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.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
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
17. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
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