service repair manual

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

2. I
Printed in Germany
TABLE OF CONTENT

3. ST3000 10/2004 • Printed in Germany MS-IDX-3130
III
TABLE OF CONTENT
Table of Content
MA – SAFETY PAGE SER-NO. CUT.................. REV.
Safety Symbols used in the Manual ...................................... 3
General Maintenance and Repair Safety Notes ................... 3
Maintenance and Repair ................................................ 3
Before Leaving the Truck ................................................ 4
Before Carrying out Work on the Truck.......................... 4
Before Operating the Truck............................................. 4
Warnings and Labels on the Truck ........................................ 4
ITD – INTRODUCTION PAGE SER-N0. CUT REV.
General ..................................................................................... 7
Operating Instructions .................................................... 7
Service Training .............................................................. 7
Ordering Spare Parts...................................................... 7
Using the Manual ............................................................ 7
Model-Number ......................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0. CUT .................. REV.
COMPONENT ACCESS ........................................................... 11
Lifting and Blocking................................................................ 13
Outriggers ................................................................................ 14
Recommended Lubricants and Oils .............................. 15
Lubricants ................................................................... 15
Cold Store Trucks........................................................ 15
Truck Decommissioning.................................................. 15
Restoring the Truck to Service .............................................. 15
Maintenance ............................................................................ 19
Lubrication points and intervals ..................................... 19
Inspection and Maintenance Schedule ......................... 21
Casters ..................................................................................... 30
Torques .................................................................................... 31
M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV.
Hydraulic Symbols.................................................................. 35
Hydraulic Unit Removal .......................................................... 39
Hydraulic System ............................................................ 40
Operation......................................................................... 40
Raise (Refer to Illustration) ......................................... 40
Lower .......................................................................... 41
Hydraulic Reservoir Capacity......................................... 42
Changing the hydraulic oil and hydraulic filter ............ 42
MOTOR & PUMP ASSEMBLY ........................................ 44
HYDRAULIC LINES AND FITTINGS .......................... 44
General Rules for Hydraulic Lines and
Fittings ........................................................................ 44
CIRCUIT BLEEDING .................................................. 45
DRIFT TEST ............................................................... 45
Proportional function:................................................ 45
REMOVAL ....................................................................... 45
MOTOR............................................................................ 46
PUMP .............................................................................. 46
After replacing pump:................................................ 46
Replacing the relief valve ............................................... 47
Relief valve setting.......................................................... 47
Relief valve test and setting ........................................ 47
HYDRAULIC TROUBLESHOOTING CHART ................ 48

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

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

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

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

8. ST3000 10/2004 • Printed in Germany
MS-IDX-3130
VIII
TABLE OF CONTENT
M7 – MAST PAGE SER-N0. CUT .................. REV.
Worn Connection Plates ............................................. 144
Protruding or Turned Chain Pins................................. 144
Corrosion .................................................................... 144
Chain Lateral Wear ..................................................... 145
Uneven Chain Tension .............................................. 145
Misaligned Lift Components ..................................... 145
Lift Chain Lubrication...................................................... 146
Separating Lift Chains .................................................... 147
Tools and Equipment Required ...................................... 147
Detachment ..................................................................... 147
Fork Tines ................................................................................ 148
General ............................................................................ 148
Terms .......................................................................... 148
Fork Identification ....................................................... 148
Repairs ............................................................................ 148
Fork Inspection ............................................................... 148
Crack Inspection ......................................................... 148
Verticality Test ............................................................. 149
Fork Blade Warping .................................................... 149
Measuring the Fork Tip Width ........................................ 149
Fork Tine Height Difference ........................................... 149
Fork Stop ......................................................................... 149
Fork Blade Wear ............................................................. 150
M8 – CYLINDERS PAGE SER-N0. CUT .................. REV.
General ............................................................................ 153
Safety when working on hydraulic systems ................ 153
General Instructions
for Repairing Hydraulic Components.......................... 153
Rod Seal Assembly ................................................................. 154
General ............................................................................ 154
Large Rod Seal Assembly .............................................. 154
Small Seal Rod Assembly .............................................. 155
Rod Seal Assembly, Sealing Lip First............................ 156
Cylinders .................................................................................. 157
Mast Lift Cylinder ............................................................ 157
Seal Replacement ...................................................... 157
Installing Mast Lift Cylinders ....................................... 158
Carriage Cylinder ............................................................ 159
Seal Replacement ...................................................... 159
Installing Carriage Cylinder ........................................ 160
Cylinder Bleeding and Flushing ..................................... 160
Bleeding — Mast Lift Cylinders................................... 160
Bleeding — Carriage Cylinder (if applicable).............. 160
Flushing – Mast Lift Cylinders
and Carriage Cylinder (if applicable) .......................... 160
Drift Test ...................................................................... 161
Cylinder Shimming.......................................................... 161
Scondary Cylinder Shim ............................................. 161
Primary Cylinder Shim ................................................ 161
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
ST 3000 Standard .................................................................... 165
Overview.......................................................................... 165
Traction Controller - Semo Logic ................................... 166
Traction Controller - Semo Power Circuit ...................... 167
Power Unit Control Circuit .............................................. 168

9. ST3000 10/2004 • Printed in Germany MS-IDX-3130
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TABLE OF CONTENT
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
Control Handle - Control Circuit ..................................... 169
Hydraulic Control Module (HCM) ................................... 170
ST 3000 with Options.............................................................. 171
Overview.......................................................................... 171
Traction Controller - Semo Logic ................................... 172
Traction Controller -
Semo Power Circuit ........................................................ 173
Power Unit - Control Circuit ............................................ 174
Control Handle - Control Circuit ..................................... 175
Hydraulic Control Module (HCM) - Travel Alarm and Flashing Beacon...... 176
Remote Control - Power Part ......................................... 177
Remote Control - Operator Platform .............................. 178
Wire Harness ........................................................................... 179
Control Handle Wiring .................................................... 180
Power Cables .................................................................. 181
HYD – HYDRAULIC SCHEMATIC PAGE SER-N0. CUT .................. REV.
Hydraulic Schematic............................................................... 185

10. 1
Printed in Germany
SAFETY

11. 3
MS-MA-0000
ST3000 10/2004 • Printed in Germany
SAFETY
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 guide-
lines.
DANGER
Follow all national/local safety regula-
tions 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.
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 well-
ventilated.
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.
Safety Symbols used in the Manual
To help guide you through the manual and to highlight parti-
cular 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.
● 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.

12. 4
MS-MA-0000 ST3000 10/2004 • Printed in Germany
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.
● 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.
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.

13. 5
Printed in Germany
INTRODUCTION

14. 7
M1.0-0000-0007
7
ST3000 10/2004 • Printed in Germany MS-ITD 3130
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 com-
ponents.
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.
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 safety
and error free functioning of your CROWN vehicle.
Service Training
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
● The truck model number
● The truck serial number
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 your 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.
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15. 8
M1.0-0000-0008
8
ST3000 10/2004 • Printed in Germany
MS-ITD-3130
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
ST 3000N-1.0 TL
ST 3000N-1.0 TT
ST 3000N-1.35 TL
ST 3000N-1.35 TT

16. 9
Printed in Germany
LUBRIFICATION AND ADJUSTMENT

17. M1.0-0000-00011
11
MS-1.0-3130
ST3000 10/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
COMPONENT ACCESS
The following is a list of covers, panels, etc. that must be
removed to allow access when performing service and/
or maintenance to components. Refer to the illustrations
in this section as an aid in locating parts that require at-
tention.
WARNING
Always remove the battery connector
before carrying out maintenance work.
This applies especially if the connector
and plug connection have to be separate.
Power Unit Cover
Provides access to:
● Traction Motor (TM)
● Drive Unit
● Brake
● Pump motor (PM), Lift Contactor (P) Lowering
Valve (PV, SVCL)
● Hydraulic reservoir
● Horn (HN)
● Alarm (ALM)
● Diode block (DB)
● Transistor controller (TCM)
● Line contactor (Line)
● Fuse, FU1 (traction)
● Fuse, FU2 (lift)
● Relay (K2)
● Alarm Filter Block (FIL)
● Diagnostic LED for TCM (LED)
● Hydraulic Control Modul (HCM)
● Combination Instruments (TT/BDI)
● Key Switch (KYS)
● Fuse 3, FU3 (signal)
Control Handle
Provides access to:
● Horn switch (HNS1, HNS2)
● Fork lower switch (LOS1, LOS2)
● Lift switch (RAS)
● High speed switch (HSS)
● Safety Switch Assembly (SAS)
● Potentiometer (POT), Forward Switch (FS),
Reverse Switch (RS)
Knuckle
● Brake Switch (BRS)
● Override Switch (ORS)
Mast
● Flashing Light Assembly (FLS)
● Lift Limit Switch (LMS)

18. M1.0-0000-00012
12
MS-1.0-3130 ST3000 10/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
MS01-3130-001
Battery, Connectors
Control Handle
Instrument
Panel
Knuckle
Transistors
Contactors
Pump
Drive Motor
Caster Wheels
Outriggers,
Load Wheels
Forks
Mast, Lift Chains,
Anchors

19. M1.0-0000-00013
13
MS-1.0-3130
ST3000 10/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
Lifting and Blocking
WARNING
Always support a raised truck with
wooden blocks or other appropriate
equipment to relieve the jack.
● Move truck to a secure non traffic maintenance
area with a level floor.
● No load on forks.
WARNING
Truck stability decreases dramatically if
load wheels are raised more than 13 mm
(0.5 inch). Attach sling and overhead
lifting device to all cross members of the
mast to prevent truck from tipping over
when raising the side of the truck.
INFORMATION
To raise truck for additional jack clear-
ance, fabricate a 1/2 board for load
wheel or 3/4 board for drive wheel (8 x
12 with stop and bevel). Drive truck onto
board and proceed with step 3. If truck
can not be moved, use overhead lifting
device for additional jack clearance.
● Disconnect the battery and prevent the truck from
being switched on again.
Tools required
● Hydraulic Jack - Capacity 3620 kg. (8000 lbs.)
Crown part number: 122599
Collapsed height minimum: 60 mm (2.25 in.)
Raised height maximum: 400 mm (16 in.)
● Jack Stand - capacity 4500 kg. (10,000 lbs.)
Commercially available.
● Lifting Straps - Capacity 900 kg (2000 lbs.)
Commercially available.
● Barrel Hooks - Capacity 900 kg (2000 lbs.)
Commercially available.
Lower Forks
Completely
Fabricated
Board
Load Wheel
MS01-3130-002
Hard Wood Block
Steer Wheel
Raise Forks
70 to 150 mm
from Floor
Place Jack
Stand on
Opposite Side
of other Jack
Set Jack Stand Height
as Required
Not to Exceed 300 mm
Wheel Chock
Load Wheel
Both Outriggers
MS01-3130-0003

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21. M1.0-0000-00014
14
MS-1.0-3130 ST3000 10/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
Outriggers
Note that the outriggers are evenly distanced from the
chassis: Dimension A= Dimension B
INFORMATION
Outrigger bolt torque:
380 Nm!
Dimension
A
Dimension
B
Outrigger internal length
MS01-3130-004
M01-GB
l
e
d
o
M e
l
d
d
a
r
t
S
e
d
i
s
n
I
0
0
0
3
T
S m
m
0
7
2
1
-
m
m
5
6
9
N
0
0
0
3
T
S m
m
5
6
1
1
-
m
m
5
6
8
Outrigger bolts

22. M1.0-0000-00015
15
MS-1.0-3130
ST3000 10/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
Recommended Lubricants and Oils
Lubricants
The following page lists typical lubricants which are also
used by Crown in the factory. However, any lubricants
with the same technical specifications can be used.
Cold Store Trucks
Special hydraulic oil, lubricant oils and grease for low
temperature applications must be used for cold store
trucks (see table on following page). All screws, wash-
ers, nuts, pins, retaining rings etc. must be treated regu-
larly with an anti-corrosion solution CROWN no. 805236-
004. Electrical connections and components must be
carefully protected against corrosion. For more details
refer to chapter 4.
Maintenance intervals must be adapted to the conditions
of use. They should be as frequent as possible to pre-
vent excess wear.
Truck Decommissioning
When taking the truck out of service for more than 3
months, proceed as follows:
● Disconnect the battery.
● Decommission the battery in accordance with the
manufacturer's instructions.
● Clean the truck*). Wipe off any grease in accord-
ance with the maintenance manual.
● If the truck is to be stored in hostile ambient
conditions (e.g. saline atmosphere) treat the
surfaces of the truck with a suitable solution to
prevent corrosion.
● Jack up the truck. Lower the chassis onto suit-
able wooden blocks in order to clear the wheels
from the ground (this prevents the wheels from
flattening under constant pressure).
● Every 3 months connect the battery, carry out a
daily check and test the truck functions. Then
disconnect the battery again.
Restoring the Truck to Service
When restoring the truck to service, proceed as follows:
● Remove any addition corrosion protection applied
(except for cold store protection)*.
● Jack up the truck, remove the wooden blocks and
lower the truck.
● Charge the battery or install a charged battery.
● Connect the battery.
● Carry out the daily check.
* Do not use high pressure cleaners and/or solvents
on the truck. Do not use metal brushes. Do not wet-
clean the electrical system and do not use flamma
ble cleaning solutions.