Crown WP2000 Series Forklift Service Manual

Service Manual Wartungshandbuch Manuel de maintenance WP2000 Series

Printed in Germany TABLE OF CONTENT

Printed in Germany Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany IDX-1720-001 TABLE OF CONTENT REV.1 09/00 Table of Content MA – SAFETY Safety Symbols used in the Manual ......................................................................................................... MA-1720-001 General Maintenance and Repair Safety Notes ....................................................................................... MA-1720-001 Maintenance and Repair ......................................................................................................................... MA-1720-001 Before Leaving the Truck ........................................................................................................................ MA-1720-002 Before Carrying out Work on the Truck .................................................................................................. MA-1720-002 Before Operating the Truck .................................................................................................................... MA-1720-002 Warnings and Labels on the Truck .......................................................................................................... MA-1720-002 ITD – INTRODUCTION General ....................................................................................................................................................... ITD-1720-001 Structure of the Manual .......................................................................................................................... ITD-1720-001 Page Numbers ....................................................................................................................................... ITD-1720-003 Operating instruction .............................................................................................................................. ITD-1720-003 Service training ....................................................................................................................................... ITD-1720-003 Replacement parts orders ...................................................................................................................... ITD-1720-003 Truck Data Numbering Sheet .................................................................................................................... ITD-1720-004 M1 – LUBRICATION AND ADJUSTMENT Component Access ................................................................................................................................ M1.0-1720-001 Jacking up the Truck .............................................................................................................................. M1.0-1720-001 Lifting by Crane ........................................................................................................................................ M1.0-1720-001 Lifting by Truck ........................................................................................................................................ M1.0-1720-002 Components ............................................................................................................................................. M1.0-1720-003 Maintenance ............................................................................................................................................. M1.1-1720-001 Driver Participation ................................................................................................................................ M1.1-1720-001 Daily Maintenance Log .......................................................................................................................... M1.1-1720-001 Recommended Lubricants and Oils ....................................................................................................... M1.1-1720-001 Lubricants ........................................................................................................................................ M1.1-1720-001 Cold Store Trucks ............................................................................................................................. M1.1-1720-001 Check and Maintenance Schedule ........................................................................................................ M1.2-1720-001 Safety Reverse Switch - Functional Test .............................................................................................. M1.2-1720-003 Grease items and grease intervals ........................................................................................................ M1.2-1720-010 Castors ...................................................................................................................................................... M1.5-1720-001 Torques ..................................................................................................................................................... M1.9-1720-001 M2 – HYDRAULICS Hydraulic Symbols ................................................................................................................................. M2.0-1720-001 Hydraulic System ................................................................................................................................... M2.1-1720-001 Operation ............................................................................................................................................. M2.1-1720-001 Removal .............................................................................................................................................. M2.2-1720-001 Filter .................................................................................................................................................... M2.2-1720-002 Pressure Filter ................................................................................................................................ M2.2-1720-002 Suction and Return Filters .............................................................................................................. M2.2-1720-002 Oil Change .......................................................................................................................................... M2.2-1720-002 Hydraulic Pump .................................................................................................................................... M2.3-1720-001 Commissioning ................................................................................................................................ M2.3-1720-001 M3 – DRIVE UNIT Gear Unit ................................................................................................................................................. M3.1-1720-001 Oil Change .......................................................................................................................................... M3.1-1720-001 Gear Unit Assembly / Disassembly ...................................................................................................... M3.1-1720-003 Drive Motor Disassembly ............................................................................................................... M3.1-1720-003 Pinion Shaft Disassembly ............................................................................................................... M3.1-1720-003 Driven Shaft Disassembly .............................................................................................................. M3.1-1720-003

Printed in Germany IDX-1720-002 TABLE OF CONTENT REV.1 09/00 Driven Shaft Assembly .................................................................................................................... M3.1-1720-003 Pinion Shaft Assembly .................................................................................................................... M3.1-1720-003 Drive Motor Pre-Assembly ............................................................................................................... M3.1-1720-004 Housing Lid Assembly ..................................................................................................................... M3.1-1720-004 Drive Motor Assembly ..................................................................................................................... M3.1-1720-004 Drive Unit Assembly ............................................................................................................................. M3.1-1720-004 M4 – ELECTRICS Electrics - General .................................................................................................................................. M4.0-1720-001 Wire Colour Codes .............................................................................................................................. M4.0-1720-001 Abbreviations ....................................................................................................................................... M4.0-1720-002 Electrical Symbols ............................................................................................................................... M4.0-1720-004 Electrical Components ........................................................................................................................... M4.2-1720-001 Transmitter (POT, FS, RS) .................................................................................................................. M4.2-1720-001 Fast / Slow Travel Switch (HSS) .......................................................................................................... M4.2-1720-001 Reverse Safety Switch (SAS) .............................................................................................................. M4.2-1720-001 Brake Switch (BRS) ............................................................................................................................. M4.2-1720-001 Override Switch (ORS) ........................................................................................................................ M4.2-1720-001 Lift / Lower Switch (RAS, LOS) ........................................................................................................... M4.2-1720-002 Limit Switch (LMS) .............................................................................................................................. M4.2-1720-002 Horn Switch (HNS) .............................................................................................................................. M4.2-1720-002 Key Switch (KYS) ................................................................................................................................ M4.2-1720-002 Emergency Disconnect ....................................................................................................................... M4.2-1720-002 Fuses (FU) .......................................................................................................................................... M4.2-1720-002 ZAPI SEM Zero Traction Controller ....................................................................................................... M4.3-1720-001 General ............................................................................................................................................... M4.3-1720-001 Precautionary Measures ................................................................................................................ M4.3-1720-001 Operational Features ........................................................................................................................... M4.3-1720-001 Speed Control ................................................................................................................................ M4.3-1720-001 Reduced Speed Ranges ................................................................................................................ M4.3-1720-001 Downhill Speed Control .................................................................................................................. M4.3-1720-001 Regenerative Braking ..................................................................................................................... M4.3-1720-001 Anti - Roll Down Function ............................................................................................................... M4.3-1720-001 Hourmeter ...................................................................................................................................... M4.3-1720-002 Self Test ......................................................................................................................................... M4.3-1720-002 Monitored Circuits .......................................................................................................................... M4.3-1720-002 Protective Devices ............................................................................................................................... M4.3-1720-002 Polarity Protection .......................................................................................................................... M4.3-1720-002 Wiring Errors .................................................................................................................................. M4.3-1720-002 Temperature ................................................................................................................................... M4.3-1720-002 Start Sequence ............................................................................................................................... M4.3-1720-002 Safety Class ................................................................................................................................... M4.3-1720-002 Maintenance ........................................................................................................................................ M4.3-1720-003 ZAPI SEM Zero Traction Controller Connections ................................................................................... M4.3-1720-004 ZAPI SEM Zero Pin Layout ............................................................................................................. M4.3-1720-005 Status LED ...................................................................................................................................... M4.3-1720-006 Programmer ............................................................................................................................................. M4.4-1720-001 General ................................................................................................................................................. M4.4-1720-001 Operating Menu ZAPI SEM Zero Controller ........................................................................................... M4.4-1720-002 General ............................................................................................................................................ M4.4-1720-002 Operating Menu - Overview .............................................................................................................. M4.4-1720-003 Menu Functions ............................................................................................................................... M4.4-1720-003 Settings and Alarms ................................................................................................................................ M4.5-1720-001 PARAMETER CHANGE Menu .............................................................................................................. M4.5-1720-001 TESTER Menu ..................................................................................................................................... M4.5-1720-002 ALARMS Menu ..................................................................................................................................... M4.5-1720-003 PROGRAM VACC Menu ....................................................................................................................... M4.5-1720-005 CONFIG Menu ...................................................................................................................................... M4.5-1720-006 Traction Controller Safety Test ............................................................................................................... M4.20-1720-001

Printed in Germany IDX-1720-003 TABLE OF CONTENT REV.1 09/00 Battery ...................................................................................................................................................... M4.25-1720-001 General ................................................................................................................................................ M4.25-1720-001 Operation ............................................................................................................................................. M4.25-1720-001 Reading the Electrolyte Level ............................................................................................................... M4.25-1720-001 Replacing the Battery ........................................................................................................................... M4.25-1720-001 Removing the Battery .......................................................................................................................... M4.25-1720-001 Charging the Battery ............................................................................................................................ M4.25-1720-002 Battery Discharge Indicator (BDI) ........................................................................................................... M4.30-1720-001 General ................................................................................................................................................ M4.30-1720-001 Adjusting the Battery Discharge Indicator ............................................................................................ M4.30-1720-001 Traction / Pump Motor Maintenance ...................................................................................................... M4.35-1720-001 Access ................................................................................................................................................ M4.35-1720-001 Maintenance ........................................................................................................................................ M4.35-1720-001 M5 – BRAKE Brake ....................................................................................................................................................... M5.0-1720-001 Operation ............................................................................................................................................. M5.0-1720-001 Removal .............................................................................................................................................. M5.0-1720-001 Assembly ............................................................................................................................................. M5.0-1720-002 Air Gap Setting .................................................................................................................................... M5.0-1720-002 Brake Moment Setting ......................................................................................................................... M5.0-1720-002 Testing the Brakes ............................................................................................................................... M5.0-1720-002 M6 – STEERING Live Ring Bearing ................................................................................................................................... M6.1-1720-001 Disassembly ........................................................................................................................................ M6.1-1720-001 Installation ........................................................................................................................................... M6.1-1720-001 Multitask Handle - Springs for Return Function .................................................................................. M6.1-1720-002 Adjustment .......................................................................................................................................... M6.1-1720-002 Removal .............................................................................................................................................. M6.1-1720-002 Assembly ............................................................................................................................................. M6.1-1720-002 M7 – LIFTING MECHANISM Lift Linkage ............................................................................................................................................. M7.0-1720-001 Fork Height Setting .............................................................................................................................. M7.0-1720-001 M8 – CYLINDERS Lift Cylinders .......................................................................................................................................... M8.1-1720-001 Operation ............................................................................................................................................. M8.1-1720-001 Removal .............................................................................................................................................. M8.1-1720-001 Inspection ............................................................................................................................................. M8.1-1720-003 Replacing the Piston Seal ..................................................................................................................... M8.1-1720-003 DIA – ELECTRICAL DIAGRAMS Standard Version ........................................................................................................................................ DIA-1720-001 Control Circuit ......................................................................................................................................... DIA-1720-001 Traction Controller ................................................................................................................................... DIA-1720-002 Brake and Battery Discharge Indicator .................................................................................................... DIA-1720-004 Handle Circuit ......................................................................................................................................... DIA-1720-005 Power Cables .......................................................................................................................................... DIA-1720-006 Freezer / Corrosion .................................................................................................................................... DIA-1720-025 Control Circuit / Freezer Condition ........................................................................................................... DIA-1720-025 Traction Controller / Freezer Condition ..................................................................................................... DIA-1720-026 Brake and Battery Discharge Indicator / Freezer Condition ...................................................................... DIA-1720-028 Handle Circuit / Freezer Condition ........................................................................................................... DIA-1720-029 Power Cables / Freezer Condition ............................................................................................................ DIA-1720-030 Key .............................................................................................................................................................. DIA-1720-031 HYD – HYDRAULIC SCHEMATIC Hydraulic Schematic ............................................................................................................................... HYD-1720-001

Printed in Germany SAFETY

Printed in Germany 1 SAFETY OPTION Safety Symbols used in the Manual To help guide you through the manual and to highlight particular danger areas, we have used graphic illustra- tions: DANGER This symbol indicates life-threatening risks Failure to comply with this notice may result in severe or fatal injuries to yourself or other people. WARNING This symbol indicates the risk of serious injury and/or serious material damage. Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. CAUTION This symbol indicates the risk of minor injury and/or minor material damage. Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. INFORMATION Contains additional information with supplementary notes and hints. OPTION These items relate to optional features not supplied with the standard version. General Maintenance and Repair Safety Notes DANGER Read the safety notices in the truck Mainte- nance and Operator's Manuals. Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines. Maintenance and Repair 1. Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices. 2. Only qualified and authorised personnel may carry out work on the truck. 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. 4. To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness. 5. Keep the service area clean, dry and well-venti- lated. 6. Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed. MA-1720-001

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Crown WP2000 Series Forklift Service Manual

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