Crown ST3000 Series Forklift Complete Workshop Service Repair Manual

ST3000 Series Order Number: 812557-006 Printed in Germany ● Revision Level A Service Manual

A ST3000 10/2004 • Printed in Germany MS-REV-3130 REVISION Overview of Revisions:

B Printed in Germany Blank page

I Printed in Germany TABLE OF CONTENT

II Printed in Germany Blank page

ST3000 10/2004 • Printed in Germany MS-IDX-3130 III TABLE OF CONTENT Table of Content MA – SAFETY PAGE SER-NO. CUT .................. REV. Safety Symbols used in the Manual ...................................... 3 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 ITD – INTRODUCTION PAGE SER-N0. CUT REV. 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. COMPONENT ACCESS ........................................................... 11 Lifting and Blocking ................................................................ 13 Outriggers ................................................................................ 14 Recommended Lubricants and Oils .............................. 15 Lubricants ................................................................... 15 Cold Store Trucks ........................................................ 15 Truck Decommissioning .................................................. 15 Restoring the Truck to Service .............................................. 15 Maintenance ............................................................................ 19 Lubrication points and intervals ..................................... 19 Inspection and Maintenance Schedule ......................... 21 Casters ..................................................................................... 30 Torques .................................................................................... 31 M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV. Hydraulic Symbols .................................................................. 35 Hydraulic Unit Removal .......................................................... 39 Hydraulic System ............................................................ 40 Operation ......................................................................... 40 Raise (Refer to Illustration) ......................................... 40 Lower .......................................................................... 41 Hydraulic Reservoir Capacity ......................................... 42 Changing the hydraulic oil and hydraulic filter ............ 42 MOTOR & PUMP ASSEMBLY ........................................ 44 HYDRAULIC LINES AND FITTINGS .......................... 44 General Rules for Hydraulic Lines and Fittings ........................................................................ 44 CIRCUIT BLEEDING .................................................. 45 DRIFT TEST ............................................................... 45 Proportional function: ................................................ 45 REMOVAL ....................................................................... 45 MOTOR ............................................................................ 46 PUMP .............................................................................. 46 After replacing pump: ................................................ 46 Replacing the relief valve ............................................... 47 Relief valve setting .......................................................... 47 Relief valve test and setting ........................................ 47 HYDRAULIC TROUBLESHOOTING CHART ................ 48

ST3000 10/2004 • Printed in Germany MS-IDX-3130 IV TABLE OF CONTENT M3 – DRIVE UNIT PAGE SER-N0. CUT .................. REV. Gear Unit .................................................................................. 51 Drive unit, general ................................................................... 52 Drive unit removal ........................................................... 52 Drive motor removal ....................................................... 52 Motor disassembly .......................................................... 53 Motor assembly ............................................................... 53 Drive motor assembly ..................................................... 55 Gear unit disassembly .................................................... 56 General ....................................................................... 56 Preparation ................................................................. 56 Draining the oil ............................................................ 56 Drive unit removal ....................................................... 56 Gear unit cover removal .............................................. 56 Gear unit disassembly ................................................ 57 Gear unit assembly ..................................................... 57 Gear unit cover installation ......................................... 59 Adding Oil ................................................................... 59 Drive unit installation ...................................................... 59 M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. Electrics - General .................................................................. 63 Wire Colour Codes .................................................................. 63 Abbreviations .......................................................................... 64 Electrical Symbols .................................................................. 67 Electrical Components ........................................................... 68 Traction Pod (POT, FS, RS) ............................................ 68 Fast / Slow Travel Switch (HSS) ..................................... 68 Safety Reverse Switch (SAS) ......................................... 68 Brake Switch (BRS) ........................................................ 68 Override Switch (ORS) ................................................... 68 Raise / Lower Switches (RAS, LOS) ............................. 69 Limit Switch (LMS) .......................................................... 69 Horn Switch (HNS) ......................................................... 69 Key Switch (KYS) ............................................................ 69 Emergency Disconnect (BD) .......................................... 69 Fuses (FU) ...................................................................... 69  Thermal Switch (THS) ......................................... 69 Hydraulic Control Module (HCM) ................................... 69 Unigage (BDI) ................................................................. 69 Integrated Charger .......................................................... 69 Plug Holder (PC) ............................................................. 69 Drive motor (M1) ............................................................. 69 Hydraulic Motor (M2) ...................................................... 69 Main Contactor (Line/LC) ............................................... 70 Lift Contactor (P/P1+P2) ................................................ 70 Electromagnetic Brake (BRK) ........................................ 70 Terminal Board (TB) ....................................................... 70 Travel Alarm Driver (DR) ................................................ 70 Aux. Hydraulic Switch (SLS/SRS) .................................. 70 Remote Control Toggle Switch (ECS) ............................ 70 Aux. Hydraulic Valves (SVA1/SVA2) .............................. 70 Horn (HN) ........................................................................ 70 Main Circuit Board (MAIN PCB) ..................................... 70 Hydraulic Circuit Board (HYD PCB) ............................... 70 Travel Alarm (ALM) ......................................................... 70 Receiver .......................................................................... 70 Transmitter ....................................................................... 70

ST3000 10/2004 • Printed in Germany MS-IDX-3130 V TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. SEM0 Traction Controller ........................................................ 74 General ............................................................................ 74 Precautionary Measures ............................................. 74 Functional Characteristics .............................................. 74 Speed control .............................................................. 74 Reduced speed ranges .............................................. 74 Downhill speed control ................................................ 74 Regenerative braking .................................................. 74 Anti Roll Down Function ............................................. 75 Hourmeter ................................................................... 75 Self-Diagnostic System ............................................... 75 Monitored Circuits ....................................................... 75 Safety Mechanisms ......................................................... 75 Incorrect polarity ............................................................. 75 Wiring Errors ............................................................... 75 Temperature protection ............................................... 75 Start sequence ........................................................... 75 Protection rating .......................................................... 75 Maintenance .................................................................... 76 Replacing the SEM0 Traction Controller ......................................................................... 77 Parameter Setting after Replacing the Traction Controller .................................................... 77 Preparatory Measures ................................................ 77 Adjustment .................................................................. 77 Status LED ...................................................................... 79 Programmer ............................................................................. 80 General ............................................................................ 80 Crown Handset P/N 793548 (Includes Cord) ........... 80 Operating SEM0 Controller Menu .......................................... 81 General ............................................................................ 81 Menu structure ............................................................ 81 Menu Functions .............................................................. 82 PARAMETER CHANGE .............................................. 82 TEST ........................................................................... 82 ALARMS ..................................................................... 82 PROGRAM VACC ....................................................... 82 CONFIG ...................................................................... 82 Functions Menu, general ................................................ 83 Parameter Change Menus ............................................. 84 Settings and Error Messages ......................................... 85 Tester Menu ..................................................................... 86 TESTER Menu ................................................................ 87 Alarms Menu ................................................................... 88 ALARMS Menu ................................................................ 89 Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu ................................................. 92 Preparatory Measures ................................................ 92 Calibration ................................................................... 92 Config. Menu ................................................................... 93 CONFIG Menu ................................................................ 94 SET MODEL ............................................................... 94 SET OPTIONS ............................................................ 94 ADJUSTMENTS ......................................................... 94 On Board Charger ................................................................... 95 General ............................................................................ 95 Battery Charging Phases ............................................... 95 First Phase (I1) ........................................................... 95

ST3000 10/2004 • Printed in Germany MS-IDX-3130 VI TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. Second Phase (P) ....................................................... 95 Third Phase (U) .......................................................... 95 Fourth Phase (I2) ........................................................ 95 End of Normal Charging ............................................. 96 Special Charging Phases ............................................... 96 Compensating Charge ................................................ 96 Float Charge ............................................................... 96 Partial Charging .......................................................... 96 Charging Errors ............................................................... 97 Green LED is not lit ..................................................... 97 Possible Causes: ...................................................... 97 Green LED flashing .................................................... 97 Important Technical Data ................................................ 98 Replacing the Charger ................................................... 98 Removal / Installation .................................................. 98 Traction Motor Maintenance .................................................. 99 Access to brushes .......................................................... 99 Maintenance .................................................................... 99 Armature ..................................................................... 99 Bearings ...................................................................... 99 Pump Motor Maintenance ...................................................... 100 Access to brushes .......................................................... 100 Maintenance .................................................................... 100 Armature .......................................................................... 100 REPLACING PUMP MOTOR BRUSHES ....................... 100 Contactors ............................................................................... 102 Inspection ........................................................................ 102 Contacts ...................................................................... 102 Coils ............................................................................ 102 Springs ........................................................................ 102 Servicing ......................................................................... 103 Dismantling ................................................................. 103 Assembly .................................................................... 103 Hydraulic Control Module (HCM) ........................................... 104 Battery Discharge Indicator (BDI) ......................................... 105 OPERATION .................................................................... 105 General ............................................................................ 106 Battery Discharge Indicator Setting (BDI) ..................... 106 Calibration for wet batteries ........................................... 107 TROUBLESHOOTING .................................................... 108 Traction Controller Safety Test ....................................... 109 M5 – BRAKE PAGE SER-N0. CUT .................. REV. Brake ........................................................................................ 113 Function ........................................................................... 113 Disassembly .................................................................... 113 Assembly ......................................................................... 115 Air gap setting ................................................................. 115 Brake moment setting ..................................................... 116 Brake test ........................................................................ 116 Definition of run-in/new rotor ...................................... 116 General Notes ............................................................. 116 M6 – DIRECTION PAGE SER-N0. CUT .................. REV. Live ring bearing ..................................................................... 121 Disassembly .................................................................... 121 Assembly ......................................................................... 121

ST3000 10/2004 • Printed in Germany MS-IDX-3130 VII TABLE OF CONTENT M6 – DIRECTION PAGE SER-N0. CUT .................. REV. Control handle return springs ............................................... 122 Adjustment ...................................................................... 122 Disassembly .................................................................... 122 Assembly ......................................................................... 122 Control Handle Grip ................................................................ 123 Main Components ........................................................... 123 Hand grip component removal and assembly ..................... 124 Hand Grip Shells ............................................................. 124 Upper and lower shell removal ................................... 124 Upper and lower shell assembly ................................. 125 Switch Unit ...................................................................... 126 Disassembly ............................................................... 126 Switch unit assembly .................................................. 126 “Rabbit/Turtle” toggle switch ........................................... 127 Disassembly ............................................................... 127 Assembly .................................................................... 127 Hydraulic PC board ......................................................... 127 Disassembly ............................................................... 127 Assembly .................................................................... 127 Main PC Board Removal/Installation ............................. 128 Potentiometer .................................................................. 129 Disassembly ............................................................... 129 Assembly .................................................................... 130 Safety Reverse Switch .................................................... 130 Disassembly ............................................................... 130 Assembly .................................................................... 130 Horn switch ..................................................................... 131 Disassembly ............................................................... 131 Assembly .................................................................... 132 Hand Grip ........................................................................ 132 Disassembly ............................................................... 132 Assembly .................................................................... 132 M7 – MAST PAGE SER-N0. CUT .................. REV. Mast .......................................................................................... 135 General ............................................................................ 135 Torque Requirements ................................................. 135 Lifting Gear Minimum Capacity ................................... 135 TL Mast ....................................................................... 135 TT Mast ....................................................................... 135 Mast Removal ................................................................. 135 Installation ....................................................................... 136 Fork Carriage Removal .................................................. 136 Fork Carriage Installation ............................................... 137 Fork Carriage Adjustment .............................................. 137 Mast Maintenance .......................................................... 138 Lubricating Roller Tracks ............................................. 138 Mast shims .................................................................. 139 TL Mast Assembly .......................................................... 140 TT Mast Assembly .......................................................... 141 Lift chains ................................................................................ 142 General ............................................................................ 142 Inspection ........................................................................ 142 Cleaning ...................................................................... 142 Wear ........................................................................... 142 Freedom of Movement of Chain Links ........................ 143 Chain Tension ............................................................. 143 Chain Anchor and Pulleys .......................................... 144

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Crown ST3000 Series Forklift Complete Workshop Service Repair Manual

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