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Service Manual: Wartungshandbuch Manuel de Maintenance Series
Service Manual: Wartungshandbuch Manuel de Maintenance Series
Wartungshandbuch
Manuel de maintenance RT3010 Series
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TABLE OF CONTENT
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TABLE OF CONTENT
Table of Content
Printed in Germany
M-IDX-2800-001
TABLE OF CONTENT
Valve Setting Control ........................................................ M-2.3-2800-004
Non-return valve control ............................................... M-2.3-2800-004
Safety Valve Control .................................................... M-2.3-2800-004
Safety Valve Setting .................................................... M-2.3-2800-004
Printed in Germany
M-IDX-2800-002
TABLE OF CONTENT
- Hourmeter .................................................................. M-4.3-2800-002
Self Test ....................................................................... M-4.3-2800-002
- Monitored Circuits ...................................................... M-4.3-2800-002
Protective Devices ............................................................ M-4.3-2800-003
- Polarity Protection ..................................................... M-4.3-2800-003
- Wiring Errors .............................................................. M-4.3-2800-003
- Temperature ............................................................... M-4.3-2800-003
- Start Sequence ......................................................... M-4.3-2800-003
- Safety Class .............................................................. M-4.3-2800-003
Maintenance ..................................................................... M-4.3-2800-003
ES1 Traction Controller Connections ................................. M-4.3-2800-004
Printed in Germany
M-IDX-2800-003
TABLE OF CONTENT
M-5 – BRAKE PAGE SER-NR. CUT REV.
Brake ..................................................................................... M-5.0-2800-001
- Function ......................................................................... M-5.0-2800-001
- Removal ......................................................................... M-5.0-2800-001
- Assembly ....................................................................... M-5.0-2800-002
- Air Gap Setting ............................................................... M-5.0-2800-002
- Brake Moment Setting .................................................... M-5.0-2800-002
- Brake Test ....................................................................... M-5.0-2800-003
Printed in Germany
M-IDX-2800-004
SAFETY
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SAFETY
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.
Printed in Germany
REV. 1 4/00
M/P-MA-0000-002
2
INTRODUCTION
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INTRODUCTION
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
A01M-gb
Printed in Germany
M-ITD-2800-001
1
INTRODUCTION
Page Numbering in the Manual
The page numbers are on the left and right-hand sides
of the page footer.
MS-ESR4000-GB-D-F 02/00
A page beginning with M/P- is identical in both the maintenance and spare parts manuals:
M/P-1.2-2800-001
M = Maintenance Manual
P = Spare Parts Manual
M-1.2-2800-001
M = Maintenance Manual
Printed in Germany
M/P-ITD-2800-002
2
INTRODUCTION
A page beginning with P- is only contained in the spare parts manual:
P-1.0-2800-001
P = Spare Parts Manual
Model-Number
RT3010
Modeldescription
RT3020
Modeldescription
RT3030
Modeldescription
Printed in Germany
M/P-ITD-2800-003
3
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LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT
Jacking up the Truck
Apply a jack with sufficient capacity, hard wooden
blocks and wedges as shown in Fig. M1802.
DANGER
M1802
Printed in Germany
M-1.0-2800-001
1
LUBRICATION AND ADJUSTMENT
Raising the Truck with a Crane Towing the Truck
Attach the chains / slings as illustrated in the diagram. 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
DANGER with a minimum 1.000 kg capacity.
Make sure the crane / fork lift and the lifting ● Position the forks under the chassis as illustrated
equipment have sufficient capacity. in the diagram.
● If the crane / lift truck crash or a load falls, ● Raise the truck approximately 20 mm off the
fatal injuries can result. ground. The drive wheel should not be in contact
with the ground.
M1800
M1801
Printed in Germany
M-1.0-2800-002
2
LUBRICATION AND ADJUSTMENT
Component Access
Access can be gained either by unscrewing the panels
or simply by flipping up and lifting the top cover.
WARNING
- Lift cylinder
Under the - Lift limit switch
Floorboard - Gas pressure spring
- Pedal
mechanism and
switches
- Steer motor
control system*
M1809
Under the panel
- Drive unit
- Hydraulic pump
- Hydraulic tank
- Valve block
- Brakes
- Electronic control system
- Fuses
- Vent
- Lehnenverstellung drive motor
- Steering motor * Electrical steering optional feature
Printed in Germany
M-1.0-2800-003
3
LUBRICATION AND ADJUSTMENT
Component Access
Vents
Load wheels
Printed in Germany
M-1.0-2800-004
4
LUBRICATION AND ADJUSTMENT
Removing the Floorboard Access to Drive Unit, Hydraulic
Remove screws (A, Fig. M1804). Lift out the floorboard System and Electrical Components
from the top.
Remove the four screws (see Fig. M1808) from the
skirting rail and set it to one side.
M1804
M1808
M1807
Printed in Germany
M-1.0-2800-005
5
LUBRICATION AND ADJUSTMENT
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.
Printed in Germany
M-1.1-2800-001
6
LUBRICATION AND ADJUSTMENT
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
Mobilube SHC Mobil 053002-006 AA
transmission oil
L01-gb
Printed in Germany
M-1.1-2800-002
7
LUBRICATION AND ADJUSTMENT
Grease Points, Overview
L-7,L-8,L-9
M1799
L-7
3
L-4,L-5
M1798
L-7
L-4
M1793
L-6 L-1,L-2,L-4,L-5,L-6,L-10
M1792
L-5
L-1,L-2
L-10
M1796 M1794
Printed in Germany
M-1.2-2800-001
8
LUBRICATION AND ADJUSTMENT
L-2 Replace hydraulic oil and filter D A/R Initially after 500 service hours X
L08-GB
Inspection and Maintenance When carrying out maintenance routinely check for
Schedule wear, corrosion, damage, component operation and
safety. If in doubt, replace components.
The following inspection and maintenance schedule
assumes single-shift operation under normal conditions. Battery Maintenance
The frequency of maintenance intervals must however
WARNING
be constantly adapted to the prevailing operating
conditions.
The battery must be serviced in accordance
In dusty or otherwise extreme operating conditions, the with the manufacturer's instructions.
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
Printed in Germany
M-1.2-2800-002
9
LUBRICATION AND ADJUSTMENT
I-2 Battery connector Check for damage. Check contacts for any signs of burning.
I-3 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.
Check all functions. The hydraulics must cut out when the lift
I-11 Hydraulic functions
limit position is reached.
Printed in Germany
M-1.2-2800-003
10
LUBRICATION AND ADJUSTMENT
I-7
I-8 I-12
I-13, I-14
I-7
I-9
I-11
I-13
M1875
M1813
I-2
I-1
M1811
I-5
I-14
I-4
M1793
I-3*
M1816
I-4
Printed in Germany
M-1.2-2800-004
11
LUBRICATION AND ADJUSTMENT
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-1.2-2800-005
12
LUBRICATION AND ADJUSTMENT
I-2
I-4, I-5
M1814
M1793
I-3
I-1, I-5
L02-part3-GB
I-1
M1794
M1815
Printed in Germany
M-1.2-2800-006
13
LUBRICATION AND ADJUSTMENT
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-1.2-2800-007
14
LUBRICATION AND ADJUSTMENT
I-6
M1811
I-7
M1793
I-8
M1808
Printed in Germany
M-1.2-2800-008
15
LUBRICATION AND ADJUSTMENT
Carry out first gear oil change. Thereafter every 2000 service
I-13 Gear system
hours or every 2 years.
Printed in Germany
M-1.2-2800-009
16
LUBRICATION AND ADJUSTMENT
I-15, I-16
M1816
I-17 I-12
I-11
I-17
I-17
M1793 I-18
I-14, I-15,I-16
I-9
I-10
(6x)
M1815
M1808
M1794
Printed in Germany
M-1.2-2800-010
17
LUBRICATION AND ADJUSTMENT
L07-GB
Printed in Germany
M-1.2-2800-011
18
LUBRICATION AND ADJUSTMENT
M1793 I-18
I-14, 15,I-16
I-21
L03-part2-gb
M1815
24
I-24
18 M1808
M1794
23
M1702
M1704
Printed in Germany
M-1.2-2800-012
19
LUBRICATION AND ADJUSTMENT
Caster
The twin caster is located at the rear right of the truck
below the chassis.
Grease Nipple
Printed in Germany
M-1.5-2800-001
20
LUBRICATION AND ADJUSTMENT
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.
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-1.9-2800-001
21
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HYDRAULICS
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HYDRAULICS
Hydraulic System
M1781
Printed in Germany
M/P-2.1-2800-001
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-2.2-2800-001
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-1.1-2800-002)!
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-2.3-2800-003: ● 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-2.3-2800-001
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!
Printed in Germany
M-2.3-2800-002
M1.0-0000-0004
HYDRAULICS
M1826
Printed in Germany
M1.0-0000-0005
M-2.3-2800-003
HYDRAULICS
Valve Setting Control
Non-return valve control
● Remove the hydraulic motor cover so that the
collector is visible.
● Collect the load with the forks and activate the lift
function.
● Tighten the set screw jam nut and repeat the test.
Printed in Germany
M-2.3-2800-004
M1.0-0000-0006
HYDRAULICS
M1770
Printed in Germany
M1.0-0000-0007
M-2.3-2800-005
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DRIVE UNIT
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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:
Removal D
B
Disconnect the battery and remove the key.
Remove the stop screw (D). Raise the truck until the drive assembly below the
chassis is free.
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.
Printed in Germany
M1.0-0000-0001
M-3.1-2800-001
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!
General
M1774
M1558-1
Printed in Germany
M-3.1-2800-002
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.
Printed in Germany
M1.0-0000-0003
M-3.1-2800-003
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.
● 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).
Printed in Germany
3.1-2800-004
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-3.1-2800-001) 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).
Chain Tensioner
M1870
M1869
Printed in Germany
M1.0-0000-0005
M-3.1-2800-005
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).
Thread Pins
Loctite 574
Grease Nipple
Chassis Attachment
Holes
M1871
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
M1873
Printed in Germany
M-M-3.1-2800-006
M1.0-0000-0006
ELECTRICS
Printed in Germany
Page intentionally left blank
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Printed in Germany
ELECTRICS
Electrical Components The Lower switch (PCD) activates the “Lower” solenoid
via the auxiliary relay (RLD). The pump contactor (K4)
simultaneously opens via the control system while the
DANGER pump motor (M2) is inactive.
Jack up the truck before repairing or
troubleshooting the electrical system. Lift Limit Switch (MFF)
The limit switch (MFF) interrupts the auxiliary relay
(RLS) power circuit when the preset maximum height is
reached. Consequently the control system cuts out the
Transmitter (MMI,MMA,PT) pump contactor and the pump motor is inactive.
The transmitter is manually activated via a cam switch. Pressure Switch (PS)
It comprises the switches (MMI and MMA) which
indicate forward and reverse travel and a potentiometer The pressure switch is applied, when the load raised
(PT) which governs the travel speed. exceeds 500 kg, due to the rise in pressure in the
hydraulic system. The second brake level is then made
Fast / Slow Switch (HES) available.
The Fast / Slow switch is activated via a toggle switch Horn Switch (PCX)
(rabbit / tortoise & rabbit symbols) on the instrument
panel. High and low speeds can be selected via the The buzzer sounds when this switch is pressed.
switch signal to the traction controller.
Horn (CX)
Safety Pedal (PCT)
The horn is located in the truck’s engine compartment.
The safety pedal (PCT) activates the brakes via the
control system. The brake is released and at the same Key Switch (QC)
time power supply is released to the drive motor (M1)
via the input (A5) of the traction controller. The key switch activates the traction controller (input
A2).
When the safety pedal is released the input (A5) of the
traction controller is de-energised. The traction controller Seat Height Adjustment Switch
cuts out the power supply to the drive motor and the
spring-loaded brake. The brake magnet is disengaged (PSDS)
and the truck brakes.
The commutator changes the polarity of the power
OPTION
Trucks with Electrical Power Steering: supply (positive from A5 output of traction contoller) of
The safety pedal (PCT) applies the brake via the EPS- the variable displacement motor (M5) depending on its
DC steering control system. The brake is released and position. A spindle drive adjusts the seat backrest
at the same time power supply is released to the drive accordingly.
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.
Lift / Lower Switch (PCS, PCD) Input C3 of the traction controller falls to 0 volts and the
control system reduces the max. travel speed. This is a
The lift (PCS) and lower (PCD) switches are both safety function to avoid excessive curve speeds.
manually activated via a press button in the instrument
panel.
Printed in Germany
M1.0-0000-0001
M-4.2-2800-001
ELECTRICS
Seat Height Adjustment Limit Switch of the control system falls to 0 volts, the pump contac-
tor is activated and the pump motor remains inactive.
(MF)
Main Contactor (K4)
This microswitch senses a cam switch on the spindle of
the seat variable displacement motor. The main contactor governs the entire power supply to
the traction and pump motors.
Fans (VNT)
When the key switch (QC) is engaged, positive battery
Both fans supply air from the motor compartment to voltage is led from the emergency disconnect switch
cool the drive components. Both receive positive volt- (PE) to input A2 of the traction controller. The traction
age supply from output A5 of the traction controller. controller activates output A7 (after internal tests). The
coil of the main contactor is activated, the contacts
Brake (FE) switch the battery voltage via fuse F1 to the traction
motor (M1) and via fuse F2 to the pump contactor.
The two-stage electromagnetic brake is spring-loaded
and applies when the truck is de-energised (parking Steering Motor (M3)
brake). In travel mode the brake only applies when the
safety pedal (PCT) opens or the emergency stop switch The steering motor is a DC motor. It is governed by the
is pressed. steering controller EPS-DC.
Printed in Germany
M-4.2-2800-002
M1.0-0000-0002
ELECTRICS
Steering Controller
M1852
OPTION
Steering
Encoder
Safety Pedal
M1864
Traction Motor (M1) M1805
Pump Motor (M2)
Vents.
OPTION
Steering Motor
Vents (VNT)
Pressure Switch (PS)
Electromagnetic Brake (FE)
Hydraulic Valves (EVD, EVS)
Horn (CX)
Traction Controller,
contactors and
fuses of the traction
current circuit
M1848
Printed in Germany
M1.0-0000-0003
M-4.2-2800-003
ELECTRICS
Contactors K3 and K4
Power Fuses
F1 and F2
Traction Controller
SEM1
Printed in Germany
M-4.2-2800-004
M1.0-0000-0004
ELECTRICS
● When the key switch has been turned off the filter Anti - Roll Down Function
capacitors in the controller remain charged for a
few minutes. If work is performed on the controller This function prevents the truck from accidentally rolling
during this time it must be disconnected from the down a slope. When the key switch is on the controller
battery (disconnect battery). Finally, to discharge monitors anchor current of the traction motor. If the
the capacitors short-circuit the positive and truck starts to roll down the slope without a travel
negative terminals of the power part together over comand, the controller detects the change in the achor
a resistance (10 - 100 Ohm, min. 5 W) for a few current and braking is automatically activated. After
seconds. this, the monitoring cycle starts over again.
Printed in Germany
M1.0-0000-0005
M-4.3-2800-001
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.
Monitored Circuits
See the following diagram for a explanation:
SELF DIGNOSTICS
Executed In Four Conditions
BATTERY
VOLTAGE
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-4.3-2800-002
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
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.
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-4.3-2800-003
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
Printed in Germany
M-4.3-2800-004
M1.0-0000-0008
ELECTRICS
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-4.4-2800-001
ELECTRICS
Description of Keys
4 OUT * Quits a sub-menu or an option. Step by step return to the main menu.
* You can undo a change by switching the truck off and on again. The controller will be reset to the output values.
E05-gb
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-4.4-2800-002
M1.0-0000-00010
ELECTRICS
Operating Menu - Overview
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
MOTOR DATA NOT AVAILABLE
MAIN MENU
CONFIG. MENU
Printed in Germany
M1.0-0000-00011
M-4.4-2800-003
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
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.
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.
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-4.5-2800-001
M1.0-0000-00012
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
E06-2-GB
Max. Speed Setting
DANGER
Preliminary Measures
The max. speeds (unladen) of 10 km/h and
(laden) of 8.5 km/h must not be exceeded. The motor brushes must be run in (at least 10 hours
The “MAX SPEED FRW”, “MAX SPEED FRW travel time). For new brushes set the recorded value a
FINE” and “MAX SPEED BCK W”, “MAX level lower. This is because the performance improves
SPEED BCK FINE” determine the maximum the more the brushes are run in.
speed in both travel directions.
After the brushes have been run in (at least 10 hours
The recommended settings in tables (E06-1- travel time), measure the actual truck speed again.
GB and E06-2-GB) are approximate. You
must always record the actual speed of the
truck and adjust the setting so that the truck
travels no faster than 10 km/h or 8.5 km/h.
Printed in Germany
M1.0-0000-00013
M-4.5-2800-002
ELECTRICS
Speed Measurement
Repeat the test twice and obtain the mean time taken.
Example:
Speed Calculation:
Printed in Germany
M-4.5-2800-003
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
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
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.
E07-GB
Printed in Germany
M1.0-0000-00015
M-4.5-2800-004
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
Printed in Germany
M-4.5-2800-006
M1.0-0000-00016
ELECTRICS
ALARMS Menu
SAM
Handset Error Message Description Possible Cause
Display
Main contactor drive test error during auto- Control logic error.
19 LOGIC FAILURE #1
diagnostic function on truck power-up. Replace logic system.
E08-GB
Printed in Germany
M1.0-0000-00017
M-4.5-2800-007
ELECTRICS
ALARMS Menu
SAM
Handset Error Message Description Possible Cause
Display
Printed in Germany
M-4.5-2800-008
M1.0-0000-00018
ELECTRICS
ALARMS Menu
SAM
Handset Error Message Description Possible Cause
Display
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
Printed in Germany
M1.0-0000-00019
M-4.5-2800-009
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
QUICK INVERSION:
Not available on this truck.
BELLY / TIMED
Printed in Germany
M-4.5-2800-010
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.
Printed in Germany
M1.0-0000-00021
M-4.5-2800-011
ELECTRICS
● 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.
Test lead
1
FU 10A
2
3
Traction Controller
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
schedule will help maintain the battery’s performance
and working life.
Operation
During battery discharge the battery connector is con-
nected to the truck electrical circuit and during battery M1862
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.
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-4.25-2800-001
ELECTRICS
● Open the battery compartment lid Replacing the Battery with a Crane
● Remove the battery connector With the aid of a truck with sufficient capacity and
suitable lifting gear, remove the battery from the truck
● Place the battery cable on the battery and secure as follows:
it.
● Provide a 30 cm high stable support on which to
● Make sure that all battery terminals are protective lower one end of the battery.
with insulating caps. If they are not, provide
suitable insulation. CAUTION
Cable loom
Fixing
Mecha- Strap
nism
M1859
M1860
● As indicated in the above illustration with the white
arrows, attach a lifting sling (or a chain with a
hook) to each of the diagonally opposed lifting
eyes of the battery. Never connect the two
opposite sides of the battery with just a single
lifting sling! The lifting slings must be of the same
length to ensure the battery remains horizontal
when being lifted.
WARNING
Printed in Germany
M-4.25-2800-002
M1.0-0000-00024
ELECTRICS
● Raise the battery slightly and gently pull it Replacing the Battery with a Trolley
sideways out of the truck until one end of the
battery just remains on the truck. Lower the other The battery is at a height of 335 mm on the truck. The
end of the battery onto the support (see 2, battery replacement trolley must be the same height.
M1858).
● Link the battery replacement trolley to the fork lift
● Suspend the lifting sling from the crane hook onto truck (see illustration).
the end of the battery which is still on the truck,
pull it through under the strap and attach it again
to the crane hook.
Lifting
Sling Hook
opening
Strap
1 Battery
Support
Risk of Accidents
After installing the battery always refit the
side panel and fix it securely.
● An unsecured battery can slide off the
truck and cause serious damage or fatal
injuries.
3
M1858
Printed in Germany
M1.0-0000-00025
M-4.25-2800-003
ELECTRICS
Charging the Battery
DANGER
CAUTION
DANGER
Printed in Germany
M-4.25-2800-004
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:
Printed in Germany
M1.0-0000-00027
M-4.35-2800-001
ELECTRICS
Traction Motor Maintenance
Locking springs
for tensioning
M1865
belt
● Carbon brush wear limit: 13 mm
Armature
● New armatures have a diameter of 64 mm.
● The armature can be oversped, however the
diameter must be no less than 62.5 mm.
Bearings
● Both conical bearings are maintenance-free. If the
bearings are removed during repairs they must be
replaced. The seals (shaft seals etc.) must always
● Blast the motor with compressed air. M1815
be replaced.
● Remove all carbon brushes (Fig. M1865) and
● The bearings must be replaced after 10,000
check with the armature in accordance with the
service hours.
instructions on page M-4.35-2800-001.
Maintenance
● Remove all carbon brushes (Fig. M1865) and
check with the armature in accordance with the
instructions on page M-4.35-2800-001.
Printed in Germany
M-4.35-2800-002
M1.0-0000-00028
ELECTRICS
M1867
Printed in Germany
M1.0-0000-00029
M-4.35-2800-003
ELECTRICS
OPTION
Steering Motor Maintenance Seat Variable Displacement Motor
Adjustment
Access to the Brushes
The seat variable displacement motor itself is
● Unplug the battery connector. maintenance-free. It is sufficient to occasionally clean
the outside with dry compressed air and to lubricate the
● Remove the tensioning belt from the motor. drive spindle (Fig. M1806) with multi-purpose grease.
Maintenance
Insulation
Limit switch
Spindle
Gear unit
M1866
● Remove all carbon brushes (Fig. M1866) and
check with the armature in accordance with the
instructions on page M-4.35-2800-001.
Motor
● Carbon brush length, new: 16 mm
Printed in Germany
M-4.35-2800-004
M1.0-0000-00030
BRAKE
Printed in Germany
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Printed in Germany
BRAKE
Brake
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).
Printed in Germany
M1.0-0000-0001
M-5.0-2800-001
BRAKE
circle.
Printed in Germany
M-5.0-2800-002
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.
Banjo bolt
Printed in Germany
M1.0-0000-0003
M-5.0-2800-003
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Printed in Germany
STEERING
Printed in Germany
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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 transmitted by the steering wheel
with two steering chains to a cardan shaft via a sliding
clutch. Another steering chain transfers the movement
from the cardan shaft to the synchronised drive unit.
M1772
Printed in Germany
M1.0-0000-0001
M-6.1-2800-001
STEERING
Adjusting the Upper Steering Chains Adjusting the Lower Steering Chain
Insufficient chain tension will result in steering play. Insufficient chain tension will result in steering play.
Check the chain for wear and damage before tensioning Check the chain for wear and damage before tensioning
and if in doubt replace the chain. To tension, proceed as and if in doubt replace the chain. To tension, proceed as
follows: follows:
● The chain tensioner is at the top left underneath ● Position the steering so that the chain tensioner is
the chassis panel (see Fig. M1835) easily accessible.
A B B
M1835
Printed in Germany
M-6.1-2800-002
M1.0-0000-0002
STEERING
Checking the Sliding Clutch Replacing the Sliding Clutch
A sliding clutch is fitted to avoid overloading the ● Remove the upper panel by loosening the 3
steering mechanism. The sliding clutch opens in the screws (Fig. M1837)
event of excessive steering forces.
M1838
Printed in Germany
M1.0-0000-0003
M-6.1-2800-003
STEERING
Steering Sensor Removal / Instal-
OPTION
lation 12
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-6.1-2800-004
M1.0-0000-0004
STEERING
M1773
Printed in Germany
M1.0-0000-0005
M-6.1-2800-005
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Printed in Germany
LIFTING MECHANISM
Printed in Germany
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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.
Printed in Germany
M1.0-0000-0001
M-7.0-2800-001
LIFTING MECHANISM
M1769-1
Printed in Germany
M-7.0-2800-002
M1.0-0000-0002
CYLINDERS
Printed in Germany
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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 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.
M1475
Printed in Germany
M-8.0-0000-001
1
MAINTENANCE
Piston Cylinder (Double-Acting
Cylinder)
Printed in Germany
M-8.0-0000-002
2
MAINTENANCE
Single-Acting Cylinder
Piston Rod
M0822
Double-Acting Cylinder
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.
Printed in Germany
M-8.0-0000-004
4
MAINTENANCE
Seal Installation
General
NOTE 4
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
M1828
Printed in Germany
M-8.6-2800-001
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 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 piston (4), O ring (5) and seal (6) from
the piston rod (7).
Inspection
● Clean and grease all components with suitable
agents.
Assembly
● Do not re-use any seals marked with a * in Fig.
M1768. These should always be replaced.
Printed in Germany
M-8.6-2800-002
6
MAINTENANCE
Gas Pressure Spring Removal and
Assembly
WARNING
M1829
M1828
1
2
Removal
● Unscrew the cover plate.
Assembly
● Assembly is the reverse order of removal.
Printed in Germany
M-8.6-2800-003
7
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ELECTRICAL DIAGRAMS
Printed in Germany
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Printed in Germany
BROWN/YELLOW BROWN/YELLOW
GREY/BLACK
Printed in Germany
RED/WHITE
YELLOW/RED
Control Circut
BLUE/WHITE
VIOLET
WHITE
BLACK
BLUE
BROWN BLUE/BLACK
YELLOW/RED YELLOW/RED
BLUE
PINK
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/GREEN
BLAKE
3
M/P-DIA-2800-001
DIAGRAMS
M1797_gb
BROWN/YELLOW
4
BROWN/YELLOW
GREY/BLACK
RED/WHITE
YELLOW/RED
BLUE/WHITE
VIOLET
WHITE
M/P-DIA-2800-002
BLACK
BLUE
BROWN BLUE/BLACK
YELLOW/RED
YELLOW
BLUE
PINK
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
Control Circut/Steering Motor
BLUE/WHITE
BLUE
BROWN WHITE
BLACK RED/WHITE
BROWN/BLACK VIOLET
BROWN
GREY
BLUE
BLUE
BROWN/YELLOW
YELLOW/RED
RED/GREEN
YELLOW/BLACK
RED/GREEN
BLACK
GREY/BLACK
WHITE/BLACK
WHITE/GREEN
RED/BLACK
PINK
PINK/BLACK
YELLOW/BLACK
YELLOW
YELLOW/RED
Printed in Germany
DIAGRAMS
M1810_gb
HYDRAULIC SCHEMATIC
Printed in Germany
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Printed in Germany
HYDRAULIK SCHEMATIC
M1781
Printed in Germany
HYD-2800-001
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