Crown Forklift WP2300S Series Maintenance Manual 812529-006

Description

Crown Forklift WP2300S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WP2300S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

Language : English
Pages :158
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WP2300S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

ITD – INTRODUCTION PAGE SERNR 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
ModelNumber 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SERNR CUT REV
Jacking up the Truck 11
Raising the Truck with a Crane 11
Fixed Platform 11
Folding Platform 12
Both Platforms 13
Raising with a Forklift Truck 14
Component Access and Components 15
Maintenance 18
Recommended Lubricants and Oils 18
Lubricants 18
Cold Store Trucks 18
Truck Decommissioning 18
Restoring the Truck to Service 18
Check and Maintenance Schedule 20
Safety Reverse Switch –
Functional Test 22
Grease items and grease intervals 30
Adjusting the Contact Pressure of the Castors
and the Drive Wheel 32
Torques 33
M2 – HYDRAULICS PAGE SERNR CUT REV
Hydraulic Symbols 37
Hydraulic System 41
Operation 41
Removing the Hydraulic Unit 42
Replacing the Hydraulic Pump 43
Removal 43
Installation 43
Commissioning and Bleeding the System 43
Filters 45
Replacing the Pressure Filter 45
Replacing the Suction and Return Filters 45
Oil Change 45
Replacing the Safety Valve 46
Safety Valve Setting 46
Safety Valve Test and Setting 46
Testing and Setting the Load
Dependent Pressure Switch 47
IV
TABLE OF CONTENT
MSWP2300SGB 05/03 • Printed in Germany
M3 – DRIVE UNIT PAGE SERNR CUT REV
Gear Unit 51
Preparatory Measures 51
Removal 51
Maintenance 51
General 51
Gear Unit Disassembly / Assembly 53
Disassembly 53
Assembly 53
Preparing the Gear Unit 53
Flange Shaft Assembly 53
Pinion Shaft Assembly 54
Adjusting the Bevel Gear Assembly 54
Final Assembly 54
Assembly 55
M4 – ELECTRICS PAGE SERNR CUT REV
Electrics General 59
Wire Colour Codes 59
Abbreviations 60
Electrical Symbols 62
Electrical Components 63
Travel Switch (POT, FS, RS) 63
Fast/Slow Switch (HSS) 63
Safety Reverse Switch (SAS) 63
Brake Switch (BRS) 63
Raise/Lower Switch (RAS, LOS) 63
Pressure Switch (PS) 63
Platform Control Switches (GCSR, GCSL, PLS) 64
Lift Limit Switch (LMS) 64
Horn Switch (HNS) 64
Foot Switch (FTS) 64
Key Switch (KYS) 64
Emergency Disconnect (BD) 64
Fuses (FU) 64


 Thermal Switch (THS) 64
Battery 67
General 67
Replacing the battery 67
Battery Discharge Indicator (BDI) 67
General 67
Battery Discharge Indicator Setting (BDI) 68
Calibration 68
SEM1 Traction Controller 69
General 69
Precautionary Measures 69
Operational Features 69
Speed Control 69
Reduced Speed Ranges 69
Downhill Speed Control 69
Regenerative Braking 69
Anti Roll Down Function 69
Hourmeter 70
Self Test 70
Monitored Circuits 70
Protective Devices 70
Polarity Protection 70
Wiring Errors 70
Temperature 70
V
TABLE OF CONTENT
MSWP2300GB 05/03 • Printed in Germany
M4 – ELECTRICS PAGE SERNR CUT REV
Start Sequence 70
Safety Class 70
Maintenance 71
Replacing the SEM1 Traction Controller 72
Parameter Setting after Replacing the Traction Controller 72
Preparatory Measures 72
Setting 72
Status LED 74
Programmer 75
General 75
Operating SEM1 Controller Menu 76
General 76
Menu Functions 76
PARAMETER CHANGE 76
Menu Structure for Folded Platform 77
Menu Structure for Fixed Platform 78
Parameter Setting, Folded Platform 79
Parameter Setting, Folded Platform 80
Parameter Setting, Fixed Platform 80
TESTER Menu 82
ALARMS Menu 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu 86
Preparatory Measures 86
Calibration 86
CONFIG Menu 87
SET MODEL 87
SET OPTIONS 87
Adjustments 87
Traction Controller Safety Test 88
Electric Motors 89
General Maintenance Instructions 89
Preparation 89
Important Maintenance Instructions 89
Traction Motor Maintenance 90
Access to Brushes 90
Maintenance 90
Armature 90
Bearings 90
Pump Motor Maintenance 91
Access to brushes 91
Maintenance 91
Armature 91
M5 – BRAKE PAGE SERNR CUT REV
Brake 95
Removal 95
Disassembly 96
Test and Inspection 96
Assembly 96
Assembly 97
Air Gap Setting 97
Brake Moment Setting 98
Testing the Brakes 98
VI
TABLE OF CONTENT
MSWP2300SGB 05/03 • Printed in Germany
M6 – STEERING PAGE SERNR CUT REV
Multitask Handle Springs for
Return Function 101
Adjustment 101
Removal 101
Assembly 101
Tiller Handle 103
Main Components 103
Tiller Handle Component
Removal / Installation 104
Tiller Handle Shells 104
Removing the Upper and Lower Shells 104
Fitting the Upper and Lower Shells 105
Switch Unit 106
Removal 106
Switch Unit Installation 106
“Fast/Slow” Toggle Switch 107
Removal 107
Installation 107
Hydraulic Board 107
Removal 107
Installation 107
Potentiometer 108
Removal 108
Installation 108
Safety Reverse Switch 109
Removal 109
Installation 109
Horn Switch 110
Removal 110
Installation 110
Handle 111
Removal 111
Installation 111
M7 – LIFTING MECHANISM PAGE SERNR CUT REV
Lift Linkage 115
Fork Height Setting 115
Lift Limit Cutout 117
Lift Limit Cutout Setting 117
M8 – CYLINDERS PAGE SERNR CUT REV
Lift Cylinders 121
Operation 121
Removal 121
Inspection 123
Replacing the Piston Seal 123
M9 – PLATFORM PAGE SERNR CUT REV
Folding Platform 127
Mechanical Setting 127
Platform Switch Setting (PLS) 128
Platform Suspension 129
Plate Spring Layers 129
Side Gates, Mechanical Setting 130
Fixed Platform 131
Replacing the Deadman Switch 131
VII
TABLE OF CONTENT
MSWP2300GB 05/03 • Printed in Germany
DIA – ELECTRICAL DIAGRAMS PAGE SERNR CUT REV
Overall Wiring Diagram, Standard, Folded Platform 135
Overall Wiring Diagram, Folded Platform with Options 136
Overall Wiring Diagram, Standard, Fixed Platform 137
Overall Wiring Diagram, Fixed Platform with Options 138
Wire harness overview,
folded platform,
all versions 139
Wire harness overview,
fixed platform,
all versions 140
Power Cables 141
HYD – HYDRAULIC SCHEMATIC PAGE SERNR CUT REV
Hydraulic Schematic 145

IMAGES PREVIEW OF THE MANUAL:

S.M 5/24