service repair manual download

1. SC3200 Series
Order Number: 812548-006
Printed in Germany ●
Status 2, Revision Level A
Maintenance Manual

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

3. I
Printed in Germany
TABLE OF CONTENT

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

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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

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TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0. CUT REV.
Wiring Errors ............................................................... 67
Overheating ................................................................ 67
Protection.................................................................... 67
Key Terms ........................................................................ 67
Shunt or Shunt Resistor (+SH/-SH) ............................ 67
Volt Motor Negative (VMN) ......................................... 67
Functional Description .................................................... 67
Acceleration / Delay Rate ........................................... 67
Travel Switch ............................................................... 67
Travel Switch Signal Response .................................. 67
Fault Log ..................................................................... 67
Fault Identification ....................................................... 67
Sparkless Contactors ................................................. 68
Inversion Braking ........................................................ 68
Creep Mode ................................................................ 68
Slow Travel .................................................................. 68
Steering Controller ...................................................... 68
45° Steering Angle ...................................................... 68
Pedal Braking
(Inversion Braking with Battery Supply Regeneration) 68
Ramp Start.................................................................. 68
Key Switch .................................................................. 68
Self Test ...................................................................... 68
Reverse Travel Alarm ........................................ 68
Seat Switch ................................................................. 69
Current Limit ............................................................... 69
Overvoltage ................................................................ 69
Overheating ................................................................ 69
Low Voltage Reduction ............................................... 69
ZAPIMOS B1S 48/700 Traction Controller Connections 70
ZAPIMOS B1S 48/700 Pin Layout .............................. 71
Programmer Connection "B"....................................... 73
Status LED "A" ............................................................ 73
Status LED Diagnosis ................................................. 73
ZAPIMOS HP 350A Pump Controller ..................................... 74
General ............................................................................ 74
Protective Devices .......................................................... 74
Polarity Protection ....................................................... 74
Wiring Errors ............................................................... 74
Overheating ................................................................ 74
Protection.................................................................... 74
Key Terms ........................................................................ 74
Shunt or Shunt Resistor (+SH/-SH) ............................ 74
Volt Motor Negative (VMN) ......................................... 74
Functional Description .................................................... 75
Acceleration / Delay Rate ........................................... 75
Hydraulic Switches ..................................................... 75
Lift Cutout ................................................................... 75
Lift potentiometer ........................................................ 75
Lift Potentiometer Response ...................................... 75
Fault Log ..................................................................... 75
Fault Identification ....................................................... 75
Steering Support......................................................... 75
Key Switch .................................................................. 75
Self Test ...................................................................... 75
Current Limit ............................................................... 75
Overvoltage ................................................................ 75
Overtemperature......................................................... 75

7. SC3200 03/2004 • Printed in GermanyMS-IDX-2232
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TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0. CUT REV.
Low Voltage Reduction ............................................... 75
ZAPIMOS HP 350A Pump Controller Connections ...... 76
ZAPIMOS HP 350 A Pin Layout ..................................... 77
Pump Controller, LED error code................................... 78
Programmer Connection "B"....................................... 78
Status LED "A" ............................................................ 78
Status LED Diagnosis ................................................. 78
Pump Controller Removal ........................................... 79
Pump Controller Assembly ......................................... 79
Traction Controller Removal ....................................... 79
Traction Controller Assembly ...................................... 80
Programmer ............................................................................. 81
General ............................................................................ 81
Display Window........................................................... 82
Operating Keys ........................................................... 82
Connecting the Programmer .......................................... 83
Operating Menu .............................................................. 83
General ....................................................................... 83
Traction Controller Operating Menu............................... 84
Programmer Start Routine ............................................. 85
Traction Controller Menu Functions ..................................... 86
PROGRAM ...................................................................... 86
TESTER........................................................................... 86
ALARMS .......................................................................... 86
PROGRAM PEDAL ......................................................... 86
CONFIG ........................................................................... 86
PROGRAM Menu ............................................................ 87
TESTER Menu ................................................................ 88
ALARMS Menu................................................................ 89
PROGRAM PEDAL Menu ............................................... 91
CONFIG Menu ................................................................ 92
Pump Controller Operating Menu .................................. 93
Menu Functions Pump Controller ......................................... 94
PROGRAM ...................................................................... 94
TESTER........................................................................... 94
ALARMS .......................................................................... 94
PROGRAM VACC ........................................................... 94
CONFIG ........................................................................... 94
PROGRAM Menu ............................................................ 95
TESTER Menu ................................................................ 99
ALARMS Menu................................................................ 100
PROGRAM VACC Menu ................................................. 102
CONFIG Menu ................................................................ 103
Calibrating the Steering Potentiometer ................................ 104
Preparation...................................................................... 104
Calibration ....................................................................... 104
Calibrating the Lift Potentiometer ......................................... 105
Preparation...................................................................... 105
Calibration ....................................................................... 105
Calibrating the Accelerator Potentiometer ........................... 106
Preparation...................................................................... 106
Calibration ....................................................................... 106
Traction Controller Safety Test .............................................. 108
Pulse Monitor Trip Test (PMT) ........................................ 108
Equipment................................................................... 108
Test ............................................................................. 108
PMT Safety Test Wiring .................................................. 109

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VII
TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0. CUT REV.
Battery...................................................................................... 110
General ............................................................................ 110
Replacing the battery ..................................................... 110
Battery Discharge Indicator (BDI) ......................................... 110
General ............................................................................ 110
Battery Discharge Indicator Setting (BDI) ..................... 111
Calibration ....................................................................... 111
Electric Motors ........................................................................ 112
General Maintenance Instructions ................................. 112
Preparation ................................................................. 112
Important Maintenance Instructions ........................... 112
Traction Motor Maintenance .................................................. 113
Access to Brushes .......................................................... 113
Maintenance.................................................................... 113
Armature ..................................................................... 113
Bearings...................................................................... 113
Pump Motor Maintenance ...................................................... 114
Access to brushes .......................................................... 114
Maintenance.................................................................... 114
Armature ..................................................................... 114
M5 – BRAKE PAGE SER-N0. CUT REV.
Brakes ...................................................................................... 117
General ............................................................................ 117
Brake Lining Wear Limits................................................ 117
Brake Removal ................................................................ 117
Brake Assembly .............................................................. 119
Before Assembling ...................................................... 119
Assembly .................................................................... 119
Foot Brake ....................................................................... 120
Foot Brake Adjustment ............................................... 120
Checking the braking distance ................................... 120
Handbrake Adjustment ............................................... 121
M6 – STEERING PAGE SER-N0. CUT REV.
Steering .................................................................................... 125
Hydraulics........................................................................ 125
Function ...................................................................... 125
Steering Components ..................................................... 126
Steering wheel......................................................................... 127
Disassembly .................................................................... 127
Assembly ......................................................................... 127
Direction Control Switches .................................................... 128
Switch Removal .............................................................. 128
Switch Assembly ............................................................. 128
Steer Sensor Module .............................................................. 130
Disassembly .................................................................... 130
Assembly ......................................................................... 130
Steering Sensor ...................................................................... 130
Disassembly .................................................................... 130
Assembly ......................................................................... 130
Steering Column Adjustment ................................................ 131
Gas Pressure Cylinder Removal.................................... 131
Gas Pressure Cylinder Assembly and Adjustment ..... 131
Steering column ...................................................................... 132
Disassembly .................................................................... 132
Steering Column Removal .......................................... 132

9. SC3200 03/2004 • Printed in GermanyMS-IDX-2232
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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

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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

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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

12. 1
Printed in Germany
SAFETY

13. 3
SC3200 03/2004 • Printed in Germany MS-MA-0000
Rev. 03/04
SAFETY
Rev. 01/03
General Maintenance and Repair
Safety Notes
DANGER
Read the safety notices in the truck
Maintenance and Operator's Manuals.
● Failure to do so could result in severe or fatal
injuries to maintenance personnel and/or other
persons.
Motorised vehicles can be dangerous if maintenance and
service are neglected. For this reason maintenance and
inspections must be carried out at regular short intervals
by trained personnel working to approved company guide-
lines.
DANGER
Follow all national/local safety regula-
tions applicable for maintenance work,
e.g. for work on higher levels.
● Failure to do so could result in severe or fatal
injuries to maintenance personnel and/or other
persons.
Maintenance and Repair
1. Maintenance work must only be carried out in
accordance with the test and maintenance
program contained in the present Maintenance
Manual and any applicable service notices.
2. Only qualified and authorised personnel may
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.
4. To clean, use a non flammable, non combustible
cleaning solution which is groundwater-neutral.
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.
Safety Symbols used in the Manual
To help guide you through the manual and to highlight parti-
cular danger areas, we have used graphic illustrations:
DANGER
This symbol indicates life-threatening
risks
● Failure to comply with this notice may result in
fatal injuries to yourself or other people.
WARNING
This symbol indicates the risk of serious
injury and/or serious material damage.
● Failure to comply with this notice may result in
severe injuries to yourself or other people and/or
serious material damage.
CAUTION
This symbol indicates the risk of minor
injury and/or minor material damage.
● Failure to comply with this notice may result in
minor injuries to yourself or other people and/or
minor material damage.
INFORMATION
Contains additional information with
supplementary notes and hints.
OPTION
These items relate to optional features
not supplied with the standard version.

14. 4
SC3200 03/2004 • Printed in GermanyMS-MA-0000
Rev. 03/04
SAFETY
9. Make sure that capacity and data plates, warnings
and labels are legible at all times.
10. Alterations or modifications by the owner or
operator are not permitted without the express
written authorisation from Crown.
11. Only use original Crown spare parts to ensure
the reliability, safety and suitability of the Crown
truck.
Before Leaving the Truck
● 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.
Warnings and Labels on the Truck
During regular maintenance check that the warnings and
labels on the truck are complete and legible.
● Clean any illegible labels.
● Replace any faulty or missing labels.
The order and meaning of the warnings and labels on
the truck are described in section 10.9 of the parts
manual.

15. 5
Printed in Germany
INTRODUCTION

16. SC3200 03/2004 • PRINTED IN GERMANY MS-ITD-2232
7
INTRODUCTION
General
The present manual is designed for Customer Service
engineers who wish to familiarise themselves with the
maintenance work required for the various truck compo-
nents.
It also contains troubleshooting sections which can be
used to identify and remedy truck faults.
INFORMATION
This book is not an operating manual. It
is designed solely for specialist person-
nel who have been trained and author-
ised to carry out the work described in
the manual.
This manual therefore contains fewer and less detailed
warnings than the Operator’s Manual, as the latter is
aimed at persons who have very little or no prior experi-
ence at all.
Operating Instructions
This manual contains no operating instructions. An oper-
ating instructions manual is supplied with the vehicle.
Additional copies can be ordered as required.
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.
Service Training
CROWN offers the appropriate vehicle related training
for service personnel. Details on this training can be ob-
tained from CROWN on request.
Ordering Spare Parts
The maintenance manual does not cover spare parts.
These are listed in a separate manual.
Spare parts can be ordered by quoting:
● The truck specification number
● The truck model number
● The truck serial number
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.
Please refer to the Technical Specifications Sheet for the
utilisable loads, technical data and dimensions for
thisseries.Brochures can be obtained from your CROWN
dealer or from the following address:
CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
80809 Munich
GERMANY
Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 oder 133
Using the Manual
The manual is divided into sections. The following table
shows how the manual is structured.
ecnanetniaMsnoitceS
noitceS noitpircseD
XDI tnetnoCfoelbaT
AM ytefaS
DTI noitcudortnI
1M tnemtsujdAdnanoitacirbuL
2M sciluardyH
3M tinUevirD
4M lacirtcelE
5M ekarB
6M gnireetS
7M msinahceMgnitfiL/tsaM
8M rednilyC
AID smargaiDlacirtcelE
DYH citamehcSciluardyH
A01M-gb

17. 8
SC3200 03/2004 • Printed in GermanyMS-ITD-2232
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
tsaM
- tsamoN
TT
,egatseerhT
tsamcipocselet
10-DTI
epyT
- dradnatS
C cificepsremotsuC
S ngisedlaicepS
20-DTI
)tsaMTT(thgieHtfiL
mm0734
mm5284
mm5825
mm0475
mm0216
mm5736
mm0196
mm5947
30-DTI
tnemtrapmoCyrettaB
eziS
mm814
mm625
mm436
40-DTI
noisreVerotSdloC
- enoN
F noisreverotsdlochtiW
50-DTI
seryT
S dradnatS
O noitpO
60-DTI
noitcnuF.xuAciluardyH
- oN
S noitcnuf.xuats1
D noitcnuf.xuadn2
70-DTI
retfihsediS
- retfihsedisoN
H retfihsedisno-kooH
I retfihsedisdetargetnI
80-DTI
ledoMretfihsediS
-- retfihsedisoN
AC edacsaC
AK puaK
90-DTI
snoitpOmralA
- mralalevartesreveroN
1 mralalevartesreveR
01-DTI
rotacidnIegrahcsiDyrettaB
1 dradnatS
2 noitpO
11-DTI
C TT 4370 526 - S S H CA 1 -

18. 9
Printed in Germany
LUBRIFICATION AND ADJUSTMENT

19. Printed in Germany
11
MS-1.0-2232
LUBRICATION AND ADJUSTMENT
0,51 m
G_SC32-Heben-seitl
Lifting the Truck
CAUTION
Scalding hazard!
Spilled battery acid can cause injuries
and damage the truck.
You must remove the battery before
transporting the truck.
DANGER
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.
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-Kran
Centre of
Gravity of the
Truck
Tow
coupling
Between
Chassis and
Drive Wheel
Lifting by another truck
The SC 3200 can be lifted by another truck from the side.
Calculate the minimum capacity requirement based on the
weight of the truck. This information can be found on the
truck data plate.
● Position the forks of the truck which is doing the
lifting as shown by the diagram below.
● Secure the SC 3200 firmly to the forks of the truck
which is doing the lifting (e.g. with appropriate
straps).

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21. 12
Printed in GermanyMS-1.0-2232
LUBRICATION AND ADJUSTMENT
Towing the Truck
If the truck is out of order it can only be towed if the hand-
brake is released.
WARNING
Towing is only allowed with a tow bar.
● The brakes of the towing vehicle must be capable
of braking the towed vehicle.
Jacking up the Truck
DANGER
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.
● First jack up the rear section of the truck:
● Support one side with a wooden block.
● Then jack up the truck at the opposite side until
the steered wheels are free (see figure).
● Support the raised side.
● Then lift the opposite side and support it.
● To jack up the front section of the truck, place the
jack under the chassis frame behind one of the
front wheels.
● As soon as this drive wheel is free, support the
outer part of the mast on this side.
● Repeat this process to lift and support the oppo-
site side.
MO-2232-035
Wooden blocksJack
Steered
wheel

22. Printed in Germany
13
MS-1.0-2232
LUBRICATION AND ADJUSTMENT
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:
1. For disassembly you will need a crane or forklift
(minimum capacity 200 kg at 2.5m elevation) to
support the overhead guard.
2. A second crane or forklift (minimum capacity 1000
kg at 2m elevation) to prevent the counterweight
from tipping.
3. A pallet truck (minimum capacity 1000 kg) with
forks that will lower to fit under the counterweight.
4. Hard wooden blocks to fit under the outer mast
stages.
● Drive the truck into a secure maintenance area.
● Tilt the mast back as far as it will go (in the
direction of the driver).
● Lower the mast and fork carriage fully.
● Place two wooden blocks, one on the left and one
on the right hand side underneath the outer mast
stage. This will prevent the truck from tilting onto
the fork tips.
● Remove the battery.
● Attach a load sling to the rear of the overhead
guard.This will secure the overhead guard when
you loosen the attachment. Alternatively, you can
support the overhead guard from the side using a
forklift.
● Remove the tow pin from the counterweight.
● Remove the mounting screw of the electrical base
plate from the counterweight.
● Remove the mounting screws of the overhead
guard from the counterweight.
● Raise the back of the overhead guard 1 – 2 cm
and pull a load sling through the hole for the tow
pin in the counterweight.
● Insert the load sling into a crane hook (crane
minimum capacity 1000 kg). If you are using a
forklift instead of a crane, prevent the load sling
on the fork of the truck from sliding.
● Tighten the load sling slightly.
● Drive a pallet truck (minimum capacity 1000 kg)
underneath the counterweight.The forks must be
positioned under the flat surfaces of the counter-
weight.
● Raise the forks of the pallet truck until they are
touching the counterweight.
● Remove the mounting screws of the counter-
weight.
● Pull the counterweight approx. 10 cm away from
the forklift, using the pallet truck.
● Raise the counterweight off the pallet truck using
the crane, and place it of a flat surface.