The document provides an overview of maintenance and repair for a WP2300 series truck. It includes sections on lubrication and adjustment, hydraulics, drive unit, electrics, brakes, steering, lifting mechanism, cylinders, electrical diagrams and hydraulic schematics. Safety symbols and notes are defined. The manual is intended for trained service personnel and does not include operating instructions. Replacement parts should reference the truck specification, model, and serial numbers.
2137ad - Characters that live in Merindol and are at the center of main storiesluforfor
Kurgan is a russian expatriate that is secretly in love with Sonia Contado. Henry is a british soldier that took refuge in Merindol Colony in 2137ad. He is the lover of Sonia Contado.
2137ad - Characters that live in Merindol and are at the center of main storiesluforfor
Kurgan is a russian expatriate that is secretly in love with Sonia Contado. Henry is a british soldier that took refuge in Merindol Colony in 2137ad. He is the lover of Sonia Contado.
Hadj Ounis's most notable work is his sculpture titled "Metamorphosis." This piece showcases Ounis's mastery of form and texture, as he seamlessly combines metal and wood to create a dynamic and visually striking composition. The juxtaposition of the two materials creates a sense of tension and harmony, inviting viewers to contemplate the relationship between nature and industry.
2137ad Merindol Colony Interiors where refugee try to build a seemengly norm...luforfor
This are the interiors of the Merindol Colony in 2137ad after the Climate Change Collapse and the Apocalipse Wars. Merindol is a small Colony in the Italian Alps where there are around 4000 humans. The Colony values mainly around meritocracy and selection by effort.
Explore the multifaceted world of Muntadher Saleh, an Iraqi polymath renowned for his expertise in visual art, writing, design, and pharmacy. This SlideShare delves into his innovative contributions across various disciplines, showcasing his unique ability to blend traditional themes with modern aesthetics. Learn about his impactful artworks, thought-provoking literary pieces, and his vision as a Neo-Pop artist dedicated to raising awareness about Iraq's cultural heritage. Discover why Muntadher Saleh is celebrated as "The Last Polymath" and how his multidisciplinary talents continue to inspire and influence.
2. 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.
4. 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
5. 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
OPTION
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
6. 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
10. 3
3
MP/MS-0000-MA
SAFETY
MS-WP2000-GB 04/03 • Printed in Germany
REV. 1 4/00
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.
DANGER
Follow all national/local safety regulations
applicable for maintenance work, e.g. for
work on higher levels.
● Failure to do so could result in severe or
fatal injuries to maintenance personnel
and/or other persons.
Maintenance and Repair
1. Maintenance work must only be carried out in
accordance with the test and maintenance pro-
gram 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.
7. Neutralise and thoroughly rinse any spilled
battery fluid immediately.
11. 4
4
MP/MS-0000-MA
SAFETY
MS-WP2000-GB 04/03 • Printed in Germany
REV. 1 4/00
8. Keep the truck clean. This will facilitate the loca-
tion of loose or faulty components.
9. Make sure that capacity and data plates, warn-
ings 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.
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.
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.
13. 7
M1.0-0000-0007
7
INTRODUCTION
MS-WP2300-GB 04/03 • Printed in Germany MS-ITD-1723
General
The present manual is designed for Customer Service
engineers who wish to familiarise themselves with the
maintenance work required for the various truck com-
ponents.
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 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.
Spare parts can be ordered by quoting:
● The truck specification number
● The truck model number
● The truck serial number
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
The manual is divided into sections. The following table
shows how the manual is structured.
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14. 8
M1.0-0000-0008
8
INTRODUCTION
MS-WP2300-GB 04/03 • Printed in Germany
MS-ITD-1723
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
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I02a-gb
I03a-gb
Capacity
1.6 = 1600 kg
2.0 = 2000 kg
Model Description
WP = Electric Pedestrian Pallet Truck
Load Wheels
S = Single
T = Tandem
Battery Box Size (l x w x h)
2315 = 150 Ah (146 x 660 x 604)
2320 = 240 Ah (212 x 624 x 627)
1.6 WP 2015 – 3 – 2 – S
16. M-1.0-0000-00011
11
MS-1.0-1723
LUBRICATION AND ADJUSTMENT
MS-WP2300-GB 04/03 • Printed in Germany
M1458-a
Component Access
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.
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.
Lifting by Crane
Attach the straps to the hitch points as shown and
prevent them from sliding off.
Jacking Points
MS1723-005
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18. M-1.0-0000-00012
12
MS-1.0-1723
LUBRICATION AND ADJUSTMENT
MS-WP2300-GB 04/03 • Printed in Germany
2000
WP
90
600
>
800
MS-1723-002
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.
19. M-1.0-0000-00013
13
MS-1.0-1723
LUBRICATION AND ADJUSTMENT
MS-WP2300-GB 04/03 • Printed in Germany
M1454-new
Battery Connector
(Emergency Disconnect)
Main Contactor
Pump Contactor
Lift Cylinder
RH
Lift Cylinder LH
Magnetic Brake
Drive Motor
Horn
Hydraulic Reservoir
with Integrated Pump
Drive Wheel
Pump Motor
Traction Controller
(Power) Fuse
Control fuse
Components
FU3 F/C
Lowering Valve
