SC3200 Service

Maintenance Manual
SC3200 Series
Printed in Germany ● Status 2, Revision Level A
Order Number: 812548-006
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0) 89 93 00 2 - 0

Fax +49 (0) 89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2004
CROWN Equipment Corporation
REVISION
Overview of Revisions:
Page 3 .... Rev.1 04/00 .......... General corrections and additions to the text.
.............................................. Reference to authorised service personnel added.
Chap. MA Rev. 01/99 ............ now Rev. 03/04 1. DANGER box,

.............................................. warning: Failure to comply with this notice may
.............................................. result in severe or fatal injuries to yourself or other people.
SC3200 03/2004 • Printed in Germany MS-REV-2232
A
Blank page
Printed in Germany
B
TABLE OF CONTENT
Printed in Germany
I
Blank page
Printed in Germany
II
TABLE OF CONTENT
Table of Content
MA – SAFETY PAGE SER-NO. CUT REV.
Safety Symbols used in the Manual ...................................... 3 ........................... N/A ................................ 03/04
ITD – INTRODUCTION PAGE SER-N0. CUT REV.

General Maintenance and Repair Safety Notes ................... 3
Maintenance and Repair ................................................ 3
Before Leaving the Truck ................................................ 4
Before Carrying out Work on the Truck .......................... 4
Before Operating the Truck............................................. 4
Warnings and Labels on the Truck ........................................ 4
General ..................................................................................... 7
Operating Instructions .................................................... 7
Service Training .............................................................. 7
Ordering Spare Parts ...................................................... 7
Using the Manual ............................................................ 7
Model-Number ......................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0. CUT REV.

Lifting the Truck ....................................................................... 11
Lifting by Crane ............................................................... 11
Lifting by another truck ................................................... 11
Towing the Truck ..................................................................... 12
Jacking up the Truck ............................................................... 12
Counterweight ......................................................................... 13
Disassembly .................................................................... 13
Assembly .................................................................... 14
Lubrication and Adjustment .................................................. 15
Component Access ......................................................... 15
Recommended Lubricants and Oils .............................. 18
Lubricants ................................................................... 18
Cold Store Truck Lubricants ........................................ 18
Taking the truck out of service ....................................... 18
Bringing the truck back into service ............................ 18
Lubricant Points and Intervals ............................................... 20
Inspection and Maintenance Schedule ................................. 21
Daily Maintenance (or every 8 service hours) .............. 22
Monthly Maintenance or every 100 service hours ........ 24
3-Monthly Maintenance (or every 250 service hours) .. 26
6-Monthly Maintenance (or every 500 service hours) .. 28
Annual Maintenance (or every 1000 service hours) ..... 28
2-Yearly Maintenance (or every 2000 service hours) ... 28
Torque Requirements ............................................................. 30
Standard Torque Tables .................................................. 30
Special Torque Tables ..................................................... 34
M2 – HYDRAULICS PAGE SER-N0. CUT REV.

Hydraulic Symbols .................................................................. 41
Valve Block ...................................................................... 45
Pump motor ..................................................................... 45
Hydraulic pump ............................................................... 45
Commissioning ........................................................... 45
Bleeding ...................................................................... 45
Oil Change ...................................................................... 45
Bleeding the hydraulic system .............................................. 46
Bleeding the tilt cylinders ............................................... 46
Bleeding the free lift cylinder .......................................... 46
SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232
III
TABLE OF CONTENT
M2 – HYDRAULICS PAGE SER-N0. CUT REV.
Bleeding the lift cylinders ............................................... 46
Flushing the cylinders ..................................................... 47
Drift Tests ................................................................................. 47
Lift cylinder drift test ....................................................... 47
Tilt cylinder drift test ....................................................... 47
Steer unit drift test .......................................................... 47
Overload Valves (RV) .............................................................. 48
M3 – DRIVE UNIT PAGE SER-N0. CUT REV.

Drive Unit ................................................................................. 51
Gear Unit ......................................................................... 51
Disassembly ............................................................... 51
Disassembly ............................................................... 51
Assembly .................................................................... 51
General ............................................................................ 53
Dismantling the Gear Unit ...................................................... 53
Gear Unit Assembly ................................................................ 53
Pre-assembly of the housing with flange shaft ........... 53
Bevel gear spur wheel pinion shaft pre-assembly ...... 53
Spur wheel flange shaft assembly .............................. 53
Bevel gear assembly ................................................... 54
Bevel pinion assembly ................................................ 54
Flank tooth bearing ..................................................... 55
Correcting the flank tooth bearing .............................. 55
Reducing the installation path of the conical pinion . 55
Maintenance .................................................................... 55
Adding oil .................................................................... 55
Types of oil .................................................................. 55
Oil level ....................................................................... 55
Oil change ................................................................... 55
M4 – ELEKTRICS PAGE SER-N0. CUT REV.

Electrics - General .................................................................. 59
Wire Colour Codes ......................................................... 59
Abbreviations .................................................................. 60
Electrical Symbols .......................................................... 61
Electrical Components ........................................................... 63
Switch Functions ............................................................. 63
Brake Switch (BRS) .................................................... 63
Encoder (ENC), Encoder Module (EM) ...................... 63
Accelerator Pedal Switch (ACS, POT1) ...................... 63
Direction Indicator Switch (DIS) .................................. 63
Handbrake Switch (HBS) ............................................ 63
Raise Potentiometer (POT2) ....................................... 63
Steering Axle Potentiometer (POT3) .......................... 63
Tilt (TLT), Sideshift (SSS), Auxiliary Switch (AXS) ..... 63
Emergency Disconnect ............................................... 63
Key Switch (KYS) ........................................................ 63
Fuses (FU) .................................................................. 63
Seat Switch (SES) ...................................................... 64
Electrical Components - Overview ............................. 64
Horn Switch (HNS) ..................................................... 64
Electrical Board ............................................................... 65
Zapimos B1S 48/700 Controller ............................................. 67
General ............................................................................ 67
Protective Devices .......................................................... 67
Polarity Protection ....................................................... 67
MS-IDX-2232 SC3200 03/2004 • Printed in Germany
IV
TABLE OF CONTENT
Wiring Errors ............................................................... 67
Overheating ................................................................ 67
Protection .................................................................... 67
Key Terms ........................................................................ 67
Shunt or Shunt Resistor (+SH/-SH) ............................ 67
Volt Motor Negative (VMN) ......................................... 67
Functional Description .................................................... 67
Acceleration / Delay Rate ........................................... 67
Travel Switch ............................................................... 67
Travel Switch Signal Response .................................. 67
Fault Log ..................................................................... 67
Fault Identification ....................................................... 67
Sparkless Contactors ................................................. 68
Inversion Braking ........................................................ 68
Creep Mode ................................................................ 68
Slow Travel .................................................................. 68
Steering Controller ...................................................... 68
45° Steering Angle ...................................................... 68
Pedal Braking
(Inversion Braking with Battery Supply Regeneration) 68
Ramp Start .................................................................. 68
Key Switch .................................................................. 68
Self Test ...................................................................... 68
Reverse Travel Alarm ........................................ 68
Seat Switch ................................................................. 69
Current Limit ............................................................... 69
Overvoltage ................................................................ 69
Overheating ................................................................ 69
Low Voltage Reduction ............................................... 69
ZAPIMOS B1S 48/700 Traction Controller Connections 70
ZAPIMOS B1S 48/700 Pin Layout .............................. 71
Programmer Connection "B" ....................................... 73
Status LED "A" ............................................................ 73
Status LED Diagnosis ................................................. 73
ZAPIMOS HP 350A Pump Controller ..................................... 74
General ............................................................................ 74
Protective Devices .......................................................... 74
Polarity Protection ....................................................... 74
Wiring Errors ............................................................... 74
Overheating ................................................................ 74
Protection .................................................................... 74
Key Terms ........................................................................ 74
Shunt or Shunt Resistor (+SH/-SH) ............................ 74
Volt Motor Negative (VMN) ......................................... 74
Functional Description .................................................... 75
Acceleration / Delay Rate ........................................... 75
Hydraulic Switches ..................................................... 75
Lift Cutout ................................................................... 75
Lift potentiometer ........................................................ 75
Lift Potentiometer Response ...................................... 75
Fault Log ..................................................................... 75
Fault Identification ....................................................... 75
Steering Support ......................................................... 75
Key Switch .................................................................. 75
Self Test ...................................................................... 75
Current Limit ............................................................... 75
Overvoltage ................................................................ 75
Overtemperature ......................................................... 75
V
TABLE OF CONTENT
Low Voltage Reduction ............................................... 75
ZAPIMOS HP 350A Pump Controller Connections ...... 76
ZAPIMOS HP 350 A Pin Layout ..................................... 77
Pump Controller, LED error code ................................... 78
Programmer Connection "B" ....................................... 78
Status LED "A" ............................................................ 78
Status LED Diagnosis ................................................. 78
Pump Controller Removal ........................................... 79
Pump Controller Assembly ......................................... 79
Traction Controller Removal ....................................... 79
Traction Controller Assembly ...................................... 80
Programmer ............................................................................. 81
General ............................................................................ 81
Display Window ........................................................... 82
Operating Keys ........................................................... 82
Connecting the Programmer .......................................... 83
Operating Menu .............................................................. 83
General ....................................................................... 83
Traction Controller Operating Menu ............................... 84
Programmer Start Routine ............................................. 85
Traction Controller Menu Functions ..................................... 86
PROGRAM ...................................................................... 86
TESTER ........................................................................... 86
ALARMS .......................................................................... 86
PROGRAM PEDAL ......................................................... 86
CONFIG ........................................................................... 86
PROGRAM Menu ............................................................ 87
TESTER Menu ................................................................ 88
ALARMS Menu ................................................................ 89
PROGRAM PEDAL Menu ............................................... 91
CONFIG Menu ................................................................ 92
Pump Controller Operating Menu .................................. 93
Menu Functions Pump Controller ......................................... 94
PROGRAM ...................................................................... 94
TESTER ........................................................................... 94
ALARMS .......................................................................... 94
PROGRAM VACC ........................................................... 94
CONFIG ........................................................................... 94
PROGRAM Menu ............................................................ 95
TESTER Menu ................................................................ 99
ALARMS Menu ................................................................ 100
PROGRAM VACC Menu ................................................. 102
CONFIG Menu ................................................................ 103
Calibrating the Steering Potentiometer ................................ 104
Preparation ...................................................................... 104
Calibration ....................................................................... 104
Calibrating the Lift Potentiometer ......................................... 105
Preparation ...................................................................... 105
Calibration ....................................................................... 105
Calibrating the Accelerator Potentiometer ........................... 106
Preparation ...................................................................... 106
Calibration ....................................................................... 106
Traction Controller Safety Test .............................................. 108
Pulse Monitor Trip Test (PMT) ........................................ 108
Equipment ................................................................... 108
Test ............................................................................. 108
PMT Safety Test Wiring .................................................. 109
VI
TABLE OF CONTENT
Battery ...................................................................................... 110
General ............................................................................ 110
Replacing the battery ..................................................... 110
Battery Discharge Indicator (BDI) ......................................... 110
General ............................................................................ 110
Battery Discharge Indicator Setting (BDI) ..................... 111
Calibration ....................................................................... 111
Electric Motors ........................................................................ 112
General Maintenance Instructions ................................. 112
Preparation ................................................................. 112
Important Maintenance Instructions ........................... 112
Traction Motor Maintenance .................................................. 113
Access to Brushes .......................................................... 113
Maintenance .................................................................... 113
Armature ..................................................................... 113
Bearings ...................................................................... 113
Pump Motor Maintenance ...................................................... 114
Access to brushes .......................................................... 114
Maintenance .................................................................... 114
Armature ..................................................................... 114
M5 – BRAKE PAGE SER-N0. CUT REV.

Brakes ...................................................................................... 117
General ............................................................................ 117
Brake Lining Wear Limits ................................................ 117
Brake Removal ................................................................ 117
Brake Assembly .............................................................. 119
Before Assembling ...................................................... 119
Assembly .................................................................... 119
Foot Brake ....................................................................... 120
Foot Brake Adjustment ............................................... 120
Checking the braking distance ................................... 120
Handbrake Adjustment ............................................... 121
M6 – STEERING PAGE SER-N0. CUT REV.

Steering .................................................................................... 125
Hydraulics ........................................................................ 125
Function ...................................................................... 125
Steering Components ..................................................... 126
Steering wheel ......................................................................... 127
Disassembly .................................................................... 127
Assembly ......................................................................... 127
Direction Control Switches .................................................... 128
Switch Removal .............................................................. 128
Switch Assembly ............................................................. 128
Steer Sensor Module .............................................................. 130
Disassembly .................................................................... 130
Assembly ......................................................................... 130
Steering Sensor ...................................................................... 130
Disassembly .................................................................... 130
Assembly ......................................................................... 130
Steering Column Adjustment ................................................ 131
Gas Pressure Cylinder Removal .................................... 131
Gas Pressure Cylinder Assembly and Adjustment ..... 131
Steering column ...................................................................... 132
Disassembly .................................................................... 132
Steering Column Removal .......................................... 132
VII
TABLE OF CONTENT
M6 – STEERING PAGE SER-N0. CUT REV.
Removing the steering shaft
from the steering column .......................................... 132
Replacing the slip rings ............................................ 132
Steering Gear Removal .................................................. 134
Steering axle ............................................................................ 135
Design ............................................................................. 135
Steering Gear Assembly ................................................ 135
Wheel hub pre-assembly ............................................ 135
Steering knuckle pre-assembly ................................... 135
Steering Knuckle and Wheel Hub Assembly .............. 135
Spur pinion flange shaft pre-assembly ....................... 136
Housing pre-assembly ................................................ 136
Adjusting the bearing clearance ................................. 137
Cylinder Pre-Assembly ............................................... 140
Inserting the cylinder .................................................. 140
Assembling the Axle Bracket to the Steering Gear ..... 140
Operational and Leakage Test .................................... 141
Steering axle 2.12.01.1............................................................ 142
Steering axle 2.12.09.0............................................................ 143
M7 – MAST PAGE SER-N0. CUT REV.

Mast (TT Series) ...................................................................... 147
General ............................................................................ 147
Torques ....................................................................... 147
Mast bearing mounting screws ................................. 147
Mast Stoppers ........................................................... 147
Lifting Gear Minimum Capacity ................................... 147
Mast Testing (Assembled) .............................................. 147
Flaking ............................................................................. 147
Mast Disassembly ................................................................... 149
Dismantling the Mast (Attached) .................................... 149
General ....................................................................... 149
Fork Carriage Removal ............................................... 151
Free Lift Cylinder Removal ......................................... 151
Removing the individual mast stages ......................... 153
Replacing the Mast Rollers
on the Mast Stages and the Fork Carriage ................. 153
Mast Stage Rollers ................................................... 153
Fork Carriage Mast Rollers ....................................... 155
Lift Cylinder Removal .................................................. 155
Removing the Mast from the Truck ................................ 156
Mast Assembly ................................................................ 157
Lift Chains ............................................................................... 158
General ............................................................................ 158
Inspection ........................................................................ 158
Cleaning ...................................................................... 158
Wear ........................................................................... 158
Freedom of Movement of Chain Links ........................ 159
Chain Tension ............................................................. 159
Chain Anchor and Pulleys .......................................... 160
Worn Connection Plates ............................................. 160
Protruding or Turned Chain Pins................................. 160
Corrosion .................................................................... 160
Chain Lateral Wear ..................................................... 161
Uneven Chain Tension .............................................. 161
Misalignment of Lift Components ............................. 161
Lift Chain Lubrication ...................................................... 162
Detaching Lift Chains ..................................................... 163
VIII
TABLE OF CONTENT
M7 – MAST PAGE SER-N0. CUT REV.
Tools and Equipment Required ...................................... 163
Detachment ..................................................................... 163
Fork Tines ................................................................................ 164
General ............................................................................ 164
Terms .......................................................................... 164
Fork Identification ....................................................... 164
Repairs ............................................................................ 164
Checking the Fork ........................................................... 164
Crack Inspection ......................................................... 164
Verticality Test ............................................................. 165
Fork Blade Warping .................................................... 165
Measuring the Fork Tip Width ........................................ 165
Fork Tine Height Difference ........................................... 165
Stop Mechanism ............................................................. 166
Fork Blade Wear ............................................................. 166
Sideshifter ............................................................................... 167
General ............................................................................ 167
Integrated Sideshifter ..................................................... 169
Removal, Repair and Assembly ................................. 169
Hook-on Sideshifter ................................................................ 171
Removal, Repair and Assembly ..................................... 171
M8 – CYLINDERS PAGE SER-N0. CUT REV.

Cylinders .................................................................................. 175
General ............................................................................ 175
Safety when working on hydraulic systems ................ 175
General Instructions for
Repairing Hydraulic Components ............................... 175
Rod Seal Assembly ................................................................. 176
General ............................................................................ 176
Large Rod Seal Assembly .............................................. 176
Small Seal Rod Assembly .............................................. 177
Rod Seal Assembly, Sealing Lip First ............................ 178
Tilt Cylinders ........................................................................... 179
General ............................................................................ 179
Removal .......................................................................... 179
Tilt Cylinder Sectional Drawing ...................................... 180
Dismantling ..................................................................... 182
Component Inspection ................................................ 182
Assembly .................................................................... 182
Assembly ......................................................................... 184
Lift Cylinders ........................................................................... 187
General ............................................................................ 187
Removal and Assembly .................................................. 187
Dismantling ..................................................................... 187
Rod Seal Removal .......................................................... 187
Piston Rod Removal ................................................... 189
Assembly ......................................................................... 189
Piston Rod Assembly .................................................. 189
Installing the Rod seal ................................................ 189
Free-Lift Cylinder .................................................................... 191
General ............................................................................ 191
Removal and Assembly .................................................. 191
Dismantling ..................................................................... 191
Rod Seal Removal ...................................................... 191
Piston Rod Removal ................................................... 191
Assembly ......................................................................... 191
Piston Rod Assembly .................................................. 191
IX
TABLE OF CONTENT
M8 – CYLINDERS PAGE SER-N0. CUT REV.
Installing the Rod Seal ................................................ 191
Hook-on Sideshifter, Cylinder ................................................ 195
Integrated Sideshifter, Cylinder ............................................. 197
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT REV.

Key ............................................................................................ 201
Connectors ...................................................................... 201
Contactors ....................................................................... 201
Abbreviations .................................................................. 201
Control Circuit ......................................................................... 203
Power Circuit ........................................................................... 204
Option Brush Wear & Over Temperature Indicator Circuit
Diagram .................................................................................... 205
Option Lighting Diagram ........................................................ 206
Seat Switch and Steer Pot ...................................................... 208
Steer Column ........................................................................... 208
BDI, Horn and Brake Switches ............................................... 209
Control Levers ......................................................................... 209
Star Points ............................................................................... 210
Panel Wiring ............................................................................. 210
Traction Controller .................................................................. 211
Pump Controller ...................................................................... 211
Power Cable Diagram ............................................................. 212
Main Loom, Part 1 ................................................................... 213
Main Loom, Part 2 ................................................................... 214
Steer Column Loom ................................................................ 215
Fan Standard ........................................................................... 216
Option: Main Harness, Middle East Fan ............................... 217
Option Lights, Main Loom Lights .......................................... 218
Option Lights, Panel to Switch .............................................. 219
Option Lights, Module to Panel ............................................. 220
Option Lights, Panel to Main Loom Lights ........................... 221
Option Lights, Reverse Alarm to Module .............................. 222
Option, Brush Wear and Overtemperature Display Loom ... 223
Option, 5th Hydraulic Function .............................................. 224
Option, Cold Store Model Additional Loom, Part 1 of 2 ...... 225
Option, Cold Store Model Additional Loom, Part 2 of 2 ...... 226
Option, Cold Store Model Additional Loom,
Heating Control Module .......................................................... 227
HYD – HYDRAULIC SCHEMATICS PAGE SER-N0. CUT REV.

Hydraulic Schematic ............................................................... 231
X
SAFETY
Printed in Germany
1
Blank page
Printed in Germany
2
SAFETY
Safety Symbols used in the Manual General Maintenance and Repair

To help guide you through the manual and to highlight parti- Safety Notes
cular danger areas, we have used graphic illustrations:
DANGER
DANGER
Read the safety notices in the truck
This symbol indicates life-threatening Maintenance and Operator's Manuals.
risks
● Failure to do so could result in severe or fatal
● Failure to comply with this notice may result in injuries to maintenance personnel and/or other
fatal injuries to yourself or other people. persons.
Motorised vehicles can be dangerous if maintenance and

WARNING service are neglected. For this reason maintenance and
inspections must be carried out at regular short intervals
This symbol indicates the risk of serious
by trained personnel working to approved company guide-
injury and/or serious material damage.
lines.
● Failure to comply with this notice may result in
severe injuries to yourself or other people and/or DANGER
serious material damage.
Follow all national/local safety regula-
tions applicable for maintenance work,
e.g. for work on higher levels.
CAUTION ● Failure to do so could result in severe or fatal
injuries to maintenance personnel and/or other
This symbol indicates the risk of minor
persons.
injury and/or minor material damage.
● Failure to comply with this notice may result in
minor injuries to yourself or other people and/or Maintenance and Repair
minor material damage.
1. Maintenance work must only be carried out in
accordance with the test and maintenance
program contained in the present Maintenance
INFORMATION Manual and any applicable service notices.
Contains additional information with 2. Only qualified and authorised personnel may
supplementary notes and hints. carry out work on the truck.
3. Always keep fire extinguishers in good working
condition. Do not approach fluid levels or leaks
with a naked flame.
OPTION
4. To clean, use a non flammable, non combustible
These items relate to optional features
cleaning solution which is groundwater-neutral.
not supplied with the standard version.
Only carry out cleaning with an oil separator.
Protect the electrical system from dampness.
5. Keep the service area clean, dry and well-
ventilated.
6. Do not allow oil to penetrate the ground or enter
the draining system. Used oil must be recycled.
Oil filters 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.
8. Keep the truck clean. This will facilitate the
location of loose or faulty components.
SC3200 03/2004 • Printed in Germany MS-MA-0000

Rev. 01/03
03/04
3
SAFETY
9. Make sure that capacity and data plates, warnings Warnings and Labels on the Truck
and labels are legible at all times.
During regular maintenance check that the warnings and
10. Alterations or modifications by the owner or
labels on the truck are complete and legible.
operator are not permitted without the express
written authorisation from Crown. ● Clean any illegible labels.
11. Only use original Crown spare parts to ensure ● Replace any faulty or missing labels.
the reliability, safety and suitability of the Crown
The order and meaning of the warnings and labels on
truck.
the truck are described in section 10.9 of the parts
Before Leaving the Truck manual.
● Stop the truck.

● Lower the fork carriage fully.
● Apply the parking brake.
● Turn off the truck 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.
MS-MA-0000 SC3200 03/2004 • Printed in Germany

Rev. 03/04
4
INTRODUCTION
Printed in Germany
5
Blank page
Printed in Germany
6
INTRODUCTION
General Please refer to the Technical Specifications Sheet for the

utilisable loads, technical data and dimensions for
The present manual is designed for Customer Service thisseries. Brochures can be obtained from your CROWN
engineers who wish to familiarise themselves with the dealer or from the following address:
maintenance work required for the various truck compo-
nents. CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
It also contains troubleshooting sections which can be
80809 Munich
used to identify and remedy truck faults.
GERMANY
Tel.: +49 (0)89 / 93 002 -0
INFORMATION
Fax: +49 (0)89 / 93 002 -175 or 133
This book is not an operating manual. It
is designed solely for specialist person- Using the Manual
nel who have been trained and author-
ised to carry out the work described in The manual is divided into sections. The following table
the manual. shows how the manual is structured.
This manual therefore contains fewer and less detailed Sections Maintenance
warnings than the Operator’s Manual, as the latter is
aimed at persons who have very little or no prior experi- Section Description
ence at all.
Operating Instructions IDX Table of Content
This manual contains no operating instructions. An oper-

MA Safety
ating instructions manual is supplied with the vehicle.
Additional copies can be ordered as required.
ITD Introduction
With the help of this manual you and your personnel will
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle. M1 Lubrication and Adjustment
Service Training M2 Hydraulics

CROWN offers the appropriate vehicle related training
for service personnel. Details on this training can be ob- M3 Drive Unit
tained from CROWN on request.
Ordering Spare Parts M4 Electrical
The maintenance manual does not cover spare parts.

These are listed in a separate manual. M5 Brake
Spare parts can be ordered by quoting:

M6 Steering
● The truck specification number
● The truck model number M7 Mast / Lifting Mechanism
● The truck serial number

M8 Cylinder
This information can be found on the truck’s data plate.
Only if this information is provided can the order be proc-
essed quickly, correctly and reliably. DIA Electrical Diagrams
HYD Hydraulic Schematic
A01M-gb
SC3200 03/2004 • PRINTED IN GERMANY MS-ITD-2232
7
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
Lift Height (TT Mast)
4370 mm
4825 mm
Battery Compartment
5285 mm
Size
5740 mm 418 mm
6120 mm 526 mm
6375 mm 634 mm
6910 mm ITD-04
7495 mm
ITD-03
Cold Store Version
- N one
Mast F With cold store version
- No mast ITD-05
Three stage,
TT Tyres
telescopic mast
ITD-01
S Standard
O Option
T yp e ITD-06
- Standard
Hydraulic Aux. Function
C Customer specific
- No
S S p e ci a l d e si g n
S 1st aux. function
ITD-02
D 2nd aux. function
ITD-07
C TT 4370 526 - S S H CA 1 -
Sideshifter
- No sideshifter
Alarm Options
H Hook-on sideshifter
- No reverse travel alarm
I Integrated sideshifter
1 Reverse travel alarm
ITD-08
ITD-10
Sideshifter Model
-- No sideshifter Battery Discharge Indicator
CA C a sca d e 1 Standard
KA K aup 2 Option
ITD-09 ITD-11
MS-ITD-2232 SC3200 03/2004 • Printed in Germany
8
LUBRIFICATION AND ADJUSTMENT
Printed in Germany
9
Blank page
Printed in Germany
10
LUBRICATION AND ADJUSTMENT
Lifting the Truck Lifting by another truck

The SC 3200 can be lifted by another truck from the side.
CAUTION
Calculate the minimum capacity requirement based on the
Scalding hazard! weight of the truck. This information can be found on the
Spilled battery acid can cause injuries truck data plate.
and damage the truck. ● Position the forks of the truck which is doing the
You must remove the battery before lifting as shown by the diagram below.
transporting the truck. ● Secure the SC 3200 firmly to the forks of the truck
which is doing the lifting (e.g. with appropriate
DANGER straps).
Falling loads are hazardous!
Accidents can result from lifting gear with
insufficient capacity and unsecured loads.
Always use lifting gear with sufficient
capacity and prevent the load slings from
sliding.
0,51 m
Lifting by Crane
Calculate the minimum capacity requirement based on the
weight of the truck. This information can be found on the
truck data plate.
Attach the 3 straps to the hitch points as shown.
G_SC32-Heben-seitl
Centre of
Gravity of the
Truck
Between
Chassis and
Tow Drive Wheel
coupling
G_SC32-Heben-Kran
Printed in Germany MS-1.0-2232
11
Towing the Truck ● First jack up the rear section of the truck:
● Support one side with a wooden block.
If the truck is out of order it can only be towed if the hand-
brake is released. ● Then jack up the truck at the opposite side until
the steered wheels are free (see figure).
WARNING
● Support the raised side.
Towing is only allowed with a tow bar.
● Then lift the opposite side and support it.
● To jack up the front section of the truck, place the
● The brakes of the towing vehicle must be capable jack under the chassis frame behind one of the
of braking the towed vehicle. front wheels.
Jacking up the Truck ● As soon as this drive wheel is free, support the
outer part of the mast on this side.
DANGER ● Repeat this process to lift and support the oppo-
site side.
Always support a raised truck with
wooden blocks or other appropriate
equipment to relieve the jack.
Never reach your hands or other parts of
your body under the truck before it has
been supported, or while jacking the truck
up!
● Improper handling of the truck or of the auxiliary
equipment can result in fatal accidents.
To jack up the truck, the forks must be completely low-
ered (with no load on them) and the parking brake applied.
Required capacity of the jack = 0.5 × overall truck weight.
Do not forget to include the battery weight.
Steered
wheel
Jack Wooden blocks
MO-2232-035
MS-1.0-2232 Printed in Germany
12
Counterweight
WARNING
Trapping hazard!
The counterweight weighs at least 800 kg.
Hands and feet can be trapped.
Only use levers and suitable tools when
assembling and disassembling. Never use
hands or feet.
WARNING
Falling load hazard!
A falling counterweight can result in
serious trapping.
Prevent the counterweight from falling.
To do this, use a load sling suspended to
a crane. The load sling must be pulled
through the hole for the tow pin. The crane
must have a minimum capacity of 1000 kg.
Disassembly
Tools required: ● Remove the mounting screw of the electrical base
plate from the counterweight.
1. For disassembly you will need a crane or forklift
(minimum capacity 200 kg at 2.5m elevation) to ● Remove the mounting screws of the overhead
support the overhead guard. guard from the counterweight.
2. A second crane or forklift (minimum capacity 1000 ● Raise the back of the overhead guard 1 – 2 cm
kg at 2m elevation) to prevent the counterweight and pull a load sling through the hole for the tow
from tipping. pin in the counterweight.
3. A pallet truck (minimum capacity 1000 kg) with ● Insert the load sling into a crane hook (crane
forks that will lower to fit under the counterweight. minimum capacity 1000 kg). If you are using a
forklift instead of a crane, prevent the load sling
4. Hard wooden blocks to fit under the outer mast
on the fork of the truck from sliding.
stages.
● Tighten the load sling slightly.
● Drive the truck into a secure maintenance area.
● Drive a pallet truck (minimum capacity 1000 kg)
● Tilt the mast back as far as it will go (in the
underneath the counterweight. The forks must be
direction of the driver).
positioned under the flat surfaces of the counter-
● Lower the mast and fork carriage fully. weight.
● Place two wooden blocks, one on the left and one ● Raise the forks of the pallet truck until they are
on the right hand side underneath the outer mast touching the counterweight.
stage. This will prevent the truck from tilting onto
● Remove the mounting screws of the counter-
the fork tips.
weight.
● Remove the battery.
● Pull the counterweight approx. 10 cm away from
● Attach a load sling to the rear of the overhead the forklift, using the pallet truck.
guard. This will secure the overhead guard when
● Raise the counterweight off the pallet truck using
you loosen the attachment. Alternatively, you can
the crane, and place it of a flat surface.
support the overhead guard from the side using a
forklift.
● Remove the tow pin from the counterweight.
13
Assembly
● Assemble the counterweight in the reverse order
of disassembly.
14
Lubrication and Adjustment

Component Access
In the course of regular maintenance the contactor panel,
drive unit, hydraulic system and electrical components in
the chassis can be reached by removing or opening the
panels.
MO-2232-037
MO-2232-038
15
MS-2232-043
B
MS-2232-040
A
MS-2232-039
C
MS-2232-038
MS-2232-042
E
D
MS-2232-041
16
Fig. A: Battery compartment lid ● Wiring
Provides access to: ● Steer unit
● Battery To remove:
● Contactor panel including impulse controls ● Loosen 6 hex. socket screws
● Steering axle and potentiometer ● Remove panel
● Hydraulic motor and pump Fig. C: Valve and Control Handle Panel
● Seat switch and plug connector Provides access to:
● Valve Block
CAUTION
● Switch, potentiometer
When the battery compartment lid is
opened it can tip over if the lid centre of ● Control handle mechanism
gravity moves over the pivot point /
To remove:
attachment point of the lid.
● Remove the base plate
● Loosen the two hex. socket screws at the rear
Access:
upper section.
Pull the handle on the front of the lid and open the battery
● Remove the single hex. socket screw at the front
compartment lid.
below the floor board
When you have removed the battery and the side panels
● Lift up the panel
you will have access to:
When you have lifted out the floor boards you will have
● the hydraulic lines on the right hand side of the
access to:
battery compartment.
● Brake pedal and mechanism
● the cable duct on the left hand side of the battery
compartment. ● Brake
● the flow controller on the right hand side (only for ● Accelerator pedal / travel switch and
lift heights above 5000 mm) potentiometer
● Tilt cylinder attachment (frame)
Fig. B: Steering column front panel ● Valve block hydraulic lines
Provides access to: ● Wiring
● Key switch ● LH and RH drive motor
● Direction control switch To remove the floor boards:
● Encoder ● Move the floor boards away from each other and
lift them out.
● Wiring
● Steering unit and distributor block
● Hydraulic lines
To remove:
● Loosen two hex. socket screws
● Lift panel slightly and lever out at the bottom
Fig. E: Inner dashboard

Provides access to:
● Handbrake
● Battery display
17
Recommended Lubricants and Oils Bringing the truck back into service
Lubricants If you wish to bring the truck back into service, proceed
as follows:
The next page shows typical lubricants used by Crown
● Remove any anti-corrosion agents which have
itself in its factories. However, you can use any lubricants
been additionally applied (apart from the cold store
provided they meet the same technical criteria.
agents)*.
Cold Store Truck Lubricants ● Jack up the truck, remove the wooden blocks and
Special hydraulic oil, lubrication oil and grease must be lower the truck.
used for cold store trucks operating in low temperature ● Charge the battery or fit a charged battery.
conditions (see table on following page). An anticorrosion
fluid (Crown no. 805236-004) must be applied to all screws, ● Connect the battery.
washers, nuts, pins, retaining rings etc. Carefully protect ● Carry out the daily inspection.
all electrical connections and components against corro-
sion. For detailed information, refer to chapter 4. * Do not apply high pressure cleaning agents and/
or solvents to the truck. Do not use metallic brushes.
Service intervals must be adapted to the conditions of Do not wet clean the electrical system and do not use
use. This means they must be reduced as far as possible flammable solvents.
to prevent excessive wear.
Taking the truck out of service

If you wish to take the truck out of service for more than 3
months, proceed as follows:
● Disconnect the battery from the truck.
● Decommission the battery in accordance with the
manufacturer’s instructions.
● Clean the truck*). Lubricate in accordance with the
maintenance manual.
● If the truck is to be stored in harsh conditions (e.g.
saline atmosphere) treat the surface of the truck
with a suitable preservative to prevent corrosion.
● Do not park the truck in the open air or in a humid
environment. The ideal place is a dry room where
the temperature and air humidity are as constant
as possible. If the truck has to be covered, use an
air-permeable material. Do not use plastic sheets.
Otherwise, condensation may form.
● Jack up the truck. Lower the chassis onto suitable
wooden blocks so that the wheels clear the ground
(prevents the wheels from flattening from constant
pressure).
● Every 3 months connect the battery, carry out a
daily inspection and activate all the truck func-
tions. Now disconnect the battery again.
18
Lubricant Type Product Description Manufacturer CROWN Part No. Type
Aralube HLP-2 Aral

LM-Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
Grease (multi purpose) 053002-001 B
EP2 Maxol
Mobiluxe E2 Mobil
Retinax LX Shell
LGWM1 SKF
Low temperature Aralube SKL2 Aral

053002-005 BB
grease Unirex Lotemp EP Mobil
Kowal 40 Aral
Lubrication oil (chain) Essolube HD + 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
Nuto H32 Esso
Hydraulic oil 053001-003 D
DTE 24 Mobil
Tellus 32 Shell
B110 Fuchs Mineralölwerke GmbH
Low temperature Univis J 13 Esso

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-LS75W-90 Mobil 053002-006 AA
transmission oil
Rubber and vinyl

H
dressing
Special grease MOS2 Lithium Dow Corning 063002-022 M
Universal lubrication oil SEA40 C
Corrosion agent for cold

Anti-corrosion agent Tectyl 805236-004 -
store trucks
L62-GB
19
Lubricant Points and Intervals
Lubricant Points / Intervals

100 250 500 1000 2000
Item Component Type Qty.
hrs hrs hrs hrs hrs
Batter y compar tment lid lock and batter y compar tment lid
1 C A/R X
hinges
2 Brake pedal pivots & brake main pivot B A/R X
3 Accelerator pedal pivots, resetter rollers B A/R X
4 Fork lock & fork carriage tines B A/R X
5 Handbrake pivot B A/R X

6 Handbrake cable C A/R X
7 Handbrake ratchet B A/R X
8 Mast channels B A/ R X
9 Check hydraulic oil, replenish if necessar y D A/R X
10 All lift chains B A/R X

11 Mast pivots B A/R X
12 Potentiometer pivots; lift, traction and steer potentiometers C A/R X
13 Rollers: Mast column and fork carriage rollers B A/R X
14 Plastic guide pulleys, mast H A/R X

Batter y compar tment lid bearing journals for the hydraulic
15 levers and the respective hook on the batter y compar tment C A/R X
lid.
16 Tilt cylinder pivots B A/R X
17 Steering axle pivot B A/R X
18 Steer column adjustment C A/R X
19 Motor : Drive motor to gearbox spline M A/R X
20 Motor : Pump motor to pump spline M A/R X
21 Replace transmission oil A A/R X

22 Replace hydraulic oil D A/R X
23 Seat runners B A/R X
24 Steering column: Orbital steer unit spline B A/R X
L63-GB
20
Inspection and Maintenance

Schedule
The following pages show the inspection and maintenance
schedule for this truck.
The service intervals are based on single shift operation
under normal conditions.
They should be reduced accordingly if the truck is to be
operated in dusty or extreme conditions such as a cold
store. Exact details should be discussed with a Crown
service engineer.
When carrying out maintenance routinely check for wear,
corrosion, damage, component operation and safety. If in
doubt, always replace a questionable part.
The lubrication work for longer service intervals must
also include the items covered under the shorter in-
tervals.
21
Daily Maintenance (or every 8 service hours)
Daily or every 8 service hours

Item Component Action
1 Truck Clean if necessary.
2 Seat Make sure that the seat is properly engaged and attached.
3 Seat belt Check operation. Check support and belt for wear.
Make sure battery connector is secure and check for any damage, check
contacts for signs of burning.
4 Battery Check battery compar tment for any spilled acid.
Check / service battery as required in accordance with battery manufacturer's
service manual
5 Gear unit Check for leaks (oil on the ground by the drive wheels?).
6 Hydraulic lines and screws Check for leaks. If leakage is found, take the truck out of service.
Check for possible damage, cracks and excessive wear.

7 Forks, fork carriage
The forks should be firmly engaged.
Load guard, any
8 Ensure it is securely fitted and check for damage
accessories
Check for possible distor tion, cracks and any other damage.
9 Lift chains, chain anchor
The forks should be firmly engaged.
10 Wheels Check for damage and foreign bodies. Remove any foreign bodies
11 Labels and stickers Check they are all present and legible (2-10, 2-11).
Turn key switch ON (green) and test operation of battery discharge indicator and
12 Key switch
the hourmeter (+ any optional displays).
13 Emergency Disconnect Check operation.
14 Seat switch Check operation.
15 Horn Check operation.
Test all functions.
Check freedom of movement of control handle.
16 Hydraulics
Check the mast, chains, hoses and rollers while the forks are being raised and
lowered to ensure they work correctly.
17 Steering Check operation and safety
Move the truck in both directions, first slowly and then at full speed.
Travel, regenerative
18 Test brakes: While the truck is moving set the travel selection lever to the
braking
opposite direction
Apply the brake pedal: Has the braking distance changed since the last
19 Brake pedal
inspection?
Apply the parking brake lever: Check operation.
20 Parking brake
Does the traction motor cut out after 5 seconds?
21 if applicable: lights Check operation
L70-GB
22
21 9
20
12
12 8
16 9
13
14
MS-2232-044
10
MS-2232-045
2 3
9
M0324
4
MS-2232-038
23
Monthly Maintenance or every 100 service hours
Monthly or every 100 service hours

1 Battery Service in accordance with the battery manufacturer's instructions
2 Mast column cylinder Check for leaks; check piston rods for damage
3 Wheels Torque wheel nuts to correct level (141Nm)
Mast column and freelift

4 cylinder chains and Check for wear, corrosion and damage
chain anchor
5 Guide pulley yoke Check for damage
L71-GB
4
2
MS-2232-046
24
4
1
MS-2232-044
3
5
4
2
M0324
25
3-Monthly Maintenance (or every 250 service hours)
Every 3 months or 250 service hours

1 Contactors Clean, check, replace if necessary.
2 Mast end stops Check for wear, grease if necessary
Clean bearings and contact surfaces, check for wear, if necessary replace,
3 Mast column
check mast column itself for wear, lubricate
Battery compar tment lid lock &
4 Check operation, lubricate
battery compar tment lid pivot
Check gear unit for leaks, first oil change after 250 service hours,otherwise
5 Gear unit
after 2000 service hours. Ensure bolts are tight.
Accelerator pedal / accelerator
6 Check for wear, lubricate pivots, linkage
pedal linkage
Brake pedal, brake linkage and brake
7 Check for wear; grease pivot points.
pivots
8 Guide pulleys Check for wear; lubricate
9 Fork lock and fork carriage slide Check / lubricate
10 Handbrake cable Check / lubricate

11 Handbrake ratchet and pivot Check / lubricate
12 Hydraulic oil level Check hydraulic oil, replenish if necessary
13 Lift Chains Check and lubricate
14 Mast bearings Check and lubricate
Lift, traction and steer potentiometer
15 Check for freedom of movement and lubricate
pivots
16 Mast Rollers Check for freedom of movement and lubricate
Check operation of the bearing journals of the battery compar tment lid
17 Battery compar tment lid lock for the hydraulic levers and the respective hook on the battery
compar tment lid, and lubricate.
18 Tilt cylinder pivots Check / lubricate
L72-GB
26
17
12
MS-2232-039
MS-2232-047
17 2, 3, 8,
13, 16
10, 11
1
14
7
6
MS-2232-038
18
27
6-Monthly Maintenance (or every 500 service hours)
Every 6 months or 500 service hours
19 Battery connector Clean contacts, check contact springs.
20 Hydraulic cylinder Ensure it is securely fitted.
Blast off abrasion with pressurised air, check brake lining and brake
21 Brakes
springs for wear.
22 Steering axle pivot Check / lubricate
23 Steer column adjustment Check / lubricate
Pump motor to pump spline and
24 Check / lubricate
traction motor to gear unit spline
L73-GB
Annual Maintenance (or every 1000 service hours)

Annually or every 1000 service hours
Pump and drive motor carbon Clean, apply pressurised air, check for wear and freedom of
1
brushes movement, replace if necessary.
Check wiring, switches & connections are secure, check insulation for
2 Electrical cables & connections
damage.
3 Steer unit Check steering column teeth on steer unit for wear.
4 UVV testing Carry out UVV testing at prescribed intervals.

5 PMT test Check traction controller safety circuit
L74-GB
2-Yearly Maintenance (or every 2000 service hours)

Every 2 years or 2000 service hours
1 Seat runners Check for wear, grease.
First oil change after 250 service hours, thereafter every 2000 service
2 Gear unit
hours. Ensure bolts are tight.
3 Steering axle Ensure bolts are tight.
4 Hydraulic reservoir Replace ventilation and pressure filters. Replace hydraulic oil
5 Orbital steer unit spline Check and lubricate
L75-GB
28
17
5, 6
2
11 MS-2232-047
9
MS-2232-039
8
7,12
3, 10
5, 6
MS-2232-038
29
Torque Requirements Festigkeitsmarkierung für Festigkeitsmarkierung für

Schrauben Muttern
The information on the following pages can be used to
determine the correct torque. Torques deviating from the 8 .8
standard ratings are summarised in tables.
8 .8 8
Always use the standard torque unless otherwise indicated
in the maintenance manual.
1 2 .9
1 2 .9
WARTUNG 07
Standard Torque Tables
Standard Allen screws and hex. bolts
Grade 8.8 10.9 12.9
Thread size Torque (Nm)
M5 x 0.8 5-8 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 15 - 16
M8 x 1,25 20 - 25 28 - 31 34 - 37
M10 x 1.5 39 - 43 56 - 61 68 - 75
M12 x 1.75 71 - 76 100 - 107 119 - 127
M14 x 2 113 - 122 159 - 171 190 - 205
M16 x 2 175 - 190 247 - 267 296 - 320
M20 x 2.5 340 - 357 479 - 518 574 - 621
M24 x 3 587 - 635 824 - 892 990 - 1071
M30 x 3.5 1175 - 1274 1654 - 1792 1985 - 2150
Torque wrench tolerance ± 25% T58-GB
30
Hex. countersunk screws
Grade 8.8 10.9 12.9
M5 x 0.8 4-7 5-8 7 - 10
M6 x 1 7 - 10 9 - 12 11 - 14
M8 x 1.25 16 - 19 23 - 26 27 - 30
M10 x 1.5 31 - 34 45 - 49 54 - 58
M12 x 1.75 56 - 60 79 - 84 94 - 102
M14 x 2 - - -
M16 x 2 124 - 146 190 - 206 228 - 247
M20 x 2.5 259 - 281 363 - 395 437 - 473
M24 x 3 416 - 451 586 - 635 702 - 762
M30 x 3.5 - - -
31
Hex. head cap screws
Grade 8.8 10.9 12.9
M5 x 0.8 6-8 7-9 8 - 11
M6 x 1 9 - 12 12 - 15 15 - 18
M8 x 1.25 22 - 24 30 - 33 35 - 38
M10 x 1.5 42 - 45 58 - 64 71 - 76
M12 x 1.75 72 - 77 102 -110 122 - 132
M14 x 2 115 - 125 161 - 175 194 - 210
M16 x 2 179 - 194 251 - 273 301 - 327
M20 x 2.5 348 - 377 489 - 530 588 - 637
M24 x 3 601 - 651 846 - 915 1014 - 1098
M30 x 3.5 1196 - 1296 1681 - 1822 2017 - 2187
32
Umbrako screws and nuts
Grade 8.8 10.9 12.9
M5 x 0.8 - 8 - 11 9 - 12
M6 x 1 - 14 - 16 16 - 19
M8 x 1.25 - 31 - 34 38 - 41
M10 x 1.5 - 62 - 68 75 - 81
M12 x 1.75 - 108 - 117 130 - 141
M14 x 2 - 174 - 187 209 - 225
M16 x 2 - 273 - 294 327 - 354
M20 x 2.5 - - -
33
Special Torque Tables
Torque Settings MECHANICAL
Location Size / Fittings Maximum Torque
Accelerator Assembly to Chassis M8 20-25nm
Brake Actuator Arms Retaining Nuts M10 All Metal Prevailing Torque Nuts 30nm
Brake Disc Assembly Retaining Nuts M10 All Metal Prevailing Torque Nuts 40-45nm
Counterweight to Chassis M20 380 Nm
Drive Motor to Gearbox M10 Durlock 60nm
Footbrake Pedal Assembly to Chassis M10 40-45nm
Gearbox to Chassis Durlock M16 Bolts & Nuts 330nm
Lower Brake Adjuster Locknuts M10 39-43nm
Mast Pivots M20 Bolts 574-621nm
Oil Tank to Chassis M10 Nuts & Special Washer 6nm
Steer Axle to Chassis Durlock M16 X 45 327-354nm
Steering Wheel Center Nut 3/4 37nm
Tilt Eye Fixing Pins M8 20-25nm
Wheel Nuts M14 Nuts 141nm
T56_1-GB
34
Torque Settings HYDRAULIC
Control Valve to Chassis M10 40-45 Nm
Steering Column to Steering Valve M10 39-43nm
Oil Tank Suction Flange M6 4nm
Pump Inlet Adapter M6 8-10nm
Pump Motor to Rear Bulkhead M10 (Clamp) to be evaluated
Pump Outlet Elbow M6 8-10nm
Pump to Motor (Steel Motor Only) M10 Durlock 63nm
Return Filter Head (Plastic) to Tank M8 Hand Tight
T56_2-GB
Torque Settings ELECTRICAL
Nut Connections on Contactors 10mm Steel Nut 20nm
Drive Motor Cable Connections M8 Hex Head 13nm
Control Unit Heatsink to Chassis M10 Nut 40-45nm
Handbrake Assembly to Chassis M5 7nm
Microswitch to Metal 0.5nm
Potentiometer to Metal 1nm
Pump Motor Cables to Motor M8 Hex Head 13nm
Overhead Load Guard to Chassis (Front) M12 76nm
Overhead Load Guard to Chassis (Rear) M20 380 Nm
Front Scuttle Console M6 16-19nm
T56_3-GB
35
Specific Fastener Torque Requirements
Location Fastener Size Grade Torque Nm
Accelerator Assembly to Cowl M8 Hx Socket Button Hd, Black Oxide 8.8 22
Counterweight to Chassis M20 Hx Hd, Black Oxide 8.8 359
Drive Motor to Gearbox M10 FI Hd, Durlock Nut, Black chr 12.9 62
Footbrake Pedal Assembly to Chassis M10 Plow bolt / nut, Zinc pl 8.8 37
Drive Unit to Chassis M16 FI Hd Durlock, Black chr 12.9 339
Steer Axle to Chassis M16 FI Hd, Durlock Nut, Black chr 12.9 339
Mast Lower Pivot Mount M20 Hx Socket, Black oxide 12.9 569
Tilt Cylinder Pin Keeper M8 Hx Hd, Zinc pl 8.8 22
Tilt Cylinder Clevis M12 Hx Hd, Zinc pl 8.8 102
Pump Motor Mount To Chassis M10 Fl Csk Sq Neck, Zink pl 8.8 37
Contactor Panel to Chassis M10 Fl Csk Sq Neck, Zinc pl 8.8 37
Steering Wheel Center Nut 3/4" Hx Nut, Black Oxide SAE Gr 8 37
Drive Wheel Nuts M14 spherical nut, Zinc pl CI 10 141
Control Valve to Chassis M8 Csk Screw, Zinc pl 8.8 18
Tool accuracy required ± 25% T57_1-GB
36
Specific Fastener Torque Requirements
Location Fastener Size Grade Torque Nm
Lift Lever Bracket to Chassis M10 Plow Bolt / nut, Zinc pl 8.8 37
Steering Control Unit Mounting to Cowl M10 Hx Socket Hd, Zinc pl 8.8 42
Steering Column Mounting to Cowl M10 Hx Socket Hd, Zinc pl 8.8 42
Parking Brake Mounting to Cowl M5 Hx Hd Screw, Zinc pl 8.8 7
Overhead Guard Front Mount To Chassis M12 Hx Hd Screw, Zinc pl 8.8 76
Overhead Guard Rear Mount To Chassis M20 Hx Hd, Zinc pl 8.8 359
Seat Deck Latch Bar to Chassis M10 Plow bolt, M10 Flanged Nut 8.8 37
Seat Deck Gas Strut M10 Flanged Nut 8.8 42
Load Backrest 1/2" Hex Head bolt, Zinc pl SAE Gr 5 102
Tool accuracy required ± 25% T57_2-GB
37
Blank page
Printed in Germany
3 8
HYDRAULICS
Printed in Germany
39
Blank page
Printed in Germany
40
HYDRAULICS
Hydraulic Symbols
Vented reservoir with lines above the

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

fluid level
M Electric motor with unidirectional turn

and variable speed
Filter or strainer
Hydraulic pump with fixed displace-

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

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

type
Flow meter
M3559
SC3200 03/2004 • Printed in Germany MS-2.0-0000
41
HYDRAULICS
Pressure switch Manual actuator
Double-acting cylinder;unequal Spring, (bias to normal

area deenergised position)
Double-acting cylinder;equal area
Solenoid single coil or winding
Single-acting cylinderwith spring

returned (rod end vented)
Hydraulic pilot operated
Single-acting cylinder ram type
Solenoid valve, pilot operated
Single-acting cylinder, with cushion
Dual solenoid
Assembly housing, manifold block

Proportional solenoid
Manual lever actuator

Pilot check valve (pilot to open)
M3560
MS-2.0-0000 SC3200 03/2004 • Printed in Germany
42
HYDRAULICS
Throttle, fixed Shuttle valve
Throttle, adjustable
Single counterbalance valve

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

with reverse flow bypass; fixed.
Flow divider/combiner
Velocity fuse
Bypass flow control with controlled

flow, pressure-regulated
Relief valve, fixed setting Shut-off valve, manual
P Torque generator
Relief valve, adjustable T
Hydraulic steer unit

T L
Check valve
P R
M3561
43
HYDRAULICS
Valve block with 3

2/2 way valve (two way, two switch operating units
positions)
3/2 way valve (three way, two

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

positions)

positions)

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

switch positions); Spring bias
solenoid control
M3562
44
HYDRAULICS
Valve Block ● If necessary, remove the foaming oil at zero
pressure circulation by carefully opening the
The valve block consists of an input unit, three (standard) pressure flange (taking care to protect yourself
or four operating units and an end unit. against spray). When bubble-free oil flows out refit
The input unit comprises the main relief valve for limiting the flange.
the system pressure (set to 235 bar), the priority valve for
preferential supply to the steering system when several Oil Change
hydraulic functions are activated and the relief valve for
The hydraulic tank (capacity 37 litres) does not contain a
the steering (set to 70 bar).
drain plug. When changing the oil, the used oil must there-
The pressure relief valve settings must not be changed. fore be suctioned off via a suction pump.
In the event of a fault, always replace the pressure relief
valves. New valves are pre-set to the correct pressure.
Pump motor
Refer to Chapter 4 for pump motor maintenance and re-
pair instructions.
Hydraulic pump
INFORMATION
The hydraulic pump should not be re-
paired on site.
For this reason it is supplied as a com-
plete assembly only.
When commissioning a new or repaired hydraulic pump
proceed as follows:
Commissioning
● Check that the assembly is clean and correctly
assembled.
● When adding hydraulic oil, you must use a filter
with the prescribed minimum retention rate (10 µ).
● Note the arrow direction.
● Start the pump unladen and leave it to operate for
a few seconds without pressure to allow for
sufficient lubrication.
● Never run a pump without oil.
● If after 20 seconds the oil is still not free of
bubbles, check the unit again.
● When operating temperature has been reached
check the pipes are not leaking.
Bleeding
● To ensure maximum operating safety and mini-
mum wear it is advisable to fill the pump housing
with oil before starting.
45
HYDRAULICS
Bleeding the hydraulic system ● Slowly open the vent screw on one of the tilt
cylinders.
WARNING ● Tighten the vent screw as soon as bubble-free oil
emerges.
Risk of serious injury from pressurized
hydraulic oil. ● Repeat the previous stages on the second tilt
cylinder.
Pressurized hydraulic oil can penetrate
the skin. This is a serious medical emer-
gency which requires immediate medical Bleeding the free lift cylinder
attention.
● Prepare the work area to collect spilled oil.
The skin will not show any obvious initial
● Cover the brake disks with a plastic sheet to
damage and the physical effects will not
prevent the brake linings becoming contaminated
be manifested immediately. Seek medical
with oil.
assistance if your skin has been affected
by pressurized hydraulic oil. ● Raise the fork carriage to approx. 1,200 mm.
Always take the following precautions: ● Wear protective clothing, safety glasses and
gloves before carrying out the next step.
Depressurise the hydraulic system before
starting assembly work on the hydraulic ● Slowly open the vent screw on the free lift cylin-
system. der.
After carrying out assembly work carefully ● Tighten the vent screw as soon as bubble-free oil
check to see that all ports are tightened emerges.
before re-pressurising the system.
● Clean any oily components on the truck.
Wear protective clothing, safety glasses
and safety gloves when tracing leaks or Bleeding the lift cylinders
bleeding the system.
Use a piece of absorbent paper to trace
leaks, never use your hands. ● Cover the brake disks with a plastic sheet to
Follow the hydraulic oil manufacturer’s with oil.
safety instructions when handling these
oils. ● Raise the fork carriage to approx. 1,200 mm.
Bleed the system after carrying out repairs to the free lift, ● Wear protective clothing, safety glasses and
lift and tilt cylinders. gloves before carrying out the next step.
● Slowly open the vent screw on one of the lift
CAUTION cylinders.
Possible damage! ● Tighten the vent screw as soon as bubble-free oil
On hydraulic connections with O ring emerges.
seals the O rings will be damaged if ● Repeat the previous stages on the other lift
opened under pressure. cylinder.
Do not open connections with O ring ● Clean any oily components on the truck.
seals for ventilation. Use only the vent
screws provided on the assemblies.
Bleeding the tilt cylinders

● Cover the brake disks with a plastic sheet to
with oil.
● Raise the fork carriage to approx. 1,200 mm.
● Wear protective clothing, safety glasses and
gloves before carrying out the next step.
46
HYDRAULICS
Flushing the cylinders If this distance is exceeded, this could indicate internal
leakage in one of the lift cylinders. It may also be caused
After bleeding the cylinders: by a foreign body in one of the valve seats. Flush the
● Extend the mast fully. system again (extend and retract the mast at least 10
times). Now carry out the test again.
● Check the cylinders for leaks.
● Fully extend and retract the mast at least 10 times Tilt cylinder drift test
at max. speed to flush the system.
● Fully extend and retract the mast several times
from one end to the other to flush the hydraulic
Drift Tests system.
After carrying out repairs to the hydraulic system perform ● Collect the maximum permissible load for a lift
a drift test. This is the only way of identifying internal leak- height of 2500 mm (see capacity plate on truck).
age.
● Tilt the mast backwards (towards the driver) up to
the limit.
INFORMATION
● Raise the test load so that one of the fork tips is
Whenever you carry out a drift test the
2500 mm above the ground.
hydraulic oil temperature must be 30 -
40 °C. ● Switch off the truck and disconnect the battery.
Measure the temperature in the hydraulic ● Remove one of the floorboards to provide access
reservoir before carrying out the tests. to one of the tilt cylinders.
The test load must correspond to the ● Measure the distance from the front of the cylinder
maximum capacity at the respective lift gland to the clevis. Note down the reading.
height (see capacity plate on truck).
● Wait for 5 minutes.
DANGER ● Measure again the distance from the front of the
cylinder gland to the clevis.
Falling loads are hazardous!
● The difference should be max. + 16 mm.
You could be fatally injured by a falling
load. If this distance is exceeded, this could indicate internal
leakage in one of the tilt cylinders. It may also be caused
Never stand underneath a raised load.
by a foreign body in one of the valve seats. Flush the
The test load must be evenly distributed. system again (tilt the mast from one end to the other at
The load centre of gravity must be cen- least 10 times). Now carry out the test again.
trally located and must not exceed the
capacity plate specification. Secure the Steer unit drift test
test load to prevent it from slipping and
falling. ● Turn the steering wheel as far as it will go.
● Keep holding the steering wheel against the stop,
Lift cylinder drift test applying gentle pressure. The steering wheel
should continue to turn max. 1 revolution within 60
● Fully extend and retract the mast several times to
seconds.
flush the hydraulic system.
● Collect the maximum permissible load for the
highest lift height (see capacity plate on truck).
● Attach a measuring tape to one of the fork tips.
● Extend the mast fully.
● Switch off the truck and disconnect the battery.
● Measure the distance from the fork tip to the
ground.
● Wait for 10 minutes.
● Measure again the distance from the fork tip to the
ground.
● The load should lower max. 100 mm.
47
HYDRAULICS
Overload Valves (RV)

The main overload valve and the steering overload valve
are pre-set. In the event of a fault, replace the valves. It is
not necessary to adjust them after replacement.
48
DRIVE UNIT
Printed in Germany
49
Blank page
Printed in Germany
50
DRIVE UNIT
Drive Unit Disassembly

The drive unit of the truck consists of the drive motor and WARNING
the gear unit. For drive motor maintenance and repair de-
tails, see Chapter 4. Do not test the disassembled motor on
the test bench as the motor could be
Gear Unit damaged without the lower support.
NOTE
Assembly
The drive transmission unit must only be
serviced by authorised and trained per- Assemble the gear unit in the reverse order of
sonnel. disassembly.
The manufacturer’s warranty is invalidated ● When re-assembling, lubricate the spline shaft
if incorrect maintenance is performed on connection between the motor and the gear unit
the transmission system. with grease, part no. 063002-022.
● Torque the mounting screws to 60 Nm.
Disassembly ● Torque the drive motor power cable to 13 Nm.
● Remove the mast (see Chapter 7).

To remove the drive motor:
● Remove the electrical connections.
● Remove the 4 mounting screws from the lower
section.
● Lift the motor out from the top.
MS-2232-100
● Remove the stabiliser between the drive units.

● Remove the brake linkage (Fig. MS-2232-100).
● Remove the wheel.
● Support the gear unit with a wooden block. Loosen
the mounting screws.
● Push the gear unit towards the centre of the truck
and loosen the two mounting studs.
● Lift out the gear unit from the side. This will also
facilitate re-assembly.
51
DRIVE UNIT
23 Nm
4
0
5 6
7
1
339 Nm 339 Nm
13
0
0
25 24 8
9
3
2
10
14
11
40 45
12
43
22 10
41
26
42 23
15
34
35
0
42 - 45 Nm
37
3 27 28
29
30
32 39
31
16
33 17
34 18
5
36 44
19 21 20
4
0
45 Nm 38
MP-2232-016
52
DRIVE UNIT
General Bevel gear spur wheel pinion shaft pre-as-
sembly
The reference numbers contained in the following assem-
bly instructions refer to the exploded diagram in section 3.1 ● Before placing the spur wheel (item 15) on the
of the parts manual. flange shaft, space must be created in the hous-
ing for the conical roller bearing (item 23). Assem-
Dismantling the Gear Unit ble the spur wheel pinion shaft and the conical
Clean the gear unit thoroughly before dismantling it. roller bearing pair (items 23, 27) in the housing and
set the vacuum resistance using the shims (item
Note that the gear unit cover (item 5) and the two trans- 22, 29) to 0.4 - 0.6 Nm.
mission housing halves (item 3) are fixed with parallel pins.
Make sure the raised and flat faces are not damaged dur- ● Now assemble the bevel gear (item 10) together
ing disassembly. with the spur wheel pinion shaft (item 26).
Dismantle the gear unit in accordance with diagram MP- Spur wheel flange shaft assembly
2232-016. ● Heat the spur wheel (item 15) to approx. 135°C
and place it on the flange shaft (item 1) (fig. MS-
Gear Unit Assembly 2232-102).
Replace all bearings and seals.
Pre-assembly of the housing with flange
shaft
● Thoroughly clean the housing (item 3) with a cold
cleaning solution. Assemble the conical roller
bearing (item 14) and the rotary shaft seal (item
13) in the housing neck (Fig. MS-2232-101).
MS-2232-102
● Now assemble the previously cleaned housing lid

(item 3), fitted with shim (item 12), the outer ring
of the conical roller bearing (item 11) and the hex.
socket screws (items 35, 36) with the lock wash-
ers (item 34) positioned underneath.
MS-2232-101
● Press the wheel nuts (item 2) into the holes in the

shaft flange using a hydraulic tool.
● Now press the flange shaft into the housing
transmission neck.
53
DRIVE UNIT
● Centre both housing halves using the cylinder pins Bevel pinion assembly
(item 37).
● Press the conical roller bearings (items 9, 11) onto
● To complete the assembly of the spur wheel the bevel pinion (item 10) (Fig MS-2232-103).
flange shaft, assemble the following components
in the following order: ● Adjust the bearing pre-tension to 0.2 - 0.4 Nm
using the shims (items 8, 12).
● The ground supporting ring (item 16), the conical
roller bearing (item 17), the washer (item 18) and
the hex. socket screws (item 19, 45 Nm torque,
secure with Loctite Crown No. 053050-019) for
securing the flange shaft tensioned on the block.
● The bearing pre-tension of the flange shaft should
be 5.0 - 6.5 Nm and can be adjusted using the
shim (item 16).
● Insert the snap ring (item 20) in the housing
groove and seal the transmission in this area via
the filler cap (item 21).
Bevel gear assembly
● To complete the assembly of the bevel gear insert
the outer ring of the conical roller bearing (item 27)
in the respective lid section.
● Now place the bearing race (item 28, secure with
Loctite Crown No. 053050-019) followed by the
shims (items 22, 29) previously obtained when
setting the bearing pre-tensioning on the spur MS-2232-103
wheel pinion shaft.
● Now insert the shaft seal ring (item 30) in the ● To obtain the ideal flank tooth bearing of the bevel
section provided in the brake backplate (item 38) gear coat with paste and then manually apply the
and screw the backplate onto the housing lid (item transmission. If necessary, use the imprints to
3) using the hex. socket screws (item 4) and the adjust the tooth bearing with the shims (items 8,
lock washers (item 5) underneath (23 Nm torque). 12) (Fig. MS-2232-104).
Proceed as follows:
● Remove all grease from the screw threads in the
transmission housing (item 3) with solvent.
NOTE
All residual grease and solvent must be
removed with pressurised air.
● Remove all grease from the six screws (item 4).

● Apply LOCTITE No. 577 (CROWN P/N 053050-
019) to screws. Fit brake bracket and torque
screws to 23 Nm.
MS-2232-104
54
DRIVE UNIT
● Insert the conical nipple (item 6) in the upper part Maintenance
of the transmission lid (item 7). Finally, screw the
transmission lid to the pre-assembled transmis- Adding oil
sion halves (23 Nm torque) using the screws (item
4) and the lock washers (item 5). Before use, check that the level of the gear oil is correct.
● Finally, assemble the bleed valve (item 45) with its The level should read 0.9 litres.
conical nipple (item 24) and the oil filler caps Types of oil
(items 32, 33) with their respective conical nipples
(item 31). See lubricant table in Chapter 1.
Flank tooth bearing Oil level

The following diagram shows the flank tooth bearing toler- Fill gear oil to the lower mark of the dipstick (item 33).
ances. The capacity is 0.9 litres.
Correcting the flank tooth bearing Oil change
If the flank system differs from the example illustrated, Perform the first oil change after 250 operating hours. Fur-
the shims (items 8, 12) must be used to correct the tooth ther oil changes every 2000 operating hours, and at least
bearing. annually.
Correct flank system for

inner conical pinion
High
Low
High Low
Correct flank system for

M1565-1
inner bevel gear
Reducing the installation path of the conical pinion

If the flank system on the conical pinion is too high, the
installation path of the conical pinion must be reduced. If
the flank system is too low, increase the installation path.
55
Blank page
Printed in Germany
56
ELECTRICS
Printed in Germany
57
Blank page
Printed in Germany
58
ELECTRICS
Electrics - General
Wire Colour Codes
The wires used in the truck are colour-coded and num-
bered according to their function. The first digit or the
first two digits indicate the wire colour while the last two
digits are counter numbers.
ABBREVIATION COLOUR NUMBER FUNCTION
BLK Black 0 ** Digital signal
BRN Brown 1 ** Analog signal
RED Red 2 ** Positive not connected
ORG Orange 3 ** +12 V DC conver ter
YEL Yellow 4 ** Third DC conver ter
GRN Green 5 ** Negative not connected
BLU Blue 6 ** Insulated negative
VIO Violet 7 ** +5 V DC conver ter
GREY Grey 8 ** Four th DC conver ter
WHT White 9 ** Various
RED/WHT Red/White 29 ** Positive connected
GRN/WHT Green/White 59 ** Negative connected
** Numbers 01 to 99 E01-gb
59
ELECTRICS
Abbreviations
Switch Symbol Abbreviation List *
Abbreviation Component Abbreviation Component
K* Relay LMS Limit switch
ACS Accelerator pedal switch LOS Lower switch
AXS Auxiliary function switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Direction control switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency Disconnect Switch REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Reverse safety switch
FS Forward switch SDS Star t switch
HBS Handbrake switch SES Seat switch
HSS Fast / Slow Travel switch SSS Sideshifter switch
HNS Horn switch THS Thermo switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk along switch
* If one of the above abbreviations is used more than once, a number extension
will be used, e.g . SV1, SV2 etc. E02-gb
60
ELECTRICS
Electrical Symbols
EUROPE USA DESCRIPTION EUROPE USA DESCRIPTION

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

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

Operating devices,
slow releasing Breakdown diode
Operating device,
slow operating LED
Hand operated
NO push button Transistor
c
Mechanically actuated MOSFET
c Hydraulically actuated Thyristor
c
Emergency disconnect Comparator
Motor armature
.
M0056-gb
61
Blank page
Printed in Germany
62
ELECTRICS
Electrical Components Raise Potentiometer (POT2)

The key movement of the "Raise" operating lever is con-
DANGER verted into a control signal by potentiometer POT2 and
The truck must be jacked up prior to at C1 is fed into the pump controller. The controller in
carrying out repair work or troubleshoot- turn governs the pump motor speed.
ing the electrical system.
Steering Axle Potentiometer (POT3)
Switch Functions The steering axle potentiometer POT3 is mounted on the
steering axle input shaft and gives the following control
The pin references relate to the drive and pump control
signals to the traction controller:
inputs.
● Travel direction;
Brake Switch (BRS) ● Steering wheel angle of turn.
The brake switch switches the power supply to pin G6 of This signal enables the traction controller to steer the
the traction controller. This amplifies inversion braking traction motors accordingly.
via the traction controller.
Tilt (TLT), Sideshift (SSS), Auxiliary Switch
Encoder (ENC), Encoder Module (EM)
(AXS)
Impulses are generated via the steering wheel, the steer-
The switches for tilting, sideshift and auxiliary function
ing column and the connected encoder ENC. These im-
switch the battery supply to connections E2, E3 and E5
pulses are digitalised in the encoder module EM and
of the pump controller.
transfered to the pump controller via pin E8.
The impulse controller governs the pump motor speed
Accelerator Pedal Switch (ACS, POT1) via preset voltages.
The accelerator pedal key movement is converted into a

Emergency Disconnect
control signal via potentiometer POT1 and transfered to
pin G1. The power supply to the truck is disconnected by pulling
the battery connector.
The accelerator pedal switch ACS cuts off the electric
circuit from the direction indicator switch DIS.
Key Switch (KYS)
Direction Indicator Switch (DIS) The key switch energises the traction and pump control-
ler via pins E1 and D1 as well as the battery discharge
The direction indicator switch has three switch positions:
indicator BDI.
forward, neutral and reverse. When the forward or re-
verse positions are selected, power is supplied to the
traction controller on pin G8 (F) or G7 (R). This causes Fuses (FU)
the controller to activate the respective direction contac- The main drive motor circuit is protected by fuse FU1
tors. and the lift motor circuit by fuse FU2.
The controller circuit is protected by fuse FU3 and the
Handbrake Switch (HBS)
horn by fuse FU4. FU5 protects the supply voltage to the
The handbrake switch sends battery supply to pin F1 of BDI.
the traction controller. This causes the control system to
disconnect the traction current. It is also possible to travel
for 5 seconds with the handbrake applied (starting on an
incline) before the controller interrupts the traction cur-
rent.
63
ELECTRICS
Seat Switch (SES) Horn Switch (HNS)
When the operator is seated, the seat switch SES is The horn switch HNS is located in the centre of the steer-
closed and the traction controller on Pin L7 is energised, ing wheel. The horn HN sounds when the horn switch is
enabling the truck to travel. pressed.
If the operator leaves the seat, the seat switch opens
and after an interval of 1.5 seconds travelling is inhibited
by the controller.
Electrical Components - Overview
DIS
KYS
ENC / EM
SES
Emerg.
Disconnect
POT 3
Electrical board
M0369
PM
HNS BDI / TT
M0367
HBS
ACS / POT 1
BRS 1 2 3 4
+ AXS
FU5
M0368 SSS
TM TLT
POT 2
64
ELECTRICS
Electrical Board
10 A control fuses Back wall
FU2 (Hydraulic circuit, 350 A)

Pump controller FU4
FU3 FU3 (Traction circuit, 500 A)
RGB
contactor
Main contactor
(LC)
Resistor
Diode module
Traction controller
LH travel contactor (LHS) RH travel contactor

(RHS)
CAUTION WARNING
Risk of damage to the controllers and Risk of personal injury.
contactors.
Swapping the control lines leading to the
Incorrect polarity between the control travel contactors (left connected to right)
lines and the contactors will short-circuit will cause the truck to steer unpredict-
the existing freewheel diodes. ably at a given steering angle.
Mark the position of the control lines Mark the position of the control lines
relative to the contactors before removal. relative to the contactors before removal.
Check the connections again to ensure Check the connections again to ensure
correct polarity before powering up the correct polarity before powering up the
truck. truck.
After working on the travel contactors
test the steering over the full steering
range in a secure environment.
65
Blank page
Printed in Germany
66
ELECTRICS
Zapimos B1S 48/700 Controller Key Terms
General Shunt or Shunt Resistor (+SH/-SH)

The controller logic can measure the current flowing
through the motor using a pre-defined resistance (shunt)
in series with the motor and thus control the MOSFETs.
Volt Motor Negative (VMN)

The measurement point for the controller logic. The volt-
age range on the terminal is measured and tests carried
out to determine whether the controller power part
Functional Description
M0201
Acceleration / Delay Rate
The acceleration rate is the time taken for the voltage
applied to the motor to rise incrementally to 100 % of the
battery supply. The acceleration rate can be changed by
the programmer.
Travel Switch
ZAPIMOS B1S 48/700 Traction Controller The travel switch stroke is 0 - 100% proportional to the
controller output.
Checking the travel switch signal on the control input pre-
vents the truck from starting without the driver.
Protective Devices
Travel Switch Signal Response
Polarity Protection
The controller responds to the incoming travel potentio-
Wiring must be laid out in accordance with the wiring meter signal in accordance with the programmed accel-
diagram to avoid damaging the transistors and capaci- eration rate. Changes in the travel potentiometer signal
tors. The logic system itself is internally protected against are converted linearly.
incorrect polarity.
Fault Log
Wiring Errors
The last 5 faults are stored in the controller memory along
The driver outputs for the contactors tolerate only a max. with the relevant number of service hours, the control
charge of 3A, even though they are protected against temperature and the fault frequency.
overload and short-circuiting.
Fault Identification
Overheating
The internal microprocessor monitors the controller. When
When the temperature exceeds 80°C, the maximum cur- a fault is identified, the controller status LED flashes a
rent is reduced in proportion to the rise in temperature. If fault code. For critical faults the controller cuts out. For
the temperature exceeds 85°C the traction controller cuts intermittent faults, e.g. low voltage, the error message
out. automatically fades out after a while.
Protection Automatic Fault Identification covers:

● Both travel directions operated simultaneously.
The traction controller is protected against dust and spray
water (IP54) and is contained within a sealed housing. ● Logic error.
67
ELECTRICS
● Incorrect start sequency; travel switch operated. When the steering angle is between approx. 65° and 73°
the inside motor runs at idle speed. If the steering angle
● Volt Motor Negative Test (VMN) error.
is greater than 73° the inside motor will turn in the oppo-
● High acceleration potentiometer resistance level site direction.
when idle.
This function is dependant on the steering angle meas-
● Current measurement error: ured by the potentiometer on the steering axle, the axle
base and the track.
– Travel: Maximum level exceeded;
The ratio of the two motor speeds corresponds to the
– Idle: Current ≠ zero.
ratio of the radii of the two load wheels.
● Contactor drivers faulty.
● Controller temperature above 80°C. 45° Steering Angle
● Contactors do not close or Volt Motor Negative is Beyond a steering angle of 45° the controller automati-
too high when idle. cally switches to creep speed.
● Contactors welded. Pedal Braking (Inversion Braking with Bat-

tery Supply Regeneration)
Sparkless Contactors
In pedal braking the energy from the motor coil is not
If a direction switch is switched off, the output voltage
transfered into heat as in inversion braking but a part is
rapidly falls to zero. This causes the current to fall to zero
fed back to the battery by the controller via the brake
before the direction contactor drops.
contactor.
Inversion Braking Pedal braking is activated when the operator's foot is taken
off the accelerator pedal, the travel direction changed or
With inversion braking the motor is electrically driven in the operating brakes are applied.
the opposite direction to which it is mechanically turning.
The controller governs the field current in order to achieve If the voltage generated falls to a preset value – (Vgen-
a controlled braking moment. During inversion braking Vbat) < 0.7 V – pedal braking is cut out (brake contactor
the current is automatically restricted and the armature re-opens) and the truck is stopped by the operating brakes
current is greater than the field current. The inverse cur- (brake pedal).
rent limit for fast travel can be adjusted using the pro-
grammer. Ramp Start
Here the truck is started with a higher inverse braking
Creep Mode current which prevents the truck from rolling backwards
Creep speed is applied when the travel potentiometer is when it starts. Ramp start increases the current limit in
activated. Creep speed can be adjusted between 0 and the direction which has just been applied. Switching to
25 % of the output voltage. the opposite travel direction ends the ramp start func-
tion.
The setting can be adjusted via the potentiometer or the
programmer. Key Switch
Slow Travel The key switch switches the voltage to the logic section
of the impulse controller.
In slow travel the maximum speed is reduced. However,
the travel switch is still fully extended. Self Test
The maximum speed setting can only be adjusted by the
The controller is monitored by means of internal self tests.
programmer.
If an error occurs the controller is cut out. Switching the
key switch off and on will cause it to re-start.
Steering Controller
When travelling around corners with the steering wheel Reverse Travel Alarm
at an angle of less than 65° the motors are controlled so
The traction controller sends a signal via Pin H2 to the
that the inside motor is slower and the outside motor cor-
lighting module and from there to the horn to activate the
respondingly faster.
alarm when reversing.
68
ELECTRICS
Seat Switch
The seat switch circuit contains a time delay relay which
interrupts the truck circuit when the operator has left the
truck for a period of time. This prevents the truck from
switching off caused by the operator moving or jolts re-
ceived from the truck.
Current Limit
The current limit function reduces the PWM signal to the
controller power part until the motor current falls below
the value of the current limit.
Overvoltage
In the event of overvoltage the PWM cuts out and opens
the contactors. When the permissable voltage has been
reached the controller resumes operation.
Overheating
At a temperature of 80°C the current limit is linearly re-
duced. At 85°C the controller cuts out.
Low Voltage Reduction

The controller reduces the speed when the batteries are
discharged to less than the minimum charge level. If the
motor current is so high that the battery voltage falls be-
low the low voltage level, the controller reduces the speed
until the voltage exceeds above the level.
69
ELECTRICS
ZAPIMOS B1S 48/700 Traction Controller Connections
Contactor Coils / Vacant Programmer connection

KYS
LED
E D C B A
9 8 7 6 5 4 3 2 1 2 1 3 2 1 8 7 6 5 4 3 2 1 2 1
+B -B
VMN R VMN L
Potentiometer
Steering Axle, Drive Motor, Line Contactor and Switch Handbrake
Seat
Vacant
L J H G F
9 8 7 6 5 4 3 2 1 2 1 3 2 1 8 7 6 5 4 3 2 1 2 1
- SHL - SHR
+ SHL + SHR
70
ELECTRICS
ZAPIMOS B1S 48/700 Pin Layout
Pin Function Additional Info
A1 - LED Alarm
A2 + LED Alarm, output current 12 mA, for standard LED
B1 + Serial interface receiver

B2 - Serial interface receiver
B3 + Serial interface sender
B4 - Serial interface sender
B5 - Programmer power supply
B6 + Programmer power supply 12 volts
B7 Pin free
B8 Pin free
E1 + Key switch input

E2 + Travel direction contactor coil
E3 Pin free
E4 - Travel direction contactor coil RH drive motor
E5 - Travel direction contactor coil RH drive motor
E6 - Travel direction contactor coil LH drive motor
E7 - Travel direction contactor coil LH drive motor
E8 + Pedal braking contactor
E9 - Pedal braking contactor
F1 + Input HBS
F2 Pin free
G1 - Accelerator pedal potentiometer

G2 Accelerator pedal potentiometer loop O volt min. speed, 10 V max. speed
G3 + Accelerator pedal potentiometer 12 volt output
G4 Pin free
G5 Common output for travel and brake switches
G6 Input BRS
G7 Input for reverse switch Travel direction switch
G8 Input for forward switch Travel direction switch
H1 Pin free
H2 Pin free
H3 + Battery contactor
71
ELECTRICS
J1 Pin free
J2 Pin free
L1 - Output B
L2 Steering axle potentiometer loop
L3 - Steering axle potentiometer
L4 + Steering axle potentiometer +7 V
L5 - For options Connected to battery negative terminal via L1
L7 - Seat switch input
Note:
+ = Positive potential
- = Negative potential
72
ELECTRICS
Programmer Connection "B" Status LED Diagnosis
A socket is provided to connect the programmer. The When the truck is powered up the Status LED flashes
cable is supplied with the programmer. briefly to indicate that the test program is being booted
up by the controller.
Status LED "A" In normal start up the Status LED is off.
In the event of a fault the LED indicates the fault via a When a fault occurs the Status LED flashes the respec-
flashing code. The fault can be identified more closely tive code (see table, LED Codes) until the fault is recti-
via the programmer (see table, LED Codes). fied.
LE D C ode Display Explanation
LED off ❍ Traction controller operates error-free.
Permanently on ● Both travel directions selected simultaneously
1 ★ Error in electronics (EEPROM KO, WATCH DOG)
On power up a travel direction is selected or the start

2 ★★ sequence is not maintained (INCORRECT START, SEAT
SWITCH OPEN)
VMN not ok (R VMN LOW, L VMN LOW, R NO FULL

3 ★★★ COND., BRAKE CONTACTOR OPEN)
Error in potentiometer signal (VACC NOT OK) or in signal

4 ★★★★ from steering angle sensor (STEER SENSOR KO, BAD
S TE E R )
Current flow in main circuit not ok (R STBY I HIGH, L STBY

5 ★★★★★ I HIGH, R I=0 EVER, L I=0 EVER)
Contactor driver error (DRIVER SHORTED, COIL

6 ★★★★★★ SHORTED)
Temperature > 70°C (TH PROTECTION); Motor

7 ★★★★★★★ temperature option (THERMIC LEVEL 2)
Contactors do not close or VMN high when truck is idle (R

8 ★★★★★★★★ DIR. CONT. OPEN, L DIR. CONT. OPEN, R VMN HIGH, L
VMN HIGH)
Contactors do not open (BRAKE CONT. CLOSED, R DIR.

9 ★★★★★★★★★ CONT. CLOSED, L DIR. CONT. CLOSED)
E55-GB
73
ELECTRICS
ZAPIMOS HP 350A Pump Controller Key Terms

General Shunt or Shunt Resistor (+SH/-SH)
The key features are: The controller logic can measure the current flowing
through the motor using a pre-defined resistance (shunt)
● Infinitely variable lift control. in series with the motor. This controls the output current
● Overvoltage / Low voltage protection. of the power part.
● Circuits and software recognise errors in the Volt Motor Negative (VMN)
pump circuit, driver circuit and the power part.
The measurement point for the controller logic. The volt-
● Power up sequence monitoring. age range on the power part is measured. The result ob-
tained is used to check the power part for faults.
Protective Devices
Polarity Protection
Wiring must be laid out in accordance with the wiring
diagram to avoid damaging the transistors and capaci-
tors. The logic system itself is internally protected against
incorrect polarity.
Wiring Errors
The driver outputs for the contactors tolerate only a max.
charge of 3A, even though they are protected against
overload and short-circuiting.
Overheating
If the temperature on the heat dissipator of the power
part exceeds 80°C, the output current is reduced in pro-
portion to the rise in temperature. At 85°C the pump con-
troller cuts out.
Protection
The pump controller is protected against dust and spray
water (IP54).
74
ELECTRICS
Functional Description Steering Support
Signals are generated via an encoder. These are digital-
Acceleration / Delay Rate ized in the encoder module and sent to the pump con-
The acceleration rate is the time taken for the voltage troller. The pump controller then drives the pump motor
applied to the motor to rise incrementally to 100 % of the at a speed which is preset by the programmer. Steering
battery supply. The acceleration rate can be changed by has priority over lifting. This is controlled by a priority valve
the programmer. in the valve block.
Hydraulic Switches Key Switch

The sideshift, tilt and aux. hydraulic functions are driven The key switch switches the voltage to the logic section
by switches. If applying an operating lever causes the of the impulse controller.
switch to close, the pump motor operates at a preset
speed controlled by the programmer. Self Test
Steering has priority over lifting. Priority control is gov- The controller is monitored by means of internal self tests.
erned by a priority valve in the valve block. If an error occurs the controller is cut out. Switching the
key switch off and on will cause it to re-start.
Lift Cutout
Current Limit
If the battery capacity falls below 20%, the battery dis-
charge indicator sends a signal to the controller. The con- The current limit function reduces the PWM signal to the
troller cuts out lifting. controller power part until the motor current falls below
the value of the current limit.
Lift potentiometer
Overvoltage
The travel switch stroke is 0 - 100% proportional to the
controller output. In the event of overvoltage the controller range limit cuts
out and opens the contactors. When the permissible volt-
Lift Potentiometer Response age has been reached the controller resumes operation.
The controller responds to the incoming travel potentiometer Overtemperature

signal in accordance with the programmed acceleration rate.
Changes in the travel potentiometer signal are converted At a temperature of 80°C the output current is linearly
linearly. reduced. At 85°C the controller cuts out.
Fault Log Low Voltage Reduction

The last 5 faults are stored in the controller memory along The controller reduces the speed when the batteries are
with the relevant number of service hours, the control discharged to less than the minimum charge level. If the
temperature and the fault frequency. motor current is so high that the battery voltage falls be-
low the low voltage level, the controller reduces the speed
Fault Identification until the voltage exceeds above the level.
The internal microprocessor monitors the controller. When

a fault is identified, the controller status LED flashes a
fault code. For critical faults the controller cuts out. For
intermittent faults, e.g. low voltage, the error message
automatically fades out after a while.
Automatic Fault Identification covers:
● Logic error.
● Incorrect start sequence.
● Volt Motor Negative Test (VMN) error.
● High resistance level on the lift potentiometer
when truck is idle.
● Current when truck is idle. Current > 0 A
● Temperature above 80°C
75
ELECTRICS
ZAPIMOS HP 350A Pump Controller Connections
Lift potentiometer
Hydraulic functions, encoder
Key Switch Programmer connection
E D C B A LED
9 8 7 6 5 4 3 2 1 2 1 3 2 1 8 7 6 5 4 3 2 1 2 1
+B +M -B
-M
MS-2232-051
76
ELECTRICS
ZAPIMOS HP 350 A Pin Layout
A1 - LED Alarm
A2 + LED Alarm Output current 12 mA, for standard LED
B1 + Serial interface receiver

B2 - Serial interface receiver
B3 + Serial interface sender
B4 - Serial interface sender
B5 - Programmer power supply
B6 + Programmer power supply 12 volts
B7 Pin free
B8 Pin free
C1 Lift potentiometer loop 0 volt min. speed, 10 volt max. speed

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

D2 + connected
E1 Pin free
E2 Aux. function switch input Active when B + is applied
E3 Sideshift switch input Active when B + is applied
E4 Pin free
E5 Tilt switch input Active when B + is applied
E6 Lift cutout input Active when B + is applied
E7 Pin free
E8 Encoder input
E9 Pin free
Note: + = Positive potential

– = Negative potential
77
ELECTRICS
Pump Controller, LED error code Status LED Diagnosis
When the truck is powered up the Status LED flashes
Programmer Connection "B" briefly to indicate that the test program is being booted
A socket is provided to connect the programmer. The up by the controller.
cable is supplied with the programmer. In normal start up the Status LED is off.
When a fault occurs the Status LED flashes the respec-
Status LED "A" tive code (see table, LED Codes) until the fault is recti-
In the event of a fault the LED indicates the fault via a fied.
flashing code. The fault can be identified more closely
via the programmer (see table, LED Codes).
LE D C ode Display Explanation
LED off ❍ Lift controller operates error-free.
1 ★ Error in electronics (EEPROM KO, WATCH DOG)
On power up a hydraulic switch function is activated

2 ★★ (INCORRECT START)
VMN not okay

3 ★★★ (NO FULL COND)
Error in potentiometer signal

4 ★★★★ VAC C > 1
Current flow in main circuit not ok

5 ★★★★★ (I HIGH AT STAND)
Contactor driver error (DRIVER SHORTED, COIL

6 ★★★★★★ SHORTED)
7 ★★★★★★★ Temperature > 80°C (TH PROTECTION)
E67-GB
78
ELECTRICS
Pump Controller Assembly
WARNING
● Thoroughly clean the back of the pump controller
Incorrect wiring when carrying out re- and the contact surface in the truck. The surfaces
pairs can cause the truck to start acci- must be free of grease and foreign bodies. Apply
dentally. a thin layer of heat conducting past (Crown P/N
Jack up the truck until the drive wheel is 053051-008) to the back of the traction controller.
free and no longer touches the ground. The amount applied correct if the heat conduct-
ing paste covers the entire surface and the
Always disconnect the battery from the structure of the metal surface can still be seen
truck when working on the electrical through the heat conducting paste. Too much or
system. too little paste will adversely affect the transfer of
Prevent the truck from being switched on heat.
again. ● Reposition the pump controller exactly in its
mounting plate and screw it tight. Torque:
WARNING 5.5 – 6 Nm.
Risk of injury through burning. ● Screw the power cables back on.
Short circuits can form an arc with high ● Reconnect the control lines.
currents!
● Re-fit the ventilator.
The controller capacitors have a high
capacity and can store energy for a long ● Jack up the truck until the drive wheels are free.
time. ● Connect the programmer and check the settings
Use only insulated tools. of the new controller. Make any necessary
adjustments.
Wear eye protection.
● Re-fit the side panel.
Do not wear jewelry.
Pump Controller Removal

● Connectors, wire bundles and lines are normally
labelled. If the writing is illegible or missing, mark
the connections prior to removal.
● Disconnect the battery.
● Prevent the truck from rolling away and being
switched on again.
● Open the battery compartment lid.
● Remove the retaining screws from the left hand
side panel.
● Lift out the left hand side panel.
● Unscrew the ventilator panel and the ventilator.
● Remove the internal capacitors. Briefly bypass
connections -B und +B with a resistance of 10 to
0
100 ohms (min. 5 watts).

5.5 - 6 Nm
● Remove the connectors from the pump controller. M0189
● Unscrew the power cables.

Traction Controller Removal
● Remove the 4 mounting screws from the pump
controller and remove the pump controller. Connectors, wire bundles and lines are normally labelled.
If the writing is illegible or missing, mark the connections
prior to removal.
79
ELECTRICS
● Remove the counterweight (see Chapter 1).
● Remove the retaining screws from the left hand
side panel.
● Lift out the left hand side panel.
● Unscrew the ventilator panel and the ventilator.
● Remove the internal capacitors of the traction
controller. Briefly bypass connections -B and +B
with a resistance of 10 to 100 ohms (min. 5
watts).
● Remove the connectors from the traction control-
ler.
● Unscrew the power cables.
● Remove the 6 mounting screws from the traction
controller and remove the traction controller.
Traction Controller Assembly

● Thoroughly clean the back of the traction control-
ler and the contact surface in the truck. The
surfaces must be free of grease and foreign
bodies.
● Apply a thin layer of heat conducting past (Crown
P/N 053051-008) to the back of the traction
controller. The amount applied correct if the heat
conducting paste covers the entire surface and
the structure of the metal surface can still be
seen through the heat conducting paste. Too
much or too little paste will adversely affect the
transfer of heat.
● Reposition the pump controller exactly in its
mounting plate and screw it tight. Torque: 5.5 – 6
Nm.
● Screw the power cables back on.
● Reconnect the control lines.
● Re-fit the ventilator.
● Re-install the counterweight and the battery (see
chapter 1).
● Jack up the truck until the drive wheels are free.
● Connect the programmer and check the settings
of the new controller. Make any necessary
adjustments.
● Carry out the PMT test.
● Re-fit the side panel.
80
ELECTRICS
Programmer
General
The optional ZAPI programmer, Crown P/N 793548, is
used to program, test and perform diagnostic functions
on the traction controller.
The programmer is connected to the traction controller
via a cable, thus powered by the controller.
M0271-neu
MS-2232-034
81
ELECTRICS
Key Description
K ey Description Explanation
K ey 1 ROLL up Selects the next sub-menu or an option.
K ey 2 ROLL down Selects the previous sub-menu or an option.
K ey 3 E N TE R Enters the main menu. Stores the pin configuration.
Quits a sub-menu or an option. Step by step return to the main

K ey 4 OUT *
menu.
K ey 5 P A R A M up Increases setting values or selects configuration.
K ey 6 S E T dow n Decreases setting values or selects configuration.
* You can undo a change by switching the truck off and on again. E54-GB
The controller will be reset to the output values.
Display Window
● Alpha-numeric LCD display
● 2 lines @ 16 characters
I MAX B.REVERSE
BREAKING COMPENS:
ACCEL. R.BRAKE
2 TESTER
MAX SP. SPEED I
S.P.I SPEED II
3 SAVE S.P.II SPEED III
BYPASS FIELD WEAK..
4 RESTORE
5 ALARMS
6 ACCELERATOR
7 MOTOR DATA
1 3 5
ROLL ENTER PARAM
ROLL OUT SET
Operating Keys
2 4 6
MS-2232-023
82
ELECTRICS
Connecting the Programmer
The programmer can be connected to the traction or pump
controller via a plug. The controller acts as a power sup-
ply source for the programmer.
CAUTION
Only connect and disconnect the pro-
grammer to the controller when the truck
is switched off.

M0272
Operating Menu
General
When the programmer has been connected a self test
start routine is performed. When it is complete, use the
ROLL up/down and ENTER to select the required menu.
The following two pages show a menu structure for trac-
tion and pump control with an explanation of the indi-
vidual menu functions.
83
ELECTRICS
Traction Controller Operating Menu
START ROUTINE
PROGRAM TESTER ALARMS PROGRAM PEDAL CONFIG
ACCELERATION L VMN R
VIEW ALARM(S) PROGRAM VACC
INVERSE BRAKING L MOTOR R
RELEASE BRAKING BATTERY VOLTAGE
PEDAL BRAKING STEER ANGLE
TRACTION BRAKING ACCELERATION
TRACTION I MAX SEAT SWITCH
(2) SPEED CUTBACK I FORWARD SWITCH CLEAR ALARM(S)
CREEP SPEED BACKWARD SWITCH
(1) SPEED LIMIT TEMPERATURE
BRAKE SWITCH
CUTBACK SWITCH 1
CUTBACK SWITCH 2
SET MODEL SET OPTIONS ADJUSTMENTS
STEER TABLE HOURS RUNNING / KEY ON STEER POT

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

(2) Not available in version B1SHA1.05
84
ELECTRICS
Programmer Start Routine
Connect
programmer
Connect
truck
Control logic Internal check

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

YES off truck and check wiring
display
C h e c k C h e c k
W A IT C O N N E C T Switch off truck; check pro-

N O C O N N E C T
YES grammer - controller connection
No
error
C h e c k C h e c k
C H O P P E R N O T O K Switch off truck; programmer and

YES controller are incompatible
C h e c k C h e c k
Information Display
Traction Controller
W A IT C O N N E C T YES C R O W N B 1 V .1 .0
R E G E N E R 3 5
Information Display
NO Pump Controller
C R O W N H 2 V .1 .0
YES P U M P S T D 3 5
Current error
Error during travel
*** A L A R M ***
S T E E R S E N S O R K O
M0288d
85
ELECTRICS
Traction Controller Menu Functions

PROGRAM
In the PROGRAM menu the listed truck parameters can
be read and set in real time.
TESTER
In the TESTER menu the listed truck parameters can be
read in real time.
ALARMS
In the ALARMS menu error messages generated and
stored during operation can be called up and processed.
PROGRAM PEDAL
In the PROGRAM PEDAL menu item the traction
potentiometer is calibrated. The traction controller reads
and records the potentiometer's minimum and maximum
output voltage.
CONFIG
The Configuration menu is used to adapt the program-
mer to the respective truck model.
In addition, auxiliary functions can be activated or de-
activated. The steering potentiometer is calibrated in the
"Adjustments" sub-menu.
86
ELECTRICS
PROGRAM Menu
The following table describes the various truck param-
eters which can be set in the PROGRAM menu.
Traction Controller Settings
Recommended
Menu item Setting range Explanation
Setting
Acceleration delay. Minimum time required for the motor

A C C . D E LA Y 0-9 4
current to rise from the minimum to the maximum level.
Braking intensity for inversion braking by changing travel

INVERSE
0-9 5 direction. The brake force is dependant on the accelerator
BREAKING
pedal position and the maximum traction current setting.
Braking intensity during release braking (accelerator pedal
R E LE A S E
0-9 3 in neutral). The brake force is dependant on the maximum
BREAKING
traction current setting.
Braking intensity when the brake pedal is applied. The
PED AL
0-9 9 brake force is dependant on the maximum traction current
BREAKING
setting.
Defines the maximum motor current. All current settings are
expressed as a percentage of the I max value which is set
TRACTION I MAX 0-6 6
here. The setting range is from 50% (level 0) to 100% (level
9) of the maximum current of the controller.
Reduced travel speed. Active when potential B- is applied
C U TB A C K to input Cutback 1. If this input is not used for reduced
0-9 5
SPEED 1 travel speed, the CUT BACK SPEED 1 value must be set
to level 9.
Defines the minimum value for the motor current when the
travel switch has just been closed. When the travel switch
C R EEP SPEED 0-9 2
is activated voltage is applied to the motor; this provokes a
rapid response to the travel command.
E53-GB
87
ELECTRICS
TESTER Menu
The following table describes the various truck param-
eters which can be selected and checked in the TESTER
menu.
TESTER menu (traction controller)
Menu item Explanation
Displays in real time the output voltage for the traction motors applied to the Volt
L VMN R Motor Negative. An important reading which provides information on the status of the
MOSFETs.
Displays in real time the current flowing through the pre-resistors (SH). Displayed
L IMOTOR R
during travel as well as braking.
BATTERY VOLTS Displays in real time the voltage applied to the traction controller.
Displays in real time the steer angle. The display ranges from +90° to -90° and is
STEER ANGLE
measured with reference to the forward position of the steering wheels.
Displays the output voltage from the traction potentiometer applied to the traction
controller up to a value of 10 V. Also displays the accelerator pedal stroke as a
ACCELLEATOR
percentage which can be used to check whether the traction potentiometer is calibrated
correctly.
SEAT SWITCH Tests the operation of the seat switch and wiring.
FORWARD SWITCH Tests the operation of the ""Forward"" switch and its wiring.
BACKWARD SWITCH Tests the operation of the ""Forward"" switch and its wiring.
Displays in real time the MOSFET heat dissipator temperature in the traction
TEMPERATURE
controller.
BRAKE SWITCH Tests the operation of the brake switch and its wiring.
CUTBACK SWITCH 1 & 2 Tests the operation of the speed cutback switch and its wiring
E52-GB
88
ELECTRICS
ALARMS Menu
The traction controller can collect and store operational
faults during operation. The ALARMS menu can be used
to call up and read the respective fault codes.
The programmer can display 5 different types of fault
codes up to 99 times together with the applicable number
of service hours.
ALARMS menu (traction controller)
Error code Description Possible cause
The test is performed during operation or

- Regenerative brake contactor jammed
at the start of inverse braking. The alarm is
BRAKE CON CLOSED - External connection from E9 to B-
activated when the supply to the VMN
- Logic error
exceeds 2/3 of the battery voltage.
Tests the operation of the direction - Direction contactor does not close
R DIR CONT OPEN
contactors by measuring the VMN - Faulty motor wiring
L DIR CONT OPEN
voltage. - Direction contactor faulty
The test is performed when the
regenerative brake contactor has closed. - Regenerative brake contactor faulty
BRAKE CONT OPEN
Tests whether the VMN is rising from 1/3 - Magnetic coil or wiring faulty
to 2/3 of the battery voltage.
R DIR CONT CLOSED Tests the operation of the direction - Direction contactor jammed
L DIR CONT CLOSED contactors at idle speed or braking. - Logic error
The test is performed in standby mode or - Direction contactor faulty
during operation at 100% to 80% of the - Motor insulation between armature
R VMN LOW
PWM signal. The alarm sounds when the and field faulty
L VMN LOW
VMN falls to below 1/3 of the battery - Brake contactors closed
voltage. - Logic error
The test is performed in standby mode. - Short circuit between battery + and
R VMN HIGH
The alarm is activated when the VMN VMN
L VMN HIGH
exceeds 2/3 of the battery voltage. - Logic error
The test is performed in operational
R I=0 EVER mode. The alarm is activated when the - Current sensor faulty.
L I=0 EVER minimum supply level is exceeded and - Power supply fault
travelling is inhibited.
Displays fault in hourmeter memory
EEPROM DATA KO range. Followed by reset to zero, traction - Logic section error (not permanent)
controller continues to operate however.
- Steer potentiometer wiring faulty
Steer sensor faulty. Input signal at L2 - Steer potentiometer incorrectly
STEER SENSOR KO
>4.8 V or < 0.2 V. calibrated
- Steer potentiometer faulty
E50_1-GB
89
ELECTRICS
ALARMS menu (traction controller) Contd. 1
Microprocessor self test: performed

WATCH DOG - Logic faulty
during standby and travel modes.
- Shor t circuit or more than 6A

constant current in one of the
contactor coils.
Detects the shor t circuit current when the - Negative connection from one of the
COIL SHORTED
contactor coils are activated. contactor tips to battery positive shor t-
circuited.
- Coils incorrectly connected with
recovery diode
Tests the voltage applied to the contactor
DRIVER SHORTED drivers. Performed when contactor drivers - Traction controller faulty
are not activated.
Informs the operator that the required
- Handbrake on while travel function
function cannot be selected while the
activated.
CHOPPER RUNNING traction controller is operating.
- Handbrake switch faulty.
(Communication only between the
- Handbrake switch wiring faulty.
programmer and the controller).
- Driver's seat not occupied while
Informs the operator that a travel function
travel function activated
HANDBRAKE ERROR has been performed with the handbrake
- Seat switch faulty
on for more than 5 seconds.
- Seat switch wiring faulty
Informs the operator that a travel function
SEAT SWITCH OPEN has been performed with the seat switch
open.
Indicates that the heat dissipator
HIGH TEMPERATURE temperature has reached 70°C. At 85°C
the maximum current is reduced to 0.
Can only appear if Battery Check is

BATTERY LOW - Disable function
activated in the Config Menu.
- Incorrect operating sequence.

INCORRECT START Incorrect star ting sequence. - Wiring error.
- Direction and/or travel switch jammed
E50_2-GB
90
ELECTRICS
ALARMS menu (traction controller) Contd. 2
The test is performed permanently and

- Wiring error
FORW-BACK checks if both travel directions are applied
- Direction contactors faulty
simultaneously.
The test is performed in standby mode. - Negative connection to potentiometer
The alarm indicates that the potentiometer interrupted.
VACC NOT OK
loop voltage is more than 1 V higher than - Potentiometer incorrectly calibrated.
the stored minimum. - Potentiometer faulty
- Current control circuit error in the
The test is performed in standby mode.
R STBY HIGH controller.
The alarm indicates that the motor current
L STBY HIGH - Problem with the battery or the power
is not 0.
circuit
- Motor temperature too high.
Motor temperature too high. For
THERMIC LEVEL 2 - Wiring error.
temperature control option only.
- Temperature sensor faulty
E50_3-GB
PROGRAM PEDAL Menu

The PROGRAM VACC sub-menu enables each traction
potentiometer to be calibrated individually for each truck
by taking and storing the minimum and maximum output
voltages of the traction potentiometer.
The minimum output voltage is read as the travel switch
is closed, the maximum output voltage when the travel
switch is fully applied.
Approx. 14V is applied to the travel switch via the trac-
tion controller. The signal range used by the potentiometer
is from 0V (minimum speed) to 10V (maximum speed).
91
ELECTRICS
CONFIG Menu
The CONFIG menu provides access to the SET MODEL,
SET OPTIONS and ADJUSTMENTS sub-menus.
CONFIG Menu
Sub menu Option Description
Used to select the correct wheelbase. The display 3013

SET MODEL corresponds to model 3210, 3016 to model 3220 and 3018 to
model 3240.
Determines the mode of the hourmeter in the traction control
system. The following options are available:
SET OPTIONS Hours running / key on - RUNNING: Counts the hours while the traction motor is
activated
- KEY ON: Counts the hours while the truck is switched on
Activates battery monitoring system in the traction controller. If
the battery voltage falls to below 10% and this function is
Battery check on / off activated (ON):
- the traction controller restricts the max. current to 50 %;
- the respective Service LED on the display star ts to flash.
Activates the release braking function. When set to OFF the truck
Release braking on / off does not brake when the travel switch is released or returns to
zero, but continues to coast.
When set to ON the traction controller can power the drive motor
Antiroll back on / off in the opposite sense to its direction of turn up to the
programmed maximum value
- OFF position: Traction controller sets a pin to 0V when the brake
pedal is applied.
Autobrake light on / off1
- ON position: Traction controller sets a pin to 0V during release
braking and inversion braking.
Used to calibrate the steering potentiometer. The minimum and
maximum output voltages of the steering potentiometer are
ADJUSTMENTS Steerpot recorded and stored. Based on these minimum/maximum values
the traction controller calculates the respective steer angle within
a range of +90° to -90° -> see instructions.
E69-GB
92
ELECTRICS
Pump Controller Operating Menu
START ROUTINE
PROGRAM TESTER ALARMS PROGRAM CONFIG
ACCELERATION VMN
DECELERATION VIEW ALARM(S) PROGRAM VACC
MOTOR VOLTAGE
CURRENT LIMIT MOTOR CURRENT
HYDRO SPEED COARSE
BATTERY VOLTAGE
HYDRO SPEED FINE
HYDRO SPEED COMP.
TEMPERATURE
CREEP SPEED LIFTING CONTROL
(1) LIFTING SWITCH CLEAR ALARM(S)
HYDRO TIME
1ST SPEED FINE (1) DESCENT SWITCH
1ST SPEED COMP. 1ST SPEED SWITCH
2ND SPEED COARSE 2ND SPEED SWITCH
2ND SPEED FINE 3RD SPEED SWITCH
2ND SPEED COMP.
4TH SPEED SWITCH
3RD SPEED COARSE
3RD SPEED FINE
HYDRO SPEED REQ.
3RD SPEED COMP.
4TH SPEED COARSE
4TH SPEED FINE
4TH SPEED COMP.
SET MODEL SET OPTIONS ADJUSTMENTS
(1) PUMP (1) BYPYSS (1) SET BATTERY

(1) PUMP + HYDRO BATTERY CHECK TYPE
HOUR COUNTER
(1) MAIN CONTACTOR
(1) AUX. FUNCTIONS
(1) SET BATTERY
VOLTAGE
(1) No longer available with version HPHA1.73
93
ELECTRICS
Menu Functions Pump Controller
PROGRAM
In the PROGRAM menu the listed truck parameters can
be read and set in real time.
TESTER
In the TESTER menu item the listed truck parameters
can be read in real time.
ALARMS
In the ALARMS menu error messages generated and
stored during operation can be called up and processed.
PROGRAM VACC
In the PROGRAM VACC menu the lift potentiometer is
calibrated. The pump controller reads and records the
potentiometer's minimum and maximum output voltages.
CONFIG
The Configuration menu is used to activate or de-acti-
vate various auxiliary functions.
94
ELECTRICS
PROGRAM Menu
The following table describes the various parameters
which can be set in the PROGRAM menu for the pump
controller.
Traction Controller Settings
Recommended
Menu item Setting Range Explanation
Setting
Acceleration delay: Time required for the motor

A C C . D E LA Y 0-9 4 current to rise from the minimum to the maximum
level.
DECELERATION Coast delay: Time required for the motor current to fall
0-9 0
D E LA Y from the maximum to the minimum level.
Defines the maximum current of the pump motor. All

current settings are expressed as a percentage of the
MAXIMUM
0-9 9 MAXIMUM CURRENT value which is set here. The
C U R R EN T
setting range is from 50% (level 0) to 100% (level 9) of
the maximum current of the controller.
Approximate setting for the maximum pump motor
H YD R O SPEED speed. The actual pump speed is based on the
0-9 1
COARSE respective SPEED COARSE and SPEED FINE values.
This value is based on the steering function.
Fine setting for the maximum pump motor speed. The
H YD R O SPEED actual pump speed is based on the respective
0-6 4
FINE SPEED COARSE and SPEED FINE values. This
value relates to the steering function.
Speed compensation for load peaks. With this
function the pump controller varies the pump speed,
HYDRO COMPEN 0-9 2 thereby compensating for speed reductions caused by
peak demand. This value is related to the steering
function.
Defines the minimum voltage applied to the pump

C R EEP SPEED 0-9 4
motor
Hydraulic pump delay period when no steering input

HYDRO TIME 0-9 1
signal is applied to the controller
E68_1-GB
95
ELECTRICS
Traction Controller Settings (Contd. 1)
Recommended
Setting
Approximate setting for the maximum pump motor speed.

1 st
The actual pump speed is based on the respective
SPEED 0-9 2
SPEED COARSE and SPEED FINE values. This value
COARSE
relates to the second hydraulic function, tilt.
Fine setting for the maximum pump motor speed. The
actual pump speed is based on the respective SPEED
1st SPEED FINE 0-9 2
COARSE and SPEED FINE values. This value relates to
the second hydraulic function, tilt.
Speed compensation for load peaks. With this function the
pump controller varies the pump speed, thereby
1 st S P E E D
0-9 2 compensating for any speed reduction caused by peak
COMP
demand. This value relates to the second hydraulic
function, tilt.
Approximate setting for the maximum pump motor voltage, this
has a direct influence on the pump speed. The actual pump
speed is based on the respective SPEED COARSE and
2nd S P E E D SPEED FINE values. This value relates to the first auxiliary
0-9 0 (2)
COARSE function (=third hydraulic function), normally the sideshifter.
Values without brackets if the function is not used (standard).
Values in brackets for optional sideshifter, for all other
accessories the values must be individually selected.
Fine setting for the maximum pump motor voltage, this has a
direct influence on the pump speed. The actual pump speed
is based on the respective SPEED COARSE and SPEED
2nd S P E E D FINE values. This value relates to the first auxiliary function
0-9 0 (0)
FINE (= third hydraulic function), normally the sideshifter. Values
without brackets if the function is not used (standard). Values
in brackets for optional sideshifter, for all other accessories
the values must be individually selected.
E68_2-GB
96
ELECTRICS
Recommended
Setting
Speed compensation (motor voltage) dependent on the

current when traveling at reduced speed. With this function
the pump controller varies the pump speed via the output
voltage and can thereby compensate for any load changes.
2nd S P E E D
0-9 0 (2) This value relates to the first auxiliary function (=third
COMP
hydraulic function), normally the sideshifter. Values without
brackets if the function is not used (standard). Values in
brackets for optional sideshifter, for all other accessories the
values must be individually selected.
Approximate setting for the maximum pump motor voltage,
this has a direct influence on the pump speed. The actual
pump speed is based on the respective SPEED COARSE
3rd SPEED and SPEED FINE values. This value relates to the second
0-9 0
COARSE auxiliary function (=third hydraulic function), for example the
paper roll clamp. Values in the event the function is not filled
(standard), for all accessories the values must be selected
individually.
FINE values. This value relates to the second auxiliary
3rd SPEED FINE 0-9 0
function (=fourth hydraulic function), for example the paper
roll clamp. Values in the event the function is not used
individually.
3rd SPEED FINE values. This value relates to the second auxiliary
0-9 0
COMP function (=fourth hydraulic function), for example the paper
roll clamp. Values in the event the function is not used
individually.
E68_3-GB
97
ELECTRICS
Recommended
Setting
Approximate setting for the maximum pump motor voltage, this

has a direct influence on the pump speed. The actual pump
4th SPEED
0-9 0 speed is based on the respective SPEED COARSE and
COARSE
SPEED FINE values. This value relates to input E1, reserved
for later applications and not used here.
4th SPEED FINE 0-9 0 is based on the respective SPEED COARSE and SPEED
FINE values. This value relates to input E1, reserved for later
applications and not used here.
4th SPEED
0-9 0 is based on the respective SPEED COARSE and SPEED
COMP
FINE values. This value relates to input E1, reserved for later
applications and not used here.
AUXILLIARY
0-9 0 Sets the time delay for auxiliary functions, not used
TIME
E68_4-GB
98
ELECTRICS
TESTER Menu
The following table shows the various truck parameters
which can be selected and tested in the TESTER menu.
TESTER menu (pump controller)
Menu item Explanation
Displays in real time the output voltage for the pump motor applied to the Volt Motor
VMN
Negative.
MOTOR VOLTAGE Displays in real time the voltage applied to the pump motor.
Displays in real time the motor current flowing through the pre-resistor (SH) in the
MOTOR CURRENT
pump controller.
BATTERY VOLTS Displays in real time the battery voltage applied to the pump controller.
TEMPERATURE Displays in real time the MOSFET heat dissipator temperature in the pump controller.
Displays the output voltage from the lift potentiometer applied to the pump controller
LIFTING CONTROL
up to a value of 10 V.
1ST SPEED SWITCH Displays the signal status for the 2nd hydraulic function.
2ND SPEED SWITCH Displays the signal status for the 3rd hydraulic function.
3RD SPEED SWITCH Displays the signal status for the 4th hydraulic function.
4TH SPEED SWITCH Not used.
BRAKE SWITCH Tests the operation of the brake switch and its wiring.
HYDRO SPEED
Displays the signal status for the steering function.
REGULATION
E51-GB
99
ELECTRICS
ALARMS Menu
The pump controller can detect and store any faults which
occur during operation. The ALARMS menu can be used
to call up and read the respective fault codes.
The programmer can display 5 different types of fault
codes up to 99 times together with the applicable number
of service hours.
ALARMS Menu (Pump controller)
The test is performed in standby mode or

- Motor wiring faulty
during operation at 100% to 80% of the
- Motor insulation between armature
STAND BY VMN LOW PWM signal. The alarm sounds when the
and field faulty
VMN falls to below 1/3 of the battery
- Logic error
voltage.
The test is performed in standby mode. - Short circuit between battery + and
No FULL COND The alarm is activated when the VMN VMN
exceeds 2/3 of the battery voltage. - Logic error
The test is performed in operational
mode. The alarm is activated when the - Current sensor faulty.
I=0 EVER
minimum supply level is exceeded and - Power supply fault
travelling is inhibited.
Displays fault in hourmeter memory
EEPROM DATA KO range. Followed by reset to zero, traction - Logic section error (not permanent)
controller continues to operate however.
EEPROM KO Shows fault in controller memory range - Logic section error
E64-GB
100
ELECTRICS
ALARMS Menu (Pump controller) Contd. 1
Microprocessor self test: performed

WATCH DOG - Logic faulty
during standby and travel modes.
- Shor t circuit or more than 6A

constant current in one of the contactor
coils.
Detects the shor t circuit current when the - Negative connection from one of the
COIL SHORTED
contactor coils are activated. contactor tips to batter y positive shor t-
circuited.
- Coils incorrectly connected with
recover y diode
Tests the voltage applied to the contactor
DRIVER SHORTED drivers. Performed when contactor drivers - Traction controller faulty
are not activated.
Informs the operator that the required
- Handbrake on while travel function
function cannot be selected while the
activated.
CHOPPER RUNNING traction controller is operating.
- Handbrake switch faulty.
(Communication only between the
- Handbrake switch wiring faulty
programmer and the controller).
Indicates that the heat dissipator
TH. PROTECTION temperature has reached 80°C. Maximum
current is reduced to 0 at 85°C.
Can only appear if Batter y Check is

BATTERY - Disable function
activated in Config Menu.
- Incorrect operating sequence.

INCORRECT START Incorrect star ting sequence. - Wiring error
- Direction and/or travel switch jammed
E65-GB
101
ELECTRICS
ALARMS Menu (Pump controller) Contd. 2
The test is performed in standby mode. - Negative connection to potentiometer

VACC NOT OK The alarm indicates that the interrupted
VACC > 1 V potentiometer loop voltage is more than 1 - Potentiometer incorrectly calibrated
V higher than the stored minimum. - Potentiometer faulty
- Current control circuit error in the
The test is performed in standby mode.
controller
I HIGH AT STAND The alarm indicates that the motor current
- Problem with the battery or the power
is not 0.
circuit
- If the error persists after resetting
Error in memory range. The settings have
EEPROM PAR. KO (key switch OFF/ON) -> replace the
been reset to default values.
controller
Error in configuration range. The - If the error persists after resetting
EEPROM CONF. KO
configuration data have been reset to (key switch OFF/ON) -> replace the
CHOP. NO CONF.
default values. controller
- If the error persists after resetting
Error in memory range of the error
EEPROM OFF lINE (key switch OFF/ON) -> replace the
memory, hourmeter and settings
controller
E66-GB
PROGRAM VACC Menu

The PROGRAM VACC sub-menu is used to calibrate the
lift potentiometer. The maximum potentiometer voltage
corresponds to the full lever displacement. The minimum
voltage is always 0V.
14V is supplied to the lift potentiometer via the pump
controller logic. The signal range used by the potentio-
meter is between 0V (minimum speed) and 10V (max.
speed) as signals above 10V are reduced to 10V by the
internal logic system.
102
ELECTRICS
CONFIG Menu
The CONFIG menu provides access to the SET OP-
TIONS sub-menu.
CONFIG Menu
Sub Menu Option Description
Determines the mode of the hourmeter in the pump controller. The

following options are available:
SET OPTIONS Hours running / key on
- RUNNING: Counts the hours while the drive motor is activated
- KEY ON: Counts the hours while the truck is switched on
Activates battery monitoring system in the pump controller. If the
battery voltage falls to below 10% and this function is activated
Battery check on / off (ON):
- the traction controller restricts the max. current to 50 %;
- the respective Service LED on the display starts to flash.
MAIN CONTACTOR RUNNING STATUS Must not be changed
AUX. FUNCTION RUNNING STATUS Must not be changed
BYPASS CONTACTOR BYPASS Must not be changed
BATTERY CHECK OFF Must not be changed
Model Type
Set Model Must not be changed
Standard Pump
Adjustments Set Battery Type 48 V Must not be changed
Adjust Battery Brings the battery display in line with the battery voltage.
E76-GB
103
ELECTRICS
Calibrating the Steering Crown B1S V1.0

48V 320A 0
Potentiometer
The steering transmitter potentiometer must always be
calibrated if:
● The steering potentiometer has been replaced.
MAIN MENU
● The traction controller has been replaced. PARAMETER CHANGE
Preparation
● Power down the truck and jack it up so that
the drive wheel is free (see chapter 1). MAIN MENU
CONFIG. MENU
● Connect the programmer to the traction controller
(connector B, via diagnostic LED).
● Switch on the truck.
Calibration CONFIG MENU

SET MODEL
● Using the ROLL UP or ROLL DOWN keys scroll
through to the CONFIG MENU, ADJUSTMENTS
menu.
● Press ENTER.
CONFIG MENU
● The display shows SET STEER MIN and the ADJUSTMENTS
stored minimum level of the potentiometer.
● Press ENTER.
● Turn the steering wheel to the left until the level
displayed does not change.
SET STEER MIN
● Using ROLL UP or ROLL DOWN select the SET 0.5 V
STEER MAX menu item.
● The display shows SET STEER MAX and the
stored maximum level of the potentiometer.
● Press ENTER. SET STEER MIN
0.4 V
● Turn the steering wheel to the right until the level
displayed does not change.
● Now press OUT
● The display will ask “Are you sure?” If you want
SET STEER MAX
to save the new levels, press ENTER. Otherwise, 4.4 V
press OUT.
● Press OUT to quit the VACC menu.
SET STEER MAX

4.4 V
ARE YOU SURE?

YES=ENTER NO=OUT
MS-2232-035
104
ELECTRICS
HP PUMP STD V.1.7 Calibrating the Lift Potentiometer

48V 320A 0
The lift potentiometer must always be calibrated if:
● The lift potentiometer has been replaced.
(After replacement adjust the potentiometer
before calibrating it, see chapter 1)
MAIN MENU ● The pump controller has been replaced.
PARAMETER CHANGE
Preparation
● Park the truck in such a way that accidental
lift movements will not cause damage.
MAIN MENU
PROGRAM VACC ● Connect the programmer to the lift controller
(connector B, via diagnostic LED).
Calibration
VACC SETTING
1.3 10.0 ● Press ENTER.
● Using the ROLL UP or ROLL DOWN keys
scroll through to the PROGRAM VACC menu.
● Press ENTER.
MIN VACC MAX ● The display shows the stored minimum and
1.3 - 1.3 maximum levels of the potentiometer.
● Press ENTER to delete the stored levels.
● Slowly activate lifting until you reach the stop.
The display now shows the minimum level and
the maximum level.
MIN VACC MAX
1.3 10.0 ● Now press OUT
● The display will ask “Are you sure?” . If you
wish to save the new levels, press ENTER.
Otherwise, press OUT.
● Press OUT to quit the VACC menu.
ARE YOU SURE?
YES=ENTER NO=OUT
MS-2232-056
105
ELECTRICS
Crown B1S V1.0 Calibrating the Accelerator

48V 320A 0
Potentiometer
The accelerator potentiometer must always be cali-
brated if:
● The accelerator potentiometer has been re-
MAIN MENU placed.
PARAMETER CHANGE
(After replacement adjust the potentiometer
before calibrating it, see chapter 1).
● The traction controller has been replaced.
MAIN MENU Preparation

PROGRAM VACC
● Power down the truck and jack it up so that
the drive wheel is free (see chapter 1).
● Connect the programmer to the traction control-
ler (connector B, via diagnostic LED).
VACC SETTING ● Switch on the truck.
1.5 10.0
Calibration
● Press ENTER.
● Using the ROLL UP or ROLL DOWN keys
MIN VACC MAX scroll through to the PROGRAM VACC menu.
1.5 - 1.5
● Press ENTER.
● The display shows the stored minimum and
maximum levels of the potentiometer.
● Press ENTER to delete the stored levels.
MIN VACC MAX
1.5 - 10.0 ● Slowly depress the accelerator pedal until you
reach the stop. The display now shows the
minimum level and the maximum level. An
arrow is also indicated. The arrow shows the
travel direction currently selected*.
ARE YOU SURE? ● Now press OUT

YES=ENTER NO=OUT
● The display will ask “Are you sure?” . If you
wish to save the new levels, press ENTER.
Otherwise, press OUT.
MS-2232-055 ● Press OUT to quit the VACC menu.

* It is sufficient to calibrate for just one travel direction.
The value for the opposite direction will be set auto-
matically.
106
Blank page
Printed in Germany
107
ELECTRICS
Traction Controller Safety Test

Pulse Monitor Trip Test (PMT)
CAUTION
In compliance with EU Norm PREN1175-1
the following test must be carried out to
monitor the traction controller fuse
circuit.
Equipment
A test cable with a 10A fuse and an insulated crocodile
clip at each end.
Test
● Switch off the truck.
● Jack up the front wheels of the truck.
● Connect the test cable between - B and VMN L.
● Connect the programmer to the controller.
● Press the seat switch.
● LED code (lights up three times)
and following message displayed:
"ALARM L VMN LOW".
● Select truck forward or reverse.
● Depress accelerator pedal:
1. Travel mode does not start.
Test performed successfully
2. No LED display, travel mode starts.
Replace traction controller.
● Switch off the truck.
● Connect the test cable between - B and VMN R.
● Repeat the test for VMN R.
● Disconnect the test cable between - B and
VMN R.
● Lower the front wheels.
The truck is now operational.
108
ELECTRICS
PMT Safety Test Wiring
+ S H L + S H R
S H S H
L D 2 R D 2
-S H L -S H R
L D 1
V M N L V M N R R D 1
B 1 S 4 8 V / 3 5 0 + 3 5 0
L O G IC
- B
1 0 A 1 0 A
F U F U
M0341
Test Cable
109
ELECTRICS
Battery Battery Discharge Indicator (BDI)
General WARNING
The battery condition has a considerable impact on the The following setting and calibration
performance of the truck. Effective maintenance will main- instructions for the BDI apply only to wet
tain the performance levels and lifespan of the battery. batteries.
● For maintenance-free batteries follow the manu-
WARNING facturer's instructions regarding the discharge
The battery must be serviced solely in terminal voltage.
accordance with the battery manufactur-
er's instructions. General
● Incorrect or inadequate maintenance will initially A battery from the factory will require approx. 5 - 10 charge
reduce the performance of the truck and ulti- and discharge cycles to reach its full capacity.
mately result in premature failure of the battery.
A battery is considered to be technically discharged when
It is essential to adjust the battery discharge indicator it has reached 20% residual capacity. For example, a batte-
(BDI) correctly to ensure on the one hand that the bat- ry with a 500 amp hour capacity has an actual available
tery is not fully discharged and on the other that there is output of 400 amp hours.
maximum battery capacity available for the task in hand.
In addition, the effective output will depend on the dis-
charge speed, which in turn is affected by the particular
Replacing the battery truck application.
WARNING The battery discharge indicator must therefore be set in

accordance with the truck's particular application condi-
Only use batteries of the permitted size, tions.
weight and specifications for this truck.
The battery discharge indicator controls the lift cutout
● An incorrect battery type can cause damage to system. The lift cutout system is designed to prevent the
the truck. battery from being operated to the point where is fully dis-
● An incorrect weight and size will alter the centre charged.
of gravity of the truck, potentially resulting in If the battery is constantly discharged to below 20% of
accidents. residual capacity it will be damaged.
There are several different battery compartment versions. If the lift cutout system is activated above 20% of the
Refer to the truck operator manual to battery replace- battery's residual capacity the battery will not be dam-
ment instructions. aged, but the truck's maximum operating time under a
The operator manual contains the latest safety instruc- single battery charge will not be attained.
tions and information. The lift cutout system should therefore be activated as
close to 20% of the battery's residual capacity as possible.
If at all, it may be slightly above 20%, but never below.
NOTE
For new trucks the battery discharge
indicator should be set at the latest after
ten discharge and charge cycles.
110
ELECTRICS
Battery Discharge Indicator Setting battery manufacturer's maintenance instructions
to check if the battery is actually 100% charged.
(BDI) Faulty battery cells will make calibration impossi-
The acid density is a very reliable indicator of the charge ble.
status of a lead acid battery. However, since it is unreal- ● Operate the truck as usual under normal operat-
istic to continually measure the acid density of a truck ing conditions until the battery is empty: both
battery to an industrial standard, the battery voltage is LEDs of the BDI will flash and the lift cutout
used to determine the charge status over longer jour- system will be triggered.
neys.
● Leave the battery for at least 10 to12 hours (one
To adapt the BDI to the battery used and the truck's spe- hour at the very minimum!).
cific application profile, you need the battery manufac-
turer's data sheet. The values you require are the den- ● After this interval measure the acid density on at
sity of the electrolyte for an 80% discharged battery (20% least three different battery cells. The smallest
battery residual capacity) and for a fully charged battery recorded value is the one you need.
(100% battery capacity). ● Compare the recorded density with the density
Finally, via the potentiometer on the back of the BDI the specified by the manufacturer for an 80% dis-
display is set to the actual discharge terminal voltage of charged battery (20% residual capacity).
the battery at 20% residual capacity. ● If the battery is more than 80% discharged (less
The factory default setting of the battery discharge indi- than 20% residual capacity), set the potentio-
cator is "M" (any setting from K to U is possible). meter on the back of the BDI to direction K.
● If the battery is less than 80% discharged (more
Calibration than 20% residual capacity), set the potentio-
meter on the back of the BDI to direction U.
● Fully charge the battery as indicated by the battery
manufacturer in the operating instructions. Meas- ● Charge the battery again and then check the
ure the acid density in accordance with the calibration.
Discharge Terminal Voltage Setting in Volts/Cell
K L M N O P Q R S T U
1.57 1.63 1.68 1.73 1.78 1.82 1.84 1.86 1.89 1.91 1.93
E77-GB
111
ELECTRICS
Electric Motors ● The brush edges must not be cracked. Brushes

with cracking along the long edge of the surface
will have been damaged by a worn collector.
General Maintenance Instructions If information is provided in the manual, restore
The following instructions apply to all motors. Details the collector to the specified limits. Otherwise,
relating to specific models and designs are provided in replace the armature in full.
the sub-sections (traction motor, pump motor etc.). ● Loose brush connections are a clear sign of
motor overload. In this case inspect the collector
Preparation for burning and repair or replace as necessary.
● Disconnect the battery ● When fitting the brush take care to place the
(= EMERGENCY DISCONNECT). spring gently on the brush. If the contact is too
hard the brush will be damaged.
● Secure the truck from rolling away.
● Make sure that all brushes contact the armature
Important Maintenance Instructions at the same pressure.
● Remove all carbon brushes and check for wear. ● New brushes must be run in with a medium load
If one or more carbon brushes need to be re- in the first hours. Never fully charge the motor
placed, replace all brushes. In addition to the straight away.
carbon brushes the pressure springs must also
be replaced to ensure the correct pressure.
The length of the shortest brush determines
whether the brush set needs to be replaced.
Even if the minimum length has not been reached
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), immedi-
ately 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
probably have been thermally overloaded. Ther-
mal overloading (temperatures >160 ºC) causes
the brushes to swell up.
Brushes which jam in the brush support produce
intense sparking and destroy the collector.
112
ELECTRICS
Traction Motor Maintenance
MS-2232-053
Maintenance
● Apply dry compressed air to the motor.
● Remove all carbon brushes and check them with
the armature in accordance with the instructions
in "Key Maintenance Instructions".
● A new carbon brush is 28 mm long
● Carbon brush wear limit: 15 mm
● Refit the tensioning belt
Armature
● A new armature has a max. diameter of 64.5 mm.
● The armature can be overwound provided the
remaining diameter is no less than 61.5mm.
MS-2232-039 ● The armature must be replaced if the diameter is

60.5 mm or less.
Access to Brushes ● After overwinding cut the mica down to a depth of
● Disconnect the battery 0.5 mm without changing the gap width between
the multi-plates.
● The multi-plate edges must be carefully de-burred.
● Remove the tensioning belt from the motor.
Bearings
● The ball bearings are maintenance-free. They
must always be replaced if removed for repair
work.
113
ELECTRICS
Pump Motor Maintenance
M0076
Maintenance
● Apply dry compressed air to the motor.
● Remove all carbon brushes and check them with
the armature in accordance with the instructions
in "Key Maintenance Instructions".
● A new carbon brush is 20 mm long
● Carbon brush wear limit: 10 mm
Armature
● A new armature has a diameter of 40 mm.
The wear limit is 38.3 mm.
● The armature must not be overwound. Instead it
must be replaced when the wear limit is reached.
Refit the hydraulic unit as described in Chapter 2.
MS-2232-052
Access to brushes
● Disconnect the battery
● Remove the hydraulic unit as described in Chap-
ter 2.
● Unscrew the commutator bearing lid and remove
the insulating protective cap.
114
BRAKE
Printed in Germany
115
Blank page
Printed in Germany
116
BRAKE
Brakes On the brake linings which contact the rotor (brake

applied), measure the distance between the two fixed
plates (see Fig. MS-2232-010). The brake linings are
General worn if the distance is 11.8 mm or less.
DANGER
Brake Removal
A falling mast section can have fatal
consequences. ● Secure the truck with blocks under the wheels to
prevent it from rolling away. Raise the inner mast
When carrying out work which requires
until you can access the brakes through the mast.
the mast sections to be raised: secure
Lower the inner mast onto suitable square hard
the raised mast stages to prevent them
wooden blocks and secure it. De-pressurise the
from suddenly falling (hard wooden
hydraulic system (see Chapter 2). Disconnect the
blocks underneath the raised sections
battery.
and if necessary chains around the cross
arms of the mast stages)! ● If necessary, with the hydraulic system de-
pressurised, remove the hydraulic lines and
hoses in order to access the brakes.
● Remove the floor boards. Remove the lower
instrument panel cover. Undo the jam nut from
the handbrake cable and discharge the brake
cable (A, Fig. MS-2237-004).
MS-2232-002 A
NOTE
To remove the brakes, replace the brake
disks and the linings, you may need to
disconnect the hydraulic connections,
depending on the type of mast. Cover
the brakes with a plastic sheet
MS-2232-004
beforehand. This will prevent the brake
linings from being contaminated with oil. ● If you have difficulty reaching the brakes, remove
the drive motors (see Chapter 4). Although this is
Brake Lining Wear Limits not strictly necessary, it can save considerable
time.
● Unscrew the cross strut which connects the two
brake units (Fig. MS-2232-006 on following
page).
● Remove the bolts (16, Fig. MP-2232-007 on
following page) from the clamping plate (15).
● Remove the nut and washer (10) from the lever
(18). Remove the lever from the pin (A) on the
base plate (1). The connecting rod (19 to 21) can
remain attached to the lever (18).
MS-2232-010
> 11.8 mm
SC3200 03/2004 • PRINTED IN GERMANY MS-M5-2232

Rev. 01/03
117
BRAKE
Right brake
1 A
2
3
4
5
6
7
8
B 9
4
10 10
22
21 A
19
19 18
24
20 16
21
11
12 23
13 14
17
16
Left brake
15
B 17
16 18 17
21
16 15
20
C
17 10
24 19
17 22
11 21 4
14 9
17 23 8
D
13 7
17 6
12 5
4
10
3
2
1
C
MS-2232-007
MS-M5-2232 SC3200 03/2004 • Printed in Germany
118
BRAKE
● Fit the hub (8) to the rotor (7): align the hub and
the rotor so that you bring both ends of the
torsional springs (9) into the notches. Now pre-
tension the torsional springs with a half turn of
the hub and push the hub into the brake disk.
● Push the rotor with the pre-assembled hub onto
the drive shaft.
● Place the second fixed plate (4) onto the stud
bolts (5) of the base plate.
MS-2232-006 ● Fit the washers and nuts (10) onto the stud bolts.
Tighten the nuts crosswise and evenly.
● Tilt the spherical head of the connecting rod out
of the clamping plate (15) and remove the ● Insert the supporting plate (13) and fix the
clamping plate. supporting plate with a new washer (23) and the
screw (14). Bend a bracket of the washer (23)
● Remove the screw (14), the lock washer (23) and
over a flat side of the screw (14) to secure the
the supporting plate (13) from the drive shaft.
screw.
● Remove the four nuts and washers (10) from the
● Using the pin (16) re-attach the clamping plate
stud bolts (5). At the same time counter-fix the
(15) to the base plate (1). Push the washer (17)
stud bolts with a pin to prevent them from coming
up and secure the pin with the retaining spring
undone on the transmission side.
(17).
● Remove the first fixed plate (4) from the stud
● Insert the spherical head of the connecting rod
bolts.
(19-21) into the clamping plate (15). Attach it with
● Remove the torsional spring (9). Remove the hub the pin (16). Push up the washer (17) again and
(8) and the rotor (7) from the drive shaft. secure the pin with the retaining spring (17).
● Remove the 4 pressure springs from the stud ● Re-connect any previously dismantled hydraulic
bolts and then take off the second fixed plate. lines and bleed the hydraulic system (see Chapter
2).
Brake Assembly Now carry out the following adjustments and
inspections:
Before Assembling ● Adjust the foot brake
● Clean all parts with a brake cleaning agent or any ● Adjust the handbrake
other oil and silicon-free agent.
● Check the braking distance
● Check all parts of the brakes for damage and
wear. Replace any faulty or worn parts. The fixed See the following pages for instructions.
plates (with the brake lining) must always be
replaced in pairs.
● Replace any brake linings which have become
oily over a long period of time. These will soak up
too much oil. Cleaning is generally superficial and
the oil will seep back to the surface during
operation.
Only when the oil has a short effect - e.g. when
you have removed the brakes - can the it be
removed with a brake cleaning agent and the
brake lining re-used .
Assembly
● Place the first fixed plate (4) on the stud bolts (5)
of the base plate.
● Push the pressure springs (6) onto the four stud
bolts.
119
BRAKE
Foot Brake ● Turn the linkage clockwise to increase the distance
between the pedal base and the floor. Turn anti-
DANGER clockwise to reduce the distance. Adjust the linkage
Before carrying out work on the brake so that the brake pedal free travel is 15 to 23 mm.
system block the drive wheels to prevent ● Temporarily replace the right floorboard and
the truck from moving in any direction. check the distance between the pedal base and
the floor (> / = 20 mm).
● If both measurements are within the tolerance
Foot Brake Adjustment range, remove the floorboard again.
4.5 kg ● Fasten the linkage again using the jam nut (A,
Brake pedal Fig. MS-2232-009).
20 mm ● Adjust the brake switch so that it engages after 2

to 3 mm pedal travel.
Floor
● Adjust the handbrake.
● Check the truck‘s braking distance.
Checking the braking distance

WARNING
Always check the brakes in a secure area
MS-2232-008
to avoid endangering other people.
The ground for the brake test must be
Adjustment is necessary whenever:
level, dry, clean and afford some grip
At a pedal pressure of approx. 4.5 kg the distance (concrete ground).
between the bottom of the pedal and the floor is 20 mm
● With the truck unladen and at operating temperature,
or less. However, before adjusting the brake, make sure
accelerate to maximum speed.
that the linings have not reached the wear limit (see first
page of this chapter). If they have reached the wear limit, ● Brake the truck and measure the stopping
replace the linings and then adjust the brake. distance. The braking distance from the time of
applying the brakes to the truck coming to rest
The brake pedal free travel until contacting the brake lining
should be approx. 3100 mm.
is less than 15 mm or more than 23 mm.
● Remove the floorboards.
● Release the handbrake.
● Undo the jam nut from the linkage (A, Fig. MS-
2232-009).
MS-2232-009
MS-M5-2232 SC3200 03/2004 • Printed in Germany
120
BRAKE
Handbrake Adjustment
The handbrake is correctly set when:
The brake linings just touch the rotor when the pawl
(A) is in the first tooth of the ratchet (B).
The handbrake switch [HBS] (D) engages before the
pawl is in the first tooth of the ratchet.
If the handbrake requires more than one tooth until the
brake linings are contacted:
● Undo the jam nuts (E) from the brake cable
holder.
● Pull the cable sheath down suddenly and turn the
lower jam nut until it contacts the retaining plate.
● Use the top nut to jam the brake cable.
● Check the setting and adjust if necessary.
● Check the point of application of the handbrake
application point. Adjust the handbrake switch if
the switching point is not before the first tooth
reaches the ratchet.
MS-2232-003
121
Blank page
Printed in Germany
122
STEERING
Printed in Germany
123
Blank page
Printed in Germany
124
STEERING
Steering When the steering wheel is applied, oil flows from the oil
tank to the spool valve via the hydraulic pump. The prior-
ity valve (2) distributes the flow of oil: the amount cur-
Hydraulics rently required for steering is routed to the steer unit (3).
The rest is routed to the downstream hydraulic functions.
Function
The proportions are determined by the LS signal (4) sent
The input unit of the spool valve (1) contains a priority from the steer unit to the priority valve. As the load pres-
valve (2). If the steering and at least one other hydraulic sure increases, so the amount of oil flowing to the steer
function are activated at the same time, the priority valve unit rises. A pressure relief valve restricts the operating
controls the distribution of the oil between the required pressure in the steer unit to 70 bar.
functions. Steering always takes priority over the other
function. Refer to the HYD chapter for a illustration of the steering
hydraulic system.
2
3
1
MS-2232-058
SC3200 03/2004 • Printed in Germany MS-6-2232
125
STEERING
Steering Components ● Wheel hub and receptacle
● Steering cylinder and hydraulic port
Key switch
Steering
wheel
Gas pressure
cylinder
Steering
column
Bracket
Steer unit
MS-2232-059
Remove the top and bottom panel, the instrument cover

and the steering column covers to open up the following:
● Steering column
● Steering sensor (detects the movement of the

steering shaft to activate the pump via the pump
controller).
● Encoder module
● Direction control switch
● Key switch
● Slip ring contacts from the horn to the steering

shaft
● Steer unit (5 ports: pump, LS signal, LH steering

cylinder, RH steering cylinder, return flow)
● Gas pressure cylinder for the steering column

adjustment
After removing the counterweight (see Chapter 1) you have

access to:
● Steering potentiometer and plug connection
● Steering gear
MS-6-2232 SC3200 03/2004 • Printed in Germany
126
STEERING
Steering wheel ● Tighten both screws alternately and evenly to pull

the steering wheel from the shaft. If the steering
wheel is too tight, use a rubber hammer to tap on
Disassembly the inner ring of the steering wheel until the
steering wheel can be removed with the screws.
● Jack up the truck until the drive wheels are free
(see Chapter 1). Assembly
● Apply a small amount of anti-adhesive (part no.
065005-003) to the cone of the steering shaft. Do
not apply the anti-adhesive to the thread!
● Lift off the horn button.
● Fit the steering wheel in position, turn it slightly
until the steering wheel fits into the spline of the
● Undo the horn cable connections from the contact
steering shaft. Press the steering wheel down onto
ring.
the cone of the steering shaft.
● Pull the horn cables through a 1 1/4“ wrench.
● Manually fit the steering wheel nuts.
Place the wrench on the steering wheel nuts. Push
back the horn wires into the wrench so that the
● Pull the horn cables through a 1 1/4“ wrench.
square in the wrench is available for the extension
Place the wrench on the steering wheel nuts. Push
shaft. Attach a ratchet with an extension and undo
back the horn wires into the wrench so that the
the steering wheel nuts. Remove the tool and
square in the wrench is available for the extension
manually unscrew the steering wheel nuts.
shaft. Attach a torque wrench with an extension.
Torque the steering wheel nuts to 36 Nm. Do not
● Attach the steering wheel extractor (part no.
over-tighten!
129256) with 2 off M8 x 70 screws (see illustra-
tion). Guide the horn cables into the recess in the
● Screw the horn cables back onto the contact
tool to avoid trapping the cables.
rings.
● Refit the horn button. Press it down until it en-

gages.
● Re-connect the battery.

M8 x 70
● Test the horn.
129256 ● Jack down the truck.
MS-2232-060
127
STEERING
Direction Control Switches

INFORMATION
The illustration shows the direction con-
trol switch in the position for left-handed
application. For right-handed application,
apply the lever at an angle of 180°.
Forward switch
Reverse
switch
MS-2232-061
Switch Removal
● Remove the covers from the steering column.
● Remove the cables from the travel switches.
● Pull the retaining clips (2) off the pins (1).
● Pull out the pins. Be careful not to lose any parts.
Switch Assembly
● Replace any faulty components. Assemble the
switches in the reverse order of disassembly. Use
the new retaining clips (2) for the pins (1).
● Now test the direction control switches.
128
SAFETY
Blank page
Printed in Germany
129
STEERING
Steer Sensor Module Steering Sensor

Disassembly Disassembly
● Disconnect the battery. ● Disconnect the battery.
● Remove the covers from the steering column. ● Remove the covers from the steering column.
● Remove the cables from the sensor module (21). ● Remove the steering sensor module (21).
● Loosen the mounting screws (23). ● Remove the cable from the steering sensor (16).
● Remove the sensor module. ● Remove the adhesive from the gearwheel (17) and
remove the gearwheel.
Assembly
● Undo the locknut of the steering sensor (16).
● Assemble the sensor module in the reverse order
of disassembly. ● Remove the steering sensor.
● Now test the sensor module.
Assembly
● Assemble the steering sensor in the reverse order
of disassembly.
● Apply adhesive (part no. 061001-007) to the pinion

(17).
● Now test the steering sensor.
23
22
18
19 21
16
20
15
24
14
17 MP-2232-010
9
130
STEERING
Steering Column Adjustment

Gas Pressure Cylinder Removal
Retaining Ring
Unlocking lever
● Remove the bottom covers.

Unlocking head
● Fold up the steering column completely. This will
relieve the gas pressure cylinder.
Gas pressure
cylinder
● Loosen the bottom attachment from the gas
pressure cylinder to the truck chassis and the top Part of
retaining ring. Lift out the gas pressure cylinder Counternut chassis
unit.
● Undo the counternuts from the piston rod.
● Unscrew the piston rod from out of the head of the

unlocking lever.
Part of steering
MS-2232-063
column
Gas Pressure Cylinder Assembly and Adjust-
ment
● Screw the counternut (1) onto the piston rod (2) of

the cylinder.
● Screw the piston rod into the head (4) of the

unlocking lever until the stud (3) of the piston rod 5
contacts the bottom corner of the lever (5).
● Now continue to turn the piston rod. The unlocking 2

lever will move up. Keep turning until the lever
reaches the stop and there is no more clearance. 1
4
● Turn the piston rod a further ¼ turn and tighten the
counternut.
● Put the gas pressure cylinder back in the truck.

3
● Attach the cylinder again and test it. MS-2232-064
131
STEERING
Steering column Removing the steering shaft from the steering column
First disassemble the steering column.

Disassembly
WARNING
Steering Column Removal Risk of damage.
● Disconnect the battery. Removing the steering shaft with the
brushes and brush holder still in place
● Remove all the covers. will damage them.
Remove the brush holder (3, Fig. MP-2232-
● Remove the steering wheel (see previous section). 008) and the brushes (2) before removing
the steering shaft.
● Remove all the wires from the steering column (1,
Figure MP-2232-008). ● Remove the brush holder and the brushes (3 and
2, Fig. MP-2232-008) from the steering column.
● Fold up the steering column completely. This will
relieve the gas pressure cylinder. Loosen the ● Remove the retaining ring (1, Fig. MP-2232-008).
bottom attachment from the gas pressure cylinder
to the truck chassis and the top retaining ring. Lift ● Pull the steering shaft (7, Fig. MP-2232-008) from
out the gas pressure cylinder unit. out of the base of the steering column.
● Remove the 4 mounting screws from the steer unit Replacing the slip rings
to the steering column.
The steering shaft has 2 slip ring contacts for the horn’s
● Remove the mounting screws from the steer unit electrical power supply.
to the chassis.
Refer to figure MS-2232-062 when assembling. The insu-
● Pull the steering column up out of the toothing in lating tape must cover the soldering joint and the keep the
the steer unit. connecting wire flat against the shaft.
● Place the steering column on a clean workbench.
17 mm
Soldering
Insulating joint
tape max. 2 mm
Slip ring Insulator

MS-2232-062
132
STEERING
MP-2232-008
133
STEERING
Steering Gear Removal ● Loosen the steering potentiometer plug connection
and remove the potentiometer.
● Jack-up and secure the truck
● Secure the gear unit from the top with a rope to
● Dismantle both steering wheels; prevent it from falling.
● Prepare to collect any spilled hydraulic oil. ● Support the gear unit below with wooden blocks.
● Dismantle the two hydraulic lines from the steering ● Undo the 3 screws from the mounting flange;
cylinders;
● Lower the gear unit.
M0118
792341lenk
134
STEERING
Steering axle Steering Gear Assembly
Design Wheel hub pre-assembly
The steering axle consists of the steering gear and the ● Press in the wheel bolts (item 34) using a hydrau-
axle bracket. The steering gear consists of a hydraulically lic device (Fig. M1248).
actuated spur wheel steering rack transmission which
connects to the axle bracket via a flange. ● Drive the bearing shells of the conical roller
bearings (item 28) into their seat and grease the
NOTE bearing shell of the inner conical roller bearing
(grease = Crown part no. 053002-001).
For spare parts it should be noted that the
axle bracket is only available as a whole Steering knuckle pre-assembly
assembly, i.e. with the axle already pre-
assembled. ● For 2.12.01.1 push the Nilos ring (item 27), for
Important: There are 2 different steering 2.12.09.0 push the guard ring (item 37) and shaft
axle types. They differ in the type of seal seal (item 27) filled with grease (Crown part no.
used in the steering knuckle. 053002-001) onto the steering knuckle.
The data plate indicates which type is
used (2.12.01.1 or 2.12.09.0) ● Heat up the inner conical roller bearing (item 28 for
2.12.01.1, item 36 for 2.12.09.0) and drive it into
The reference numbers contained in the following assem- its seat. Now lubricate with Crown part no. 053002-
bly instructions refer to the exploded diagrams at the end 001.
of this chapter.
Steering Knuckle and Wheel Hub Assembly
As mentioned at the beginning, the steering knuckles is

supplied as a complete assembly (item 25) with the axle
already assembled.
For further assembly proceed as follows:
● Push the wheel hub (item 29) onto the steering

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

steering knuckle with Crown part no. 053002-001.
● Lubricate the outer conical roller bearing (item 28)

with Crown part no. 053002-001 and insert it into
the wheel hub.
● Fit the U washer (item 30) and fix the castle nut
(item 32).
● Turn the wheel hub to check the bearing clearance.

The torque should be 2 – 6 Nm. If necessary,
adjust via the torque of the castle nut.
● After correct adjustment of the bearing clearance

secure the castellated nuts with the splint (item
31).
● Strike in the protective cover (item 33) filled with

Crown part no. 053002-001 to protect the assem-
M1248 bly from external influences.
135
STEERING
Spur pinion flange shaft pre-assembly ● Fit the shim and the ground washers (item 6). Fit
another shim over the ground washers.
● Fill the Nilosring (item 22) with grease (Crown part
no. 053002-001) and place it in position. ● Drive the bearing shell of the conical roller bearing
(item 5) into its seat (Figs. M1251, M1252).
● Press on the conical roller bearing (item 23).
● Heat up the bearing race (item 21) to approx.

120°C and secure with LOCTITE 620, Crown part
no. 794102, (Fig. M1249).
M1251
M1249
Housing pre-assembly
● Thoroughly clean the housing (item 9) with a cold

cleaning solution and apply compressed air to it.
● Insert the retaining ring (item 7) for the upper

conical roller bearing (Fig. M1250).
M1252
● Turn the housing and drive the bearing shell of the

conical roller bearing (item 23) into its seat (Fig.
M1253).
● Insert the conical roller bearing (item 5) (Fig.

M1254). Now fit the flange shaft into the housing.
M1250
136
STEERING
ring slightly and fit new shims. Re-tighten the
bearing and check the clearance as described
above.
After setting the bearing clearance dismantle the spur pin-

ion flange shaft again to prepare the housing, and pro-
ceed as follows:
● Gently lubricate the shaft seals (items 8, 20) and

drive them into their seats (Figs. M1255 - M1258).
M1253
M1256
M1254
Adjusting the bearing clearance
Place two shims onto the bearing.
● Apply a medium torque to the groove nut (item 1).
● After tightening, gently tap on the upper section of

the housing with the plastic hammer to position
the bearings.
● Manually check the bearing clearance. The bearing

should be more stiff than free (torque 2 – 5 Nm). If
the bearing is too free, replace the ground shim
(bore hole gauge, item 6). Estimate how many
washers are needed. To repalce, remove the
retaining ring (item 7). Turn out the bearing inner M1255
137
STEERING
M1258
M1257
M1259
M1260
● Generously lubricate the bearing shell of the ● Insert the steering rack (item 36) in the housing.
conical roller bearing (item 23) with Crown part no. Make sure that the groove is positioned centrally
053002-001 (Fig. M1260). in the housing.
● Lubricate the conical roller bearing (item 23) and On the spur pinion flange shaft 2 teeth are marked with a
the spur pinion flange shaft with Crown part no. bevel. The housing must be positioned so that the groove
053002-001 (Fig. M1259). of the steering rack lies between the marked teeth (Fig.
M1261).
138
STEERING
Tooth bevelment Steering rack
M1263
M1261 ● Fill the Nilos ring (item 4) with grease (use surplus
grease from the previous step) and fit it in place.
Groove Flange shaft
● Put the shim (item 3) and the safety plate (item 2)
in position (Fig. M1264).
● Fill the bearing shell of the upper conical roller
bearing (item 5) with grease (Crown part no. ● Tighten the groove nut (item 1) and fix it by
053002-001) so that grease emerges when the rotating a tappet of the safety plate (item 2) (Fig.
bearing is inserted (Figs. M1262, M1263). M1265).
M1262 M1264
139
STEERING
● Insert the slightly greased O rings (item 16) into
the housing groove provided for them. Make sure
they are seated correctly.
● Manually screw in the cylinder (item 17) with

Loctite 242, Crown part no. 053050-006 and using
the wrench tighten it to a medium degree in a
clamping device.
Assembling the Axle Bracket to the Steering

Gear
● Strike the clamping sleeve (item 19) in the upper

prepared area of the axle bracket.
M1265
Cylinder Pre-Assembly
● Insert the pistons (item 13) with the piston guide

rings (item 12) and the compact seal (item 14) into
the cylinder (item 17) without twisting. Make sure
the cylinder contact surfaces are totally clean.
● Now fill each cylinder with gear liquid grease G00F

(to DIN 51502 The level for each cylinder should
M1267
be 125 cm3. ● Place the axle bracket on the transmission hous-
ing.
Inserting the cylinder
● Insert the Tensilock screws (item 26) and using a
● Strike the sleeve (item 15) into the housing. To do torque wrench apply the prescribed torque (320
this, apply a thin film of oil to the steering rack Nm).
(item 35) (Fig. M1266).
● Final check: Use compressed air to move the
cylinder from one side to the other and test the
operation.
To complete the assembly of the steering axle, fit the seal

screw (item 10) with the packing washer underneath (item
11).
M1266
140
STEERING
Operational and Leakage Test
Finally, an operational and leakage test should be per-

formed where possible.
● To do this, turn the steering wheel two or three

times in either direction until it reaches the stop.
● Remove the cylinder again and perform a visual

inspection. Look out for any damage, leaks,
grooves on the cylinder contact surfaces etc.
After re-installing in the truck:
● The steering gear should reach the stop after 5.5

turns of the steering wheel. There may be air in the
system if the stop is not reached after 5.5 turns.
141
STEERING
Steering axle 2.12.01.1
MP-2232-006
142
STEERING
Steering axle 2.12.09.0
36
37
36
37
MS-2232-065
143
SAFETY
Blank page
Printed in Germany
144
MAST
Printed in Germany
145
Blank page
Printed in Germany
146
MAST
Mast (TT Series) Lifting Gear Minimum Capacity

Note the minimum capacity for the lifting gear whenever
DANGER carrying out work on the mast. The required minimum
Risk of trapping and severing limbs! capacity is as follows:
When carrying out work on the mast and Complete mast: 1,200 kg
the attachments: always block the mast Attachments: 100 kg
stages and attachments to prevent them
from accidentally moving.
Mast Testing (Assembled)
Make sure the wooden blocks and lifting
gear used have sufficient capacity. Clean the mast channels and test the tracking paths of
the rollers in the mast channels. There should only be
wear in the rear section of the I beam where the rollers
General slide. There should not be any grooving or cutting in the
I beam caused by the mast rollers. If grooving or cutting
Torques is evident, it will normally take place at the side of the
roller; 10 mm from the channel face. In this case the mast
Mast bearing mounting screws rollers will have to be adjusted. Remove a shim from un-
derneath the affected mast roller.
Torque the 4 mounting screws on the mast bearing blocks
to 550 – 600 Nm. A recheck of the mast channel will be required. De-grease
the running area of the roller in the mast channel and
spray on a thin layer of paint. Extend and retract the mast,
and then check the tracking path of the roller (the paint
will show up the tracking path).
If the contact pattern matches requirements, apply grease
to the contact surfaces (see lubrication table, chapter 1).
When the mast is raised and nearly fully extended, it
should not tilt to the right or left but should be even and
straight. All mast stages should be aligned. If a tilting
condition exists, it is a sign that the shimming is too loose
or unbalanced and will need to be adjusted.
0
550 - 600 Nm All hose guide pulleys should move freely, check hoses
for chafing.
Flaking
It is not uncommon for a new mast to appear as if it is
flaking or peeling. This appearance indicates that the
rollers are seating on the mast channel and this is con-
sidered normal. Eventually, this condition will disappear.
The grease applied to the channel will retain these parti-
cles.
MS-2232-011
Mast Stoppers
Torque the mast stoppers to 122 – 149 Nm.
Apply the standard torque to all the other screws (see
table in Chapter 1).
147
MAST
31
A
34
32 35
42 36
37
40
38
41 35
36 39
43 33 3
68
69
44 9
53 50 45 9 64
52 49
46 70
12 51 48 71
13 47 A
14 18 46
2 62
15 30 30 60
18
9 20 59 61
9 19 21
57
22
17
18 18 63
12
10 13 67
58 A 54
1 4
5 66
18 6 14
7 65 55
56
8 9 21
67
16 22
18
9 9
29 17
18
18
28 9
11
25
26
27 24
24
29
23 MP-2232-028
28
25 26
27
148
MAST
Mast Disassembly Dismantling the Mast (Attached)

DANGER General
All assembly work on the mast is hazard- For the complete mast you required lifting gear with
ous. a minimum capacity of 1,200 kg. For attachments (fork
Unsecured stage masts and attachments carriage etc.) the minimum capacity of the lifting gear
can sever limbs or even cause fatal is 100 kg.
injuries. Always block and secure the ● Remove the load backrest and fully lower the
respective components properly prior to mast.
starting assembly.
Pressurised hydraulic systems can
cause serious injury when the opened. ● Reduce the system hydraulic pressure: To do
this move the sideshift lever and if applicable the
Pressurised hydraulic oil can result in auxiliary function lever a few times backward and
serious injury. forward.
Any fluid which penetrates the skin at ● Place a flat tray underneath the mast area and
high pressure must be considered as a collect any spilled hydraulic oil.
serious medical emergency even if the
skin does not initially show any unusual ● Cover the brakes with a plastic sheet. This will
signs. prevent the brake lining from being contami-
nated with oil.
The pain may take time to set in.
● Immediately seal any open hydraulic ports
Tighten all connections before pressur- with filler plugs.
ing the system again. Keep your hands
and body away from holes as hydraulic ● Item numbers in brackets refer to Figure MP-
oil could emerge at high pressure. 2232-028.
Always use a piece of absorbent paper to

trace leaks, never use your hands.
The mast can be dismantled while attached to the truck,
provided there is sufficient height and the crane used
has the necessary lift height. Alternatively, dismantle the
mast from the chassis, turn it over and dismantle it in a
horizontal position.
DANGER
Note the minimum capacity for the lifting
gear required.
Falling assemblies can sever limbs and
cause fatal injuries.
149
MAST
31
A
34
32 35
42 36
37
40
38
41 35
36 39
43 33 3
68
69
44 9
53 50 45 9 64
52 49
46 70
12 51 48 71
13 47 A
14 18 46
2 62
15 30 30 60
18
9 20 59 61
9 19 21
57
22
17
18 18 63
12
10 13 67
58 A 54
1 4
5 66
18 6 14
7 65 55
56
8 9 21
67
16 22
18
9 9
29 17
18
18
28 9
11
25
26
27 24
24
29
23 MP-2232-028
28
25 26
27
150
MAST
Fork Carriage Removal ● Remove the screw of the lower cylinder attach-
ment (56). Take care not to lose the locking
4
mechanism (55).
● Remove the clamp (57) from the cylinder pipe.
3
● Lift the cylinder out.
5
6
MP-2232-027
● Using a crane raise the fork carriage until the lift

chain becomes slack.
● Remove the upper pulleys and their correspond-
ing hoses from the yoke (64).
● Unscrew the yoke from the free lift cylinder (54).
● Loosen the chain and the hydraulic lines from the
fork carriage.
● Unscrew the hose guide from beneath the free lift
cylinder.
● Now lower the fork carriage to the ground using
the crane.
● Attach a load sling to the cross member of the
third mast stage.
● Raise the third mast stage with the crane until the
fork carriage can be taken out of the mast from
the front.
Free Lift Cylinder Removal

● Undo the hydraulic connection to the free lift
cylinder.
● Attach a load sling directly below the chain
anchor block to the cylinder pipe and the crane
hook in order to secure the cylinder on disassem-
bly (risk of tipping on removal).
151
MAST
31
A
34
32 35
42 36
37
40
38
41 35
36 39
43 33 3
68
69
44 9
53 50 45 9 64
52 49
46 70
12 51 48 71
13 47 A
14 18 46
2 62
15 30 30 60
18
9 20 59 61
9 19 21
57
22
17
18 18 63
12
10 13 67
58 A 54
1 4
5 66
18 6 14
7 65 55
56
8 9 21
67
16 22
18
9 9
29 17
18
18
28 9
11
25
26
27 24
24
29
23 MP-2232-028
28
25 26
27
152
MAST
Removing the individual mast stages Replacing the Mast Rollers on the Mast
To replace the mast rollers you need to remove the mast Stages and the Fork Carriage
stages. First remove the fork carriage and the individual mast
● Attach a load sling to the cross member of the stages as described in the previous section. If it is im-
third mast stage. possible to remove the mast stages with the mast at-
tached (height), completely detach the mast from the truck
● Raise the third mast stages until the lift chains (see Removing the Mast from the Truck) and dismantle
become slack. the mast in a horizontal position.
● Remove the lift cylinder attachments (15, 16, 17) The mast rollers are available in three diameters:
● Disconnect all the hydraulic connections to the standard (part no. 074668-001), with 0.635 mm oversize
third mast stage so that it can be freely lifted out. (part no. 124321-025) and with 1.27 mm oversize (part
no. 124321-050).
● At the top of the second mast stage remove the
lift chain, the pulleys and the hydraulic hoses. A maximum of 6 shims may be placed under a roller.
● Remove the cover (38) and the screws (42) from Mast Stage Rollers
the top of the left-hand side of the second mast
stage. Replace the cover (38) back on the pulley 1. First determine the roller diameter required
assembly. for each mast stage. Use the roller with the
diameter which just runs over the entire running
● Now remove the screw (33) and take off the area in the mast channel without jamming.
pulley assembly with the hydraulic hoses.
2. Push the appropriate rollers onto the mast stage
● Remove the pulley (50) and the lift chain from the bolts until they come to rest on the shoulder.
top right hand side of the second mast stage.
3. Lift the second mast stage into the first stage.
● Remove the lift chains and the hoses from the
bottom of the third mast stage. 4. Lower the second mast stage into the first stage
to leave an overlap of 455mm.
● Check again if there are any connections which
could be damaged when the third mast stage is 5. Using a crowbar press against the upper mast
lifted out. rollers of the second mast stage until it rests
against the opposite roller in the mast channel.
● Using the crane pull the third mast stage out from
the top. Place the third mast stage on the ground. 6. Keep holding the crowbar under pressure and
using a feeler gauge measure the distance
● Attach a load sling to the cross member of the between the edge of the roller and the mast
second mast stage. channel.
● Slightly raise the second mast stage. Remove the 7. Divide the reading by 2. The figure now obtained
screw (30) in order to loosen the lift cylinder is the play that needs to be compensated for on
piston rod. each side of the mast by placing shims
● Raise the second mast stage until the stop block underneath a roller. Divide the measurement
at the top of the first mast stage can be accessed previously obtained by 0.76 to give you the
via the lower hole in the second mast stage. number of shims needed to place under the mast
rollers (the shims are 0.76mm thick). After
● Remove the stop block (4 to 8, 66). inserting the shims the maximum residual play
● Check again if there are connections which could can be 0.76 mm.
be damaged when the second mast stage is 8. Repeat stages 5 to 7 on the lower mast roller.
lifted out.
9. Lift the second mast stage out again and place
● Using the crane pull the second mast stage out the number of shims calculated in stages 7 and 8
from the top. Place the second mast stage on the underneath the mast rollers. It is important to use
ground. the same number of shims on either side.
153
MAST
31
A
34
32 35
42 36
37
40
38
41 35
36 39
43 33 3
68
69
44 9
53 50 45 9 64
52 49
46 70
12 51 48 71
13 47 A
14 18 46
2 62
15 30 30 60
18
9 20 59 61
9 19 21
57
22
17
18 18 63
12
10 13 67
58 A 54
1 4
5 66
18 6 14
7 65 55
56
8 9 21
67
16 22
18
9 9
29 17
18
18
28 9
11
25
26
27 24
24
29
23 MP-2232-028
28
25 26
27
154
MAST
10. Lift the second mast stage into the first stage. Finally, generously lubricate all the running tracks (see
Lubricant table in Chapter 1).
11. Now move the second mast stage carefully over
the entire running area in the first stage. The
rollers should not jam. Lift Cylinder Removal
12. Repeat stages 1 to 9 with the third mast stage in The lift cylinder should only be removed if it needs to be
the second mast stage. repaired.
Finally, generously lubricate all the running tracks (see ● Prepare the working area to collect any spilled
Lubricant table in Chapter 1). hydraulic oil (see General section).
● Detach the hydraulic line from the lift cylinder and
Fork Carriage Mast Rollers the distributor block.
1. First determine the roller diameter required. ● Remove all the clamps (15, 16, 17, 18).
Use the roller with the diameter which just runs
over the entire running area in the mast channel ● Attach a load sling directly below the upper
without jamming. attachment block on the cylinder pipe and the
crane hook in order to secure the cylinder on
2. Push the appropriate rollers onto the fork car- disassembly (risk of tipping on removal).
riage bolts until they come to rest on the shoul-
der. ● Remove the split pin (14) and the bolt (12) and
washer (13).
3. Using the crane lift the third mast stage until the
fork carriage can be pushed underneath it. ● Remove the retaining ring (23) from the bottom of
the cylinder.
4. Lower the third mast stage over the fork carriage.
● Check again if there are any connections which
5. Suspend the fork carriage on the crane and pull it could be damaged when the cylinder is lifted out.
up to its maximum lift height in the third mast
stage. ● Lift the cylinder out.
6. Now use a crowbar to press against one of the For cylinder repair work, see Chapter M8.
upper mast rollers of the fork carriage until the
opposite roller in the mast channel makes contact
with it.
7. Keep holding the crowbar under pressure and
using a feeler gauge measure the distance
between the edge of the roller and the mast
channel.
8. Divide the reading by 2. The figure now obtained
is the play that needs to be compensated for on
each side of the fork carriage by placing shims
underneath a roller. Divide the measurement
previously obtained by 0.76 to give you the
number of shims needed to place under the mast
rollers (the shims are 0.76mm thick). After insert-
ing the shims the maximum residual play can be
0.76 mm.
9. Repeat stages 5 to 7 on one of the lower mast
rollers of the fork carriage.
10. Remove the fork carriage from the mast and
place the required number of shims under the
mast rollers. It is important to use the same
number of shims on either side.
11. Re-fit the fork carriage (items 3 to 4)
12. Now move the fork carriage carefully over the
entire running area in the third mast stage. The
rollers should not jam.
155
MAST
Removing the Mast from the Truck ● Place a load sling around the cross member of
the first mast stage. Note the minimum capacity
of the crane and the sling (see Mast Weight table
in this chapter). Lift with the crane so that the
sling is slightly tensioned. This will secure the
mast when it is unscrewed.
● Undo the connections of both tilt cylinders to the
mast (Fig. MS-2232-012). Unscrew the safety
plate (1) of the bolts and drive bolt (2) out.
550 - 600 Nm
MS-2232-012
● Unscrew the left and right mast bearings (Fig.

MS-2232-011).
MS-2232-011
● With the crane, extend the mast far enough out at
● Remove the load backrest and fully lower the the front.
mast. ● When you pull off the mast bearings, it is essen-
● Disconnect the battery. tial to mark the side of the mast on which the
bearing was fitted. Keep the removed bearing
● Reduce the system hydraulic pressure: To do and the corresponding shims together. Otherwise
this move the sideshift lever and if applicable the the mast will not be centred on re-assembly.
auxiliary function lever a few times backward and
forward. ● Place the mast with its back (the side normally
facing the driver) on the ground.
● Place a flat tray underneath the mast area and
collect any spilled hydraulic oil. If the mast has to be further dismantled, refer to Disman-
tling the Mast (Attached).
● Cover the brakes with a plastic sheet. This will
prevent the brake lining from being contami- CAUTION
nated with oil.
Risk of injury from falling components.
● Immediately seal any open hydraulic ports Using the crane, hold the cylinder and
with filler plugs. the mast assemblies at their centre of
● Item numbers in brackets refer to Figure MP- gravity and prevent the load slings from
2232-028. sliding off.
● Disconnect all electrical connections between

the mast and the truck chassis and secure the
cable ends in the mast area with an adhesive
tape.
● Disconnect the hydraulic lines between the mast
and the truck chassis.
156
MAST
The procedure is practically identical to removing the mast
components with the mast assembled. Only the crane
movements are horizontal. You will therefore need a por-
tal or gantry crane.
Mast Assembly
Assemble the mast in the reverse order of the procedure
in Mast Removal.
Refit the mast bearings (Fig. MS-2232-011) and the
corresponding number of shims on their original side.
Torque the mast bearing mounting screws to 550 -
600 Nm.
Apply liquid sealant part no. 060015-016 to the mast
stopper (66) screws and torque to 122 - 149 Nm.
Apply liquid sealant part no. 060017-014 to the lift
cylinder mounting studs prior to assembly.
Apply a thin layer of grease to the tilt cylinder bear-
ing studs (2, Fig. MS-2232-012). For grease type see
Lubricant table in Chapter 1.
157
MAST
Lift Chains Inspection

The chain must be inspected every 100 hours for any
General signs of faults or damage. If used in a corrosive or dusty
environment, this interval must be reduced to 50 hours.
Lift chains are a major component of a fork lift truck. The
If this cannot be performed on the truck, the lift chains
chain system on this mast is designed to transmit the lift
must be removed.
force from the hydraulic cylinder to the fork reliably and
efficiently. Safe, uninterrupted truck operation depends Irrespective of the result of the inspection, the lift
on careful servicing and maintenance of the lift chains. chains, detachable chain anchors and anchor bolts
must be replaced after max. 6000 service hours or
Most complaints about the chain performance are due to
three years, whichever comes first.
lack of maintenance. Highly stressed precision chains
require regular maintenance to ensure a long useful life. The inspection should include the following:
● Chain wear and elongation.
● Pitting due to rust or corrosion, in particular on
the outer surfaces of the connection plates.
● Pins turning in or extruding from the outside
plates.
● Loss of freedom of movement.
● Damage to the anchor bolt attachment
● Wear and corrosion to the anchor bolt and
anchor.
● Wear between the bolts and the connection
plates.
The following sections cover the above items in detail.
Cleaning
WARNING
Never use chemical solvents or steam to
clean the chains.
The lubricant applied at the factory will
be removed from the inner plate sur-
faces.
The chain surface should be cleaned with paraffin, a hard
bristle brush and lint-free cloth.
After inspection apply another film of chain spray. The oil
acts both as a lubricant and as an anti-corrosive protec-
tion.
Wear
The chain bends as it passes over the chain rollers. This
leads to a gradual wearing of the joints.
Any slack a chain undergoes during its lifetime is due to
wear to the links and the chain plate eyelet.

Rev. 01/03
158
MAST
DANGER Freedom of Movement of Chain Links
When checking for chain wear be sure to Each individual chain link must flex freely. Tight joints (Fig.
measure a part of the chain which 2775si) increase friction and the chain tension during lift-
passes over the guide pulleys. Never ing. Excessive chain tension in turn accelerates material
repair chains by cutting out the worn wear.
section and replacing it with a new
section. If a chain is worn, always replace
both lift chains.
Chain wear can be measured with a wear gauge (Crown
No. 106440) or a steel tape measure (see Fig. 2271).
Before testing the chain slack it is important to tension 2775si
the lift chain if necessary. For non-detachable lift chains
the weight of the fork carriage or mast is sufficient. If the Possible causes of stiff joints are as follows:
lift chain is detached it must be kept taut during meas- ● Bent pins or plates
urement.
● Rusty joints.
The chain slack test must cover at least ten links, over at
least three different points in a section of the chain which ● Peened plate edges.
always passes over a pulley during operation. Plate edge distortion is caused by:
● Ruptured chain pinion.
● Constant overloading of the chain.
● Chain striking the mast components.
Immediately replace any chains with stiff joints.
Chain Tension
When installed, both lift chains should have the same
chain tension to ensure even distribution of the load over
the two chains when lifting.
Centre Chain Dimensions (Dimension C in Fig. 2271).
When replacing the forks make sure that both forks lie
New: 10 links = 254 mm evenly on the surface. If they are not even, compensate
Wear limit: 10 links = 262 mm the chain length via the chain anchor so that both chains
have the same chain tension.
Outer Chain Dimensions
After adjusting, tighten the counternuts of the chain an-
New: 10 links = 190.5 mm chor again (for correct torques see Chapter 1, Torque
Wear limit: 10 links = 196 mm table).
DANGER
If just one of the faults mentioned in this
chapter is detected, both chains together
with their chain anchors or bolts must be
immediately replaced.
Never repair damaged chains!
This can result in fatal accidents!
159
MAST
Chain Anchor and Pulleys Protruding or Turned Chain Pins
DANGER
Never attempt to repair the chain by
driving pins back into the chain. This can
result in accidents with severe or even
2774si
fatal injuries if the chain tears. Fit new
chains.
In the course of checking the chain system, the chain
anchors, chain bolts and pulleys must be checked for
wear.
On the chain anchor watch out for wear and cracking of
the individual fingers. If one of the above problems oc-
curs replace the chain anchor.
Detachable chain anchors and anchor bolts must be
replaced after max. 6000 service hours or three years,
whichever comes first.
Pulleys with heavily worn flanges and contact surfaces
must be replaced. Worn flanges are due to misalignment.
The chain tension and mast roller setting must be 2776si
checked.
Considerable frictional forces between the connection
Worn Connection Plates plates and the pins occur when lifting heavy loads with
an insufficient or non-existent film of oil. In extreme cases
Generally speaking, material wear is the cause of worn the frictional torque in the joints can be such that the
or missing connection plates. The plates near the chain pins turn and gradually work out of the chain (Fig. 2776si).
pin hole (Fig. 2774si) can crack after a large number of This can result in chain failure.
lifting cycles with heavy loads.
Turned pins can be rapidly identified if the flat ends are
Replace both chains immediately if cracking shows or not all pointing in the same direction.
plates are missing.
Chains with twisted or protruding pins must be replaced
immediately.
Corrosion
2773si
The chains used on fork lift trucks are highly stressed

precision components. It is particularly important to main-
tain the original fatigue strength throughout its useful life.
Corrosion considerably reduces the capacity of a lift
chain. It results in cracking in the side plates.
Lift chains must therefore be protected from corrosion.
The layer of grease applied in the factory hot dip galva-
nizing process is an excellent protection and fully pen-
etrates the joints.
160
MAST
Do not remove this layer! After commissioning the chain
supplement the factory lubrication through a regular lu-
brication schedule.
Rust film on lift chains can be removed and neutralised
by cleaning with chain oil. Always replace heavily cor-
roded and rusting chains. The risk of cracking as a
result of rust is too great.
Chain Lateral Wear

Wear traces along a stretch of the chain on the pin heads
and the outer plates indicate misalignment. This can have
one of two causes: uneven chain tension or misalign-
ment between the pulleys and the chain anchors.
Uneven Chain Tension

When fitting or adjusting the chains make sure that they
are evenly charged. If for example the fork heel height or
the platform height are changed, the chain anchors must
be loosened until both forks touch the ground. Both chains
must have equal amounts of air or tension at this point.
The lower chain anchor nuts must be tightened by the
same number of turns. When the required height has been
reached, fix the setting with the top (chain side) lock nut
and its respective lock washer.
Misalignment of Lift Components

Misalignment of the chain pinion and the chain due to
the wrong number of washers on the mast or a damaged
mast or cylinder components can also contribute to wear-
ing of the chain sides.
To test whether this is the case, proceed as follows: Place
the truck on a horizontal surface in the service station.
Support the fork carriage and detach both ends of the lift
chain from the chain anchor and visually inspect the align-
ment with the anchor slots.
161
MAST
Lift Chain Lubrication bolt (see Fig. 277si) and allow the oil to penetrate to the
bearing surface on the chain bolt, even when the chain
Lubrication is the most important factor in lift chain main- is dirty.
tenance. It considerably affects the chain’s useful life.
In normal operating conditions the chains should be
Highly stressed chains under constant use cannot last cleaned and immediately lubricated every 100 service
sufficiently long if they are not regularly lubricated within hours. In extreme conditions this interval must be reduced
a planned maintenance schedule. accordingly.
As with all contact surfaces, the tensiled steel precision
moving parts require a durable lubricant film between
the contact surfaces to avoid excessive wear.
Maintaining a lubricant film on all the chain surfaces pro-
vides the following benefits:
● Restricts joint wear to a minimum (chain elonga-
tion)
● Avoids corrosion
● Reduces the risk of chain bolts turning
● Restricts the danger of chain joints turning in to a
minimum
● Ensures an even movement of the chains and Oil film
thus reduces noise levels
● Reduces the chain tension due to less friction in
the chain system
Key factors when considering which lubricant to use are

as follows:
● High degree of penetration in the narrowest of
gaps
277si
● Maximum tolerance of pressure and shearing
forces before the lubricant film comes off.
● Suitability to the operating temperature range,
especially important for cold store trucks.
You will find details of Crown approved chain oils in
the Lubricant table in Chapter 1 of this manual.
Lubrication intervals depend on the operating conditions
and the environment. Trucks parked outdoors, in cold
stores or which are subjected to extreme weather condi-
tions must be lubricated more frequently.
Dust will gather on oiled chains in dusty environments.
However, even in these conditions, regular lubrication can
considerably reduce wear.
A paste mixture of oil and dirt will gather on the chain
joints, but they will not wear as fast as they would if they
were left to dry, leaving a metal to metal contact between
the pins and plates.
Note: A lift chain must never be allowed to dry.
In dusty operating conditions the multi-plate chains can
be more efficiently lubricated than roller chains.
Multi-plate chains consist of several plates. Therefore they
provide several paths for the lubricant to reach the chain
162
MAST
Detaching Lift Chains

Lift chains are supplied by the meter and must be cut to
the required length.
Tools and Equipment Required

● A secure working plate with a hole slightly larger
than the head diameter of a chain bolt. The hole
must be deeper than the chain bolt length.
● A bearing ring (washer) with a hole slightly larger
than the head diameter of a chain bolt. The
bearing ring thickness must be slightly larger than
the height of the head of a chain bolt.
● A grinder.
● A hole with a diameter slightly shorter than the
chain bolt and a hammer. Or a press with a
suitable mandrel.
Detachment
WARNING
Wear protective glasses.
● Carefully grind the head of the chain bolt. The

inner plate surface must not be damaged.
● Place the bearing ring onto the hole in the work-
ing plate. The bearing ring prevents the inner
plate surface from being damaged when you
drive out the chain bolt.
● Place the head of the chain bolt to be driven out
into the bearing ring.
● Make sure the chain bolt, the bearing ring and the
hole are aligned in the working plate and drive the
chain bolt out.
Grinder
Connecting plate
Bearing ring Hole in working plate
163
MAST
Fork Tines Repairs
General DANGER
Never carry out repair welding to surface
The fork tines (Fig. M0344) must be checked by trained
cracks, damaged or worn parts around
personnel at the specified maintenance intervals (see
the heel of the fork.
chapter 1) for cracks, damage and wear.
Fork repairs must only be carried out by the manufac-
If the forks are used to transport abrasive loads the in-
turer / qualified personnel. When repairing supporting
spection must be carried out at shorter intervals.
members always carry out a load test and check for signs
of cracking.
Terms
Checking the Fork
Fork blade
DANGER
Forks showing signs of cracking, distor-
Fork hanger
tion or wear beyond the stated tolerance
levels must be de-commissioned. They
Fork shank endanger the life of the operator and
other people.
Crack Inspection
Inspect all fork tine surfaces for signs of cracks.
Fatigue cracking tends to occur around the heel of the
M0344 forks. Check this area with particular care. If necessary
Fork heel carry out a non-rupturing crack test (paint penetration
process or Magnaflux).
Fork Identification
The data plate is on the side of the fork back (Fig. 0345)
and comprises the following data: Welding seams
● Capacity
● Load centre of gravity
● Manufacturing Data (Month / Year) Cracks
M0346 M0347
● Company logo
For upper and lower fork hangers (Fig. M0347) including
● Manufacturing site
their fork back attachments check for cracks on the weld-
ing seam. If any cracking is discovered which could af-
fect safety remove the relevant fork.
Fork identification
M0345
164
MAST
Verticality Test Measuring the Fork Tip Width
Check verticality of fork tip (Fig. M0350). If the tolerance
level has been exceeded, de-commission the fork.
Fork stop
Ruler
2 mm
M0355
250 mm If the fork tip width S is less than a + 6 mm (a = fork back

M0350 width) do not use the fork (Fig. 0355).
Fork Tine Height Difference

Check the height of the fork tines in relation to each other
(Fig. M0354) if the fork is fixed to the fork carriage. If the
difference is greater than 3 % of the fork blade length the
fork tines must be correctly aligned.
Example: If the length of the fork blade is 1150mm the
maximum permissible deviation is approx. 35mm.
500 mm L
Ruler
3%
from L
max. 6 mm
1st fork
Fork Blade Warping

Measure the angle deflection between the top of the fork
blade and the front of the fork shank (Fig. M0353). If di- 2nd fork M0354
mension x is outside the tolerance range, the fork must
be aligned by a specialist and re-checked. However, this would prevent the fork from working. In
practice, forks must be aligned if the deviation is max. 10
mm.
500 mm
x - 17 mm
x + 8.5 mm
M0353
165
MAST
Stop Mechanism Fork Blade Wear
Check the stop mechanism (Fig. M0356) on both fork Check the fork blade for wear, the heel is particularly sub-
tines. The mechanism should lock securely, otherwise ject to wear. If the width is 90 % or less than the original
the fork must be de-commissioned. value, the fork must be taken out of service. For the in-
spection, use the calliper with part no. 107330 (see Fig.
0357).
Stop
mechanism 100%
90%
M0357
This calliper has 2 opposite tappets. The outer tappet is

M0356
used to determine the original fork blade thickness at a
section with no wear. This is the fork shank. This deter-
mines the 100% value. The inner tappets correspond to
90% of the value previously obtained.
● Scan the thickness of the fork shank using the outer
tappets (Point a = 100% in Fig. MS-2232-013).
Fix the calliper.
● Now use the inner tappets (90%) to scan the fork
blade between the shank and the start of the
curved area. If the calliper fits at any point over
the fork blade, then the fork is worn. Take the fork
out of service.
a = 100%
Scanning area
90% wear limit

MS-2232-013
166
MAST
Sideshifter DANGER
Falling components are hazardous!
DANGER
Note the minimum capacity for the lifting
All assembly work on the mast is hazard- gear required.
ous.
To assemble the sideshifter you require
Unsecured stage masts and attachments lifting gear with a minimum capacity of
can sever limbs or even cause fatal inju- 500 kg.
ries. Always block and secure the respec-
tive components properly prior to starting ● Disconnect the battery.
assembly. ● Prevent the truck from being switched on again.
Pressurised hydraulic systems can cause ● Reduce the system hydraulic pressure: To do
serious injury when the system is opened. this move the sideshift lever and if applicable the
Pressurised hydraulic oil can result in auxiliary function lever a few times backward and
serious injury. forward.
Any fluid which penetrates the skin at ● Place a flat tray underneath the mast area and
high pressure must be considered as a collect any spilled hydraulic oil.
serious medical emergency even if the ● Cover the brakes with a plastic sheet. This will
skin does not initially show any unusual prevent the brake lining from being contami-
signs. nated with oil.
Physical effects may take time to set in. ● Immediately seal any open hydraulic ports
Tighten all connections before pressuring with filler plugs.
the system again. Keep your hands and
body away from holes as hydraulic oil
could emerge at high pressure.
Always use a piece of absorbent paper to
trace leaks, never use your hands.
General
The truck can be fitted with 2 different sideshifters. The
standard sideshifter is integrated in the fork carriage. The
fork carriage can also be equipped with a hook-on
sideshifter as an option.
167
MAST
4
2
1 MS-2232-030
168
MAST
Integrated Sideshifter
DANGER
Risk of serious, even fatal injuries!
There is a risk of trapping and severing
limbs if the mast and the fork carriage are
not protected against accidental move-
ment.
Secure the mast stages and the fork
carriage to prevent them from lowering
whenever you work on them (see Mast
section).
For the assembly you will require lifting gear with a mini-
mum capacity of 500 kg.
Removal, Repair and Assembly

● De-pressurise the hydraulic system and prevent
the truck from being switched on again (see
General Section, Page 1 of this chapter).
● Remove the load backrest.
● Remove the forks.
● Remove the screws (1) and replace them with eye
bolts M12 DIN 850.
● Remove the screws (3). Remove the bracket (5).
● Insert a load lifting gear into the eye bolts.
● Slightly raise the fork carriage (2) with the crane.
Pull out the lower edge approx. 50 mm to the front.
Lift off the fork carriage.
● Clean the slide pieces (5) and all bearings.
● Check the slide pieces and replace if worn.
● Lubricate the slide pieces and the bearings before
re-assembling (for greases see lubricant chart in
Chapter 1).
● Re-assemble the fork carriage in the reverse
order.
Refer to chapter 8 for instructions on how to repair
the integrated cylinder.
169
MAST
Glands
MS-2232-031
Wear limit mark
min. 46 mm
Lower attachment hook
Sideshifter
Fork Carriage
Fork direction
Bearing clearance:
Min. 0.8 mm
Max. 1.6 mm
0
165 Nm MS-2232-032
170
MAST
Hook-on Sideshifter After assembly:

● Adjust the lower bearings as indicated at the left
DANGER hand side of figure MS-2232-032. This is the only
way of ensuring functionality!
Risk of serious, even fatal injuries!
● Lubricate the bearings with grease (see Lubricant
There is a risk of trapping and severing
table in Chapter 1).
limbs if the mast and the fork carriage are
not protected against accidental move-
ment.
Secure the mast stages and the fork
carriage to prevent them from lowering
whenever you work on them (see Mast
section).
For the assembly you will require lifting gear with a
minimum capacity of 500 kg.
Removal, Repair and Assembly

● De-pressurise the hydraulic system and prevent
the truck from being switched on again (see
General Section, Page 1 of this chapter).
● Remove the forks.
● Remove the load backrest.
● Mark the position of the hydraulic hoses on the
sideshifter cylinder for re-assembly purposes.
● Only if the hydraulic cylinder is to be re-
paired: Loosen the glands on the hydraulic
cylinder. Otherwise ignore this instruction. Refer
to chapter 8 for instructions on how to repair
the cylinder.
● Detach the lower attachment hooks. If they are
worn, use new hooks on re-assembly.
● Insert a load lifting gear into the eye at the top of
the fork carriage.
● Lift off the fork carriage with the crane.
Before re-assembling the fork carriage in the reverse
order.
● Clean all components.
● Inspect all components for wear and cracks.
● Replace any damaged components.
● The wear limit for the sliding bearings at the top
and bottom is 2.5 mm.
171
MAST
Blank page
172
CYLINDERS
Printed in Germany
173
Blank page
Printed in Germany
174
CYLINDERS
Cylinders applies to the open ports and lines on the truck

when you remove any hydraulic components.
General ● Do not refinish any cylinder surfaces! Replace

any damaged components.
Safety when working on hydraulic systems ● When carrying out repairs always replace all
the seals in the assembly. Never recycle
WARNING seals which have already been used.
Risk of serious injury from pressurized
hydraulic oil.
Pressurized hydraulic oil can penetrate
the skin. This is a serious medical emer-
gency which requires immediate medical
attention.
The skin will not show any obvious initial
damage and the physical effects will not
be manifested immediately. Seek medical
assistance if your skin has been affected
by pressurized hydraulic oil.
For your personal protection:
Depressurise the hydraulic system
before starting assembly work on the
hydraulic system.
After carrying out assembly work care-
fully check to see that all ports are tight-
ened before re-pressurising the system.
Wear protective clothing, safety glasses
and safety gloves when tracing leaks or
bleeding the system.
Use a piece of absorbent paper to trace
leaks, never use your hands.
Follow the hydraulic oil manufacturer’s
safety instructions when handling these
oils.
General Instructions for Repairing Hydraulic

Components
Hydraulic systems are sensitive to dirt.
● Thoroughly clean any hydraulic components you
have removed before dismantling them and
placing them on a workbench.
● Always repair hydraulic components in a clean
working environment.
● Immediately protect cleaned and de-greased
components with a thin coating of hydraulic oil.
Use the same type as is used in the truck.
● Protect all components from re-contaminating
until they are installed again.
● Immediately seal any open hydraulic ports on
repaired assemblies with filler plugs. This also
175
CYLINDERS
Rod Seal Assembly Large Rod Seal Assembly

Tools required:
General
● Tool body (outer diameter must fit the internal
All tools and equipment used for rod seals must be diameter of the gland).
burr-free and not have sharp edges. The tools should
● Three pins (1, 2 and 3). Pin (1) is fixed; pins (2)
be made either of soft metal (aluminium, brass) or a
and (3) are moveable.
suitable plastic.
Assembly:
Do not use hooks to remove seals. The same rule ap-
plies: Burr-free, rounded tips and made of soft metal to ● Apply a thin coating of hydraulic oil to the rod
avoid damaging the seal seat. seal and the seal seat in the gland.
Screwdrivers or similar tools will damage the seal seats ● Place the rod seal over the fixed pin (1).
and the seals. This will result in leaks.
● Bend the rod seal under pin (2) (see Fig. MS-
2232-019).
1
3
2
MS-2232-013
To remove rod seals from the lift cylinder and the free-
lift cylinder, you will require 2 specially produced tools MS-2232-019
(see Figure MS-2232-016).
If the seal has to be pushed over sharp edges, cracks ● Bend the loop created in this way so far up that
or nicks, use appropriate protective mechanisms. pin (3) can be pushed into the loop.
● Now push the tool body into the gland until the
Screwdriver, rod seal is aligned with the seal seat (see Fig.
shaft min . 150 mm long, max. 4mm Ø MS-2232-020).
4mm self-tapping
screw
Insulating 3
tape
Hard-soldered screw, soldering joint sanded.
MS-2232-016 1
2
We will now demonstrate 2 processes – depending on
the seal rod diameter – for ensuring safe assembly.
MS-2232-020
176
CYLINDERS
● Pull back pin (3). A section of the rod seal jumps Small Seal Rod Assembly
into the seal seat (Fig. MS-2232-022).
Tools required:
Groove aligning arbor. The outer diameter must fit the
3 internal diameter of the gland. The arbor should end at
the bottom of the seal seat.
Arbor to drive in the seal.
● Apply a thin coating of hydraulic oil to the rod seal
and the seal seat in the gland.
● Place the gland onto the groove aligning arbor.
● Gently squeeze the rod seal together.
2 ● Place the rod seal at one point of the seal seat.
MS-2232-022
● Now pull back pin (2). The rod seal is now fully
seated in the seal seat.
MS-2232-024
MS-2232-021
● Press the rod seal and the arbor into the seal
● Pull the tool body out of the gland. seat.
177
CYLINDERS
Rod Seal Assembly, Sealing Lip First
The sealing lip is sensitive and must not be damaged.
You therefore require special protective sleeves when
pushing the seal over the thread and holes.
Sealing lip assembly direction: Always to the pres-
sure side!
Protective
sleeve
Seal
Tool
Bearing
ring MS-2232-025
178
CYLINDERS
Tilt Cylinders Removal
INFORMATION
General
Always leave one tilt cylinder installed!
Make sure the components and the working area are
clean. Thoroughly clean the tilt cylinder before disman- If both tilt cylinders have to be repaired
tling it. Hydraulic systems are sensitive to contamination. on a truck, first remove one cylinder,
repair it and then install it again. Then
When carrying out repairs, always replace all the seals
remove the second cylinder for repair
and bearing rings. Apply a thin layer of hydraulic oil to all
and refit it.
the seals and internal metal surfaces prior to assembly.
Use hydraulic oil according to the temperature range of If both tilt cylinders were to be removed
the area of application (see Lubricant table in Chapter 1). at the same time, you would need and
inclinometer and a horizontal surface to
Various tilt angles are possible depending on the truck
re-adjust the mast tilt angle with a
model. The key factors in deciding the tilt angle are the
tolerance of 15 angular minutes.
spacer bushings (9 and 17, Fig. MP-2232-031). When
ordering spare parts refer to the parts table in the spare ● Tilt the mast fully forward (the tilt cylinders must
parts catalog. be fully extended). The mast must remain at
this angle until the tilt cylinder is re-installed.
● Disconnect the battery and depressurise the
hydraulic system (see Chapter 7 Mast).
● Remove the screw (6, Fig. MP-2232-031) and
the safety plate (5, MP-2232-031) from the
clevis of one of the tilt cylinders.
● Remove the screw (6) and pull the retaining pin
(27, MP-2232-031) out of the bearing stud (26,
MP-2232-031).
CAUTION
Possible damage!
Do not drive the bearing studs in or out.
Any knocks will damage the studs and
the bearings and will distort the forks on
the cylinder tube and the clevis.
Push or pull the studs with a suitable
tool.
While doing so, ensure that the tool is
supporting the opposite side of the fork.
● Press out the stud (4, MP-2232-031).
● Press out the stud (26).
● Remove the tilt cylinder from the truck.
● Remove the bearings (24 and 2, MP-2232-031)
from their seats in the frame or the mast.
179
CYLINDERS
Tilt Cylinder Sectional Drawing
Clevis
Counternut
Shims
Spacer Sleeve
O Ring
Deflector Ring
Rod Seal
Retaining Ring
O Ring
Conical Nipple
Bearing Ring
Piston Rod
Spacer Sleeve
Bearing Ring
Rod Seal
Cylinder Tube
MS-2232-014
180
CYLINDERS
3
4
7 2
8 6
5
9
10
17
11
12
13 23
14
18 22
15
16 21
25 26
19
20
27
24
MP-2232-031
181
CYLINDERS
● Clean the bearings and check them for damage Component Inspection
and wear. Replace the bearings if necessary.
● Scratches, grooves and corrosion on the piston
rod will result in leaks. If this has occured replace
Dismantling the piston rod.
CAUTION ● Burrs on the cylinder tube near the hole for the
wire retainer and the connecting threads for the
Possible damage! hydraulic ports will also result in leakage on
The cylinder tube can become damaged assembly. Deburr these areas if necessary and
when you clamp the cylinder in a vice. smooth the edges.
Do not overtighten the vice. ● Now thoroughly clean any refinished components.
Apply weak, dry compressed air to the compo-
● Clamp the cylinder upright in a vice with the nents until they are dry. Immediately protect shiny
piston rod facing up. metal surfaces with a hydraulic oil film (for the oil
● Mark the position of the hydraulic ports (23) and type refer to the lubricant table in Chapter 1).
unscrew the hydraulic ports from the cylinder tube.
Assembly
● Remove the clevis (3).
● Remove the retaining ring (22). CAUTION
● Using a pin wrench (42 mm pin distance, 5 mm Possible damage!
pin diameter) turn the gland until the retaining
Incorrect handling during assembly can
ring (22) is no longer blocking the gland.
result in leaks. Take care not to jam the
● Pull the piston rod (18) and the gland (14) out of piston rod and the gland in the cylinder
the cylinder tube. tube during assembly. Otherwise the
seals in the hole for the retaining ring
● Make sure the spacer bushing (17) is refitted in
(22) could be damaged.
this cylinder, as it determines the mast tilt angle.
Apply a thin coating of hydraulic oil to all seals and com-
CAUTION ponents prior to assembly. Observe the general instruc-
tions on assembling seal rods in this chapter.
Possible damage!
● Pull the conical nipple (20) and the bearing ring
Never use a screwdriver or any other
(19) onto the piston rod (18).
sharp-edged tools to remove seals. This
could result in irreparable damage to the ● Guide the piston rod into the cylinder tube (21),
seal seats. Use a small, burr-free hook. taking care not to damage the seals.
● Remove all seals, bearing rings and the deflector ● Push the spacer bushing (17) previously re-
ring (11, 12, 13, 15, 16, 19, 20) moved from this cylinder up onto the piston rod.
(This bushing determines the mast tilt angle).
● Thoroughly clean all components with a suitable
solvent. In particular, the seats of the seals and ● Insert the guide ring (13), the seal (12) and the
the bearing rings must be absolutely clean and deflector (11) into the gland.
free of foreign bodies. Apply weak, dry com-
● Pull the O ring (15) and the bearing ring (16) up
pressed air to the components until they are dry.
on the outside of the gland.
Immediately protect shiny metal surfaces with a
hydraulic oil film (for the oil type refer to the ● Lubricate the retaining ring (22) with hydraulic oil.
lubricant table in Chapter 1).
● Push the gland over the piston rod. At the same
time insert the retaining ring (22) and its hook
into the hole of the gland. Turn the gland 360
degrees using a pin wrench (42 mm pin distance,
5 mm pin diameter) while at the same time
pressing the gland until it is seated in the cylinder
tube. The retaining ring (22) should “snap” into
the recess in the cylinder tube.
182
CYLINDERS
3
4
7 2
0
8 6
5
9
10
17
11
12
13 23
14 0
18 22
15
16 21
25 26
19
20
27
24
MP-2232-031
183
CYLINDERS
● Insert the O ring (10) into the spacer bushing (9) ● Attach the retaining pin (27) and secure it with
belonging to this cylinder. Lubricate the hole and the screw (6).
the O ring of the spacer bushing with universal
● Now use a fork wrench to turn the piston rod (18)
grease (see lubricant table in Chapter 1). Push
until the holes of the clevis (3) are aligned with
the spacer bushing and the shims (8) over the
the bearing holes (2) on the mast side.
piston rod.
● Place a bearing stud (4) on the mast side of the
● Screw in the counternut onto the piston rod (7)
tilt cylinder.
until it comes to rest.
● Align the bearing stud so that after the bearing
● Screw on the clevis(3).
stud is pressed in, the safety plate (5) will fit into
● Refit the hydraulic ports (23). Align the hydraulic the recess in the bearing stud and the safety
ports in accordance with the positions marked plate can be screwed on.
prior to dismantling them. Torque them to 23 Nm.
● Press in the bearing stud and fix it with the safety
● Attach filler plugs to the hydraulic ports to protect plate and the screw (6).
the cylinder from contamination until it is re-
● Counter-fix the nut (7) with a 330 Nm torque.
connected in the truck.
● Refit the hydraulic lines and the battery.
Assembly ● Bleed the tilt cylinder by tilting several times in
both directions.
CAUTION
● While doing so, check that the cylinder and the
Possible damage! ports are sealed (note warnings in Chapter 2,
Do not drive the bearing studs in or out. Hydraulics).
Any knocks will damage the studs and ● Tilt the mast back fully.
the bearings and will distort the fork on
the cylinder tube and the clevis. ● With the cylinder still installed, check whether
the spacer sleeve (4) is contacting the gland. It
Push the studs using a suitable tool. should not be possible to turn it manually.
While doing so, ensure that the tool is
supporting the opposite side of the fork. ● On the previously re-installed cylinder, now check
whether the spacer sleeve (4) is contacting the
● Insert 2 bearings into each receptacle in the gland. It should not be possible to turn it manu-
chassis and the mast. The outer surfaces of the ally.
bearings should lie approx. 1 mm below the
receptacle surfaces. If the spacer sleeve can still be manually turned:
● Ensure that the M8 threaded holes for the retain- ● Calculate the clearance with a feeler gauge.
ing components on the tilt cylinder are facing the ● Fully tilt the mast forward.
outside of the truck and insert the tilt cylinder.
● Loosen the counternut (7).
● Place a bearing stud (26) on the chassis side of
the tilt cylinder, the M16 threaded hole in the ● Using a fork wrench turn the piston rod to com-
bearing stud should face the outside of the truck. pensate for the previously calculated clearance.
● Align the cross hole for the retaining pin so that

● Counter-fix the nut (7) with a 330 Nm torque.
the eye of the retaining pin will lie over the M8 ● Now check again whether the spacer sleeve (4)
threaded hole when the bearing stud is pressed is still contacting the gland and can be manually
in. turned.
● Press in the bearing stud (26). ● When you have adjusted the setting, check the
clearance on the cylinder which has not yet been
removed.
184
CYLINDERS
● The spacer sleeves on both cylinders should
make contact and it should not be possible to
turn them manually.
● Activate tilting a few times. Now check the cylin-
der for leaks.
185
CYLINDERS
15 13
12
1
14 11
10
12
13
13
1 12
14 11
11
14 10
10 15 15
7
1
5
4
6
7/8
2 9
9 3 4
6
5
6
2
4
3
6
5
6
MP-2232-024
186
CYLINDERS
Lift Cylinders ● Now turn 2 of the prepared seal extractors – at
180 degrees to each other – into the rod seal.
(See General section, Fig. MS-2232-016).
General Make sure you don’t damage the piston rod.
Make sure the components and the working area are ● Pull out the rod seal (11) evenly using the two
clean. Thoroughly clean the cylinder before dismantling tools.
it. Hydraulic systems are sensitive to contamination.
● Remove the bearing ring (10).
Use hydraulic oil according to the application tempera-
ture range (see Lubricant table in Chapter 1).
Removal and Assembly

Inspect the piston rod for damage over the full lift
height before removing it. Damaged piston rods dam-
age the seals very rapidly. Replace the damaged piston
rod whenever you fit new seals.
● Refer to the Mast chapter for the removal and
assembly of the lift cylinders.
Dismantling ● Thoroughly clean all components with a suit-

able light solvent. In particular, the seats of the
CAUTION seals and the bearing rings must be absolutely
Possible damage! clean and free of foreign bodies. Apply weak,
dry compressed air to the components until
The cylinder tube can become damaged they are dry. Immediately protect shiny metal
when you clamp the cylinder. Do not surfaces with a thin film of hydraulic oil (for the
overtighten the devices for holding the oil type refer to the lubricant table in Chapter 1).
cylinder.
Rod Seal Removal

● Clamp the removed cylinder to prevent it from
twisting.
● Unscrew the gland (12) from the cylinder tube.
● Remove the deflector ring (13).
12
7/8
MS-2232-015
187
CYLINDERS
15 13
12
1
14 11
10
12
13
13
1 12
14 11
11
14 10
10 15 15
7
1
5
4
6
7/8
2 9
9 3 4
6
5
6
2
4
3
6
5
6
MP-2232-024
188
CYLINDERS
Piston Rod Removal Installing the Rod seal
● If the piston rod has to be replaced, you should ● Insert a new guide ring (10) into the cylinder
now pull the piston rod out of the cylinder tube. tube (8).
Otherwise the piston rod could remain in the
● Push a suitable guide bushing into the cylinder
cylinder tube.
tube to cover the thread. Otherwise you will
● Remove the inner retaining ring (4). Remove the damage the sealing lip of the rod seal on
piston (3) and the spring (2) from the piston rod. assembly. Apply a thin layer of oil to the guide
bushing.
Assembly ● Push a new rod seal over the piston rod with
the sealing lips in front.
CAUTION
● Using a suitable mandrel (without sharp edges!)
Possible damage! drive the rod seal further until it makes uniform
Incorrect handling during assembly can contact with the guide bushing.
result in leaks. Take care not to damage
the piston rod and the new seals during
assembly. Use guide bushing and burr-
free tools without sharp edges.
Apply a thin coating of hydraulic oil to all seals and com-
ponents prior to assembly. Observe the general instruc-
Seal seat
Piston Rod Assembly

● Insert a retaining ring (6) into the upper groove of
the piston rod.
MS-2232-018
● Push a new, oiled bush (5) onto the piston rod.
● Fix the bush with the retaining ring (6). ● Insert a new deflector ring (13) into the gland
(12).
● Push the spring (2) and the piston (3) into the
piston rod. ● Screw the gland back in and tighten it.
● Fix the spring and the piston with the inner ● Refit the lift cylinder (see Mast chapter).
retaining ring (4).
● Bleed the cylinder (see Hydraulics chapter).
● Perform a drift test (see Hydraulics chapter).
189
CYLINDERS
10
14
13 14
13
12
4 11
12
3
3 4
11
1 10
1
6
9 5
8
6
2
7
6
5
MP-2232-025
190
CYLINDERS
Free-Lift Cylinder Piston Rod Removal

● If the piston rod has to be replaced, you should
General now pull the piston rod out of the cylinder tube.
Otherwise the piston rod could remain in the
Make sure the components and the working area are clean. cylinder tube.
Thoroughly clean the cylinder before dismantling it. Hy-
draulic systems are sensitive to contamination. ● Remove the inner retaining ring (5). Remove the
piston (8) and the spring (9) from the piston rod.
Assembly
Use hydraulic oil according to the application tempera-
ture range (see Lubricant table in Chapter 1). CAUTION
Possible damage!
Removal and Assembly Incorrect handling during assembly can
Inspect the piston rod for damage over the full lift result in leaks. Take care not to damage
height before removing it. Damaged piston rods dam- the piston rod and the new seals during
age the seals very rapidly. Replace the damaged piston assembly. Use guide bushing and burr-
rod whenever you fit new seals. free tools without sharp edges.
● Refer to the Mast chapter for the removal and Apply a thin coating of hydraulic oil to all seals and com-
assembly of the free-lift cylinder. ponents prior to assembly. Observe the general instruc-
Dismantling
Piston Rod Assembly
CAUTION ● Insert a retaining ring (6) into the upper groove of
Possible damage! the piston rod.
The cylinder tube can become damaged ● Push a new, oiled bush (7) onto the piston rod.
when you clamp the cylinder. Do not ● Fix the bush with the lower retaining ring (6).
overtighten the devices for holding the
cylinder. ● Push the spring (9) and the piston (8) into the
piston rod.
Rod Seal Removal ● Fix the spring and the piston with the inner
retaining ring (5).
● Clamp the removed cylinder to prevent it from
twisting.
Installing the Rod Seal
● Unscrew the gland (13) from the cylinder tube.
● Insert a new guide ring (11) into the cylinder tube
● Remove the deflector ring (14). (1)
● Now turn 2 of the prepared seal extractors – at ● Push a suitable guide bushing into the cylinder
180 degrees to each other – into the rod seal. tube to cover the thread. Otherwise you will
Make sure you don’t damage the piston rod. damage the sealing lip of the rod seal on assem-
● Using the two tools pull the rod seal (12) evenly bly. Apply a thin layer of oil to the guide bushing.
up off the piston rod. ● Push a new rod seal over the piston rod with the
● Remove the bearing ring (11). sealing lips in front.
● Thoroughly clean all components with a suitable ● Using a suitable mandrel (without sharp edges!)
light solvent. In particular, the seats of the seals drive the rod seal further until it makes uniform
and the bearing rings must be absolutely clean contact with the guide bushing.
and free of foreign bodies. Apply weak, dry ● Insert a new deflector ring (14) into the gland
compressed air to the components until they are (13).
dry. Immediately protect shiny metal surfaces with
a thin film of hydraulic oil (for the oil type refer to ● Screw the gland back in and tighten it.
the lubricant table in Chapter 1). ● Refit the lift cylinder (see Mast chapter).
● Bleed the cylinder (see Hydraulics chapter).
● Perform a drift test (see Hydraulics chapter).
191
CYLINDERS
10
14
13 14
13
12
4 11
12
3
3 4
11
1 10
1
6
9 5
8
6
2
7
6
5
MP-2232-025
192
CYLINDERS
Blank page
193
CYLINDERS
MP-2232-004
Rod seal
Deflector Ring
MS-2232-028
194
CYLINDERS
Hook-on Sideshifter, Cylinder ● Screw off the glands from both ends of the
cylinder.
INFORMATION
The sideshifter must be removed from the
truck in order to repair the cylinder. For
removal instructions see chapter 7.
If there are grooves on the piston rod or if
the piston rod is bent, replace the entire
cylinder unit.
● Remove the pins (9, Fig. MP-2232-004).
● Lift out the cylinder unit.
CAUTION
Possible damage!
The cylinder tube can be damaged when
you clamp the cylinder.
MS-2232-027
Do not clamp the cylinder tube. Clamp
the cylinder unit around the core plate.
● Remove the seals and the deflector from the
● Clamp the cylinder unit in a vice with protective gland using the hook tool (see General section).
jaws.
● Thoroughly clean the piston rod and the seal
● Push the piston rod into the central position. seats of the glands with a solvent.
● Remove any burrs from the piston rod ends.
Core plate
● Lubricate the new rod seal with hydraulic oil and
place it in the gland. Note the assembly posi-
tion (Fig. MS-2232-028): Pressure seals are
Gland installed with the lip facing the pressure side!
● Fit the new O ring and the new deflector ring into
the gland.
● Lubricate the piston rods with hydraulic oil. Push
the glands carefully onto the piston rod.
● Hand-tighten the glands.
The glands should only be fixed once the sideshift
has been fitted in the truck. Torque: 165 Nm.
MS-2232-026
195
CYLINDERS
21
23
27 22
27
14 25 26
15
9
21
8
24
13
12 5
10
11
6
20
4
19
17
16
18
1
2
3
MP-2232-030
196
CYLINDERS
Integrated Sideshifter, Cylinder

INFORMATION
The integrated sideshifter (1) must be
removed from the truck in order to repair
the cylinder. For removal instructions see
chapter 7.
● Make sure that the hydraulic system is de-pressu-
rised (see removal instructions in Chapter 7).
● Undo the hydraulic connections from the fork
carriage.
● Pull the corresponding piston rod (15) from out of
the fork carriage frame.
● Pull the washer (13) out from the side.
● Remove the seal (12), the deflector (14) and the
bushing (11). No tools are required for this.
● Dispose of the seal and the deflector.
● Thoroughly clean all components with a solvent.
● Examine the piston rod and the bushing for
damage. Replace any damaged components.
● Apply a thin coating of hydraulic oil to all the
components.
● Re-assemble the cylinder in the reverse order.
● Refit the sideshifter and carry out the necessary
tests (see Chapter 7).
197
SAFETY
Blank page
Printed in Germany
198
ELECTRICAL DIAGRAMS
Printed in Germany
199
Blank page
Printed in Germany
200
DIAGRAMS
Key
Connectors Contactors
Traction Controller Connectors FA Left Motor Forward Contactor
CA 201 E RA Left Motor Reverse Contactor
CA 202 D FB Right Motor Forward Contactor
CA 203 C RB Right Motor Reverse Contactor
CA 204 B LC Line Contactor
CA 205 A RGB Regenerative Braking Contactor
CA 206 F
CA 207 G
CA 208 H Abbreviations
CA 209 J ACS Accelerator Switch
Pump Controller Connectors AXS Auxiliary Function Switch
CA 210 L BDI Battery Discharge Interrupt
CA 211 E BRS Brake Switch
CA 212 D DIS Direction Switch
CA 213 C EM Encoder Module
CA 214 B ENC Encoder
CA 215 A HBS Handbrake Switch
CA 216 Panel HF Hash Filter
CA 217 Seat Switch HN Horn
CA 218 Steering Feedback Potentiometer HNS Horn Switch
CA 401 Accelerator Potentiometer KYS Key Switch
CA 402 Accelerator Switch POT 1 Accelerator Potentiometer
CA 403 Lift Potentiometer POT 2 Lift Potentiometer
CA 404 Tilt Switch POT 3 Steer Potentiometer
CA 405 Side Shift Switch SES Seat Switch
CA 406 Auxiliary Switch SH Shunt
CA 407 Pedal Brake Switch SSS Side Shift Switch
CA 408 Handbrake Switch TLT Tilt Switch
CA 409 Horn TT Hour Meter
CA 410 BDI Supply

CA 411 BDI
CA 412 Steering Column
CA 601 Horn Switch
CA 602 Steering Encoder Module
NOTE: CA Connectors are a combination of the JC -XXX

jack and the PC -XXX plug components (example CA 601
is a combination of PC 601 and JC 601).
SC3200 03/2004 • Printed in Germany MS-DIA-2232

Rev. 01/99
201
DIAGRAMS
Blank page
Printed in Germany
202
DIAGRAMS
Control Circuit
PCM
DIRC DIRC
RH LH
TCM
796324_2a_1_2
203
DIAGRAMS
Power Circuit
TM LH TM RH
PCM
TCM
796324_2a_2_2
MS-DIA-2232 SC3200 03/2004 • Printed in Germany
204
DIAGRAMS
Option Brush Wear & Over Temperature Indicator Circuit Diagram
B WAY FROM EXISTING

MAIN LOOM
STAR POINT
* STAR POINT
METER
STAR POINT
TM LOW LH
+
STAR POINT TM LOW RH
TM HIGH LH
switched -
PM LOW TM HIGH RH
STAR POINT
TCM
Existing BWI & TEMP LOOM

Main Loom
Option: Brush Wear and Overtemperature
Note:
Temperature/Brush wear switches are normally closed,
opening at the over temperature/brush worn condition. STAR POINT
* HBS: Applied Shown
205
DIAGRAMS
Option Lighting Diagram
Control Starpoint A
CONNECT TO PANEL WIRE S3 after LC
Panel
LOCATED ON LINE CONTACTOR COIL
switched open
Cable Assy
813071
Starpoint B
Cable Assy
switch
supplies from 8 way plug
control panel 793793 module
Cable Assy
12 way plug Rev./Brake Starpoint C
Light module
switch
Rev. Alarm Cable Assy
115565
strobe
TAIL
BRAKE
Cable Assy
813072
BACK UP
worklight
TAIL rear
Cable Assy
BRAKE
BACK UP
PCB Tail
813070_2e_1_1
worklight Front RH worklight Front LH
206
DIAGRAMS
Cold Store Option
POT3
POT1
POT2
HBS
AXS
ACS
BRS
SSS
DIS
TLT
810350_2b_1_1
207
DIAGRAMS
Seat Switch and Steer Pot Steer Column

PC 216 JC 216
PC 412 JC 412
201 PC 412 - 1 1 1 ZAPI A1 FU 3

201 JC 216 - 1 1 1 201 PC 603
202 PC 412 - 2 2 2 ZAPI A2 FU 4
202 JC 216 - 2 2 2
2903 PC 412 - 3 3 3 ZAPI A3 PC 201 - 1
2903 JC 216 - 3 3 3
NOT USED 4 4 A4 only for lighting option 2904 PC 402 - C 4 4
F DIS
NOT USED 5 5
2905 PC 207 - 8 5 5
NOT USED 6 6 R
2906 PC 207 - 7 6 6 HNS
562 PC 409 - 2 7 7 ZAPI A7 (B-)
2907 PC 409 - 1 7 7
509 PC 412 - 9 8 8 ZAPI A8 (B-)
5908 PC 211 - 8 8 8 5908 PC 602 - 2
NOT USED 9 9 A9 only for lighting option
509 JC 216 - 8 9 9 509 PC 602 - 1
2935 STAR A 10 10 ZAPI A 10 PC 212 - 2
2910 PC 411 - 2 10 10
NOT USED 11 11 A11 only for lighting option
NOT USED 11 11
NOT USED 12 12 A12 only for lighting option NOT USED 12 12
2999 PC 603
JC 217 PC 217
PC 603 JC 603
5938 STAR E 1 1
SES 201 JC 412 - 1 A A
5945 STAR C 2 2 KYS
NOT USED B B
2999 JC 412-3 C C
PC 218 JC 218
PC 602 JC 602 EM
719 PC 210 - 4 1 1 1
2
1 1
120 PC 210 - 2 2 POT 3
2 3
(Steering Feedback) 2 2 ENC
4
521 PC 210 - 3 3 3
3 3
NOT USED 4 4
4 4
814590_2a_1-8 814590_2a_2-8
208
DIAGRAMS
BDI, Horn and Brake Switches Control Levers
PC 407 JC 407 PC 401 JC 401
2928 STAR D A A 722 PC 207 - 3 1 1 1
2
2929 PC 207 - 6 BRS 123 PC 207 - 2 POT 1
B B 2 2 3
NOT USED C C 524 PC 207 - 1 3 3

4
(Accellerator)
NOT USED 4 4
PC 408 JC 408
PC 402 JC 402
2926 STAR B A A
2925 STAR B A A
NOT USED B B HBS
NOT USED B B ACS
2950 STAR D C C
2904 PC 412 - 4 C C
PC 403 JC 403
PC 409 JC 409
716 PC 213 - 3 1 1 1
2907 PC 412 - 7 A A R 2
HN 117 PC 213 - 1 POT 2
C 2 2 3
562 JC 216 - 7 B B (Lift)
4
518 PC 213 - 2 3 3
NOT USED 4 4
PC 410 JC 410
PC 404 JC 404
263
244 PC 411 - 8 A A to Battery Connector (B+ BDI)
FU 5
543 PC 411 - 5 B B to Battery Connector (B- BDI) 2915 PC 211 - 5 A A
NOT USED B B TLT
2959 STAR A C C
PC 411 JC 411
PC 405 JC 405
5939 STAR E 1 1
2914 PC 211 - 3 A A
2910 PC 412 - 10 2 2
NOT USED B B SSS
2936 STAR A 3 3
BDI 2960 STAR A C C
2937 PC 211 - 6 4 4
+
543 PC 410 - 2 5 5
TT
NOT USED 6 6 PC 406 JC 406
NOT USED 7 7
+ 48 V 2913 PC 211 - 2 A A
244 PC 410 - 1 8 8
NOT USED AXS
B B
2961 STAR A C C
814590_2a_3-8 814590_2a_4-8
209
DIAGRAMS
Star Points Panel Wiring
STAR POINT A FU 3
ZAPI A 1 PC 216 - 1
2961 PC 406 - C ZAPI A 4 PC 216 - 4 B+ LC
FU 4
2960 PC 405 - C ZAPI A 2 PC 216 - 2
2935 JC 216 - 10
2959 PC 404 - C ZAPI A 5 PC 216 - 5
2936 PC 411 - 3 ZAPI A 3 PC 216 - 3

ZAPI A 6 PC 216 - 6
ZAPI A 7 PC 216 - 7
B- (BUSBAR)
ZAPI A 8 PC 216 - 8
STAR POINT B
ZAPI A 9 PC 216 - 9
2925 PC 402 - A
2927 PC 207 - 5 ZAPI A 10 PC 216 - 10
2926 PC 408 - A
ZAPI A 12 PC 201 - 3 ZAPI A 12 PC 216 - 12
ZAPI R 9 PC 201 - 9 RGB

STAR POINT C ZAPI R 8 PC 201 - 8
ZAPI R 7 PC 201 - 7 FA
5933 PC 210 - 5
ZAPI R 6 PC 201 - 6 RA
5934 PC 210 - 6
ZAPI R 5 PC 201 - 5 FB
5932 PC 210 - 1 5945 JC 217 - 2
ZAPI R 4 PC 201 - 4 RB
5957 PC 210 - 8
ZAPI R 2 PC 201 - 2
5958 PC 210 - 9 ZAPI A 3/L PC 201 - 1
ZAPI S3 PC 208 - 3 LC
STAR POINT D
ZAPI A 11 PC 208 - 2 ZAPI A 11 PC 216 - 11
ZAPI A 10
2928 PC 407 - A ZAPI A 10 PC 212 - 2
2930 PC 206 - 1 ZAPI L
ZAPI L PC 212 - 1
2950 PC 408 - C
814590_2a_6-8
STAR POINT E
5938 JC 217 - 1
5931 PC 210 - 7
5939 PC 411 - 1
814590_2a_5-8
210
DIAGRAMS
Traction Controller Pump Controller
CA 201 CA 206 CA 211
ZAPI R 9 9 9 NOT USED 9 9

1 1 2930 STAR D
ZAPI R 8
F 5908 PC 412 - 8
8 8 2 2 NOT USED 8 8
ZAPI R 7 7 7 NOT USED 7 7

CA 207 PCM
ZAPI R 6 6 6 2937 PC 411 - 4 6 6
1 1
ZAPI R 5 5 5 E TCM
524 PC 401 - 3 2915 PC 404 - A 5 5 E
ZAPI R 4 2 2 123 PC 401 - 2 NOT USED
4 4 4 4
NOT USED 3 3 722 PC 401 - 1 2914 PC 405 - A
3 3 3 3
ZAPI R 2 4 4 NOT USED
2 2 G 2913 PC 406 - A 2 2
5 5 2927 STAR B
ZAPI A 3 / L 1 1 NOT USED 1 1
6 6 2929 PC 407 - D
CA 202 7 7 2906 PC 412 - 6 CA 212
NOT USED 2 8 8 2905 PC 412 - 5 ZAPI A 10 JC 216 - 10 2 2

D D
NOT USED 1 ZAPI L CA 201 - 1 1 1
CA 203 CA 213
CA 208
NOT USED 3 716 PC 403 - 1 3 3
1 1 NOT USED
NOT USED 2 C H 2
518 PC 403 - 3 2 2 C
2 NOT USED
NOT USED 1 117 PC 403 - 2 1 1
3 3 ZAPI S 3
CA 204 CA 209 CA 214
8 1 1 NOT USED 8
J
7 2 2 NOT USED 7
6 6
CA 210
(Handset Connector)
(Handset Connector)
5 5
B 1 1 5932 STAR C B
4 4
2 2 120 PC 218 - 2
3 3
2 3 3 521 PC 218 - 3 2
1 4 4 719 PC 218 - 1 1
L 5 5 5933 STAR C
6 6 5934 STAR C
CA 205 CA 215
7 7 5931 STAR E
2 LED 8 8 5957 STAR C 2 LED
A A
1 9 9 5958 STAR C 1
814590_2a_7-8 814590_2a_8-8
211
DIAGRAMS
Power Cable Diagram
808742-00x
792878-023 792878-019
-007 -003
-015 -011
792878-020
-004
-012
792878-024
-008
-016
KEY:
792878-018 * = Control Panel Copper Link

792878-022
-006 -002 808742-001 = SC3210-1.3
-013 -010
808742-002 = SC3210-1.3H; SC3220-1.3; SC3220-1.6
808742-003 = SC3220-1.3H; SC3220-1.6H; SC3240-1.8
808742-004 = SC3240-1.6H; SC3240-1.8H
792878-021 792878-017
-005 -001 792878-009 to -016 = SC3210
-013 -009 792878-001 to -008 = SC3220
792878-017 to -024 = SC3240
813167_2b_1_1
212
DIAGRAMS
Main Loom, Part 1
CAP
CAP INSERT
INSERT PIN PLUG
Data of terminals and connections see next page! PIN PLUG
PLUG CAP
INSERT
CAP PIN PLUG
INSERT
PIN PLUG
Q
(see next page)
PLUG
LABEL
PLUG CAP
INSERT
PIN PLUG
PLUG
CAP
INSERT
PLUG
CAP
INSERT
PIN PLUG
doc-794929_f_2_3
213
DIAGRAMS
PLUG Main Loom, Part 2
CONTACT
PLUG
INSERT
PIN PLUG PLUG
INSERT
PLUG
INSERT
PIN PLUG
PLUG
INSERT
PIN PLUG
CAP
INSERT
(see previous page)
PLUG PLUG
INSERT INSERT
PIN PLUG PIN PLUG
LEFT TERMINAL RIGHT TERMINAL
LEAD DATA
CONNECTS DATA DATA
doc-794929_f_3_3
LEAD COLOR NO. PART # NO. PART # LEFT TERMINAL RIGHT TERMINAL
LEAD DATA
1 T O 37 2613 RED/WHT 1 062800-001 37 062704-004 CONNECTS DATA DATA
2 T O 39 2914 RED/WHT 2 062800-001 39 062704-004 LEAD COLOR NO. PART # NO. PART #
3 T O 41 2915 RED/WHT 3 062800-001 41 062704-004 26 TO 59 2613 RED 26 062704-003 59 062704-004
4 T O 56 2937 RED/WHT 4 062800-001 56 116858 27 TO 60 2914 RED 27 062704-003 60 062704-004
5 T O 66 5908 GRN/WHT 5 062800-001 66 062704-004 28 TO 61 2915 RED/WHT 28 062704-003 61 062704-004
6 T O 44 117 BRN 6 062800-001 44 062704-004 29 TO 70 2937 GRN 29 062704-003 70 062704-004
7 T O 45 518 GRN 7 062800-001 45 062704-004 30 TO 67 5908 GRN 30 062704-003 67 062704-004
8 T O 43 716 VIO 8 062800-001 43 062704-004 31 TO 86 117 RED/WHT 31 062704-0031 86 062007-107
9 T O 80 5932 GRN/WHT 9 062800-001 80 062007-107 35 TO 77 518 GRN/WHT 35 062704-003 77 TO #77
10 T O 33 120 BRN 10 062800-001 33 062704-004 36 TO 80 716 GRN/WHT 36 062704-003 80 TO #80
11 T O 34 521 GRN 11 062800-001 34 062704-004 38 TO 86 5932 RED/WHT 38 062704-004 86 TO #86
12 T O 32 719 VIO 12 062800-001 32 062704-004 40 TO 86 120 RED/WHT 40 062704-004 86 TO #86
13 T O 80 5933 GRN/WHT 13 062800-001 80 TO #80 42 TO 86 521 RED/WHT 42 062704-004 86 TO #86
15 T O 77 5931 GRN/WHT 15 062800-001 77 062007-107 50 TO 62 5933 RED/WHT 50 062704-004 62 062704-004
18 T O 48 524 GRN 18 062800-001 48 062704-004 53 TO 77 5957 GRN/WHT 53 116858 77 TO #77
19 T O 47 123 BRN 19 062800-001 47 062704-004 54 TO 68 5958 RED/WHT 54 116858 68 062704-004
20 T O 46 722 VIO 20 062800-001 46 062704-004 55 TO 86 524 RED/WHT 55 116858 86 TO #86
21 T O 91 2927 RED/WHT 21 062800-001 91 062007-107 57 TO 72 123 GRN 57 116858 72 062704-003
22 T O 76 2929 RED/WHT 22 062800-001 76 062704-004 58 TO 74 722 RED 58 116858 74 062007-068
23 TO 64 2906 RED/WHT 23 062800-001 64 062704-004 69 TO 65 2927 RED/WHT 69 062704-004 65 062704-004
24 T O 63 2905 RED/WHT 24 062800-001 63 062704-004 71 TO 73 2929 RED 71 062704-003 73 062007-068
25 TO 94 2930 RED/WHT 25 062800-001 94 TO #94 75 TO 94 2906 RED/WHT 75 062704-004 94 062007-107
794929-1_T-GB 794929-2_T-GB
214
DIAGRAMS
Steer Column Loom
BUTTSPLICE
CAP
INSERT
SEALING PLUG
PLUG
INSERT
SEALING PLUG
PLUG
INSERT
SEALING PLUG
810209_e

LEAD DATA
CONNECTS DATA DATA
LEAD COLOR NO. PART # NO. PART #
1 TO 15 201 RED 1 062704-003 15 062704-004
2 TO 21 202 RED 2 062704-003 21 062007-032
3 TO 22 2903 RED/WHT 3 062704-003 22 062007-103
4 TO 12 2904 RED/WHT 4 062704-003 12 062007-078
5 TO 13 2905 RED/WHT 5 062704-003 13 062007-068
6 TO 14 2906 RED/WHT 6 062704-003 14 062007-068
7 TO 20 2907 RED/WHT 7 062704-003 20 062007-032
8 TO 18 5908 GRN/WHT 8 062704-003 18 062704-004
9 TO 17 509 GRN 9 062704-003 17 062704-004
10 TO 22 2910 RED/WHT 10 062704-003 22 TO #22
11 TO 12 2953 RED/WHT 11 062007-068 12 TO #12
16 TO 22 2999 RED/WHT 16 062704-004 22 TO #22
19 TO 22 2951 RED/WHT 19 062704-004 22 TO #22
810209_T-GB
215
DIAGRAMS
Fan Standard

LEAD DATA
CONNECTS DATA DATA
1 TO 2 RED/WHT 1 062007-003 2 062530
3 TO 6 RED/WHT 3 TO 062530 6 062007-112
4 TO 5 GRN 4 062007-003 5 062007-112
794878_T-GB
Fuse Holder
10 A Fuse
doc-794878_b
216
DIAGRAMS
Option: Main Harness, Middle East Fan

LEAD DATA
CONNECTS DATA DATA
1 TO 2 201 RED/WHT 1 062007-003 2 062530
3 TO 6 202 RED/WHT 3 TO 062530 6 062007-063
4 TO 5 2903 GRN 4 062007-003 5 062007-050
132427_T-GB
Fuse Holder
10 A Fuse
doc-132427_a
217
DIAGRAMS
Option Lights, Main Loom Lights
LEAD DATA
CONNECTS DATA DATA
1 TO 11 283 RED 1 062007-063 11 062007-076
2 TO 14 284 RED 2 062007-063 14 062007-050
3 TO 17 5944 GRN/WHT 3 062007-063 17 062007-050
4 TO 16 5943 GRN/WHT 4 062007-063 16 062007-050 Front RT W/L
5 TO 13 550 GRN 5 062007-063 13 062007-050
7 TO 12 5942 GRN/WHT 7 062007-050 12 TO #12
6 TO 12 5940 GRN/WHT 6 062007-076 12 062007-076
8 TO 10 286 RED 8 062007-050 10 062007-050
9 TO 11 285 RED 9 062007-050 11 TO #11
6 TO 15 5941 GRN/WHT 6 TO #6 15 062007-050
813072-t-DE
Front Left W/L
CA817
Tail
CA818 reverse
Back Up
Brake
switched
Rear W/L + BV Rear W/L neg
doc-813072_a
Option Lights
Main Loom Lights
218
DIAGRAMS
Option Lights, Panel to Switch

LEAD DATA
CONNECTS DATA DATA
1 TO 2 RED 1 062007-003 2 062530
3 TO 10 RED 3 TO 062530 10 062007-103
4 TO 6 540 GRN 4 062007-003 6 062007-076
5 TO 10 281 RED 5 062007-050 10 TO #10
6 TO 7 541 GRN 6 TO #6 7 062007-050
8 TO10 280 RED 8 062007-050 10 TO #10
9 TO 10 282 RED 9 062007-050 10 TO #10
813071-T-GB
Panel
-
doc-813071_a
219
DIAGRAMS
Option Lights, Module to Panel

LEAD DATA
DATA DATA
CONNECTS
1 TO 5 2613 RED/WHT 1 062704-004 5 062704-003
2 TO 6 2914 GRN/WHT 2 062704-004 6 062704-003
3 TO 7 2915 GRN/WHT 3 062704-004 7 062704-003
4 TO 8 2937 GRN/WHT 4 062704-004 8 062704-003
794314_T-GB
Connector
Insert
Sealing Plug
doc-794314_c
220
DIAGRAMS
Option Lights, Panel to Main Loom Lights

LEAD DATA
CONNECTS DATA DATA
1 TO 2 5934 GRN/WHT 1 062007-050 2 062704-004
3 TO 4 5933 GRN/WHT 3 062007-050 4 062704-004
793794_T-GB
P
CA 817
CA 818
doc-793794_b
221
DIAGRAMS
Option Lights, Reverse Alarm to Module

LEAD DATA
CONNECTS DATA DATA
1 TO 3 5991 GRN/WHT 1 062007-036 3 062704-004
2 TO 4 292 RED 2 062007-036 4 062704-004
793803_T-GB
-
Reverse Alarm I
doc-793803_b
222
DIAGRAMS
LEAD DATA
LEFT TERMINAL RIGHT TERMINAL Option, Brush Wear and Overtemperature Display Loom
CONNECTS DATA DATA
1 T O 19 2985 RED/WHT 1 062704-004 19 116858
2 T O 53 591 GRN 2 062704-004 53 062007-103
3 T O 50 5989 GRN/WHT 3 062704-004 50 TO #50
4 T O 56 2990 RED/WHT 4 062704-004 56 TO #56
5 T O 11 5939 GRN/WHT 5 129761-001 11 116858
6 T O 43 2910 RED/WHT 6 129761-001 43 062007-103
7 T O 13 2936 RED/WHT 7 129761-001 13 116858 Connector 116851-001
8 T O 14 2998 RED/WHT 8 129761-001 14 116858

9 T O 39 543 GRN 9 129761-001 39 TO #39
10 T O 16 244 RED 10 129761-001 16 116858
Connector
12 T O 43 2989 RED/WHT 12 116858 43 TO #43 insert
15 T O 39 575 GRN 15 116858 39 062007-103 seal
17 TO 31 2984 RED/WHT 17 116858 31 062007-021
18 T O 24 2982 RED/WHT 18 116858 24 062007-021
20 T O 50 5988 GRN/WHT 20 1168584 50 TO #50
21 T O 47 5977 GRN/WHT 21 116858 47 062007-103
22 T O 47 5976 GRN/WHT 22 062800-001 47 TO #47
23 T O 43 2981 RED/WHT 23 062007-021 43 TO #43 Connector
25 T O 39 573 GRN 25 062007-021 39 TO #39
26 T O 30 5987 GRN/WHT 26 062007-021 30 062007-021
28 T O 53 580 GRN 28 062007-021 53 TO #53
29 T O 37 5972 GRN/WHT 29 062007-021 37 062007-021
32 T O 36 2983 RED/WHT 32 062007-021 36 062007-021
33 T O 47 5978 GRN/WHT 33 062007-021 47 TO #47
34 T O 27 5979 GRN/WHT 34 062007-021 27 062007-021
35 T O 56 2992 RED/WHT 35 062007-021 56 TO #56
38 T O 50 5970 GRN/WHT 38 062007-021 50 062007-103
793896_T-DE
39 T O 53 592 GRN 39 TO #39 53 TO #53
43 T O 56 2963 RED/WHT 43 TO #43 56 062007-103
doc-793896_c_2_2
223
DIAGRAMS
Option, 5th Hydraulic Function

LEAD DATA
CONNECTS DATA DATA
1 TO 5 29111 RED/WHT 1 5 062704-004
2 TO 3 29110 RED/WHT 2 3 062007-063
4 TO 6 506 GRN 4 062007-063 6 062704-004
127511_T-GB
Inner
housing
doc-127511_c
224
DIAGRAMS
LEAD DATA
LEFT TERMINAL RIGHT TERMINAL Option, Cold Store Model Additional Loom, Part 1 of 2
CONNECTS DATA DATA
1 TO 24 501 GRN 1 062800-001 24 062007-103
2 TO 20 2901 RED/WHT 2 062800-001 20 062007-103
3 TO 6 5901 GRN/WHT 3 062800-001 6 062007-068
4 TO 24 502 GRN 4 062800-001 24 TO #24
5 TO 20 2902 RED/WHT 5 062800-001 20 TO #20
7 TO 32 508 GRN 7 062800-001 32 TO #32
Connector Connector
8 TO 32 505 GRN 8 062800-001 32 TO #32 insert insert
9 TO 28 2905 RED/WHT 9 062800-001 28 TO #28
10 TO 24 503 GRN 10 062800-001 24 TO #24
11 TO 20 2903 RED/WHT 11 062800-001 20 TO #20
12 TO 36 506 GRN 12 062800-001 36 TO #36
13 TO 28 2906 RED/WHT 13 062800-001 28 TO #28
14 TO 43 510 GRN 14 062800-001 43 TO #43
15 TO 39 2908 RED/WHT 15 062800-001 39 TO #39
16 TO 43 511 GRN 16 062800-001 43 TO #43
17 TO 39 2909 RED/WHT 17 062800-001 39 TO #39
18 TO 43 512 GRN 18 062800-001 43 TO #43
19 TO 39 2910 RED/WHT 19 062800-001 39 TO #39
20 TO 28 2904 RED/WHT 20 062800-001 28 062007-103
24 TO 32 504 GRN 24 062800-001 32 062007-103 Connector
insert
28 TO 39 2907 RED/WHT 28 062800-001 39 062007-103
32 TO 36 507 GRN 32 062800-001 36 062007-103
36 TO 43 509 GRN 36 062800-001 43 062007-103
794588-T-GB
Connector
insert
I
To following page
doc-794588_e_2_3
225
DIAGRAMS
LEAD DATA
LEFT TERMINAL RIGHT TERMINAL Option, Cold Store Model Additional Loom, Part 2 of 2
CONNECTS DATA DATA
1 TO 24 501 GRN 1 062800-001 24 062007-103
2 TO 20 2901 RED/WHT 2 062800-001 20 062007-103
3 TO 6 5901 GRN/WHT 3 062800-001 6 062007-068
4 TO 24 502 GRN 4 062800-001 24 TO #24
5 TO 20 2902 RED/WHT 5 062800-001 20 TO #20
7 TO 32 508 GRN 7 062800-001 32 TO #32
8 TO 32 505 GRN 8 062800-001 32 TO #32
9 TO 28 2905 RED/WHT 9 062800-001 28 TO #28
10 TO 24 503 GRN 10 062800-001 24 TO #24
11 TO 20 2903 RED/WHT 11 062800-001 20 TO #20
12 TO 36 506 GRN 12 062800-001 36 TO #36
13 TO 28 2906 RED/WHT 13 062800-001 28 TO #28
14 TO 43 510 GRN 14 062800-001 43 TO #43
15 TO 39 2908 RED/WHT 15 062800-001 39 TO #39
16 TO 43 511 GRN 16 062800-001 43 TO #43 Housing
17 TO 39 2909 RED/WHT 17 062800-001 39 TO #39 insert
18 TO 43 512 GRN 18 062800-001 43 TO #43

19 TO 39 2910 RED/WHT 19 062800-001 39 TO #39
20 TO 28 2904 RED/WHT 20 062800-001 28 062007-103
24 TO 32 504 GRN 24 062800-001 32 062007-103
28 TO 39 2907 RED/WHT 28 062800-001 39 062007-103
32 TO 36 507 GRN 32 062800-001 36 062007-103
36 TO 43 509 GRN 36 062800-001 43 062007-103
794588-T-GB
/
Connector
insert
Connector
insert
To previous page
Connector
insert
doc-794588_e_3_3
226
DIAGRAMS
Option, Cold Store Model Additional Loom, Heating Control Module

LEAD DATA
CONNECTS DATA DATA
1 TO 6 201 RED 1 062007-116 6 062007-021
2 TO 3 501 GRN 2 062007-071 3 062704-004
4 TO 13 2901 RED/WHT 4 062704-004 13 062007-021
5 TO 15 5901 GRN/WHT 5 062704-004 15 TO #15
7 TO 1 202 RED 7 062007-021 1 TO #1
8 TO 12 203 RED 8 062007-021 12 062007-021
9 TO 14 204 RED 9 062007-021 14 062007-048
1 0 TO 2 514 GRN 10 062007-068 2 TO #2
11 TO 17 5911 GRN/WHT 11 062007-068 17 62007-110
17 TO 15 5912 GRN/WHT 17 TO #17 15 62007-048
16 TO 14 205 RED 16 062007-110 14 TO #14
810263_t-GB
Connector
insert
doc-810263_b
227
DIAGRAMS
Blank page
Printed in Germany
228
HYDRAULIC SCHEMATIC
Printed in Germany
229
Blank page
Printed in Germany
230
HYDRAULICS
Free lift cylinder
Lowering orifices Tilt cylinder
Steering cylinder
Lift cylinder LH Lift cylinderRH
2
L R CBV
setting
pressure
130 bar 115 bar
3 1
Wire break safety
devices
C D
E
Flow controller
(Only available for lift heights
Orbitrol above 5000 mm)
Dynamic steering signal, no
steering signal (LS) without
steering movement
A B
LS
Sideshifter Sideshifter
1A 1B 2A 2B 3A 3B 3A 3B 4A 4B
LS CF
P T Steering RV
70 bar
Opto
Encoder
Main RV
235 bar
Motor
Suction filter Priority valve Lift Tilt Aux. Aux. Aux.

dynamic LS function 1 function 1 function 2
With 2 auxiliary functions
Pump
Return filter
Based on: 808819_2d_1_1
231
HYDRAULICS
Blank page
232

SC3200 Service

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SC3200 Service

Uploaded by

Copyright:

Available Formats

Maintenance Manual

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0) 89 93 00 2 - 0

All rights reserved under international and Pan-American Copyright Agreement.

Chap. MA Rev. 01/99 ............ now Rev. 03/04 1. DANGER box,

SC3200 03/2004 • Printed in Germany MS-REV-2232

ITD – INTRODUCTION PAGE SER-N0. CUT REV.

M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0. CUT REV.

M2 – HYDRAULICS PAGE SER-N0. CUT REV.

SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232

M3 – DRIVE UNIT PAGE SER-N0. CUT REV.

M4 – ELEKTRICS PAGE SER-N0. CUT REV.

MS-IDX-2232 SC3200 03/2004 • Printed in Germany

SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232

MS-IDX-2232 SC3200 03/2004 • Printed in Germany

M5 – BRAKE PAGE SER-N0. CUT REV.

M6 – STEERING PAGE SER-N0. CUT REV.

SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232

M7 – MAST PAGE SER-N0. CUT REV.

MS-IDX-2232 SC3200 03/2004 • Printed in Germany

M8 – CYLINDERS PAGE SER-N0. CUT REV.

SC3200 03/2004 • PRINTED IN GERMANY MS-IDX-2232

DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT REV.

HYD – HYDRAULIC SCHEMATICS PAGE SER-N0. CUT REV.

MS-IDX-2232 SC3200 03/2004 • Printed in Germany

Safety Symbols used in the Manual General Maintenance and Repair

Motorised vehicles can be dangerous if maintenance and

SC3200 03/2004 • Printed in Germany MS-MA-0000

● Stop the truck.

Before Carrying out Work on the Truck

Before Operating the Truck

MS-MA-0000 SC3200 03/2004 • Printed in Germany

General Please refer to the Technical Specifications Sheet for the

Operating Instructions IDX Table of Content

This manual contains no operating instructions. An oper-

Service Training M2 Hydraulics

Ordering Spare Parts M4 Electrical

The maintenance manual does not cover spare parts.

Spare parts can be ordered by quoting:

● The truck serial number

HYD Hydraulic Schematic

SC3200 03/2004 • PRINTED IN GERMANY MS-ITD-2232

MS-ITD-2232 SC3200 03/2004 • Printed in Germany

Lifting the Truck Lifting by another truck

Printed in Germany MS-1.0-2232

Jack Wooden blocks

MS-1.0-2232 Printed in Germany

Printed in Germany MS-1.0-2232

MS-1.0-2232 Printed in Germany

Lubrication and Adjustment

Printed in Germany MS-1.0-2232

MS-1.0-2232 Printed in Germany

Fig. E: Inner dashboard

Printed in Germany MS-1.0-2232

Taking the truck out of service

MS-1.0-2232 Printed in Germany

Lubricant Type Product Description Manufacturer CROWN Part No. Type

Aralube HLP-2 Aral

Low temperature Aralube SKL2 Aral

Low temperature Univis J 13 Esso

Hyp 85W90 Aral

Rubber and vinyl

Special grease MOS2 Lithium Dow Corning 063002-022 M

Universal lubrication oil SEA40 C