Crown Forklift WP2300 Series Maintenance Manual – PDF DOWNLOAD

Description

Crown Forklift WP2300 Series Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WP2300 Series Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :146
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WP2300 Series Maintenance Manual – PDF DOWNLOAD

ITD – INTRODUCTION PAGE SER-NR CUT REV
Safety Symbols used in the Manual 3 Rev1 04/00
General Maintenance and Repair Safety Notes 3
Maintenance and Repair 3 Rev1 04/00
Before Leaving the Truck 4
Before Carrying out Work on the Truck 4
Before Operating the Truck 4
Warnings and Labels on the Truck 4
General 7
Operating Instructions 7
Service Training 7
Ordering Spare Parts 7
Using the Manual 7
Model-Number 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR CUT REV
Component Access 11
Jacking up the Truck 11
Lifting by Crane 11
Lifting by Truck 12
Components 13
Maintenance 16
Recommended Lubricants and Oils 16
Lubricants 16
Cold Store Trucks 16
Truck Decommissioning 16
Restoring the Truck to Service 16
Check and Maintenance Schedule 18
Safety Reverse Switch – Functional Test 20
Grease items and grease intervals 28
Castors 30
Torques 31
M2 – HYDRAULICS PAGE SER-NR CUT REV
Hydraulic Symbols 35
Hydraulic System 39
Operation 39
Removing the Hydraulic Unit 40
Replacing the Hydraulic Pump 41
Removal 41
Installation 41
Commissioning and Bleeding the System 41
Filters 43
Replacing the Pressure Filter 43
Replacing the Suction and Return Filters 43
Oil Change 43
Replacing the Safety Valve 44
Safety Valve Setting 44
Safety Valve Test and Setting 44
M3 – DRIVE UNIT PAGE SER-NR CUT REV
Gear Unit 47
Drive Unit, General 48
Removing the Drive Unit
M3 – DRIVE UNIT PAGE SER-NR CUT REV
Traction Motor Removal 48
Dismantling the Motor 49
Assembling the Motor 49
Traction Motor Assembly 51
Gear Unit Disassembly 52
General 52
Preparation 52
Draining the oil 52
Removing the drive unit 52
Dismantling the gear unit lid 52
Dismantling the gear unit 53
Gear Unit Assembly 53
Installing the gear unit lid 55
Adding Oil 55
Installing the drive unit 55
M4 – ELECTRICS PAGE SER-NR CUT REV
Electrics – General 59
Wire Colour Codes 59
Abbreviations 60
Electrical Symbols 62
Electrical Components 63
Transmitter (POT, FS, RS) 63
Fast / Slow Travel Switch (HSS) 63
Reverse Safety Switch (SAS) 63
Brake Switch (BRS) 63
Override Switch (ORS) 63
Raise / Lower Switch (RAS, LOS) 64
Limit Switch (LMS) 64
Horn Switch (HNS) 64
Key Switch (KYS) 64
Emergency Disconnect 64
Fuses (FU) 64


 Thermal Switch (THS) 65
Battery 67
General 67
Replacing the battery 67
Battery Discharge Indicator (BDI) 67
General 67
Battery Discharge Indicator Setting (BDI) 68
Calibration 68
SEM0 Traction Controller 67
General 67
Precautionary Measures 67
Operational Features 67
Speed Control 67
Reduced Speed Ranges 67
Downhill Speed Control 67
Regenerative Braking 67
Anti – Roll Down Function 67
Hourmeter 68
Self Test 68
Monitored Circuits 68
Protective Devices 68
Polarity Protection 68
Wiring Errors 68
Temperature 68
Start Sequence 68
V
TABLE OF CONTENT
MS-WP2300-GB 04/03 • Printed in Germany
M4 – ELECTRICS PAGE SER-NR CUT REV
Safety Class 68
Maintenance 69
Replacing the SEM0 Traction Controller 70
Parameter Setting
after Replacing the Traction Controller 70
Preparatory Measures 70
Setting 70
Status LED 72
Programmer 73
General 73
Operating SEM0 Controller Menu 74
General 74
Operating Menu – Overview 75
Menu Functions 75
PARAMETER CHANGE 75
Settings and Alarms 76
TESTER Menu 77
ALARMS Menu 78
PROGRAM VACC Menu 79
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu 81
Preparatory Measures 81
Calibration 81
CONFIG Menu 82
SET MODEL 82
SET OPTIONS 82
Adjustments 82
Traction Controller Safety Test 83
Battery 85
General 85
Replacing the battery 85
Battery Discharge Indicator (BDI) 85
General 85
Battery Discharge Indicator Setting (BDI) 86
Calibration 86
On Board Charger 87
General 87
Battery Charging Phases 87
Special Charging Phases 87
Charging Errors 88
Green LED is not lit 88
Green LED flashing 88
Important Technical Data 89
Replacing the Charger 89
Removal / Installation 89
Electric Motors 91
General Maintenance Instructions 91
Preparation 91
Important Maintenance Instructions 91
Traction Motor Maintenance 92
Access to Brushes 92
Maintenance 92
Armature 92
Bearings 92
Pump Motor Maintenance 93
Access to brushes 93
Maintenance 93
Armature 93
VI
TABLE OF CONTENT
MS-WP2300-GB 04/03 • Printed in Germany
M5 – BRAKE PAGE SER-NR CUT REV
Brake 97
Operation 97
Removal 97
Assembly 99
Air Gap Setting 99
Brake Moment Setting 99
Testing the Brakes 99
M6 – STEERING PAGE SER-NR CUT REV
Live Ring Bearing 103
Disassembly 103
Installation 103
Multitask Handle – Springs for Return Function 104
Adjustment 104
Removal 104
Assembly 104
Tiller Handle 105
Main Components 105
Tiller Handle Component Removal / Installation 106
Tiller Handle Shells 106
Removing the Upper and Lower Shells 106
Fitting the Upper and Lower Shells 107
Switch Unit 108
Removal 108
Switch Unit Installation 108
“Fast/Slow” Toggle Switch 109
Removal 109
Installation 109
Hydraulic Board 109
Removal 109
Installation 109
Potentiometer 110
Removal 110
Installation 110
Safety Reverse Switch 111
Removal 111
Installation 111
Horn Switch 112
Removal 112
Installation 112
Handle 113
Removal 113
Installation 113
M7 – LIFTING MECHANISM PAGE SER-NR CUT REV
Lift Linkage 117
Fork Height Setting 117
M8 – CYLINDERS PAGE SER-NR CUT REV
Lift Cylinders 121
Operation 121
Removal 121
Inspection 123
Replacing the Piston Seal 123
VII
TABLE OF CONTENT
MS-WP2300-GB 04/03 • Printed in Germany
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR CUT REV
Overall Wiring Diagram, Standard Version 127
Overall Wiring Diagram with Options 128
Wire harness overview, all versions 129
HYD – HYDRAULIC SCHEMATIC PAGE SER-NR CUT REV
Hydraulic Schematic 133

IMAGES PREVIEW OF THE MANUAL:

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