Crown DT 3000 Double Stacker Service Manual
444 pages · Publication 812591-006
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- Models
- DT 3000
- Manual type
- Service Manual
- Pages
- 444
- Publication
- 812591-006
- Condition
- Brand new
What's inside
From the manual's own table of contents: 462 sections, 476 entries. See sample pages (PDF, 834 KB)
General1 topic
- TABLE OF CONTENTS INTRODUCTION
Important Information
Service personnel qualification
Ordering spare parts
Ordering documentation
Manual structure
Conventions
Text mark-ups in the manual
Brief description of equipment
Truck Data Number
SAFETY
Safety Notices
Basic Safety Notices
Organisational measures
Truck modifications and additions
Personal safety equipment
Protecting the hazardous area
Hazards from stored energy
Repair work
Restoring the truck to service after repair work
Cleaning work
Handling batteries
Warning and instruction decals on the truck
Lifting gear and slings
Show all 463 sections
Environmental protection
LUBRICATION & ADJUSTMENT
Transport and Storage
Lifting the truck
Lifting the truck by crane
Lifting the truck with a forklift truck
Towing the truck
Jacking up the Truck
Transporting the Truck
Securing the truck for transport on a truck bed
Storing the Truck
Placing the truck in storage
Periodically starting a truck that has been in storage
Restoring the Truck to Service
Cleaning the Truck and Components
Effects of incorrect cleaning
Electrical components
Roller and slide bearings
Corrosion-protected surfaces
Cleaning the entire truck
Cleaning removed components
Cleaning other mechanical components
Recommended Lubricants and Consumables1 topic
- TABLE OF CONTENTS Cold store truck requirements
Abbreviations used in the table
Planned Maintenance
Maintenance schedule
Annual inspection in accordance with FEM 4.004
Terms and abbreviations used
Electrical System
Lift mechanism
Drive system, steering and wheels
Safety mechanisms
Finger Guard
Testing the finger guard
Checking the finger guard mechanism for freedom of movement
Repairing the finger guard mechanism
Finger guard mechanism disassembly
Attaching the finger guard mechanism
Adjusting the finger guard mechanism
Battery Retainer
Testing the bar monitoring system
Troubleshooting
Adjusting the BLS sensor
Adjusting the Outrigger Lift Limit Switch (LMS1)
Castor Wheel Replacement
Replacing single castor wheels
Replacing the single castor wheel pivot bearing
Replacing the single castor wheel
Replacing tandem castor wheels
Replacing the tandem castor wheel pivot bearing
Replacing the tandem castor wheel bearings
Replacing the tandem castor wheels
Torques
Standard torques
HYDRAULIC SYSTEM
Replacing the Hydraulic Unit
Hydraulic unit removal
Hydraulic unit assembly
Repairing the Hydraulic Unit
Replacing the hydraulic pump
Preparation
Hydraulic pump removal
Hydraulic pump assembly
Hydraulic unit reassembly
Torques and references, without traction control
Torques and references, with traction control
Changing the Hydraulic Oil and Return Filter
Bleeding the Hydraulic System
Replacing the Relief Valve RV1
Relief valve test
Flushing the Hydraulic System
Drift Test
Preconditions for all drift tests1 topic
- TABLE OF CONTENTS Outrigger lift drift test
Fork lift drift test
Hydraulic System Troubleshooting
DRIVE UNIT
Components
Trucks with mechanical steering
Trucks with electrical steering
Replacing the Drive Wheel
Drive wheel disassembly
Drive Wheel Assembly
Changing the Gear Oil
DT 3040 -MW and -MF Components
DT 3040 -EF Components
Accessing the Service Levels
Software Versions
Menu Structure
Operator and Service Menu
Analyzer Menu, A1 – A2
Analyzer Menu, A3 Outputs
Analyzer Menu, A4 Test Outputs
Calibration Menu, C2 Steer System
Calibration, C3 Lift/Lower Rotary Encoder menu
Analyzer Menu, A2.5.1 – A2.5.8, Access 5 Inputs
Features F6 – F7
Features F4 Menu, Truck Type
Features Menu, F10 – F13
Events Menu, E1
Events Menu, E2 – E3
Performance Menu, P1 (DT 3040 MW)
Performance Menu, P2 (DT 3040 MW)
Performance Menu, P3 (DT 3040 MW)
Performance Menu, P1 (DT 3040 -MF -EF)
Performance Menu, P2 (DT 3040 -MF -EF)
Performance Menu, P21 (DT 3040 -MF -EF)
Performance Menu, P3 (DT 3040 -MF -EF)
Performance Menu, P4 – P11
Performance Menu, P12 – P16
Utilities Menu, U1
Input Signals
Initial truck status
SAS and BRS
Operating mode definition1 topic
- TABLE OF CONTENTS Pedestrian mode
Comfort mode
Rider mode
Platform and Side Restraint Logic
Folding platform
Side restraint and platform setting definition
DT 3040 -MW Software Parameter Settings
Operation modes
Markings
DT 3040 -MF Software Parameter Settings
Operating modes
DT 3040 -EF Software Parameter Settings
Calibration
Selecting the CALIBRATION Menu
Calibrating the traction potentiometer
Travel direction definition
Electric steering calibration
Proportional lift and lower calibration
Event Codes
Malfunctions with event code display
Locating malfunctions
Digit convention for event codes
Event Code 100
Event Code 202
Event Code 203
Event Code 204
Event Code 205
Event code 208
Event code 228
Event code 229
Event code 230
Event code 231
Event code 232
Event code 2331 topic
- TABLE OF CONTENTS Event Code 234 (DT 3040 -MW, -MF)
Event code 234
Event code 236
Event code 239
Event code 300
Event code 301
Event code 302
Event code 303
Event code 304
Event code 305
Event code 306
Event code 307
Event code 308
Event code 309
Event code 310
Event code 314
Event code 315
Event code 316
Event code 317
Event code 320
Event code 321
Event code 322
Event code 326
Event code 328
Event code 329
Event code 333
Event code 334
Event code 337
Event code 338
Event code 3411 topic
- TABLE OF CONTENTS Event code 342
Event code 343
Event code 348
Event code 351
Event code 352
Event code 353
Event code 354
Event code 355
Event code 356
Event code 357
Event code 358
Event code 359
Event code 361
Event code 362
Event Code 364
Event code 3651 topic
- TABLE OF CONTENTS Event code 235
Event code 237
Event code 238
Event code 324
Event code 3351 topic
- TABLE OF CONTENTS Event Code 337 (DT 3040 -EF)
Event code 342
Event code 368
Event Code 500
Event Code 501
Event Code 502
Event Code 503
Event Code 504
Event Code 505
Event Code 506
Event code 508
Event code 509
Event code 5101 topic
- TABLE OF CONTENTS Event code 511
Event code 512
Event code 513
Event code 514
Event code 515
Event code 516
Event Code 517
Event code 518
Event code 519
Event code 520
Event code 521
Event code 522
Event code 523
Event code 524
Event code 525
Event code 526
Event code 527
Event code 528
Event code 529
Event code 530
Event code 532
Event code 533
Event code 535
Event code 536
Event code 537
Event code 538
Event code 539
Event code 540
Event code 541
Event code 5421 topic
- TABLE OF CONTENTS Event Code 543 (DT 3040 -EF)
Event code 543
Event code 544
Event code 545
Event code 8xx
Event code 9xx
Events with Text Messages
Platform Failure
Truck Stopped
Hightemp TCM
Hightemp traction motor
Release control handle
Release travel control
Hightemp steering controller
Hightemp steering motor
General DC Motor Maintenance Instructions
Brushes
Motor
Rotor
Traction Motor (M1)
Traction motor disassembly
Traction motor assembly
Repairing the traction motor
Dismantling the rotor assembly
Assembling the rotor assembly
Final tasks
Pump motor (M2)
Steer motor (M3)
Special tools required
Steer motor disassembly
Steer motor assembly
Repairing the steer motor
Servicing and Replacing the Control Modules
General
Power fuses
Discharging the capacitors
Servicing the control modules
Replacing control modules
Removing the control module
Assembling the control module
Control Module PMT Test
Required tools
PMT Test
Testing Access 21 topic
- TABLE OF CONTENTS Testing Access 3
Testing Access 5
Battery Information
Charging the battery
Replacing the battery
Battery Discharge Indicator (BDI)
Load profile and discharge curve
Adapting the BDI setting
Repairing Contactors
Wear test
Checking the contacts
Checking the coils
Checking the springs
Modifications
Converting the truck from Enter key to key switch power-up function
Mechanical conversion
Changing the software
Converting the truck from key switch to Enter key power-up function
Glossary
BRAKE SYSTEM
Components and Operation
Service brake
Parking brake
Servicing the Parking Brake
Measuring the air gap
Replacing the Parking Brake
Parking brake disassembly
Parking brake assembly
Testing the Braking Distance
Requirements
Performing the test
Braking distance tables
Max. braking distances DT 3040 -MW, with or without max. rated load
Max. braking distances DT 3040 -MF
Max. braking distances DT 3040 -EF
STEERING
Repairing the Control Handle
Replacing the control handle shells
Shell removal
Shell assembly
Replacing the switch unit
Switch unit removal
Switch unit assembly
Replacing the “rabbit/turtle” toggle module
Toggle module removal
Toggle module assembly
Replacing the control handle grip PC boards
Hydraulic PC board removal1 topic
- TABLE OF CONTENTS Hydraulic PC board assembly
Main PC board removal
Main PC board assembly
Replacing the traction potentiometer
Traction potentiometer removal
Traction potentiometer assembly
Replacing the safety reverse switch (SAS)
Removing the safety reverse switch (SAS)
SAS / BRS switch assembly
Replacing the grips and horn switch
Replacing the outrigger lift switch
Removing the outrigger lift switch
Assembling the outrigger lift switch
Repairing Control Handle Return Springs
Panel removal
Return spring pre-tension adjustment
Replacing the return springs
Return spring removal
Return spring assembly
LIFTING MECHANISM
Forks
Fork inspection
Checking forks for cracks
Chain Supports and Lift Chains
Periodic inspection of chain supports and lift chains
Periodic replacement of chain supports and lift chains
Cleaning lift chains
Inspecting Chain Supports and Lift Chains
Checking the service hours for the lift chains and anchor bolts
Checking the lift chain for elongation
Preparatory measures
Freedom of movement
Worn or missing plates
Turned pins
Corrosion
Chain lateral wear
Checking chain supports and anchor bolts
Checking the chain pulleys
Checking and adjusting the chain tension
Checking the lifting components for misalignment
Lubricating Lift Chains
General information
Lubrication intervals and lubricants
Separating Lift Chains
Tools and equipment required
Replacing Mast Guards
Replacing mast guards on the TL mast with 1700 mm lift height
Removing mast guards
Assembling mast guards1 topic
- TABLE OF CONTENTS Replacing the mast guard on the TL mast with 2100 mm lift height
Replacing the mast guard on the TF mast with 2600 mm lift height
CYLINDERS
Hydraulic system repair instructions
Replacing the rod seals
Tools
Small hook
Extractor
Producing extractors
Groove aligning arbor for small rod seals
Assembly devices for large rod seals
Protective mechanisms
Rod Seal Removal and Assembly
Removing a large rod seal
Removing a small rod seal
Inserting a large rod seal
Fitting a small rod seal
Rod seal assembly, sealing lip first
Replacing the Lift Cylinder on the TL Mast
Removing the lift cylinder (TL mast)
Lift cylinder (TL mast) assembly
Repairing the Lift Cylinder for the TL Mast
Replacing the Lift Cylinder on the TF Mast
Lift cylinder (TF mast) removal
Lift cylinder (TF mast) assembly
Repairing the Lift Cylinder for the TF Mast
Replacing the Free Lift Cylinder on the TF Mast
Free lift cylinder (TF mast) removal
Free lift cylinder (TF mast) assembly
Repairing the Free Lift Cylinder for the TF Mast
Replacing the Outrigger Lift Cylinders
Removing the outrigger lift cylinders
Outrigger lift cylinder assembly
Repairing the Outrigger Lift Cylinders
Replacing the Traction Cylinder
Removing the traction cylinder
Traction cylinder assembly
Repairing the Traction Cylinder
PLATFORM
Adjusting the Folding Platform Switch
Pre-tensioning the spring assembly
Checking and adjusting switch PLS1 for rider mode1 topic
- TABLE OF CONTENTS Adjusting switch PLS2 for pedestrian mode
Replacing the Folding Platform Springs
Spring removal
Spring assembly
SCHEMATIC DIAGRAMS
Wire Colour Code
General contact symbol abbreviations
Electrical wiring diagrams
Wire Harness List
DT 3040-EF Main Wire Harness
Spline list
DT 3040-MF Main Wire Harness
DT 3040-MW Main Wire Harness
DT 3040-EF, Standard
DT 3040-EF, with Options
DT 3040-MF, Standard
DT 3040-MF with Options
DT 3040-MW, Standard
DT 3040-MW with Options
CAN Connections, DT 3040-MF, -MW
CAN Connections, DT 3040-EF
HYDRAULIC SCHEMATIC
Hydraulic Symbols
DT 3040 without Traction Cylinder
DT 3040 with Traction Cylinder
Inside this manual
Real pages from this service manual (444 pages). Open the sample pages (PDF, 834 KB)
- Troubleshooting, page 74: HYDRAULIC SYSTEM
- Specifications, page 134: DT 3040 -MF Software Parameter Settings
- Diagram, page 422: SCHEMATIC DIAGRAMS
- Foldout diagram, page 137: DT 3000 Series
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 444 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).