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Crown WP2000 Series Pallet Truck Service Repair Manual

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Crown WP2000 Series Pallet Truck Service Repair Manual

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  1. Service Manual Wartungshandbuch Manuel de maintenance WP2000 Series

  2. TABLE OF CONTENT Printed in Germany

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

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

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

  6. SAFETY Printed in Germany

  7. 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 illustra- tions: DANGER Read the safety notices in the truck Mainte- nance 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. Maintenance and Repair ? Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. 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. CAUTION This symbol indicates the risk of minor injury and/or minor material damage. 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. ? Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. 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. INFORMATION Contains additional information with supplementary notes and hints. 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. OPTION These items relate to optional features not supplied with the standard version. OPTION Printed in Germany MA-1720-001 1

  8. SAFETY Before Operating the Truck 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. Check the safety devices. ? 8. Keep the truck clean. This will facilitate the location of loose or faulty components. Get into the driver's seat. ? 9. Make sure that capacity and data plates, warn- ings and labels are legible at all times. Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes. ? 10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck. Clean any illegible labels. ? Before Leaving the Truck Replace any faulty or missing labels. ? Stop the truck. ? The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual. Lower the fork carriage fully. ? Apply the parking brake. ? Turn off the travel switch 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. ? Printed in Germany 2 MA-1720-002

  9. INTRODUCTION Printed in Germany

  10. INTRODUCTION General series. Brochures can be obtained from your CROWN dealer or from the following address: The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. CROWN Gabelstapler GmbH Kronstadter Str. 11 81677 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133 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. Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French. 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. Each language block in turn is divided into chapters and sections. The table on the following page shows how the manual is structured. Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. S o i t c e n s n i a M e t n a n c e S o i t c e n D e s p i r c o i t n 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. I D X e l b a T f o C e t n o t n M A y t e f a S Service Training T I D o r t n I d o i t c u n CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request. M 1 L c i r b u o i t a n a n d u j d A t s m t n e M 2 H a r d y c i l u s Ordering Spare Parts The maintenance manual does not cover spare parts. These are listed in a separate manual. M 3 v i r D e t i n U M 4 e l E c i r t c l a Spare parts can be ordered by quoting: M 5 a r B k e The truck specification number G M 6 n i r e e t S g The truck model number G The truck serial number G M 7 M / t s a n i t f i L g M e c h s i n a m 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. M 8 n i l y C r e d D I A e l E c i r t c l a a r g a i D m s Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this H Y D H a r d y c i l u S c h e c i t a m A01M-gb Printed in Germany M-ITD-0000-001 1

  11. INTRODUCTION Page Numbering in the Manual The page numbers are on the left and right-hand sides of the page footer. If a page has been modified since the last edition, a revision number will be found in the middle of the footer: 02 REV. 2/99 means the second amendment to this page in February 1999. The page numbers are not necessarily consecutive! The back page of the manual contains a print number in the following form: MS-WP2000-GB-D-F 11/99 In this example, 11/99 is the edition date. A page beginning with M/P- is identical in both the maintenance and spare parts manuals: M/P-1.2-1720-001 M = Maintenance Manual P = Spare Parts Manual Chapter Page Number Section Truck Code e.g. 1.2 = Test and Maintenance Schedule (Pages which are identical for all trucks are given the code 0000 here) A page beginning with M- is only contained in the maintenance manual: M-1.2-1720-001 M = Maintenance Manual Chapter Page Number Section Truck Code e.g. 1.2 = Test and Maintenance Schedule (Pages which are identical for all trucks are given the code 0000 here) Printed in Germany M/P-ITD-1720-002 2

  12. INTRODUCTION A page beginning with P- is only contained in the spare parts manual: P-1.0-1720-001 P = Spare Parts Manual Chapter Page Number Section e.g. 1.0 = Panels Truck Code (Pages which are identical for all trucks are given the code 0000 here) Printed in Germany M/P-ITD-1720-003 3

  13. INTRODUCTION Truck Data Numbering Sheet 1.6 WP 2015 – 3 – 2 – S Capacity Loadwheels 1.6 = 1600 kg 2.0 = 2000 kg S = Single T = Tandem Model designation F o r k L e n g t h WP = Walkie Pallet Truck D a s h m m n i c h 1 3 6 2 9 9 5 Battery tray dimensions (l x b x h) 3 4 2 2015 = 150 Ah (146 x 660 x 604) 2020 = 240 Ah (212 x 624 x 627) 4 1 1 2 5 5 4 6 6 1 2 1 0 4 8 7 5 4 8 6 0 I02a-gb F o r k S p r e a d D a s h m m n i c h 1 1 8 2 5 2 0 2 0 3 5 4 0 2 2 4 6 7 0 2 7 I03a-gb Printed in Germany M/P-ITD-1720-004 4

  14. LUBRICATION AND ADJUSTMENT Printed in Germany

  15. LUBRICATION AND ADJUSTMENT Component Access For regular maintenance purposes, the drive unit, hydraulic system, contactor panel etc. can be reached by removing the panel (fig. M1453 on page M-1.0-1720- 003). The panel is fastened by two screws to the chassis. For trucks with an internal charger: Before removing the panel pull the charger plug from the protective socket (see fig. M1453 on page M-1.0-1720-003). After removing the screws the panel can be tilted to the front and removed via the multi-task handle. 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. M1459 Lifting by Crane Attach the straps to the hitch points as shown and prevent them from sliding off. 1 Jacking Points 3 4 2 2000 WP 3 M1458 M1499 Printed in Germany REV.1 09/00 M-1.0-0000-0001 M-1.0-1720-001 M-1.0-1720-001

  16. 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. G Drive the forklift sideways underneath the truck (see diagram). G Place hard wooden blocks under the truck. G Secure the truck to prevent it from sliding off the forks. G Raise the truck. G 90 600 > 800 2000 WP Printed in Germany REV.1 09/00 M-1.0-0000-0002 M-1.0-1720-002

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  18. LUBRICATION AND ADJUSTMENT Components Control fuse Battery Connector (Emergency Disconnect) (Power) Fuse Traction Controller Lift Cylinder RH Main Contactor Pump Contactor Lift Cylinder LH Pump Motor Lowering Valve M1454 Magnetic Brake Hydraulic Reservoir with Integrated Pump Drive Motor Horn Drive Wheel Printed in Germany REV.1 09/00 M-1.0-0000-0003 M-1.0-1720-003 M-1.0-1720-003

  19. LUBRICATION AND ADJUSTMENT Fast / Slow Travel Switch Lift / Lower Switch Button, Horn Travel Switch M 1452 Reverse Safety Switch Battery Monitor Displays Socket for storing Charger Plug Key Switch Hourmeter and Battery Discharge Display M 1453 Printed in Germany REV.1 09/00 M-1.0-0000-0004 M-1.0-1720-004

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