Crown WP2300 Series Pallet Truck Service Repair Manual

Maintenance Manual

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

REVISION Overview of Revisions: Page 3

Rev.1 04/00 General corrections and additions to the text.

Reference to authorised service personnel added.

MS-WP2300-GB 04/03 • Printed in Germany

MS-REV-1723

M1.0-0000-000A A

TABLE OF CONTENT

Printed in Germany

I

TABLE OF CONTENT Table of Content ITD – INTRODUCTION Safety Symbols used in the Manual ..................................

General Maintenance and Repair Safety Notes ................

Maintenance and Repair ..................................................

Before Leaving the Truck ..................................................

Before Carrying out Work on the Truck ............................

Before Operating the Truck ...............................................

Warnings and Labels on the Truck .....................................

General .................................................................................

Operating Instructions ......................................................

Service Training ................................................................

Ordering Spare Parts .......................................................

Using the Manual .............................................................

Model-Number .....................................................................

M1 – LUBRICATION AND ADJUSTMENT Component Access .............................................................

Jacking up the Truck ...........................................................

Lifting by Crane ...................................................................

Lifting by Truck .................................................................

Components ........................................................................

Maintenance ........................................................................

Recommended Lubricants and Oils .................................

Lubricants ...................................................................

Cold Store Trucks ........................................................

Truck Decommissioning .....................................................

Restoring the Truck to Service ...........................................

Check and Maintenance Schedule .....................................

Safety Reverse Switch – Functional Test ..........................

Grease items and grease intervals ....................................

Castors .................................................................................

Torques ................................................................................

M2 – HYDRAULICS Hydraulic Symbols ..............................................................

Hydraulic System ................................................................

Operation .........................................................................

Removing the Hydraulic Unit ............................................

Replacing the Hydraulic Pump .........................................

Removal ......................................................................

Installation ...................................................................

Commissioning and Bleeding the System ........................

Filters ...............................................................................

Replacing the Pressure Filter ......................................

Replacing the Suction and Return Filters ....................

Oil Change .......................................................................

Replacing the Safety Valve ...............................................

Safety Valve Setting .........................................................

Safety Valve Test and Setting ......................................

M3 – DRIVE UNIT

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Gear Unit .............................................................................. 47 Drive Unit, General .............................................................. 48 Removing the Drive Unit ..................................................... 48

MS-WP2300-GB 04/03 • Printed in Germany

III

TABLE OF CONTENT M3 – DRIVE UNIT Traction Motor Removal ...................................................

Dismantling the Motor ......................................................

Assembling the Motor ......................................................

Traction Motor Assembly ..................................................

Gear Unit Disassembly ....................................................

General .......................................................................

Preparation .................................................................

Draining the oil ............................................................

Removing the drive unit ..............................................

Dismantling the gear unit lid ........................................

Dismantling the gear unit ............................................

Gear Unit Assembly ....................................................

Installing the gear unit lid ............................................

Adding Oil ...................................................................

Installing the drive unit .....................................................

M4 – ELECTRICS Electrics - General ...............................................................

Wire Colour Codes ...........................................................

Abbreviations ...................................................................

Electrical Symbols ............................................................

Electrical Components .......................................................

Transmitter (POT, FS, RS) ................................................

Fast / Slow Travel Switch (HSS) .......................................

Reverse Safety Switch (SAS) ...........................................

Brake Switch (BRS)..........................................................

Override Switch (ORS) .....................................................

Raise / Lower Switch (RAS, LOS) ....................................

Limit Switch (LMS) ...........................................................

Horn Switch (HNS) ...........................................................

Key Switch (KYS) .............................................................

Emergency Disconnect ....................................................

Fuses (FU) .......................................................................

OPTION

Thermal Switch (THS) ...........................................

Battery ..................................................................................

General ............................................................................

Replacing the battery .......................................................

Battery Discharge Indicator (BDI) ......................................

General ............................................................................

Battery Discharge Indicator Setting (BDI) ........................

Calibration ........................................................................

SEM0 Traction Controller ....................................................

General ............................................................................

Precautionary Measures .............................................

Operational Features .......................................................

Speed Control .............................................................

Reduced Speed Ranges .............................................

Downhill Speed Control ...............................................

Regenerative Braking ..................................................

Anti - Roll Down Function ............................................

Hourmeter ...................................................................

Self Test ......................................................................

Monitored Circuits .......................................................

Protective Devices ............................................................

Polarity Protection .......................................................

Wiring Errors ...............................................................

Temperature ................................................................

Start Sequence ...........................................................

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MS-WP2300-GB 04/03 • Printed in Germany

IV

TABLE OF CONTENT M4 – ELECTRICS Safety Class ................................................................

Maintenance ....................................................................

Replacing the SEM0 Traction Controller...........................

Parameter Setting after Replacing the Traction Controller .............................

Preparatory Measures ................................................

Setting .........................................................................

Status LED ..................................................................

Programmer .........................................................................

General ............................................................................

Operating SEM0 Controller Menu ....................................

General .......................................................................

Operating Menu - Overview ........................................

Menu Functions ..........................................................

PARAMETER CHANGE ..............................................

Settings and Alarms............................................................

TESTER Menu .................................................................

ALARMS Menu ................................................................

PROGRAM VACC Menu ..................................................

Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu ..................................................

Preparatory Measures ................................................

Calibration ...................................................................

CONFIG Menu ......................................................................

SET MODEL ....................................................................

SET OPTIONS .................................................................

Adjustments .....................................................................

Traction Controller Safety Test ...........................................

Battery ..................................................................................

General ............................................................................

Replacing the battery .......................................................

Battery Discharge Indicator (BDI) ......................................

General ............................................................................

Battery Discharge Indicator Setting (BDI) ........................

Calibration ........................................................................

On Board Charger ...............................................................

General ............................................................................

Battery Charging Phases ............................................

Special Charging Phases ............................................

Charging Errors ................................................................

Green LED is not lit .....................................................

Green LED flashing .....................................................

Important Technical Data .................................................

Replacing the Charger .....................................................

Removal / Installation ..................................................

Electric Motors ....................................................................

General Maintenance Instructions ...................................

Preparation .................................................................

Important Maintenance Instructions ............................

Traction Motor Maintenance ...............................................

Access to Brushes ...........................................................

Maintenance ....................................................................

Armature .....................................................................

Bearings ......................................................................

Pump Motor Maintenance ...................................................

Access to brushes ............................................................

Maintenance ....................................................................

Armature .....................................................................

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MS-WP2300-GB 04/03 • Printed in Germany

V

TABLE OF CONTENT M5 – BRAKE Brake ....................................................................................

Operation .........................................................................

Removal ...........................................................................

Assembly ..........................................................................

Air Gap Setting .................................................................

Brake Moment Setting ......................................................

Testing the Brakes ............................................................

M6 – STEERING Live Ring Bearing ................................................................

Disassembly .....................................................................

Installation ........................................................................

Multitask Handle - Springs for Return Function ...............

Adjustment .......................................................................

Removal ...........................................................................

Assembly ..........................................................................

Tiller Handle .........................................................................

Main Components ............................................................

Tiller Handle Component Removal / Installation ..............

Tiller Handle Shells ..........................................................

Removing the Upper and Lower Shells .......................

Fitting the Upper and Lower Shells .............................

Switch Unit .......................................................................

Removal ......................................................................

Switch Unit Installation ................................................

"Fast/Slow" Toggle Switch ................................................

Removal ......................................................................

Installation ...................................................................

Hydraulic Board ................................................................

Removal ......................................................................

Installation ...................................................................

Potentiometer ...................................................................

Removal ......................................................................

Installation ...................................................................

Safety Reverse Switch .....................................................

Removal ......................................................................

Installation ...................................................................

Horn Switch ......................................................................

Removal ......................................................................

Installation ...................................................................

Handle ..............................................................................

Removal ......................................................................

Installation ...................................................................

M7 – LIFTING MECHANISM

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Lift Linkage .......................................................................... 117 Fork Height Setting .......................................................... 117

M8 – CYLINDERS Lift Cylinders .......................................................................

Operation .........................................................................

Removal ...........................................................................

Inspection .........................................................................

Replacing the Piston Seal ................................................

PAGE 121 121 121 123 123

MS-WP2300-GB 04/03 • Printed in Germany

VI

TABLE OF CONTENT DIA – ELECTRICAL DIAGRAMS

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Overall Wiring Diagram, Standard Version ........................ 127 Overall Wiring Diagram with Options ................................ 128 Wire harness overview, all versions .................................. 129

HYD – HYDRAULIC SCHEMATIC

PAGE

Hydraulic Schematic ........................................................... 133

MS-WP2300-GB 04/03 • Printed in Germany

VII

SAFETY

Printed in Germany

1

SAFETY Safety Symbols used in the Manual

General Maintenance and Repair Safety Notes

To help guide you through the manual and to highlight particular danger areas, we have used graphic illustrations:

DANGER Read the safety notices in the truck Maintenance and Operator's Manuals.

DANGER

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.

This symbol indicates life-threatening risks ● Failure to comply with this notice may result in severe or fatal injuries to yourself or other people.

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.

WARNING This symbol indicates the risk of serious injury and/or serious material damage.

DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels.

● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.

CAUTION This symbol indicates the risk of minor injury and/or minor material damage.

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-ventilated.

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.

7.

Neutralise and thoroughly rinse any spilled battery fluid immediately.

● 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 OPTION

These items relate to optional features not supplied with the standard version.

MS-WP2000-GB 04/03 • Printed in Germany

MP/MS-0000-MA

REV. 1 4/00 3

SAFETY 8.

Keep the truck clean. This will facilitate the location of loose or faulty components.

9.

Make sure that capacity and data plates, warnings and labels are legible at all times.

10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown.

11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck.

Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. ●

Clean any illegible labels.

●

Replace any faulty or missing labels.

The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual.

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the truck and remove the key.

●

Block all wheels when parking on an uneven surface.

Before Carrying out Work on the Truck ●

Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.

●

Prevent the truck from rolling away.

●

Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.

●

Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes.

MP/MS-0000-MA

MS-WP2000-GB 04/03 • Printed in Germany

REV. 1 4/00 44

INTRODUCTION

Printed in Germany

5

INTRODUCTION General The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components.

It also contains troubleshooting sections which can be used to identify and remedy truck faults.

INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual.

This information can be found on the truck's data plate.

Only if this information is provided can the order be processed quickly, correctly and reliably.

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

Using the Manual This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.

Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle.

Additional copies can be ordered as required.

With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle.

Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.

Ordering Spare Parts The maintenance manual does not cover spare parts.

These are listed in a separate manual.

The manual is divided into sections. The following table shows how the manual is structured.

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

Spare parts can be ordered by quoting: ●

The truck specification number

M6

Steering

●

The truck model number

M7

Mast / Lifting Mechanism

●

The truck serial number

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic A01M-gb

MS-WP2300-GB 04/03 • Printed in Germany

MS-ITD-1723

M1.0-0000-0007 7

INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions:

1.6

WP

2015

–

3

–

2

–

S

Capacity

Load Wheels

1.6 = 1600 kg 2.0 = 2000 kg

S = Single T = Tandem

Model Description WP = Electric Pedestrian Pallet Truck

Fork Length Dash

mm

1

Battery Box Size (l x w x h) 2315 = 150 Ah (146 x 660 x 604) 2320 = 240 Ah (212 x 624 x 627)

2

36 995

3 4

42 1125

5 6

inch

46 1210

48

7

54

8

60 I02a-gb

Fork Spread Dash

mm

1

inch 18

2

520

20

3

540

22

4

670

27 I03a-gb

MS-ITD-1723

88 M1.0-0000-0008

MS-WP2300-GB 04/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT

Printed in Germany

9

LUBRICATION AND ADJUSTMENT Component Access

Lifting by Crane

Lifting off the panel will provide access to the drive unit, hydraulic system, contactors, traction controller etc.

The panel is fixed to the chassis via two screws.

By removing the screws you can lift up the panel from the lower lugs, tilt and lift it out over the tiller.

Attach the straps to the hitch points as shown and prevent them from sliding off.

Jacking up the Truck CAUTION Always support a raised truck with wooden blocks or other suitable equipment, thereby relieving the jack.

Please follow the instruction "Jack up the truck" in this manual by jacking up the truck and supporting it with wooden blocks.

MS1723-005

Jacking Points

M1458-a MS-WP2300-GB 04/03 • Printed in Germany

MS-1.0-1723

M-1.0-0000-00011 11

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LUBRICATION AND ADJUSTMENT Lifting by Truck DANGER Use a forklift with sufficient capacity and prevent the truck from sliding off the forks.

Raise the forks to their maximum height.

●

Drive the forklift sideways underneath the truck (see diagram).

●

Place hard wooden blocks under the truck.

●

Secure the truck to prevent it from sliding off the forks.

●

Raise the truck.

600

WP 2000

> 800

90

●

MS-1723-002

MS-1.0-1723

12M-1.0-0000-00012

MS-WP2300-GB 04/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT Components

Battery Connector (Emergency Disconnect)

Control fuse (Power) Fuse

FU3 F/C

Traction Controller

Lift Cylinder RH

Main Contactor

Pump Contactor

Lift Cylinder LH Pump Motor

Lowering Valve

Hydraulic Reservoir with Integrated Pump

Horn Magnetic Brake Drive Motor

Drive Wheel M1454-new

MS-WP2300-GB 04/03 • Printed in Germany

MS-1.0-1723

M-1.0-0000-00013 13