Technical Service Manual for Crown WP2000S Series Forklift PDF

Description

Crown Forklift WP2000S Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WP2000S Series Service Manual – PDF DOWNLOAD

Language : English
Pages :139
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WP2000S Series Service Manual – PDF DOWNLOAD

WP2000S 1
TABLE OF CONTENT 3
M-IDX-1720-501 5
M-IDX-1720-502 6
M-IDX-1720-503 7
SAFETY 9
Safety Symbols used in the Manual 11
Manual General Maintenance and Repair Safety Notes 11
Maintenance and Repair 11
Before Leaving the Truck 12
Before Carrying out Work on the Truck 12
Before Operating the Truck 12
Warnings and Labels on the Truck 12
INTRODUCTION 13
General 15
Operating Instructions 15
Service Training 15
Ordering Spare Parts 15
Using the Manual 15
Page Numbering in the Manual 16
Model Number 18
LUBRICATION AND ADJUSTMENT 19
Component Access 21
Jacking up the Truck 21
Lifting with a Crane 21
Lifting by Truck 22
Components 23
Maintenance 26
Driver Participation 26
Daily Maintenance Log 26
Recommended Lubricants and Oils 26
Lubricants 26
Cold Store Trucks 26
Cold Store Trucks 26
Table of Recommended Lubricants 27
Check and Maintenance Schedule 28
Daily or 8 hours 28
Safety Reverse Switch – Functional Test 30
Monthly or 100 hours 32
3 months or 250 hours 34
6 months or 500 hours 34
Annually or 1000 hours 36
2 years or 2000 hours 36
Grease items and grease intervals 38
Adjusting the Contact Pressure of Castors and the Drive Wheel 40
Torques 41
HYDRAULICS 43
Hydraulic Symbols 45
Hydraulic System 49
Operation 49
Removing the Hydraulic Unit WARNING 50
Replacing the Hydraulic Pump 51
Removal 51
Installation 51
Commissioning 52
Pump Motor 52
Filters 52
Replacing the Pressure Filter 52
Replacing the Suction and Return Filters 52
Oil Change 52
DRIVE UNIT 55
Gear Unit 57
Preparatory Measures 57
Required Tools: 57
Removal 57
Maintenance 57
General 57
Gear Unit Disassembly / Assembly 59
Assembly 59
Preparing the Gear Unit 59
Flange Shaft Assembly 59
Pinion Shaft Assembly 60
Adjusting the Bevel Gear Assembly 60
Basic Rules: 60
If necessary, reduce the torque Checking the Flank Tooth Bearing 60
Final Assembly 60
Assembly 61
Drive Motor 61
ELECTRICS 63
Electrics – General 65
Electrics – General 65
Wire Colour Codes 65
Abbreviations 66
Electrical Symbols 68
Electrical Components 69
Transmitter (POT, FS, RS) 69
Fast / Slow Travel Switch (HSS) 69
Safety Reverse Switch (SAS) 69
Brake Switch (BRS) 69
Tiller Position and Functions 69
Illustrated Component Overview 70
Illustrated Component Overview 71
Lift / Lower Switch (RAS, LOS) 72
Limit Switch (LMS) 72
Horn Switch (HNS) 72
Key Switch (KYS) 72
Emergency Disconnect 72
Fuses (FU) 72
Temperature Switch (THS) 72
Adjustment of Lift-Limit Switch 72
SEM 1 Traction Controller 73
General 73
Precautionary Measures 73
Operational Features 73
Speed Control 73
Reduced Speed Range 73
Downhill Speed Control 73
Regenerative Braking 73
Anti – Roll Down Function 73
Hourmeter 74
Self Test 74
Monitored Circuits 74
Schematic, Monitored Circuits 74
Protective Devices 75
Polarity Protection 75
Wiring Errors 75
Temperature 75
Start Sequence 75
Safety Class 75
Maintenance 75
Traction Controller, Diagnostic Sheet 76
SEM-1 Traction Controller Connections 77
Power Connections 77
Control Connections 77
SEM-1 Pin Layout 78
Status LED 78
Descriptio of Alarms shown by LED 79
Programmer 80
Description of Keys 81
Operating Menu SEM 1 Controller 81
Operating Menu – Overview 82
Menu Functions 83
PARAMETER CHANGE 83
TESTER 83
ALARMS 83
PROGRAM VACC 83
CONFIG 83
Settings 84
Parameter Change Menu 84
Adjustment of “MAX SPEED FRW W” and “MAX SPEED BCK W” 85
Presets 85
Measuring the speed 85
Calculate the speed: 85
TESTER Menu 87
ALARMS Menu 88
PROGRAM VACC Menu 90
CONFIG Menu 91
Traction Controller Safety Test 92
Battery 93
General 93
Operation 93
Reading the Electrolyte Level 93
Replacing the Battery 93
Removing the Battery 93
Charging the Battery 94
Battery Discharge Indicator (BDI) 94
connection is secure Adjusting the Battery Discharge Indicator 94
Traction / Pump Motor Maintenance 95
Access 95
Maintenance 95
BRAKE 97
General Functional Description 99
Removal 99
Assembly100
Air Gap Setting100
Brake Moment Setting101
Brake Test101
Nominal Braking Distances and Screw Depth101
STEERING103
Multitask Handle – Springs for Return Function105
Adjustment105
Removal105
Assembly105
LIFTING MECHANISM107
Lift Linkage109
Fork Height Setting109
CYLINDERS111
Lift Cylinders113
Operation113
Removal113
Inspection115
Replacing the Piston Seal115
ELECTRICAL DIAGRAMS117
WP 2000-S STANDARD119
TRACTION CONTROLLER – LOGIC SIDE120
TRACTION CONTROLLER – POWER SIDE121
POWER UNIT CIRCUIT122
CONTROL HANDLE CIRCUIT123
WALKIE / RIDER CIRCUIT124
Power-Cables125
Main-Harness126
Handle-Harness127
WP 2000-S OPTIONS F/C128
TRACTION CONTROLLER – SEM1 LOGIC SIDE129
TRACTION CONTROLLER – ZAPI POWER SIDE130
POWER UNIT CIRCUIT131
CONTROL HANDLE CIRCUIT132
WALKIE / RIDER CIRCUIT133
HANDLE HARNESS F/ C134
HYDRAULIC SCHEMATIC135
HYDRAULIC SCHEMATIC137

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