Crown Forklift SC3200 Series Maintenance Manual 812548-006 – PDF DOWNLOAD
FILE DETAILS:
Crown Forklift SC3200 Series Maintenance Manual 812548-006 – PDF DOWNLOAD
Language : English
Pages :246
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Crown Forklift SC3200 Series Maintenance Manual 812548-006 – PDF DOWNLOAD
SC3200 1
REVISION 3
TABLE OF CONTENT 7
Table of Content 1 7
Table of Content 2 8
Table of Content 3 9
Table of Content 4 10
Table of Content 5 11
Table of Content 6 12
Table of Content 7 13
Table of Content 8 14
SAFETY 17
Safety Symbols used in the Manual Safety Notes 17
General Maintenance and Repair Safety Notes 17
Maintenance and Repair 17
Before Leaving the Truck 18
Before Carrying out Work on the Truck 18
Before Operating the Truck 18
Warnings and Labels on the Truck 18
INTRODUCTION 21
General 21
Operating Instructions 21
Service Training 21
Ordering Spare Parts 21
Using the Manual 21
A01M-gb 21
Model-Number 22
LUBRICATION AND ADJUSTMENT 25
Lifting the Truck 25
Lifting by Crane 25
G_SC32-Heben-Kran 25
Lifting by another truck 25
G_SC32-Heben-seitl 25
Towing the Truck 26
Jacking up the Truck 26
MO-2232-035 26
Counterweight 27
Disassembly 27
Tools required: 27
Assembly 28
Lubrication and Adjustment 29
Component Access 29
MO-2232-037 29
MO-2232-038 29
MS-2232-040 30
MS-2232-043 30
MS-2232-039 30
MS-2232-038 30
MS-2232-042 30
MS-2232-041 30
Fig A: Battery compartment lid 31
Provides access to: 31
Access: 31
Fig B: Steering column front panel 31
Provides access to: 31
To remove: 31
Fig E: Inner dashboard 31
Provides access to: 31
To remove: 31
Fig C: Valve and Control Handle Panel 31
Provides access to: 31
To remove: 31
When you have lifted out the floor boards you will have access to: 31
To remove the floor boards: 31
Recommended Lubricants and Oils 32
Lubricants 32
Cold Store Truck Lubricants 32
Taking the truck out of service 32
Bringing the truck back into service 32
L62-GB 33
L63-GB 34
Inspection and Maintenance Schedule 35
Daily Maintenance (or every 8 service hours) L70-GB 36
MS-2232-045 37
MS-2232-044 37
MS-2232-038 37
M0324 37
Monthly Maintenance or every 100 service hours L71-GB 38
MS-2232-046 38
MS-2232-044 39
M0324 39
3-Monthly Maintenance (or every 250 service hours) L72-GB 40
6-Monthly Maintenance (or every 500 service hours) L73-GB 42
Annual Maintenance (or every 1000 service hours) L74-GB 42
2-Yearly Maintenance (or every 2000 service hours) L75-GB 42
MS-2232-047 43
MS-2232-039 43
MS-2232-038 43
Torque Requirements 44
WARTUNG 07 44
Standard Torque Tables T58-GB 44
Hex countersunk screws T59-GB 45
Hex head screws T60-GB 46
Umbrako screws and nuts T61-GB 47
Special Torque Tables 48
Torque Settings MECHANICAL T56_1-GB 48
Torque Settings HYDRAULIC T56_2-GB 49
Torque Settings ELECTRICAL T56_3-GB 49
Specific Fastener Torque Requirements T57_1-GB 50
Specific Fastener Torque Requirements T57_2-GB 51
HYDRAULICS 55
Hydraulic Symbols 1 55
Hydraulic Symbols 2 56
Hydraulic Symbols 3 57
Hydraulic Symbols 4 58
Valve Block 59
Pump motor 59
Hydraulic pump 59
Commissioning 59
Bleeding 59
Oil Change 59
Bleeding the hydraulic system 60
Bleeding the tilt cylinders 60
Bleeding the free lift cylinder 60
Bleeding the lift cylinders 60
Flushing the cylinders 61
Drift Tests 61
Lift cylinder drift test 61
Tilt cylinder drift test 61
Steer unit drift test 61
Overload Valves (RV) 62
Drive Unit 65
Gear Unit 65
Disassembly 65
MS-2232-100 65
Disassembly 65
Assembly 65
MP-2232-016 66
General 67
Dismantling the Gear Unit 67
Gear Unit Assembly 67
Pre-assembly of the housing with flange shaft MS-2232-101 67
Bevel gear spur wheel pinion shaft pre-assembly 67
Spur wheel flange shaft assembly MS-2232-102 67
Bevel gear assembly 68
Bevel pinion assembly MS-2232-103 68
MS-2232-104 68
Flank tooth bearing 69
Correcting the flank tooth bearing 69
M1565-1 69
Maintenance 69
Adding oil 69
Types of oil 69
Oil level 69
Oil change 69
ELECTRICS 73
Electrics – General 73
Wire Colour Codes E01-gb 73
Abbreviations E02-gb 74
Electrical Symbols M0056-gb 75
Electrical Components 77
Switch Functions 77
Brake Switch (BRS) 77
Encoder (ENC), Encoder Module (EM) 77
Accelerator Pedal Switch (ACS, POT1) 77
Direction Indicator Switch (DIS) 77
Handbrake Switch (HBS) 77
Raise Potentiometer (POT2) 77
Steering Axle Potentiometer (POT3) 77
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) 77
Emergency Disconnect 77
Key Switch (KYS) 77
Fuses (FU) 77
Seat Switch (SES) 78
Electrical Components – Overview 78
Horn Switch (HNS) 78
Electrical Components – Overview 78
M0369 78
M0367 78
M0368 78
Electrical Board 79
Zapimos B1S 48/700 Controller 81
General 81
M0201 81
Protective Devices 81
Polarity Protection 81
Wiring Errors 81
Overheating 81
Protection 81
Key Terms 81
Shunt or Shunt Resistor (+SH/-SH) 81
Volt Motor Negative (VMN) 81
Functional Description 81
Acceleration / Delay Rate 81
Travel Switch 81
Travel Switch Signal Response 81
Fault Log 81
Fault Identification 81
Sparkless Contactors 82
Inversion Braking 82
Creep Mode 82
Slow Travel 82
Steering Controller 82
45° Steering Angle 82
Pedal Braking (Inversion Braking with Battery Supply Regeneration) 82
Ramp Start 82
Key Switch 82
Self Test 82
Reverse Travel Alarm 82
Seat Switch 83
Current Limit 83
Overvoltage 83
Overheating 83
Low Voltage Reduction 83
ZAPIMOS B1S 48/700 Traction Controller Connections 84
ZAPIMOS B1S 48/700 Pin Layout 85
Programmer Connection “B” 87
Status LED “A” 87
Status LED Diagnosis 87
E55-GB 87
ZAPIMOS HP 350A Pump Controller 88
General 88
Protective Devices 88
Polarity Protection 88
Wiring Errors 88
Overheating 88
Protection 88
Key Terms 88
Shunt or Shunt Resistor (+SH/-SH) 88
Volt Motor Negative (VMN) 88
Functional Description 89
Acceleration / Delay Rate 89
Hydraulic Switches 89
Lift Cutout 89
Lift potentiometer 89
Lift Potentiometer Response 89
Fault Log 89
Fault Identification 89
Steering Support 89
Key Switch 89
Self Test 89
Current Limit 89
Overvoltage 89
Overtemperature 89
Low Voltage Reduction 89
ZAPIMOS HP 350A Pump Controller Connections MS-2232-051 90
ZAPIMOS HP 350 A Pin Layout 91
Pump Controller, LED error code 92
Programmer Connection “B” 92
Status LED “A” 92
Status LED Diagnosis 92
E67-GB 92
Pump Controller Removal 93
Pump Controller Assembly 93
M0189 93
Traction Controller Removal 93
Traction Controller Assembly 94
Programmer 95
General 95
MS-2232-034 95
E54-GB 96
MS-2232-023 96
Connecting the Programmer 97
M0272 97
Operating Menu 97
General 97
Traction Controller Operating Menu 98
Programmer Start Routine M0288d 99
Traction Controller Menu Functions100
PROGRAM100
TESTER100
ALARMS100
PROGRAM PEDAL100
CONFIG100
PROGRAM Menu E53-GB101
TESTER Menu E52-GB102
ALARMS Menu103
ALARMS Menu (traction controller) E50_1-GB103
ALARMS Menu (traction controller) E50_2-GB104
ALARMS Menu (traction controller) E50_3-GB105
PROGRAM PEDAL Menu105
CONFIG Menu E69-GB106
Pump Controller Operating Menu107
Menu Functions Pump Controller108
PROGRAM108
TESTER108
ALARMS108
PROGRAM VACC108
CONFIG108
PROGRAM Menu109
Traction Controller Settings E68_1-GB109
Traction Controller Settings E68_2-GB110
Traction Controller Settings E68_3-GB111
Traction Controller Settings E68_4-GB112
TESTER Menu113
TESTER Menu (pump controller) E51-GB113
ALARMS Menu114
ALARMS Menu (Pump controller) E64-GB114
ALARMS Menu (Pump controller) E65-GB115
ALARMS Menu (Pump controller) E66-GB116
PROGRAM VACC Menu116
CONFIG Menu E76-GB117
Calibrating the Steering Potentiometer118
Preparation118
Calibration118
MS-2232-035118
Calibrating the Lift Potentiometer119
Preparation119
Calibration119
MS-2232-056119
Calibrating the Accelerator Potentiometer120
Preparation120
Calibration120
MS-2232-055120
Traction Controller Safety Test122
Pulse Monitor Trip Test (PMT)122
Equipment122
Test122
PMT Safety Test Wiring123
M0341123
Battery124
General124
Replacing the battery124
Battery Discharge Indicator (BDI)124
General124
Battery Discharge Indicator Setting (BDI)125
Calibration125
E77-GB125
Electric Motors126
General Maintenance Instructions126
Preparation126
Important Maintenance Instructions126
Traction Motor Maintenance127
MS-2232-039127
Access to Brushes127
MS-2232-053127
Maintenance127
Armature127
Bearings127
Pump Motor Maintenance128
MS-2232-052128
Access to brushes128
M0076128
Maintenance128
Armature128
BRAKE131
Brakes131
General131
MS-2232-002131
Brake Lining Wear Limits131
MS-2232-010131
Brake Removal131
MS-2232-004131
Right brake132
Left brake132
MS-2232-007132
MS-2232-006133
Brake Assembly133
Before Assembling133
Assembly133
Foot Brake134
Foot Brake Adjustment134
MS-2232-008134
MS-2232-009134
Checking the braking distance134
Handbrake Adjustment135
MS-2232-003135
STEERING139
Steering139
Hydraulics139
Function139
MS-2232-058139
Steering Components140
MS-2232-059140
Steering wheel141
Disassembly141
MS-2232-060141
Assembly141
Direction Control Switches142
MS-2232-061142
Switch Removal142
Switch Assembly142
Steer Sensor Module144
Disassembly144
Assembly144
Steering Sensor144
Disassembly144
Assembly144
MP-2232-010144
Steering Column Adjustment145
Gas Pressure Cylinder Removal145
MS-2232-063145
Gas Pressure Cylinder Assembly and Adjustment145
MS-2232-064145
Steering column146
Disassembly146
Steering Column Removal146
Removing the steering shaft from the steering column146
Replacing the slip rings146
MS-2232-062146
MP-2232-008147
Steering Gear Removal148
M0118148
Steering axle149
Design149
M1248149
Steering Gear Assembly149
Wheel hub pre-assembly149
Steering knuckle pre-assembly149
Steering Knuckle and Wheel Hub Assembly149
Spur pinion flange shaft pre-assembly150
M1249150
Housing pre-assembly150
M1250150
M1251150
M1252150
M1253151
M1254151
Adjusting the bearing clearance151
M1256151
M1255151
M1258152
M1257152
M1259152
M1260152
M1261153
M1262153
M1263153
M1264153
M1265154
Cylinder Pre-Assembly154
Inserting the cylinder154
M1266154
Assembling the Axle Bracket to the Steering Gear154
M1267154
Operational and Leakage Test155
After re-installing in the truck:155
Steering axle 212011 MP-2232-006156
Steering axle 212090 MS-2232-065157
MAST161
Mast (TT Series)161
General161
Torques161
Mast bearing mounting screws161
MS-2232-011161
Mast Stoppers161
Lifting Gear Minimum Capacity161
Mast Testing (Assembled)161
Flaking161
MP-2232-028162
Mast Disassembly163
Dismantling the Mast (Attached)163
General163
MP-2232-028164
Fork Carriage Removal165
MP-2232-027165
Free Lift Cylinder Removal165
MP-2232-028166
Removing the individual mast stages167
Replacing the Mast Rollers on the Mast Stages and the Fork Carriage167
Mast Stage Rollers167
MP-2232-028168
Fork Carriage Mast Rollers169
Lift Cylinder Removal169
Removing the Mast from the Truck170
MS-2232-011170
MS-2232-012170
Mast Assembly171
Lift Chains172
General172
Inspection172
Cleaning172
Wear172
Fig 2271173
Freedom of Movement of Chain Links 2775si173
Chain Tension173
Chain Anchor and Pulleys 2774si174
Worn Connection Plates174
Protruding or Turned Chain Pins 2776si174
Corrosion 2773si174
Chain Lateral Wear175
Uneven Chain Tension175
Misalignment of Lift Components175
Lift Chain Lubrication176
277si176
Detaching Lift Chains177
Tools and Equipment Required177
Detachment177
Fork Tines178
General178
Terms178
M0344178
Fork Identification178
M0345178
Repairs178
Checking the Fork178
Crack Inspection178
M0346, M0347178
Verticality Test179
M0350179
Fork Blade Warping179
M0353179
Measuring the Fork Tip Width179
M0355179
Fork Tine Height Difference179
M0354179
Stop Mechanism180
M0356180
Fork Blade Wear180
M0357180
MS-2232-013180
Sideshifter181
General181
MS-2232-030182
Integrated Sideshifter183
Removal, Repair and Assembly183
MS-2232-031184
MS-2232-032184
Hook-on Sideshifter185
Removal, Repair and Assembly185
Before re-assembling the fork carriage in the reverse order185
After assembly:185
CYLINDERS189
Cylinders189
General189
Safety when working on hydraulic systems189
General Instructions for Repairing Hydraulic Components189
Rod Seal Assembly190
General190
MS-2232-013190
MS-2232-016190
Large Rod Seal Assembly190
Tools required:190
Assembly:190
MS-2232-019190
MS-2232-020190
MS-2232-022191
MS-2232-021191
Small Seal Rod Assembly191
Tools required:191
MS-2232-024191
Rod Seal Assembly, Sealing Lip First192
MS-2232-025192
Tilt Cylinders193
General193
Removal193
Tilt Cylinder Sectional Drawing194
MS-2232-014194
MP-2232-031195
Dismantling196
Component Inspection196
Assembly196
MP-2232-031197
Assembly198
MP-2232-024200
Lift Cylinders201
General201
Removal and Assembly201
Dismantling201
Rod Seal Removal201
MS-2232-015201
MS-2232-016201
MP-2232-024202
Piston Rod Removal203
Assembly203
Piston Rod Assembly203
Installing the Rod seal203
MS-2232-018203
MP-2232-025204
Free-Lift Cylinder205
General205
Removal and Assembly205
Dismantling205
Rod Seal Removal205
Piston Rod Removal205
Assembly205
Piston Rod Assembly205
Installing the Rod Seal205
MP-2232-025206
MP-2232-004208
MS-2232-028208
Hook-on Sideshifter, Cylinder209
MS-2232-026209
MS-2232-027209
MP-2232-030210
Integrated Sideshifter, Cylinder211
DIAGRAMS215
Key215
Connectors215
Contactors215
Abbreviations215
Control Circuit, 796324_2a_1_2217
Power Circuit, 796324_2a_2_2218
Option Brush Wear & Over Temperature Indicator Circuit Diagram219
Option Lighting Diagram, 813070_2e_1_1220
Cold Store Option, 810350_2b_1_1221
Seat Switch and Steer Pot, 814590_2a_1-8222
Steer Column, 814590_2a_2-8222
BDI, Horn and Brake Switches, 814590_2a_3-8223
Control Levers, 814590_2a_4-8223
Star Points, 814590_2a_5-8224
Panel Wiring, 814590_2a_6-8224
Traction Controller, 814590_2a_7-8225
Pump Controller, 814590_2a_8-8225
Power Cable Diagram, 813167_2b_1_1226
Main Loom, Part 1, doc-794929_f_2_3227
Main Loom, Part 2, 794929-1_T-GB, 794929-2_T-GB, doc-794929_f_3_3228
Steer Column Loom, 810209_T-GB, 810209_e229
Fan Standard, 794878_T-GB, doc-794878_b230
Option: Main Harness, Middle East Fan, 132427_T-GB, doc-132427_a231
Option Lights, Main Loom Lights, 813072-t-DE, doc-813072_a232
Option Lights, Panel to Switch, 813071-T-GB, doc-813071_a233
Option Lights, Module to Panel, 794314_T-GB, doc-794314_c234
Option Lights, Panel to Main Loom Lights, 793794_T-GB, doc-793794_b235
Option Lights, Reverse Alarm to Module, 793803_T-GB, doc-793803_b236
Option, Brush Wear and Overtemperature Display Loom, 793896_T -DE, doc-793896_c_2_2237
Option, 5th Hydraulic Function, 127511_T-GB, doc-127511_c238
Option, Cold Store Model Additional Loom, Part 1 of 2, 794588-T-GB, doc-794588_e_2_3239
Option, Cold Store Model Additional Loom, Part 2 of 2, 794588-T-GB, doc-794588_e_3_3 240
Option, Cold Store Model Additional Loom, Heating Control Module, 810263_t-GB, doc-810263_b241
HYDRAULICS245
Based on: 808819_2d_1_1245
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