CROWN WP2300 Series Forklift Service Repair Manual

WP2300 Series Order Number: 812528-006 MS-WP2300 04/03 • Printed in Germany Maintenance Manual

This master maintenance manual is subject to continual updates. It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties. CROWN Gabelstapler GmbH & Co. KG - European Headquarter - Moosacher Str. 52 80809 Munich Germany Phone +49 (0)89 93 00 2 – 0 Fax +49 (0)89 93 00 2 – 133 All rights reserved under international and Pan-American Copyright Agreement. Copyright 2002 CROWN Equipment Corporation

M1.0-0000-000A A REVISION MS-WP2300-GB 04/03 • Printed in Germany MS-REV-1723 Overview of Revisions: Page 3 Rev.1 04/00 General corrections and additions to the text. Reference to authorised service personnel added.

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I Printed in Germany TABLE OF CONTENT

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III TABLE OF CONTENT MS-WP2300-GB 04/03 • Printed in Germany Table of Content ITD – INTRODUCTION PAGE SER-NR. CUT REV. Safety Symbols used in the Manual .................................. 3 ............................................................... Rev.1 04/00 General Maintenance and Repair Safety Notes ................ 3 Maintenance and Repair .................................................. 3 ............................................................... Rev.1 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 ..................................................... 48

IV TABLE OF CONTENT MS-WP2300-GB 04/03 • Printed in Germany 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

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CROWN WP2300 Series Forklift Service Repair Manual

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