Crown WF 3000-1.0, WF 3000-1.2 Service Manual
Service Manual
WF3000 Series
Printed in
Germany ● Revision Level A
Order Number: 812556-006
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CRO WN Gabelstapler GmbH & Co. KG
- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0)89 93 00 2 - 0
Fax +49 (0)89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement.
CROWN Equipment Corporation
Copyright 2005
Overview of Revisions:
REVISION
WF3000 09/2005 • Printed in Germany MS-REV-3300
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TABLE OF CONTENTS
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TABLE OF CONTENTS
Table of Contents
MA – SAFETY PAGE SER-NO. CUT.................. REV.
Safety Symbols used in the Manual...................................... 3
ITD – INTRODUCTION PA GE 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 Tr uck ............................................. 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.
Raising And T owing The Truck ............................................... 11
Raising With Another Forklift Truck................................ 11
Lifting by Crane............................................................... 12
Towing the Truck ............................................................. 13
Component Access ................................................................ 14
Maintenance ............................................................................ 16
Recommended Lubricants and Oils .............................. 16
Lubricants ................................................................... 1 6
Cold Store Trucks........................................................ 16
Taking the tr uck out of service ....................................... 16
Bringing the truck back into service .............................. 16
Lubricant T able ........................................................................ 17
Adjuvants T able ....................................................................... 18
T ruck Tilt Settings ................................................................... 22
Testing and Adjusting the Lateral Inclination ................ 22
Lowering Plumb Test ....................................................... 22
M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV.
Hydraulic Symbols.................................................................. 27
Hydraulics................................................................................ 31
Hydraulic Reservoir Capacity ......................................... 31
Changing the Hydraulic oil and
Hydraulic Filter................................................................ 31
Hydraulic system ............................................................ 33
Function........................................................................... 33
Lifting (see diagram) ................................................... 33
Lowering (see diagram) .............................................. 34
MOTOR AND PUMP ASSEMBLY................................... 35
Hydraulic Lines and Fittings ....................................... 35
General Rules for Hydraulic Lines and Connections.. 35
Bleeding the Hydraulic System................................... 35
Drift T est...................................................................... 35
Proportional function:................................................ 35
REMOVAL ....................................................................... 35
MOTOR............................................................................ 3 6
PUMP .............................................................................. 36
After replacing the pump: ......................................... 36
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TABLE OF CONTENTS
M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV.
Replacing the relief valve....................................................... 37
Relief valve test and setting................................................... 37
Hydraulic System Troubleshooting ................................. 38
M3 – DRIVE UNIT PAGE SER-N0. CUT .................. REV .
Gear Unit.................................................................................. 41
Drive unit, general................................................................... 42
Drive unit removal........................................................... 42
Drive motor removal ....................................................... 42
Motor disassembly.......................................................... 43
Motor assembly ............................................................... 43
Drive motor assembly..................................................... 45
Gear unit disassembly.................................................... 46
General ....................................................................... 46
Preparation ................................................................. 46
Draining the oil............................................................ 46
Drive unit removal....................................................... 46
Gear unit cover removal.............................................. 46
Gear unit disassembly ................................................ 47
Gear unit assembly..................................................... 47
Gear unit cover installation ......................................... 49
Adding Oil ................................................................... 49
Drive unit installation ...................................................... 49
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
Electrics - General .................................................................. 53
Wire Colour Codes ......................................................... 53
Abbreviations .................................................................. 54
Electrical Symbols .......................................................... 57
Electrical Components ........................................................... 58
Traction Pod (POT, FS, RS)............................................ 58
Fast / Slow Travel Switch (HSS)..................................... 58
Safety Reverse Switch (SAS)......................................... 58
Brake Switch (BRS) ........................................................ 58
Override Switch (ORS)................................................... 58
Raise / Lower Switches (RAS, LOS) ............................. 59
Limit Switch (LMS).......................................................... 59
Horn Switch (HNS) ......................................................... 59
Key Switch (KYS)............................................................ 59
Emergency Disconnect (BD).......................................... 59
Fuses (FU) ...................................................................... 59
OPTION
Thermal Switch (THS) ......................................... 59
Thermal switch (THS2)................................................... 5 9
Hydraulic Control Module (HCM)................................... 59
Unigage (BDI) ................................................................. 59
Integrated Charger .......................................................... 59
Plug Holder (PC)............................................................. 5 9
Drive motor (M1)............................................................. 59
Hydraulic Motor (M2) ...................................................... 60
Main Contactor (Line/LC) ............................................... 60
Lift Contactor (P/P1+P2) ................................................ 60
Electromagnetic Brake (BRK) ........................................ 60
Ter minal Board (TB) ....................................................... 60
Travel Alarm Driver (DR) ................................................ 60
Aux. Hydraulic Switch (SLS/SRS).................................. 60
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TABLE OF CONTENTS
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
Remote Control Toggle Switch (ECS)............................ 60
Aux. Hydraulic Valves (SVA1/SVA2) .............................. 60
Horn (HN) ........................................................................ 60
Main Circuit Board (MAIN PCB)..................................... 60
Hydraulic Circuit Board (HYD PCB) ............................... 60
Travel Alarm (ALM) ......................................................... 60
Receiver .......................................................................... 60
Transmitter....................................................................... 6 0
SEM0 T raction Controller........................................................ 64
General............................................................................ 64
Precautionary Measures............................................. 64
Functional Characteristics.............................................. 64
Speed control.............................................................. 64
Reduced speed ranges .............................................. 64
Downhill speed control................................................ 64
Regenerative braking.................................................. 64
Anti Roll Down Function ............................................. 65
Hourmeter................................................................... 65
Self-Diagnostic System ............................................... 65
Monitored Circuits....................................................... 65
Safety Mechanisms......................................................... 65
Incorrect polarity ......................................................... 65
Wiring Errors............................................................... 65
Temperature protection............................................... 65
Start sequence ........................................................... 65
Protection rating.......................................................... 65
Maintenance.................................................................... 66
Replacing the SEM0 Traction Controller............................... 67
Parameter Setting after Replacing
the Traction Controller .................................................... 6 7
Preparatory Measures ................................................ 67
Adjustment.................................................................. 67
Status LED ...................................................................... 69
Programmer............................................................................. 70
General............................................................................ 70
Crown Handset P/N 793548 (Includes Cord) ........... 70
Operating SEM0 Controller Menu.......................................... 71
General............................................................................ 71
Menu structure............................................................ 71
Menu Functions .............................................................. 72
PARAMETER CHANGE.............................................. 72
TEST........................................................................... 72
ALARMS ..................................................................... 7 2
PROGRAM VACC ....................................................... 72
CONFIG ...................................................................... 72
Functions Menu, general................................................ 73
Parameter Change Menus ............................................. 74
Settings and Error Messages......................................... 75
Tester Menu..................................................................... 80
TESTER Menu ................................................................ 81
Alar m s M en u ................................................................... 8 2
ALARMS Menu ................................................................ 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu................................................. 86
Preparatory Measures ................................................ 86
Calibration................................................................... 86
Conf ig . Menu ................................................................... 8 7
CONFIG Menu ................................................................ 88
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TABLE OF CONTENTS
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
SET MODEL ............................................................... 88
SET OPTIONS............................................................ 88
ADJUSTMENTS ......................................................... 88
On Board Charger ................................................................... 89
General............................................................................ 89
Battery Charging Phases ............................................... 89
First Phase (I1) ........................................................... 89
Second Phase (P)....................................................... 89
Third Phase (U) .......................................................... 8 9
Fourth Phase (I2)........................................................ 89
End of Normal Charging ............................................. 90
Special Charging Phases............................................... 90
Compensating Charge................................................ 90
Float Charge ............................................................... 90
Partial Charging .......................................................... 90
Charging Errors ............................................................... 91
Green LED is not lit..................................................... 91
Possible Causes: ...................................................... 91
Green LED flashing .................................................... 91
Important Technical Data................................................ 92
Replacing the Charger ................................................... 92
Removal / Installation.................................................. 92
Electric Motors ........................................................................ 93
General Maintenance Instructions ........................................ 93
Preparation...................................................................... 93
Important Maintenance Instructions ........................... 93
Traction Motor Maintenance (WF 1.0 t) ................................. 94
Access to brushes .......................................................... 94
Maintenance.................................................................... 94
Armature ..................................................................... 94
Bearings...................................................................... 94
Traction Motor Maintenance (WF 1.2 t) ................................. 95
Access to brushes .......................................................... 95
Maintenance.................................................................... 95
Armature ..................................................................... 95
Bearings...................................................................... 95
Pump Motor Maintenance ...................................................... 96
Access to brushes .......................................................... 96
Maintenance.................................................................... 96
Armature.......................................................................... 96
Contactors ............................................................................... 97
Inspection........................................................................ 97
Contacts...................................................................... 97
Coils ............................................................................ 97
Springs........................................................................ 97
Servicing ......................................................................... 98
Dismantling ................................................................. 98
Assembly .................................................................... 98
Hydraulic Control Module (HCM)........................................... 99
Battery Discharge Indicator (BDI) ......................................... 100
OPERATION.................................................................... 100
General............................................................................ 101
Battery Discharge Indicator Setting (BDI) ..................... 101
Calibration for wet batteries ........................................... 1 02
TROUBLESHOOTING.................................................... 103
Traction Controller Safety Test ....................................... 104
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TABLE OF CONTENTS
M5 – BRAKE PAGE SER-N0. CUT .................. REV .
Brake ........................................................................................ 107
Function........................................................................... 107
Disassembly.................................................................... 107
Assembly......................................................................... 109
Air gap setting ................................................................. 109
Brake moment setting ..................................................... 110
Brake test ........................................................................ 110
Definition of run-in/new rotor ...................................... 110
General Notes............................................................. 110
M6 – STEERING PAGE SER-N0. CUT .................. REV.
Steering.................................................................................... 11 5
Live ring bearing ............................................................. 115
Disassembly ............................................................... 115
Installation................................................................... 115
Control handle return springs ............................................... 116
Adjustment ...................................................................... 116
Disassembly.................................................................... 116
Installation ....................................................................... 116
Steering Chain......................................................................... 117
Permissible Elongation................................................... 11 7
Chain Tension Adjustment.............................................. 117
Tiller Handle ............................................................................ 119
Main Components........................................................... 119
Tiller Handle Component Removal / Installation ................. 120
Tiller Handle Shells......................................................... 120
Removing the Upper and Lower Shells ...................... 120
Fitting the Upper and Lower Shells ............................. 121
Switch Unit ...................................................................... 122
Removal...................................................................... 122
Switch Unit Installation................................................ 122
"Fast/Slo w" Toggle Switch .............................................. 123
Removal...................................................................... 123
Installation................................................................... 123
Hydraulic Board .............................................................. 123
Removal...................................................................... 123
Installation................................................................... 123
Potentiometer.................................................................. 124
Removal...................................................................... 124
Installation................................................................... 124
Safety Reverse Switch.................................................... 125
Removal...................................................................... 125
Installation................................................................... 125
Horn Switch..................................................................... 126
Removal...................................................................... 126
Installation................................................................... 126
Handle ............................................................................. 127
Removal...................................................................... 127
Installation................................................................... 127
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TABLE OF CONTENTS
M7 – MAST PAGE SER-N0. CUT .................. REV .
Mast.......................................................................................... 131
General............................................................................ 131
Torque Requirements ................................................. 131
Lifting Gear Minimum Capacity................................... 131
Mast Removal ................................................................. 131
Installation ....................................................................... 132
Fork Carriage Removal .................................................. 132
Fork Carriage Installation............................................... 132
Fork Carriage Adjustment .............................................. 133
Mast Maintenance .......................................................... 134
Lubricating Roller Tracks............................................. 134
Lowering Plumb Test .............................................................. 135
Preparatory measures.................................................... 135
Carrying out the vertical plumb test............................... 135
Lift chains ................................................................................ 136
General............................................................................ 136
Inspection........................................................................ 136
Cleaning...................................................................... 136
Wear ........................................................................... 136
Freedom of Movement of Chain Links ........................ 137
Chain Tension ............................................................. 137
Chain Anchor and Pulleys .......................................... 138
Worn Connection Plates ............................................. 138
Protruding or Turned Chain Pins................................. 138
Corrosion .................................................................... 138
Chain Lateral Wear ..................................................... 13 9
Uneven Chain Tension .............................................. 139
Misaligned Lift Components ..................................... 139
Lift Chain Lubrication...................................................... 140
Separating Lift Chains .................................................... 14 1
Tools and Equipment Required ...................................... 141
Detachment..................................................................... 141
Fork Tines ................................................................................ 142
General............................................................................ 142
Terms .......................................................................... 142
Fork Identification ....................................................... 142
Repairs ............................................................................ 142
Fork Inspection ............................................................... 142
Crack Inspection ......................................................... 142
V erticality Test ............................................................. 143
Fork Blade Warping .................................................... 143
Measuring the Fork Tip Width........................................ 143
Fork Tine Height Difference ........................................... 143
Fork Stop......................................................................... 143
Fork Blade Wear ............................................................. 144
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TABLE OF CONTENTS
M8 – CYLINDERS PAGE SER-N0. CUT .................. REV .
Cylinders.................................................................................. 147
General............................................................................ 147
Safety when working on hydraulic systems ................ 147
General Instructions for Repairing Hydraulic
Components ............................................................... 147
Rod Seal Assembly................................................................. 148
General............................................................................ 148
Large Rod Seal Assembly.............................................. 148
Small Seal Rod Assembly .............................................. 149
Rod Seal Assembly, Sealing Lip First............................ 150
Cylinders.................................................................................. 151
TL Mast Lift Cylinder....................................................... 151
Seal Replacement ...................................................... 151
Installing TL Mast Lift Cylinders.................................. 152
TF Mast Lift Cylinders .................................................... 154
Removing the TF Mast Lift Cylinders.......................... 154
Seal Replacement ...................................................... 154
Installing TF Mast Lift Cylinders.................................. 155
Free Lift Cylinder TF and Mono Mast ............................ 156
Seal Replacement ...................................................... 156
Installing Free Lift Cylinder............................................. 157
Cylinder Bleeding and Flushing ..................................... 157
Bleeding — Mast Lift Cylinders................................... 157
Bleeding — Free Lift Cylinder (if applicable) .............. 1 57
Flushing – Mast Lift Cylinders
and Free Lift Cylinders (if applicable) ......................... 158
Drift T est...................................................................... 15 8
Cylinder Shimming .......................................................... 158
Lift Cylinder Shims...................................................... 158
Free Lift Cylinder Shims .............................................. 15 8
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
WF 3000-10 Standard.............................................................. 163
Overview.......................................................................... 163
WF3000-10 Standard,
Traction Controller - SEM0 Logic ................................... 164
WF3000-10 Standard,
Traction Controller - SEM0 Power Circuit...................... 165
WF3000-10 Standard,
Power Unit Control Circuit .............................................. 166
WF3000-10 Standard,
Control Handle - Control Circuit..................................... 167
WF3000-10 Standard,
Hydraulic Control Module (HCM)................................... 168
WF3000-10 with Options ........................................................ 169
Overview.......................................................................... 169
WF3000-10 with Options,
Traction Controller - SEM0 Logic ................................... 170
WF3000-10 with Options,
Traction Controller - SEM0 Power Circuit...................... 171
WF3000-10 with Options,
Power Unit - Control Circuit............................................ 172
WF3000-10 with Options,
Control Handle - Control Circuit..................................... 1 73
WF3000-10 with Options,Hydraulic Control Module (HCM)
- Travel Alarm and Flashing Beacon.............................. 174
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TABLE OF CONTENTS
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
WF 3000-12 Standard.............................................................. 175
Overview.......................................................................... 175
WF3000-12 Standard,
Traction Controller - SEM0 Logic ................................... 176
WF3000-12 Standard,
Traction Controller - SEM0 Power Circuit...................... 177
WF3000-12 Standard,
Power Unit Control Circuit .............................................. 178
WF3000-12 Standard,
Control Handle - Control Circuit..................................... 179
WF3000-12 Standard,
Hydraulic Control Module (HCM)................................... 180
WF3000-12 with Options ........................................................ 181
Overview.......................................................................... 181
WF3000-12 Swith Options,
Traction Controller - SEM0 Logic ................................... 182
WF3000-12 with Options,
Traction Controller - SEM0 Power Circuit...................... 183
WF3000-12 with Options,
Power Unit - Control Circuit............................................ 184
WF3000-12 with Options,
Control Handle - Control Circuit..................................... 1 85
WF3000-12 with Options, Hydraulic Control Module (HCM)
- Travel Alarm and Flashing Beacon.............................. 186
Wire Harness ........................................................................... 187
Control Handle Wiring .................................................... 188
Power Cab les .................................................................. 18 9
HYD – HYDRAULIC SCHEMATICS PAGE SER-N0. CUT .................. REV .
Hydraulik Schematic Standard Lift ....................................... 193
Hydraulik Schematic Soft Lift ................................................ 194
XII
WF3000 09/2005 • Printed in GermanyMS-IDX-3300
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SAFETY
1
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2
SAFETY
Safety Symbols used in the Manual
T o help guide you through the man ual and to highlight particular 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.
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.
DANGER
Follow all national/local safety regulations 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.
● 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.
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 wellventilated.
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.
WF3000 09/2005 • Printed in Germany MS-MA-0000
3
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.
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.
● 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.
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INTRODUCTION
5
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6
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 components.
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 personnel
who have been trained and authorised 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
experience at all.
This information can be found on the truck's data plate.
Only if this information is provided can the order be
processed 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 y our 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 or133
Using the Manual
The manual is divided into sections. The following table
shows how the manual is structured.
ecnanetniaMsnoitceS
Operating Instructions
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 saf ety
and error free functioning of your CROWN vehicle.
Service T raining
CROWN offers the appropriate vehicle related training
for service personnel. Details on this training can be
obtained 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
noitceS noitpircseD
XDItnetnoCfoelbaT
AMytefaS
DTInoitcudortnI
1MtnemtsujdAdnanoitacirbuL
2MsciluardyH
3MtinUevirD
4MlacirtcelE
5MekarB
6MgnireetS
● The truck model number
● The truck serial number
WF3000 09/2005 • Printed in Germany MS-ITD 3300
7MmsinahceMgnitfiL/tsaM
8MrednilyC
AIDsmargaiDlacirtcelE
DYHcitamehcSciluardyH
A01M-gb
7M1.0-0000-00077
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
WF 3000-1.0
WF 3000-1.2
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8M1.0-0000-00088
Printed in Germany
LUBRICATION AND ADJUSTMENT
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10
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LUBRICATION AND ADJUSTMENT
Raising And T owing The T ruck
Raising With Another Forklift Truck
DANGER
Failure to read the instructions can
cause the truck to tip over or fall from the
forks. Fatal accidents could result.
● Position the forks of the truck which is doing the
lifting as shown by the diagram below.
● The centre of gravity of the WF 3000 with and
without the battery is near the battery compartment. It should always be between the forks of
the truck doing the lifting.
● Secure the WF 3000 firmly to the forks of the
truck which is doing the lifting (e.g. with appropriate straps).
Schwerpunkt
> 850
> 650
MO-3300-014
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11
LUBRICATION AND ADJUSTMENT
Lifting by Crane
DANGER
Make sure the crane / fork lift and the
lifting equipment have sufficient capacity.
If the crane / lift truck crash or a load
falls, fatal injuries can result.
Capacity required: 900 kg
Attach lifting gear as shown in the following diagram and
prevent the truck from slipping.
12
MO-3300-013
WF3000 09/2005 • Printed in GermanyMS-1.0-3300
LUBRICATION AND ADJUSTMENT
Towing the Truck
DANGER
Tipovers can result in fatal accidents.
If the towing truck negotiates a bend, a
fork will slip under the truck that is being
towed. This can cause the towed truck to
tip over and result in fatal injuries.
Only travel straight ahead when towing.
When the truck is de-energised, the brake (acting on the
drive wheel) is applied. To remove the truck from an aisle,
for example , it can be raised and pulled by a f orklift truck.
The required capacity (WF unladen, with battery , 800 kg):
1100 kg. The load wheels remain on the ground when
the truck is towed.
CAUTION
Risk of damage to the drive system.
If the drive wheel is still touching the
ground, the drive system will be damaged when the truck is towed.
Only raise the truck so far that the drive
wheel is not touching the ground.
● Position the forks as shown in the diagram.
● Raise the truck (at its front) approx. 20 mm, but
no higher than necessary as otherwise the
bottom of the WF’s fork tips will scratch the
ground.
MO-3300-015
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13
LUBRICATION AND ADJUSTMENT
Component Access
Undo the 3 screws securing the dashboard. Lift off the
dashboard and panel to gain access to the components
beneath the panel.
Note: The illustration shows the model with the TT mast.
Mast
Fork
Load wheel
Safety Screen
Control handle
Free lift cylinder
Dashboard
Control handle knuckle
Controller and contactors
Traction and pump motors
Caster wheel
14
Battery and battery connector
Drive wheel
WF3000 09/2005 • Printed in GermanyMS-1.0-3300
LUBRICATION AND ADJUSTMENT
After disassembling the top panel you will be able to
access the:
● Diagnostic LED on the TCM
● Fuse FU1 (travel power fuse)
● Fuse FUS (raise power fuse)
● Combination instrument
● Fuse FU3 (signal)
● Fuse FU4 (cold store versions only)
After lifting off the bottom panel you will be able to
access the:
● Traction motor
● Power unit
● Brake
● Pump motor
The control handle knuckle contains the:
● BRS (brake switch)
● ORS (brake override zone switch)
The mast contains the:
● FLS (flashing light)
● LMS (lift limit switch)
● Hydraulic unit
● Horn
● Alarm transmitter
● Diode block
● Main contactor
● Relay K2
● Alarm filter block
● TCM (traction control module)
● HCM (hydraulic control module)
The hand grip contains:
● HNS1 & HNS2 (horn switches)
● LOS1 & LOS2 (fork lower switches)
● RAS (raise switch)
● HSS (fast / slow travel switch)
● SAS (safety reverse switch)
● FS, RS, POT (travel switch unit and
potentiometer)
WF3000 09/2005 • Printed in Germany MS-1.0-3300
15
LUBRICATION AND ADJUSTMENT
Maintenance
Recommended Lubricants and Oils
Lubricants
The next page shows typical lubricants used by Crown
itself in its factories. Howe ver , you can use any lubricants
provided they meet the same technical criteria.
Cold Store Trucks
Special hydraulic oil, lubrication oil and grease must be
used for cold store trucks operating in low temperature
conditions (see table on following page). An anticorrosion
fluid (Crown no. 805236-004) must be applied to all
screws, washers, nuts, pins, retaining rings etc. Carefully protect all electrical connections and components
against corrosion. F or detailed information, refer to chapter 4.
Service intervals must be adapted to the conditions of
use. This means they must be reduced as far as possible to prevent excessive wear.
Taking the truck out of service
● Every 3 months connect the battery, carry out a
daily inspection and activate all the truck functions. Now disconnect the battery again.
Bringing the truck back into service
● If you wish to bring the truck back into service,
proceed as follows:
● Remove any anti-corrosion agents which have
been additionally applied (apart from the cold
store agents)*.
● Jack up the truck, remove the wooden blocks and
lower the truck.
● Charge the battery or fit a charged battery.
● Connect the battery.
● Carry out the daily inspection.
* Do not apply high pressure cleaning agents and/or
solvents to the truck. Do not use metallic brushes. Do not
wet clean the electrical system and do not use flammable solvents.
If you wish to take the truck out of service for more than
3 months, proceed as follows:
● Disconnect the battery from the truck.
● Decommission the battery in accordance with the
manufacturer’s instructions.
● Clean the truck*). Lubricate in accordance with
the maintenance manual.
● If the truck is to be stored in harsh conditions
(e.g. saline atmosphere) treat the surface of the
truck with a suitable preservative to prevent
corrosion.
● Do not park the truck in the open air or in a
humid environment. The ideal place is a dry room
where the temperature and air humidity are as
constant as possible. If the truck has to be
covered, use an air-permeable material. Do not
use plastic sheets. Otherwise, condensation may
form.
● Jack up the truck. Lower the chassis onto suit-
able wooden blocks so that the wheels clear the
ground (prevents the wheels from flattening from
constant pressure).
16
WF3000 09/2005 • Printed in GermanyMS-1.0-3300
Rev. 01/03
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