Crown Forklift WE/WS2300 Series Service Manual – PDF DOWNLOAD

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Crown Forklift WEWS2300 Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WEWS2300 Series Service Manual – PDF DOWNLOAD

Language : English
Pages :268
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WEWS2300 Series Service Manual – PDF DOWNLOAD

WE/WS2300 1
TABLE OF CONTENT 3
Table of Content 1 3
Table of Content 2 4
Table of Content 3 5
Table of Content 4 6
GENERAL MAINTENANCE INSTRUCTION 15
SAFETY INSTRUCTIONS 1 15
SAFETY INSTRUCTIONS 2 16
SAFETY INSTRUCTIONS 3 17
INTRODUCTION 19
General 19
Using the manual 19
Maintenance 19
Spare parts catalog 20
Operating instruction 21
Service training 21
Replacement parts ordering 21
MAINTENANCE 23
COMPONENT ACCESS 23
Access to the components 23
ILLUSTRATION / BILD / ILLUSTRATION M0400 23
RAISING THE VEHICLE 24
WARNING! 24
ILLUSTRATION / BILD / ILLUSTRATION M1247 24
Support Points ILLUSTRATION M0401, ILLUSTRATION M0402 25
INSPECTION AND MAINTENANCE PLAN 27
Service scope 27
DAILY OR AFTER 8 HOURS OF OPERATION 28
ILLUSTRATION / BILD / ILLUSTRATION M0403 29
MONTHLY OR EVERY 100 HOURS OF OPERATION 30
ILLUSTRATION / BILD / ILLUSTRATION M0404 31
QUARTERLY OR EVERY 250 HOURS OF OPERATION 32
EVERY SIX MONTHS OR EVERY 500 HOURS OF OPERATION 32
ILLUSTRATION / BILD / ILLUSTRATION M0405 33
YEARLY OR EVERY 1000 HOURS OF OPERATION 34
ILLUSTRATION / BILD / ILLUSTRATION M0406 35
LUBRICATION 37
General 37
Lubricants 37
Cold store trucks 37
Operator involvement 37
Daily Maintenance Check 37
LUBRICANTS AND OIL RECOMMENDATIONS TABLE 1 39
LUBRICANTS AND OIL RECOMMENDATIONS TABLE 2 40
HYDRAULIC SCHEMATIC SYMBOLS 41
HYDRAULIC SCHEMATIC SYMBOLS 1 41
HYDRAULIC SCHEMATIC SYMBOLS 2 42
HYDRAULIC SCHEMATIC SYMBOLS 3 43
HYDRAULIC SCHEMATIC SYMBOLS 4 44
HYDRAULIC 53
General 53
HYDRAULIC OIL TANK 54
Cover on hydraulic oil tank 54
Disassembly 54
ILLUSTRATION / BILD / ILLUSTRATION M0410 55
Assembly 55
Assembly 56
Maintenance 56
Valve block 57
Disassembly 57
ILLUSTRATION / BILD / ILLUSTRATION M0412 57
Repair 57
Assembly 57
Hydraulic oil pump 58
Disassembly 58
ILLUSTRATION / BILD / ILLUSTRATION M0413 58
Assembly 58
Repair 58
HYDRAULIC SYSTEM SOFTLIFT 59
General: 59
Description: 59
ILLUSTRATION / BILD / ILLUSTRATION M0439 59
Hydraulic System, softlift 60
Lowering speed: 60
Bleed procedure: 60
Troubleshooting: 60
Vent hydraulic system on mast TF and TT Mast 61
ILLUSTRATION / BILD / ILLUSTRATION M0411 61
TL MAST 61
DRIVE UNIT 63
Drive wheel 63
Disassembly 63
ILLUSTRATION / BILD / ILLUSTRATION M0419 63
Assembly 63
DRIVE UNIT 64
General 64
Disassembly 64
ILLUSTRATION / BILD / ILLUSTRATION M0414 64
Assembly 65
Gearbox 65
Disassembly 65
ILLUSTRATION / BILD / ILLUSTRATION M1154 65
Assembly 66
ILLUSTRATION / BILD / ILLUSTRATION M0415 66
Repair 67
Assembly 68
Maintenance, oil change 69
Turntable bearing 70
Disassembly 70
Assembly 70
ILLUSTRATION / BILD / ILLUSTRATION M1155 70
PIVOTING CARRIAGE 71
General 71
Disassembly 71
ILLUSTRATION / BILD / ILLUSTRATION M0416 71
Assembly 72
Setting the pivoting carriage, type WE vehicle 72
Setting the pivoting carriage, type WS vehicle 72
WHEELS AND TYRES 73
General 73
Load wheel, single axle 73
Disassembly 73
ILLUSTRATION / BILD / ILLUSTRATION M0417 73
Assembly 73
Load wheel, tandem axle 74
Disassembly 74
ILLUSTRATION / BILD / ILLUSTRATION M0418 74
Assembly 74
Support wheel 74
Disassembly 74
Assembly 75
Support wheel mounting, 75
Disassembly 75
Assembly 75
ILLUSTRATION / BILD / ILLUSTRATION M0468 75
BASIC ELECTRICS 77
WIRING COLOUR CODE 77
ABBREVIATION, COLOUR, NUMBER, FUNCTION 77
COLOUR CODING IN ACCORDANCE WITH DIN 47100 78
Index of Abbreviations Switch symbols * 79
Other Abbreviations * 80
TYPICAL ELETRICAL SYMBOLS 81
Transistor control with pulse width modulation 82
ILLUSTRATION / BILD / ILLUSTRATION M0421 82
ILLUSTRATION / BILD / ILLUSTRATION M0422 83
ELECTRICAL COMPONENTS 85
SAFETY INSTRUCTIONS 85
SWITCHES 85
General 85
Key switch (KYS) 85
Brake switch (BRS) 85
Safety reverse switch (SAS) 85
Direction control (POT, FS, RS) 85
Lift/Lower switches (RAS, LOS) 86
Brake override switch (ORS) 86
Horn (HNS) 86
Speed limiter switch (LMS) 86
Battery connector/Emergency Battery disconnect 86
Fuses (FU) 86
Fast/Slow Switch (HSS) 86
ILLUSTRATION / BILD / ILLUSTRATION 813754_2a 87
ILLUSTRATION / BILD / ILLUSTRATION 813761_2a 88
CONTROLLER (1207-1115) 89
General 89
The most important characteristics are: 89
ILLUSTRATION / BILD / ILLUSTRATION M0024 89
EXPLANATION OF FUNCTION 90
Emergency reverse Only by walky trucks 90
Acceleration/deceleration rate 90
Brake 90
Throttle 90
Throttle response 90
Fault recording 91
Fault detection 91
The automatic fault detection system includes: 91
Arcless contactor switching: 92
Plug braking 92
Creep speed at first throttle 92
Low speed 92
MOSFET 93
Pulse with modulation (PWM) 93
Ramp start (anti roll-back) 93
Key switch 93
Quick start 93
Watchdog (external, internal) 93
Current limiting 94
Overvoltage cutoff 94
Overtemperatur 94
Undervoltage cutback 94
ILLUSTRATION / BILD / ILLUSTRATION M0025 95
ADJUSTMENT PANEL (1207-1115) 96
ILLUSTRATION / BILD / ILLUSTRATION M0026 96
Manually adjustable potentiometer 96
Programmer connector 96
Status LED 96
LED Diagnostics 96
LED CODES 97
MAINTENANCE 99
SAFETY 99
Cleaning of the controller 99
REMOVAL/INSTALLATION OFTRACTION CONTROLLER100
SAFETY INSTRUCTIONS100
Removal100
Installation of controller101
CONTROLER CHECK102
Attention102
No reaction102
Problem102
Problem 2103
PROGRAMMER105
General105
ILLUSTRATION / BILD / ILLUSTRATION M0031105
Connections105
Keypad definition106
ILLUSTRATION / BILD / ILLUSTRATION M0045106
Display107
ILLUSTRATION / BILD / ILLUSTRATION M0060107
SCROLL DISPLAY ARROWS107
ILLUSTRATION / BILD / ILLUSTRATION M0032108
CHANGE VALUE ARROWS108
MORE INFO KEY109
OPERATING MODES110
PROGRAM MODE110
ILLUSTRATION / BILD / ILLUSTRATION M0061110
The MORE INFO KEY110
ILLUSTRATION / BILD / ILLUSTRATION M0033111
TEST MODE111
DIAGNOSTIC MODE112
SPECIAL DIAGNOSTIC MODE112
SPECIAL PROGRAM MODE112
For instance:113
Controller cloning113
NOTE:113
Peace-of-Mind Programming113
Programmer Self Test114
ILLUSTRATION / BILD / ILLUSTRATION M0046114
Programmer (1311)115
ILLUSTRATION / BILD / ILLUSTRATION 10485-1115
OVERVIEW116
ILLUSTRATION / BILD / ILLUSTRATION 10466116
Menu Navigation Key116
Bookmark Keys116
Display Screen116
Data INC/DEC Key116
HANDSET OPERATION117
ILLUSTRATION / BILD / ILLUSTRATION 10468117
ILLUSTRATION / BILD / ILLUSTRATION 10532118
ILLUSTRATION / BILD / ILLUSTRATION 10533118
HANDSET MENUS119
Program Menu119
Monitor Menu119
Faults Menu120
SYSTEM FAULTS120
Functions Menu120
Information Menu120
Programmer Setup Menu121
VALUES AND FAULT123
WE 125t/WE-S 12t/WS 135t123
WE 16t/WE-S 14t/WS 18t/WS-S 14t124
PROGRAM MENU Table 1 tab0001doc125
TEST MENU Table 2 b0002doc126
Diagnostic and Special Diagnostic Menu Table 3 b0003doc127
SPECIAL PROGRAM MENU Table 4 b0004doc128
Trouble shooting chart tab0011doc129
Fault recovery (including recovery from disable)132
BATTERY LEVEL INDICATOR / OPERATING HOURS COUNTER BDI/TT133
Disassembly133
Repairs133
Assembly133
ILLUSTRATION / BILD / ILLUSTRATION M1246133
KEY SWITCH KYS135
Disassembly135
Repairs135
Assembly135
ILLUSTRATION / BILD / ILLUSTRATION M1156135
Speed limit switch136
Disassembly136
Assembly136
Brake switch (BRS)137
Disassembly137
ILLUSTRATION / BILD / ILLUSTRATION M1160137
Assembly137
ILLUSTRATION / BILD / ILLUSTRATION M1161137
Override switch (ORS)139
Disassembly139
Assembly139
Emergency Off switch (EDS)140
Disassembly140
Repair140
Assembly140
ILLUSTRATION / BILD / ILLUSTRATION M1162140
Distributor board141
Disassembly141
Repair141
Assembly141
ILLUSTRATION / BILD / ILLUSTRATION M1163141
MOTOR143
General143
PUMP MOTOR144
Disassembly144
ILLUSTRATION / BILD / ILLUSTRATION M0428144
Assembly144
Maintenance WE 125/WS135145
ILLUSTRATION / BILD / ILLUSTRATION M0429145
Repair145
Assembly147
ILLUSTRATION / BILD / ILLUSTRATION M0430147
Maintenance WE 16/WS18148
ILLUSTRATION / BILD / ILLUSTRATION M0616148
Repair149
DRIVE MOTOR150
Disassembly150
ILLUSTRATION / BILD / ILLUSTRATION M1154150
Repair151
ILLUSTRATION / BILD / ILLUSTRATION M0431152
Assembly153
Maintenance153
Electrics panel155
General155
Disassembly155
Assembly155
ILLUSTRATION M1163155
Direction of contactor156
Checking safety getting contacts156
Checking coils156
Disassembly156
ILLUSTRATION / BILD / ILLUSTRATION M0423157
Repairs157
Assembly157
Assembly157
Pump contactor158
Disassembly158
Repairs158
ILLUSTRATION / BILD / ILLUSTRATION M0424158
Assembly159
BATTERY161
WARNING161
Disassembly with lifting device161
Assembly161
BATTERY Removal with battery roller option161
INSTRUCTIONS ON BATTERY MAINTENANCE162
Checking the electrolyte level162
NOTE162
Charging the battery163
Trickle charging163
Using the battery at high temperature164
Daily maintenance164
Weekly maintenance164
Monthly maintenance164
Cleaning165
Storage165
Spilled or leaking electrolyte:165
Battery connections165
Disassembly165
Repair166
WARNING166
ILLUSTRATION / BILD / ILLUSTRATION M0427166
Assembly166
TEST PROCEDURES167
PULSE MONITOR TRIP – TEST (PMT)167
Equipment167
Test procedure167
ILLUSTRATION / BILD / ILLUSTRATION M0461167
PMT – TEST CONNECTING DIAGRAM ILLUSTRATION M0460168
BRAKE169
General169
Drive wheel Brakes169
Removal169
ILLUSTRATION / BILD / ILLUSTRATION M0432170
Note:170
Installation170
Setting up Air Gap171
ILLUSTRATION / BILD / ILLUSTRATION 0036171
Setting up brake torque171
Carrying out Brake Test171
STEERING173
General173
REMOVAL OF CONTROL HANDLE174
Removal174
Attention Pre loaded springs174
see FigM0465174
see FigM0466175
Installation175
Cross joint steering176
Disassembly176
ILLUSTRATION / BILD / ILLUSTRATION M0433176
Assembly176
Chain tensioning device, steering177
Disassembly177
ILLUSTRATION / BILD / ILLUSTRATION M0434177
Assembly177
Steering chain178
Disassembly178
ILLUSTRATION / BILD / ILLUSTRATION M0435178
Assembly179
Tiller Handle181
Main Components181
MS518181
Tiller Handle Component183
Removal / Installation183
MS514184
MS502184
MS501184
MS517184
MS503184
Tiller Handle Shells185
Removing the Upper and Lower Shells185
Fitting the Upper and Lower Shells185
MS513186
MS514186
Switch Unit187
Removal187
Switch Unit Installation187
MS511188
MS504188
“Fast/Slow” Toggle Switch189
Removal189
Installation189
MS511190
Hydraulic Board191
Removal191
Installation191
MS508192
MS509192
Potentiometer192
Removal192
Installation193
MS508194
Safety Reverse Switch194
Removal194
Installation195
MS502196
MS503196
Horn Switch197
Removal197
Installation197
MS501198
MS502198
Handle199
Removal199
Installation199
M0467200
Auxiliary Switch201
Removal201
Assembly201
LIFTING GEAR203
General203
Single lifting gear (Simplex) TL203
Double lifting gear (Duplex) TF203
Triple lifting gear (Triplex) TT204
Lifting gear204
Disassembly204
Assembly205
Fork carriage205
Disassembly205
Assembly205
Setting the fork carrier play206
If there is too much play:206
Mast maintenance206
WARNING206
Greasing roller tracks206
Disassembling rollers207
Assembly207
LIFT CHAIN INSPECTION209
General209
ILLUSTRATION / BILD / ILLUSTRATION M2777S209
The presence of an adequate lubricant coating guarantees:209
Maintenance210
Note210
Special attention must be given to the following types of damage and wear:210
Warning211
Detailed Explanation211
Cracked or Missing Link plates211
ILLUSTRATION / BILD / ILLUSTRATION M2774S211
Pitting and Corrosion211
ILLUSTRATION / BILD / ILLUSTRATION M2773S211
Protruding or Turned Pins212
Warning212
ILLUSTRATION / BILD / ILLUSTRATION M2776S212
Free Movement and Edge Wear212
ILLUSTRATION / BILD / ILLUSTRATION M2775S213
Chain Length Measurement213
ILLUSTRATION / BILD / ILLUSTRATION M2771S213
Chain Tension214
Chain Anchors and Pulleys214
FORK INSPECTION215
General215
Fork Identification215
WARNING215
Repairs216
Visual Inspection for Cracks216
WARNING216
Fig M0346216
Fig M0348216
Fig M0347216
Straightness InspectionFig M0350/0351/0349217
Fork Blade Bending Fig M0352, Fig M0353217
Inspection of Fork Tip Thickness Fig M0355217
Fork Blade Height Difference Fig M0354218
Fork Locking Fig M0356218
Wear218
Fig M0357219
Fig M0358/0359219
Fig M0360219
HYDRAULIC CYLINDER221
General221
WARNING221
Simplex mast cylinder221
Disassembly221
Lifting cylinder222
Disassembly222
PANELS, COVERS223
General223
Protective cover223
Disassembly223
Assembly223
Battery cover223
Disassembly223
Assembly223
Nuckle cover224
Disassembly224
Assembly224
Nuckle cover adjustment224
ILLUSTRATION / BILD / ILLUSTRATION M0436224
Folding Platform M1550226
Mechanical Setting 227
M1550228
Platform Switch Setting (PLS)229
Platform Suspension230
Plate Spring Layers230
MS1720-101230
ELECTRICAL DIAGRAMS231
WE/WS 2300 STANDARD SCHEMATIC DIAGRAM 813488231
WE/WS 2300 STANDARD DISTRIBUTION PANEL 813488-2A232
WE/WS 2300 STANDARD TRACTION CONTROLLER – POWER SIDE 813488-3A233
WE/WS 2300 STANDARD BRAKE CIRCUIT 813488-4A234
WE/WS 2300 STANDARD INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813488-5A235
WE/WS 2300 STANDARD CONTROL HANDLE CIRCUIT 813488-6A236
WE/WS 2300 OPTION SCHEMATIC DIAGRAM 813489-1A237
WE/WS 2300 OPTION DISTRIBUTION PANEL 813489-2A238
WE/WS 2300 OPTION TRACTION CONTROLLER – POWER SIDE 813489-3A239
WE/WS 2300 BRAKE CIRCUIT OPTION 813489-4A240
WE/WS 2300 OPTION INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 81348_2A_5241
WE/WS 2300 OPTION CONTROL HANDLE CIRCUIT 813489_2A_6242
WE2300S / WS2300S STANDARD SCHEMATIC DIAGRAM 813519_2A_1243
WE2300S / WS2300S STANDARD DISTRIBUTION PANEL 813519_2A_2244
WE2300S / WS2300S STANDARD TRACTION CONTROLLER – POWER SIDE 813519_2A_3245
WE2300S / WS2300S STANDARD BRAKE CIRCUIT 813519_2A_4246
WE2300S / WS2300S STANDARD WALKIE / RIDER CIRCUIT 813519_2A_5247
WE2300S / WS2300S STANDARD INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813519_2A_6248
WE2300S / WS2300S STANDARD CONTROL HANDLE CIRCUIT 813519_2A_7249
WE2300S / WS2300S OPTION SCHEMATIC DIAGRAM 813520_2A_1250
WE2300S / WS2300S OPTION DISTRIBUTION PANEL 813520_2A_2251
WE2300S / WS2300S OPTION TRACTION CONTROLLER – POWER SIDE 813520_2A_3252
WE2300S / WS2300S OPTION BRAKE CIRCUIT 813520_2A_4253
WE2300S / WS2300S OPTION WALKIE / RIDER CIRCUIT 813520_2A_5254
WE2300S / WS230 OPTION INSTRUMENT & PROPORTIONAL ELECTRONIC CIRCUIT 813520_2A_6255
WE2300S / WS2300S OPTION CONTROL HANDLE CIRCUIT 813520_2A_7256
POWER CABLES 803466_2D_1257
Global Handle Harness 813426_2B_1 258
Horn Harness 811931_2B_1259
Main Harness 803459_2G_1260
Main Harness261
Brake Harness262
Platform Harness263
Interface Connector 813472_2A_1264
WE/WS TL M0440265
HYDRAULIC SCHEMATIC265
WE/WS TF, WE/WS TT M0441266
WS Hydraulic Accessories TL Mast M1996267
WS Hydraulic Accessories TT Mast M1997268

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