PDF Service Manual Crown ST3000 Series Forklift - 712 KB
This is the factory service manual for the Crown ST3000 Series of walkie stacker forklifts.
It contains in-depth information for technicians on troubleshooting, repairing, and maintaining these machines.
The manual includes detailed electrical and hydraulic schematics, component teardown procedures, and service specifications.
It's the definitive guide for professional-level service on your Crown ST3000 forklift.
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--- Page 1 ---
Service Manual
ST3000 Series
Printed in Germany โ Revision Level A
Order Number: 812557-006
--- Page 3 ---
TABLE OF CONTENT
M6 โ 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
โRabbit/Turtleโ 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 โ 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
ST3000 10/2004 โข Printed in Germany MS-IDX-3130
VII
--- Page 4 ---
INTRODUCTION
General This information can be found on the truck's data plate.
Only if this information is provided can the order be
The present manual is designed for Customer Service processed quickly, correctly and reliably.
engineers who wish to familiarise themselves with the
maintenance work required for the various truck com- Please refer to the Technical Specifications Sheet for the
ponents. utilisable loads, technical data and dimensions for
thisseries. Brochures can be obtained from your CROWN
It also contains troubleshooting sections which can be dealer or from the following address:
used to identify and remedy truck faults.
INFORMATION CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
This book is not an operating manual. It is 80809 Munich
designed solely for specialist personnel GERMANY
who have been trained and authorised to Tel.: +49 (0)89 / 93 002 -0
carry out the work described in the Fax: +49 (0)89 / 93 002 -175 or133
manual.
Using the Manual
This manual therefore contains fewer and less detailed The manual is divided into sections. The following table
warnings than the Operator's Manual, as the latter is shows how the manual is structured.
aimed at persons who have very little or no prior
experience at all.
Sections Maintenance
Operating Instructions
Section Description
This manual contains no operating instructions. An
operating instructions manual is supplied with the vehicle. IDX Table of Content
Additional copies can be ordered as required.
With the help of this manual you and your personnel will MA Safety
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle. ITD Introduction
Service Training M1 Lubrication and Adjustment
CROWN offers the appropriate vehicle related training
for service personnel. Details on this training can be M2 Hydraulics
obtained from CROWN on request.
M3 Drive Unit
Ordering Spare Parts
The maintenance manual does not cover spare parts. M4 Electrical
These are listed in a separate manual.
M5 Brake
Spare parts can be ordered by quoting:
M6 Steering
โ The truck specification number
โ The truck model number M7 Mast / Lifting Mechanism
โ The truck serial number
M8 Cylinder
DIA Electrical Diagrams
HYD Hydraulic Schematic
A01M-gb
ST3000 10/2004 โข Printed in Germany MS-ITD 3130
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7
--- Page 5 ---
LUBRIFICATION AND ADJUSTMENT
Page intentionally blank
ST3000 10/2004 โข Printed in Germany MS-1.0-3130
M1.0-0000-00017
17
--- Page 6 ---
LUBRIFICATION AND ADJUSTMENT
Months 3 6 12 24
Inspection Work (Part 2)
Hours 100 250 500 1000
I-18 Wiring / Switches Check all line connections are secure x
Clean truck, battery and charger connector contacts
I-19 x
and check contact springs.
Check mast cable connectors are secure, strain
I-20 x
relief present? Check and adjust cable pre-tension
I-21 Visually inspect the charger connection lead x
Check wiring, switches & connections are secure,
I-22 x
check insulation for damage.
Check line connections to traction controller,
I-23 EMERGENCY DISCONNECT switch and main x
fuses FU1 & 2 are secure
Check power cables from drive and lift motors for
I-24 x
damage
I-25 Check battery cables and connectors for damage x
Check / service battery as required in accordance
I-26 Battery x
with battery manufacturer's service manual.
I-27 Check battery condition x
I-28 Check acid density and acid level x
Clean and check main contactor tips, replace if
I-29 Contactors x
necessary.
Clean and check pump contactor tips, replace if
I-30 x
necessary.
I-31 Traction controller Check operation. Read the error log x
x
I-32 Ensure it is securely fixed
Blast off abrasion with pressurised air; check
I-33 Brake x
conical nipple for damage; check air gap.
Check brake lining and friction surfaces for wear,
I-34 x
replace parts as required.
Check air gap and brake lining wear on the motor
x
I-35 brake; clean brake linings (apply dry compressed
air), and replace if necessary
I-36 Control Handle Test return spring operation. x
L04_2-GB
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--- Page 7 ---
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
T L Hydraulic steer unit
Check valve
P R
M3561
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--- Page 8 ---
HYDRAULICS
Replacing the relief valve Relief valve test and setting
โ Remove the locking mechanism (see Fig.) and โ With the truck at operating temperature, raise a
unscrew the relief valve (3), test load on the forks that corresponds to 110%
of rated capacity (= minimum load). It should be
โ Remove the O ring and the strainer from the easy to raise the load.
valve seat if they are still in there.
โ Now raise a test load that corresponds to 110%
โ Apply a thin coat of hydraulic oil to the new O ring of rated capacity + 100 kg (=maximum load). It
and place it in the valve seat with the strainer. should not be possible to raise this load. (relief
valve opens).
โ Apply hydraulic oil to the relief valve, insert it into
the valve seat and tighten. Tap in the new locking If necessary, adjust the relief valve so that it opens within
mechanism. the above mentioned tolerance range.
โ Refit the hydraulic unit and adjust the relief valve. โ Hold onto the setscrew and loosen the jam nut
(see Fig.):
Relief valve setting โ Turn the setscrew clockwise to increase the
threshold? until the valve opens, turn it anti-
The relief valve protects the hydraulic system and the
clockwise to reduce the threshold.
lifting mechanism from overloading.
โ Counter-fix the setscrew again with the nut.
WARNING
Do not let the pump unit run unless it is
fixed to the chassis.
The amount of torque will twist the unit.
This can result in short circuits and
damage.
Rated
Model Min. Load Max. Load
Capacity
S T 3000 1.0 t 1,100 kg 1,200 kg
S X 3000 1.2 t 1,320 kg 1,420 kg
M3563
H01-GB
Relief valve setscrew
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--- Page 9 ---
DRIVE UNIT
Gear unit disassembly โ Press the shaft seal (31) from the outside into the
seat on the gear unit housing.
NOTE
โ Fit the outer ring of the roller bearing (24) and
All item numbers in the following sec- insert the retaining ring (43).
tions refer to Figure MS-1723-0027-A on
the following page unless another figure โ Place the bushing (9) onto the rollers of the
number is indicated. bearing (24) and press the bearing (23) into the
gear unit housing and insert the retaining ring
โ Remove the retaining ring (61, Fig. MS1723- (44).
027A) and the supporting ring (62).
โ Place the wheel (4) in position and guide the
โ Using a suitable extractor pull off the wheel (2). drive shaft carefully into the shaft seal. Align the
bushing in the process.
โ Remove the retaining ring (45) and the two shims
(48, 49). โ Align the wheel (4) with the tooth shaft profile of
the drive shaft (7).
โ Press off the driven shaft (7) in the direction of
the drive wheel. This will inevitably damage the โ Support the wheel (4) with suitable bushing and
bearing (23). press the drive shaft (7) into the wheel (4).
โ Remove the retaining ring (44) and extract the โ Using an appropriate number of shims (49),
bearing (23). The bearing can no longer be distance the drive shaft (7) between the two
used. shims (48) so that there is no slack and insert the
retaining ring (45).
โ Remove the retaining ring (43) and extract the
bearing (24) via the outer ring. โ Press the bearing (22) onto the pinion shaft (3).
โ Now press out the shaft seal (31). โ Hold against the inner ring of the bearing (21)
and fit the pinion shaft (3). Press in the retaining
โ Remove the retaining ring (42) and the sealing ring (42).
cover (30).
โ The contact surfaces of the cover and gear unit
โ Press off the pinion shaft (3) in the direction of housing must be clean and oil-free. If necessary,
the gear unit cover (6). Both bearings (21 and 22) clean the surfaces as described in the Gear Unit
will remain on the pinion shaft. Cover Removal section.
โ Remove the two bearings (21 and 22) from the โ Apply a layer of Dirkoยฎ sealant (part no. see
pinion shaft (3). chapter one, lubricants) all around the contact
surfaces of the gear unit cover.
NOTE
โ Insert the feather key (51) into the pinion shaft
The output gear is part of the motor. The (3).
procedure for removing the pinion and
the bearings is described in the Drive โ Hold against the inner ring of the bearing (21)
Motor section on the previous pages. and fit the wheel (2) onto the pinion shaft (3).
Gear unit assembly โ Thread the supporting ring (62) onto the pinion
shaft (3) and insert the retaining ring (61).
Replace all bearings and seals. Used bearings and
seals will result in premature failure of the unit. โ Press the sealing cover (30) into the housing.
โ Press the bearing (21) into the housing via the
outer ring.
โ Press the inner ring of the roller bearing (24) onto
the drive shaft (7).
ST3000 10/2004 โข Printed in Germany MS-3.1-3130
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--- Page 10 ---
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
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--- Page 11 ---
ELECTRICS
Replacing the SEM0 Traction โ For cold store versions: Apply a coat of Dow
Corningยฎ 4 Compound, part no. 053051-006, to
Controller the control line connectors. Apply a layer of acid-
resistant clearseal paint to the controller.
WARNING
Important: After replacing the controller check and ad-
Make sure you are operating the truck just the settings. You can adjust the settings to suit the
with the correct controller. customerโs requirements. Follow the order described as
follows.
The use of SEM0 traction controllers with
different part numbers can change the
characteristics and result in accidents.
Parameter Setting after Replacing the
Traction Controller
When fitting a new SEM0 traction controller in a truck
you must select the right truck model through the hard- Preparatory Measures
ware (on the WP2300 jumper between C2 and C3 and
configuration menu selection, on the ST3000 or SX3000 โ Power down the truck and jack it up so that
the appropriate selction in the configuration menu). the drive wheel is free (see Chapter 1).
If you have changed and stored the standard configura- โ When the truck is powered down connect the
tion with the programmer, the stored parameters will be programmer to the traction controller.
loaded the next time the controller is started.
โ Power up the truck.
โ Prepare to remove the traction controller as
previously described in the Maintenance section. Adjustment
โ Remove the 4 mounting screws and remove the 1. If required, change the options for the safety
traction controller. reverse switch and the internal service hourmeter
of the controller. The standard setting is con-
โ Check the contact pattern left behind by the tained in Table 11-GB. If you have made
controller back plate on the heat dissipation changes, switch the truck off and on again. This
sheet. The controller must lie fully flat on the heat will activate the changes.
dissipation sheet. If there are large areas with no
contact to the controller, replace the heat dissipa- 2. Measure the battery voltage directly at the battery
tion sheet to avoid thermal problems. and adjust the reading measured and displayed
by the traction controller (see CONFIG MENU
โ Clean the contact surface of the traction control- section).
ler on the truck chassis with a lint-free cloth and
use an industry-standard silicon removal agent to 3. Using the TEST menu check the wiring and
remove the residue of the heat conducting paste. operation of the switches (see TEST menu
section).
โ Apply a thin and even layer of Dow Corningยฎ 340
heat conducting paste, part no. 053051-008 to 4. Re-calibrate the traction potentiometer (see
the floorboard (= contact surface of the traction โTraction pod โ calibrate potentiometer, PRO-
controller on the truck chassis). GRAM VACC menu).
โ Secure the traction controller again with the 4 5. Test the traction pod starting point at creep
screws. speed. The drive wheel should start when the
travel switch closes. If necessary increase the
โ If necessary clean the contact surfaces and refit value accordingly. Repeat the test for both travel
the power cable (you must follow the instruc- directions (see PARAMETER CHANGE menu
tions in the Maintenance section on the section).
previous page) and refit the connectors for the
control lines.
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--- Page 13 ---
ELECTRICS
TESTER Menu
The following table describes the various truck parameters which can be selected and checked in the TESTER menu.
TESTER Menu
Menu Item Description
BATTERY VOLTAGE Battery voltage measured at key switch input.
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
MOTOR CURRENT Current received by motor armature.
FIELD CURRENT Current received by field coil.
Measures the current between VMN (Volt Motor Negativ) and -BATT.
VMN
The reading indicates the potential difference over the controller power par t.
TEMPERATURE Controller temperature, measured at the aluminium base plate next to the MOSFETs.
Displays the nominal signal of the traction potentiometer. The left hand side displays
ACCELERATOR the voltage reading, the right-hand side the percentage relating to the maximum
operating signal calibrated via PROGRAM VACC.
Tests the operation of the "Forward" (FS) switch.
FORWARD SWITCH
Displays the open (OFF) and closed (ON) status.
Tests the operation of the "Reverse" (RS) switch.
BACKWARD SWITCH
Displays the open (OFF) and closed (ON) status.
Tests the operation of the "Override" (ORS) switch.
HANDLE/SEAT SWITCH
Displays the open (OFF) and closed (ON) status.