Crown WF3000 Series User manual

WF3000 Series
Order Number: 812556-006
Printed in Germany ●Revision Level A
Service Manual

A
WF3000 09/2005 • Printed in Germany MS-REV-3300
REVISION
Overview of Revisions:

B
Printed in Germany
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Printed in Germany
TABLE OF CONTENTS

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Printed in Germany
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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 PAGE 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 Truck............................................. 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 AndTowingTheTruck ............................................... 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 ................................................................... 16
Cold Store Trucks........................................................ 16
Taking the truck out of service ....................................... 16
Bringing the truck back into service .............................. 16
LubricantTable ........................................................................ 17
Adjuvants Table ....................................................................... 18
TruckTilt 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 Test...................................................................... 35
Proportional function:................................................ 35
REMOVAL ....................................................................... 35
MOTOR............................................................................ 36
PUMP .............................................................................. 36
After replacing the pump: ......................................... 36

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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)................................................... 59
Hydraulic Control Module (HCM)................................... 59
Unigage (BDI) ................................................................. 59
Integrated Charger.......................................................... 59
Plug Holder (PC)............................................................. 59
Drive motor (M1)............................................................. 59
Hydraulic Motor (M2) ...................................................... 60
Main Contactor (Line/LC) ............................................... 60
Lift Contactor (P/P1+P2) ................................................ 60
Electromagnetic Brake (BRK) ........................................ 60
Terminal Board (TB) ....................................................... 60
Travel Alarm Driver (DR) ................................................ 60
Aux. Hydraulic Switch (SLS/SRS).................................. 60

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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....................................................................... 60
SEM0Traction 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 SEM0Traction Controller............................... 67
Parameter Setting after Replacing
the Traction Controller .................................................... 67
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 ..................................................................... 72
PROGRAM VACC ....................................................... 72
CONFIG ...................................................................... 72
Functions Menu, general................................................ 73
Parameter Change Menus ............................................. 74
Settings and Error Messages......................................... 75
Tester Menu..................................................................... 80
TESTER Menu ................................................................ 81
Alarms Menu ................................................................... 82
ALARMS Menu................................................................ 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu ................................................. 86
Preparatory Measures ................................................ 86
Calibration................................................................... 86
Config. Menu ................................................................... 87
CONFIG Menu ................................................................ 88

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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) .......................................................... 89
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 ........................................... 102
TROUBLESHOOTING .................................................... 103
Traction Controller Safety Test ....................................... 104

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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.................................................................................... 115
Live ring bearing ............................................................. 115
Disassembly ............................................................... 115
Installation................................................................... 115
Control handle return springs ............................................... 116
Adjustment ...................................................................... 116
Disassembly.................................................................... 116
Installation ....................................................................... 116
Steering Chain......................................................................... 117
Permissible Elongation ................................................... 117
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/Slow" 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