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Crown WP2000S Series Pallet Truck Service Repair Manual.pdf

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This document is a service manual that provides maintenance and repair instructions for a WP2000S series truck. It contains sections covering safety, introduction/overview, lubrication and adjustment, hydraulics, drive unit, electrics, traction controller, programmer, settings and alarms, and batteries. The manual includes information on accessing components, recommended maintenance schedules, hydraulic and electrical system diagrams, controller connections and programming, and testing procedures.

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Service Manual Wartungshandbuch Manuel de maintenance WP2000S Series
Printed in Germany TABLE OF CONTENT
Printed in Germany M-IDX-1720-501 TABLE OF CONTENT Rev.1 09/00 Table of Content MA – SAFETY PAGE SER-NR. CUT REV. Safety Symbols used in the Manual ................................... M/P-MA-0000-001 . General Maintenance and Repair Safety Notes................... M/P-MA-0000-001 - Maintenance and Repair ................................................. M/P-MA-0000-002 - Before Leaving the Truck................................................. M/P-MA-0000-002 - Before Carrying out Work on the Truck ............................ M/P-MA-0000-002 - Before Operating the Truck.............................................. M/P-MA-0000-002 Warnings and Labels on the Truck ...................................... M/P-MA-0000-002 ITD – INTRODUCTION PAGE SER-NR. CUT REV. General ................................................................................. M/P-ITD-1720-501 - Operating instruction ....................................................... M/P-ITD-1720-501 - Service training ............................................................... M/P-ITD-1720-501 - Replacement parts orders ............................................... M/P-ITD-1720-501 - Structure of the Manual .................................................. M/P-ITD-1720-501 - Page Numbers ................................................................ M/P-ITD-1720-502 Truck Data Numbering Sheet ............................................... M/P-ITD-1720-504 M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV. Component Access .............................................................. M-1.0-1720-001 Jacking up the Truck ............................................................ M-1.0-1720-001 Lifting by Crane.................................................................... M-1.0-1720-001 Lifting by Truck .................................................................... M-1.0-1720-002 .......................................... Rev.1 09/00 Components ......................................................................... M-1.0-1720-003 .......................................... Rev.1 09/00 Maintenance ......................................................................... M-1.1-1720-004 - Driver Participation ......................................................... M-1.1-1720-001 - Daily Maintenance Log.................................................... M-1.1-1720-001 - Recommended Lubricants and Oils ................................ M-1.1-1720-001 - Lubricants .................................................................. M-1.1-1720-001 - Cold Store Trucks ...................................................... M-1.1-1720-001 - Check and Maintenance Schedule .................................. M-1.2-1720-001 - Safety Reverse Switch - Functional Test ......................... M-1.2-1720-003 ---------------------------------- Rev.1 09/00 - Grease items and grease intervals.................................. M-1.2-1720-010 ---------------------------------- Rev.1 09/00 Adjustment of castor- and drivewheel pressure ................. M-1.5-1720-501 Torques ................................................................................. M-1.9-0000-001 M2 – HYDRAULICS PAGE SER-NR. CUT REV. Hydraulic Symbols .............................................................. M-2.0-0000-001 Hydraulic System ................................................................. M-2.1-1720-001 - Removal ......................................................................... M-2.2-1720-001 - Hydraulikpump ................................................................ M-2.3-1720-001 - Filter ............................................................................... M-2.3-1720-002 - Pressure Filter ........................................................... M-2.3-1720-002 - Suction and Return Filters ......................................... M-2.3-1720-002 - Oil Change................................................................. M-2.3-1720-002 - Commissioning .......................................................... M-2.3-1720-002 M3 – DRIVE UNIT PAGE SER-NR. CUT REV. Gear Unit............................................................................... M-3.1-1720-501 - Removal ......................................................................... M-3.1-1720-501 - Repair ............................................................................. M-3.1-1720-501 - Disassembly/Assembly ............................................. M-3.1-1720-503 - Installation ...................................................................... M-3.1-1720-505
https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/
Printed in Germany M-IDX-1720-502 TABLE OF CONTENT M4 – ELECTRICS PAGE SER-NR. CUT REV. Electrics - General................................................................ M-4.0-0000-001 - Wire Colour Codes .......................................................... M-4.0-0000-001 - Abbreviations .................................................................. M-4.0-0000-002 - Electrical Symbols .......................................................... M-4.0-0000-004 Electrical Components ........................................................ M-4.2-1720-500 - Transmitter (POT, FS, RS) ............................................... M-4.2-1720-500 - Fast / Slow Travel Switch (HSS)...................................... M-4.2-1720-500 - Reverse Safety Switch (SAS) ......................................... M-4.2-1720-500 - Brake Switch (BRS) ........................................................ M-4.2-1720-500 - Override Switch (ORS).................................................... M-4.2-1720-503 - Lift / Lower Switch (RAS, LOS)....................................... M-4.2-1720-503 - Limit Switch (LMS) ......................................................... M-4.2-1720-503 - Horn Switch (HNS) .......................................................... M-4.2-1720-503 - Key Switch (KYS) ........................................................... M-4.2-1720-503 - Emergency Disconnect ................................................... M-4.2-1720-503 - Fuses (FU) ..................................................................... M-4.2-1720-503 - Temperature Switch (THS) (Freezer/Corrosion Truck only) M-4.2-1720-503 SEM 1 Traction Controller ................................................... M-4.3-1720-001 General ............................................................................. M-4.3-1720-001 - Precautionary Measures ............................................ M-4.3-1720-001 Operational Features......................................................... M-4.3-1720-001 - Speed Control ............................................................ M-4.3-1720-001 - Reduced Speed Ranges ............................................ M-4.3-1720-001 - Downhill Speed Control .............................................. M-4.3-1720-001 - Regenerative Braking................................................. M-4.3-1720-001 - Anti-Roll-Down-Function............................................. M-4.3-1720-001 - Hourmeter .................................................................. M-4.3-1720-002 - Self Test .................................................................... M-4.3-1720-002 - Monitored Circuits ...................................................... M-4.3-1720-002 Protective Devices............................................................ M-4.3-1720-003 - Polarity Protection ..................................................... M-4.3-1720-003 - Wiring Errors .............................................................. M-4.3-1720-003 -Temperature ............................................................... M-4.3-1720-003 - Start Sequence ......................................................... M-4.3-1720-003 - Protective Class ........................................................ M-4.3-1720-003 Maintenance ..................................................................... M-4.3-1720-003 Controller connections SEM-1 ........................................... M-4.3-1720-004 - Pin Layout SEM-1 ..................................................... M-4.3-1720-005 - Status-LED ................................................................ M-4.3-1720-006 Programmer ......................................................................... M-4.4-1720-001 General ............................................................................. M-4.4-1720-001 Operating Menu Controller SEM-1 ..................................... M-4.4-1720-002 - Operating Menu - Overview ....................................... M-4.4-1720-003 - Menu Functions ......................................................... M-4.4-1720-004 Settings and Alarms ......................................................... M-4.5-1720-001 - Menue PARAMETER CHANGE ................................. M-4.5-1720-001 - Menue TESTER......................................................... M-4.5-1720-004 - Menue ALARMS ........................................................ M-4.5-1720-006 - Menue PROGRAM VACC .......................................... M-4.5-1720-008 - Menü CONFIG ........................................................... M-4.5-1720-009 Traction Controller Safety Test ............................................ M-4.20-1720-001 Battery................................................................................... M-4.25-1720-001 Function............................................................................ M-4.25-1720-001 Reading the Electrolyte Level ........................................... M-4.25-1720-001 Replacing the Battery........................................................ M-4.25-1720-001 Removing the Battery ....................................................... M-4.25-1720-001 Charging the Battery ......................................................... M-4.25-1720-002
Printed in Germany M-IDX-1720-503 TABLE OF CONTENT Battery Discharge Indicator (BDI) ........................................ M-4.25-1720-002 - General ........................................................................... M-4.25-1720-002 - Adjusting the Battery Discharge Indicator ....................... M-4.25-1720-002 Traction / Pump Motor Maintenance ................................... M-4.35-1720-001 - Access ........................................................................... M-4.35-1720-001 -Maintenance .................................................................... M-4.35-1720-001 M5 – BRAKE PAGE SER-NR. CUT REV. Brake ..................................................................................... M-5.0-1720-501 - Function ......................................................................... M-5.0-1720-501 - Removal ......................................................................... M-5.0-1720-501 - Assembly ....................................................................... M-5.0-1720-502 - Air Gap Setting ............................................................... M-5.0-1720-502 - Brake Moment Setting .................................................... M-5.0-1720-503 - Testing the Brake ............................................................ M-5.0-1720-503 M6 – STEERING PAGE SER-NR. CUT REV. Multitask Handle - Springs for Return Function................ M-6.1-1720-501 - Adjustment ..................................................................... M-6.1-1720-501 - Removal ......................................................................... M-6.1-1720-501 - Assembly ....................................................................... M-6.1-1720-501 M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV. Lift Linkage........................................................................... M-7.0-1720-501 - Fork Height Setting ......................................................... M-7.0-1720-002 M8 – CYLINDERS PAGE SER-NR. CUT REV. Lift Cylinders ........................................................................ M-8.1-1720-501 - Operation ........................................................................ M-8.1-1720-501 - Removal ......................................................................... M-8.1-1720-501 - Inspection ....................................................................... M-8.1-1720-503 - Replacing the Piston Seal ............................................... M-8.1-1720-503 DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV. Standard Version .................................................................. M/P-DIA-1720-001 - Schematic Diagram ........................................................ M/P-DIA-1720-001 - Traction Controller ........................................................... M/P-DIA-1720-002 - Power Unit Circuit ........................................................... M/P-DIA-1720-004 - Control Handle Circuit ..................................................... M/P-DIA-1720-005 - Walkie- / Rider Circuit..................................................... M/P-DIA-1720-006 - Power Cables .................................................................. M/P-DIA-1720-007 - Main Harness ................................................................. M/P-DIA-1720-008 - Tiller Harness .................................................................. M/P-DIA-1720-009 Freezer- / Corrosion Trucks ................................................. M/P-DIA-1720-010 - Schematic Diagram ........................................................ M/P-DIA-1720-010 - Traction Controller ........................................................... M/P-DIA-1720-011 - Power Unit Circuit ........................................................... M/P-DIA-1720-013 - Control Handle Circuit ..................................................... M/P-DIA-1720-014 - Walkie- / Rider Circuit..................................................... M/P-DIA-1720-015 - Tiller Harness .................................................................. M/P-DIA-1720-016 HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV. Hydraulic Schematic ......................................................... M-HYD-1720-501
Printed in Germany SAFETY
Printed in Germany M/P-MA-0000-001 SAFETY 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. 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.
Printed in Germany SAFETY M/P-MA-0000-002 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. 8. Keep the truck clean. This will facilitate the location 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 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. 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.
Printed in Germany INTRODUCTION
Printed in Germany 1 INTRODUCTION M-ITD-1720-501 series. Brochures can be obtained from your CROWN dealer or from the following address: 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 Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French. Each language block in turn is divided into chapters and sections. The table on the following page shows how the manual is structured. A01M-gb e c n a n e t n i a M s n o i t c e S n o i t c e S n o i t p i r c s e D X D I t n e t n o C f o e l b a T A M y t e f a S D T I n o i t c u d o r t n I 1 M t n e m t s u j d A d n a n o i t a c i r b u L 2 M s c i l u a r d y H 3 M t i n U e v i r D 4 M l a c i r t c e l E 5 M e k a r B 6 M g n i r e e t S 7 M m s i n a h c e M g n i t f i L / t s a M 8 M r e d n i l y C A I D s m a r g a i D l a c i r t c e l E D Y H c i t a m e h c S c i l u a r d y H 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 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 this
Printed in Germany 2 INTRODUCTION M/P-ITD-1720-502 Truck Code (Pages which are identical for all trucks are given the code 0000 here) Page Number A page beginning with M- is only contained in the maintenance manual: M/P-1.2-1720-001 P = Spare Parts Manual Chapter Section e.g. 1.2 = Test and Maintenance Schedule 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-WP2000S-GB-D-F 11/99 In this example, 11/99 is the edition date. M = Maintenance Manual M-1.2-1720-001 Chapter Page Number Section e.g. 1.2 = Test and Maintenance Schedule M = Maintenance Manual A page beginning with M/P- is identical in both the maintenance and spare parts manuals: Truck Code (Pages which are identical for all trucks are given the code 0000 here)
Printed in Germany 3 INTRODUCTION M/P-ITD-1720-503 A page beginning with P- is only contained in the spare parts manual: P-1.0-1720-001 Chapter Page Number Section e.g. 1.0 = Panels P = Spare Parts Manual Truck Code (Pages which are identical for all trucks are given the code 0000 here)
Printed in Germany 4 INTRODUCTION h t g n e L k r o F h s a D m m h c n i 1 6 3 2 5 9 9 3 2 4 4 5 2 1 1 5 6 4 6 0 1 2 1 8 4 7 4 5 8 0 6 d a e r p S k r o F h s a D m m h c n i 1 8 1 2 0 2 5 0 2 3 0 4 5 2 2 4 0 7 6 7 2 I02a-gb I03a-gb Model Number Capacity 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) 2030 = 360 Ah (288 x 624 x 627) 2.0 WP 2030S – 3 – 2 – S M/P-IT-1720-504
Printed in Germany LUBRICATION AND ADJUSTMENT
Printed in Germany M1.0-0000-0001 LUBRICATION AND ADJUSTMENT M-1.0-1720-001 1 2 3 3 4 2000 WP Rev.1 09/00 M1916 Component Access For regular maintenance purposes the drive unit, hy- draulic system, contactor panel etc. can be reached by removing the panel. The panel is fixed to the chassis by three screws, (Fig. 1515),located left , right and frontside. Remove the screws and lift the panel upward and then forward to remove it. Use the grip in the plastic-cover on top of the panel. Jacking up the Truck CAUTION Always support a raised truck with wooden blocks or other suitable equipment, thereby relieving the jack. The instruction "jack up the truck" always assumes that the raised truck will be lowered onto a secure surface. M1515 Lifting with a Crane Attach the straps to the hitch points as shown and ensure they cannot slide off. M1528 Jacking Points Fastening screws
Printed in Germany M1.0-0000-0002 LUBRICATION AND ADJUSTMENT > 800 2000 WP 90 600 M-1.0-1720-002 Rev.1 09/00 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.
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.
Printed in Germany M1.0-0000-0003 LUBRICATION AND ADJUSTMENT M-1.0-1720-003 Rev.1 09/00 Components M1563 Contactor panel LH lift cylinder Magnetic brake Drive motor Hydraulic tank and in-built pump Lowering valve Drive wheel Pump motor Traction control sy- stem Power safety device Control safety device Horn Pressure Switch for load-sensitive speed reduction
Printed in Germany M1.0-0000-0004 LUBRICATION AND ADJUSTMENT M-1.0-1720-004 Rev.1 09/00 M 1516 Hourmeter and Battery Discharge Display Key Switch Emergency Dis- connect Battery Box Lock Model and Data Capacity Plate Fast / Slow Travel Switch Lift / Lower Switch Travel Switch Horn button Safety Reverse Switch M1568

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Crown WP2000S Series Pallet Truck Service Repair Manual.pdf

  • 1. Service Manual Wartungshandbuch Manuel de maintenance WP2000S Series
  • 3. Printed in Germany M-IDX-1720-501 TABLE OF CONTENT Rev.1 09/00 Table of Content MA – SAFETY PAGE SER-NR. CUT REV. Safety Symbols used in the Manual ................................... M/P-MA-0000-001 . General Maintenance and Repair Safety Notes................... M/P-MA-0000-001 - Maintenance and Repair ................................................. M/P-MA-0000-002 - Before Leaving the Truck................................................. M/P-MA-0000-002 - Before Carrying out Work on the Truck ............................ M/P-MA-0000-002 - Before Operating the Truck.............................................. M/P-MA-0000-002 Warnings and Labels on the Truck ...................................... M/P-MA-0000-002 ITD – INTRODUCTION PAGE SER-NR. CUT REV. General ................................................................................. M/P-ITD-1720-501 - Operating instruction ....................................................... M/P-ITD-1720-501 - Service training ............................................................... M/P-ITD-1720-501 - Replacement parts orders ............................................... M/P-ITD-1720-501 - Structure of the Manual .................................................. M/P-ITD-1720-501 - Page Numbers ................................................................ M/P-ITD-1720-502 Truck Data Numbering Sheet ............................................... M/P-ITD-1720-504 M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV. Component Access .............................................................. M-1.0-1720-001 Jacking up the Truck ............................................................ M-1.0-1720-001 Lifting by Crane.................................................................... M-1.0-1720-001 Lifting by Truck .................................................................... M-1.0-1720-002 .......................................... Rev.1 09/00 Components ......................................................................... M-1.0-1720-003 .......................................... Rev.1 09/00 Maintenance ......................................................................... M-1.1-1720-004 - Driver Participation ......................................................... M-1.1-1720-001 - Daily Maintenance Log.................................................... M-1.1-1720-001 - Recommended Lubricants and Oils ................................ M-1.1-1720-001 - Lubricants .................................................................. M-1.1-1720-001 - Cold Store Trucks ...................................................... M-1.1-1720-001 - Check and Maintenance Schedule .................................. M-1.2-1720-001 - Safety Reverse Switch - Functional Test ......................... M-1.2-1720-003 ---------------------------------- Rev.1 09/00 - Grease items and grease intervals.................................. M-1.2-1720-010 ---------------------------------- Rev.1 09/00 Adjustment of castor- and drivewheel pressure ................. M-1.5-1720-501 Torques ................................................................................. M-1.9-0000-001 M2 – HYDRAULICS PAGE SER-NR. CUT REV. Hydraulic Symbols .............................................................. M-2.0-0000-001 Hydraulic System ................................................................. M-2.1-1720-001 - Removal ......................................................................... M-2.2-1720-001 - Hydraulikpump ................................................................ M-2.3-1720-001 - Filter ............................................................................... M-2.3-1720-002 - Pressure Filter ........................................................... M-2.3-1720-002 - Suction and Return Filters ......................................... M-2.3-1720-002 - Oil Change................................................................. M-2.3-1720-002 - Commissioning .......................................................... M-2.3-1720-002 M3 – DRIVE UNIT PAGE SER-NR. CUT REV. Gear Unit............................................................................... M-3.1-1720-501 - Removal ......................................................................... M-3.1-1720-501 - Repair ............................................................................. M-3.1-1720-501 - Disassembly/Assembly ............................................. M-3.1-1720-503 - Installation ...................................................................... M-3.1-1720-505
  • 4. https://www.aservicemanualpdf.com/ My Dear Friend! Thank you very much for visiting. Full manual if required, please enter the following URL into your browser. https://www.aservicemanualpdf.com/
  • 5. Printed in Germany M-IDX-1720-502 TABLE OF CONTENT M4 – ELECTRICS PAGE SER-NR. CUT REV. Electrics - General................................................................ M-4.0-0000-001 - Wire Colour Codes .......................................................... M-4.0-0000-001 - Abbreviations .................................................................. M-4.0-0000-002 - Electrical Symbols .......................................................... M-4.0-0000-004 Electrical Components ........................................................ M-4.2-1720-500 - Transmitter (POT, FS, RS) ............................................... M-4.2-1720-500 - Fast / Slow Travel Switch (HSS)...................................... M-4.2-1720-500 - Reverse Safety Switch (SAS) ......................................... M-4.2-1720-500 - Brake Switch (BRS) ........................................................ M-4.2-1720-500 - Override Switch (ORS).................................................... M-4.2-1720-503 - Lift / Lower Switch (RAS, LOS)....................................... M-4.2-1720-503 - Limit Switch (LMS) ......................................................... M-4.2-1720-503 - Horn Switch (HNS) .......................................................... M-4.2-1720-503 - Key Switch (KYS) ........................................................... M-4.2-1720-503 - Emergency Disconnect ................................................... M-4.2-1720-503 - Fuses (FU) ..................................................................... M-4.2-1720-503 - Temperature Switch (THS) (Freezer/Corrosion Truck only) M-4.2-1720-503 SEM 1 Traction Controller ................................................... M-4.3-1720-001 General ............................................................................. M-4.3-1720-001 - Precautionary Measures ............................................ M-4.3-1720-001 Operational Features......................................................... M-4.3-1720-001 - Speed Control ............................................................ M-4.3-1720-001 - Reduced Speed Ranges ............................................ M-4.3-1720-001 - Downhill Speed Control .............................................. M-4.3-1720-001 - Regenerative Braking................................................. M-4.3-1720-001 - Anti-Roll-Down-Function............................................. M-4.3-1720-001 - Hourmeter .................................................................. M-4.3-1720-002 - Self Test .................................................................... M-4.3-1720-002 - Monitored Circuits ...................................................... M-4.3-1720-002 Protective Devices............................................................ M-4.3-1720-003 - Polarity Protection ..................................................... M-4.3-1720-003 - Wiring Errors .............................................................. M-4.3-1720-003 -Temperature ............................................................... M-4.3-1720-003 - Start Sequence ......................................................... M-4.3-1720-003 - Protective Class ........................................................ M-4.3-1720-003 Maintenance ..................................................................... M-4.3-1720-003 Controller connections SEM-1 ........................................... M-4.3-1720-004 - Pin Layout SEM-1 ..................................................... M-4.3-1720-005 - Status-LED ................................................................ M-4.3-1720-006 Programmer ......................................................................... M-4.4-1720-001 General ............................................................................. M-4.4-1720-001 Operating Menu Controller SEM-1 ..................................... M-4.4-1720-002 - Operating Menu - Overview ....................................... M-4.4-1720-003 - Menu Functions ......................................................... M-4.4-1720-004 Settings and Alarms ......................................................... M-4.5-1720-001 - Menue PARAMETER CHANGE ................................. M-4.5-1720-001 - Menue TESTER......................................................... M-4.5-1720-004 - Menue ALARMS ........................................................ M-4.5-1720-006 - Menue PROGRAM VACC .......................................... M-4.5-1720-008 - Menü CONFIG ........................................................... M-4.5-1720-009 Traction Controller Safety Test ............................................ M-4.20-1720-001 Battery................................................................................... M-4.25-1720-001 Function............................................................................ M-4.25-1720-001 Reading the Electrolyte Level ........................................... M-4.25-1720-001 Replacing the Battery........................................................ M-4.25-1720-001 Removing the Battery ....................................................... M-4.25-1720-001 Charging the Battery ......................................................... M-4.25-1720-002
  • 6. Printed in Germany M-IDX-1720-503 TABLE OF CONTENT Battery Discharge Indicator (BDI) ........................................ M-4.25-1720-002 - General ........................................................................... M-4.25-1720-002 - Adjusting the Battery Discharge Indicator ....................... M-4.25-1720-002 Traction / Pump Motor Maintenance ................................... M-4.35-1720-001 - Access ........................................................................... M-4.35-1720-001 -Maintenance .................................................................... M-4.35-1720-001 M5 – BRAKE PAGE SER-NR. CUT REV. Brake ..................................................................................... M-5.0-1720-501 - Function ......................................................................... M-5.0-1720-501 - Removal ......................................................................... M-5.0-1720-501 - Assembly ....................................................................... M-5.0-1720-502 - Air Gap Setting ............................................................... M-5.0-1720-502 - Brake Moment Setting .................................................... M-5.0-1720-503 - Testing the Brake ............................................................ M-5.0-1720-503 M6 – STEERING PAGE SER-NR. CUT REV. Multitask Handle - Springs for Return Function................ M-6.1-1720-501 - Adjustment ..................................................................... M-6.1-1720-501 - Removal ......................................................................... M-6.1-1720-501 - Assembly ....................................................................... M-6.1-1720-501 M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV. Lift Linkage........................................................................... M-7.0-1720-501 - Fork Height Setting ......................................................... M-7.0-1720-002 M8 – CYLINDERS PAGE SER-NR. CUT REV. Lift Cylinders ........................................................................ M-8.1-1720-501 - Operation ........................................................................ M-8.1-1720-501 - Removal ......................................................................... M-8.1-1720-501 - Inspection ....................................................................... M-8.1-1720-503 - Replacing the Piston Seal ............................................... M-8.1-1720-503 DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV. Standard Version .................................................................. M/P-DIA-1720-001 - Schematic Diagram ........................................................ M/P-DIA-1720-001 - Traction Controller ........................................................... M/P-DIA-1720-002 - Power Unit Circuit ........................................................... M/P-DIA-1720-004 - Control Handle Circuit ..................................................... M/P-DIA-1720-005 - Walkie- / Rider Circuit..................................................... M/P-DIA-1720-006 - Power Cables .................................................................. M/P-DIA-1720-007 - Main Harness ................................................................. M/P-DIA-1720-008 - Tiller Harness .................................................................. M/P-DIA-1720-009 Freezer- / Corrosion Trucks ................................................. M/P-DIA-1720-010 - Schematic Diagram ........................................................ M/P-DIA-1720-010 - Traction Controller ........................................................... M/P-DIA-1720-011 - Power Unit Circuit ........................................................... M/P-DIA-1720-013 - Control Handle Circuit ..................................................... M/P-DIA-1720-014 - Walkie- / Rider Circuit..................................................... M/P-DIA-1720-015 - Tiller Harness .................................................................. M/P-DIA-1720-016 HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV. Hydraulic Schematic ......................................................... M-HYD-1720-501
  • 8. Printed in Germany M/P-MA-0000-001 SAFETY 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. 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.
  • 9. Printed in Germany SAFETY M/P-MA-0000-002 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. 8. Keep the truck clean. This will facilitate the location 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 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. 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.
  • 11. Printed in Germany 1 INTRODUCTION M-ITD-1720-501 series. Brochures can be obtained from your CROWN dealer or from the following address: 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 Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French. Each language block in turn is divided into chapters and sections. The table on the following page shows how the manual is structured. A01M-gb e c n a n e t n i a M s n o i t c e S n o i t c e S n o i t p i r c s e D X D I t n e t n o C f o e l b a T A M y t e f a S D T I n o i t c u d o r t n I 1 M t n e m t s u j d A d n a n o i t a c i r b u L 2 M s c i l u a r d y H 3 M t i n U e v i r D 4 M l a c i r t c e l E 5 M e k a r B 6 M g n i r e e t S 7 M m s i n a h c e M g n i t f i L / t s a M 8 M r e d n i l y C A I D s m a r g a i D l a c i r t c e l E D Y H c i t a m e h c S c i l u a r d y H 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 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 this
  • 12. Printed in Germany 2 INTRODUCTION M/P-ITD-1720-502 Truck Code (Pages which are identical for all trucks are given the code 0000 here) Page Number A page beginning with M- is only contained in the maintenance manual: M/P-1.2-1720-001 P = Spare Parts Manual Chapter Section e.g. 1.2 = Test and Maintenance Schedule 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-WP2000S-GB-D-F 11/99 In this example, 11/99 is the edition date. M = Maintenance Manual M-1.2-1720-001 Chapter Page Number Section e.g. 1.2 = Test and Maintenance Schedule M = Maintenance Manual A page beginning with M/P- is identical in both the maintenance and spare parts manuals: Truck Code (Pages which are identical for all trucks are given the code 0000 here)
  • 13. Printed in Germany 3 INTRODUCTION M/P-ITD-1720-503 A page beginning with P- is only contained in the spare parts manual: P-1.0-1720-001 Chapter Page Number Section e.g. 1.0 = Panels P = Spare Parts Manual Truck Code (Pages which are identical for all trucks are given the code 0000 here)
  • 14. Printed in Germany 4 INTRODUCTION h t g n e L k r o F h s a D m m h c n i 1 6 3 2 5 9 9 3 2 4 4 5 2 1 1 5 6 4 6 0 1 2 1 8 4 7 4 5 8 0 6 d a e r p S k r o F h s a D m m h c n i 1 8 1 2 0 2 5 0 2 3 0 4 5 2 2 4 0 7 6 7 2 I02a-gb I03a-gb Model Number Capacity 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) 2030 = 360 Ah (288 x 624 x 627) 2.0 WP 2030S – 3 – 2 – S M/P-IT-1720-504
  • 16. Printed in Germany M1.0-0000-0001 LUBRICATION AND ADJUSTMENT M-1.0-1720-001 1 2 3 3 4 2000 WP Rev.1 09/00 M1916 Component Access For regular maintenance purposes the drive unit, hy- draulic system, contactor panel etc. can be reached by removing the panel. The panel is fixed to the chassis by three screws, (Fig. 1515),located left , right and frontside. Remove the screws and lift the panel upward and then forward to remove it. Use the grip in the plastic-cover on top of the panel. Jacking up the Truck CAUTION Always support a raised truck with wooden blocks or other suitable equipment, thereby relieving the jack. The instruction "jack up the truck" always assumes that the raised truck will be lowered onto a secure surface. M1515 Lifting with a Crane Attach the straps to the hitch points as shown and ensure they cannot slide off. M1528 Jacking Points Fastening screws
  • 17. Printed in Germany M1.0-0000-0002 LUBRICATION AND ADJUSTMENT > 800 2000 WP 90 600 M-1.0-1720-002 Rev.1 09/00 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.
  • 18. 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.
  • 19. Printed in Germany M1.0-0000-0003 LUBRICATION AND ADJUSTMENT M-1.0-1720-003 Rev.1 09/00 Components M1563 Contactor panel LH lift cylinder Magnetic brake Drive motor Hydraulic tank and in-built pump Lowering valve Drive wheel Pump motor Traction control sy- stem Power safety device Control safety device Horn Pressure Switch for load-sensitive speed reduction
  • 20. Printed in Germany M1.0-0000-0004 LUBRICATION AND ADJUSTMENT M-1.0-1720-004 Rev.1 09/00 M 1516 Hourmeter and Battery Discharge Display Key Switch Emergency Dis- connect Battery Box Lock Model and Data Capacity Plate Fast / Slow Travel Switch Lift / Lower Switch Travel Switch Horn button Safety Reverse Switch M1568