Crown Forklift WE/WS 2000 Series Service Manual – PDF DOWNLOAD

Description

Crown Forklift WE/WS 2000 Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WE/WS 2000 Series Service Manual – PDF DOWNLOAD

Language : English
Pages :229
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WE/WS 2000 Series Service Manual – PDF DOWNLOAD

WE/WS 1
ELECTRICAL DIAGRAMS208
Schematic Wiring Diagram208
Distribution Panel209
Handle and Travel Timer210
Traction Controller211
Brake and Charger Cicuit212
WE/WS Option Softlift Schematic214
WE/WS Option Softlift215
Handle and Travel Timer216
Traction Controller217
Brake and Charger Cicuit218
Proportional Electronic219
INDEX 2
IDX – 4220 – 002 3
IDX – 4220 – 003 4
IDX – 4220 – 004 5
INTRODUCTION 20
General 20
Using the manual 20
Maintenance 20
Spare parts catalog 21
page numbers 21
Operating instruction 22
Service training 22
Replacement parts ordering 22
GENERAL MAINTENANCE INSTRUCTION 24
SAFETY INSTRUCTIONS 24
MAINTENANCE 28
COMPONENT ACCESS 28
RAISING THE VEHICLE 29
Support Points 30
INSPECTION AND MAINTENANCE PLAN 32
Service scope 32
DAILY OR AFTER 8 HOURS OF OPERATION 33
Illustration 34
MONTHLY OR EVERY 100 HOURS OF OPERATION 35
Illustration 36
QUARTERLY OR EVERY 250 HOURS OF OPERATION 37
EVERY SIX MONTHS OR EVERY 500 HOURS OF OPERATION 37
Illustration 38
YEARLY OR EVERY 1000 HOURS OF OPERATION 39
JÄHRLICH ODER ALLE 1000 BETRIEBSSTUNDEN 39
Illustration 40
LUBRICATION 42
General 42
Cold store trucks 42
Operator involvement 42
Daily Maintenance Check 42
LUBRICANTS AND OIL RECOMMENDATIONS TABLE 44
TORQUE VALUES 46
HYDRAULIC SCHEMATIC SYMBOLS 48
HYDRAULIC 60
General 60
HYDRAULIC OIL TANK 61
Cover on hydraulic oil tank 61
Disassembly 61
Assembly 62
Maintenance 63
Valve block 64
Disassembly 64
Repair 64
Assembly 64
Hydraulic oil pump 65
Disassembly 65
Assembly 65
Repair 65
HYDRAULIC SYSTEM SOFTLIFT 66
General: 66
Description: 66
Lowering speed: 67
Bleed procedure: 67
Troubleshooting: 67
Vent hydraulic system on mast TF and TT 68
TL MAST 68
DRIVE UNIT 70
Drive wheel 70
Disassembly 70
Assembly 70
DRIVE UNIT 71
General 71
Disassembly 71
Assembly 72
Gearbox 72
Disassembly 72
Assembly 73
Repair 74
Assembly 75
Maintenance, oil change 76
Turntable bearing 77
Disassembly 77
Assembly 77
PIVOTING CARRIAGE 78
General 78
Disassembly 78
Assembly 79
Setting the pivoting carriage, type WE truck 79
Setting the pivoting carriage, type WS truck 79
WHEELS AND TYRES 80
General 80
Load wheel, single axle 80
Disassembly 80
Assembly 80
Load wheel, tandem axle 81
Disassembly 81
Assembly 81
Support wheel 81
Disassembly 81
Assembly 82
Support wheel mounting 82
Disassembly 82
Assembly 82
ELECTRIC 84
BASIC ELECTRICS 84
WIRING COLOUR CODE 84
COLOUR CODING IN ACCORDANCE WITH DIN 47100 85
Index of AbbreviationsSwitch Symbols 86
Other Abbreviations 87
Typical Electrical Symbols 88
Transistor control 89
ELECTRICAL COMPONENTS 92
SAFETY INSTRUCTIONS 92
SWITCHES 92
General 92
Key switch (KYS) 92
Brake switch (BRS) 92
Safety reverse switch (SAS) 92
Direction control (POT, FS, RS) 92
Lift/Lower switches (RAS, LOS) 93
Brake override switch (ORS) 93
Horn (HNS) 93
Speed limiter switch (LMS) 93
Battery connector/Emergency Battery Disconnect 93
Fuses (FU) 93
Electric Parts Layout 94
CONTROLLER (1207-1115) 96
General 96
Function 97
Emergency reverse 97
Acceleration/deceleration rate 97
Brake 97
Throttle 97
Throttle response 97
Fault recording 98
Fault detection 98
Plug braking 99
Creep speed at first throttle 99
Low speed 99
MOSFET100
Pulse with modulation100
Ramp start (anti roll-back)100
Key switch100
Quick start100
Watchdog (external, internal)101
Current limiting101
Overvoltage cutoff101
Overtemperatur101
Undervoltage cutback101
Pilot wire pins (Model 1207)102
ADJUSTMENT PANEL103
Manually adjustable potentiometer103
Programmer connector103
Status LED103
LED Diagnostics103
LED CODES104
MAINTENANCE106
SAFETY106
Cleaning of the controller106
Removal/Installation107
CONTROLER CHECK109
PROGRAMMER112
General112
Connections112
Keypad definition113
Display114
OPERATING MODES117
PROGRAM MODE117
TESTMODE118
DIAGNOSTIC MODE119
SPECIAL DIAGNOSTIC MODE119
SPECIAL PROGRAM MODE119
Programmer Self Test121
VALUES AND FAULT CODES122
WE 125t/WS 135t122
WE 16t/WS 18t124
PROGRAM MENU126
TEST MENU127
Diagnostic and Special Diagnostic Menu128
Trouble shooting chart130
BDI / TT134
Disassembly134
Repairs134
Assembly134
KEY SWITCH KYS136
Disassembly136
Repairs136
Assembly136
Reverse safety switch SAS137
Disassembly137
Assembly137
Drive switch FS/RS137
Disassembly137
Assembly138
Setting drive switch139
Checking settings139
Raise switch (RAS)/lower 1 (LOS1)/lower 2 (LOS2)140
Disassembly140
Assembly140
Horn switch (HMS)141
Disassembly141
Assembly141
Speed limit switch (LMS)141
Disassembly141
Assembly142
Brake switch (BRS)142
Disassembly142
Assembly143
Override switch (ORS)144
Disassembly144
Assembly144
Emergency Off Switch (EDS)145
Disassembly145
Assembly145
Distributor Board146
Disassembly146
Assembly146
MOTORS148
General148
PUMP MOTOR149
Disassembly149
Assembly149
Maintenance WE 125/WS135150
Repair150
Assembly152
Maintenance WE 16/WS18153
Repair154
DRIVE MOTOR155
Disassembly155
Repair156
Assembly158
Maintenance158
Electrics panel160
General160
Disassembly160
Assembly160
Contactor Drive Direction161
Checking contacts161
Checking coils161
Disassembly161
Repairs162
Assembly162
Unbenannt162
Pump contactor163
Disassembly163
Repairs163
Assembly164
Assembly164
BATTERY166
Disassembly with lifting device166
Assembly166
Removal with battery roller option:166
MAINTENANCE167
Checking the electrolyte level167
Charging the battery168
Using the battery at high temperature169
Daily maintenance169
Weekly maintenance169
Monthly maintenance169
Cleaning170
Storage170
Spilled or leaking electrolyte:170
Battery connections170
Disassembly170
Repair171
Assembly171
TEST PROCEDURES172
PMT – TEST CONNECTING DIAGRAM173
BRAKE174
Drive wheel Brakes174
Removal174
Installation175
Setting up Air Gap176
Setting up brake torque176
Carrying out Brake Test176
STEERING178
General178
CONTROL HANDLE179
Removal179
Attention179
Installation180
Cross joint steering181
Disassembly181
Assembly181
Chain tensioning device, steering182
Disassembly182
Assembly182
Steering chain183
Disassembly183
Assembly184
LIFTING GEAR186
General186
Single lifting gear (Simplex) TL186
Double lifting gear (Duplex) TF186
Triple lifting gear (Triplex) TT187
Disassembly187
Assembly188
Fork carriage188
Disassembly188
Assembly188
Setting the fork carrier play189
Mast maintenance189
WARNING189
Greasing roller tracks189
Disassembling rollers190
Assembly190
LIFT CHAIN INSPECTION192
Maintenance193
Detailed Explanation194
Cracked or Missing Link plates194
Pitting and Corrosion194
Protruding or Turned Pins195
Free Movement and Edge Wear195
Chain Length Measurement196
Chain Tension197
Chain Anchors and Pulleys197
FORK INSPECTION198
Fork Identification198
Repairs199
Visual Inspection for Cracks199
Straightness Inspection200
Fork Blade Bending200
Inspection of Fork Tip Thickness200
Fork Blade Height Difference201
Fork Locking201
Wear201
HYDRAULIC CYLINDER204
General204
Simplex mast cylinder204
Disassembly204
Lifting cylinder205
Disassembly205
PANELS, COVERS206
General206
Protective cover206
Disassembly206
Assembly206
Battery cover206
Disassembly206
Assembly206
Nuckle cover207
Disassembly207
Assembly207
Nuckle cover adjustment207
HYDRAULIC SCHEMATICS220
Simplex220
Duplex221
Triplex221
MAIN HARNESS224
KBL-4220-002225
KBL-4220-003226
Tooling / Plugs228
WZ-4220-002229

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