Crown Forklift SC3200 Series Maintenance Manual 812548-006

Description

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

MA – SAFETY PAGE SER-NO CUT REV
Safety Symbols used in the Manual 3 N/A 03/04
ITD – INTRODUCTION PAGE SER-N0 CUT REV
General Maintenance and Repair Safety Notes 3
Maintenance and Repair 3
Before Leaving the Truck 4
Before Carrying out Work on the Truck 4
Before Operating the Truck 4
Warnings and Labels on the Truck 4
General 7
Operating Instructions 7
Service Training 7
Ordering Spare Parts 7
Using the Manual 7
Model-Number 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0 CUT REV
Lifting the Truck 11
Lifting by Crane 11
Lifting by another truck 11
Towing the Truck 12
Jacking up the Truck 12
Counterweight 13
Disassembly 13
Assembly 14
Lubrication and Adjustment 15
Component Access 15
Recommended Lubricants and Oils 18
Lubricants 18
Cold Store Truck Lubricants 18
Taking the truck out of service 18
Bringing the truck back into service 18
Lubricant Points and Intervals 20
Inspection and Maintenance Schedule 21
Daily Maintenance (or every 8 service hours) 22
Monthly Maintenance or every 100 service hours 24
3-Monthly Maintenance (or every 250 service hours) 26
6-Monthly Maintenance (or every 500 service hours) 28
Annual Maintenance (or every 1000 service hours) 28
2-Yearly Maintenance (or every 2000 service hours) 28
Torque Requirements 30
Standard Torque Tables 30
Special Torque Tables 34
M2 – HYDRAULICS PAGE SER-N0 CUT REV
Hydraulic Symbols 41
Valve Block 45
Pump motor 45
Hydraulic pump 45
Commissioning 45
Bleeding 45
Oil Change 45
Bleeding the hydraulic system 46
Bleeding the tilt cylinders 46
Bleeding the free lift cylinder 46
M2 – HYDRAULICS PAGE SER-N0 CUT REV
Bleeding the lift cylinders 46
Flushing the cylinders 47
Drift Tests 47
Lift cylinder drift test 47
Tilt cylinder drift test 47
Steer unit drift test 47
Overload Valves (RV) 48
M3 – DRIVE UNIT PAGE SER-N0 CUT REV
Drive Unit 51
Gear Unit 51
Disassembly 51
Disassembly 51
Assembly 51
General 53
Dismantling the Gear Unit 53
Gear Unit Assembly 53
Pre-assembly of the housing with flange shaft 53
Bevel gear spur wheel pinion shaft pre-assembly 53
Spur wheel flange shaft assembly 53
Bevel gear assembly 54
Bevel pinion assembly 54
Flank tooth bearing 55
Correcting the flank tooth bearing 55
Reducing the installation path of the conical pinion 55
Maintenance 55
Adding oil 55
Types of oil 55
Oil level 55
Oil change 55
M4 – ELEKTRICS PAGE SER-N0 CUT REV
Electrics – General 59
Wire Colour Codes 59
Abbreviations 60
Electrical Symbols 61
Electrical Components 63
Switch Functions 63
Brake Switch (BRS) 63
Encoder (ENC), Encoder Module (EM) 63
Accelerator Pedal Switch (ACS, POT1) 63
Direction Indicator Switch (DIS) 63
Handbrake Switch (HBS) 63
Raise Potentiometer (POT2) 63
Steering Axle Potentiometer (POT3) 63
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) 63
Emergency Disconnect 63
Key Switch (KYS) 63
Fuses (FU) 63
Seat Switch (SES) 64
Electrical Components – Overview 64
Horn Switch (HNS) 64
Electrical Board 65
Zapimos B1S 48/700 Controller 67
General 67
Protective Devices 67
Polarity Protection 67
SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232
V
TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0 CUT REV
Wiring Errors 67
Overheating 67
Protection 67
Key Terms 67
Shunt or Shunt Resistor (+SH/-SH) 67
Volt Motor Negative (VMN) 67
Functional Description 67
Acceleration / Delay Rate 67
Travel Switch 67
Travel Switch Signal Response 67
Fault Log 67
Fault Identification 67
Sparkless Contactors 68
Inversion Braking 68
Creep Mode 68
Slow Travel 68
Steering Controller 68
45° Steering Angle 68
Pedal Braking
(Inversion Braking with Battery Supply Regeneration) 68
Ramp Start 68
Key Switch 68
Self Test 68
Reverse Travel Alarm 68
Seat Switch 69
Current Limit 69
Overvoltage 69
Overheating 69
Low Voltage Reduction 69
ZAPIMOS B1S 48/700 Traction Controller Connections 70
ZAPIMOS B1S 48/700 Pin Layout 71
Programmer Connection “B” 73
Status LED “A” 73
Status LED Diagnosis 73
ZAPIMOS HP 350A Pump Controller 74
General 74
Protective Devices 74
Polarity Protection 74
Wiring Errors 74
Overheating 74
Protection 74
Key Terms 74
Shunt or Shunt Resistor (+SH/-SH) 74
Volt Motor Negative (VMN) 74
Functional Description 75
Acceleration / Delay Rate 75
Hydraulic Switches 75
Lift Cutout 75
Lift potentiometer 75
Lift Potentiometer Response 75
Fault Log 75
Fault Identification 75
Steering Support 75
Key Switch 75
Self Test 75
Current Limit 75
Overvoltage 75
Overtemperature 75
MS-IDX-2232 SC3200 03/2004 • Printed in Germany
VI
TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0 CUT REV
Low Voltage Reduction 75
ZAPIMOS HP 350A Pump Controller Connections 76
ZAPIMOS HP 350 A Pin Layout 77
Pump Controller, LED error code 78
Programmer Connection “B” 78
Status LED “A” 78
Status LED Diagnosis 78
Pump Controller Removal 79
Pump Controller Assembly 79
Traction Controller Removal 79
Traction Controller Assembly 80
Programmer 81
General 81
Display Window 82
Operating Keys 82
Connecting the Programmer 83
Operating Menu 83
General 83
Traction Controller Operating Menu 84
Programmer Start Routine 85
Traction Controller Menu Functions 86
PROGRAM 86
TESTER 86
ALARMS 86
PROGRAM PEDAL 86
CONFIG 86
PROGRAM Menu 87
TESTER Menu 88
ALARMS Menu 89
PROGRAM PEDAL Menu 91
CONFIG Menu 92
Pump Controller Operating Menu 93
Menu Functions Pump Controller 94
PROGRAM 94
TESTER 94
ALARMS 94
PROGRAM VACC 94
CONFIG 94
PROGRAM Menu 95
TESTER Menu 99
ALARMS Menu 100
PROGRAM VACC Menu 102
CONFIG Menu 103
Calibrating the Steering Potentiometer 104
Preparation 104
Calibration 104
Calibrating the Lift Potentiometer 105
Preparation 105
Calibration 105
Calibrating the Accelerator Potentiometer 106
Preparation 106
Calibration 106
Traction Controller Safety Test 108
Pulse Monitor Trip Test (PMT) 108
Equipment 108
Test 108
PMT Safety Test Wiring 109
SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232
VII
TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0 CUT REV
Battery 110
General 110
Replacing the battery 110
Battery Discharge Indicator (BDI) 110
General 110
Battery Discharge Indicator Setting (BDI) 111
Calibration 111
Electric Motors 112
General Maintenance Instructions 112
Preparation 112
Important Maintenance Instructions 112
Traction Motor Maintenance 113
Access to Brushes 113
Maintenance 113
Armature 113
Bearings 113
Pump Motor Maintenance 114
Access to brushes 114
Maintenance 114
Armature 114
M5 – BRAKE PAGE SER-N0 CUT REV
Brakes 117
General 117
Brake Lining Wear Limits 117
Brake Removal 117
Brake Assembly 119
Before Assembling 119
Assembly 119
Foot Brake 120
Foot Brake Adjustment 120
Checking the braking distance 120
Handbrake Adjustment 121
M6 – STEERING PAGE SER-N0 CUT REV
Steering 125
Hydraulics 125
Function 125
Steering Components 126
Steering wheel 127
Disassembly 127
Assembly 127
Direction Control Switches 128
Switch Removal 128
Switch Assembly 128
Steer Sensor Module 130
Disassembly 130
Assembly 130
Steering Sensor 130
Disassembly 130
Assembly 130
Steering Column Adjustment 131
Gas Pressure Cylinder Removal 131
Gas Pressure Cylinder Assembly and Adjustment 131
Steering column 132
Disassembly 132
Steering Column Removal 132
MS-IDX-2232 SC3200 03/2004 • Printed in Germany
VIII
TABLE OF CONTENT
M6 – STEERING PAGE SER-N0 CUT REV
Removing the steering shaft
from the steering column 132
Replacing the slip rings 132
Steering Gear Removal 134
Steering axle 135
Design 135
Steering Gear Assembly 135
Wheel hub pre-assembly 135
Steering knuckle pre-assembly 135
Steering Knuckle and Wheel Hub Assembly 135
Spur pinion flange shaft pre-assembly 136
Housing pre-assembly 136
Adjusting the bearing clearance 137
Cylinder Pre-Assembly 140
Inserting the cylinder 140
Assembling the Axle Bracket to the Steering Gear 140
Operational and Leakage Test 141
Steering axle 212011 142
Steering axle 212090 143
M7 – MAST PAGE SER-N0 CUT REV
Mast (TT Series) 147
General 147
Torques 147
Mast bearing mounting screws 147
Mast Stoppers 147
Lifting Gear Minimum Capacity 147
Mast Testing (Assembled) 147
Flaking 147
Mast Disassembly 149
Dismantling the Mast (Attached) 149
General 149
Fork Carriage Removal 151
Free Lift Cylinder Removal 151
Removing the individual mast stages 153
Replacing the Mast Rollers
on the Mast Stages and the Fork Carriage 153
Mast Stage Rollers 153
Fork Carriage Mast Rollers 155
Lift Cylinder Removal 155
Removing the Mast from the Truck 156
Mast Assembly 157
Lift Chains 158
General 158
Inspection 158
Cleaning 158
Wear 158
Freedom of Movement of Chain Links 159
Chain Tension 159
Chain Anchor and Pulleys 160
Worn Connection Plates 160
Protruding or Turned Chain Pins 160
Corrosion 160
Chain Lateral Wear 161
Uneven Chain Tension 161
Misalignment of Lift Components 161
Lift Chain Lubrication 162
Detaching Lift Chains 163
SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232
IX
TABLE OF CONTENT
M7 – MAST PAGE SER-N0 CUT REV
Tools and Equipment Required 163
Detachment 163
Fork Tines 164
General 164
Terms 164
Fork Identification 164
Repairs 164
Checking the Fork 164
Crack Inspection 164
Verticality Test 165
Fork Blade Warping 165
Measuring the Fork Tip Width 165
Fork Tine Height Difference 165
Stop Mechanism 166
Fork Blade Wear 166
Sideshifter 167
General 167
Integrated Sideshifter 169
Removal, Repair and Assembly 169
Hook-on Sideshifter 171
Removal, Repair and Assembly 171
M8 – CYLINDERS PAGE SER-N0 CUT REV
Cylinders 175
General 175
Safety when working on hydraulic systems 175
General Instructions for
Repairing Hydraulic Components 175
Rod Seal Assembly 176
General 176
Large Rod Seal Assembly 176
Small Seal Rod Assembly 177
Rod Seal Assembly, Sealing Lip First 178
Tilt Cylinders 179
General 179
Removal 179
Tilt Cylinder Sectional Drawing 180
Dismantling 182
Component Inspection 182
Assembly 182
Assembly 184
Lift Cylinders 187
General 187
Removal and Assembly 187
Dismantling 187
Rod Seal Removal 187
Piston Rod Removal 189
Assembly 189
Piston Rod Assembly 189
Installing the Rod seal 189
Free-Lift Cylinder 191
General 191
Removal and Assembly 191
Dismantling 191
Rod Seal Removal 191
Piston Rod Removal 191
Assembly 191
Piston Rod Assembly 191
MS-IDX-2232 SC3200 03/2004 • Printed in Germany
X
TABLE OF CONTENT
M8 – CYLINDERS PAGE SER-N0 CUT REV
Installing the Rod Seal 191
Hook-on Sideshifter, Cylinder 195
Integrated Sideshifter, Cylinder 197
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0 CUT REV
Key 201
Connectors 201
Contactors 201
Abbreviations 201
Control Circuit 203
Power Circuit 204
Option Brush Wear & Over Temperature Indicator Circuit
Diagram 205
Option Lighting Diagram 206
Seat Switch and Steer Pot 208
Steer Column 208
BDI, Horn and Brake Switches 209
Control Levers 209
Star Points 210
Panel Wiring 210
Traction Controller 211
Pump Controller 211
Power Cable Diagram 212
Main Loom, Part 1 213
Main Loom, Part 2 214
Steer Column Loom 215
Fan Standard 216
Option: Main Harness, Middle East Fan 217
Option Lights, Main Loom Lights 218
Option Lights, Panel to Switch 219
Option Lights, Module to Panel 220
Option Lights, Panel to Main Loom Lights 221
Option Lights, Reverse Alarm to Module 222
Option, Brush Wear and Overtemperature Display Loom 223
Option, 5th Hydraulic Function 224
Option, Cold Store Model Additional Loom, Part 1 of 2 225
Option, Cold Store Model Additional Loom, Part 2 of 2 226
Option, Cold Store Model Additional Loom,
Heating Control Module 227
HYD – HYDRAULIC SCHEMATICS PAGE SER-N0 CUT REV
Hydraulic Schematic 231

IMAGES PREVIEW OF THE MANUAL:

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