Crown Forklift DT 3000 Series Maintenance Manual 812591-006 – PDF DOWNLOAD

Description

Crown Forklift DT 3000 Series Maintenance Manual 812591-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift DT 3000 Series Maintenance Manual 812591-006 – PDF DOWNLOAD

Language : English
Pages :444
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift DT 3000 Series Maintenance Manual 812591-006 – PDF DOWNLOAD

Table of Contents 5
Introduction 19
Important Information 21
Service personnel qualification 21
Ordering spare parts 21
Ordering documentation 21
Manual structure 21
Conventions 21
Text mark-ups in the manual 21
Brief description of equipment 21
Truck Data Number 22
Safety 23
Safety Notices 25
Basic Safety Notices 26
Organisational measures 26
Truck modifications and additions 26
Personal safety equipment 26
Protecting the hazardous area 26
Hazards from stored energy 26
Repair work 27
Restoring the truck to service after repair work 27
Cleaning work 27
Handling batteries 27
Warning and instruction decals on the truck 27
Lifting gear and slings 27
Environmental protection 28
Lubrication & Adjustment 29
Transport and Storage 31
Lifting the truck 31
Lifting the truck by crane 31
Lifting the truck with a forklift truck 32
Towing the truck 33
Jacking up the Truck 34
Transporting the Truck 35
Securing the truck for transport on a truck bed 35
Storing the Truck 36
Placing the truck in storage 36
Periodically starting a truck that has been in storage 36
Restoring the Truck to Service 36
Cleaning the Truck and Components 37
Effects of incorrect cleaning 37
Electrical components 37
Roller and slide bearings 37
Corrosion-protected surfaces 37
Environmental protection 37
Cleaning the entire truck 37
Cleaning removed components 38
Cleaning other mechanical components 38
Recommended Lubricants and Consumables 39
Cold store truck requirements 39
Abbreviations used in the table 39
Planned Maintenance 41
Maintenance schedule 41
Annual inspection in accordance with FEM 4004 41
Terms and abbreviations used 41
Maintenance Schedule 42
Electrical System 42
Electrical system 44
Lift mechanism 46
Drive system, steering and wheels 48
Safety mechanisms 50
Finger Guard 52
Testing the finger guard 52
Checking the finger guard mechanism for freedom of movement 52
Repairing the finger guard mechanism 53
Finger guard mechanism disassembly 53
Attaching the finger guard mechanism 53
Adjusting the finger guard mechanism 53
Battery Retainer 54
Testing the bar monitoring system 54
Troubleshooting 54
Adjusting the BLS sensor 54
Adjusting the Outrigger Lift Limit Switch (LMS1) 55
Castor Wheel Replacement 56
Replacing single castor wheels 56
Replacing the single castor wheel pivot bearing 56
Replacing the single castor wheel 56
Replacing tandem castor wheels 58
Replacing the tandem castor wheel pivot bearing 58
Replacing the tandem castor wheel bearings 58
Replacing the tandem castor wheels 58
Torques 60
Standard torques 60
Hydraulic System 61
Replacing the Hydraulic Unit 63
Hydraulic unit removal 63
Hydraulic unit assembly 63
Repairing the Hydraulic Unit 64
Replacing the hydraulic pump 64
Preparation 64
Hydraulic pump removal 64
Hydraulic pump assembly 64
Hydraulic unit reassembly 64
Torques and references, without traction control 67
Torques and references, with traction control 68
Changing the Hydraulic Oil and Return Filter 69
Bleeding the Hydraulic System 70
Replacing the Relief Valve RV1 71
Relief valve test 71
Flushing the Hydraulic System 72
Drift Test 73
Preconditions for all drift tests 73
Outrigger lift drift test 73
Fork lift drift test 73
Hydraulic System Troubleshooting 74
Drive Unit 75
Components 77
Trucks with mechanical steering 77
Trucks with electrical steering 77
Replacing the Drive Wheel 78
Drive wheel disassembly 78
Drive Wheel Assembly 78
Changing the Gear Oil 79
Electrical System 81
Components 83
DT 3040 -MW and -MF Components 84
DT 3040 -EF Components 86
Accessing the Service Levels 89
Software Versions 90
Menu Structure 92
Operator and Service Menu 93
Analyzer Menu, A1 – A2 95
Analyzer Menu, A3 Outputs 96
Analyzer Menu, A4 Test Outputs 97
Calibration Menu, C2 Steer System 98
Calibration, C3 Lift/Lower Rotary Encoder menu 99
Analyzer Menu, A221 – A2219, Access 2 Inputs100
Analyzer, A231 – A2315, Access 3 Inputs Menu101
Analyzer, A221 – A2219, Access 81 Inputs Menu102
Analyzer Menu, A251 – A258, Access 5 Inputs103
Features F6 – F7104
Features F4 Menu, Truck Type105
Features Menu, F71 – F 74106
Features Menu, F10 – F13107
Hour Menu, H1 –– H5108
Events Menu, E1109
Events Menu, E2 – E3110
Performance Menu, P1 (DT 3040 MW)111
Performance Menu, P2 (DT 3040 MW)112
Performance Menu, P3 (DT 3040 MW)113
Performance Menu, P1 (DT 3040 -MF -EF)114
Performance Menu, P1 (DT 3040 -MF -EF)115
Performance Menu, P2 (DT 3040 -MF -EF)116
Performance Menu, P21 (DT 3040 -MF -EF)117
Performance Menu, P3 (DT 3040 -MF -EF)118
Performance Menu, P3 (DT 3040 -MF -EF)119
Performance Menu, P4 – P11120
Performance Menu, P12 – P16121
Utilities Menu, U1122
Input Signals123
Initial truck status123
SAS and BRS123
Operating mode definition123
Pedestrian mode123
Comfort mode123
Rider mode123
Conventions123
Brief description of equipment123
Input Signals125
Platform and Side Restraint Logic129
Brief description of equipment129
Folding platform129
Side restraint and platform setting definition129
DT 3040 -MW Software Parameter Settings131
Brief description of equipment131
Operation modes131
Markings131
DT 3040 -MF Software Parameter Settings133
Brief description of equipment133
Operating modes133
Markings133
DT 3040 -EF Software Parameter Settings136
Brief description of equipment136
Operating modes136
Markings136
Calibration139
Selecting the CALIBRATION Menu139
Calibrating the traction potentiometer139
Travel direction definition139
Electric steering calibration140
Proportional lift and lower calibration141
Event Codes143
Malfunctions with event code display143
Locating malfunctions143
Digit convention for event codes143
Event Code 100 (DT 3040 -MW, -MF)144
Event Code 100144
Event Code 202 (DT 3040 -MW, -MF)146
Event Code 202146
Event Codes 203 – 204 (DT 3040 -MW, -MF)148
Event Code 203148
Event Code 204148
Event Code 205 (DT 3040 -MW, -MF)151
Event Code 205151
Event Code 208 (DT 3040 -MW, -MF)153
Event code 208153
Event Code 228 (DT 3040 -MW, -MF)154
Event code 228154
Event Code 229 (DT 3040 -MW, -MF)155
Event code 229155
Event Code 230 (DT 3040 -MW, -MF)157
Event code 230157
Event Code 231 (DT 3040 -MW, -MF)159
Event code 231159
Event Codes 232 – 233 (DT 3040 -MW, -MF)161
Event code 232161
Event code 233161
Event Code 234 (DT 3040 -MW, -MF)161
Event code 234161
Event Code 236 (DT 3040 -MW, -MF)163
Event code 236163
Event Code 239 (DT 3040 -MW, -MF)164
Event code 239164
Event Code 300 (DT 3040 -MW, -MF)166
Event code 300166
Event Codes 301 – 302 (DT 3040 -MW, -MF)167
Event code 301167
Event Code 302 (DT 3040 -MW, -MF)167
Event code 302167
Event Code 303 (DT 3040 -MW, -MF)168
Event code 303168
Event Code 304 (DT 3040 -MW, -MF)169
Event code 304169
Event Codes 305 – 306 (DT 3040 -MW, -MF)172
Event code 305172
Event code 306172
Event Code 307 (DT 3040 -MW, -MF)173
Event code 307173
Event Code 308 (DT 3040 -MW, -MF)174
Event code 308174
Event Codes 309 – 310 (DT 3040 -MW, -MF)175
Event code 309175
Event code 310175
Event Code 314 (DT 3040 -MW, -MF)176
Event code 314176
Event Code 315 (DT 3040 -MW, -MF)177
Event code 315177
Event Code 316 (DT 3040 -MW, -MF)178
Event code 316178
Event Code 317 (DT 3040 -MW, -MF)179
Event code 317179
Event Code 320 (DT 3040 -MW, -MF)180
Event code 320180
Event Code 321 (DT 3040 -MW, -MF)181
Event code 321181
Event Codes 322 – 326 (DT 3040 -MW, -MF)182
Event code 322182
Event code 326182
Event Codes 328 – 329 (DT 3040 -MW, -MF)183
Event code 328183
Event code 329183
Event Codes 333 – 334 (DT 3040 -MW, -MF)184
Event code 333184
Event code 334184
Event Code 337 (DT 3040 -MW, -MF)185
Event code 337185
Event Code 338 (DT 3040 -MW, -MF)186
Event code 338186
Event Code 341 (DT 3040 -MW, -MF)187
Event code 341187
Event Code 342 (DT 3040 -MW, -MF)188
Event code 342188
Event Code 343 (DT 3040 -MW, -MF)190
Event code 343190
Event Codes 348 – 351 (DT 3040 -MW, -MF)192
Event code 348192
Event code 351192
Event Code 352 (DT 3040 -MW, -MF)193
Event code 352193
Event Code 353 (DT 3040 -MW, -MF)194
Event code 353194
Event Codes 354 – 355 (DT 3040 -MW, -MF)195
Event code 354195
Event code 355195
Event Code 356 (DT 3040 -MW, -MF)196
Event code 356196
Event Code 357 (DT 3040 -MW, -MF)197
Event code 357197
Event Code 358 (DT 3040 -MW, -MF)198
Event code 358198
Event Code 359 (DT 3040 -MW, -MF)199
Event code 359199
Event Code 361 (DT 3040 -MW, -MF)201
Event code 361201
Event Code 362 (DT 3040 -MW, -MF)202
Event code 362202
Event Code 364 (DT 3040 -MW, -MF)203
Event Code 364203
Event Code 365 (DT 3040 -MW, -MF)205
Event code 365205
Event Code 100 (DT 3040 -EF)206
Event Code 100206
Event Code 202 (DT 3040 -EF)208
Event Code 202208
Event Codes 203 – 204 (DT 3040 -EF)210
Event Code 203210
Event Code 204210
Event Code 205 (DT 3040 -EF)212
Event Code 205212
Event Code 208 (DT 3040 -EF)214
Event code 208214
Event Code 228 (DT 3040 -EF)215
Event code 228215
Event Code 229 (DT 3040 -EF)216
Event code 229216
Event Code 230 (DT 3040 -EF)218
Event code 230218
Event Code 231 (DT 3040 -EF)219
Event code 231219
Event Codes 232 – 233 (DT 3040 -EF)221
Event code 232221
Event code 233221
Event Code 234 (DT 3040 -EF)222
Event code 234222
Event Code 235 (DT 3040 -EF)223
Event code 235223
Event Code 236 (DT 3040 -EF)224
Event code 236224
Event Code 237 (DT 3040 -EF)225
Event code 237225
Event Codes 238 – 239 (DT 3040 -EF)226
Event code 238226
Event Code 239 (DT 3040 -EF)226
Event code 239226
Event Code 300 (DT 3040 -EF)228
Event code 300228
Event Codes 301 – 302 (DT 3040 -EF)229
Event code 301229
Event Code 302 (DT 3040 -EF)229
Event code 302229
Event Code 303 (DT 3040 -EF)230
Event code 303230
Event Code 304 (DT 3040 -EF)231
Event code 304231
Event Codes 305 – 306 (DT 3040 -EF)234
Event code 305234
Event code 306234
Event Codes 307 – 308 (DT 3040 -EF)235
Event code 307235
Event Code 308 (DT 3040 -EF)236
Event code 308236
Event Codes 309 – 310 (DT 3040 -EF)237
Event code 309237
Event code 310237
Event Code 314 (DT 3040 -EF)238
Event code 314238
Event Code 315 (DT 3040 -EF)239
Event code 315239
Event Code 316 (DT 3040 -EF)240
Event code 316240
Event Code 317 (DT 3040 -EF)241
Event code 317241
Event Code 320 (DT 3040 -EF)242
Event code 320242
Event Code 321 (DT 3040 -EF)243
Event code 321243
Event Codes 322 – 324 (DT 3040 -EF)244
Event code 322244
Event code 324244
Event Code 326 (DT 3040 -EF)245
Event code 326245
Event Codes 328 – 329 (DT 3040 -EF)246
Event code 328246
Event code 329246
Event Codes 333 – 334 (DT 3040 -EF)247
Event code 333247
Event code 334247
Event Code 335 (DT 3040 -EF)248
Event code 335248
Event Code 337 (DT 3040 -EF)249
Event code 337249
Event Code 338 (DT 3040 -EF)250
Event code 338250
Event Code 341 (DT 3040 -EF)251
Event code 341251
Event Code 342 (DT 3040 -EF)252
Event code 342252
Event Code 343 (DT 3040 -EF)253
Event code 343253
Event Codes 348 – 351 (DT 3040 -EF)255
Event code 348255
Event code 351255
Event Code 352 (DT 3040 -EF)256
Event code 352256
Event Code 353 (DT 3040 -EF)257
Event code 353257
Event Codes 354 – 355 (DT 3040 -EF)258
Event code 354258
Event code 355258
Event Code 356 (DT 3040 -EF)259
Event code 356259
Event Code 357 (DT 3040 -EF)260
Event code 357260
Event Code 358 (DT 3040 -EF)261
Event code 358261
Event Code 359 (DT 3040 -EF)262
Event code 359262
Event Code 361 (DT 3040 -EF)264
Event code 361264
Event Code 362 (DT 3040 -EF)265
Event code 362265
Event Code 364 (DT 3040 -EF)266
Event Code 364266
Event Code 365 (DT 3040 -EF)268
Event code 365268
Event Code 368 (DT 3040 -EF)268
Event code 368268
Event Codes 500 – 501 (DT 3040 -EF)269
Event Code 500269
Event Code 501269
Event Codes 502 – 504 (DT 3040 -EF)270
Event Code 502270
Event Code 503270
Event Code 504270
Event Codes 505 – 506 (DT 3040 -EF)271
Event Code 505271
Event Code 506271
Event code 508272
Event Code 509 (DT 3040 -EF)273
Event code 509273
Event Code 510 (DT 3040 -EF)275
Event code 510275
Event Code 511 (DT 3040 -EF)277
Event code 511277
Event Codes 512 – 513 (DT 3040 -EF)278
Event code 512278
Event code 513278
Event Code 514 (DT 3040 -EF)279
Event code 514279
Event Codes 515 – 516 (DT 3040 -EF)281
Event code 515281
Event code 516281
Event Code 517 (DT 3040 -EF)282
Event Code 517282
Event Code 518 (DT 3040 -EF)284
Event code 518284
Event Code 519 (DT 3040 -EF)285
Event code 519285
Event Code 520 (DT 3040 -EF)286
Event code 520286
Event Code 521 (DT 3040 -EF)286
Event code 521286
Event Code 522 (DT 3040 -EF)287
Event code 522287
Event Code 523 (DT 3040 -EF)288
Event code 523288
Event Code 524 (DT 3040 -EF)290
Event code 524290
Event Code 525 (DT 3040 -EF)290
Event code 525290
Event Code 526 (DT 3040 -EF)292
Event code 526292
Event Code 527 (DT 3040 -EF)293
Event code 527293
Event Codes 528 – 529 (DT 3040 -EF)294
Event code 528294
Event code 529294
Event Code 530 (DT 3040 -EF)295
Event code 530295
Event Code 532 (DT 3040 -EF)297
Event code 532297
Event Code 533 (DT 3040 -EF)298
Event code 533298
Event Codes 535 – 536 (DT 3040 -EF)299
Event code 535299
Event code 536299
Event Code 537 (DT 3040 -EF)300
Event code 537300
Event Code 538 (DT 3040 -EF)301
Event code 538301
Event Code 539 (DT 3040 -EF)303
Event code 539303
Event Code 540 (DT 3040 -EF)304
Event code 540304
Event Codes 541 – 542 (DT 3040 -EF)305
Event code 541305
Event code 542305
Event Code 543 (DT 3040 -EF)307
Event code 543307
Event Code 544 (DT 3040 -EF)307
Event code 544307
Event Codes 545, 800 to 905 (DT 3040 -EF)309
Event code 545309
Event code 8xx309
Event code 9xx309
Events with Text Messages310
Platform Failure310
Truck Stopped312
Hightemp TCM313
Hightemp traction motor314
Release control handle316
Release travel control317
Hightemp steering controller317
Hightemp steering motor319
General DC Motor Maintenance Instructions321
Brushes321
Motor321
Rotor321
Traction Motor (M1)322
Traction motor disassembly322
Traction motor assembly322
Repairing the traction motor322
Preparation323
Dismantling the rotor assembly323
Assembling the rotor assembly323
Final tasks323
Pump motor (M2)325
Brushes325
Rotor325
Steer motor (M3)326
Special tools required327
Steer motor disassembly327
Steer motor assembly327
Repairing the steer motor327
Preparation327
Steer motor disassembly327
Steer motor assembly327
Final tasks327
Servicing and Replacing the Control Modules328
General328
Power fuses328
Discharging the capacitors328
Servicing the control modules328
Replacing control modules328
Removing the control module328
Assembling the control module329
Control Module PMT Test330
General330
Required tools330
PMT Test330
Testing Access 2330
Testing Access 3331
Testing Access 5332
Battery Information333
Charging the battery333
Replacing the battery333
Battery Discharge Indicator (BDI)334
Load profile and discharge curve334
Adapting the BDI setting334
Repairing Contactors336
Wear test336
Checking the contacts336
Checking the coils336
Checking the springs336
Modifications337
Converting the truck from Enter key to key switch power-up function337
Mechanical conversion337
Changing the software337
Converting the truck from key switch to Enter key power-up function338
Mechanical conversion338
Changing the software338
Glossary339
Brake System341
Components and Operation343
Service brake343
Parking brake343
Servicing the Parking Brake344
Measuring the air gap344
Troubleshooting344
Replacing the Parking Brake345
Parking brake disassembly345
Parking brake assembly345
Testing the Braking Distance347
Requirements347
Performing the test347
Braking distance tables347
Max braking distances DT 3040 -MW, with or without max rated load347
Max braking distances DT 3040 -MF347
With max rated load in rider mode347
Without load in rider mode347
With or without max rated load in pedestrian mode347
Max braking distances DT 3040 -EF348
With max rated load in rider mode348
Without load in rider mode348
With or without max rated load in pedestrian mode348
Steering349
Repairing the Control Handle351
Replacing the control handle shells352
Shell removal352
Shell assembly353
Replacing the switch unit353
Switch unit removal354
Switch unit assembly354
Replacing the “rabbit/turtle” toggle module354
Toggle module removal354
Toggle module assembly355
Replacing the control handle grip PC boards355
Hydraulic PC board removal355
Hydraulic PC board assembly355
Main PC board removal355
Main PC board assembly355
Replacing the traction potentiometer356
Traction potentiometer removal356
Traction potentiometer assembly357
Replacing the safety reverse switch (SAS)357
Removing the safety reverse switch (SAS)357
SAS / BRS switch assembly358
Replacing the grips and horn switch358
Replacing the outrigger lift switch358
Removing the outrigger lift switch358
Assembling the outrigger lift switch358
Repairing Control Handle Return Springs359
Panel removal359
Return spring pre-tension adjustment359
Replacing the return springs360
Return spring removal360
Return spring assembly360
Tools required:360
Lifting Mechanism361
Forks363
General363
Fork inspection363
Checking forks for cracks363
Chain Supports and Lift Chains364
General364
Periodic inspection of chain supports and lift chains364
Periodic replacement of chain supports and lift chains364
Cleaning lift chains364
Inspecting Chain Supports and Lift Chains365
Checking the service hours for the lift chains and anchor bolts365
Checking the lift chain for elongation365
General365
Preparatory measures365
Freedom of movement366
Worn or missing plates366
Turned pins367
Corrosion367
Chain lateral wear367
Checking chain supports and anchor bolts367
Checking the chain pulleys368
Checking and adjusting the chain tension368
Checking the lifting components for misalignment368
Lubricating Lift Chains369
General information369
Lubrication intervals and lubricants369
Separating Lift Chains370
Tools and equipment required370
Replacing Mast Guards371
Replacing mast guards on the TL mast with 1700 mm lift height371
Preparation371
Removing mast guards371
Assembling mast guards371
Replacing the mast guard on the TL mast with 2100 mm lift height372
Preparation372
Removing mast guards372
Assembling mast guards373
Replacing the mast guard on the TF mast with 2600 mm lift height374
Preparation374
Removing mast guards374
Assembling mast guards374
Cylinders377
General379
Safety notices379
Hydraulic system repair instructions379
Replacing the rod seals379
Tools380
Small hook380
Extractor380
Producing extractors380
Groove aligning arbor for small rod seals380
Assembly devices for large rod seals381
Protective mechanisms381
Rod Seal Removal and Assembly382
Removing a large rod seal382
Removing a small rod seal382
Inserting a large rod seal382
Fitting a small rod seal383
Rod seal assembly, sealing lip first383
Replacing the Lift Cylinder on the TL Mast384
Removing the lift cylinder (TL mast)384
Lift cylinder (TL mast) assembly385
Repairing the Lift Cylinder for the TL Mast387
Replacing the Lift Cylinder on the TF Mast389
Lift cylinder (TF mast) removal389
Lift cylinder (TF mast) removal389
Lift cylinder (TF mast) assembly390
Repairing the Lift Cylinder for the TF Mast392
Replacing the Free Lift Cylinder on the TF Mast394
Free lift cylinder (TF mast) removal394
Free lift cylinder (TF mast) assembly394
Repairing the Free Lift Cylinder for the TF Mast396
Replacing the Outrigger Lift Cylinders398
Removing the outrigger lift cylinders398
Outrigger lift cylinder assembly399
Repairing the Outrigger Lift Cylinders400
Replacing the Traction Cylinder402
Removing the traction cylinder402
Traction cylinder assembly403
Repairing the Traction Cylinder404
Platform407
Adjusting the Folding Platform Switch409
Pre-tensioning the spring assembly409
Checking and adjusting switch PLS1 for rider mode409
Adjusting switch PLS2 for pedestrian mode410
Replacing the Folding Platform Springs411
Spring removal411
Spring assembly411
Schematic Diagrams413
Wire Colour Code415
General contact symbol abbreviations416
Electrical wiring diagrams418
Wire Harness List420
DT 3040 -MW and DT 3040 -MF420
DT 3040 -EF421
DT 3040-EF Main Wire Harness423
Spline list424
DT 3040-MF Main Wire Harness425
Spline list426
DT 3040-MW Main Wire Harness427
Spline list428
DT 3040-EF, Standard429
DT 3040-EF, with Options430
DT 3040-MF, Standard431
DT 3040-MF with Options432
DT 3040-MW, Standard433
DT 3040-MW with Options434
CAN Connections, DT 3040-MF, -MW435
CAN Connections, DT 3040-EF436
Hydraulic Schematic437
Hydraulic Symbols439
DT 3040 without Traction Cylinder443
DT 3040 with Traction Cylinder444

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