Crown Forklift WP3200S Series Maintenance Manual 812529-006

Description

Crown Forklift WP3200S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WP3200S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Crown Forklift WP3200S Series Maintenance Manual 812529-006 – PDF DOWNLOAD

WP2300S 1
REVISION 3
Overview of Revisions: 3
TABLE OF CONTENT 7
SAFETY 15
Safety Symbols used in the Manual 15
General Maintenance and Repair Safety Notes 15
Maintenance and Repair 15
Before Leaving the Truck 16
Before Carrying out Work on the Truck 16
Before Operating the Truck 16
Warnings and Labels on the Truck 16
INTRODUCTION 19
General 19
Operating Instructions 19
Service Training 19
Ordering Spare Parts 19
Using the Manual 19
Model-Number 20
LUBRICATION AND ADJUSTMENT 23
Jacking up the Truck 23
Raising the Truck with a Crane 23
Fixed Platform 23
Folding Platform 24
Both Platforms 25
Raising with a Forklift Truck 26
Component Access and Components 27
Maintenance 30
Recommended Lubricants and Oils 30
Lubricants 30
Cold Store Trucks 30
Truck Decommissioning 30
Restoring the Truck to Service 30
Lubricant Type, Product Description, Manufacturer, CROWN-Part-No, Type 31
Product, Product Name, Application, Crown Part No 31
Check and Maintenance Schedule 32
Daily or every 8 service hours 32
Safety Reverse Switch – Functional Test 34
Monthly or every 100 service hours 36
Every 3 months or 250 service hours 38
Every 6 months or 500 service hours 38
Annually or every 1000 service hours 40
Every 2 years or 2000 service hours 40
Grease items and grease intervals 42
Adjusting the Contact Pressure of the Castors and the Drive Wheel 44
Torques 45
Screw grade marking Nut grade marking 45
Standard Screws and Nuts 46
Umbrako Screws and Nuts 46
HYDRAULICS 49
Hydraulic Symbols 49
Hydraulic System 53
Operation 53
Removing the Hydraulic Unit 54
Replacing the Hydraulic Pump 55
Removal 55
Installation 55
Commissioning and Bleeding the System 55
Pump Motor 57
Filters 57
Replacing the Pressure Filter 57
Replacing the Suction and Return Filters 57
Oil Change 57
Replacing the Safety Valve 58
Safety Valve Setting 58
Safety Valve Test and Setting 58
Testing and Setting the Load- Dependent Pressure Switch 59
DRIVE UNIT 63
Gear Unit 63
Preparatory Measures 63
Removal 63
Maintenance 63
General 63
Gear Unit Disassembly / Assembly 65
Disassembly 65
Assembly 65
Preparing the Gear Unit 65
Flange Shaft Assembly 65
Pinion Shaft Assembly 66
Adjusting the Bevel Gear Assembly 66
Final Assembly 66
Assembly 67
Drive Motor 67
ELECTRICS 71
Electrics – General 71
Wire Colour Codes 71
Abbreviations 72
Switch Symbol Abbrevation List 72
Sunrdy Abbrevations 73
Other Abbrevations 74
Electrical Symbols 74
Electrical Components 75
Travel Switch (POT, FS, RS) 75
Fast/Slow Switch (HSS) 75
Safety Reverse Switch (SAS) 75
Brake Switch (BRS) 75
Raise/Lower Switch (RAS, LOS) 75
Pressure Switch (PS) 75
Platform Control Switches (GCSR, GCSL, PLS) 76
Lift Limit Switch (LMS) 76
Horn Switch (HNS) 76
Foot Switch (FTS) 76
Key Switch (KYS) 76
Emergency Disconnect (BD) 76
Fuses (FU) 76
Thermal Switch (THS) 76
Battery 79
General 79
Replacing the battery 79
Battery Discharge Indicator (BDI) 79
General 79
Battery Discharge Indicator Setting (BDI) 80
Calibration 80
Discharge Terminal Voltage Setting in Volts/Cell 80
SEM1 Traction Controller 81
General 81
Precautionary Measures 81
Operational Features 81
Speed Control 81
Reduced Speed Ranges 81
Downhill Speed Control 81
Regenerative Braking 81
Anti – Roll Down Function 81
Hourmeter 82
Self Test 82
Monitored Circuits 82
Protective Devices 82
Polarity Protection 82
Wiring Errors 82
Temperature 82
Start Sequence 82
Safety Class 82
Maintenance 83
Replacing the SEM1 Traction Controller 84
Parameter Setting after Replacing the Traction Controller 84
Preparatory Measures 84
Setting 84
Status LED 86
No of Flashes, Console Display, Notes 86
Programmer 87
General 87
Description of Keys 88
Operating SEM1 Controller Menu 88
General 88
Menu Functions 88
Menu Structure for Folded Platform 89
Menu Structure for Fixed Platform 90
Parameter Setting, Folded Platform 91
PARAMETER CHANGE Menu, folded platform, SW#006B 91
PARAMETER CHANGE Menu, folded platform, SW#006B 92
Parameter Setting, Fixed Platform 92
PARAMETER CHANGE Menu, fixed platform, SW#0105 92
PARAMETER CHANGE Menu, fixed platform, SW#105 93
TESTER Menu 94
ALARMS Menu 95
ALARMS Menu (Contd) 96
ALARMS Menu (Contd) 97
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu 98
Preparatory Measures 98
Calibration 98
CONFIG Menu 99
SET MODEL 99
SET OPTIONS 99
ADJUSTMENTS 99
Traction Controller Safety Test100
Electric Motors101
General Maintenance Instructions101
Preparation101
Important Maintenance Instructions101
Traction Motor Maintenance102
Access to Brushes102
Maintenance102
Armature102
Bearings102
Pump Motor Maintenance103
Access to brushes103
Maintenance103
Armature103
BRAKE107
Removal107
Disassembly108
Test and Inspection108
Assembly108
Assembly109
Air Gap Setting109
Brake Moment Setting110
Testing the Brakes110
WP2300S Nominal Braking Distances and Screw Depth110
STEERING113
Multitask Handle – Springs for Return Function113
Adjustment113
Removal113
Assembly113
Tiller Handle115
Main Components115
Tiller Handle Component Removal / Installation116
Tiller Handle Shells116
Removing the Upper and Lower Shells116
Fitting the Upper and Lower Shells117
Switch Unit118
Removal118
Switch Unit Installation118
“Fast/Slow” Toggle Switch119
Removal119
Installation119
Hydraulic Board119
Removal119
Installation119
Potentiometer120
Removal120
Installation120
Safety Reverse Switch121
Removal121
Installation121
Horn Switch122
Removal122
Installation122
Handle123
Removal123
Installation123
LIFTING MECHANISM127
Lift Linkage127
Fork Height Setting127
Lift Limit Cutout129
Lift Limit Cutout Setting129
CYLINDERS133
Lift Cylinders133
Operation133
Removal133
Inspection135
Replacing the Piston Seal135
PLATFORM139
Folding Platform139
Mechanical Setting139
Platform Switch Setting (PLS)140
Platform Suspension141
Plate Spring Layers141
Side Gates, Mechanical Setting142
Fixed Platform143
Replacing the Deadman Switch143
DIAGRAMS147
Overall Wiring Diagram, Standard, Folded Platform147
Overall Wiring Diagram, Folded Platform with Options148
Overall Wiring Diagram, Standard, Fixed Platform149
Overall Wiring Diagram, Fixed Platform with Options150
Wire harness overview, folded platform, all versions151
Wire harness overview, fixed platform, all versions152
Power Cables153
HYDRAULIC CIRCUIT157

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