service repair manual

1. Parts Manual
Ersatzteilhandbuch
Manual de pièces detachés SC3000 Series
PU1.p65 19.10.99, 09:34
1

2. Printed in Germany
TABLE OF CONTENT

3. 01/99
TABLE OF CONTENT
Printed in Germany
DESCRIPTION PAGE ID NUMBER
Table of Content ............................................................................................................................ IDX -2230-001
Safety ............................................................................................................................................. MA -2230-001
Introduction .................................................................................................................................... ITD -2230-001
Lubrication ..................................................................................................................................... M1.1-1710-002
Electrical Diagrams ....................................................................................................................... DIA -2230-001
Hydraulic Schematic ..................................................................................................................... HYD -2230-001
SECTION 1 POWER UNIT PARTS / COVERS
Covers (Instrumentation)................................................................................................................... 1.0 -2230-025
Drive wheel ......................(Pneumatic 1.25/1.6t) .............................................................................. 1.5 -2230-001
Drive wheel ......................(Super Elastic 1.8t).................................................................................. 1.5 -2230-075
Drive wheel ......................(Super Elastic 1.25/1.6t) .......................................................................... 1.5 -2230-125
Drive wheel ......................(Cushion) ................................................................................................. 1.5 -2230-175
Drive wheel ......................(Super Elastic 1.25/1.6t-Non-Marking) ..................................................... 1.5 -2230-185
Drive wheel ......................(Super Elastic 1.8t-Non-Marking) ............................................................. 1.5 -2230-195
Steer wheel .....................(Pneumatic 1.25/1.6t) .............................................................................. 1.5 -2230-200
Steer wheel .....................(Super Elastic)......................................................................................... 1.5 -2230-275
Steer wheel .....................(Super Elastic-Non-Marking) .................................................................... 1.5 -2230-285
Steer wheel .....................(Cushion) ................................................................................................. 1.5 -2230-325
Seat ................................................................................................................................................. 1.7 -2230-025
Rear Mirror ....................................................................................................................................... 1.9 -2230-001
SECTION 2 HYDRAULIC PARTS
Tube-/Hose Layout ........................................................................................................................... 2.1 -2230-025
Control valve linkage ........(two/three/four functions).......................................................................... 2.2 -2230-125
Control levers ................................................................................................................................... 2.2 -2230-150
Hydraulic tank .................................................................................................................................. 2.3 -2230-025
Hydraulic TL mast ............................................................................................................................ 2.4 -2230-001
Hydraulic accessories TL mast ........................................................................................................ 2.5 -2230-025
Hydraulic TF mast ............................................................................................................................ 2.6 -2230-001
Hydraulic accessories TF mast ........................................................................................................ 2.7 -2230-001
Hydraulic TT mast ............................................................................................................................ 2.8 -2230-025
Hydraulic accessories TT mast ........................................................................................................ 2.9 -2230-025
Valve bank.......................(three functions) ....................................................................................... 2.10 -2230-001
Valve bank.......................(four functions) ......................................................................................... 2.10 -2230-050
Pump ............................................................................................................................................... 2.12 -2230-001
Pump motor ..................................................................................................................................... 2.13 -2230-001
Pump motor and Pump .................................................................................................................... 2.13 -2230-025
SECTION 3 DRIVE UNIT PARTS
Drive unit .......................................................................................................................................... 3.1 -2230-025
Drive motor ....................................................................................................................................... 3.3 -2230-001
SECTION 4 ELECTRICAL PARTS
Contactor panel ...............(Contactors & Controllers) ....................................................................... 4.1 -2230-025
Contactor panel ...............(Bus Bars & Cables) ................................................................................ 4.1 -2230-027
Contactor panel ...............(Bus Bars,Cables & Fuses) ..................................................................... 4.1 -2230-029
Direction contactor ........................................................................................................................... 4.4 -2230-001
Line contactor .................................................................................................................................. 4.4 -2230-050
IDX - 2230 - 001

4. 01/99
Printed in Germany
TABLE OF CONTENT
DESCRIPTION PAGE ID NUMBER
Regenerative braking contactor ........................................................................................................ 4.4 -2230-100
Accelerator ...................................................................................................................................... 4.6 -2230-025
Emergency disconnect/Battery connector ........................................................................................ 4.7 -2230-001
Working light .................................................................................................................................... 4.10 -2230-001
Light rear .......................................................................................................................................... 4.10 -2230-025
Reverse alarm .................................................................................................................................. 4.10 -2230-050
Flashing beacon ............................................................................................................................... 4.10 -2230-075
Horn ................................................................................................................................................. 4.13 -2230-001
SECTION 5 BRAKE PARTS
Brake pedal...................................................................................................................................... 5.5 -2230-025
Brake ............................................................................................................................................... 5.6 -2230-025
Parking brake ................................................................................................................................... 5.7 -2230-025
SECTION 6 STEERING
Steer axle......................................................................................................................................... 6.6 -2230-025
Steer axle / Potentiometer................................................................................................................ 6.6 -2230-050
Steering column ............................................................................................................................... 6.7 -2230-025
SECTION 7 MAST / LIFT STRUCTURE PARTS
TL mast............................................................................................................................................ 7.1 -2230-025
Lift chain TL mast............................................................................................................................. 7.2 -2230-001
TF mast ........................................................................................................................................... 7.3 -2230-001
Lift chain TF mast ............................................................................................................................ 7.4 -2230-001
TT mast............................................................................................................................................ 7.5 -2230-025
Lift chain TT mast............................................................................................................................. 7.6 -2230-025
Fork carriage ...................(1.25/1.6t) ................................................................................................ 7.7 -2230-001
Fork carriage ...................(1.8t)........................................................................................................ 7.7 -2230-050
Side Shift ......................................................................................................................................... 7.7 -2230-175
Integrated Side Shift ........TL (1.25/1.6t) ........................................................................................... 7.7 -2230-225
Integrated Side Shift ........TF/TT (1.25/1.6t) ...................................................................................... 7.7 -2230-275
Integrated Side Shift ........TL (1.8t) ................................................................................................... 7.7 -2230-325
Integrated Side Shift ........TF/TT (1.8t) .............................................................................................. 7.7 -2230-375
Load backrest .................................................................................................................................. 7.10 -2230-001
Yoke ................................................................................................................................................ 7.11 -2230-025
SECTION 8 CYLINDER PARTS
Lift cylinder TL/TT mast .................................................................................................................... 8.1 -2230-025
Lift cylinder TF mast......................................................................................................................... 8.2 -2230-025
Free lift cylinderTF/TT mast .............................................................................................................. 8.3 -2230-025
Tilt cylinder ...................................................................................................................................... 8.6 -2230-001
SECTION 10 MISCELLANEOUS SERVICE INFORMATION
Labels and decals ............................................................................................................................ 10.9 -2230-001
IDX - 2230 - 002

5. Printed in Germany
SAFETY

6. Printed in Germany
1
01/99
SAFETY
MA-2230-001
OPTION
Safety Symbols used in the
Manual
To help guide you through the manual and to highlight
particular danger areas, we have used graphic illustra-
tions:
DANGER
This symbol indicates life-threatening risks
● Failure to comply with this notice may
result in severe or 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.
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 guidelines.
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.
9. Make sure that capacity and data plates, warnings
and labels are legible at all times.

7. Printed in Germany
2
01/99
SAFETY
MA-2230-002
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
l Stop the truck.
l Lower the fork carriage fully.
l Apply the parking brake.
l Turn off the travel switch and remove the
key.
l Block all wheels when parking on an uneven
surface.
Before Carrying out Work on the Truck
l Raise the truck to free the drive wheel.
Press the Emergency Stop button and
disconnect the battery.
l Prevent the truck from rolling away.
l 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.
l 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
l Check the safety devices.
l Get into the driver's seat.
l Check the operation of the lifting device,
travel direction switch, speed control,
steering, warning devices and brakes.
Warnings and Labels on the Truck
l During regular maintenance check that the
warnings and labels on the truck are
complete and legible.
l Clean any illegible labels.
l Replace any faulty or missing labels.
The order and meaning of the warnings and labels on
the truck are described on pages 10.9-2230-001, -002,
-025 and -026 in the present manual.

8. Printed in Germany
INTRODUCTION

9. Printed in Germany
01/99
1
INTRODUCTION
ITD-2230-001
Operating instruction
This manual contains no operating instructions. An
operating 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 obtained
from CROWN on request.
Replacement parts orders
When ordering spare parts from this manual please always
give the full description of the vehicle model as well as
the order number. These details enable us to process your
orders in an accurate, quick and reliable way.
Please refer to the Technical Specifications Sheet for the
utilisable loads, technical data and dimensions for this
series.
Brochures can be obtained from your CROWN dealer or
from the following address:
CROWN Gabelstapler GmbH
Moosacher Str. 52
D-80809 München
Tel.: 089/93 00 20
Fax: 089/93 00 2-175
Page Numbers
The page numbers are located on the lower left and right
hand margins of each page and have the following form:
M1.1-2230-001 X
M = Maintenance
Chapter
Truck code
Page number
Section
z. B. 1.2 = Inspection and
Maintenance Plan
Identical for each language
Section is only once in the manual

10. Printed in Germany
01/99
2
INTRODUCTION
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ITD002-gb
ITD003-gb
Truck Data Numbering Sheet
Model designation
SC = Sitdown Rider
Counterbalance
Capacity
1.3 = 1250 kg
1.6 = 1600 kg
1.8 = 1800 kg
T = Telescopic
L = Double, part free lift
F = Double, full free lift
T = Triple, full free lift
NOTE
FOR SPECIALS USE THE ACTUAL FIGURES
FOR COLLAPSED / LIFT HEIGHT AND FORK
LENGTH (SEE TABLES ITD002-GB AND
ITD.003-GB).
Example:
Truck with data 1.3SCTL-2-2 designates
l Capacity 1250 kg
l Sitdown Rider Counterbalance
l Telescopic double part free lift mast
l Collapsed height 1970 mm
l Lift height 2880 mm
l Fork length 1000 mm
1.3 SC T L – 2 – 2

11. Printed in Germany
01/99
3
INTRODUCTION
ITD-2230-003
ITD004-gb
NOTE
ALWAYS SPECIFY MODEL NO.WHEN
ORDERING SPARE PARTS.
Spare parts for model SC3013 option 2/2h
correspond to model SC3016 option 2/2h.
Spare parts for model SC3016 option 3/3h
correspond to model SC3018 option 3/3h.
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12. Printed in Germany
LUBRICATION

13. Printed in Germany
M1.0-0000-0001
01/99
LUBRICATION
W01-gb
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Lubricants and Oil Recommendations
M1.1-1710-002

14. Printed in Germany
M1.0-0000-0002
01/99
LUBRICATION
W06-gb
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M1.3-2230-002

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your reading. Please Click
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16. Printed in Germany
ELECTRICAL DIAGRAMS

17. Printed in Germany
01/99
1
ELECTRICAL DIAGRAMS
Key
Connectors
Traction Controller Connectors
CA 201 E
CA 202 D
CA 203 C
CA 204 B
CA 205 A
CA 206 F
CA 207 G
CA 208 H
CA 209 J
Pump Controller Connectors
CA 210 L
CA 211 E
CA 212 D
CA 213 C
CA 214 B
CA 215 A
CA 216 Panel
CA 217 Seat Switch
CA 218 Steering Feedback Potentiometer
CA 401 Accelerator Potentiometer
CA 402 Accelerator Switch
CA 403 Lift Potentiometer
CA 404 Tilt Switch
CA 405 Side Shift Switch
CA 406 Auxiliary Switch
CA 407 Pedal Brake Switch
CA 408 Handbrake Switch
CA 409 Horn
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).
Contactors
FA Left Motor Forward Contactor
RA Left Motor Reverse Contactor
FB Right Motor Forward Contactor
RB Right Motor Reverse Contactor
LC Line Contactor
RGB Regenerative Braking Contactor
Abbreviations
ACS Accelerator Switch
AXS Auxiliary Function Switch
BDI Battery Discharge Interrupt
BRS Brake Switch
DIS Direction Switch
EM Encoder Module
ENC Encoder
HBS Handbrake Switch
HF Hash Filter
HN Horn
HNS Horn Switch
KYS Key Switch
POT 1 Accelerator Potentiometer
POT 2 Lift Potentiometer
POT 3 Steer Potentiometer
SES Seat Switch
SH Shunt
SSS Side Shift Switch
TLT Tilt Switch
TT Hour Meter
DIA-2230-001