Crown Forklift WE/WS2300 Series Maintenance Manual 812567-006

Description

Crown Forklift WE/WS2300 Series Maintenance Manual 812567-006  – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WE/WS2300 Series Maintenance Manual 812567-006  – PDF DOWNLOAD

Language : English
Pages :432
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WE/WS2300 Series Maintenance Manual 812567-006  – PDF DOWNLOAD

WE/WS 2300 SERIES 1
Table of Contents 3
Safety 5
Introduction 5
Lubrication & Adjustment 5
Hydraulic System 6
Drive Unit 7
Electrical System 7
Brake System 12
Steering 12
Lifting Mechanism 13
Cylinders 14
Platform 14
Schematic Diagrams 14
Hydraulic Schematic 17
Safety 19
Symbols Used 21
Safety Symbols 21
General Symbols 21
Fork direction 21
General Safety Instructions 22
Maintenance and Repair Instructions 22
Maintenance and Repairs 22
Before Parking the Truck 22
Before Working on the Truck 22
Before Starting the Truck 22
Warning and Instruction Decals on the Truck 22
Introduction 25
General 27
Operator Manual 27
Service Training 27
Ordering Spare Parts 27
Using the Manual 27
Models 28
Lubrication & Adjustment 29
Component Access 31
Drive Unit Cover 31
Control Handle 31
Control Handle Knuckle 31
Mast 31
Platform and Side Restraints(2) 31
Component Access 33
Drive Unit Cover 33
Control Handle 33
Control Handle Knuckle 33
Mast 33
Platform and side restraints(2) 33
Lifting the Truck 35
Lifting with a Crane 35
Lifting with a Forklift Truck 36
Towing the Truck 37
Jacking up the Truck 38
Service 39
Recommended Lubricants 39
Cold Store Trucks 39
Taking the Truck out of Service 39
Returning the Truck to Service 39
Recommended Lubricants and Consumables 40
Inspection and Maintenance Schedule 42
Daily or Every 8 Service Hours 43
Safety Reverse Switch Test 45
Test and Maintenance Interval Chart 46
Load Wheels and Castors 52
Single Load Wheel Replacement (WE) 52
Removal 52
Assembly 52
Tandem Load Wheel Replacement (WE) 52
Removal 52
Assembly 53
Tandem Load Wheel Replacement (WS) 53
Removal 53
Assembly 53
Castor (WE/WS) 54
Removal 54
Assembly 54
Castor (WE-S/WS-S) 55
Removal 55
Assembly 55
Castor Suspension (WE/WS) 56
Removal 56
Assembly 56
Castor Suspension (WE-S/WS-S) 57
Removal 57
Assembly 57
Torques 58
Standard Torques 58
Hydraulic System 59
Hydraulic Schematic Symbols 61
General Principles 65
Hydraulic Lines and Ports 65
Bleeding the Hydraulic System 65
Drift Test 65
Lifting: 65
Pump Unit 66
Removal 66
Assembly 67
Reservoir 68
Removal 68
Assembly 68
Bleeding the Manifold 68
Replacing the Filter 69
Removal 69
Assembly 69
Valve Block 70
Removal 70
Assembly 70
Valve Block 70
Relief Valve 71
Removal 71
Assembly 71
Relief Valve Setting 71
Relief Valve Test and Setting 71
Hydraulic Pump 72
Removal 72
Assembly 72
Hydraulic System Troubleshooting 73
Drive Unit 75
Drive Wheel 77
Removal 77
Assembly 77
Drive Unit Removal and Assembly 78
Removal 78
Assembly 78
Gear Unit 79
Removal 79
Assembly 79
Repairing the Gear Unit 81
Preparation 81
Dismantling 81
Assembly 81
Adjusting the bevel gear set 82
Checking the flank tooth bearing 82
Oil Change 85
Draining Oil 85
Adding Oil 85
Live Ring Bearing 86
Removal 86
Assembly 86
Pivoting Carriage 87
General 87
Removal 87
Assembly 87
Adjusting the pivoting carriage 87
WE Trucks 87
WS Trucks 87
Pivoting Carriage 88
General 88
Removal 88
Assembly 88
Adjusting the pivoting carriage 88
WE Trucks 88
WS Trucks 88
Electrical System 89
General 91
Wire colour code 91
Contact Symbol Abbreviations 92
Electrical wiring diagrams 94
Electrical Components 96
Switch 96
(ALM) Travel alarm 96
(BBD) Battery connector 96
(BDI) Unigage 96
(BRK) Brake 96
(BRS) Brake switch 96
(Charger) On-board charger 96
(Charger) On-board charger 96
(EDS) Emergency Power Disconnect Switch 96
(F/R Contactor) Direction contactor 96
(DR) Travel alarm driver 96
(FU) Fuses 96
(GCSR) Gate closed switch right 96
(GCSR) Gate closed switch right 97
(GCSL) Gate closed switch left 97
(GCSL) Gate closed switch left 97
(HCM) Hydraulic control module 97
(HM) Horn 97
(HNS) Horn switch 97
(HSS) “Rabbit/Turtle” toggle switch 97
(HYD PCB) Hydraulic printed circuit board 97
(KYS) Key switch 97
(LMS) Limit switch 97
(LMS2) Limit switch 97
(MAIN PCB) Main circuit board 97
(M2) Pump motor 97
(ORS) Override switch 97
(P) Pump contactor 98
(PC) Plug holder 98
(PC) Plug holder 98
(PCB) Distributor PCB 98
(PLM) Platform logic 98
(PLS) Platform switch 98
(PLS) Platform switch 98
(PM / M2) Hydraulic motor 98
(POT, FS, RS) Traction pod 98
(PV) Proportional valve 99
(RAS, LOS1, LOS2) Raise / lower switches 99
Safety reverse switch (SAS) 99
(SLS / SRS) Aux hydraulics switch 99
SVH Toggle valve 99
(SVA1 / SVA2) Aux hydraulics valves 99
(THS) Motor thermal switch 99
(TM / M1) Traction motor 99
Component Assembly Locations100
From serial no 5A134882103
From serial no 5A134882104
From serial no 5A134882105
Traction Controller 1207106
Functions106
Key switch106
Current limit106
Overvoltage protection106
Overtemperature protection106
Performance reduction for low voltage106
Fault identification106
Error log106
Service107
Control Panel108
Adjusting potentiometer108
Programmer connection108
Status LED108
Diagnostics with the status LED108
Traction Controller Error Messages109
Status LED109
Error Reset111
Test Procedure112
Pulse Monitor Trip Test (PMT)112
Equipment112
Test112
PMT Test Wiring Diagram113
1307 Programmer114
General114
Connection114
Operation114
General114
Key Functions116
SCROLL DISPLAY keys116
CHANGE VALUE keys116
MORE INFO key116
PROGRAM key116
TEST key117
DIAGNOSTIC key117
Key Combinations117
SPECIAL DIAGNOSTIC menu117
SPECIAL PROGRAM menu117
Clearing the error history117
Copying (cloning) controller settings117
Resetting to defaults117
Programmer self-test118
1311 Programmer119
General119
Operation119
Menus120
Main menu120
Program menu120
Monitor menu120
Error menu120
Functions120
Hand Held Unit Settings120
Traction Controller Settings121
WE 125t/WS 135t121
Traction Controller Type 1207-1115 Setting121
WE 125t/WS 135t Platform121
Traction Controller Type 1207-1144 Setting121
WE 16t/WS 18t/WS 14 t122
Traction Controller Type 1207-1115 Setting122
WE 14t Platform / WS 14t Platform122
Traction Controller Type 1207-1144 Setting122
Programmer Menus123
“Program” Menu123
“Test” Menu124
“Diagnostics” and “Special Diagnostics” Menus125
“Special Program” Menu126
BDI / TT127
Battery Discharge Indicator / Hourmeter127
Removal127
Servicing127
Assembly127
Battery Discharge Indicator (BDI)127
General127
Battery Discharge Indicator Setting (BDI)128
Calibration128
Functional Description129
Platform Logic Controller, Part No 815043129
KYS Key Switch132
Removal132
Servicing132
Assembly132
Speed Limit Switch (LMS)133
Removal133
Assembly133
Speed Limit Switch on Mast (LMS2)133
Removal133
Assembly133
Brake Switch (BRS)134
Removal134
Assembly134
Override Switch (ORS)136
Removal136
Assembly136
Emergency Disconnect Switch (EDS)137
Removal137
Servicing137
Assembly137
On Board Charger138
General138
Battery Charging Phases138
First Phase (I1)138
Second Phase (P)138
Third Phase (U)138
Fourth Phase (I2)138
End of Normal Charging138
Special Charging Phases138
Compensating Charge138
Float Charge139
Partial Charging139
Charging Errors139
Green LED is not lit139
Possible Causes:139
Green LED flashing139
Possible Causes:139
Important Technical Data140
Replacing the Charger141
Removal / Assembly141
On Board Charger142
General142
Battery Charging Phases142
First Phase (I1)142
Second Phase (P)142
Third Phase (U)143
Fourth Phase (I2)143
End of normal charging143
Special Charging Phases143
Compensating Charge143
Float charge143
Partial charging143
Charging Errors145
Green LED not lit145
Possible Causes:145
Green LED flashing145
Possible Causes:145
Important Technical Data146
Replacing the Charger146
Removal / Assembly146
Motors147
General Maintenance Instructions147
Important Maintenance Instructions147
Traction Motor148
Servicing148
Removal148
Repairs149
Assembly150
Pump Motor151
Removal151
Assembly151
Maintenance152
Accessing brushes152
Armature (WE/WS 125 and 13)152
Armature (WE/WS 14, 16 and 18)152
Bearings152
Pump Motor153
Removal153
Assembly153
Maintenance153
Accessing brushes153
Brushes (WE/WS 125, 13)153
Brushes (WE/WS 14, 16, 18)153
Armatures (WE/WS 125, 13)153
Armature (WE/WS 14, 16, 18)154
Electrical Panel155
General156
Removal156
Assembly156
Electrical Panel157
General158
Removal158
Assembly158
Contactors159
Inspection159
Contacts159
Coils159
Springs159
Checking the coils159
Servicing160
Travel contactor, part no 802815160
Dismantling160
Assembly161
Travel contactor, part no 804226162
Dismantling162
Assembly162
Contactor Removal / Assembly164
Travel Contactor164
Removal164
Assembly164
Lift Contactor164
Removal164
Assembly164
Battery165
Removal & Installation165
Removal with a lifting device165
Assembly165
Removal using the optional battery rollers:165
Servicing the Battery165
General165
Battery Connector165
Removal165
Servicing165
Hydraulic Control Module (HCM)167
Brake System169
Brake Operation171
Repairing the Brake172
Removal172
Dismantling172
Assembly173
Assembly173
Brake Air Gap Adjustment174
Setting the Braking Distance175
Default setting175
Testing and Adjusting the Braking Distance176
Calculating the braking distance176
Steering177
Control Handle Return Springs179
Spring Tension Adjustment179
Spring Removal179
Assembly180
Cardan Joint181
Removal181
Assembly181
Steering Chain182
Removal182
Assembly182
Tensioning the steering chain182
Forward Travel183
Test and Adjustment183
Up to serial no 5A134880:183
From serial no 5A134882:183
Tiller Handle Components184
Main Components184
Tools required185
Hand Grip Shells185
Removal185
Assembly186
Switch Unit187
Removal187
Assembly187
“Rabbit/Turtle” Toggle Switch188
Removal188
Assembly188
Hydraulic PC Board188
Removal188
Assembly188
Main PC Board189
Removal189
Assembly189
Potentiometer190
Removal190
Assembly191
Safety Reverse Switch192
Removal192
Assembly193
Horn Switch193
Removal193
Assembly193
Hand grip194
Removal194
Assembly195
Auxiliary Hydraulics Switch195
Removal195
Assembly195
Lifting Mechanism197
Mast199
General199
Lifting Gear Minimum Capacity199
Removal199
Assembly199
Fork Carriage200
Removal200
Assembly200
Adjusting the fork carriage clearance200
Mast and fork carriage clearance setting example201
Mast Maintenance202
Greasing the Roller Tracks202
Mast rollers202
Removal202
Assembly202
Lift Chains203
Inspection203
Cleaning Methods203
Wear203
Freedom of Movement of Chain Links205
Chain Tension205
Chain Anchor and Pulleys205
Worn Connection Plates205
Protruding or Turned Chain Pins206
Corrosion206
Chain Lateral Wear206
Uneven Chain Tension206
Misaligned Lift Components206
Lift Chain Lubrication207
Separating Lift Chains208
Tools and Equipment Required208
Separation208
Forks209
General209
Terms209
Fork identification209
Repairs209
Checking the Forks210
Crack Inspection210
Heel area210
Welding seams210
Verticality Test211
Fork Blade Warping211
Measuring the Fork Tip Width211
Fork Tine Height Difference212
Fork Stop212
Fork Blade Wear212
Cylinders213
Seal Assembly215
General215
Safety When Working on Hydraulic Systems215
General Instructions for Repairing Hydraulic Components215
Rod Seal Assembly215
General215
Large Rod Seal Assembly216
Small Seal Rod Assembly216
Rod Seal Assembly, Sealing Lip First217
Cylinder Removal and Assembly218
TL Mast Lift Cylinder218
Seal Replacement218
Installing TL Mast Lift Cylinders219
TF Mast Lift Cylinders220
Removing the TF Mast Lift Cylinders220
Seal replacement220
Installing TF Mast Lift Cylinders221
TF Free Lift Cylinder222
Seal replacement222
Installing Carriage Cylinder223
Cylinder Bleeding and Flushing223
Bleeding – Mast Lift Cylinders223
Bleeding – Free Lift Cylinder (if applicable)223
Flushing – Mast Lift Cylinders and Free Lift Cylinders (if applicable)223
Drift Test224
Cylinder Shimming224
Lift Cylinder Shims224
Free Lift Cylinder Shims224
HYDRAULIC CYLINDERS225
General225
Simplex mast cylinder225
Removal225
Lift Cylinder225
Removal225
Platform227
Folding Platform229
Mechanical Adjustment229
Adjusting the Platform Switch (PLS)230
Platform Cushioning231
Layering the disk springs231
Side restraint231
Mechanical Adjustment231
Schematic Diagrams233
WE / WS up to serial no 5A132186235
Schematic Diagram, Standard235
Distribution Panel, Standard237
Traction Controller – Power Side, Standard238
Brake Circuit, Standard239
Instrument & Proportional Electronic Circuit, Standard240
Control Handle Circuit, Standard241
Schematic Diagram, Options242
Distribution Panel, Options244
Traction Controller – Power Side, Options245
Brake Circuit, Options246
Instrument & Proportional Electronic Circuit, Options247
Control Handle Circuit, Options248
Schematic Diagram, Auxiliary Hydraulics249
Distribution Panel, Auxiliary Hydraulics251
Traction Controller, Auxiliary Hydraulics252
Brake Circuit, Auxiliary Hydraulics253
Instrument & Prop Electronics & Sideshift Circuit254
Control Handle Circuit, Auxiliary Hydraulics255
Control Handle Wire Harness256
Connector housing256
Contact pins256
Horn Harness257
Connector housing257
Contact pins257
Main Harness, Standard258
Main Harness, Auxiliary Hydraulics259
Connector housing260
Contact pins260
Hourmeter Harness261
Connector housing261
Contact pins261
Harness, Brake262
Connector housing262
Contact pins262
Harness, Control Module263
Connector housing263
Contact pins263
Proportional Hydraulics Connector Lead, Standard264
Connector housing264
Contact pins264
Connector housing265
Contact pins265
Connector housing266
Contact pins266
Connector housing267
Contact pins267
Contact pins268
ORS Jumper269
Connector housing269
Contact pins269
Power Cables270
WE S / WS S up to serial no 5A132186271
Schematic Diagram, Standard271
Distribution Panel, Standard272
Traction Controller – Power Side, Standard273
Brake Circuit, Standard274
Walkie / Rider Circuit, Standard275
Instrument & Proportional Electronic Circuit, Standard276
Control Handle Circuit, Standard277
Schematic Diagram, Option278
Distribution Panel, Option280
Traction Controller – Power Side, Option281
Brake Circuit, Option282
Walkie / Rider Circuit, Option283
Instrument & Proportional Electronic Circuit, Option284
Control Handle Circuit, Option285
Schematic Diagram, Auxiliary Hydraulics286
Distribution Panel, Auxiliary Hydraulics288
Traction Controller, Power Side, Auxiliary Hydraulics289
Brake Circuit, Auxiliary Hydraulics290
Walkie / Rider Circuit, Auxiliary Hydraulics291
Instrument & Prop Electronics & Sideshift Circuit, Auxiliary Hydraulics292
Control Handle Circuit, Auxiliary Hydraulics293
Control Handle Harness294
Connector housing294
Contact pins294
Horn Harness295
Connector housing295
Contact pins295
Main Harness, Standard296
Main Harness, Auxiliary Hydraulics297
For tables for Fig 807229_2D (see page 241)298
Connector housing298
Contact pins298
Hourmeter Harness299
Connector housing299
Contact pins299
Harness, Brake300
Connector housing300
Contact pins300
Harness, Control Module301
Connector housing301
Contact pins301
Proportional Hydraulics Connector Lead, Standard302
Connector housing302
Contact pins302
Connector housing303
Contact pins303
Connector housing304
Contact pins304
Connector housing305
Contact pins306
ORS Jumper307
Contact pins307
Harness 1, Platform308
Connector housing308
Contact pins308
Harness 2, Platform309
Connector housing309
Contact pins309
Power Cables310
WE / WS from serial no 5A132188 to serial no 5A134880311
Schematic Diagram, Standard311
Distribution Panel, Standard313
Traction Controller – Power Side, Standard314
Brake Circuit, Standard315
Walkie / Rider, Standard316
Instrument & Platform Logic, Standard317
Control Handle Circuit, Standard318
Schematic Diagram, Standard319
Traction Controller, Option322
Brake Circuit, Option323
Walkie / Rider Circuit, Option324
Instrument & Platform Logic, Option325
Control Handle Circuit, Option326
Schematic Diagram, Auxiliary Hydraulics328
Distribution Panel, Auxiliary Hydraulics330
Traction Controller – Power Side, Auxiliary Hydraulics331
Brake Circuit, Auxiliary Hydraulics332
Walkie / Rider Circuit & Instrument, Auxiliary Hydraulics333
Instrument & Prop Electronics & Sideshift Circuit, Auxiliary Hydraulics334
Control Handle Circuit, Auxiliary Hydraulics335
Platform Logic, Auxiliary Hydraulics337
Control Handle Wire Harness338
Connector housing338
Contact pins338
Horn Harness339
Connector housing339
Contact pins339
Main Harness340
For tables for Fig 815408_2E (see page 322)341
Connector housing341
Contact pins341
Cable lugs and rings341
Main Harness, Auxiliary Hydraulics342
For tables for Fig 816076_2B (see page 324)343
Connector housing343
Contact pins343
Hourmeter Harness344
Connector housing344
Contact pins344
Harness, ORS – BRS – BRK345
Connector housing345
Contact pins345
Harness, TCM346
Connector housing346
Contact pins346
Proportional Hydraulics Connector Lead, Standard347
Connector housing347
Contact pins347
Connector housing348
Contact pins348
Connector housing349
Contact pins349
Connector housing350
Contact pins351
ORS Jumper352
Contact pins352
Harness, Platform Logic353
For tables for Fig 815374_2H (see page 335)354
Connector housing354
Contact pins354
Platform Cable 1355
Connector housing355
Contact pins355
Platform Cable 2356
Connector housing356
Contact pins356
Cable, LMS2357
Connector housing357
Contact pins357
WE / WS from serial no 5A134882358
Schematic Diagram, Standard358
Distribution Panel, Standard360
Traction Controller – Power Side, Standard361
Brake Circuit, Standard362
Instrument & Proportional Electronic Circuit, Standard363
Control Handle Circuit, Standard364
Option Connection, Thermal Switch, Standard366
Schematic Diagram, Options367
Distribution Panel, Options369
Traction Controller – Power Side, Options370
Brake Circuit, Options371
Instrument & Proportional Electronic Circuit, Options372
Control Handle Circuit, Options373
Option Connection, Thermal Switch, Options375
Control Handle Wire Harness376
Connector housing376
Contact pins376
Horn Harness377
Connector housing377
Main Harness378
For tables for Fig 816836_2D_1 (see page 360)379
Connector housing379
Contact pins379
Cable lugs and rings379
Hourmeter Harness380
Connector housing380
Contact pins380
Strobe & Alarm Signal Optional Harness381
Connector housing381
Contact pins381
Cable lugs and rings381
Strobe & Alarm Signal Optional Harness382
Connector housing383
Contact pins383
Mast Cable for Strobe Light384
Jumper 125 t384
Contact pins385
Power Cables386
Schematic Diagram, Standard387
Electric Diagram, Standard389
Traction Controller, Power Side, Standard390
Brake Circuit, Standard391
Instrument & Proportional Electronic Circuit, Standard392
Control Handle Circuit, Standard393
PLM – Platform Logic Module, Walkie / Rider Circuit394
Option Connection, Thermal Switch, Standard396
Schematic Diagram, Standard397
Distribution Panel, Options399
Traction Controller – Power Side, Options400
Brake Circuit, Options401
Instrument & Proportional Electronic Circuit, Options402
Control Handle Circuit, Options403
PLM – Platform Logic Module, Walkie / Rider Circuit, Options405
Option Connection, Thermal Switch, Options407
Control Handle Wire Harness408
Connector housing408
Contact pins408
Horn Harness409
Connector housing409
Main Harness410
Connector housing411
Contact pins411
Cable lugs and rings411
Hourmeter Harness412
Connector housing412
Contact pins412
Strobe & Alarm Signal Optional Harness413
Connector housing413
Contact pins413
Cable lugs and rings413
Strobe & Alarm Signal Optional Harness414
Connector housing415
Contact pins415
Mast Cable for Strobe Light416
Jumper 125 t416
Contact pins417
ORS Jumper418
Contact pins418
Platform Cable 2419
Connector housing419
Contact pins419
Cable, LMS2420
Connector housing420
Contact pins420
Power Cables421
Hydraulic Schematic423
Hydraulic Diagrams425
WE/WS TL425
WE/WS TF426
WE/WS TT426
WS Auxiliary Hydraulics TL Mast427
WS Auxiliary Hydraulics TT Mast428
TL Mast429
Abbreviations429
TT mast430
Abbreviations430
TF mast431
Abbreviations431

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