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
WP2300 1
REVISION 3
Overview of Revisions 3
TABLE OF CONTENT 7
TABLE OF CONTENT 2 8
TABLE OF CONTENT 3 9
TABLE OF CONTENT 4 10
TABLE OF CONTENT 5 11
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
Component Access 23
Jacking up the Truck 23
Lifting by Crane 23
Lifting by Truck 24
Components 25
Maintenance 28
Recommended Lubricants and Oils 28
Lubricants 28
Cold Store Trucks 28
Truck Decommissioning 28
Restoring the Truck to Service 28
Lybricant Type, Product Description, Manufacturer, CROWN-Part-No, Type 29
Product, Product Name, Application, Crown Part No 29
Check and Maintenance Schedule 30
Daily or every 8 service hours 30
Safety Reverse Switch – Functional Test 32
Monthly or every 100 service hours 34
Every 3 months or 250 service hours 36
Every 6 months or 500 service hours 36
Annually or every 1000 service hours 38
Every 2 years or 2000 service hours 38
Grease items and grease intervals 40
Castors 42
Torques 43
Screw grade marking Nut grade marking 43
Standard Screws and Nuts 44
Umbrako Screws and Nuts 44
HYDRAULICS 47
Hydraulic Symbols 47
Hydraulic System 51
Operation 51
Removing the Hydraulic Unit 52
Replacing the Hydraulic Pump 53
Removal 53
Installation 53
Commissioning and Bleeding the System 54
Pump Motor 54
Filters 54
Replacing the Pressure Filter 54
Replacing the Suction and Return Filters 54
Oil Change 54
Replacing the Safety Valve 56
Safety Valve Setting 56
Safety Valve Test and Setting 56
DRIVE UNIT 60
Gear Unit 59
Drive Unit, General 60
Removing the Drive Unit 60
Traction Motor Removal 60
Dismantling the Motor 61
Assembling the Motor 61
Traction Motor Assembly 63
Gear Unit Disassembly 64
General 64
Preparation 64
Draining the oil 64
Removing the drive unit 64
Dismantling the gear unit lid 64
Dismantling the gear unit 65
Gear Unit Assembly 65
Installing the gear unit lid 67
Adding Oil 67
Installing the drive unit 67
ELECTRICS 71
Electrics – General 71
Wire Colour Codes 71
Abbreviations 72
Switch Symbol Abbrevation List 72
Sundry Abbreviations 73
Other Abbreviations 74
Electrical Symbols 74
Electrical Components 75
Transmitter (POT, FS, RS) 75
Fast / Slow Travel Switch (HSS) 75
Reverse Safety Switch (SAS) 75
Brake Switch (BRS) 75
Override Switch (ORS) 75
Raise / Lower Switch (RAS, LOS) 76
Limit Switch (LMS) 76
Horn Switch (HNS) 76
Key Switch (KYS) 76
Emergency Disconnect 76
Fuses (FU) 76
Thermal Switch (THS) 77
SEM0 Traction Controller 79
General 79
Precautionary Measures 79
Operational Features 79
Speed Control 79
Reduced Speed Ranges 79
Downhill Speed Control 79
Regenerative Braking 79
Anti – Roll Down Function 79
Hourmeter 80
Self Test 80
Monitored Circuits 80
Protective Devices 80
Polarity Protection 80
Wiring Errors 80
Temperature 80
Start Sequence 80
Safety Class 80
Maintenance 81
Replacing the SEM0 Traction Controller 82
Parameter Setting after Replacing the Traction Controller 82
Preparatory Measures 82
Setting 82
Status LED 84
No of Flashes, Console Display, Notes 84
Programmer 85
General 85
Description of Keys 86
Operating SEM0 Controller Menu 86
General 86
Operating Menu – Overview 87
Menu Functions 87
Settings and Alarms 88
PARAMETER CHANGE Menu 88
TESTER Menu 89
ALARMS Menu 90
ALARMS Menu (Contd) 91
PROGRAM VACC Menu 91
ALARMS Menu (contd) 92
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu 93
Preparatory Measures 93
Calibration 93
CONFIG Menu 94
SET MODEL 94
SET OPTIONS 94
ADJUSTMENTS 94
Traction Controller Safety Test 95
Battery 97
General 97
Replacing the battery 97
Battery Discharge Indicator (BDI) 97
General 97
Battery Discharge Indicator Setting (BDI) 98
Calibration 98
Discharge Terminal Voltage Setting in Volts/Cell 98
On Board Charger 99
General 99
Battery Charging Phases 99
Special Charging Phases 99
Charging Errors100
Green LED is not lit100
Green LED flashing100
Charging Phases100
Electric Motors103
General Maintenance Instructions103
Preparation103
Important Maintenance Instructions103
Traction Motor Maintenance104
Access to Brushes104
Maintenance104
Armature104
Bearings104
Pump Motor Maintenance105
Access to brushes105
Maintenance105
Armature105
BRAKE109
Operation109
Removal109
Assembly111
Air Gap Setting111
Brake Moment Setting111
Testing the Brakes111
Nominal Braking Distance (unladen)111
STEERING115
Live Ring Bearing115
Disassembly115
Installation115
Multitask Handle – Springs for Return Function116
Adjustment116
Removal116
Assembly116
Tiller Handle117
Main Components117
Tiller Handle Component Removal / Installation118
Tiller Handle Shells118
Removing the Upper and Lower Shells118
Fitting the Upper and Lower Shells119
Switch Unit120
Removal120
Switch Unit Installation120
“Fast/Slow” Toggle Switch121
Removal121
Installation121
Hydraulic Board121
Removal121
Installation121
Potentiometer122
Removal122
Installation122
Safety Reverse Switch123
Removal123
Installation123
Horn Switch124
Removal124
Installation124
Handle125
Removal125
Installation125
Lift Linkage129
Fork Height Setting129
CYLINDERS133
Lift Cylinders133
Operation133
Removal133
Inspection135
Replacing the Piston Seal135
DIAGRAMS139
Overall Wiring Diagram, Standard Version139
Overall Wiring Diagram with Options140
Wire harness overview, all versions141
HYDRAULIC CIRCUIT145
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