Service Manual: Wartungshandbuch Manuel de Maintenance Serie

Service Manual
Wartungshandbuch
Manuel de maintenance RT3020 Serie
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Printed in Germany
TABLE OF CONTENT
Printed in Germany
Printed in Germany
TABLE OF CONTENT
Table of Content
MA – SAFETY PAGE SER-NR. CUT REV.

Safety Symbols used in the Manual .................................. M/P-MA-0000-001
General Maintenance and Repair Safety Notes ............... M/P-MA-0000-001
- Maintenance and Repair ................................................. M/P-MA-0000-002
- Before Leaving the Truck ................................................. M/P-MA-0000-002
- Before Carrying out Work on the Truck ............................ M/P-MA-0000-002
- Before Operating the Truck .............................................. M/P-MA-0000-002
Warnings and Labels on the Truck .................................... M/P-MA-0000-002
ITD – INTRODUCTION PAGE SER-NR. CUT REV.

General ................................................................................. M/P-ITD-2900-001
- Operating instruction ....................................................... M/P-ITD-2900-001
- Service training ............................................................... M/P-ITD-2900-001
- Replacement parts orders ............................................... M/P-ITD-2900-001
- Structure of the Manual .................................................. M/P-ITD-2900-001
- Page Numbers ................................................................ M/P-ITD-2900-002
Truck Data Numbering Sheet ............................................... M/P-ITD-2900-004
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV.

Jacking up the Truck ............................................................ M-1.0-2900-001
Raising the Truck with a Crane ............................................ M-1.0-2900-002
Lifting the Truck with a second Truck ................................. M-1.0-2900-002
Towing the Truck .................................................................. M-1.0-2900-002
Component Access .............................................................. M-1.0-2900-003
Removing the Floorboard .................................................. M-1.0-2900-005
Removing the Side Panel .................................................. M-1.0-2900-005
Access to Drive Unit, Hydraulic System
and Electrical Components ............................................... M-1.0-2900-005
Maintenance ......................................................................... M-1.1-2900-001
- Driver Participation ......................................................... M-1.1-2900-001
- Daily Maintenance Log .................................................... M-1.1-2900-001
- Recommended Lubricants and Oils ................................ M-1.1-2900-001
- Lubricants .................................................................. M-1.1-2900-002
Grease items and grease intervals .................................... M-1.2-2900-002
- Inspection and Maintenance Schedule ............................ M-1.2-2900-002
- Daily or every 8 service hours ................................... M-1.2-2900-003
- Monthly or every 100 service hours ........................... M-1.2-2900-005
- Every three months or 250 service hours ................... M-1.2-2900-007
- Every six months or 500 service hours ...................... M-1.2-2900-009
- Annually or every 1.000 service hours ....................... M-1.2-2900-011
- Every 2 years or 2.000 service hours ........................ M-1.2-2900-011
Caster .................................................................................... M-1.5-2900-001
Torques ................................................................................. M-1.9-2900-002
M2 – HYDRAULICS PAGE SER-NR. CUT REV.

Hydraulic System ................................................................. M/P-M2.1-2900-001
Operation .......................................................................... M/P-M2.1-2900-001
Removing the Hydraulic Unit ............................................. M-2.2-2900-001
Replacing the Hydraulic Pump .......................................... M-2.3-2900-001
- Disassembly .............................................................. M-2.3-2900-001
- Assembly .................................................................. M-2.3-2900-001
- Start-up ..................................................................... M-2.3-2900-001
Replacing the Hydraulic Filter ........................................... M-2.3-2900-001
- Replacing the Suction Filter ....................................... M-2.3-2900-001
- Oil Change ................................................................. M-2.3-2900-002
Printed in Germany
M-IDX-2900-001
TABLE OF CONTENT
Valve Setting Control ........................................................ M-2.3-2900-004
Non-return valve control ............................................... M-2.3-2900-004
Safety Valve Control .................................................... M-2.3-2900-004
Safety Valve Setting .................................................... M-2.3-2900-004
M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

Gear Unit ............................................................................... M-3.1-2900-001
Preparation ....................................................................... M-3.1-2900-001
Maintenance ..................................................................... M-3.1-2900-002
- General ...................................................................... M-3.1-2900-002
Drive Unit Disassembly ..................................................... M-3.1-2900-003
Assembly .................................................................... M-3.1-2900-003
Adjusting the Bevel Wheel Set ..................................... M-3.1-2900-004
Final Assembly ............................................................ M-3.1-2900-004
Drive Unit Re-Installation ............................................. M-3.1-2900-005
Live Ring Bearing Replacement ........................................ M-3.1-2900-005
Forcing out the Live Ring Bearing ................................ M-3.1-2900-005
Pressing in the Live Ring Bearing ................................ M-3.1-2900-005
Installation of the Live Ring Bearing in the Drive Unit ... M-3.1-2900-005
M4 – ELECTRICS PAGE SER-NR. CUT REV.

Electrical Components ........................................................ M-4.2-2900-001
Transmitter (MC,MN,PT) ................................................... M-4.2-2900-001
Fast / Slow Switch (HES) .................................................. M-4.2-2900-001
Safety Pedal (PCT) ........................................................... M-4.2-2900-001
Lift / Lower Switch (PCS, PCD) ......................................... M-4.2-2900-001
Lift Limit Switch (MFF) ...................................................... M-4.2-2900-001
Pressure Switch (PS) ........................................................ M-4.2-2900-001
Horn Switch (PCX) ............................................................ M-4.2-2900-001
Horn (CX) .......................................................................... M-4.2-2900-001
Key Switch (QC) ............................................................... M-4.2-2900-001
Emergency Disconnect Switch (PE) ................................. M-4.2-2900-001
Steering Angle-Dependent Speed Reduction Microswitch . M-4.2-2900-001
Brake (FE) ........................................................................ M-4.2-2900-002
Fuses (F1, F2, FA) ............................................................ M-4.2-2900-002
Traction Motor (M1) ........................................................... M-4.2-2900-002
Pump Motor (M2) .............................................................. M-4.2-2900-002
Pump Contactor (K3) ........................................................ M-4.2-2900-002
Main Contactor (K4) .......................................................... M-4.2-2900-002
Raise Contactor (RLS) and Lower Contactor (RLD) ........... M-4.2-2900-002
Steering Motor (M3) ....................................................
OPTION
M-4.2-2900-002
Encoder (MS) .............................................................
OPTION
M-4.2-2900-002
Limit Switch (MF) .......................................................
OPTION
M-4.2-2900-002
Steering-Contactor (K6) ..............................................
OPTION
M-4.2-2900-002
Fuses (F3, FA3) .........................................................
OPTION
M-4.2-2900-002
Travel Direction Display ..................................................... M-4.2-2900-002
ES1 Traction Controller ........................................................ M-4.3-2900-001

General ............................................................................. M-4.3-2900-001
- Precautionary Measures ............................................ M-4.3-2900-001
Operational Features ......................................................... M-4.3-2900-001
- Speed Control ............................................................ M-4.3-2900-001
- Reduced Speed Range .............................................. M-4.3-2900-001
- Downhill Speed Control .............................................. M-4.3-2900-001
- Regenerative Braking ................................................. M-4.3-2900-001
- Anti-Roll-Down-Function ............................................. M-4.3-2900-001
Printed in Germany
M-IDX-2900-002
TABLE OF CONTENT
- Hourmeter .................................................................. M-4.3-2900-002
Self Test ....................................................................... M-4.3-2900-002
- Monitored Circuits ...................................................... M-4.3-2900-002
Protective Devices ............................................................ M-4.3-2900-003
- Polarity Protection ..................................................... M-4.3-2900-003
- Wiring Errors .............................................................. M-4.3-2900-003
- Temperature ............................................................... M-4.3-2900-003
- Start Sequence ......................................................... M-4.3-2900-003
- Safety Class .............................................................. M-4.3-2900-003
Maintenance ..................................................................... M-4.3-2900-003
ES1 Traction Controller Connections ................................. M-4.3-2900-004
Programmer ......................................................................... M-4.4-2900-001

General ............................................................................. M-4.4-2900-001
Operating Menu ES1 Controller ......................................... M-4.4-2900-002
- General ...................................................................... M-4.4-2900-002
- Menu Functions ......................................................... M-4.4-2900-002
- Operating Menu - Overview ....................................... M-4.4-2900-003
Adjustment ....................................................................... M-4.5-2900-001
- Menu PARAMETER CHANGE ................................... M-4.5-2900-001
- Max. Speed Setting ................................................... M-4.5-2900-002
- TESTER Menu ........................................................... M-4.5-2900-004
- Error Code Display in SAM Hourmeter ....................... M-4.5-2900-006
- ALARMS Menu .......................................................... M-4.5-2900-006
- PROGRAM VACC Menu ............................................ M-4.5-2900-009
CONFIG Menu ............................................................. M-4.5-2900-010
SAM Hourmeter ................................................................ M-4.5-2900-01
Traction Controller Replacement and Transfer of
Service Hours into the new Controller: ......................... M-4.5-2900-011
Traction Controller Safety Test ............................................ M-4.20-2900-001
Battery ................................................................................... M-4.25-2900-001

General ............................................................................. M-4.25-2900-001
Operation .......................................................................... M-4.25-2900-001
Battery Replacement ........................................................ M-4.25-2900-001
Battery Removal ............................................................... M-4.25-2900-001
- Replacing the Battery with a Crane ............................ M-4.25-2900-002
- Replacing the Battery with a Battery Trolley ............... M-4.25-2900-003
Charging the Battery .................................................... M-4.25-2900-004
Electric Motors ..................................................................... M-4.35-2900-001

General Maintenance Instructions ..................................... M-4.35-2900-001
Preparation .................................................................. M-4.35-2900-001
Important Maintenance Instructions ............................. M-4.35-2900-001
Traction Motor Maintenance ................................................ M-4.35-2900-002
Access to the Brushes ..................................................... M-4.35-2900-002
Maintenance ..................................................................... M-4.35-2900-002
- Armature .................................................................... M-4.35-2900-002
- Bearings .................................................................... M-4.35-2900-002
Pump Motor Maintenance ................................................... M-4.35-2900-003
Maintenance ..................................................................... M-4.35-2900-003
Steering Motor Maintenance .........................................
OPTION
M-4.35-2900-004
Maintenance ..................................................................... M-4.35-2900-004
Printed in Germany
M-IDX-2900-003
TABLE OF CONTENT
M-5 – BRAKE PAGE SER-NR. CUT REV.
Brake ..................................................................................... M-5.0-2900-001
- Function ......................................................................... M-5.0-2900-001
- Removal ......................................................................... M-5.0-2900-001
- Assembly ....................................................................... M-5.0-2900-002
- Air Gap Setting ............................................................... M-5.0-2900-002
- Brake Moment Setting .................................................... M-5.0-2900-002
- Brake Test ....................................................................... M-5.0-2900-003
M6 – STEERING PAGE SER-NR. CUT REV.

Steering ................................................................................ M-6.1-2900-001
Operation .......................................................................... M-6.1-2900-001
Lower Steering Chain Adjustment ..................................... M-6.1-2900-002
Adjusting the Drive Unit Steering Chain ............................ M-6.1-2900-002
Checking the Sliding Clutch .............................................. M-6.1-2900-003
Replacing the Sliding Clutch ............................................. M-6.1-2900-003
Steering Sensor Removal / Installation ......................
OPTION
M-6.1-2900-004
Steering Motor Removal / Installation ........................
OPTION
M-6.1-2900-004
Limit Switch Removal / Installation ...........................
OPTION
M-6.1-2900-004
M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

Lifting Mechanism ............................................................... M-7.0-2900-001
Test ................................................................................... M-7.0-2900-001
Adjusting the Stop ............................................................ M-7.0-2900-001
M8 – CYLINDERS PAGE SER-NR. CUT REV.

Cylinders .............................................................................. M-8.0-0000-001
General ............................................................................. M-8.0-0000-001
Plunger Cylinders (single-acting) .................................. M-8.0-0000-001
Piston Cylinder (Double-Acting Cylinder) ...................... M-8.0-0000-002
Maintenance ..................................................................... M-8.0-0000-004
Inspection ......................................................................... M-8.0-0000-001
Seal Installation ................................................................... M-8.6-2900-001
General ............................................................................. M-8.6-2900-001
Lift Cylinder ....................................................................... M-8.6-2900-001
Removal Preparation ......................................................... M-8.6-2900-001
Removal ........................................................................... M-8.6-2900-001
Repairing the Lift Cylinder ................................................. M-8.6-2900-002
- Disassembly .............................................................. M-8.6-2900-002
- Inspection .................................................................. M-8.6-2900-002
- Assembly .................................................................. M-8.6-2900-002
Assembly ......................................................................... M-8.6-2900-002
Gas Pressure Spring Removal and Assembly ................... M-8.6-2900-003
- Removal Preparation ................................................. M-8.6-2900-003
- Removal .................................................................... M-8.6-2900-003
- Assembly .................................................................. M-8.6-2900-003
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.

Standard Version .................................................................. M/P-DIA-2900-001
With electrical steering .................................................. M/P-DIA-2900-002
OPTION
HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

Hydraulic Schematic ......................................................... M/P-HYD-2900-001
Printed in Germany
M-IDX-2900-004
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 Mainte-
nance and Operator's Manuals.
DANGER
● Failure to do so could result in severe or
This symbol indicates life-threatening risks fatal injuries to maintenance personnel
and/or other persons.
● 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
WARNING
company guidelines.
This symbol indicates the risk of serious DANGER
injury and/or serious material damage.
Follow all national/local safety regulations
● Failure to comply with this notice may applicable for maintenance work, e.g. for
result in severe injuries to yourself or other work on higher levels.
people and/or serious material damage.
● Failure to do so could result in severe or
fatal injuries to maintenance personnel and/
or other persons.
CAUTION
Maintenance and Repair
This symbol indicates the risk of minor
injury and/or minor material damage. 1. Maintenance work must only be carried out in
accordance with the test and maintenance pro-
● Failure to comply with this notice may
gram contained in the present Maintenance
result in minor injuries to yourself or other
Manual and any applicable service notices.
people and/or minor material damage.
2. Only qualified and authorised personnel may
carry out work on the truck.
INFORMATION
3. Always keep fire extinguishers in good working
Contains additional information with condition. Do not approach fluid levels or leaks
supplementary notes and hints. with a naked flame.
4. To clean, use a non flammable, non combustible

OPTION cleaning solution which is groundwater-neutral.
Only carry out cleaning with an oil separator.
OPTION
These items relate to optional features not Protect the electrical system from dampness.
supplied with the standard version.
5. Keep the service area clean, dry and well-venti-
lated.
6. Do not allow oil to penetrate the ground or enter

the draining system. Used oil must be recycled.
Oil filters and desiccants must be treated as
special waste products. Relevant applicable
regulations must be followed.
7. Neutralise and thoroughly rinse any spilled battery

fluid immediately.
Printed in Germany
REV. 1 4/00
M/P-MA-0000-001
1
SAFETY
8. Keep the truck clean. This will facilitate the loca- Warnings and Labels on the Truck
tion of loose or faulty components.
During regular maintenance check that the warnings
9. Make sure that capacity and data plates, warnings and labels on the truck are complete and legible.
and labels are legible at all times.
● Clean any illegible labels.
10. Alterations or modifications by the owner or
operator are not permitted without the express ● Replace any faulty or missing labels.
written authorisation from Crown.
The order and meaning of the warnings and labels on
11. Only use original Crown spare parts to ensure the the truck are described in section 10.9 of the parts
reliability, safety and suitability of the Crown truck. manual.
Before Leaving the Truck

● Stop the truck.
● Lower the fork carriage fully.
● Apply the parking brake.
● Turn off the travel switch and remove the key.
● Block all wheels when parking on an uneven

surface.
Before Carrying out Work on the Truck

● Raise the truck to free the drive wheel. Press the
emergency Stop button and disconnect the
battery.
● Prevent the truck from rolling away.
● Before carrying out work on the hoist frame, the

lift mast or on the fork carriage: Block these parts
according to maintenance instructions in order to
prevent them from dropping.
● Only carry out operational testing when there is

sufficient room to manoeuvre, to avoid the risk of
injury to yourself and others.
Before Operating the Truck

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

direction switch, speed control, steering, warning
devices and brakes.
Printed in Germany
REV. 1 4/00
M/P-MA-0000-002
2
INTRODUCTION
Printed in Germany
Printed in Germany
INTRODUCTION
General series. Brochures can be obtained from your CROWN

dealer or from the following address:
The present manual is designed for Customer Service
engineers who wish to familiarise themselves with the
maintenance work required for the various truck CROWN Gabelstapler GmbH
components. Moosacher Str. 52
80809 Munich
It also contains troubleshooting sections which can be GERMANY
used to identify and remedy truck faults. Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 oder 133
INFORMATION
This book is not an operating manual. It is
designed solely for specialist personnel
who have been trained and authorised to
Using the Manual
carry out the work described in the manual. The Maintenance Manual is written in three independent
language blocks: English, German and French.
This manual therefore contains fewer and less detailed Each language block in turn is divided into chapters and
warnings than the Operator's Manual, as the latter is aimed sections.
at persons who have very little or no prior experience at
all. The table on the following page shows how the manual is
structured.
Operating Instructions
This manual contains no operating instructions. An Sections Maintenance
operating instructions manual is supplied with the vehicle.
Additional copies can be ordered as required. Section Description
With the help of this manual you and your personnel will
IDX Table of Content
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle.
MA Safety
Service Training
ITD Introduction
CROWN offers the appropriate vehicle related training for
service personnel. Details on this training can be obtained M1 Lubrication and Adjustment
from CROWN on request.
M2 Hydraulics
Ordering Spare Parts
The maintenance manual does not cover spare parts. M3 Drive Unit
These are listed in a separate manual.
M4 Electrical
Spare parts can be ordered by quoting:
M5 Brake
● The truck specification number
● The truck model number M6 Steering
● The truck serial number M7 Mast / Lifting Mechanism
This information can be found on the truck's data plate. M8 Cylinder

Only if this information is provided can the order be
processed quickly, correctly and reliably.
DIA Electrical Diagrams
Please refer to the Technical Specifications Sheet for the

utilisable loads, technical data and dimensions for this HYD Hydraulic Schematic
A01M-gb
Printed in Germany
M-ITD-2900-001
1
INTRODUCTION
Page Numbering in the Manual
The page numbers are on the left and right-hand sides
of the page footer.
If a page has been modified since the last edition, a

revision number will be found in the middle of the
footer:
02 REV. 2/99 means the second amendment to this

page in February 1999.
The page numbers are not necessarily consecutive!
The back page of the manual contains a print

number in the following form:
MS-RT3020-GB-D-F 02/00
In this example, 02/00 is the edition date.
A page beginning with M/P- is identical in both the maintenance and spare parts manuals:
M/P-1.2-2900-001
M = Maintenance Manual
P = Spare Parts Manual
Chapter Page Number
Section Truck Code

e.g. 1.2 = Test and
Maintenance (Pages which are
Schedule
identical for all trucks
are given the code 0000
here)
A page beginning with M- is only contained in the maintenance manual:
M-1.2-2900-001
M = Maintenance Manual
Chapter Page Number
Section Truck Code

e.g. 1.2 = Test and
Maintenance (Pages which are
Schedule
here)
Printed in Germany
M/P-ITD-2900-002
2
INTRODUCTION
A page beginning with P- is only contained in the spare parts manual:
P-1.0-2900-001
P = Spare Parts Manual
Chapter Page Number
Section Truck Code

e.g. 1.0 = Panels
(Pages which are
here)
Model-Number
RT3010
Modeldescription
Rider Pallet Truck with 2.000 kg capacity
RT3020
Modeldescription
RT3030
Modeldescription
Printed in Germany
M/P-ITD-2900-003
3
Printed in Germany
LUBRICATION AND ADJUSTMENT
Printed in Germany
Printed in Germany
Jacking up the Truck
Apply a jack with sufficient capacity, hard wooden
blocks and wedges as shown in Fig. M1883.
DANGER
Always support the raised truck on square

blocks or other appropriate material to
relieve the trolley. Never put your hands or
other parts of the body underneath a non-
supported truck.
● Improper handling of the truck or the 1

auxiliary equipment can result in fatal
accidents.
● Lift the forks to maximum height. 3
● Secure both loadwheels with a wedge (1). 4

● Apply a jack with sufficient capacityat the middle
of the chassis frame and raise the truck (2). 2
● Slide hard wooden blocks underneath the left and
right-hand sides and lower the truck onto them.
● Place sufficiently sized wooden blocks (hard wood)

on both sides underneath the chassis and lower
3
the truck onto the blocks (3).
M1883
● Apply the jack to the forks.
● Place a wooden block under the forks and lower the

truck onto it (4).
Printed in Germany
M-1.0-2900-001
1
Raising the Truck with a Crane
Attach the straps (ropes, chains) to the hitch point as
shown.
DANGER
Make sure the crane / fork lift and the lifting

equipment have sufficient capacity.
90
700 350
● If the crane / lift truck crash or a load falls,
fatal injuries can result.
1000
Towing the Truck
If the truck has been switched off and is idle, it can be
towed over short distances without having to release
the drive wheel brake. A brokendown truck can be
removed from its operating aisle using a fork lift truck
with a minimum 1.000 kg capacity.
Lifting the Truck with a second Truck

● Make sure the drive wheel and the tandem castor M1801
wheel of the RT are facing forward; the forks must
be in a raised position (maximum height). ● Position the forks under the chassis as illustrated
in the diagram.
● See illustration for positioning the forks of the
truck which is doing the lifting. ● Raise the truck approximately 20 mm off the
ground. The drive wheel should not be in contact
● Insert a 90 mm thick block between the forks of with the ground.
the RT and the corresponding fork of the lifting
truck. ● Slowly tow the truck in a forward direction only
(black arrow).
● Firmly secure the RT to the forks of the truck
which is doing the lifting (e.g. with appropriate
straps).
Printed in Germany
M-1.0-2900-002
2
Component Access
Access can be gained either by unscrewing the panels
or simply by flipping up and lifting the top cover.
WARNING
Always remove the battery connector before

carrying out maintenance work. This applies
especially if the connector and plug
connection have to be separate.
Under the Instrument Panel
- Switch and electrical connection mechanisms, BDI connections, steering encoder*
Under the battery panel Under the panel

- Drive unit
- Battery - Hydraulic pump
- Battery connector - Hydraulic tank
- Valve block
- Brakes
- Electronic control
system
Under the front panel - Fuses
- Steering motor*
- Lift cylinder
- Lift limit switch
- Gas pressure spring
Drive wheel
M1880
Under the Floorboard
- Pedal mechanism and switches
- Steer motor control system*
Twin caster
* Electrical steering optional feature
Printed in Germany
M-1.0-2900-003
3
Component Access
Emergency Disconnect
Multifunction Indicator Lamps Indicating Travel Direction Forward / Reverse
Travel Direction Switch
M1881
Travel Speed Switch Fast / Slow

Lift
Key Switch Lower
Horn
Accelerator Pedal
M1882
Dead Man Switch
Printed in Germany
M-1.0-2900-004
4
Removing the Floorboard Access to Drive Unit, Hydraulic Sy-
Unscrew the ball head underneath the pedal. Remove stem and Electrical Components
the fastening screws (4 off) from the floorboard. Lift up
the floorboard. To assemble, proceed in the reverse Remove the four screws (see Fig. M1808) from the
order. skirting rail and set it to one side.
Removing the Side Panel

Remove the four screws (B, Fig. M1883). Pull the panel
out at the side and lift it up. Set the panel to one side.
Assembly is the reverse A order of disassembly.
M1808
M1883
Printed in Germany
M-1.0-2900-005
5
Maintenance
Driver Participation
By involving the driver in the maintenance schedule,
truck downtimes can be substantially reduced. The
driver can also contribute to determining the mainte-
nance schedule, thereby saving costs. Crown therefore
recommends that the driver carry out the daily mainte-
nance in accordance with the table on page M-1.2-1720-
002.
Daily Maintenance Log

A maintenance log is provided to keep a record of the
extent and time of maintenance performed.
Recommended Lubricants and Oils

Lubricants
Only high grade lubricants and oils should be used.
These can be obtained from any oil manufacturer. Those
listed in table on page M-1.1-1720-002 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 M-1.1-1720-002). 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 compo-
nents.
Printed in Germany
M-1.1-2900-001
6
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
Retinax 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 SAE 40 C
L01-gb
Printed in Germany
M-1.1-2900-002
7
Grease Points, Overview
L-7,L-8,L-9
M1799
L-7
L-3
M1798
L-11
L-7
L-1,L-2,L-4,L-5,L-
6,L-10
L-6
M1880
L-10
L-1,L-2
M1796
M1794
Printed in Germany
M-1.2-2900-001
8
Grease Points / Intervals
100 250 500 1000 2000

Item Component Type Vol.
hours hours hours hours hours
Check hydraulic oil level, replenish if

L-1 D A/R X
necessary
L-2 Replace hydraulic oil and filter D A/R Initially after 500 service hours X
L-3 All hinges C A/ R X
L-4 Grease steering linkage B A/ R X
L-5 Grease steering chain G A/R X
L-6 Drive unit live ring bearing B A/R X
L-7 Grease lifting mechanism B A/R X
L-8 Lift cylinder attachment B A/R X
L-9 Piston rod attachment B A/R X
L-10 Change gear oil A A/R Initially after 250 service hours X
L-11 Seat rails B A/R X

L08-GB
Inspection and Maintenance When carrying out maintenance routinely check for
wear, corrosion, damage, component operation and
Schedule safety. If in doubt, replace components.
The following inspection and maintenance schedule Battery Maintenance

assumes single-shift operation under normal conditions.
The frequency of maintenance intervals must however WARNING
be constantly adapted to the prevailing operating
conditions. The battery must be serviced in accordance
with the manufacturer's instructions.
In dusty or otherwise extreme operating conditions, the
maintenance intervals specified must be reduced. Exact Failing to follow the battery manufacturer
details should be discussed with a Crown service instruction could damage the battery.
engineer.
INFORMATION
The next following scheduled maintenance

icludes all precious .
Example To carry out the 250 -Servicehours
Inspektion, you must include the schedule
of the 8-hour and 100-hour schedule.
Printed in Germany
M-1.2-2900-002
9
Daily or every 8 service hours
Item Component Test Scope
Check / charge battery in accordance with manufacturer's

I -1 Battery and battery compar tment
instructions. Check battery compar tment for electrolyte leakage.
I -2 Battery connector Check for damage. Check contacts for any signs of burning.
I-3 Leaks
- Gear Check for leaks.
- Hydraulic system Check for leaks. If leaks are found, take truck out of service.
Check tyres for wear and for any foreign objects. Remove any
I-4 Wheels / load wheels
foreign objects found.
I-5 Forks Check for damage, cracks and excess wear.
I-6 Labels, decals Ensure they are complete and legible.
Turn on the key switch. Check operation of battery discharge

I-7 Key switch and BDI
indicator and hourmeter.
I-8 Emergency Disconnect Switch Check operation.
I-9 Horn Check operation.
I-10 Lifting mechanism Check for foreign objects.
Check all functions. The hydraulics must cut out when the lift
I-11 Hydraulic functions
limit position is reached.
I-12 Steering Check operation and freedom of movement.
Check the operation of the travel switch, the deadman pedal,

I-13 Travel and the speed reduction (which operates as a function of the
steering angle).
Check braking in both travel directions:
- By releasing the deadman pedal
I-14 Brake - By reversing the travel direction via the travel switch
- By releasing the travel switch to neutral
Repeat the above tests for both Tur tle/Rabbit switch positions.
Lo2-GB
CAUTION: Do not use high pressure cleaners and/or solvents to clean the truck.
Do not use metal brushes.
Printed in Germany
M-1.2-2900-003
10
I-13
I-8 I-13
I-7
M1881
I-11 I-13
I-1
I-2
M1882
I-13,I-14 I-13
I-5
M1882
*Note for I-3: It is sufficient to check the floor

for fluids. Covers can remain on the truck.
Note for I-6: See the operator manual for the

various location of the labels and decals.
M1880
I-4
I-3*
Printed in Germany
M-1.2-2900-004
11
Monthly or every 100 service hours
I -1 Hydraulic oil level Check level, replenish if necessary.
Clean rollers and contact surfaces. Visually inspect for wear

I-2 Lift frame
and freedom of movement. Re-grease.
I-3 Brake Remove any abrasion. Check air gap.
Visually inspect for leaks. Check piston rod for damage. Check
I-4 Lift cylinder
cylinder attachment. Check operation of lift limit switch.
I-5 Hydraulic lines Check hoses and lines for damage, replace if necessary.
Lo3-GB
Printed in Germany
M-1.2-2900-005
12
I-2
I-4, I-5
M1814
M1880
I-3
I-1, I-5
L02-part3-GB
I-1
M1794
M1815
Printed in Germany
M-1.2-2900-006
13
Every three months or 250 service hours
I-6 Battery connector to truck Clean contacts and check contact springs.
I -7 Lift linkage Check for wear, damage and ensure it is securely fit.
Carry out first gear oil change. Thereafter every 2000 service
I -8 Gear system
hours.
Lo4-GB
Printed in Germany
M-1.2-2900-007
14
I-6
M1882
M1880
I-8
I-7
M1808
Printed in Germany
M-1.2-2900-008
15
Every six months or 500 service hours
I-9 Drive unit fastening screws. Check torques.
Pump motor and drive motor

I-10 Check carbon brushes for wear and freedom of movement.
Steering motor (if present)
Check bearings for excessive play and wear.
I-11 Load wheels and casters Replace if necessary/
Check torques of fastening screws / nuts.
I-12 Drive wheel Check wheel screw torque (91 Nm).
Carry out first gear oil change. Thereafter every 2000 service
I-13 Gear system
hours or every 2 years.
Carry out first hydraulic oil and filter replacement. Thereafter

I-14 Hydraulic system
every 2000 service hours or every 2 years.
I-15 Electrics Check connections for corrosion, clean if necessary.
Visually inspect all switches, relays, contactors and wiring.

I-16 Electrical system Remove dust with dry compressed air at low pressure.
Check connections for corrosion, clean if necessary.
Check play, setting and operation of limit switches and the
I-17 Steering system
safety clutch setting.
Disassemble brake. Check brake lining for wear and damage.
I-18 Brake Check anchor disk and friction plate for any signs of
overheating and wear. Replace damaged or worn par ts.
Lo5-GB
Printed in Germany
M-1.2-2900-009
16
I-19
I-15,I-16, I-17, I-18, I-19
I-13
I-20
M1880
I-12, I-14
I-10 M1880
I-11
(6x)
M1815
M1808
M1794
Printed in Germany
M-1.2-2900-010
17
Annually or every 1000 service hours
Pump motor and drive motor

I-21 Check commutator for wear and damage.
Steering motor (if present)
I-22 Gear system Check oil level, replenish if necessar y.
I-23 Frame and panels. Check for damage, repaint if necessar y.
I-24 Hydraulic system Check safety valve operation.
The UVV test is a requirement in Germany. Different

I-25 Carr y out annual UVV test regulations apply in other countries which may differ in the
length and scope of the test.
L06-GB
Every 2 years or 2000 service hours
Replace hydraulic oil and filter. Clean lines and connections.

I-27 Hydraulic system
Make sure the system is secure and free of leakage.
I-28 Gear system Change gear oil.
L07-GB
Printed in Germany
M-1.2-2900-011
18
I-23
I-27
I-24
M1880
I-14, 15,I-16
I-22, I-28
I-21
L03-part2-gb
M1815
24
18 M1808
M1794
23
M1702
M1704
Printed in Germany
M-1.2-2900-012
19
Caster
The twin caster is located at the rear right of the truck
below the chassis.
The caster is not height-adjustable. Grease the bearing

bushing regularly as required (but at a minimum of every
500 service hours or after 6 months).
A lifetime lubrication is applied to the wheel conical

bearings. Replace the bearings if there is excessive
play or uneven travel.
The wear limit is reached when the diameter of one or

both wheels < 120 mm.
Grease Nipple
Printed in Germany
M-1.5-2900-001
20
Torques NOTE
The information contained on thise page should be used
during maintenance work to determine the correct
The torques listed in the maintenance
torques for standard screws and nuts.
section always take precidence over those
listed on this page.
Standard Screws and Nuts
Grade 8 and 8.8 10 and 10.9 12 and 12.9
Thread Size Torque (Nm)
10
M 5x0.8 6 8
17
M 6x1 10 14
42
M 8x1.25 24 35
44
M 8x1 26 37
83
M 10x1.5 49 70
87
M 10x1.25 52 73
143
M 12x1.75 84 110
150
M 12x1.5 89 125
340
M 16x2 200 280
360
M 16x1.5 215 300
660
M 20x2.5 390 550
730
M 20x1.5 430 610
1170
M 24x3 700 980
1240
M 24x2 735 1030
2320
M 30x3.5 1380 1930
2500
M 30x3 1470 2080
T02-GB
Printed in Germany
M-1.9-2900-001
21
Printed in Germany
HYDRAULICS
Printed in Germany
Printed in Germany
HYDRAULICS
Hydraulic System
Operation Lifting: The pump delivers oil from the reservoir to

the lift cylinder. The lift-valve opens, while
The hydraulic unit comprises the motor, pump, reservoir the lowering-valve closes.
all filters, valves and the lift cylinder.
Lowering: The lowering valve opens, while the lift
valve closes. The oil flow returns from the
lift cylinder to the reservoir.
M1781
Printed in Germany
M/P-2.1-2900-001
M1.0-0000-0001
HYDRAULICS
Removing the Hydraulic Unit
WARNING ● Unplug the battery connector.
De-pressurise all components before ● Secure the truck from rolling away.
carrying out maintenance work on the
hydraulic system. ● Before commencing maintenance work place a flat
● High pressure hydraulic oil can cause container or (if necessary) a large cardboard box
serious injuries. underneath the work surface.
● Whenever a high pressure fluid penetrates ● Obtain a suitable support on which to rest the
the skin it must be treated as an hydraulic unit, e.g. a heavy iron ring.
emergency, even if the skin shows no
initial reaction. Physical effects set in later. ● Disconnect all wire connections and hoses from
● Secure all connections before re-applying the hydraulic unit.
system pressure. Keep hands and body
away from any ports as high pressure ● Remove the hydraulic unit from the chassis.
hydraulic oil can emerge.
● Use absorbent paper to track leaks, never
use your hands! .
Pump motor
Hydraulic Block
Safety Valve
Non-Return Valve
Filler Neck
Solenoids
Hydraulic Container
M1825
Printed in Germany
M-2.2-2900-001
M1.0-0000-0002
HYDRAULICS
Replacing the Hydraulic Pump Start-up
NOTE WARNING
The hydraulic pump should not be replaced Use approved oils only (see table L02-D,
on site. page M-1.1-2900-002)!
The pump should be replaced by a new
one.
All seals of dismantled parts and filters ● Check that the assembly is clean and correctly
must be replaced. assembled. Above all, the pressure ports must be
tight.
Disassembly
● Initially, fill up to half the container height with
● Remove the hydraulic unit as describedin the hydraulic oil (see lubricant table), via a filter
previous chapter. with a minimum retention rate of 10 µm.
● Drain the oil via the filler neck. ● Never run the pump without oil!
See drawing M1826, page M-2.3-2900-003: ● All parts, in particular the hydraulic connections,
must be completely clean and dry before starting.
● Unscrew the 4 nuts (42). Otherwise it is impossible to prevent leaks.
● Lift out the engine from the top. When doing so, ● Operate the lifting functions for approx. 30
take care to prevent the engine from coming apart. seconds to bleed the system. This will cause
heavy frothing of the container oil.
● Remove the screws (36) on the container flange,
remove the container and the O ring (29). ● Check the pressure port and surrounding
hydraulic components for leaks.
● Remove the filter (51) and the suction pipe (50).
● Park the truck and leave it for approx. 20 minutes.
● Loosen the screws (49) and remove the pump. This will allow time for the air to separate from the
oil in the container.
● Clean all components (excluding the engine) with
a clean de-greasing agent, remove old seals and ● When there is no more foam in the container,
air-dry all components. replenish with oil up to the max. point and repeat
bleeding until no more foam is visible.
Assembly
● Finally, replenish with hydraulic oil up to the
● Fit the new filter element (51) and the suction pipe (50). bottom edge of the filler neck.
● Apply a thin coat of oil to the new seal (45) and Pump Motor
insert it.
Pump motor maintenance and repair work is detailled in
● Fit the carrier (46). chapter 4.
● Fit the pump (note the alignment) and fix it with Replacing the Hydraulic Filter
the screws (49). Tighten diagonally and evenly.
Replacing the Suction Filter
● Fit the container with a new, gently greased seal (29)
and fix with the screws (36). Tighten the screws ● To replace the filter (51), loosen the screws (36).
diagonally and evenly. Loosen the return line (2) on the fitting (1).
Remove the container (24) and O ring (29) and
● Place the engine on the support (34) in such a dispose of the oil in an environmentally safe
way that the drive shaft fits into the carrier groove. manner.
Align the engine and fix it using the nuts (42) via
the stay rods (40). ● Unscrew the filter element (28) and replace it with
a new one. Dispose of the old filter in an
● To re-fit the hydraulic unit, proceed in the reverse environmentally safe manner.
order of dis-assembly.
Printed in Germany
M1.0-0000-0003
M-2.3-2900-001
HYDRAULICS
Fill with suitable hydraulic oil (see lubricant table,
chapter 1) and bleed in accordance with the Start-Up
section on the previous page.
Oil Change
The oil container (approx. 0.75 litre capacity) does not
have an oil drain screw. Therefore either suction off the
used oil or tilt the oil container.
Disposal must be through approved methods only!
Filling and bleeding are in accordance with the Start-Up

section on the previous page.
Printed in Germany
M-2.3-2900-002
M1.0-0000-0004
HYDRAULICS
M1826
Printed in Germany
M1.0-0000-0005
M-2.3-2900-003
HYDRAULICS
Valve Setting Control
Non-return valve control
● Remove the hydraulic motor cover so that the
collector is visible.
● Raise the forks.
● Lower the forks while observing the anchor. The

anchor should not move!
If the anchor moves, proceed as follows:
● Remove the non-return valve (32, Fig. M1770) and

replace it with a new valve (available as a kit
complete with seals).
Safety Valve Control

● Assemble a test load with 10% more weight than
the maximum admissible load (see data plate).
● Collect the load with the forks and activate the lift
function.
● The load should not be raised!
Safety Valve Setting

WARNING
The safety valve setting is very critical. An
incorrect setting can cause the truck to be
overloaded and result in severe or even fatal
injuries!
● Prepare two test loads, one with 10% more weight
than the maximum admissible load (overload) and
one with the maximum truck capacity weight
(normal load).
● Unscrew the safety valve cap (33, Fig. M1770) and

loosen the set screw jam nut.
● Collect the excess load and activate the lift

function.
● First set the safety valve so as to prevent the

excess load from being lifted.
● Secondly, collect the normal load and activate the

lift function. The load should be raised.
● Tighten the set screw jam nut and repeat the test.
● After adjustment, screw the cap back on to the

safety valve and seal it.
Printed in Germany
M-2.3-2900-004
M1.0-0000-0006
HYDRAULICS
M1770
Printed in Germany
M1.0-0000-0007
M-2.3-2900-005
Printed in Germany
DRIVE UNIT
Printed in Germany
Printed in Germany
DRIVE UNIT
Drive Unit
Preparation
The truck must be raised in order to remove the drive G
unit. See chapter M1 for instructions.
Auxiliary Equipment:
● Fork lift truck with sufficient capacity, lift height

and fork length to raise the truck.
● Safety device for the forks of the lifting truck to

keep the raised truck in position. F
● A hard wooden block (minimum surface area of

250 x 250 mm, 80 mm high) or another suitable
support to secure the truck after removing the
drive unit.
● Suitable device to keep the drive assembly

vertical when the truck is raised. This device
should also be suitable for transporting the E
assembly. A
Removal D
B
Disconnect the battery and remove the key.
Prevent the truck from being switched on again.

C
Remove the engine compartment panel and the skirting
(C). Remove the six mounting screws (F) from the drive unit.
Remove the stop screw (D). Raise the truck until the drive assembly below the
chassis is free.
DANGER Refit the skirting.
NEVER WORK UNDERNEATH A SUSPENDED Lower the truck sideways in relation to the drive
LOAD. assembly and place the 80 mm high hard wooden block
underneath the skirting (all around).
SEVERE INJURIES COULD RESULT IF THE
TRUCK IS SUDDENLY LOWERED.
Lower the drive assembly onto a workbench with the
drive wheel facing upwards. Use a suitable retaining
device to do this.
Remove the electrical connections to the motor and the
brakes (G).
Remove the cam plate (A) and the switch plate (E) if
present.
Open the chain tensioner (B) and remove the chain.
Attach the truck to a fork lift and prevent it from sliding

away, or use a crane (chapter M1), but do not yet raise.
Fit the device to support the drive assembly.
Printed in Germany
M1.0-0000-0001
M-3.1-2900-001
DRIVE UNIT
Maintenance
WARNING
ONLY AUTHORISED PERSONNEL TRAINED
BY CROWN SHOULD REPAIR THE DRIVE
UNIT. FAILURE TO COMPLY WITH THIS
NOTICE WILL INVALIDATE THE WARRANTY.
Adjusting the flank tooth bearing and tensioning
the shaft bearing requires many years'
experience with drive units. Inaccurate settings
can result in premature drive unit failure. It is
therefore generally advisable to
replace the drive unit.
Replacement drive units are
always supplied without oil!
Before starting the drive unit fill

with oil in accordance with the
"Lubrication Table".
General
● Replace all bearings and

seals.
● Before disassembling the

drive unit, clean thoroughly
with a cold-cleaning solution
and blow dry with weak
compressed air.
● Use assembly devices and a

clean work station.
All reference numbers, e.g. (06) in the following

maintenance instructions relate to drawing
M1774 on this page.
M1774
M1558-1
Printed in Germany
M-3.1-2900-002
M1.0-0000-0002
DRIVE UNIT
Drive Unit Disassembly Assembly
● Loosen the wheel bolts (1) and remove the drive CAUTION
wheel.
THOROUGHLY CLEAN ALL BEARINGS AND
● Remove the oil drain plug (16) and the filler plug SEALS, CLEAN ALL COMPONENTS.
(21) and drain the oil. ● Fit the outer ring of the upper conical roller
bearing (30) in its respective position in the clean
● Remove the screws (18) and lift out the motor. housing. Make sure it lies level in the housing. Fit
the retaining ring (310).
● Remove the screws (19), followed by the flange
(26) and live ring bearing (24) and finally the O ring ● Fit the outer ring of the lower conical roller
(22). bearing (30) with spacers 37x47 and an overall
width of 0.2 mm in its respective position in the
● Remove the shaft seal (6). clean housing. Make sure it lies level in the
housing.
● Remove the retaining ring (7) and lift out the
spacers (11,12). ● Press the inner ring of the lower bearing (30)
onto the conical pinion shaft (38) until it reaches
● Remove the nut (140) from the flange shaft (36). the stop.
● Fit a removal tool to the flange shaft (36) and pull ● Place spacers 20x38 mm with an overall width of
out the flange shaft. 1.2 mm and the spacer sleeve (31) onto the
conical pinion shaft (38).
● Remove the retaining ring (9) and take the bearing
(10) out of the flange shaft. ● Push the conical pinion shaft (38) with the thread
at the front through the inside of the housing (35)
● Unscrew the self-locking nut (33) from the conical into the previously inserted bearing outer rings
pinion (37). (30).
● Push the conical pinion (37) down into the housing ● While holding the conical pinion shaft (38) by the
(35), while ensuring the inner rings of the bearing conical pinion place the inner ring of the upper
(39) remain on the shaft. conical roller bearing (30) onto the conical pinion
shaft.
● Remove the pinion (32), spacers (38) and spacer
sleeve (31). ● Place a 20 x 28 x 0.5 mm spacer on the upper
conical roller bearing.
● Pull or push out the outer bearing (30) rings from
their seats in the drive unit housing. ● Position the pinion (32) and temporarily insert a
M18 x 1.5 nut. Torque the nut to 310 Nm.
● Remove the inner bearing (30) rings from the
conical pinion shaft (37). ● Manually turn the conical pinion several times in
both directions and make sure it turns freely.
● Thoroughly clean all components and remove all
sealant and adhesive residue. ● Using a dial gauge measure the conical pinion
axial play on the roller bearings:
Rated = 0 - 0.05 mm.
● Push the bearing (10) onto the flange shaft (36)

and secure with the retaining ring (9).
● Insert spacers (12) with an overall width of 0.5

mm into the bearing seat of the flange shaft in the
housing (35).
Printed in Germany
M1.0-0000-0003
M-3.1-2900-003
DRIVE UNIT
Adjusting the Bevel Wheel Set
Correct tooth bearings of the inner
CAUTION tooth end of the conical pinion
TAKE CARE WHEN ADJUSTING.
THE USEFUL LIFE AND PERFORMANCE OF
THE DRIVE UNIT DEPEND LARGELY ON AN High
ACCURATE SETTING.
Low
The correct setting is obtained from the tooth flank
bearing.
Basic Rules: High Low
● Always adjust the bevel wheel set to the correct

flank position. The tooth ends must not form a
straight line. Correct tooth bearings of the
inner tooth end of the bevel
● The tooth bearing must always be at the end of wheel M1565-1
the inner tooth.
● The tooth bearing must range from high (top edge Final Assembly
of the tooth) to low (bottom edge of the tooth).
● Thoroughly clean all components.
To adjust, add and/or remove spacers (38 and 12).
The following rule applies: However many spacers are ● Replace the nut (33) with a self-locking nut and
removed from one side must be added on the other. This torque to 310 Nm.
maintains the axial play.
● Insert the flange shaft (36). Fit a sufficient number
Figure M1565-1 shows the tolerances for permissible of spacers (8) between the retaining ring (7) and the
tooth bearings on the conical pinion and the bevel bearing outer ring (10) so that the flange shaft fits
wheel. tightly in the housing. Secure in the housing with a
retaining ring (7).
Checking the Flank Bearing
● Apply a thin layer of Loctite 574 to the outer
● Colour the tooth flanks of the flange shaft (36) with circumference of the shaft seal (6). Grease the seat
contact paste (removable). of the shaft seal in the housing. Gently oil the
sealing lips and insert the shaft seal using an
● Carefully fit the flange shaft (36) in the housing appropriate tool.
and engage it with the conical pinion (37).
● Fit a new O ring (22) onto the flange (26).
● Temporarily insert the disk (8) and retaining ring
(7). ● Insert the flange (26) together with a live ring
bearing (24) into the housing. Drive in the flange
● Turn the bevel wheel several times in a single evenly using a rubber hammer. Do not damage the
direction. The tooth bearing is a bright point O ring.
(shown black in Fig. 1565-1) on the tooth flanks.
● Manually turn the drive unit while checking for
● Disassemble the bevel wheel and check the tooth freedom of movement and absence of play.
bearing. By removing and/or adding shims (38 and
12) bring the tooth bearing to within the tolerance ● Place the drive pinion (27) on the motor. Make sure
range (Fig. M1565-1). that the spring (41) is correctly positioned. Fit disks
(39) and nut (40). Torque the nut to 50 Nm.
Repeat the process until the tooth bearing lies
within the tolerance range. ● Fit a new O ring (28).
● Clean the oil drain plug, remove metallic chips from

the magnet and re-insert with a new seal (15).
Printed in Germany
M-3.1-2900-004
M1.0-0000-0004
DRIVE UNIT
CAUTION ● Re-fit and adjust the stop screw for the
mechanical steering angle limiter.
LEAVE THE SURFACE AND THREAD
SEALANT TO DRY FOR AT LEAST 2 HOURS
AT ROOM TEMPERATURE BEFORE FILLING
Live Ring Bearing Replacement
WITH OIL. To replace the live ring bearing remove the drive unit
(see page M-3.1-2900-001) and drain the oil.
● Add oil at the earliest 2 hours after assembly ● Remove the screws (18) and remove the motor.
(approx. 1.9 litres) in accordance with the lubricant
table - see Chapter 1. ● Remove the oil drain plug (16) and the oil filler plug
(21) and drain the oil.
● Fit a new seal (15) to the oil filler plug (21), insert
and tighten the plug. ● Remove the screws (18) and remove the motor.
● Apply a thin coat of oil to the O ring (28) and ● Remove the screws (19).
carefully fit the drive motor (34) in the housing.
Align with the hole pattern. Apply Loctite 242 to ● Using a rubber hammer drive the bearing and
the screws (18) and insert them. Tighten the flange (26) out of the drive unit by gently and
screws (18) diagonally to 25 Nm. evenly tapping the lower part of the live ring
bearing (24).
● Fit the drive wheel (5) with new lock washers.
Torque the screws to 90 Nm. ● Remove the O ring (22).
Drive Unit Re-Installation Forcing out the Live Ring Bearing

● Assembly is the reverse order of removal. Make ● Place the flange and the live ring bearing on a
sure that the grease nipple (23) is accessible suitable device and using a medium press and a
when fitted. Secure the drive unit to the chassis suitable stamp force the flange out of the live ring
with the screws (25). Torque to 85 Nm. bearing (see Fig. M1870).
● Refit the electrical connections.
● Attach the steering chain in such a way that the Stamp

chain tensioner rests as indicated in Fig. M1869-1.
Device
● Tension the steering chain. Flange
Bearing
M1870
● Carefully clean the flange and its seat in the

drive unit. Make sure that no contamination or
foreign bodies enter the drive unit.
Chain Tensioner M1869-1
Printed in Germany
M1.0-0000-0005
M-3.1-2900-005
DRIVE UNIT
Pressing in the Live Ring Bearing ● Remove the flange and the live ring bearing from
the press. Check the live ring bearing for freedom
● Degrease the flange and apply a thin and even of movement and even running.
layer of Loctite 641 to the entire area where the
inner ring of the live ring bearing will contact. ● Remove the threaded pins and the grease nipple
from the old bearing and insert them in the new
● Position the flange underneath the press and bearing.
insert a new bearing.
Installation of the Live Ring Bearing in the
● Align the bearing with the flange as shown in Fig. Drive Unit
M1872.
● Insert the O ring (22).
● Degrease the upper section of the flange and its

contact surface in the drive unit.
Thread Pins
Loctite 574
Grease Nipple
Chassis Attachment
Holes
M1871
● Apply Loctite 574 to the contact surfaces of the

flange with the drive unit.
● Fit the flange in the drive unit while observing the

M1872
hole circle.
● Using a rubber hammer drive the flange into the

drive unit. Take care only to tap the upper area of
● Using a suitable device (see Fig. M1873) press the flange - not the bearing - and make sure that
the bearing onto the flange until it is securely the O ring (22) remains in its position.
positioned. Immediately remove excess Loctite.
● Fit screws (19) with washers and screw them in
diagonally.
CAUTION Torque to 50 Nm.
THE PRESSING DEVICE MUST BE ● Wipe the bearing and turn it until the grease is
DESIGNED SO THAT PRESSURE IS ONLY evenly distributed in the bearing. Use grease as
EXERTED ON THE BEARING INNER RING. recommended in Chapter M1.
Device
Bearing
Flange Loctite 641
M1873
Printed in Germany
M-3.1-2900-006
M1.0-0000-0006
ELECTRICS
Printed in Germany
Printed in Germany
ELECTRICS
Electrical Components Lift / Lower Switch (PCS, PCD)

The lift (PCS) and lower (PCD) switches are both
DANGER manually activated via a press button in the instrument
panel.
Jack up the truck before repairing or
troubleshooting the electrical system.
The Lift (PCS) switch activates the auxiliary relay
(RLS), the lift limit switch (MFF) as well as the pump
contactor (K3) and the “Lift” solenoid via the control
system. The pump motor (M2) starts up.
Transmitter (MC,MN,PT)
The Lower switch (PCD) activates the “Lower” solenoid
The transmitter is manually activated via a cam switch. via the auxiliary relay (RLD). The pump contactor (K4)
It comprises the commutator (MN) which signals the simultaneously opens via the control system while the
required travel direction to the control system and a pump motor (M2) is inactive.
potentiometer (PT) which governs the travel speed.
Lift Limit Switch (MFF)
Fast / Slow Switch (HES)
The limit switch (MFF) interrupts the auxiliary relay
The Fast / Slow switch is activated via a toggle switch (RLS) power circuit when the preset maximum height is
(rabbit / tortoise & rabbit symbols) on the instrument reached. Consequently the control system cuts out the
panel. High and low speeds can be selected via the pump contactor and the pump motor is inactive.
switch signal to the traction controller.
Pressure Switch (PS)
Seat Switch (MPD)
The pressure switch is applied, when the load raised
This safety switch remains opens provided the driver exceeds 500 kg, due to the rise in pressure in the
seat is not occupied. Travelling and lifting are inhibited hydraulic system. The second brake level is then made
while the switch is open. available.
Safety Pedal (PCT) Horn Switch (PCX)

The safety pedal (PCT) is energised when the seat The horn sounds when this switch is pressed.
switch (MPD)is activated and when pressed applies the
brakes via the control system. The brake is released Horn (CX)
and at the same time power supply is released to the
drive motor (M1) via the input (A5) of the traction The horn is located in the truck’s engine compartment.
controller.
Key Switch (QC)
When the safety pedal is released the input (A5) of the
traction controller is de-energised. The traction controller The key switch activates the traction controller (input A2).
cuts out the power supply to the drive motor and the
spring-loaded brake. The brake magnet is disengaged Emergency Disconnect Switch (PE)
and the truck brakes.
Pressing the Emergency Disconnect Switch interrupts
OPTION
Trucks with Electrical Power Steering: the voltage supply to input (A2) of the traction controller.
The safety pedal (PCT) applies the brake via the EPS- This activates the contactors (K3) and (K4), the traction
DC steering control system. The brake is released and motor and the lift motor remain inactive, the spring-
at the same time power supply is released to the drive loaded brake (FE) is de-energised and brakes the truck.
motor (M1) via the input (A5) of the traction controller.
Steering Angle-Dependent Speed
When the safety pedal is released the input (A5) of the
traction controller is de-energised. The traction controller Reduction Microswitch
cuts out the power supply to the drive motor and the
spring-loaded brake. The brake magnet is disengaged This microswitch senses an angle on the traction motor
and the truck brakes. fitted with rotation bearings. If the steering angle is
greater than 10 degrees, the ramp opens the switch.
Input C3 of the traction controller falls to 0 volts and the
Printed in Germany
M1.0-0000-0001
M-4.2-2900-001
ELECTRICS
control system reduces the max. travel speed. This is a Raise Contactor (RLS) and Lower
safety function to avoid excessive curve speeds.
Contactor (RLD)
Brake (FE)
These contactors are auxiliary relais to modulate the lift
The two-stage electromagnetic brake is spring-loaded valve (EVS) and the lower valve (EVD).
and applies when the truck is de-energised (parking
brake). In travel mode the brake only applies when the OPTION
Steering Motor (M3)
safety pedal (PCT) opens or the emergency stop switch
is pressed. The steering motor is a DC motor. It is governed by the
steering controller EPS-DC.
Fuses (F1, F2, FA)
OPTION
Encoder (MS)
The entire drive current circuit is protected by fuse F1
while the lift current circuit is controlled by fuse F2. The The encoder converts the steering movement in im-
fine fuse (FA) protects the control circuit. pulses which are dependent on the steering movement
and deflection. This impulses are sent to the steering
Traction Motor (M1) controller as input signals.
The traction motor is a separately excited DC motor and OPTION

Steering Limit Switch (MF)
is governed by the traction controlled.
The two limit switches are located on the drive motor.
Pump Motor (M2) When the maximum steering angle is reached they
interrupt the input signal at pins D1 and D7 of the
This is a DC motor. The contactor (K3) applies positive steering controller respectively. This causes the steering
power supply for the pump motor (M2) when a lift motor to stop. Steering movement is now only possible
request is received. in the opposite direction until the previously opened
switch is closed again.
Pump Contactor (K3)
OPTION
Steering-Contactor (K6)
If a lift request is sent to the traction controller via the
switch (PCS), output D4 of the traction controller will be This contactor sends positive battery supply to the
positive. The lift valve (EVS) is simultaneously ener- power part of the steering controller. The coil of the
gised. The pump contactor coil is activated and the contactor (K6) is directly connected on one side to the
pump contactor engages the pump motor (M2). The battery negative terminal while the other side is fed
forks raise as far as the maximum lift height which is positive supply from the steering controller EPS-DC via
preset by the lift limit switch (MFF). The limit switch output E4.
opens and interrupts the voltage supply to the lift switch
(PCS). The lift valve (EVS) is de-energised. Output D5 OPTION
Fuses (F3, FA3)
of the control system falls to 0 volts, the pump contac-
tor is activated and the pump motor remains inactive. The power fuse F3 for the steering motor and power
circuit and the control circuit fuse FA3 are located in the
Main Contactor (K4) controller EPS-DC below the truck floorboard.
The main contactor governs the entire power supply to Travel Direction Display (STD)
the traction and pump motors.
These two lights display the travel direction as a func-
When the key switch (QC) is engaged, positive battery tion of the switch position (MN).
voltage is led from the emergency disconnect switch
(PE) to input A2 of the traction controller. The traction
controller activates output A7 (after internal tests). The
coil of the main contactor is activated, the contacts
switch the battery voltage via fuse F1 to the traction
motor (M1) and via fuse F2 to the pump contactor.
Printed in Germany
M-4.2-2900-002
M1.0-0000-0002
ELECTRICS
Steering Controller
Fuses (F3, FA3)
Traction motor (M1)

Pump motor (M2)
M1852 OPTION
Steering motor
(M3)
Pressure switch (PS)
Electromechanical bra-
ke (FE)
Hydraulic valves (EVD,
EVS)
Steering movement limit
switch (MF)
Steering angle depen-
dent speed reduction
Battery microswitch (MV)
All contactors (K4,
K3,K6) and relais (RLS,
RLD)
Fuses (F1, F2, FA)
Horn (CX)
M1880
Traction Controller
M1848
M1879
Printed in Germany
M1.0-0000-0003
M-4.2-2900-003
ELECTRICS
Emergency Disconnect Switch
Multi-Function Display Travel Direction Display Lights
Travel Direction Selector
M1881
Fast / Slow Commutator

Raise Button
Key Switch Lower Button
Accelerator
M1882
Safety Pedal
Printed in Germany
M-4.2-2900-004
M1.0-0000-0004
ELECTRICS
ES1 Traction Controller Operational Features

Speed Control
DANGER
Stepless, handset programmable speed control in both
Jack up the truck before carrying out repair
directions.
work or troubleshooting the electrical
system.
Reduced Speed Range
Two travel speed ranges can be chosen using the rabbit/
General turtle toggle switch HES. Reduced speeds can be
programmed between 30 % and 100 % of normal travel
The programmable ZAPI SEM Zero impulse controller speed by using the handset.
provides effective control over the driving behaviour of
the truck. Downhill Speed Control
The truck is powered by a separate excited motor When travelling downhill the controller monitors and
(SEM). This version has two variables for governing the compares the motor anchor current with the drive signal
motor output: field and armature current. from the traction potentiometer. When the motor anchor
current decreases, electrical braking with energy
Precautionary Measures retention is introduced.
● Do not attach the controller to a battery with a Regenerative Braking

different rated voltage to that of the controller
(24 - 36 VDC). Three forms of regenerative braking are available:
A higher battery voltage may destroy the
MOSFETs, while a lower power supply will result ● Deceleration braking by setting the travel switch to
in system failure. an smaller value, but still > 0, without changing
the drive direction.
● Only operate the controller with special traction
batteries. Do not connect to a rectifier or mains ● Inversion braking (quick inversion): travel switch
components. set in opposite direction.
● When commissioning jack up the truck to prevent ● Release braking: travel switch set to neutral.
it from starting suddenly if there is a wiring error.
Anti - Roll Down Function
● When the key switch has been turned off the filter
capacitors in the controller remain charged for a This function prevents the truck from accidentally rolling
few minutes. If work is performed on the controller down a slope. When the key switch is on the controller
during this time it must be disconnected from the monitors anchor current of the traction motor. If the
battery (disconnect battery). Finally, to discharge truck starts to roll down the slope without a travel
the capacitors short-circuit the positive and comand, the controller detects the change in the achor
negative terminals of the power part together over current and braking is automatically activated. After
a resistance (10 - 100 Ohm, min. 5 W) for a few this, the monitoring cycle starts over again.
seconds.
Such, if the brake is not applied manually, the truck will
therefore move down the slope very slowly.
Printed in Germany
M1.0-0000-0005
M-4.3-2900-001
ELECTRICS
Hourmeter
An hourmeter is integrated within the traction controller
which can be set via the programmer either to "KEY
ON" (hourmeter activated when key switch on) or
"RUNNING" (hourmeter activated only during travel).
Self Test
The traction controller self-test system lists up to five
different error messages which can be called up via the
programmer. The type of fault as well as the frequency,
number of service hours and the controller temperature
at the time of the error are stored and displayed.
In addition, a red LED on the controller flashes a code

for the most recent error.
Monitored Circuits
See the following diagram for a explanation:
SELF DIGNOSTICS
Executed In Four Conditions
ALLWAYS KEY ON STAND BY TRACTION

Contin. Test By Key On One Time Test By Key On Contin. As Long As Key Is On Contin. Test During Traction
BATTERY
VOLTAGE
TEMPERATURE START UP VACC NOT OK INCORRECT CONTACTOR NO FIELD

SEQUENCE START DRIVER CURRENT
COIL SHORTED CAPACITOR I FIELD HIGH FORW + BACK I = 0 EVER

CHARGE
WATCHDOG V FIELD NOT OK I HIGH AT VMN NOT OK

STAND
PEDAL WIRE KO
CONTACTOR Note: Text in the white boxes shows the messages of the programmer.
DRIVER
See table E-13-S-GB for a description of the monitored components.
Printed in Germany
M-4.3-2900-002
M1.0-0000-0006
ELECTRICS
Protective Devices Maintenance
Polarity Protection Maintenance of the ES1 controller is confined to exter-
nal cleaning. When carrying out maintenance work,
A general protection controlled by the logic system check the listed errors using the programmer.
separates the traction controller from the battery and
thus protects the power part from incorrect polarity. WARNING
Wiring Errors The SEM -1 controller operates with high

throughputs. Special safety measures are
All outputs are protected against wiring errors. The therefore required.
outputs for the general protection and the magnetic
brake can be charged with max. 3 A and are fitted with ● Only properly trained personnel must carry
both an overload and a short circuit protection. out maintenance work.
● Use non-wearying eye protection.
Temperature
● Do not wear loose clothing.
From a power part temperature of 80°C upwards the
maximum current is limited in proportion to the rise in ● Do not wear jewelry.
temperature. At 90°C the traction controller automati-
cally cuts out. ● Use insulated tools only.
At temperatures below -10°C the maximum current is

reduced in proportion to the ongoing battery discharge. ● Disconnect the battery (= emergency disconnect).
Start Sequence ● Jack up the truck.
To start the truck there is a specific start sequence ● Discharge the controller capacitors by connecting
which must be observed. Otherwise the line contactor for a short time BATT- and BATT+ of the controller
will not be activated and the truck will not function: via a cable including a resistor of about 10 Ohm.
1. Key "ON" ● Remove cables.
2. Press security switch down (= deadman ● Remove contamination and corrosion from the
switch). This opens the brake switch (PE) contact surfaces.
3. choose your direction and speed ● Wipe the controller with a clean, damp cloth.
This means, the usual behavior of some operators leads ● Before connecting the cables make sure that the
to an error. This operators normaly choose direction and controller is completely dry.
speed first and then start the truck. This is not possible
with this truck.
Safety Class
The traction controller is protected against dust and
spray water (IP54)
Printed in Germany
M1.0-0000-0007
M-4.3-2900-003
ELECTRICS
ES1 Traction Controller Connections
F1
F1 F2
F2
66 DD 11 88 EE 11
VMN
VMN
33C
C11 66 BB 11 88 AA 11
MUSTER
M1531
Power Connections Control Connections
BATT+ Positive battery supply A, B, C, D
BATT- Negative battery supply E Multifunction Instrument SAM

and Programmer connection
VMN Traction motor driver (negative)
F1, F2 Connections to tractionmotor field coils
Printed in Germany
M-4.3-2900-004
M1.0-0000-0008
ELECTRICS
Programmer The programmer is connected to the controller by a

cable, thus powered by the controller.
General
CAUTION
The optional programmer, Crown P/N 794596, enables
programming, testing and diagnostics for the controller. Only connect / disconnect the programmer
to the controller when the truck is switched
off.
M0271-neu
Display Window
● Alpha-numeric LCD display
● 2 lines @ 16 characters
1 3 5
ROLL ENTER PARAM
ROLL OUT SET Operating Keys
2 4 6
M0274
Printed in Germany
M1.0-0000-0009
M-4.4-2900-001
ELECTRICS
Description of Keys
Key Designation Explanation
1 ROLL up Selects the next sub-menu or an option.
2 ROLL down Selects the previous sub-menu or an option.
3 ENTER Enters the main menu. Stores the pin configuration.
4 OUT * Quits a sub-menu or an option. Step by step return to the main menu.
5 PARAM up Increases setting values or selects configuration.
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.
E05-gb
Operating Menu ZAPI ES1 Controller PROGRAM VACC
General In the PROGRAM VACC menu item the traction

potentiometer is calibrated. The traction controller
When the programmer has been connected a self test reads and records the potentiometer's minimum
start routine is performed. When it is complette, use the and maximum output voltage.
ROLL up/down and ENTER keys to select the required
menu. CONFIG
Menu Functions The Configuration menu is used to set the operation

of the hourmeter.
PARAMETER CHANGE
In addition, the "Adjustments" sub-menu allows for
In the PARAMETER CHANGE menu the listed truck calibration between the battery voltage measured
parameters can be read and set in real time. by the controller and the actual battery voltage.
TESTER
In the TESTER menu the listed truck parameters
can be activated, checked and set in real time.
ALARMS
In the ALARMS menu error messages generated
and stored during operation can be called up and proc-
essed.
Printed in Germany
M-4.4-2900-002
M1.0-0000-00010
ELECTRICS
Operating Menu - Overview
ACCELER DELAY 0-9

CONSOLE
DECELER DELAY 0-9
RELEASE BRAKING 0-9
INVERS. BRAKING 0-9
SOFT BRAKING 0-9
SOFT ACCELERATION 0-9
CUTBACK SPEED 1 0-9
MAIN MENU CUTBACK SPEED 2 0-9
PARAMETER
H&S CUTBACK 0-9
CHANGE
MAX SPEED FORW 0-9
MAX SP FORW FINE 0-9
MAX SPEED BACK 0-9
MAX SP BACK FINE 0-9
CREEP SPEED 0-9
MAIN MENU
TESTER
BATTERY VOLTAGE V
MOTOR VOLTAGE V
MAIN MENU CODE MOTOR CURRENT A
ALARMS hr, NO.,˚C FIELD CURRENT A
VMN V
TEMPERATURE ˚C
ACCELERATOR V%
FORWARD SWITCH ON/OFF
HARDWARE BACKWARD SWITCH ON/OFF
SETTING HANDLE SWITCH ON/OFF
QUICK INVERSION ON/OFF
LOW PERF. SWITCH ON/OFF
CUTBACK SWITCH ON/OFF
LOAD HM FROM SAM ON/OFF BRS SWITCH ON/OFF
CHECK UP DOWN ON/OFF BATTERY CHARGE %
CHECK UP TYPE 0-4
ADJUSTMENT #02 0-9
ADJUSTMENT #01 0-9
MAIN MENU VACC SETTING MIN VACC MAX

PROGRAM VACC MIN MAX 0.0 UP/DOWN 0.0
MAIN MENU
MOTOR DATA NOT AVAILABLE
MAIN MENU
CONFIG. MENU
CONFIG. MENU CONFIG. MENU CONFIG. MENU

SET MODEL SET OPTIONS ADJUSTMENTS
NOT AVAILABLE HOUR COUNTER KEY ON/RUNNING ADJUST BATTERY

QUICK INVERSION BLLY/TIMED
QUICK INVERSION ON/OFF
M1827
Printed in Germany
M1.0-0000-00011
M-4.4-2900-003
ELECTRICS
Settings
PARAMETER CHANGE Menu
Recom-
Setting
Menu item mended Description
range
setting
Acceleration delay. The time taken for the traction controller to

increase the output supply to the traction motors from 0 to 100%
ACCELER DELAY 0-9 5
(when transmitter (rocker switch) suddenly set to limit).The greater
the value, the longer the delay.
Time taken to reach the new set value when the set value on the
transmitter is changed. Corresponds to the braking intensity when
DECELER DELAY 0-9 9
the transmitter is returned. The greater the value, the longer the
time taken to reach the new value.
Release braking. Activated when the accelerator pedal is released

RELEASE BRAKING 0-9 7 or when it returns to neutral. Time taken for the motor current to fall
to zero. The greater the value, the shorter the braking distance.
Inversion braking. Activated when transmitter (rocker switch) is set

INVERSE BRAKING 0-9 5 to the opposite direction. Time taken for the motor current to fall to
zero. The greater the value, the shorter the braking distance.
Maximum current for the low speed range selected by the fast /
slow speed switch (HSS) (in % of max. current ACC for fast speed (=
normal)). Again, the entire mechanical control range of the transmitter
H&S CUTBACK 0-9 5
is available. Enables more sensitive travelling at reduced speed.The
greater the value, the greater the max. speed with the Fast/Slow
switch in the "Slow" position.
Max. forward speed: this value determines the maximum traction

motor current during forward travel.
When the armature voltage has been fully absorbed by the controller,
MAX SPEED FRW 0-9 9 the speed is increased by weakening the field current. If the value is
set to 0 the field current will not fall below the nominal value (FCN =
field current nominal) when the armature voltage is fully absorbed.
The greater the value, the greater the max. forward speed.
Fine adjustment for max. forward speed:

MAX SPEED FRW This value determines the maximum traction motor current during
0-9 5
FINE forward travel.
The greater the value, the greater the max. forward speed.
Creep speed. Setting for the minimum voltage applied to the traction
motor when the travel switch is closed.This function should be set to
one level below the value at which the truck begins to travel.
CREEP SPEED 0-9 0
This ensures that the empty run of the transmitter (rocker switch) is
kept to a minimum. The greater the value, the greater the max.
creep speed.
E06-1-GB
Printed in Germany
M-4.5-2900-001
M1.0-0000-00012
ELECTRICS
Settings
PARAMETER CHANGE Menu
Recom-
Setting
Menu item mended Description
range
setting
Braking pattern in slow mode.

This value determines the braking pattern when the Fast/Slow switch
SOFT BRAKING 0-9 5
is set to Slow. The greater the value, the softer the brake
application.
Acceleration pattern in slow mode.

SOFT This value determines the acceleration pattern when the Fast/Slow
0-9 0
ACCELERATION switch is set to Slow. The lower the value, the softer the
acceleration.
Max. reverse speed:

This value determines the maximum traction motor current during
reverse travel. When the armature voltage has been fully absorbed by
the controller, the speed is increased by weakening the field current.
MAX SPEED BCK W 0-9 9
If the value is set to 0 the field current will not fall below the nominal
value (FCN = field current nominal) when the armature voltage is fully
absorbed. The greater the value, the greater the max.reverse
speed.
Fine adjustment for max. forward speed:

MAX SPEED BCK This value determines the maximum traction motor current during
0-9 5
FINE reverse travel.
The greater the value, the greater the max.reverse speed.
CUTBACK SPEED 1 0-9 6 Speed reduction.
CUTBACK SPEED 2 0-9 6 Speed reduction.
E06-2-GB
DANGER
The max. speeds (unladen) of 10 km/h and

(laden) of 8 km/h must not be exceeded.
The “MAX SPEED FRW”, “MAX SPEED FRW Max. Speed Setting
FINE” and “MAX SPEED BCK W”, “MAX
Preliminary Measures
SPEED BCK FINE” determine the maximum
speed in both travel directions.
The motor brushes must be run in (at least 10 hours
The recommended settings in tables (E06-1- travel time). For new brushes set the recorded value a
GB and E06-2-GB) are approximate. You level lower. This is because the performance improves
must always record the actual speed of the the more the brushes are run in.
truck and adjust the setting so that the truck
travels no faster than 10 km/h or 8 km/h. After the brushes have been run in (at least 10 hours
travel time), measure the actual truck speed again.
Printed in Germany
M1.0-0000-00013
M-4.5-2900-002
ELECTRICS
Speed Measurement
In a secure area, mark a length of 10 metres. The route

must be even a have a sufficiently long entry area to
allow the truck to attain the max. speed beforehand.
Bring the unladen truck at operating temperature to

maximum speed and travel along the route.
Using a stopwatch, record the time taken to cover the

distance.
Repeat the test twice and obtain the mean time taken.
Example:
3 recordings: (3.6 s) (3.4s) (3.7 s)

Mean value: 3.567 s
Speed Calculation:
10 m : 3,567 * 3.6 = 10,09 km/h
Measurement and setting must be carried out separately

for each travel direction.
Set the truck so that the max. speed of 10 km/h is

not exceeded (unladen).
After any adjustment to a value, repeat the measure-

ment.
Repeat the measurements with full load and adjust

the truck so that the max. speed of 8 km/h is not
exceeded.
Printed in Germany
M-4.5-2900-003
M1.0-0000-00014
ELECTRICS
TESTER Menu
The following table describes the various truck param-
eters which can be selected and checked in the
TESTER menu.
TESTER Menu
Menu Item Description
BATTERY VOLTAGE Battery voltage measured at key switch input.
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
MOTOR CURRENT Current received by motor armature.
FIELD CURRENT Current received by field coil.
Measures the current between VMN (Volt Motor Negativ) and -BATT. The reading
VMN
indicates the potential difference over the controller power part.
TEMPERATURE Controller temperature, measured at the aluminium base plate next to the MOSFETs.
Displays the nominal signal of the traction potentiometer. The left hand side displays the
ACCELERATOR voltage reading, the right-hand side the percentage relating to the maximum operating
signal calibrated via PROGRAM VACC.
B6 digital input status.

FORWARD SWITCH
Displays the open (OFF) and closed (ON) status.

BACKWARD SWITCH
A5 digital input status.

HANDLE SWITCH

QUICK INVERSION
C2 digital input status.

LOW PERF. SWITCH
Control logic input is bridged.
C3 digital input status.

CUTBACK SWITCH
A8 digital input status.

BRS SWITCH
BATTERY CHARGE Displays the battery charge status as a percentage.
E07-GB
Printed in Germany
M1.0-0000-00015
M-4.5-2900-004
ELECTRICS
ALARMS Menu
The traction controller can detect and store operational
faults during various operating conditions. The last five
error messages are stored together with the following
details:
● Error type
● Frequency
● Hourmeter reading
● Power part temperature
With the ALARMS menus the corresponding error

messages can be called up and read.
Error Code Display in SAM

Hourmeter
The SAM hourmeter has an LCD display to show the

error codes. This is an alternative to quickly obtain an
overview of the most recent errors.
Printed in Germany
M-4.5-2900-006
M1.0-0000-00016
ELECTRICS
ALARMS Menu
SAM
Handset Error Message Description Possible Cause
Display
SAM not connected to control

06 None SAM cannot read data from the control system.
system or wire breakage.
Watchdog circuit (hardware) or

Error in auto-diagnostic function performed during
08 WATCH-DOG program (software) faulty. Replace
truck power-up, when parked and during travel.
logic system.
Turn key switch off and on again. If

the error persists, replace the logic
Error in non-volatile memory area where hourmeter,
13 EEPROM KO system. If the error is removed, make
error message and truck parameter data is stored.
sure that all the stored data is
deleted and reset to a default value.
- Motor loss to earth

Test performed when truck is idle and main - Motor field connections not
contactor open. The error message appears if connected or incorrectly connected
15 VFIELD NOT OK
approx. 50% of the battery voltage is not applied to to controller
the field connections. - Error in power part field controller
range
Main contactor drive test error during auto- Control logic error.
19 LOGIC FAILURE #1
diagnostic function on truck power-up. Replace logic system.
Test performed in idle mode with the main contactor

closed and during travel.
- Motor cable wiring error
The error message appears when VMN
32 VMN NOT OK - Motor loss to earth
- is below the battery voltage when truck is idle
- Power part error
- does not comply with power when truck is
travelling
- Main contactor jammed (check

Test performed during auto-diagnostic function on
contacts, if necessary replace
power-up.
contactor)
37 CONTACTOR CLOSED The motor field is energised before the main
- Faulty field circuit (check field coil
contactor is applied. The error message appears if
and field cable operation and
the power capacitors do not discharge.
connections)
- Insufficient motor contact (check

carbon brushes)
Test performed during travelling. The error message - Faulty current sensor
49 I = 0 EVER appears if the traction current does not exceed a (replace controller)
given minimum value. - Back coupling, logic system or
power part error (replace component
or entire controller)
E08-GB
Printed in Germany
M1.0-0000-00017
M-4.5-2900-007
ELECTRICS
ALARMS Menu
SAM
Display
- Faulty current sensor

Test performed during auto-diagnostic function on (replace controller)
53 STBY I HIGH power-up and when truck is idle. The error message - Back coupling, logic system or
appears if a current flow is detected. power part error (replace component
or entire controller)
- Field current measuring error

(replace controller)
HIGH FIELD CURR, Test performed constantly and checks the field
57 59 - Field cable not connected
NO FIELD CURR current.
- Power part error (replace
component or entire controller)
Test during auto-diagnostic function on power-up. If

the capacitors have not started to charge 500
Power part faulty.
60 CAPACITOR CHARGE metres after turning the key switch, an error
Replace logic system.
message appears and the main contactor does not
close.
- An error message appears if the controller

temperatue exceeds 80°C. The maximum current is
- Temperature sensor faulty (replace
reduced in proportion to the rise in temperature. At
controller)
90°C the system automatically cuts out.
- Faulty logic (replace logic system)
62 TH PROTECTION - If the temperature falls below -10°C, the maximum
- Insufficient heat transfer (check
current is reduced to 80%.
mounting bolts and the rest of the
- If the error message appears in the normal
system)
temperature range, this indicates an error in the
controller.
- Less than 63 % of the battery

An error message appears if thebattery voltage falls
voltage is applied to input A2 after
below 63% of the nominal value.The ccurrent is
the key switch is applied.
reduced in proportion to the potential difference. At
Wiring problem: poor contact,
43% of the nominal value the system automatically
66 BATTERY LOW additional consumer, cable too long,
cuts out.
small diameter etc.
- If the error message appears at a battery voltage
- Microprocessor error or battery
above 63%, this indicates an error in the controller
current measurement error (replace
or the wiring.
logic system)
- Contactor coil short-circuited, not

connected or incorrectly connected
CONTACTOR DRIVER; - Contactor drive opened or short-
75 76 Tests the main contactor circuit.
COIL SHORTED circuited (replace logic system)
- Voltage feedback errorto contactor
driver (replace logic system)
E08-2-GB
Printed in Germany
M-4.5-2900-008
M1.0-0000-00018
ELECTRICS
ALARMS Menu
SAM
Display
- Potentiometer cable broken

Test performed during auto-diagnostic function on
- Wiring error
power-up and when truck is idle. The error message
78 VACC NOT OK - Potentiometer faulty
appears if the potentiometer signal deviates by more
- PROGRAM VACC not performed or
than 2 volts from the stored minimum value.
incorrectly performed.
Start sequence incorrect. The following sequence - Travel direction switch (FS/RS) or
must be maintained: Override switch (by moving the multitask handle switch jammed
79 INCORRECT START multitask handle from idle to travel position), - Wiring error
followed by travel switch (by pressing the transmitter - Incorrect start sequence entered by
(rocker switch)). user
- Wiring error
Test is performed constantly and checks whether - Travel direction switch jammed
80 FORW + BACK
both travel directions are applied simultaneously. - Incorrect start sequence entered by
user
Test performed constantly and monitors the traction

Potentiometer connections not wired
86 PEDAL WIRE KO potentiometer and its wiring. Error message appears
or interrupted.
for broken wires.
Deactivated as standard. If this

message is displayed in the SAM,
99 CHECK UP NEEDED Scheduled service
the controller item must be
deactivated.
E08-3-GB
PROGRAM VACC 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 (rocket switch at limit). This
ensures that the full physical path of the potentiometer
is used.
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
M1.0-0000-00019
M-4.5-2900-009
ELECTRICS
CONFIG Menu
The CONFIG menu provides access to the SET OP-
TIONS and ADJUSTMENTS sub-menus. The SET
MODEL sub-menu is blocked (NOT AVAILABLE).
CONFIG Menu
Sub-Menu Option Description
SET MODEL --- Not available
Determines the operation of the hourmeter in the traction

HOUR COUNTER: controller. The following options are available:
SET OPTIONS KEY ON / RUNNING - KEY ON: Counts the hours while the truck is switched on
- RUNNING: Counts the hours while the traction motor is applied
QUICK INVERSION:
Not available on this truck.
BELLY / TIMED
Adjusts the battery current measured by the controller to the actual

ADJUSTMENTS ADJUST BATTERY battery current. This can be necessary for example in the event of
a relatively high voltage potential on the key switch.
E11-gb
Printed in Germany
M-4.5-2900-010
M1.0-0000-00020
ELECTRICS
SAM Hourmeter
When the truck is powered up (key switch ON) the
hourmeter reads and displays the previously completed
service hours from the traction controller.
Traction Controller Replacement and Trans-

fer of Service Hours into the new Controller:
If a traction controller needs to be replaced, the previ-
ous number of service hours must be transferred into
the new traction controller.
● Disconnect the battery.
● Remove the faulty controller.
● Insert the new controller.
● Connect the handset (console) to bushing “E” of

the new controller.
● Connect the battery.
● Set the key switch ON.
● In the “Hardware Setting” menu of the handset

activate item “Load HM from SAM”.
● Set the key switch OFF and remove the battery

plug.
● Unplug the handset and connect the hourmeter to

bushing “E”
● Re-plug the battery and set the key switch ON.
While the service hours are being transferred from the

controller to the hourmeter, the error code 98 is dis-
played for a minute. The travel function of the controller
is inhibited for the duration of the data transfer (1
minute).
Printed in Germany
M1.0-0000-00021
M-4.5-2900-011
ELECTRICS
Traction Controller Safety Test ● Power up the truck.

The programmer should display VFIELD NOT OK.
The traction controller safety test takes the form of a Activating the transmitter should have no effect.
Pulse Monitor Trip Test (PMT).
● Switch off the truck and remove the test lead from
In accordance with EU Norm PREN 1175-1 the follow- F1 (the other end remains connected to -BATT).
ing test must be carried out to check the fuse circuit.
● Attach test lead to F2 (item 3).
The test requires a test lead of approx. 1 mm2 diameter
and a 10A fuse. ● Power up the truck.
The programmer should display VFIELD NOT OK.
● Switch off the truck and jack it up. Activating the transmitter should have no effect.
● Connect one end of the test lead to -BATT. ● Switch off the truck, remove the test lead com-
pletely, remove the programmer.
● Connect the other end of the test lead to VMN
(item 1 in Fig. 805980_6). ● When the truck is switched on again and the
transmitter activated, the traction motor should
● Connect the programmer to the traction controller. start.
● Power up the truck. ● If the test proves unsuccessful, replace the

The programmer should display CAPACITOR traction controller.
CHARGE. Activating the transmitter should have
no effect.
● Switch off the truck and disconnect the test lead

from VMN (the other end remains connected to
-BATT).
● Attach test lead to F1 (item 2).
Test lead
1
FU 10A
2
3
Traction Controller
+BATT VMN F1 F2 -BATT
A2 F2 F1
A1
TM
Line
+ -
P
PM
FU1
125A
BD:1 24V BATT. BD:2
805980_6
Printed in Germany
M-4.20-28000-001
M1.0-0000-00022
ELECTRICS
Battery
General
The battery condition considerably affects the truck’s
performance and behaviour. A thorough maintenance OK
schedule will help maintain the battery’s performance
and working life.
Battery maintenance must only be carried out in accord-

ance with the manufacturer’s instructions.
Operation
During battery discharge the battery connector is con-
nected to the truck electrical circuit and during battery
charge it is connected to the charger. Battery Removal
Make sure that the battery connector is isolated when ● Set the wheel straight and lower the fork.
the truck is not being used and that when the truck is
operational and during charging there is a fixed connec- ● If the fork is raised the fork back cover will come
tion between the two connector halves. into contact the battery lid and prevent it from
A bad connection will cause the contacts to burn and being opened.
create faulty charging and operating patterns.
● Power down the truck and remove the key.
● Remove the side panel by turning the two quick

Battery Replacement release mechanisms (see picture) a quarter turn
anti-clockwise.
WARNING
Only use batteries with the correct
dimensions, weight and specifications for
this truck.
● An incorrect battery type can damage the
truck. Battery Lid
● Incorrect weight and dimensions alter the

truck centre of gravity. This can cause
accidents.
To replace the battery either use a battery trolley or a
crane with sufficient capacity. Quick
Release
Mechanisms
DANGER
Risk of Accidents
After installing the battery always refit the Fork Back
side panel and fix it securely. Cover
WARNING!
Risk of Injury
When closing the lid never hold it at the M1861
front or side edges.
Otherwise you may trap your fingers.
Printed in Germany
M1.0-0000-00023
M-4.25-2900-001
ELECTRICS
● Place the battery cable on the battery and secure Replacing the Battery with a Crane
it.
Lift the battery out of the truck as follows, using a crane
● Make sure that all battery terminals are protected with sufficient capacity and suitable lifting gear:
with insulating caps. Attach suitable insulation if
this is not the case.
WARNING
Risk of short circuit!

Do not touch the top side of the battery with
metalic objects.
● A short circuit can result in an electrical
arc which can cause severe burning.
● The battery can be damaged.
● Unscrew the fixing mechanism (see M1859).
Fixing Me- ● Attach a lifting sling (or a chain with a hook) to

chanism each diagonally opposite lifting eye of the battery,
as indicated in the above diagram by the white
arrows. Do not connect the two opposite sides of
RT 3020 the battery with just a single lifting sling! The
lifting slings must be of equal length in order to
keep the battery horizontal during lifting.
M1859
WARNING
Do not stand underneath a raised battery/
RT 3020
● Completely lift the battery out of the truck.
● Fit the new battery in the truck in the reverse

order.
● Attach the fixing mechanism (see M1859).
Printed in Germany
M-4.25-2900-002
M1.0-0000-00024
ELECTRICS
Replacing the Battery with a Battery Trolley
The battery is located at a height of 330 mm on the
truck. The battery replacement trolley must be the
same height.
● Attach the battery replacement trolley to the fork

lift truck (see diagram).
● Pull the battery onto the battery replacement

trolley.
● Secure the battery against sliding away.
● Fit the new battery in the truck in the reverse

order.
DANGER
Risk of accidents.
After fitting the battery always re-fit the side
panel and attach the fixing mechanism.
● An unsecured battery can slide off the
truck and result in serious damage or fatal
injuries.
Attachment opening
Printed in Germany
M1.0-0000-00025
M-4.25-2900-003
ELECTRICS
Charging the Battery
DANGER
Hydrogen is released during charging

which can ignite and explode. It is a life-
threatening danger!
● Always keep the battery compartment lid
open when charging a fixed battery.
● Make sure the charging area is well venti-
lated.
● The charging area must be free from naked
flames and sparks.
CAUTION
Before commissioning the charger make

sure that it is suitable for the battery voltage
and size.
READ and FOLLOW the instructions of the
charger manufacturer and the batterie
manufacturer!
The battery must be charged only according to the

battery manufacturers maintenance manual!
DANGER
Never travel without a side battery compart-

ment panel or with an open battery com-
partment lid.
This can result in accidents.
Printed in Germany
M-4.25-2900-004
M1.0-0000-00026
ELECTRICS
probably have been thermally overloaded. Thermal
Electric Motors overloading (temperatures >160 ºC) causes the
brushes to swell up.
General Maintenance Instructions Brushes which jam in the brush support produce
intense sparking and destroy the collector.
The following instructions apply to all motors. Details
relating to specific models and designs are provided in ● The brush edges must not be cracked. Brushes
the sub-sections (traction motor, pump motor etc.). with cracking along the long edge of the surface
will have been damaged by a worn collector.
Preparation If information is provided in the manual, restore
the collector to the specified limits. Otherwise,
● Disconnect the battery (= EMERGENCY replace the armature in full.
DISCONNECT).
● Loose brush connections are a clear sign of motor
● Secure the truck from rolling away. overload. In this case inspect the collector for
burning and repair or replace as necessary.
Important Maintenance Instructions
● When fitting the brush take care to place the
● Remove all carbon brushes and check for wear. If
spring gently on the brush. If the contact is too
one or more carbon brushes need to be replaced,
hard the brush will be damaged.
replace all brushes. In addition to the carbon
brushes the pressure springs must also be
● Make sure that all brushes contact the armature at
replaced to ensure the correct pressure.
the same pressure.
The length of the shortest brush determines
whether the brush set needs to be replaced. ● New brushes must be run in with a medium load in
the first hours. Never fully charge the motor
Even if the minimum length has not been reached straight away.
the brushes should be replaced as the remaining
useful life could be much shorter than the time
until the next inspection:
If a brush is too short the spring will lie on the

brush support. The brush sparks during operation
and burns the collector with corresponding
damage.
● Blast the motor with dry compressed air only.
● Check the armature for uneveness, burning,

grooves and cracking of the multi-plate edges.
Turn the armature if necessary. A non-oily, evenly
distributed layer on the brush surfaces is normal.
● If oil or grease is found in the motor collector

compartment (usually a paste consisting of oil,
oil vapour, dust and carbon particles),
immediately remove the cause and clean the
motor thoroughly:
Oil or grease burns in the brush sparks and

leaves behind a highly abrasive oil ash which can
very quickly destroy the collector and the
brushes.
● The brushes must be able to move freely in the

brush support (without spring tension) without
tilting. Never modify brushes if one or more
brushes cannot move freely.
In this case replace all brushes as they will
Printed in Germany
M1.0-0000-00027
M-4.35-2900-001
ELECTRICS
Traction Motor Maintenance
Access to the brushes

● Disconnect the battery
● Prevent the truck from rolling away
Carbon Brush
Strap retainer
M1865
● Carbon brush wear limit: 13 mm
● Refit the strap retainer.
Armature
● The diameter of a new armature is 64 mm.
● The armature can be oversped, however the

diameter must not fall below 62.5 mm.
● After overspeeding reduce the mica by at least 0.5

mm without changing the gap between the multi-
plates.
● Carefully remove any burrs from the multi-plate

edges.
Bearings
M1815
● Both ball bearings are maintenance-free. If the
● Remove the strap retainer from the upper section
bearings are removed during maintenance they
of the motor.
must be replaced. In particular, the seals (shaft
seals etc.) must be replaced.
● Apply compressed air to the motor.
● The bearings must be replaced after 10,000
● Remove all carbon brushes (Fig. M1865) and
service hours
check them together with the armature in accord-
ance with the instructions on page M-4.35-2900-
001.
Maintenance
check them together with the armature in accord-
ance with the instructions on page M-4.35-2900-
001.
● Carbon brush length, new: 20 mm
Printed in Germany
M-4.35-2900-002
ELECTRICS
Pump Motor Maintenance Maintenance

Access to the Brushes check with the armature in accordance with the
instructions on page M4.35-2800-001.
● Unplug the battery connector. ● Carbon brush length, new: 25.5 mm
● Lever out the brush cover from the motor housing ● Carbon brush wear limit:13 mm
using a small screwdriver (see Fig. M1867)
● Only two brush sets should be replaced in a row.
At the latest after the third brush set the motor
should either be repaired or replaced with a new
Studs to lift off the cover one.
● Press in and snap shut the covers.
M1867
Printed in Germany
M1.0-0000-00029
M-4.35-2900-003
ELECTRICS
OPTION
Steering Motor Maintenance
Access to the Brushes

● Unplug the battery connector.
● Remove the tensioning belt from the motor.
Maintenance
Insulation
M1866
check with the armature in accordance with the
instructions on page M4.35-2800-001.
● Carbon brush length, new: 16 mm
● Carbon brush wear limit:10 mm
● Check the tensioning belt insulation for damage.

Replace insulation if damaged. Refit the tensioning
belt.
Printed in Germany
M-4.35-2900-004
M1.0-0000-00030
BRAKE
Printed in Germany
Printed in Germany
BRAKE
Brake
General Functional Description

The drive motor contains the drive wheel brake which is
in the form of a disk brake.
The assembly is shown on page M-5.0-1720-502.
The brake interlocks with the motor shaft. When the

truck is de-energised the brake is applied:
If the truck must be moved in this case the brake can
be mechanically released by turning the two cheese Drive motor brake fastening screws (3 off)
head (fastening) screws.
Afterwards, always return them to their original position!
M1845
Test the brakes before operating the truck again. ● Remove rotor (16) from hub (15) while taking
care not to damage the toothing.
The brake is electro-magnetically released. The axial
force generated by compression springs acts on the ● Measure the thickness of the rotor (16). Replace
moving anchor disk. The rotor has a friction lining on the rotor if this thickness is less than 6.0 mm.
both sides and also moves axially. The force acting on A new rotor is 10.0 mm thick.
the anchor disk jams the rotor between the anchor disk
and the friction plate. When DC voltage is applied to the ● Remove the screws from their nuts.
coil a magnetic force acts on the anchor disk. The
anchor disk is pulled against the compression springs. ● Unscrew the banjo bolts (17) from the magnetic
The rotor is no longer jammed, i.e. the brake is released. body (3 off).
Removal ● Remove the anchor disk (14).
CAUTION ● Thoroughly clean components.

Do not allow the brake components to
come into contact with grease or oil. ● Check anchor disk (14) and rotor (16) for even
wear, grooves, cracks and burning. Replace
worn and damaged components.
The item numbers in brackets refer to the diagram on
the following page.
● Remove the battery connector (=Emergency

Disconnect).
● Jack up the truck until the drive wheel is free.

Secure the truck to prevent it from rolling away.
● Remove the panel.
● Remove any brake dust.
● Unplug the electric connection from the brake

wiring (20).
● Remove the three Allen screws.
● Remove the magnetic body (7) from the motor

(including everything connected to it).
Printed in Germany
M1.0-0000-0001
M-5.0-2900-001
BRAKE
circle.
● Screw the banjo bolts (17) with a drop of Loctite

medium into the magnetic body (7) until they
reach the stop.
● Insert the screws (8) into the anchor plate so that

there is a minimum gap of 1 mm between the
anchor plate and the magnetic body. Secure
screws (8) with nuts (9) in the anchor plate.
● Push the rotor (16) onto the hub (15) while

ensuring that the toothing is not damaged in the
process.
● Attach the pre-assembled magnetic body (7) to

the motor using the Allen screws (3).
● Restore the electrical connection (20).
Air Gap Setting

The operating air gap is measured between the
magnetic body and the anchor disk when the truck is
braked. The air gap should be set to 0.2 mm (see Fig.
M1467).
● Unscrew the banjo bolts (3) until they reach the

fixed position on the motor flange.
● Torque the Allen screws (3) evenly to 9.5 Nm.
● Check the operating air gap at several points

along the length using a feeler gauge. The air gap
must be even throughout.
● To increase the air gap slightly unscrew the banjo

17 17 bolts (17). To reduce the air gap screw the banjo
bolts (17) into the magnetic body. Now measure
again as described above.
M0195-1
● When the air gap is correctly set torque the Allen

screws (3) again to 9.5 Nm.
Brake Moment Setting

Assembly
Different brake moments can be set for the first and
Assembly is the reverse order of disassembly. second stages. To increase the moment of the first
stage screw the adjusting ring (1) into the magnetic
● If the thrust pieces (11) and springs (12) have body.The adjustment must be done in stages, ensuring
fallen out of the magnetic body (7), insert them in that the threadring can be secured with the lap of the
the correct position: First the springs (12), followed locking plate (2). Start with the basic setting according
by the thrust pieces (11). Table B01-gb, Screw Depth A. To increase the moment
of the second stage screw the thread ring (6).
● Insert the spring (10) and bushing (13) in the
magnetic body (7).
● Place the anchor disk (14) in the correct position

on the magnetic body: Pay attention to the scribed
Printed in Germany
M-5.0-2900-002
M1.0-0000-0002
BRAKE
Brake Test Change the brake moment with the adjusting ring (1) to
fit the tolerances specified in Table B01-gb.
● Bring the empty truck (no load on the forks!) to
max. speed at operating temperature with a fully Secure the adjusting ring (1) with the locking plate (6).
charged battery on a level, dry and non-skid
concrete surface in a secure area. Now repeat the brake test with maximum load. Adjust
the brake moment if necessary with the thread ring (6)
● Release the deadman-pedal to apply the brake. to the specified range (see Table B01-gb). Secure the
thread ring (6) with screw (4) and washer (5) when done.
● Record the braking distance from the time of
application of the brakes to the time the truck
comes to a halt.
RT3010 Nominal Braking Distances and Screw Depth
Braking Distance Braking Distance

Model Capacity Screw Depth A
(new brake) (used brake)
(nominal Unladen (nominal Unladen

load) load)
Inner ring = 5.7 mm

RT3010 2.000 kg 2,00 - 2,10 m 2,00 - 2,10 m 1,90 - 2,00 m 1,90 - 2,00 m
Outer ring = 5.2 mm
B01-GB
Inner ring Fastening screw

Outer ring
Banjo bolt
Operating air gap

Tab washer
Rotor thickness
M1467 De-energised brake
Printed in Germany
M1.0-0000-0003
M-5.0-2900-003
Printed in Germany
STEERING
Printed in Germany
Printed in Germany
STEERING
Steering OPTION
Electrical power steering is available as an option.
Here, the steering motion from the steering wheel is
mechanically transfered to a sensor. The electrical
Operation output signal of the sensor is processed in a control
system. The control system converts the input signal
The truck is fitted as standard with a mechanical from the sensor into an output signal to control the
steering system. steering motor. The steering motor moves the drive unit
in the respective direction via a steering chain.
The steering motion is transfered from the steering
wheel via a cardan shaft to a pinion. A steering chain
transfers the motion from the pinion to a second pinion
and a sliding clutch to the second steering chain which
in turn regulates the drive unit.
M1786
M1785
Printed in Germany
M1.0-0000-0001
M-6.1-2900-001
STEERING
Lower Steering Chain Adjustment
Insufficient chain tension creates play in the steering.
Check the chain for wear and damage before tensioning
it and if necessary, replace the chain. To tension the
chain, proceed as follows:
● Remove the floorboard.
● Loosen the screw (4, Fig. M1785).
● Tension the chain until you can press firmly in the

middle of the visible chain section with your thumb
without the chain giving way.
● Tighten the screw (4, Fig. M1785).
Adjusting the Drive Unit Steering

Chain
Insufficient chain tension creates play in the steering.
Check the chain for wear and damage before tensioning
and if in doubt replace the chain. To tension, proceed as
follows:
● Remove the panel.
● Position the steering so that the chain tensioner is

easily accessible.
● The chain tensioner is on the right-hand side of

the drive motor (see Fig. M1836)
● Loosen the jam nut (A, Fig. M1836).
M1836
Printed in Germany
M-6.1-2900-002
M1.0-0000-0002
STEERING
Checking the Sliding Clutch Replacing the Sliding Clutch
A sliding clutch is fitted to avoid overloading the ● Remove the floorboard.
steering mechanism. The sliding clutch opens in the
event of excessive steering forces. ● Loosen the chain tensioner (4, Fig. M1785) and
remove the chains from the pinions.
To ensure safety, check the opening moment of the
clutch: ● Remove the screw (4) and disk (5) as well as disk
(33).
● Remove the retaining ring (38).
● Turn the steering wheel until it reaches its stop.
● Lift out the sliding clutch with the pinion facing
● Fit a dynamometer (measurement range 100 - 200 upwards.
Nm) to the steering wheel button and pull
tangentially in the direction of the stop. Maintain ● Disconnect the sliding clutch from the pinion.
the tangential pulling direction until the sliding
clutch opens. At this point measure and record the ● Fit the new sliding clutch in the reverse order.
reading. Keep the sliding clutch free of grease.
M1838
● Repeat the measurement several times in both

directions of turn and calculate the mean value.
● The opening moment should be 127 - 147 Nm.
If you do not obtain this value, replace the sliding

clutch.
M1785
Printed in Germany
M1.0-0000-0003
M-6.1-2900-003
STEERING
Steering Sensor Removal / Instal-
OPTION
lation 12
The steering sensor is only available on trucks with

electrical power steering and is fitted directly below the
steering wheel.
● Remove the steering column panel and the lower

cover of the instrument panel.
● Unscrew the housing (24, Fig. M1840).
● Disconnect the electrical connections. 16

● Loosen the grub screw (12, Fig. M1840).
● Remove the nuts (18, Fig. M1840). 18

(Replace the rubber buffers (16) if they are
damaged or porous). M1840
● Remove the sensor from the bottom.
● Unscrew the panel.
● Installation is the reverse order of removal.
● Disconnect the electrical connection to the
microswitch (42 or 52, Fig. M1786).
OPTION
Steering Motor Removal / Installation
● Loosen the screws (40 or 49, Fig. M1786) and
The steering motor is only available on trucks with
remove the limit switches.
electrical power steering.
● Check that the drive is switched off before the
● Unscrew the panel.
gear reaches the mechanical stop on the chassis
(A, Fig. M1844).
● Open the chain tensioner (39, Fig. M1786).
● Disconnect the electrical connections to the

steering motor.
● Loosen the screw (40, Fig. M1773) and remove

the pinion.
● Remove the four screws (32, Fig. M1773).
● Lift out the engine, paying attention to the springs A

(27, Fig. M1773).

M1844
Note: For steering motor maintenance refer to chapter 4.
OPTION
Limit Switch Removal / Installation
The limit switches switch off the steering motor via the
steering control system whenever the maximum
steering angle is reached.
Printed in Germany
M-6.1-2900-004
M1.0-0000-0004
STEERING
M1786
Printed in Germany
M1.0-0000-0005
M-6.1-2900-005
Printed in Germany
LIFTING MECHANISM
Printed in Germany
Printed in Germany
LIFTING MECHANISM
Lifting Mechanism If the left and right-hand tension rods or both socket
joints were replaced at the same time, check for the
The lifting mechanism is self-levelling. Adjust the lifting level compensation (see diagram M1831):
mechanism and check the self-levelling after replacing
the piston rod(s) or a fork head. ● Raise the forks to approximately half the lifting
height.
WARNING
● Raise the load rollers with a suitable lever so that
Before carrying out work on or underneath the distance from ground can be measured. B= 14
raised forks, make sure that the forks and mm
the truck are wedged with wooden blocks or
other sufficiently secure items.
Test
All reference numbers relate to Fig. M1769-1, page
M7.0-2800-002.
● Fully lower the unladen fork. The entire lifting

mechanism must be free of play and slightly
tensioned. To carry out the test move the tension
rod (40) longitudinally.
● Using a feeler gauge measure between the stop

nose (A) and the underside of the fork (B). There
M1831
should be a gap of approx. 1 mm.
Adjusting the Stop

● Loosen the jam nut (39) from the tension rod.
● Loosen the screw (26) and remove the plate (36).
● Extract the bolt (35) until the socket joint (38) is

free.
● Turn the socket joint (38) to create the required

distance between the stop nose (A) and the
underside of the fork (B).
● When the required air gap has been reached,

tighten the jam nut (39).
● Do not forget the disks (37). Re-insert the bolt (35)

and secure with the screw (26) and the plate (36).
Printed in Germany
M1.0-0000-0001
M-7.0-2900-001
LIFTING MECHANISM
M1769-1
Printed in Germany
M-7.0-2900-002
M1.0-0000-0002
CYLINDERS
Printed in Germany
Printed in Germany
MAINTENANCE
Cylinders
Piston rod
General
There are two main types of hydraulic cylinder: Deflector
● Plunger cylinders, and
Guide ring
● Piston cylinders (double-acting cylinders)
The main difference between the two types of cylinder Seal

lies in their operation as well as the sealing material
design.
Guide ring
Plunger Cylinders (single-acting)
Oil
The plunger cylinder (see Fig. M1475) has only one
pressurised rod surface.
The piston rod enters the cylinder via a single or several Cylinder tube
guide rings. A rod seal in the cylinder head and a dirt
deflector protect the inside of the cylinder and the piston
rod from external contamination.
The piston rod return movement is actuated either by

the net weight of the rod or by the force acting on the
piston rod from the load.
M1475
Printed in Germany
M-8.0-0000-001
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.
Printed in Germany
M-8.0-0000-002
2
MAINTENANCE
Single-Acting Cylinder
Piston Seal Piston Guide Ring CylinderHead
Piston Rod
Oil Cylinder Rod Seal

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

Tube Head
M0824
Printed in Germany
M-8.0-0000-003
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.
High-pressure fluids can penetrate the skin and
cause severe injuries. Reduce the pressure before
disconnecting the hydraulic lines.
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.
Use paper or cardboard to trace leaks.
Do not use your hands.
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.
● Check the piston rod for scratches, nicks and

other surface damage.
● Check deflector rings and the entire cylinder

head area for individual component wear and abnor-
mal leakage.
● 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.
● 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.
● Minor irregularities on the cylinder tube surface

or on the piston rod can be removed with an aluminium
oxide cloth or a honing tool.
● 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
M-8.0-0000-004
4
MAINTENANCE
Seal Installation
General
NOTE 4
BEFORE FITTING A NEW SEAL CHECK THE

SEAL GROOVE AND PISTON ROD FOR
DAMAGE.
FAILURE TO DO SO COULD RESULT IN
FURTHER LEAKAGE AFTER THE NEW SEAL
HAS BEEN FITTED.
2
Use assembly aids and tools made of soft metal or a
suitable plastic without burrs or sharp edges to fit rod
seals. Do not use a screwdriver or a similar tool as this
could damage the seal edges.
If the seal has to be moved over sharp edges, slots or
notches, use appropriate protective mechanisms.
Lift Cylinder
The lift cylinder is a single acting cylinder. Lowering of
the cylinder is supported by a gas pressure spring. 1
Removal Preparation 3
● Fully lower the forks
● Power down the truck and disconnect the battery.
● Prepare a bowl to collect any spilled hydraulic oil. M1829
Removal ● Remove the drainage hose (2, Fig. M1829) from

the elbow and seal it.
● Unscrew the cover plate
● Remove the retaining rings (3 and 4, Fig. M1829).
● Loosen the cylinder pressure port (2, Fig. M1648)
and seal the line. ● Push the upper and lower bolts to the right until
the cylinder is free.
● Remove the cylinder and seal the hydraulic ports

with dummy plugs.
M1828
Printed in Germany
M-8.6-2900-001
5
MAINTENANCE
Repairing the Lift Cylinder Assembly
As with all work on hydraulic components, absolute ● Assembly is the reverse order of removal.
cleanliness in the operating environment is essential.
● The cylinder is self-bleeding. Carry out the lifting
All reference numbers relate to diagram M 1768 on operations a few times. Check for leaks and test
page M-8.6-2600-003. operation. If necessary, replenish with hydraulic
oil.
Disassembly
● Loosen the jam nut (12) and remove it together
with the articulated joint (13).
● Remove the cylinder nut (9).
● Remove the seal (10) and deflector (11) from the

cylinder nut (9) and remove the O ring (8).
● Remove the piston (4), O ring (5) and seal (6) from
the piston rod (7).
● Pull the piston rod (7) out from the cylinder tube
(1).
● Remove the nut (2) and retaining ring (3). Do not

tension the piston rod!
● Remove the piston (4), O ring (5) and seal (6) from
the piston rod (7).
Inspection
● Clean and grease all components with suitable
agents.
● Check all components for wear and damage:

- There should be no grooves on the piston rod or
cylinder tube.
- Check the articulated joint eye and its new bolt
for excessive play. Check the articulated joint for
cracks.
If in doubt, replace the component.
Assembly
● Do not re-use any seals marked with a * in Fig.
M1768. These should always be replaced.
● Assembly is the reverse order of disassembly.
● Apply a thin coating of hydraulic oil to the seals

before inserting them.
● Apply a thin film of hydraulic oil to all bare metallic

components before assembling them, in particular
the piston rod and the inside of the cylinder tube.
Printed in Germany
M-8.6-2900-002
6
MAINTENANCE
Gas Pressure Spring Removal and
Assembly
WARNING
The gas pressure spring is pre-tensioned.

1
Wear eye protection and protective cloth-
ing. Take care to avoid injuries when re-
moving and installing the spring.
Removal Preparation
● Fully lower the forks
● Power down the truck and disconnect the battery.
M1829
M1828
1
2
Removal
● Unscrew the cover plate.
● Loosen and remove the screw (2, Fig. M1829 on

this page).
● Carefully tilt the gas pressure spring out towards

the front (2, Fig. M1829 on this page). The spring
will expand slightly.
Assembly
● Assembly is the reverse order of removal.
Printed in Germany
M-8.6-2900-003
7
Printed in Germany
ELECTRICAL DIAGRAMS
Printed in Germany
Printed in Germany
GREY/BLACK
Printed in Germany
RED/WHITE
WHITE
Control Circut
YELLOW
VIOLET
BROWN/YELLOW
BLUE/WHITE
YELLOW
BLACK
BLUE
BROWN BLUE/BLACK
YELLOW/RED
PINK
BROWN/BLACK
BROWN/BLACK
BROWN
BLUE
YELLOW/RED
GREY/BLACK
GREY/BLACK
BLACK
WHITE
VIOLET BROWN
GREEN
BROWN
YELLOW BLUE
BLACK YELLOW/RED
RED BLACK
RED/WHITE
BLACK
BLUE/BLACK GREY
BLUE/WHITE
BLUE
BROWN WHITE
BLACK RED/WHITE
BROWN/BLACK VIOLET
BROWN
GREY
BLUE
BLUE
BROWN/YELLOW
YELLOW/RED
RED/GREEN
YELLOW/BLACK
RED RED RED/GREEN
RED/GREEN
BLACK
3
M/P-DIA-2900-001
DIAGRAMS
M1818_gb
4
GREY/BLACK
BLACK
RED/WHITE
YELLOW
VIOLET
WHITE
BROWN/YELLOW
YELLOW
BROWN/WHITE
M/P-DIA-2900-002
BLACK
BLUE
BROWN BLUE/BLACK
YELLOW/RED
PINK
YELLOW/RED
GREY/BLACK
BLUE
BROWN/BLACK
BROWN/BLACK
BROWN
GREY/BLACK
BLACK
WHITE
VIOLET BROWN
GREEN
BROWN
YELLOW BLUE
BLACK YELLOW/RED
RED BLACK
RED/WHITE
BLACK
BLUE/BLACK GREY
BLUE/WHITE
BLUE
Control Circut/Steering Motor
BROWN WHITE
BLACK RED/WHITE
BROWN/BLACK VIOLET
BROWN
GREY
BLUE
BLUE
BROWN/YELLOW
YELLOW/RED
RED/GREEN
YELLOW/BLACK
RED RED RED/GREEN
RED/GREEN
BLACK
GREY/BLACK
WHITE/BLACK
WHITE/GREEN
RED/BLACK
PINK/
BLACK
PINK
YELLOW/BLACK
YELLOW YELLOW/RED
Printed in Germany
DIAGRAMS
M1856_gb
HYDRAULIC SCHEMATIC
Printed in Germany
Printed in Germany
HYDRAULIK SCHEMATIC
M1781
Printed in Germany
HYD-2900-001
1
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

Order Number: 812543-999

Service Manual: Wartungshandbuch Manuel de Maintenance Serie

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Service Manual

MA – SAFETY PAGE SER-NR. CUT REV.

ITD – INTRODUCTION PAGE SER-NR. CUT REV.

M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV.

M2 – HYDRAULICS PAGE SER-NR. CUT REV.

M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

M4 – ELECTRICS PAGE SER-NR. CUT REV.

ES1 Traction Controller ........................................................ M-4.3-2900-001

Programmer ......................................................................... M-4.4-2900-001

Traction Controller Safety Test ............................................ M-4.20-2900-001

Battery ................................................................................... M-4.25-2900-001

Electric Motors ..................................................................... M-4.35-2900-001

M6 – STEERING PAGE SER-NR. CUT REV.

M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

M8 – CYLINDERS PAGE SER-NR. CUT REV.

DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.

HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

Safety Symbols used in the General Maintenance and Repair

4. To clean, use a non flammable, non combustible

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

7. Neutralise and thoroughly rinse any spilled battery

Before Leaving the Truck

● Lower the fork carriage fully.

● Apply the parking brake.

● Turn off the travel switch and remove the key.

● Block all wheels when parking on an uneven

Before Carrying out Work on the Truck

● Prevent the truck from rolling away.

● Before carrying out work on the hoist frame, the

● Only carry out operational testing when there is

Before Operating the Truck

● Get into the driver's seat.

● Check the operation of the lifting device, travel

General series. Brochures can be obtained from your CROWN

● The truck model number M6 Steering

● The truck serial number M7 Mast / Lifting Mechanism

This information can be found on the truck's data plate. M8 Cylinder

Please refer to the Technical Specifications Sheet for the

If a page has been modified since the last edition, a

02 REV. 2/99 means the second amendment to this

The page numbers are not necessarily consecutive!

The back page of the manual contains a print

In this example, 02/00 is the edition date.

Chapter Page Number

Section Truck Code

A page beginning with M- is only contained in the maintenance manual:

Chapter Page Number

Section Truck Code

Chapter Page Number

Section Truck Code

Rider Pallet Truck with 2.000 kg capacity

Rider Pallet Truck with 2.200 kg capacity

Rider Pallet Truck with 3.300 kg capacity

Always support the raised truck on square

● Improper handling of the truck or the 1

● Lift the forks to maximum height. 3

● Secure both loadwheels with a wedge (1). 4

● Place sufficiently sized wooden blocks (hard wood)

● Apply the jack to the forks.

● Place a wooden block under the forks and lower the

Make sure the crane / fork lift and the lifting

Lifting the Truck with a second Truck

Always remove the battery connector before