c onnection

KYS
LED
E D C B A
+ B -B
V M N R V M N L
Potentiometer
Steering Axle, Drive Motor, Vacant Line Contactor and Switch Handbrake
Seat
L J H G F
-S H L -S H R
+ S H L + S H R
M0087
Printed in Germany
01/99
M1.0-0000-00010
M4.3-2230-004
MAINTENANCE
Programmer Connection "B" Status LED Diagnosis
A socket is provided to connect the programmer. The cable When the truck is powered up the Status LED flashes
is supplied with the programmer. briefly to indicate that the test program is being booted
up by the controller.
Status LED "A"
In normal start up the Status LED is off.
In the event of a fault the LED indicates the fault via a
flashing code. The fault can be identified more closely via When a fault occurs the Status LED flashes the respective
the programmer (see table, LED Codes). code (see table, LED Codes) until the fault is rectified.
LED Code Display Explanation
LED off m Traction controller operating normally
Continually on l Both travel directions simultaneously applied
1 H Logic error
2 HH Star t order incorrect (travel direction confirmed)
3 HHH VMN (Volt Motor Negative)Test Error
High potentiometer voltage in accelerator pedal

4 HHHH potentiometer when idle (accelerator pedal potentiometer
incorrectly aligned).
Motor current measurement error

5 HHHHH Travel: 0 V measured constantly
Idle: current ¹ 0 V
6 HHHHHH Contactor drivers faulty
7 HHHHHHH Temperature above 80°C
8 HHHHHHHH Contactors do not close or VMN (Volt Motor Negativ) is

too high at idle speed
9 HHHHHHHHH Contactors welded
ELEKTRIK 04 gb
Printed in Germany
01/99
M1.0-0000-00011
M4.3-2230-005
MAINTENANCE
Control Line Connections
Traction Controller
PIN-No. PIN-No.
E 9 L 9
E 8 L 8
E 7 L 7
E 6 L 6
E 5 L 5
E 4 L 4
E 3 L 3
E 2 L 2
E 1 L 1
D 2 J 2
D 1 J 1
C 3 H 3
C 2 H 2
C 1 H 1
B 8 G 8
B 7 G 7
B 6 G 6
B 5 G 5
B 4 G 4
B 3 G 3
B 2 G 2
B 1 G 1
A 2 F 2
A 1 F 1
Truck LHS Truck RHS
Printed in Germany
01/99
M1.0-0000-00012
M4.3-2230-006
MAINTENANCE
ZAPIMOS B1S 48/700 Pin Layout
Pin Function Additional Information

A1 - LED Alarm
A2 + LED Alarm, Output Current 12 mA, for standard LED
B1 + Serial Interface Receiver

B2 - Serial Interface Receiver
B3 + Serial Interface Sender
B4 - Serial Interface Sender
B5 - Programmer Power Supply
B6 + Programmer Power Supply 12 V
B7 Pin free
B8 Pin free
E1 + Key Switch Input

E2 + Travel Direction Contactor Coil
E3 Pin free
E4 - Travel Direction Contactor Coil RH drive motor
E5 - Travel Direction Contactor Coil RH drive motor
E6 - Travel Direction Contactor Coil LH drive motor
E7 - Travel Direction Contactor Coil LH drive motor
E8 + Pedal brake contactor
E9 - Pedal brake contactor
F1 + HBS Input
F2 Pin free
G1 - Accelerator Pedal Potentiometer

G2 Loop, Accelerator Pedal Potentiometer 0 Volt Speed min., 10 V Speed. max.
G3 + Accelerator Pedal Potentiometer 12 V Output
G4 Pin free
G5 Common Output, Travel and Brake Switch
G6 BRS Input
G7 Reverse Switch Input Travel Direction Switch
G8 Forward Switch Input Travel Direction Switch
H1 Pin free
H2 Pin free
H3 + Line Contactor
J1 Pin free
J2 Pin free
L1 - B – Input
L2 Loop, Steering Axle Potentiometer
L3 - Steering Axle Potentiometer
L4 + Steering Axle Potentiometer +7 V
L5 - For Options Connected to Battery Negative via L1
L7 - Seat Switch Input
Note:
+ = Positive Potential
- = Negative Potential
Printed in Germany
01/99
M1.0-0000-00013
M4.3-2230-007
MAINTENANCE
Maintenance Removing / Installing the Traction
Maintenance of the ZAPIMOS B1S 48/700 controller is Controller
confined to external cleaning. When carrying out
maintenance work, check the listed errors using the DANGER
programmer.
BEFORE CARRYING OUT ELECTRICAL
WARNING WORK OR TROUBLESHOOTING, JACK UP
THE TRUCK.
THE ZAPIMOS B1S 48/700 CONTROLLER
OPERATES WITH HIGH THROUGHPUTS.
SPECIAL SAFETY MEASURES ARE
THEREFORE REQUIRED. To remove
l Only properly trained personnel must carry
l Remove the battery connector.
out maintenance work.
l Use non-wearying eye protection. l Prevent the truck from rolling away.
l Do not wear loose clothing. l Lift the truck until the drive wheel is free to
move.
l Do not wear jewelry.
l Use insulated tools only.

l Open the battery compartment lid.
Cleaning the Traction Controller

l Discharge the traction controller capacitors by
connecting for a short time -B and +B of the controller
l Unplug the battery connector. via a cable including a resistor of about 10 Ohm.
l Secure the truck to prevent it from rolling away. l Unplug connector.
l Lift the truck until the drive wheel is free to move. l Remove the eight power cables.
l Discharge the traction controller capacitors by l Unscrew the six mounting screws and remove
connecting for a short time -B and +B of the controller the traction controller
via a cable including a resistor of about 10 Ohm.
l Remove cables.
l Remove contamination and corrosion from the

contact surfaces.
l Wipe the traction controller with a clean, damp

cloth.
l Connect cables.
l Before connecting the battery make sure that

the traction controller is completely dry.
M0189
Printed in Germany
01/99
M1.0-0000-00014
M4.3-2230-008
MAINTENANCE
CAUTION
THE TRACTION CONTROLLER MUST ONLY

BE SUPPLIED WITH BATTERY CURRENT.
DO NOT USE RECTIFIERS OR POWER
UNITS.
DO NOT CONNECT THE CONTROLLER TO A
BATTERY WITH A DIFFERENT RATED
VOLTAGE TO THE VOLTAGE SPECIFIED ON
THE CONTROLLER DATA PLATE.
Installing the Traction Controller
Installation is the reverse procedure of removal.
l Coat the rear of the traction controller with heat

conductor paste (Crown P/N 053051-008) and install
the controller.
l Test operation of traction controller.
Printed in Germany
REV.1 10/99
M4.3-2230-009
M1.0-0000-00015
MAINTENANCE
Zapimos HP 350A Pump Controller Protective Devices

Polarity Protection
General
Wiring must be laid out in accordance with the wiring dia-
gram to avoid damaging the transistors and capacitors.
The logic system itself is internally protected against
incorrect polarity.
Wiring Errors
The driver outputs for the contactors tolerate only a max.
charge of 3A, even though they are protected against
overload and short-circuiting.
Overheating
When the temperature exceeds 80°C, the maximum
current is reduced in proportion to the rise in temperature.
If the temperature exceeds 85°C the traction controller
cuts out.
Protection
M0202
The traction controller is protected against dust and spray
The programmable impulse controller provides effective water (IP54) and is contained within a sealed housing.
control over all hydraulic functions.
Key Terms
The main features are as follows:
Shunt or Shunt Resistor (+SH/-SH)
l Stepless control of the lifting function.
The controller logic can measure the current flowing
l High level of efficiency, silent operation through through the motor using a pre-defined resistance (shunt)
MOSFETs and high level of sampling frequency. in series with the motor and thus control the MOSFETs.
l Overvoltage, low voltage protection. Volt Motor Negative (VMN)

l The circuits and software identify errors in the The measurement point for the controller logic. The
pump circuit, the MOSFET driver circuit and the voltage range on the terminal is measured and tests
MOSFET transistors. carried out to determine whether the controller power part
is faulty.
l Switch order monitoring.
Printed in Germany
01/99
M4.3-2230-200
M1.0-0000-00016
MAINTENANCE
Functional Description Key Switch
Acceleration / Delay Rate The key switch switches the voltage to the logic section
of the impulse controller.
The acceleration rate is the time taken for the voltage
applied to the motor to rise incrementally to 100 % of the Lift Cut-Out
battery supply. The acceleration rate can be altered using
the programmer. If the battery capacity falls below 20%, the battery
discharge indicator sends a signal to the controller and
Current Limit interrupts lifting.
The current limit function red uces the PWM signal to the Lift Potentiometer
controller power part until the motor current falls below
the value of the current limit. The operating lever stroke is 0 - 100% proportional to the
controller output.
Fault Identification
Lift Potentiometer Response
The internal microprocessor monitors the controller. When
a fault is identified, the controller status LED flashes a The controller responds to the incoming lift potentiometer
fault code. For critical faults the controller cuts out. For signal in accordance with the programmed acceleration
intermittant faults, e.g. low voltage, the error message rate. Changes in the lift potentiometer signal are converted
automatically fades out after a while. linearly.
Automatic fault identification covers: Low Voltage Reduction

l Logic error. The controller reduces the speed when the batteries are
discharged to less than the minimum charge level. If the
l Incorrect start sequency; travel switch motor current is so high that the battery voltage falls below
operated. the low voltage level, the controller reduces the speed
until the voltage rises above the level.
l Volt Motor Negative Test (VMN) error.
MOSFET
l High lift potentiometer resistance level when
idle. A MOSFET (Metal Oxide Semiconductor Field Effect Tran-
sistor) is a transistor with high switching speeds and very
l Current measurement error: little power loss.
– Idle: Current ≠ zero. Overheating

l Temperature above 80°C. At a temperature of 80°C the current limit is linearly
reduced. At 85°C the controller cuts out.
Fault Log
Overvoltage
The last 5 faults are stored in the controller memory along
with the relevant number of service hours, the control In the event of overvoltage the PWM cuts out and opens
temperature and the fault frequency. the contactors. When the permissable voltage has been
reached the controller resumes operation.
Hydraulic Function Switch
Pulse Width Modulation (PWM)
The sideshift, tilt and aux. hydraulic functions are governed
by switches. If the switch is closed via the operating lever In pulse width modulation the battery voltage is switched
the pump motor operates initially at a speed set by the off and on to control the motor speed.
programmer.
Steering has priority over lifting. This is controlled by a

priority valve in the valve block.
Printed in Germany
01/99
M4.3-2230-201
M1.0-0000-00017
MAINTENANCE
Seat Switch Steer Support
The seat switch circuit contains a time delay relay which A sensor generates signals which are digitalised in the
interrupts the truck circuit when the operator has left the sensor module and sent to the pump controller. The pump
truck for a period of time. This prevents the truck from controller then governs the pump motor at a speed
switching off caused by the operator moving or jolts determined by the programmer.
received from the truck.
Self Test
The controller is monitored by means of internal self tests.
If an error occurs the controller is cut out. Switching the
key switch off and on will cause it to re-start.
ZAPIMOS HP 350A Pump Controller Connections
Hydraulic functions, Programmer

sensor Key switch Lift potentiometer connection
LED
E D C B A
9 8 7 6 5 4 3 2 1 2 1 3 2 1 8 7 6 5 4 3 2 1 2 1
+ B + M -B
- M
M0264
Printed in Germany
01/99
M1.0-0000-00018
M4.3-2230-202
MAINTENANCE
Programmer Connection "B" Status LED Diagnosis
A socket is provided to connect the programmer. The cable When the truck is powered up the Status LED flashes
is supplied with the programmer. briefly to indicate that the test program is being booted
up by the controller.
Status LED "A"
In normal start up the Status LED is off.
In the event of a fault the LED indicates the fault via a
flashing code. The fault can be identified more closely via When a fault occurs the Status LED flashes the respective
the programmer. code (see table, LED Codes) until the fault is rectified.
LED Code Display Explanation
LED off m Pump controller operating normally
1 H Logic error
2 HH Star t order incorrect (travel direction confirmed)
3 HHH VMN (Volt Motor Negative)Test Error
4 HHHH High potentiometer voltage in accelerator pedal

potentiometer when idle.
Motor current measurement error

5 HHHHH Travel: 0 V measured constantly
Idle: current ¹ 0 V
6 HHHHHH Contactor drivers faulty
7 HHHHHHH Temperature above 80°C
ELEKTRIK 06 gb
Printed in Germany
01/99
M1.0-0000-00019
M4.3-2230-203
MAINTENANCE
ZAPIMOS HP 350 A Pin Layout
Pin Function Additional Information
A1 - LED Alarm
A2 + LED Alarm, Output Current 12 mA, for standard LED
B1 + Serial Interface Receiver

B2 - Serial Interface Receiver
B3 + Serial Interface Sender
B4 - Serial Interface Sender
B5 - Programmer Power Supply
B6 + Programmer Power Supply 12 V
B7 Pin free
B8 Pin free
C1 Lift potentiometer loop 0 volt speed min., 10 volt speed max.

C2 - Lift potentiometer
C3 + Lift potentiometer 14 volt output
D1 + Key switch input Connection to D2 via diode

D2 + Connected
EE1 Pin free

E2 Aux. function switch input
E3 Sideshift switch input Active when B+ applied
E4 Pin free Active when B+ applied
E5 Tilt switch input
E6 Lift cut-out input Active when B+ applied
E7 Pin free Active when B+ applied
E8 Sensor input
E9 Pin free
Note: + = Positive potential

– = Negative potential
Maintenance
Maintenance of the ZAPIMOS HP 350A controller is Cleaning the Pump Controller
confined to external cleaning. When carrying out
maintenance work, check the listed errors using the l Unplug the battery connector.
programmer.
l Secure the truck to prevent it from rolling away.
WARNING
l Lift the truck until the drive wheel is free to move.
THE ZAPIMOS HP 350A CONTROLLER
OPERATES WITH HIGH THROUGHPUTS. l Remove wire.
SPECIAL SAFETY MEASURES ARE
THEREFORE REQUIRED. l Remove contamination and corrosion from the
l Only properly trained personnel must carry
contact surfaces.
out maintenance work.
l Wipe the pump controller with a clean, damp
l Use non-wearying eye protection. cloth.
l Do not wear loose clothing. l Connect wire.
l Do not wear jewelry. l Before connecting the battery make sure that
l Use insulated tools only.
the pump controller is completely dry.
Printed in Germany
01/99
M1.0-0000-00020
M4.3-2230-204
MAINTENANCE
Removing / Installing the Pump CAUTION
Controller THE PUMP CONTROLLER MUST ONLY BE
SUPPLIED WITH BATTERY CURRENT. DO
DANGER NOT USE RECTIFIERS OR POWER UNITS.
DO NOT CONNECT THE CONTROLLER TO A
BEFORE CARRYING OUT ELECTRICAL BATTERY WITH A DIFFERENT RATED
WORK OR TROUBLESHOOTING, VOLTAGE TO THE VOLTAGE SPECIFIED ON
JACK UP THE TRUCK THE CONTROLLER DATA PLATE.
To remove Installing the Pump Controller
l Remove the battery connector. Installation is the reverse procedure of removal.
l Prevent the truck from rolling away. l Coat the rear of the traction controller with heat
conductor paste (Crown P/N 053051-008) and install
l Lift the truck until the drive wheel is free to move. the controller.
l Open the battery compartment lid. l Test operation of pump controller.
l Unplug connector.
l Remove the eight power cables.
l Unscrew the six mounting screws and remove

the pump controller
M0189
Printed in Germany
REV.1 10/99
M4.3-2230-205
M1.0-0000-00021
Printed in Germany
MAINTENANCE
Programmer
General
The optional ZAPI programmer, Crown P/N 793548, is used
to program, test and perform diagnostic functions on the
traction controller.
The programmer is connected to the traction controller

via a cable, thus powered by the controller.
M0271-a
Printed in Germany
REV.1 10/99
M4.4-2230-001
1
MAINTENANCE
Description of Keys
Key Designation Explanation
Key 1 ROLL up Selects the next sub-menu or an option.
Key 2 ROLL down Selects the previous sub-menu or an option.
Key 3 ENTER Enters the main menu. Stores the pin configuration.
Quits a sub-menu or an option. Step by step return to the main

Key 4 OUT *
menu.
Key 5 PARAM up Increases setting values or selects configuration.
Key 6 SET down Decreases setting values or selects configuration.
* You can undo a change by switching the truck off and on again. The controller will be reset to the output values.
ELEKTRIK 07gb
Display Window
l Alphanumeric LCD Display
l 2 lines @ 16 characters
1 3 5
R OL L EN TER PA R A M
R OL L OU T SET Operating Keys
2 4 6
M0274-a
Printed in Germany
REV.1 10/99
2
M4.4-2230-002
MAINTENANCE
Connecting the Programmer
The programmer can be connected to the traction or pump
controller via a plug. The controller acts as a power supply
source for the programmer.
CAUTION
ONLY CONNECT AND DISCONNECT THE

PROGRAMMER TO THE CONTROLLER
WHEN THE TRUCK IS SWITCHED OFF.
E D C B A
M0272
Operating Menu
General
When the programmer has been connected a self test start
routine is performed (see page M4.5-2230-002). When it is
complete, use the ROLL up/down and ENTER to select
the required menu.
The following two pages show a menu structure for traction

and pump control with an explanation of the individual menu
functions.
Printed in Germany
01/99
M4.4-2230-003
3
MAINTENANCE
Traction Controller Operating Menu
START ROUTINE
PROGRAM TESTER ALARMS PROGRAM PEDAL CONFIG
ACCELERATION L VMN R
VIEW ALARM(S) PROGRAM VACC
INVERSE BRAKING L MOTOR R
RELEASE BRAKING BATTERY VOLTAGE
PEDAL BRAKING STEER ANGLE
TRACTION BRAKING ACCELERATION
TRACTION I MAX SEAT SWITCH
(2) SPEED CUTBACK I FORWARD SWITCH CLEAR ALARM(S)
CREEP SPEED BACKWARD SWITCH
(1) SPEED LIMIT TEMPERATURE
BRAKE SWITCH
CUTBACK SWITCH 1
CUTBACK SWITCH 2
SET MODEL SET OPTIONS ADJUSTMENTS
STEER TABLE HOURS RUNNING / KEY ON STEER POT

SC3013 BATTERY CHECK ON/OFF
SC3016 RELEASE BRAKING ON/OFF
SC3018 ANTIROLL BACK ON/OFF
AUTO BRAKE LIGHT ON/OFF
(1) Read only, cannot be overwritten

(2) Not available in version B1SHA1.05
Printed in Germany
01/99
4
M4.5-2230-001
MAINTENANCE
Programmer Start Routine
Connect
programmer
Connect
truck
Control logic Internal check

start routine
C h e c k C h e c k
No power supply, switch

No
YES off truck and check wiring
display
C h e c k C h e c k
Switch off truck; check

W A IT C O N N E C T programmer - controller
N O C O N N E C T YES
No connection
error
C h e c k C h e c k
C H O P P E R N O T O K
Switch off truck; programmer
YES and controller are incompatible
C h e c k C h e c k
Information Display
Traction Controller
W A IT C O N N E C T YES C R O W N B 1 V .1 .0
R E G E N E R 3 5
Information Display
NO Pump Controller
C R O W N H 2 V .1 .0
YES P U M P S T D 3 5
Error during travel Current error

*** A L A R M ***
S T E E R S E N S O R K O
M0288d
Printed in Germany
01/99
M4.5-2230-002
5
MAINTENANCE
Traction Controller Menu Functions
PROGRAM
In the PROGRAM menu the listed truck parameters can
be read and set in real time.
TESTER
In the TESTER menu the listed truck parameters can be
read in real time.
ALARMS
In the ALARMS menu error messages generated and stored
during operation can be called up and processed.
PROGRAM PEDAL
In the PROGRAM PEDAL menu item the traction
potentiometer is calibrated. The traction controller reads
and records the potentiometer's minimum and maximum
output voltage.
CONFIG
The Configuration menu is used to adapt the programmer
to the respective truck model.
In addition, auxiliary functions can be activated or de-

activated. The steering potentiometer is calibrated in the
"Adjustments" sub-menu.
Printed in Germany
01/99
6
M4.5-2230-003
MAINTENANCE
PROGRAM Menu
The following table describes the various truck parameters
which can be set in the PROGRAM menu.
Traction Control System Setting Values
Recommended
Menu Item Setting Range Description
Setting
Acceleration delay. The time taken for the traction

ACC. DELAY 0-9 4 controller to increase the output supply to the traction
motors from 0 to 100%.
Inversion braking. Activated when the directional switch

is reversed. The brake force is dependant on the
INVERSE BRAKING 0-9 5
accelerator pedal position and the maximum traction
current setting.
Release braking. Activated when the accelerator pedal is

RELEASE BRAKING 0-9 3 released or when it returns to neutral. The brake effect is
dependant on the maximum traction current setting.
Pedal braking. Activated when the accelerator pedal is

released, when the directional switch returns to neutral
PEDAL BRAKING 0-9 9 or when it is set to the opposite direction. The brake
effect is dependant on the maximum traction current
setting.
Traction current limit. This value determines the

TRACTION I MAX 0-6 6 maximum supply to the drive motors during all traction
and braking operations.
Adjustable speed reduction, e.g. in relation to the lift

height or the steer angle. In order to program this
SPEED CUTBACK 1 0-9 9
parameter cable no. 5933 on Pin L5 must first be
disconnected.
Creep speed. Setting for the minimum voltage applied to

the traction motors when the travel switch is closed.This
CREEP SPEED 0-9 2
function should be set to one level below the value at
which the truck begins to travel.
ELEKTRIK 08gb
Printed in Germany
01/99
M4.5-2230-004
7
MAINTENANCE
TESTER Menu
The following table describes the various truck parameters
which can be selected and checked in the TESTER menu.
TESTER Menu
Menu Item Description
Displays in real time the output voltage from the drive motors applied to the Volt Motor
L VMN R Negative.
An important reading which provides information on the status of the MOSFETs.
Displays in real time the current flowing through the resistors. Displayed during travel as
L i MOTOR R
well as braking.
BATTERY VOLTAGE Displays in real time the voltage applied to the traction controller.
Displays in real time the steer angle. The display ranges from +90° to -90° and is
STEER ANGLE
measured with reference to the forward position (=0°) of the steering wheels.
Displays the input voltage applied to the traction potentiometer up to 10V. Also displays
ACCELERATOR the accelerator pedal stroke as a percentage which can be used to check whether the
traction potentiometer is calibrated correctly.
SEAT SWITCH Tests the operation of the seat switch and wiring.
FORWARD SWITCH Tests the operation of the "Forward" switch and its wiring.
BACKWARD SWITCH Tests the operation of the "Reverse" switch and its wiring.
Displays in real time the temperature of the MOSFET heat dissipators in the traction
TEMPERATURE
controller.
BRAKE SWITCH Tests the operation of the foot brake switch and its wiring.
CUTBACK SWITCH 1 & 2 Tests the operation of the speed cutback switch and its wiring
ELEKTRIK 09gb
Printed in Germany
01/99
8
M4.5-2230-005
MAINTENANCE
ALARMS Menu
The traction controller can collect and store operational
faults during operation. The ALARMS menu can be used
to call up and read the respective fault codes.
The programmer can display 5 different types of fault codes

up to 99 times together with the applicable number of
service hours.
ALARMS Menu
Fault Code Description Possibe Cause
The test is performed during operation or at the

start of inverse braking. The alarm is activated - Pedal braking contactor jammed
BRAKE CON CLOSED
when the supply to the VMN exceeds 2/3 of the - Logic error
battery voltage.
- Direction contactor does not close

R DIR. CONT. OPEN, Tests the operation of the direction contactors by
- Motor wiring faulty
L DIR. CONT. OPEN measuring the VMN voltage.
- Direction contactor faulty
The test is performed when the brake contactor

- Brake contactor faulty
BRAKE CONT. OPEN has closed. Tests whether the VMN is rising from
- Magnetic coil or wiring faulty
< 1/3 to > 2/3 of the battery voltage.
R DIR. CON. CLOSED, Tests the operation of the direction contactors at - Direction contactor jammed
L DIR. CON. CLOSED idle speed or braking. - Logic error
- Direction contactors faulty

The test is performed in standby mode or during
- Motor insulation between armature
operation at up to 80% of the PWM signal. The
R VMN LOW, L VMN LOW and field faulty
alarm is activated when the VMN falls below 1/3
- Brake contactors closed
of the battery voltage.
- Logic error
The test is performed in standby mode. The alarm - Short circuit between battery + and
R VMN HIGH
is activated when the VMN exceeds 2/3 of the VMN
L VMN HIGH
battery voltage. - Logic error
The test is performed during operation. The alarm

R i = 0 EVER - Current sensor faulty
is activated when the minimum supply level is
L i = 0 EVER - Power supply fault
exceeded and travelling is inhibited.
Displays a fault in the hourmeter memory.

EEPROM DATA KO Followed by reset to zero, traction controller
continues to operate however.
- Steer potentiometer wiring faulty

Steer sensor faulty. Input signal at L2 >4.8 V or <
STEER SENSOR KO - Steer potentiometer incorrectly
0.2 V.
calibrated
Microprocessor self test. Performed during

WATCH DOG - Faulty logic
standby mode and operation.
ELEKTRIK 10agb
Printed in Germany
01/99
M4.5-2230-006
9
MAINTENANCE
ALARMS Menu (contd.)
Fault Code Description Possible Cause
- Short circuit or more than 6A

constant current in one of the
Detects the short circuit current when the contactor coils.
COIL SHORTED
contactor coils are activated. - Negative connection from one of
the contactor tips to battery positive
short-circuited
Tests the voltage applied to the contactor drivers. - Logic error

DRIVER SHORTED Performed when contactor drivers are not - Faulty contactor drivers due to
activated. excessive voltage input.
Informs the operator that the required function

CHOPPER RUNNING cannot be selected while the traction controller is
operating.
Informs the operator that a travel function has - Handbrake on while travel function
HANDBRAKE ERROR been performed with the handbrake on for more activated.
than 5 seconds. - Handbrake switch faulty.
- Driver seat unoccupied.

Informs the operator that a travel function has
SEAT SWITCH OPEN - Seat switch wiring faulty
been performed with the seat switch open.
- Seat switch faulty
ELEKTRIK 10bgb
PROGRAM PEDAL Menu

The PROGRAM VACC sub-menu enables each traction
potentiometer to be calibrated individually for each truck
by taking and storing the minimum and maximum output
voltages of the traction potentiometer.
The minimum output voltage is read as the travel switch

is closed, the maximum output voltage when the travel
switch is fully applied.
Approx. 14V is applied to the travel switch via the traction

controller. The signal range used by the potentiometer is
from 0V (minimum speed) to 10V (maximum speed).
Printed in Germany
01/99
10
M4.5-2230-007
MAINTENANCE
CONFIG Menu
The CONFIG menu provides access to the SET MODEL,
SET OPTIONS and ADJUSTMENTS sub-menus.
CONFIG Menu
Sub-Menu Option Description
Used to select the correct wheel base. The following options are
SET MODEL
available: SC3013, SC3016, SC3018.
Determines the mode of the hourmeter in the traction control

system. The following options are available:
SET OPTIONS Hours running / key on
- RUNNING: Counts the hours while the traction motor is activated
- KEY ON: Counts the hours while the truck is switched on
Activates battery monitoring system in the traction controller. If the

battery voltage falls to below 10% and this function is performed
Battery check on / off (ON):
- the traction controller restricts the max. current to 50 %;
- the respective Service LED on the display starts to flash.
Activates the release braking function. When set to OFF the truck
Release braking on / off does not brake when the travel switch is released or returns to
zero, but continues to coast.
When set to ON the traction controller can power the drive motor
Antiroll back on / off in the opposite sense to its direction of turn up to the programmed
maximum value.
- OFF position: Traction controller sets a pin to 0V when the brake

pedal is applied.
Autobrake light on / off1
- ON position: Traction controller sets a pin to 0V during release
braking and inversion braking.
Used to calibrate the steer potentiometer by reading and storing

the minimum and maximum output voltages of the steer
potentiometer.
ADJUSTMENTS
Based on these minimum/maximum values the traction controller
calculates the respective steer angle within a range of +90° to -
90°.
ELEKTRIK 11gb
Printed in Germany
01/99
M4.5-2230-008
11
MAINTENANCE
Pump Controller Operating Menu
START ROUTINE
PROGRAM TESTER ALARMS PROGRAM CONFIG
ACCELERATION VMN
DECELERATION VIEW ALARM(S) PROGRAM VACC
MOTOR VOLTAGE
CURRENT LIMIT MOTOR CURRENT
HYDRO SPEED COARSE
BATTERY VOLTAGE
HYDRO SPEED FINE
HYDRO SPEED COMP.
TEMPERATURE
CREEP SPEED LIFTING CONTROL
(1) LIFTING SWITCH CLEAR ALARM(S)
HYDRO TIME
1ST SPEED FINE (1) DESCENT SWITCH
1ST SPEED COMP. 1ST SPEED SWITCH
2ND SPEED COARSE 2ND SPEED SWITCH
2ND SPEED FINE 3RD SPEED SWITCH
2ND SPEED COMP.
4TH SPEED SWITCH
3RD SPEED COARSE
3RD SPEED FINE
HYDRO SPEED REQ.
3RD SPEED COMP.
4TH SPEED COARSE
4TH SPEED FINE
4TH SPEED COMP.
SET MODEL SET OPTIONS ADJUSTMENTS
(1) PUMP (1) BYPYSS (1) SET BATTERY

(1) PUMP + HYDRO BATTERY CHECK TYPE
HOUR COUNTER
(1) MAIN CONTACTOR
(1) AUX. FUNCTIONS
(1) SET BATTERY
VOLTAGE
(1) No longer available with version HPHA1.73
Printed in Germany
01/99
12
M4.5-2230-009
MAINTENANCE
Menu Functions Pump Controller
PROGRAM
In the PROGRAM menu the listed truck parameters can
be read and set in real time.
TESTER
In the TESTER menu item the listed truck parameters
can be read in real time.
ALARMS
In the ALARMS menu error messages generated and stored
during operation can be called up and processed.
PROGRAM VACC
In the PROGRAM VACC menu the lift potentiometer is
calibrated. The pump controller reads and records the
potentiometer's minimum and maximum output voltages.
CONFIG
The Configuration menu is used to activate or de-activate
various auxiliary functions.
Printed in Germany
01/99
M4.5-2230-010
13
MAINTENANCE
PROGRAM Menu
The following table describes the various parameters which
can be set in the PROGRAM menu for the pump controller.
Pump Control System Settings
Setting Recommended
Range Setting
Acceleration. The time taken for the pump controller to

ACCELERATION DELAY 0-9 3
increase the pump speed from 0 to 100% if necessary.
Delay. The time taken for the pump controller to reduce

DECELERATION DELAY 0-9 0 the pump speed from 100 to 0% when the lift
potentiometer is reset.
CURRENT LIMIT 0-9 9 Restricts the maximum current of the pump motor.
HYDRO SPEED* coarse: 1 Parameter for pump speed setting during steering.
0-9
COARSE / FINE fine: 4 See also SPEED COARSE and SPEED FINE.
With this function the pump control system varies the

pump speed via the output voltage within a small range
HYDRO SPEED
0-9 2 and can therefore compensate for any change in load.
COMPENSATION
This function is only active for hydraulic functions with a
fixed pump speed.
Creep speed setting for lifting. When this parameter is

CREEP SPEED 0-9 4 increased the time taken to reach the maximum pump
speed automatically reduces.
Pump motor delay period: time taken for the pump motor
HYDRO TIME 0-9 1
to cut out after a steering function.
1st 0 Coarse setting of the respective pump speed in

1ST, 2ND, 3RD & 4TH** 2nd 1 increments of approx. 11%. The actual pump speed is the
0-9
SPEED COARSE 3rd 0 result of coarse and fine settings (SPEED COARSE and
4th 0 SPEED FINE).
1st 0
Fine adjustment of the respective pump speed through
1ST, 2ND, 3RD & 4TH 2nd 1
0-9 repeated sub-division of the 11% levels set in SPEED
SPEED FINE 3rd 0 (5)
COARSE by increments of 1.2 %.
4th 0
* HYDRO SPEED: Steering
** 1ST SPEED: Not used

ELEKTRIK 12gb
2ND SPEED: Tilt (2nd lever)
3RD SPEED: Sideshift (3rd lever)
4TH SPEED: Aux. function (4th lever)
Printed in Germany
01/99
14
M4.5-2230-011
MAINTENANCE
TESTER Menu
The following table shows the various truck parameters
which can be selected and tested in the TESTER menu.
TESTER Menu
Displays in real time the output voltage for the pump motor applied to the Volt Motor
VMN
Negative.
MOTOR VOLTAGE Displays in real time the voltage applied to the pump motor.
Displays in real time the motor current flowing through the pre-resistor (SH) in the pump
MOTOR CURRENT
controller.
BATTERY VOLTAGE Displays in real time the battery voltage applied to the pump controller.
TEMPERATURE Displays in real time the MOSFET heat dissipator temperature in the pump controller.
LIFTING CONTROL Displays the input voltage applied to the lift potentiometer.
1ST SPEED SWITCH Displays the signal status for the 5th hydraulic function.
2ND SPEED SWITCH Displays the signal status for the 2nd hydraulic function.
3RD SPEED SWITCH Displays the signal status for the 3rd hydraulic function.
4TH SPEED SWITCH Displays the signal status for the 4th hydraulic function.
HYDRO SPEED
Displays the signal status for the steering function.
REQUEST
ELEKTRIK 13gb
Printed in Germany
01/99
M4.5-2230-012
15
MAINTENANCE
ALARMS Menu
The pump controller can detect and store any faults which
occur during operation. The ALARMS menu can be used
to call up and read the respective fault codes.
The programmer can display 5 different types of fault codes

up to 99 times together with the applicable number of
service hours.
ALARMS Menu
The test is performed in standby mode. The alarm

- Faulty motor wiring
VMN LOW sounds when the VMN falls to below 1/3 of the
- Pump controller faulty
battery voltage.
The test is performed in operational mode. When

NO FULL COND. the VMN falls to below 1/3 of the battery voltage - Diagnostic circuit in controller faulty
the pump motor power supply is disconnected.
For cold MOSFETs:

Indicates that the temperature of the MOSFETs is - Heat sensor wiring faulty
TH. PROTECTION greater than 80°C. The maximum current is - Heat sensor faulty
gradually reduced and is zero at 85°C. - Error in logic connector
- Logic faulty
Low battery voltage. Alarm displayed only when

BATTERY BATTERY CHECK option is active. All hydraulic
functions interrupted except for steering.
- Operating error: lever applied when

key switch activated.
INCORRECT START Truck functions when key switch pressed.
- Microswitch faulty
- Wiring faulty
Checks motor current in standby mode. For a

- Current sensor faulty.
I HIGH AT STAND value other than 0V an error message is
- Logic faulty
displayed and controller is interrupted.
Checks motor current during operation. When the

I = 0 EVER minimum current is exceeded controller is - Current sensor faulty.
interrupted.
Error message interrupts pump controller - Error in truck parameter memory

EEPROM PAR. KO
operation. range; replace controller.
Error message interrupts pump controller - Error in configuration data memory

EEPROM CONF. KO
operation. range; replace controller.
ELEKTRIK 14agb
Printed in Germany
01/99
16
M4.5-2230-013
MAINTENANCE
ALARMS Menu (cont.)
Displays fault in hourmeter memory range.

EEPROM DATA KO Hourmeter is reset to zero, but controller
continues to operate.
Fault in hourmeter data, error message and truck

EEPROM OFF LINE If alarm persists, replace controller.
parameter memory range
Configuration data do not match the controller

CHOP. NO CONF. Incorrect controller
used.
Microprocessor self test: performed during

WATCH DOG Logic faulty
standby and travel modes.
ELEKTRIK 14bgb
PROGRAM VACC Menu

The PROGRAM VACC sub-menu is used to calibrate the
lift potentiometer. The maximum potentiometer voltage
corresponds to the full lever displacement. The minimum
voltage is always 0V.
14V is supplied to the lift potentiometer via the pump

controller logic. The signal range used by the potentiometer
is between 0V (minimum speed) and 10V (max. speed) as
signals above 10V are reduced to 10V by the internal logic
system.
Printed in Germany
01/99
M4.5-2230-014
17
MAINTENANCE
CONFIG Menu
The CONFIG menu provides access to the SET OPTIONS
sub-menu.
CONFIG Menu
Sub-Menu Option Description
Determines the mode of the hourmeter in the pump controller. The

following options are available:
SET OPTIONS Hours running / key on
- RUNNING: Counts the hours while the drive motor is activated
- KEY ON: Counts the hours while the truck is switched on
Activates battery monitoring system in the pump controller. If the

battery voltage falls to below 10% and this function is activated
Battery check on / off (ON):
- the traction controller restricts the max. current to 50 %;
- the respective Service LED on the display starts to flash.
ELEKTRIK 15gb
Printed in Germany
01/99
18
M4.5-2230-015
MAINTENANCE
Traction Controller Safety Test l Lower the front wheels.
The truck is now operational.

Pulse Monitor Trip Test (PMT)
CAUTION
IN COMPLIANCE WITH EU NORM

PREN1175-1 THE FOLLOWING TEST MUST
BE CARRIED OUT TO MONITOR THE
TRACTION CONTROLLER FUSE CIRCUIT.
Equipment
A test cable with a 10A fuse and an insulated crocodile

clip at each end.
Test
l Switch off the truck.
l Jack up the front wheels of the truck.
l Connect the test cable between - B and VMN L.
l Connect the programmer to the controller.
l Press the seat switch.
l Switch on the truck.
l LED code (lights up three times)
and following message displayed:
"ALARM L VMN LOW".
l Select truck forward or reverse.
l Depress accelerator pedal:
1. Travel mode does not start.
Test performed successfully
2. No LED display, travel mode starts.
Replace traction controller.
l Switch off the truck.
l Connect the test cable between - B and VMN R.
l Repeat the test for VMN R.
l Disconnect the test cable between - B and

VMN R.
Printed in Germany
01/99
M4.20-2230-001
19
MAINTENANCE
PMT Safety Test Wiring
+ S H L + S H R
S H S H
L D 2 R D 2
-S H L -S H R
L D 1
V M N L V M N R R D 1
B 1 S 4 8 V / 3 5 0 + 3 5 0
L O G IC
- B
1 0 A 1 0 A
F U F U
M0341
Test Cable
Printed in Germany
01/99
20
M4.20-2230-002
MAINTENANCE
Battery Replacing the Battery

WARNING
General ONLY USE BATTERIES WHICH COMPLY WITH
The condition of the battery considerably affects the output THE DIMENSION, WEIGHT AND CAPACITY
and behaviour of the truck. Proper maintenance enhances REQUIREMENTS FOR THIS TRUCK.
the performance and service life of the battery. An incorrect tbattery can damage the truck.
Only service the battery in accordance with the Incorrect weight and dimensions alter the truck
manufacturer's instructions. centre of gravity. This can result in accidents and
will invalidate the warranty.
The respective manufacturer's maintenance manual is
provided with all batteries supplied by Crown. To replace the battery use either a battery trolley or a crane
with sufficient capacity.
Operation
Removing the Battery
During discharge the battery connector is connected to
the truck circuit. During charging, it is connected to the l Apply the handbrake.
charger.
l Switch off the truck and remove the key.
Make sure that the battery connector is not disconnected
when the truck is in use and that there is a fixed connection l Open the battery compartment lid.
between the connector halves during truck operation and
when the battery is being charged. A poor connection will l Remove the battery connection and put the
cause the contacts to burn and damage the operation and battery cable in a safe place.
charging capacity of the battery.
l Securely fit the appropriate lifting equipment.
Reading the Electrolyte Level
l Using an appropriate lifting mechanism lift the
Check the electrolyte level on the surface of the battery battery out of the truck and rest it securely.
fluid before adding destilled water.
l Install the charged battery in the reverse order.
The electrolyte density is the most reliable indicator of
the battery's condition. When checking it, make sure that Charging the Battery
sufficient electrolyte is suctionned into the glass tube so
that the floating body can swim freely when the acid tester DANGER
is held vertically.
HYDROGEN IS RELEASED DURING
To compensate for loss of electrolyte use destilled water CHARGING WHICH CAN IGNITE AND
only. Replenish at regular intervals irrespective of the EXPLODE. IT IS A LIFE-THREATENING
ambient temperature (see maintenance schedule in DANGER!
Section M1.0). l Always keep the battery compartment lid
open when charging a fixed battery.
The battery plates must be covered. Never overfill the
battery as wet and dirty cell lids lead to leak current and l Make sure the charging area is well
can thus reduce battery power. Overfilling can also lead to ventilated.
corrosion of the battery terminals and damage to the battery
housing. l The charging area must be free from naked
flames and sparks.
Excessive loss of electrolyte indicates a faulty battery,
e.g. due to over-charging, total discharge, leak current from
individual battery cells etc.
Printed in Germany
01/99
M4.25-2230-001
21
MAINTENANCE
CAUTION
BEFORE COMMISSIONING THE CHARGER

MAKE SURE THAT IT IS SUITABLE FOR THE
BATTERY VOLTAGE AND SIZE.
READ THE INSTRUCTIONS OF THE
CHARGER MANUFACTURER.
Connect the battery to the charger. Make sure that the
connection is secure.
After charging, make sure that all insulators between the

cell connections and the battery lid are correctly positioned
before using the truck again.
DANGER
NEVER TRAVEL WITHOUT A SIDE BATTERY

COMPARTMENT PANEL OR WITH AN OPEN
BATTERY COMPARTMENT LID. THIS CAN
RESULT IN ACCIDENTS.
Printed in Germany
01/99
22
M4.25-2230-002
MAINTENANCE
Battery Discharge Indicator (BDI)
General
A battery from the factory requires between 5 - 10 discharge
cycles before it reaches its full capacity.
A battery is considered to be discharged when it has a

residual capacity of 20 %. For example, a battery with a
capacity of 500 Ah has an actual available output of 400
Ah.
In addition the usable output depends on the discharge

rate which in turn is governed by the particular truck
application. For this reason the battery discharge indicator
must be set in accordance with the conditions of use of
the truck. An incorrectly set battery discharge indicator
can result in total discharge or complete failure of the
battery.
NOTE
FOR NEW TRUCKS, ADJUST THE BATTERY
DISCHARGE INDICATOR AFTER TEN
DISCHARGE AND CHARGE CYCLES AT THE
LATEST.
Adjusting the Battery Discharge

Indicator
The standard factory setting for the battery discharge
indicator is "N" (selector at the back of the BDI module).
To adjust this setting proceed as follows:
l Measure the electrolyte density on the fully

charged battery.
The density should be measured on three different

battery cells and should be at least 1.27 - 1.28 or
1.29 - 1.30 for high density batteries (consult battery
manufacturer for exact values).
l Measure the acid density again as soon as two

red LEDs on the battery discharge indicator flash and
lifting is automatically interrupted. Take the reading
as before. The reading should not be less than
1.12- 1.13.
l For higher readings change the battery

discharge indicator setting to "K", for lower readings
change to "U".
l Make a test measurement with the battery

charged and discharged.
Printed in Germany
01/99
M4.30-2230-001
23
MAINTENANCE
Traction / Pump Motor Maintenance
Access
l Remove the battery connector.
l Remove the left hand floorboard (no screws,

Fig. M0023).
M0077
l Remove all carbon brushes and check each

one for wear. Replace if brush length is less than
20 mm (traction motor) respectively 15 mm (pump
motor) (Fig. M0076). Apply pressurised air to the
motor.
M0023
l On the right hand floorboard loosen one hex.

socket screw and lift up the floorboard (Fig. M0024).
M0076
l Check the anchor for evenness and make sure

it is not damaged in any way. An evenly distributed
layer on the brush surfaces is normal.
M0024
l Make sure that all brushes apply a uniform
l Remove the strap retainer from the upper motor pressure to the anchor.
section (Fig. M0077).
l Re-fit the strap retainer.
Printed in Germany
01/99
24
M4.35-2230-001
BRAKE
Printed in Germany
Printed in Germany
MAINTENANCE
Brake System
General
The left and right hand gear units each contain a drive
wheel brake unit (Fig. M0361) which acts as an operating
and parking brake.
The operating brake is activated via a brake pedal linkage.

The parking brake is activated by a handbrake lever and a
handbrake cable which is connected to the brake linkage.
The brakes are spring-released.
Operation
When the brake pedal is applied the two friction plates act
on the brake disk via the clamping plate to brake.
Base plate Friction plate Handbrake cable Brake pedal linkage
Brake disk
Spring
M0361
RH brake unit Spacer Clamping LH brake unit

plate
Printed in Germany
01/99
M5.0-2230-001
1
MAINTENANCE
Replacing the Brake Disks and
Linings
Preparation
To assemble new brake lining disks:
l Raise the mast and secure it with square

wedges (Fig. M0342);
l Remove the floorboards and internal panelling

(Fig. M0253b, M0254b).
Secure inside
mast with square
wedges
M0342
M0253b
Fig. M0253b: Removing the left and right-hand floorboards): Fig. M0254b: Removing the dashboard panel: M0254b
l Remove the Allen screw from the RH l Remove the 6 Allen screws.
floorboard.
l Remove the panelling.
l Move the floorboards away from each other and
lift them out.
Printed in Germany
01/99
2
M5.0-2230-002
MAINTENANCE
Brake Disk and Lining Dimensions
Always replace the LH and RH brake disks and brake lining
plates (as a set) at the same time.
l Replace the friction plate if the lining is 2.8mm

thick or less (lining thickness ≤ 2.8mm).
l Replace the brake disk if the thickness is

5.6mm thick or less (thickness ≤ 5.6mm).
l When the brake is applied the overall

thickness of the LH and RH friction plates and
brake disks should be no less than 11.2 mm
(overall thickness ≥ 11.2mm).
Printed in Germany
01/99
M5.0-2230-003
3
MAINTENANCE
Removing the Brake Disks and the Friction
Plates (Fig. M0362)
l Disconnect the battery;
l Secure the truck to prevent it from rolling away;
l Remove the 2 splints (1);
l Remove both bolts (2) from the base plate and

clamping plate (4) and press the linkage (3) down;
l Remove the clamping plate (4);
l Loosen the mounting screw (5);
l Remove the mounting pad (6) and spacer (7);
l Unscrew the 4 nuts (8) and remove the 4

washers (9);
l Remove the front friction plate (10);
l Remove springs (12, 13);
l Remove the brake disk (14) from the pinion

(15);
l Remove the pinion (15) from the transmission

shaft;
l Unscrew the 4 studs (16) and remove the back

friction plate (17).
Installation
l Installation is the reverse of removal.
NOTE
BEFORE INSTALLING THE FRONT FRICTION

PLATE (10) INSERT TWO PINS (11) TO FIX
THE SPACER (7).
l Adjust the operating and hand-brake;
l Test the brake.
Printed in Germany
01/99
4
M5.0-2230-004
MAINTENANCE
Printed in Germany
01/99
M5.0-2230-005
5
MAINTENANCE
Removing the Handbrake Cable (Fig.M0366) l Measure the air gap at three points between
the brake disk and the friction plate using a feeler
l Remove the 4 nuts (1); gauge (Fig. M0364). The nominal value is 0.5 - 0.7mm;
l Remove the pin (2); l Unscrew the counternut (Fig. M0343);
l Remove the bolt (3) from the handbrake lever l To reduce the air gap turn the threaded rod
and cable; clockwise, to increase it anticlockwise;
l Remove the upper end of the handbrake cable l Measure the air gap again at three points;
(6) from the handbrake lever;
l Fix the counternut;
l Remove the pin (4);
l Make sure that the brake disk is free to move
l Remove the bolt (5); on the toothing;
l Remove the handbrake cable (6) from the truck; l Adjust the handbrake cable.
Installation
l Installation is the reverse procedure.
0.5 - 0.7 mm
l Adjust the handbrake.
M0364
Jam nut
Reduce air gap Increase air gap

Adjusting the Operating Brake and
Handbrake
Preparation Threaded rod
To adjust the operating and handbrake, remove the
floorboards (Fig. M0253b) and inside panelling (Fig.
M0254b). M0343
Adjusting the Operating Brake Air Gap

l Push the floating brake disk towards the left or
right-hand friction plate;
Printed in Germany
01/99
6
M5.0-2230-006
MAINTENANCE
Operating Brake Test
l On a level, dry surface accelerate the empty
truck at operating temperature to maximum speed.
l Record the braking distance from the point

where the brakes were applied to the point where the
truck stops. The braking distance should not exceed
3.10m.
Handbrake Adjustment
Adjust the handbrake lever so that the lever is in the 5th
notch when applied.
l Remove the nut (1);
l Screw the nut (2) to adjust;
l Tighten the nut (1);
l Pull the handbrake cable ten times in the applied

position (5th notch);
l If the lever exceeds the 5th notch position, re-

adjust the handbrake.
CAUTION
IF THE BRAKE CABLE IS TO BE REPLACED

IN FULL, THE HANDBRAKE MUST BE SET TO
THE THIRD NOTCH POSITION TO ALLOW
FOR THE CABLE EXTENSION.
M0363
Printed in Germany
01/99
M5.0-2230-007
7
Printed in Germany
STEERING
Printed in Germany
Printed in Germany
MAINTENANCE
Steering
Hydraulic System
The input section of the pilot valve contains a so-called
priority valve (Fig. M0117) which distributes the oil flow
between the steering and the other hydraulic functions of
the truck. Priority is always given to steering.
When the steering wheel is turned, oil flows from the oil
tank to the pilot valve and from there to the steering unit
via the priority valve. Any oil not required for steering at a
given moment is also directed via the priority valve to the
in-line lifting functions.
When the oil is distributed, the composition is determined

by the LS signal transmitted by the steering unit to the
priority valve. When the load pressure increases a
proportionally greater amount of oil enters the steering
unit. An overload valve limits the operating pressure in
the steering unit to 70 bar. M0115B
Figure M0118 shows a lateral view of the complete steering
system motor. The following components can be seen:
l Steering potentiometer and connection
l 3 point mounting flange
l Wheel hub and wheel pickup
l Steering cylinder and hydraulic connection.
M0117
Components
The following components can be accessed by removing
the steering shaft cover (Fig. M0115B):
l Steering shaft and toothing
l Steer sensor (records steering shaft motion to

activate the pump via the pump controller)
l Sensor module
l Distributor system with 5 connections

(pressure, return flow, LS to priority valve and 2 outputs
to the steering drive cylinders).
The hydraulic steering unit is behind the distributor system.
M0118
Printed in Germany
01/99
M6.0-2230-001
1
MAINTENANCE
Removing the Steering Motor l Disconnect the steering potentiometer and
remove the potentiometer;
l Jack up and secure the truck;
l Attach a rope to the top of the drive unit to
l Disassemble both wheels; prevent it from falling;
l Prepare the area for the collection of spilled l Secure the lower section of the drive unit with
hydraulic oil; wooden blocks;
l Disassemble the two hydraulic lines from the l Remove the 3 screws of the mounting flange;
steering cylinders;
l Lower the drive motor.
Steering System Hydraulic Diagram
L R
O R B IT A L S T E E R IN G
C L O S E D C E N T R E
L S
L S C F 1 A 1 B
P T S T E E R R V
7 0 B A R
O P T O
T
E N C O D E R
M A IN
R V
2 1 0
B A R
M O T O R
P R IO R IT Y V A L V E L IF T T IL T
P U M P
S T R A IN E R
792341lenk-gb
Printed in Germany
01/99
2
M6.0-2230-002
MAINTENANCE
Steering Axle Steering Drive Assembly

Wheel hub pre-assembly
Design
l Insert the wheel bolts (item 34) using a
The steering axle comprises the steering drive and the hydraulic device (Fig. M1248).
axle bracket. The steering drive comprises a hydraulically
activated spur gear tooth rod drive connected to the axle l Fit the bearing halves of the conical roller
bracket via a flange. bearings (item 28) into position and grease the bearing
half of the inner conical roller bearing with Crown P/N
NOTE 053002-001.
WHEN ORDERING SPARE PARTS BEAR IN

Steering knuckle pre-assembly
MIND THAT THE AXLE BRACKET IS ONLY
AVAILABLE AS A COMPLETE ASSEMBLY, l Push the seal (item 27) up the steering knuckle
I.E. WITH PRE-ASSEMBLED AXLE. filled with grease (Crown P/N 053002-001).
The reference numbers contained in the following assembly
instructions refer to the exploded diagram in chapter 6 of l Heat the inner conical roller bearing (item 28)
the spare parts section in the second part of this manual. and fit it in position. Finally, grease with Crown P/N
053002-001.
Steering knuckle and wheel hub assembly

As mentioned at the beginning, the steering knuckle is
supplied with the pre-assembled axle as a complete
assembly (item 25).
For the remaining assembly, proceed as follows:
l Fit the wheel hub (item 29) on the steering

knuckle (item 25).
l Fill the space between the wheel hub and the

steering knuckle with Crown P/N 053002-001 grease.
l Grease the outer conical roller bearing (item

28) with Crown P/N 053002-001 and insert it in the
wheel hub.
l Position the U-shaped washer (item 30) and

firmly screw in the castellated nut (item 32).
l To check the bearing play, turn the wheel hub.

The vacuum resistance should be 2 - 6 Nm. If
necessary adjust using the torque of the castellated
nut.
l When the bearing play has been correctly set,

M1248 secure the castellated nut using the splint (item 31).
l Drive in the cover (item 33) filled with Crown P/

N 053002-001 grease, thereby sealing the assembly
from external influences.
Printed in Germany
01/99
M6.1-2230-001
3
MAINTENANCE
Spur pinion wheel shaft pre-assembly l Position the shim and the bevelled washer
(item 6). Place another shim above the bevelled
l Fill the seal (item 23) with Crown P/N 053002- washer.
001 grease and place it in position.
l Fit the bearing half of the conical roller bearing
l Press the conical roller bearing (item 22) on top. (item 5) into position (Figs. M1251, M1252).
l Heat the bearing race (item 21) to approx. 120°C

and seal with LOCTITE 620, Crown P/N 794102
(Fig. M1249).
M1251
M1249
Housing Pre-Assembly
l Clean the housing (item 9) using a cold cleaning
solution and blast out with pressurised air.
l Insert the retaining ring (item 7) for the top

conical roller bearing (Fig. M1250).
M1252
l Turn the housing and fit the bearing half of the

conical roller bearing (item 22) into position
(Fig. M1253).
M1250 l Fit the conical roller bearing (item 5) (Fig.

M1254). Now place the wheel shaft in the housing.
Printed in Germany
01/99
4
M6.1-2230-002
MAINTENANCE
When the bearing play has been set, disassemble the spur
pinion wheel shaft and proceed as follows to continue
preparation of the housing:
l Gently oil the shaft seals (items 8, 20) and press

into position (Figs. M1255-M1258).
M1253
M1256
M1254
Setting the Bearing Play:

Place two shims on the bearing.
l Screw the groove nut (item 1) to medium

tightness.
l After tightening, hammer gently on the top

section of the housing using the plastic hammer to
position the bearings. M1255
l Check the bearing play manually. It is better

for the bearing to be slow to move rather than too free
(vacuum resistance 2 - 5 Nm). If the bearing is too
free, replace the bevelled shim (gauge, item 6).
Printed in Germany
01/99
M6.1-2230-003
5
MAINTENANCE
M1260
M1258
M1257 M1259
l Thoroughly grease the bearing halves of the l Place the tooth rod (item 36) in the housing,
conical roller bearing (item 22) using GRESALIT LZ2 while ensuring that the threaded groove rests in the
(Fig. M1260). middle of the housing.
l Grease the conical roller bearing (item 22) and 2 teeth on the spur pinion wheel shaft are marked with a
the spur pinion wheel shaft with GRESALIT LZ2 (Fig. bevel. The housing must be positioned so that the tooth
M1259). rod groove lies between the bevelled teeth (Fig. M1261).
Printed in Germany
01/99
6
M6.1-2230-004
MAINTENANCE
Tooth bevelment Tooth rod
M1263
l Fill the seal (item 4) with grease (use residual

grease from previous step) and place in position.
M1261
l Position the shim (item 3) and the retaining plate

Threaded groove Drive shaft (item 2) (Fig. M1264).
l Fill the bearing half of the top conical roller l Tighten the groove nut (item 1) and fix in
bearing (item 5) with Crown P/N 053002-001 so that position by placing it over a hub of the retaining plate
grease emerges when the bearing is re-positioned (item 2) Fig. M1265).
(Figs. M1262, M1263).
M1262 M1264
Printed in Germany
01/99
M6.1-2230-005
7
MAINTENANCE
l Manually screw in the cylinder (item 17) using
screw locking device (LOCTITE 242 Crown P/N
053050-006) and tighten (medium tight) in a clamp
using the wrench.
Assembling the Axle Bracket to the Steering

Drive
l Drive the clamping sleeve (item 19) into the
top treated surface of the axle bracket (Fig. M1267).
M1265
Cylinder Pre-Assembly
l Place the pistons (item 13) complete with piston
guide rings (item 12) and the compact seal (item 14) M1267
into the cylinder (item 17) without tilting. Ensure that
the cylinder contact surfaces are totally clean. l Place the axle bracket on the transmission
housing.
l Finally, fill each cylinder with G00F (to DIN
l Fit the tensile lock screws (item 26) and torque
51502) gear lubricant. Capacity per cylinder:125 cm3.
to prescribed moment (320 Nm).
Fitting the Cylinders l Final check: move cylinder in both directions
l Drive the bushing (item 5) into the housing. with air and check operation.
Gently oil the tooth rod (item 36) (Fig. M1266).
The final assembly of the steering axle is complete when
l Place gently greased O-rings (item 16) in their the lock screw (item 10) is assembled with the seal ring
(item 11) placed underneath it.
respective housing grooves. Check correct position.
Operational and Leak Test

Finally, an operational and leak test should be carried out
if possible.
l Steer in both directions two or three times until

you reach the stop.
l Remove the cylinder again and carry out a vi-

sual inspection. Above all, check for any damage,
leaks, grooves in the cylinder surfaces etc.
M1266
Printed in Germany
01/99
8
M6.1-2230-006
MAINTENANCE
Maintenance
General
To protect cylinders and seals the machine-specific oil
checks and change schedules must be observed (see
page M1.3-2230-001 in the present manual).
In addition the steering axle must be checked in the course

of daily service and maintenance for any leakages,
corrosion or other types of damage as well as for general
operation and safety. If in doubt, replace the parts.
In particular, the seals must be aligned with the wheel

bearings (item 27) and the wheel shaft bearing (item 4),
as the bearings could run dry if damage occurs.
Gear Lubricant
The gear lubricant used is G00F (to DIN 51502) and is
suitable for use in temperatures of between -20°C and
+80°C.
For colder ambient temperatures contact your Crown dealer.
Seals
The seal material used is designed for temperatures
between -40°C and +100°C.
Printed in Germany
01/99
M6.1-2230-007
9
Printed in Germany
MAST
Printed in Germany
Printed in Germany
MAINTENANCE
Mast
Disassembly
To disassemble the lift mast proceed as follows:
l Prepare the area for the collection of spilled Mast roller

oil.
l Remove the 2 pressure lines and 1 pressure

hose from the storage housing (Fig. M0234).
Washers 0.4 - 1.52 mm M0380
The following washer dimensions are available: 0.4mm,

0.76mm and 1.52mm. Ideally, the same number of washers
should be used on all mast rollers. Although this is not
always possible, it is important to ensure at least an even
distribution of washers on each side.
An example of this would be 2 washers on each roller on

the left-hand side of the mast and 1 washer on each roller
on the right-hand side of the mast (Fig. M0381). Uneven
distribution of the mast rollers will cause the mast to tilt
(Fig. M0382).
M0234
l Secure the upper section of the mast with

suitable equipment.
l Disassemble the tilt cylinder from the mast.
l Remove the bearing halves in the lower mast

section from drive.
l Lift out the mast from the top.
Mast Roller Adjustment

The play of the mast sections is greatest when they are
retracted and least when they are extended. Accordingly,
the mast rollers can move freely when the mast is retracted
and provide maximum stability when the mast is exten-
ded. The mast sections' play should therefore only be
checked when the mast is extended.
The washers used for adjusting the mast roller play are
placed underneath the mast rollers (Fig. M0380). To do
this, the mast rollers must first be disassembled.
Printed in Germany
01/99
M7.0-2230-001
1
MAINTENANCE
Non-Adjustable 2 washers 1 washer (fork

(fork carriage) carriage)
1 washer 2 washers
1 washer 2 washers (fork carriage) (fork
(fork carriage) (fork carriage) carriage)
2 washers 1 washer
(mast) (mast)
1 washer
2 washers (mast)
(mast)
1 washer 2 washers
(mast) (mast)
M0381 M0382
Printed in Germany
01/99
2
M7.0-2230-002
MAINTENANCE
Fork Carriage Roller Adjustment
6 rollers are attached to the fork carriage in total (Fig.
M0383). The highest roller extends above the mast section
when the mast is lifted. It is secured by a retaining ring
and does not require any adjustment.
Sideshift roller,
adjustable
Mast rollers,
fixed M0384
Crow bar Caliper
Mast rollers,
adjustable
Sideshift roller,
adjustable
To adjust the other 4 rollers, proceed as follows:
l Extend the fork carriage as far as the stop and M0385

lower slightly. Add washer if play > 0.76mm
l To check the play of the fork carriage rollers
push the fork carriage on its side using a crow bar.
This will keep the opposite side held firmly against
the mast section, enabling the mast section to be
measured exactly (Fig. M0384).
l After moving the fork carriage maintain a slight

pressure to keep the fork carriage in position.
l Record the play between the roller and the mast

section at a distance of 10mm from the front of the
section (Fig. M0384). If the rollers are slightly skew,
always measure the lesser play.
l The play should be between 0mm and 0.76mm.

If it exceeds 0.76mm fit another washer behind the
roller (Fig. M0385).
Printed in Germany
01/99
M7.0-2230-003
3
MAINTENANCE
Mast Roller Adjustment Checking the Mast Play
6 rollers are attached to the TT mast in total, 4 on the TL When the mast roller play has been adjusted by adding or
and TF masts respectively. To adjust the mast rollers, removing washers, the operation of the mast rollers must
proceed as follows: be checked as follows.
l Extend the mast as far as the stop and lower l Remove grease from the mast sections with a
slightly. This prevents the mast from twisting. solvant and wipe with a cloth.
l To check the play of the mast rollers push the l Spay the mast sections with a thin layer of
mast section on its side using a crow bar. This will paint. The grooves provide a guide to the mast rollers'
keep the opposite side held firmly against the mast operation. There should only be wear on the contact
section, enabling the mast section to be measured surfaces of the mast rollers.
exactly.
l There should be no grooves or other damage
l After moving the mast section maintain a slight to the mast sections. Grooves normally form on the
pressure to keep the mast section in position. roller side approx. 10 mm from the front of the section.
If this occurs, a washer should be removed and the
l Record the play between the mast roller and mast re-aligned.
the mast section at a distance of appr. 10 mm from
the front of the section (Fig. M0386). If the rollers are
slightly skew, always measure the lesser play.
l The play should be between 0mm and 0.76mm.

If it exceeds 0.76mm place another washer behind
the roller (Fig. M0385).
M0386
Crow bar Caliper
Printed in Germany
01/99
4
M7.0-2230-004
MAINTENANCE
Lift Chain Test service hours for maintenance should be halved. The lift
chains should be cleaned with paraffin or a derivative prior
to inspection.
General
NOTE
Lift chains are a major component of a fork lift truck and
are subject to considerable stress. DO NOT USE CHEMICAL SOLVANTS OR
STEAM TO CLEAN THE CHAINS AS THE
The present maintenance instructions will contribute to LUBRICANT APPLIED AT THE FACTORY WILL
ensuring maximum operational life and prevent premature BE REMOVED FROM THE INNER PLATE
failure of the lift chains. SURFACES.
The lift chain with its numerous connection plates is
designed to provide a better flow of oil to the individual Look out for the following damage and wear:
chain pins (Fig. 2777si).
l Worn or missing connection plates
Lubricant l Pitting due to rust or corrosion, in particular on

film the outer surfaces of the connection plates;
l Pins turning in or extruding from the outside

plates;
l Loss of freedom of movement, worn connection

plate edges;
l Damage to the anchor bolt attachment;
2777si
l Wear and corrosion to the anchor bolt and
anchor;
l Wear between the bolts and the connection

A sufficient lubricant film guarantees: plates;
l Less joint wear as well as less chain elongation; l Chain elongation.
l Less corrosion; DANGER
l Less distortion of the pins; IF ONE OF THE ABOVE PROBLEMS OCCURS

IMMEDIATELY REPLACE THE CHAINS, CHAIN
l The joints are free to move; ANCHORS OR BOLTS IN PAIRS.
l Smooth and even chain flow;

NEVER ATTEMPT TO REPAIR DAMAGED
CHAINS. THIS CAN RESULT IN FATAL
l Less tension due to reduced internal friction.
ACCIDENTS.
Maintenance
The chain must be inspected every 100 hours for any signs
of faults or damage. If this cannot be performed on the
truck, the lift chains must be removed.
Irrespective of the result of the inspection, the lift chains,

detachable chain anchors and anchor bolts must be
replaced after max. 6000 service hours or three years,
whichever comes first.
In severe operating conditions (e.g. cold store) the

maintenance interval or the recommended number of
Printed in Germany
01/99
M7.5-2230-001
5
MAINTENANCE
Detailed Chain Testing DANGER
Worn or Missing Plates NEVER ATTEMPT TO REPAIR THE CHAIN BY

DRIVING PINS BACK INTO THE CHAIN. THIS
Generally speaking, material wear is the cause of worn or CAN RESULT IN ACCIDENTS WITH SEVERE
missing connection plates. The plates near the chain pin OR EVEN FATAL INJURIES.
hole (Fig. 2774si) can crack after a large number of lifting
cycles with heavy loads.
2774si
Replace both chains immediately if cracking shows or

plates are missing.
Pitting and Corrosion

Pitting and corrosion occur as a result of poor maintenance 2776si
or storage. The layer of grease applied at the factory is an
excellent protection and should never be removed by
steam jet cleaning or chemical solvants. Freedom of Movement and Worn Edges
Pitting and corrosion contribute to wear of the outside Each individual chain link must flex freely. Tight joints (Fig.
plates in particular, in the form of cracking (Fig. 2773si). 2775si) increase friction and the chain tension during lifting.
Excessive chain tension in turn accelerates material wear.
If rust is visible during inspection, immediately
disassemble the chains and inspect for any damaged or Possible causes of stiff joints are as follows:
worn plates.
l Bent pins or plates;
l Rusty joints;
l Peened plate edges.

2773si
Chains which are bent or whose edges are worn must be
Immediately replace the chains if damage or cracking is replaced immediately.
visible.
Possible causes of worn edges are as follows:
Protruding or Turned Chain Pins
l Worn pulleys;
Considerable frictional forces between the connection
plates and the pins occur when lifting heavy loads with an l Lifting too heavy loads;
insufficient or non-existant film of oil. In extreme cases
the frictional torque in the joints can be such that the pins l Chain chafed at another part of the mast.
turn and gradually work out of the chain (Fig. 2776si). This
can result in chain failure.
Turned pins can be rapidly identified if the flat ends are

not all pointing in the same direction.
Chains with twisted or protruding pins must be replaced

immediately.
2775si
Printed in Germany
01/99
6
M7.5-2230-002
MAINTENANCE
Measuring the Chain Elongation
Before testing the chain elongation it is important to tension
the lift chain if necessary. For non-detachable lift chains
the weight of the fork carriage or mast is sufficient. If the
lift chain is detached it must be kept taut during
measurement.
First mark the most heavily worn section of the lift chain
which regularly runs over the pulley. The measurement
must now be recorded within the marked area and must
cover at least ten links over at least three different points.
This can be carried out using a scale (Crown No. 106440,
Fig. 2771) or a steel tape.
2771
If an elongation of more than 3% over the nominal length

is recorded, the chain must be replaced in pairs.
Stencil with 2 measurement scales:
Measurement scale A: Scale division 19 mm
Measurement scale B: Scale division 25 mm and 16 mm
Chain Tension
When installed, both lift chains should have the same chain
tension to ensure even distribution of the load over the
two chains when lifting.
When replacing the forks make sure that both forks lie
evenly on the surface. If they are not even, compensate
the chain length via the chain anchor so that both chains
have the same chain tension.
After adjusting the counternuts tighten the chain anchor

again.
Chain Anchor and Pulleys

In the course of checking the chain system, the chain
anchors, chain bolts and pulleys must be checked for wear.
On the chain anchor watch out for wear and cracking of

the individual fingers. If one of the above problems occurs
replace the chain anchor.
Pulleys with heavily worn flanges and contact surfaces

must be replaced. Worn flanges are due to misalignment.
The chain tension and mast roller setting must be checked.
Printed in Germany
01/99
M7.5-2230-003
7
MAINTENANCE
Fork Tine Test DANGER
General FORKS SHOWING SIGNS OF CRACKING,

DISTORTION OR WEAR MUST BE DE-
The fork tines (Fig. M0344) must be checked by trained COMMISSIONED. THEY ENDANGER THE LIFE
personnel at the specified maintenance intervals (see M1.2- OF THE OPERATOR AND OTHER PEOPLE AS
2230-009) for cracks, damage and wear. WELL AS THE GENERAL OPERATION OF
THE TRUCK.
If the forks are used to transport abrasive loads the
inspection must be carried out at shorter intervals. Repairs
Fork repairs must only be carried out by the manufacturer
/ qualified personnel. When repairing supporting members
always carry out a load test and check for signs of cracking.
Fork blade Crack Inspection

Fork hanger Inspect all fork tine surfaces for signs of cracks (Fig.
M0346) and if necessary carry out a non-rupturing crack
Fork shank test (magnetic particle cracking test in accordance with
DIN 4113). For upper and lower fork hangers (Fig. M0347)
including their fork back attachments check for cracks on
the welding seam.
M0344
Curve section
Fork Identification
The data plate is on the side of the fork back (Fig. 0345)
and comprises the following data:
l Capacity
Cracks
l Load Centre of Gravity
l Manufacturing Data (Month / Year)

M0346
l Company Logo
l Manufacturing SIte
1 2
900 x 600
304 ... ../..
5 4 3
M0347
Check fork hanger welding

M0345 seams for any signs of cracking
Printed in Germany
01/99
8
M7.6-2230-001
MAINTENANCE
If any cracking is discovered which could affect safety
remove the relevant fork.
DANGER
NEVER CARRY OUT REPAIR WELDING TO
SURFACE CRACKS, DAMAGED OR WORN
PARTS AROUND THE HEEL OF THE FORK.
Verticality Test
Check verticality of fork shank (Fig. M0349) and fork tip Linear
(Fig.M0350/0351). If the readings illustrated below are
exceeded the fork must be taken out of service.
M0351 ≤ 6.0 mm
500 mm
≤ 2.5 mm Fork Blade Warping

Measure the angle deflection between the top of the fork
blade and the front of the fork shank. If it is more than 91°
or less than 88° (Fig. M0352) the fork must be re-aligned
and checked before it can be used again. For measuring
procedure see Fig. M0353.
M0349
Min. 88°
Max. 91°
Fork tip
2 mm
M0352
250 mm
M0350
500 mm
x - 17.0
mm
x + 8.5
mm
M0353
Printed in Germany
01/99
M7.6-2230-002
9
MAINTENANCE
Measuring the Fork Tip Width Fork Stop
If the fork tip width S is less than a + 6 mm (a = fork back Check the stop mechanism (Fig. M0356) on both fork tines.
width) do not use the fork (Fig. 0355). If faults or damage are discovered do not use the fork.
S ≥ a + 6 mm
Stop mecha-
nism
M0355
Fork Tine Height Difference

M0356
Check the height of the fork tines in relation to each other
(Fig. M0354) if the fork is fixed to the fork carriage. If the
difference is greater than 3 % of the fork blade length the
fork tines must be correctly aligned.
Example: If the length of the fork blade is 1150mm the

maximum permissable deviation is approx. 35mm.
It is however generally advisable to align the forks if the

deviation is max. 10mm.
3 % of L
Left Fork
M0354
Right Fork
Printed in Germany
01/99
10
M7.6-2230-003
MAINTENANCE
Wear
Check for fork blade wear, in particular at the heel. If the
width is 90 % or less than the original value, the fork must
be taken out of service. Use a caliper (Crown No. 107330)
to check for wear (Fig. 0357).
Fork Blade Cross

Section
Outside jaws 100% Inside jaws 90 %

(Fork Shank) (Fork Blade)
M0360
M0357
l First caliper the outer opening 100% in the

central area "a" (Figs. M0358, M0359) of the fork
shank.
Caliper here the

outer opening
M0358
Fork Back Section
M0359
l Using the caliper, scan the fork blade between

the taper and the curved area.
l If the inner scan point fits 90% over the fork

blade (Fig. M0360), the fork must not be used.
Printed in Germany
01/99
M7.6-2230-004
11
Printed in Germany
CYLINDERS
Printed in Germany
Printed in Germany
MAINTENANCE
Cylinders
General
There are two types of hydraulic cylinder
l Plunger cylinders
l Piston cylinders (double-acting cylinders)
The two types differ in their action as well as their

sealing material.
Plunger Cylinders (single-acting

cylinders)
The plunger cylinder has a single pressurised piston
surface which generally equates to the piston rod
diameter (see Fig. M0823).
The piston rod enters the cylinder through one or more

guide rings. The inside of the cylinder and the piston
rod are sealed from the outside by a rod seal contained
in the cylinder head and a contamination scraper ring.
The piston rod retracts either through its own weight

or through the force of the load acting on the piston
rod.
The lift cylinders on the SC3000 are single-acting.
Guide Ring Rod Seal CylinderHead
Oil Cylinder Tube Oil O Ring Piston rod
Scraper
M0823
Printed in Germany
01/99
M8.0-2230-001
1
MAINTENANCE
Piston Cylinder (Double-Acting
Cylinder)
On a piston cylinder both sides of the piston are
pressurised. The piston rod can therefore be moved in either
direction by the oil flow.
The piston rod can produce different piston areas. This

results in different forces and speeds occuring at a
constant pressure and flow volume levels.
The rod of the piston cylinder has a piston at one end

which enters the cylinder through a guide ring and whose
piston seals protect the two oil-filled chambers against
each other. The cylinder and piston rod are sealed on the
outside by a rod seal in the cylinder head. An additional
scraper ring protects the rod seal from external
contamination.
When a piston cylinder is used as a single-acting cylinder

it offers reduced operating pressure with the same cylinder
tube inside diameter compared with the plunger cylinder,
thanks to the larger piston surface. However, the operating
speed is reduced at the same flow rate. The de-pressurised
side of the cylinder must be bled.
The tilt cylinders are examples of double-acting cylinders

on the SC3000.
Printed in Germany
01/99
2
M8.0-2230-002
MAINTENANCE
Single-Acting Cylinder
Piston Seal Piston Guide Ring CylinderHead
Piston Rod
Oil Cylinder Rod Seal

Tube Scraper
Return Flow to Ring
Tank
M0822
Double-Acting Cylinder
Piston Seal Piston Guide Ring Rod Seal Scraper Ring
Oil Cylinder Oil O Ring Cylinder Piston Rod

Tube Head
M0824
Printed in Germany
01/99
M8.0-2230-003
3
MAINTENANCE
Maintenance
WARNING
DE-PRESSURISE ALL HYDRAULIC SYSTEM
COMPONENTS BEFORE CARRYING OUT
MAINTENANCE WORK.
IF PRESSURISED HYDRAULIC OIL ESCAPES
FROM THE SYSTEM IT CAN RESULT IN
SERIOUS INJURIES.
l High-pressure fluids can penetrate the skin
and cause severe injuries. Reduce the pressure
before disconnecting the hydraulic lines.
l Tighten all connections before re-
pressurising the system. Keep ands and feet away
from screw holes as high-pressure fluids can
emerge at these points.
l Use paper or cardboard to trace leaks.
Do not use your hands.
l If any high-pressure fluid penetrates the
skin it should be treated as an emergency even if
there are no markings to the skin at first. Pain will
set in later. Damage to the tissue may result.
Inspection
Before carrying out maintenance closely inspect the
cylinder unit by retracting and inserting the cylinder several
times.
l Check the piston rod for scratches, nicks and

other surface damage.
l Check scraper rings and the entire cylinder head

area for individual component wear and abnormal
leakage.
l If excess hydraulic oil emerges from the piston

rod from at the cylinder head it may be due to a
damaged rod seal. Replace the rod seal and make
sure that the seal seat is clean and intact.
l Check the pivot for signs of unusual wear or

damage. When servicing the cylinder also check the
condition of the other parts. Replace any parts
showing signs of premature wear as well as parts
which are already worn or damaged.
l Minor irregularities on the cylinder tube surface

or on the piston rod can be removed with an aluminium
oxide cloth or a honing tool.
l When all the parts have been checked clean

the cylinder components in a high-grade solvent and
dry with low-pressure pressurised air.
Printed in Germany
01/99
4
M8.0-2230-004
MAINTENANCE
Installing the Piston Seal
Connecting
General Rod
NOTE
Critical Seal
CHECK THE SEAL GROOVE AND THE Position
PISTON ROD (CRITICAL SEAL POSITION)
FOR DAMAGE BEFORE FITTING A NEW
SEAL.
OTHERWISE, LEAKAGE WILL RE-OCCUR
AFTER THE NEW SEAL HAS BEEN FITTED.
M0041B Groove Aligning
When fitting rod seals use assembly equipment and tools Arbor
made of soft metal or plastic without sharp edges. Do not
use a screwdriver or similar tools as these will damage Assembly of Large Rod Seals
the seal edges.
Equipment:
If the seal has to be pushed over sharp edges, cracks or
nicks, use appropriate protective mechanisms. l Tool body
Rod Seal Disassembly Tool l Three pins nos. 1, 2 and 3; pin no. 1 is fixed;
Assembly:
l Apply a thin layer of hydraulic oil to the rod

seal and seal position;
l Place the rod seal over fixed pin no. 1 and

wrap it around pin no. 2 (Fig. M0042);
127 mm
Pin no. 3 Tool body
M0040B
Pin no. 1
Assembly of Small Rod Seals Pin no. 2
Equipment:
M0042
l Groove aligning arbor to lock with the cylinder

union groove
l Keep bending the rod seal until pin no. 3 can
l Connecting rod fit in the loop created (Fig. M0054);
Assembly:
l Apply a thin layer of hydraulic oil to the rod

seal and fitting groove;
Pin no. 3
l Gently squeeze the seal together and place it
in the hole; Pin no. 1
l Using the connecting rod push the seal into

Pin no. 2
the groove (Fig. M0041B).
M0054
Printed in Germany
01/99
M8.0-2230-005
5
MAINTENANCE
l Fit the tool body and rod seal into the cylinder
union.
l Remove pin no. 3 so that the rod seal loop can

spring into the groove (Fig. M0043);
Pin no. 3
M0043
l Remove pin no. 2 so that the rod seal is

positioned fully in the groove (Fig. M0044);
Pin no. 2
M0044
l Remove the tool body from the cylinder union.
Printed in Germany
01/99
6
M8.0-2230-006
ELECTRICAL DIAGRAMS
Printed in Germany
Printed in Germany
ELECTRICAL DIAGRAMS
Key
Connectors Contactors
Traction Controller Connectors FA Left Motor Forward Contactor
CA 201 E RA Left Motor Reverse Contactor
CA 202 D FB Right Motor Forward Contactor
CA 203 C RB Right Motor Reverse Contactor
CA 204 B LC Line Contactor
CA 205 A RGB Regenerative Braking Contactor
CA 206 F
CA 207 G
Abbreviations
CA 208 H
ACS Accelerator Switch
CA 209 J
AXS Auxiliary Function Switch
Pump Controller Connectors
BDI Battery Discharge Interrupt
CA 210 L
BRS Brake Switch
CA 211 E
DIS Direction Switch
CA 212 D
EM Encoder Module
CA 213 C
ENC Encoder
CA 214 B
HBS Handbrake Switch
CA 215 A
HF Hash Filter
CA 216 Panel
HN Horn
CA 217 Seat Switch
HNS Horn Switch
CA 218 Steering Feedback Potentiometer
KYS Key Switch
CA 401 Accelerator Potentiometer
POT 1 Accelerator Potentiometer
CA 402 Accelerator Switch
POT 2 Lift Potentiometer
CA 403 Lift Potentiometer
POT 3 Steer Potentiometer
CA 404 Tilt Switch
SES Seat Switch
CA 405 Side Shift Switch
SH Shunt
CA 406 Auxiliary Switch
SSS Side Shift Switch
CA 407 Pedal Brake Switch
TLT Tilt Switch
CA 408 Handbrake Switch
TT Hour Meter
CA 409 Horn
CA 410 BDI Supply
CA 411 BDI
CA 412 Steering Column
CA 601 Horn Switch
CA 602 Steering Encoder Module
NOTE: CA Connectors are a combination of the JC -XXX

jack and the PC -XXX plug components (example CA 601
is a combination of PC 601 and JC 601).
Printed in Germany
01/99
DIA-2230-001
1
2
B+
FU3
EM ENC
10A FU4
2 8
B + SW 3+ FU5 10A
DIA-2230-002
Curtis 803
- 10A
4 1 5
BDI + TT
KYS
Control Circuit
B- B+
+ BDI BDI HNS
POT2
- AXS SSS TLT
HF
D2 HN
C1 C2 C3 E8 E2 E3 E5 E6
D1 PUMP CONTROL
793574_1a
01/99
DIS
ACS
HBS R
+ +
POT1 POT3
SES - -
L
BRS
RB FB RA FA RGB
LC
H3 E1 E2 E4 E5 E6 E7 E8 E9 L7 L5 L6 L1 L8 L9 G5 F1 G8 G7 G2 G1 G3 L2 L3 L4 G6
TRACTION CONTROL
B-
ELECTRICAL DIAGRAMS
Printed in Germany
B+
LC
Printed in Germany
B + SW
FU1 FU2
BDI 500A 350A
B+
RGB LEFT MOTOR (A) RIGHT MOTOR (B)

+
LA1 LA2 RA1 RA2
A A
RA FA FB RB
48V
Power Circuit
01/99
+SHL +SHR
B+
SH SH
SH
LD2 RD2
PUMP M+
TRACTION A
-SHL -SHR
CONTROLLER CONTROLLER
VMNL VMNR M-
B-
LD1 RD1
BDI
B-
B-
793574_2
ELECTRICAL DIAGRAMS
DIA-2230-003
3
ELECTRICAL DIAGRAMS
Traction Controller
CA 201 CA 206
ZAPI R 9 9 9 1 1 2930 - STAR D
ZAPI R 8 8 8 2 2 not used
ZAPI R 7 7 7 CA 207
ZAPI R 6 6 6 1 1 524 - PC 401 - 3
ZAPI R 5 5 5 2 2 123 - PC 401 - 2
ZAPI R 4 4 4 3 3 722 - PC 401 - 1
not used 3 3 not used
4 4
ZAPI R 2 2 2 5 5 2927 - STAR B
ZAPI A 3 / L 1 1 6 6 2929 - PC 407 - C
CA 202 7 7 2906 - PC 412 - 6
not used 2 8 8 2905 - PC 412 - 5
not used 1 CA 208
CA 203 1 1 not used
not used 3 2 2 not used
not used 2 3 3 ZAPI S 3
not used 1
CA 209
CA 204 1 1 not used
8 2 2 not used
7
HANDSET CONNECTOR
CA 210
6
1 1 5932 - STAR C
5
2 2 120 - PC 218 - 2
4
3 3 521 - PC 218 - 3
3
4 4 719 - PC 218 - 1
2
5 5 5933 - STAR C
1
6 6 5934 - STAR C
CA 205
7 7 5931 - STAR C
2
LED 8 8 5957 - STAR C
1
9 9 5958 - STAR C
793881-1
Printed in Germany
01/99
DIA-2230-004
4
ELECTRICAL DIAGRAMS
Pump Controller
CA 211
not used 9 9
5908 PC 601 - 8 8 8
not used 7 7
2937 PC 411 - 4 6 6
2915 PC 404 - C 5 5
not used 4 4
2914 PC 405 - C 3 3
2913 PC 406 - C 2 2
not used 1 1
CA 212
ZAPI A 10 JC 216 - 10 2 2
ZAPI L CA 201 - 1 1 1
CA 213
716 PC 403 - 1 3 3
518 PC 403 - 3 2 2
117 PC 403 - 2 1 1
CA 214
7
HANDSET CONNECTOR
CA 215
2
LED
1
793881-2
Printed in Germany
01/99
5
DIA-2230-005
ELECTRICAL DIAGRAMS
Seat Switch and Steer Pot
PC 216 JC 216
201 PC 412 - 1 1 1 ZAPI A 1 Fu 3
202 PC 412 - 2 2 2 ZAPI A 2 Fu 4
2903 PC 412 - 3 3 3 ZAPI A 3 PC 201 - 1
not used 4 4
not used 5 5
not used 6 6
562 PC 409 - 2 7 7 ZAPI A 7 ( B - )
509 PC 601 - 9 8 8 ZAPI A 8 ( B - )
not used 9 9
2935 STAR A 10 10 ZAPI A 10 PC 212 - 2
not used 11 11
not used 12 12
PC 217 JC 217
5938 STAR E 1 1
SES
5945 STAR C 2 2
PC 218 JC 218
719 PC 210 - 4 1 1 POT 3

STEERING
120 PC 210 - 2 2 2
FEEDBACK
521 PC 210 - 3 3 3
not used 4 4
793881-3
Printed in Germany
01/99
6DIA-2230-006
ELECTRICAL DIAGRAMS
Control Levers
PC 401 JC 401
722 PC 207 - 3 1 1 POT 1
123 PC 207 - 2 2 2 ACCEL.
524 PC 207 - 1 3 3
not used 4 4
PC 402 JC 402
2925 STAR B A A
ACS
not used B B
2904 PC 412 - 4 C C
PC 403 JC 403
716 PC 213 - 3 1 1 POT 2
117 PC 213 - 1 2 2 LIFT
518 PC 213 - 2 3 3
not used 4 4
PC 404 JC 404
2959 STAR A A A
not used B B TLT
2915 PC 211 - 5 C C
PC 405 JC 405
2960 STAR A A A
not used SSS
B B
2914 PC 211 - 3 C C
PC 406 JC 406
2961 STAR A A A
not used B B AXS
2913 PC 211 - 2 C C
793881-4
Printed in Germany
01/99
7
DIA-2230-007
ELECTRICAL DIAGRAMS
B.D.I., Horn and Brake Switches
PC 407 JC 407
2928 STAR D A A
not used BRS
B B
2929 PC 207 - 6 C C
PC 408 JC 408
2926 STAR B A A
not used HBS
B B
2950 STAR D C C
PC 409 JC 409
2907 PC 412 - 7 1 1
HN
562 JC 216 - 7 2 2
PC 410 JC 410
253
244 PC 411 - 8 1 1 to Battery Connector ( B + BDI )
Fu 5
543 PC 411 - 5 2 2 to Battery Connector ( B - BDI )
PC 411 JC 411
5939 STAR E 1 1
2910 PC 412 - 10 2 2
2936 STAR A 3 3
BDI
2937 PC 211 - 6 4 4
+
543 PC 410 - 2 5 5 TT
not used 6 6
not used 7 7
244 PC 410 - 1 8 8 + 48 V
793881-5
Printed in Germany
01/99
DIA-2230-008
8
ELECTRICAL DIAGRAMS
Steer Column
PC 412 JC 412
201 JC 216 - 1 1 1
202 JC 216 - 2 202 PC 601 - C KYS
2 2
2903 JC 216 - 3 3 3
2904 PC 402 - C 4 4
F
2905 PC 207 - 8 5 5 DIRECTIONAL
R
2906 PC 207 - 7 6 6 SWITCHES
2907 PC 409 - 1 7 7 2907 PC 601 - A
5908 PC 211 - 8 8 8 5908 PC 602 - 2
509 JC 216 - 8 9 9 509 PC 602 - 1
2910 PC 411 - 2 10 10
not used 11 11
not used 12 12
2951 PC 602 - 3
PC 601 JC 601
2907 JC 412 - 7 A A
not used B B HNS
202 JC 412 - 2 C C
PC 602 JC 602
ENCODER
509 JC 412 - 9 1 1 MODULE
5908 JC 412 - 8 2 2
2951 JC 412 - 3 3 3
not used 4 4 STEER
ENCODER
793881-6
Printed in Germany
01/99
9
DIA-2230-009
Star Points
STAR A
2961 PC 406 - A
2960 PC 405 - A
2935 JC 216 - 10
2959 PC 404 - A
2936 PC 411 - 3
STAR B
2925 PC 402 - A
2927 PC 207 - 5
2926 PC 408 - A
STAR C
5933 PC 210 - 5
5934 PC 210 - 6
5932 PC 210 - 1 5945 JC 217 - 2
5957 PC 210 - 8
5958 PC 210 - 9
STAR D
2928 PC 407 - A
2930 PC 206 - 1
2950 PC 408 - C
STAR E
5938 JC 217 - 1
5931 PC 210 - 7
5939 PC 411 - 1
793881-7
Printed in Germany
01/99
10
DIA-2230-010
ELECTRICAL DIAGRAMS
Panel Wiring
Fu 3
ZAPI A 1 PC 216 - 1
B+ (LINE CONTACTOR)
Fu 4
ZAPI A 2 PC 216 - 2
ZAPI A 3 PC 216 - 3
ZAPI A 7 PC 216 - 7
B- (BUSBAR)
ZAPI A 8 PC 216 - 8
ZAPI A10 PC 216 -10
ZAPI R 9 PC 201 - 9 RGB
ZAPI R 8 PC 201 - 8
ZAPI R 7 PC 201 - 7 FA
ZAPI R 6 PC 201 - 6 RA
ZAPI R 5 PC 201 - 5 FB
ZAPI R 4 PC 201 - 4 RB
ZAPI R 2 PC 201 - 2
ZAPI A3/L PC 201 - 1
ZAPI S 3 PC 208 - 3 LC
ZAPI A 10
ZAPI A10 PC 212 - 2
ZAPI L
ZAPI L PC 212 - 1
793881-8
Printed in Germany
01/99
11
DIA-2230-011
ELECTRICAL DIAGRAMS
Power Cables
LINE
794042 *
+ CONTACTOR
+
Fu 1 Fu 2
794042 794045 *
48 V BC 50-003
BC 50-002
BC 50-001
794038 B+
A M+
RGB A PUMP
+ PM CONTROLLER
794036 CONTACTOR
D
794037
794044 * D M- B-
794039 *
PC16-023
-007
-015
PC16-019
LA1 RA1 -003
-011
L/H R/H
LA2 F/R F/R RA2
CONTACTOR CONTACTOR
PC16-022 PC16-020
-006 -004
-014 -012
LA1 794040 * 794039 * RA1
A1 LA2 RA2 A1
A2 A2
LTM D D 2 RTM
2
D1 LD2 (+) RD2 D1
LD1 PC16-022 + SHL B+ + SHR PC16-018 RD1
-006 -002
-014 TRACTION -010
LD2 - SHL - SHR RD2
CONTROLLER
LD1 VMN/L B- VMN/R RD1

PC16-021 PC16-017
-005 (-) -001
-013 -009
794041 *
793882
KEY:
* = Control Panel Copper Link BC 50 = Battery cable assy 794897-XXX

PC 16 = Power cable assy 792878-XXX
BC / PC XX- XXX = SC 3018
- XXX = SC 3016
- XXX = SC 3013
Printed in Germany
01/99
DIA-2230-012
12
ELECTRICAL DIAGRAMS
Part Numbers for Connectors and Looms

ZAPI connectors: Looms
Female Truck Main Loom 794929
Socket Housing 793240- Steering Column Loom 793207
2way -001 Seat Deck Loom (not on Suspension Seat) 795289
3way -002 Flashing Beacon Cable Assy 793789
8way -003 Flashing Beacon Cable Assy 793839
9way -004 Reverse Alarm Cable Assy 793803
Socket Crimp 793241 Reverse Module to JC 216 Cable Assy 794314
L/H Work Light Cable Assy 793790
Standard Spade 062007-021 R/H Work Light Cable Assy 793791
(1/4 inch = 6.25 mm; insulated) If R/H Work Light is rear mounted, Cable Assy 793796
MOLEX Connectors:
MOLEX Free Plug 8way 803450-008
(BDI Connector)
MOLEX Socket 116858
DEUTSCH Connectors:
Male
Pin Housing 792880-
2way -001
3way -002
4way -003
6way -004
8way -005
12way -006
Anti Back Out 793090-
2way -001
3way -002
4way -003
6way -004
8way -005
12way -006
Pin Crimp 792882
Female
Socket Housing 792881-
2way -001
3way -002
4way -003
6way -004
8way -005
12way -006
Anti Back Out 793091-
2way -001
3way -002
4way -003
6way -004
8way -005
12way -006
Socket Crimp 792883
Sealing pin (for use with 793222

792880-xxx and 792881-xxx)
Printed in Germany
01/99
DIA-2230-0013
13
Printed in Germany
HYDRAULIC SCHEMATIC
Printed in Germany
Printed in Germany
M A IN L IF T
Printed in Germany
C Y L .
T IL T C Y L .
L R
H O S E B U R S T
V A L V E
7 9 3 6 8 9
F L O W C O N T R O L
P R E S S U R E R E G U L A T O R
O R B IT A L S T E E R IN G V A L V E L O W E R IN G
S e t to 1 6 0 b a r
C L O S E D C E N T R E S ID E S H IF T
L S
L S C F 1 A 1 B 2 A 2 B 3 A 3 B
01/99
P T S T E E R R V
7 0 B A R
O P T O
T
E N C O D E R
M A IN
R V
2 1 0
B A R
M O T O R
P R IO R IT Y V A L V E L IF T T IL T A U X I
P U M P
S T R A IN E R
HYD-2230-001
1
792341_c-gb
HYDRAULIC SCHEMATIC
Printed in Germany
CROWN Gabelstapler GmbH & Co. KG
- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Telephone +49 (0)89 93 00 2 - 0
Telefax +49 (0)89 93 00 2 -175 or -133
Printed in Germany • Revision Level B

Order Number: 812544-999

Service Manual: Wartungshandbuch Manuel de Maintenance

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Service Manual: Wartungshandbuch Manuel de Maintenance

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Service Manual

M1 – LUBRICATION AND ADJUSTMENT

DIA – ELECTRICAL DIAGRAMS

HYD – HYDRAULIC SCHEMATIC

Safety Symbols used in the General Maintenance and Repair

3. Always keep fire extinguishers in good working

6. Do not allow oil to penetrate the ground or enter the

l Turn off the travel switch and remove the

l Block all wheels when parking on an uneven

Before Carrying out Work on the Truck

l Prevent the truck from rolling away.

l Before carrying out work on the hoist frame,

l Only carry out operational testing when there

Before Operating the Truck

l Get into the driver's seat.

l Check the operation of the lifting device,

It also contains troubleshooting sections which can be

Using the Manual

Each language block in turn is divided into chapters and

The table on the following page shows how the manual is

IDX Table of Content

M1 Lubrication and Adjustment

DIA Electrical Diagrams

HYD Hydraulic Schematic

M = Maintenance Identical for each language

Replacement parts orders

Please refer to the Technical Specifications Sheet for the

Brochures can be obtained from your CROWN dealer or

CROWN Gabelstapler GmbH

Capacity Fork Length

Collapsed Height (mm) /

NOTE 8 3035 / 5010

l Telescopic double part free lift mast

l Lift height 2880 mm

Model Option Ah Type

300 418 x 835 x 627 SD

400 526 x 835 x 627 SD

500 634 x 835 x 627 SD

ALWAYS SPECIFY MODEL NO. WHEN

Lubrication and Adjustment

Fig. D: Steering column front panel

l Cable duct (Fig. B2) on the left hand side To remove:

l Remove the battery

Provides access to: Provides access to:

l Valve block l Brake pedal and mechanism

l Switch, potentiometer l Brake

l Control handle mechanism l Accelerator pedal / travel switch and

l Lift out the LH and RH base plates.

G M0253 F M0256 C M0259

Cold Store Trucks

Maintenance schedules should be kept as short as

Daily Maintenance Log

Lubricant Type Product Description Manufacturer CROWN-Part-No. Type

Aralube HLP-2 Aral

Aralube SKL2 Aral

Low temperature Univis J 13 Aral

Hyp 85W90 Aral

Rubber and vinyl dressing H

Special grease MOS2 Lithium Dow Corning 063002-022 M

Universal lubrication oil SEA40 C

In dusty or otherwise extreme environments, including

When performing maintenance work always check for