Crown WP2300S series Maintenance Manual

Maintenance Manual

WP2300S Series

●

Printed in Germany

Order Number: 812529-006

Revision Level B

This master manual is subject to continual updates.

It is meant exclusively for businesses authorized by CROWN.

It is not permitted to pass on the contents or copies thereof to third par ties.

CROWN Gabelstapler GmbH & Co. KG

- European Headquarter -

Moosacher Str. 52

80809 Munich

Germany

Phone [phone] - 0

Fax [phone] - 133

All rights reserved under international and Pan-American Copyright Agreement.

CROWN Equipment Corporation

Copyright 2002

Overview of Revisions:

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

Reference to authorised service personnel added.

Page 63 Rev.2 05/05 General corrections and additions to text.

Additions to Safety Reverse Switch (SAS)
Used from serial no. 5A336576, except for 5A337937.
Additions to Brake Switch (BRS)
Used from serial no. 5A336576, except for 5A337937.

Page 64 Rev.2 05/05 Additions to Platform Control Switches (GCSR, GCSL, PLS)

Used from serial no. 5A336576, except for 5A337937.

Page 64_A Rev.2 05/05 Additions to Platform Logic (PLM)

Used from serial no. 5A336576, except for 5A337937.
Page 65_A Rev.2 05/05 Updated diagram, addition to PLM.
Page 66_A Rev.2 05/05 WP2340S diagram included.
Page 80_A Rev.2 05/05 Parameter setting for trucks with folded platform.

Parameter setting for trucks with fixed platform.

REVISION

Page 88_A Rev.2 05/05 Troubleshooting addition.
from page 102

up to page 112 Switch unit, fast/slow toggle switch, hydraulic PCB, main PCB removal/

from page 131 Rev.2 05/05 Corrections to diagrams and WP2340S addition.
from page 136 Rev.2 05/05 Wiring diagram updates. WP2340S addition.

Rev.2 05/05 General text corrections. Updates and additions: Control handle grip,

installation, potentiometer, safety reverse switch, horn switch, hand grip.

WP2300S 05/2005 • Printed in Germany

MS-REV-1723

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Printed in Germany

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TABLE OF CONTENT

I

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TABLE OF CONTENT

Table of Content

REV– OVERVIEW OF REVISIONS PAGE SER-NR. CUT REV.

Overview of Revisions:....................................................... A .......................................................... Rev.2 05/2005

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.

Jacking up the Truck ........................................................... 11

Raising the Truck with a Crane ........................................... 11

Fixed Platform .................................................................. 11

Folding Platform ............................................................... 12

Both Platforms.................................................................. 13

Raising with a Forklift Truck............................................... 14

Component Access and Components .............................. 15

Maintenance ........................................................................ 18

Recommended Lubricants and Oils ................................. 18

Lubricants ................................................................... 18

Cold Store Trucks........................................................ 18

Truck Decommissioning ................................................... 18

Restoring the Truck to Service........................................... 18

Check and Maintenance Schedule .................................. 20

Safety Reverse Switch –

Functional Test ................................................................... 22

Grease items and grease intervals .................................. 30

Adjusting the Contact Pressure of the Castors

and the Drive Wheel ............................................................ 32

Torques ................................................................................ 33

M2 – HYDRAULICS PAGE SER-NR. CUT REV.

Hydraulic Symbols .............................................................. 37

Hydraulic System ................................................................ 41

Operation ......................................................................... 41

Removing the Hydraulic Unit............................................ 42

Replacing the Hydraulic Pump......................................... 43

Removal...................................................................... 43

Installation................................................................... 43

Commissioning and Bleeding the System........................ 43

Filters ............................................................................... 45

Replacing the Pressure Filter...................................... 45

Replacing the Suction and Return Filters.................... 45

Oil Change ....................................................................... 45

Replacing the Safety Valve............................................... 46

Safety Valve Setting ......................................................... 46

Safety Valve T est and Setting...................................... 46

WP2300S 05/2005 • Printed in Germany

III

TABLE OF CONTENT

Testing and Setting the Load-

Dependent Pressure Switch............................................. 47

M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

Gear Unit .............................................................................. 51

Preparatory Measures ..................................................... 51

Removal........................................................................... 51

Maintenance .................................................................... 51

General ....................................................................... 51

Gear Unit Disassembly / Assembly.................................. 53

Disassembly................................................................ 53

Assembly .................................................................... 53

Preparing the Gear Unit .............................................. 53

Flange Shaft Assembly ............................................... 53

Pinion Shaft Assembly ................................................ 54

Adjusting the Bevel Gear Assembly ............................ 54

Final Assembly............................................................ 54

Assembly .................................................................... 55

M4 – ELECTRICS PAGE SER-NR. CUT REV.

Electrics - General............................................................... 59

Wire Colour Codes........................................................... 59

Abbreviations ................................................................... 60

Electrical Symbols............................................................ 62

Electrical Components ....................................................... 63

Travel Switch (POT, FS, RS)............................................. 63

Fast/Slow Switch (HSS) ................................................... 63

Safety Reverse Switch (SAS)........................................... 63

Safety Reverse Switch (SAS)........................................... 63 .................. Used from serial no. 5A336576,

................................................................................................................. except for 5A337937...........................

........................................................................................................................................................ Rev.2 05/2005

Brake Switch (BRS).......................................................... 63

Brake Switch (BRS) .......................................................... 63 .................. Used from ser ial no. 5A336576,

................................................................................................................. except for 5A337937...........................

........................................................................................................................................................ Rev.2 05/2005

Raise/Lower Switch (RAS, LOS)...................................... 64

Pressure Switch (PS) ....................................................... 64

Platform Control Switches (GCSR, GCSL, PLS).............. 64

Platform Control Switches (GCSR, GCSL, PLS).............. 64 .................. Used from ser ial no. 5A336576,

................................................................................................................. except for 5A337937...........................

........................................................................................................................................................ Rev.2 05/2005

Lift Limit Switch (LMS) ..................................................... 64

Horn Switch (HNS)........................................................... 64

Foot Switch (FTS) ............................................................ 64

Key Switch (KYS)............................................................. 64

Emergency Disconnect (BD)............................................ 64

Fuses (FU) ....................................................................... 64

OPTION

Thermal Switch (THS) ........................................... 64

Filter (WP2340S only) ...................................................... 64 ......................................................... Rev.2 05/2005

Diode D4 .......................................................................... 64 ......................................................... Rev.2 05/2005

Diode block (DB).............................................................. 64 ......................................................... Rev.2 05/2005

Platform Logic (PLM) ....................................................... 64_A.............. Used from serial no. 5A336576,

................................................................................................................. except for 5A337937...........................

........................................................................................................................................................ Rev.2 05/2005

WP2330S ......................................................................... 65

WP2330S ......................................................................... 65_A..................................................... Rev.2 05/2005

WP2335S ......................................................................... 66_A..................................................... Rev.2 05/2005

WP2340S ......................................................................... 66_A..................................................... Rev.2 05/2005

Battery.................................................................................. 67

IV

WP2300S 05/2005 • Printed in Germany

TABLE OF CONTENT

General ............................................................................ 67

Replacing the battery ....................................................... 67

Battery Discharge Indicator (BDI)...................................... 67

General ............................................................................ 67

Battery Discharge Indicator Setting (BDI) ........................ 68

Calibration................................................................... 68

SEM1 T raction Controller .................................................... 69

General................................................................................. 69

Precautionary Measures ............................................. 69

Operational Features ....................................................... 69

Speed Control ............................................................. 69

Reduced Speed Ranges............................................. 69

Downhill Speed Control............................................... 69

Regenerative Braking.................................................. 69

Anti - Roll Down Function............................................ 69

Hourmeter ................................................................... 70

Self Test ...................................................................... 70

Monitored Circuits ....................................................... 70

Protective Devices............................................................ 70

Polarity Protection....................................................... 70

Wiring Errors ............................................................... 70

Temperature ................................................................ 70

Start Sequence ........................................................... 71

Safety Class................................................................ 71

Maintenance .................................................................... 71

Replacing the SEM1 Traction Controller ........................... 72

Parameter Setting after Replacing the Traction Controller 72

Preparatory Measures ................................................ 72

Setting......................................................................... 72

Status LED.................................................................. 74

Programmer......................................................................... 75

General ............................................................................ 75

Operating SEM1 Controller Menu .................................... 76

General ....................................................................... 76

Menu Functions .......................................................... 76

PARAMETER CHANGE .............................................. 76

Menu Structure for Folded Platform ............................ 77

Menu Structure for Fixed Platform .............................. 78

Parameter Setting, Folded Platform................................... 79

Parameter Setting, Folded Platform................................... 80

Parameter Setting, Folded or Fixed Platform.................... 80_A .................................................... Rev.2 05/2005

Parameter Setting, Fixed Platform ..................................... 80

TESTER Menu ................................................................. 82

ALARMS Menu ................................................................ 83

Calibrating the Traction Pod Potentiometer,

PROGRAM VACC menu .................................................. 86

Preparatory Measures ................................................ 86

Calibration................................................................... 86

CONFIG Menu...................................................................... 87

SET MODEL .................................................................... 87

SET OPTIONS ................................................................. 87

Adjustments ..................................................................... 87

Traction Controller Safety Test.......................................... 88

Troubleshooting Platform Logic, Controller PN 815144.... 88_A..................................................... Rev.2 05/2005

Electric Motors .................................................................... 89

General Maintenance Instructions ................................... 89

Preparation ................................................................. 89

Important Maintenance Instructions ............................ 89

Traction Motor Maintenance ............................................... 90

Access to Brushes ........................................................... 90

WP2300S 05/2005 • Printed in Germany

V

TABLE OF CONTENT

Maintenance .................................................................... 90

Armature ..................................................................... 90

Bearings...................................................................... 90

Pump Motor Maintenance................................................... 91

Access to brushes............................................................ 91

Maintenance .................................................................... 91

Armature ..................................................................... 91

M5 – BRAKE PAGE SER-NR. CUT REV.

Brake .................................................................................... 95

Removal........................................................................... 95

Disassembly................................................................ 96

Test and Inspection ..................................................... 96

Assembly .................................................................... 96

Assembly.......................................................................... 97

Air Gap Setting................................................................. 97

Brake Moment Setting...................................................... 98

Testing the Brakes....................................................... 98

M6 – STEERING PAGE SER-NR. CUT REV.

Multitask Handle - Springs for

Return Function .................................................................. 101

Adjustment ....................................................................... 101

Removal........................................................................... 101

Assembly.......................................................................... 101

Tiller Handle......................................................................... 103

Main Components ............................................................ 103

Tiller Handle Component

Removal / Installation ......................................................... 104

Tiller Handle Shells .......................................................... 104

Removing the Upper and Lower Shells....................... 104

Fitting the Upper and Lower Shells ............................. 105

Switch Unit ....................................................................... 106

Removal...................................................................... 106

Switch Unit Installation ................................................ 106

"Fast/Slow" Toggle Switch ................................................ 107

Removal...................................................................... 107

Installation................................................................... 107

Hydraulic Board ................................................................ 107

Removal...................................................................... 107

Installation................................................................... 107

Main PC Board Removal/Installation................................ 107_B................................................... Rev.2 05/2005

Potentiometer................................................................... 108

Removal...................................................................... 108

Installation................................................................... 108

Safety Reverse Switch ..................................................... 109

Removal...................................................................... 109

Installation................................................................... 109

Horn Switch...................................................................... 110

Removal...................................................................... 110

Installation................................................................... 110

Handle.............................................................................. 111

Removal...................................................................... 111

Installation................................................................... 111

M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

Lift Linkage .......................................................................... 115

Fork Height Setting .......................................................... 115

Lift Limit Cutout................................................................... 117

Lift Limit Cutout Setting .................................................... 117

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TABLE OF CONTENT

M8 – CYLINDERS PAGE SER-NR. CUT REV.

Lift Cylinders ....................................................................... 1 21

Operation ......................................................................... 121

Removal........................................................................... 121

Inspection......................................................................... 123

Replacing the Piston Seal ................................................ 123

M9 – PLATFORM PAGE SER-NR. CUT REV.

Folding Platform.................................................................. 127

Mechanical Setting........................................................... 127

Platform Switch Setting (PLS) .......................................... 128

Platform Suspension ........................................................ 129

Plate Spring Layers..................................................... 129

Side Gates, Mechanical Setting ....................................... 130

Fixed Platform WP2335S..................................................... 131

Replacing the Savety Switch............................................ 131

Fixed Platform WP2340S..................................................... 131_A .................................................. Rev.2 05/2005

Replacing the Savety Switch............................................ 131_A................................................... Rev.2 05/2005

Fixed Platform WP2340S..................................................... 132_A .................................................. Rev.2 05/2005

Replacing Switches below the Entry Bars (FPS 1 & FPS 2)132_A................................................... Rev.2 05/2005

DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.

Notes to overall wiring diagram, standard version, folded

platform, WP2330S .............................................................. 136 ....................................................... Rev.2 05/2005

Overall Wiring Diagram, Standard, Folded Platf orm,

WP2330S .............................................................................. 137 ....................................................... Rev.2 05/2005

SCHEMATIC DIAGRAM................................................... 13 8 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT..... 138 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 139 ....................................................... Rev.2 05/2005

PLATFORM CIRCUIT ...................................................... 139 ....................................................... Rev.2 05/2005

POWER UNIT CIRCUIT................................................... 140 ....................................................... Rev.2 05/2005

CONTROL HANDLE CIRCUIT......................................... 140 ....................................................... Rev.2 05/2005

PLATFORM LOGIC .......................................................... 141 .................................................... ... Rev.2 05/2005

Notes to overall wiring diagram, with Options, folded

platform, WP2330S .............................................................. 142 ....................................................... Rev.2 05/2005

Overall Wiring Diagram, with Options, Folded Platform,

WP2330S .............................................................................. 143 ....................................................... Rev.2 05/2005

SCHEMATIC DIAGRAM................................................... 14 4 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT..... 144 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 145 ....................................................... Rev.2 05/2005

PLATFORM CIRCUIT ...................................................... 145 ....................................................... Rev.2 05/2005

POWER UNIT CIRCUIT................................................... 146 ....................................................... Rev.2 05/2005

CONTROL HANDLE CIRCUIT......................................... 146 ....................................................... Rev.2 05/2005

PLATFORM LOGIC .......................................................... 147 .................................................... ... Rev.2 05/2005

Notes to overall wiring diagram, standard version,

fixed platform, WP2335S ..................................................... 148 ....................................................... Rev.2 05/2005

Overall Wiring Diagram, Standard Version,

Fixed Platform, WP2335S.................................................... 149 ....................................................... Rev.2 05/2005

Notes to overall wiring diagram, with Options,

fixed platform, WP2335S ..................................................... 150 ....................................................... Rev.2 05/2005

Overall Wiring Diagram, with Options, Fixed Platform,

WP2335S .............................................................................. 151 ....................................................... Rev.2 05/2005

Diagrams, Standard Version, Fixed Platform, WP2340S... 152 ....................................................... Rev.2 05/2005

SCHEMATIC DIAGRAM................................................... 15 2 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT..... 152 ....................................................... Rev.2 05/2005

POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 153 ....................................................... Rev.2 05/2005

PLATFORM CIRCUIT ...................................................... 153 ....................................................... Rev.2 05/2005

POWER UNIT CIRCUIT................................................... 154 ....................................................... Rev.2 05/2005

CONTROL HANDLE CIRCUIT......................................... 154 ....................................................... Rev.2 05/2005

Diagrams, with Options, Fixed Platform, WP2340S .......... 155 ....................................................... Rev.2 05/2005

WP2300S 05/2005 • Printed in Germany

VII

TABLE OF CONTENT

SCHEMATIC DIAGRAM................................................... 155 ....................................................... Rev.2 05/2005

TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT..... 15 5 ....................................................... Rev.2 05/2005

POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 156 ....................................................... Rev.2 05/2005

PLATFORM CIRCUIT ...................................................... 156 ....................................................... Rev.2 05/2005

POWER UNIT CIRCUIT................................................... 157 ....................................................... Rev.2 05/2005

CONTROL HANDLE CIRCUIT......................................... 157 ....................................................... Rev.2 05/2005

Wire harness overview , folded platform,

WP2330S all versions ......................................................... 158 ....................................................... Rev.2 05/2005

Main Harness, Folded Platform, WP2330S, All Versions .. 159 ....................................................... Rev.2 05/2005

Control Handle - Wire Harness Folded Platform,

WP2330S, All Versions........................................................ 160 ....................................................... Rev.2 05/2005

Horn Switch - Wire Harness, Folded Platform,

WP2330S, All Versions........................................................ 161 ....................................................... Rev.2 05/2005

Wire harness overview, Fixed Platf orm,

WP2340S, All Versions....................................................... 162 ....................................................... Rev.2 05/2005

Wire harness overview, Fixed Platf orm,

WP2340S, All Versions....................................................... 163 ....................................................... Rev.2 05/2005

Control Handle - Wire Harness FFixed Platform,

WP2340S, All Versions........................................................ 164 ....................................................... Rev.2 05/2005

Horn Switch - Wire Harness Fixed Platform,

WP2340S, All Versions........................................................ 165 ....................................................... Rev.2 05/2005

Cables, Platform, Fixed Platform, WP2340S,

All Ver sions .......................................................................... 166 ....................................................... Rev.2 05/2005

Power Cables ....................................................................... 167

HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

Hydraulic Schematic ........................................................... 171

VIII

WP2300S 05/2005 • Printed in Germany

Printed in Germany

SAFETY

1

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Printed in Germany

M1.0-0000-0002M1.0-0000-00022

SAFETY

Safety Symbols used in the Manual

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

DANGER

This symbol indicates life-threatening risks

●

Failure to comply with this notice ma y
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 ma y
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 ma y
result in minor injuries to yourself or other
people and/or minor material damage.

General Maintenance and Repair Safety Notes

DANGER

Read the safety notices in the truck Mainte­nance 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 pro­gram contained in the present Maintenance
Manual and any applicable service notices.

INFORMATION

Contains additional information with
supplementary notes and hints.

OPTION

These items relate to optional features not

OPTION

supplied with the standard version.

2. Only qualified and authorised personnel may
carry out work on the truck.

3. Always keep fire extinguishers in good working
condition. Do not approach fluid levels or leaks
with a naked flame.

4. To clean, use a non flammable, non combustible
cleaning solution which is groundwater-neutral.
Only carry out cleaning with an oil separator.
Protect the electrical system from dampness.

5. Keep the service area clean, dry and well-venti­lated.

6. Do not allow oil to penetrate the ground or enter
the draining system. Used oil must be recycled.
Oil filters and desiccants must be treated as
special waste products. Rele v ant applicab le
regulations must be followed.

7. Neutralise and thoroughly rinse any spilled
battery fluid immediately .

MS-WP2300S-GB 05/03 • Printed in Germany

MS-0000-MA

REV. 1 4/00

33

SAFETY

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

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

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

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

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.

W arnings and Labels on the T ruck

During regular maintenance check that the warnings
and labels on the truck are complete and legible.

● Clean any illegible labels.

● Replace any faulty or missing labels.

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

Before Carrying out Work on the Truc k

● 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: Bloc k 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.

MS-0000-MA

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REV. 1 4/00

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INTRODUCTION

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M1.0-0000-0006M1.0-0000-00066

INTRODUCTION

General

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

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

INFORMATION

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

This 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.

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 CR OWN
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.

ecnanetniaMsnoitceS

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 T raining

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 tr uck specification number

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2MsciluardyH

3MtinUevirD

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5MekarB

6MgnireetS

● The tr uck model number

● The tr uck serial number

MS-WP2300S-GB 05/03 • Printed in Germany MS-ITD-1723

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7M1.0-0000-00077

INTRODUCTION

Model-Number

This manual describes the maintenance and repairs for the following truck versions:

2.0 WP 2335S – 3 – 2 – S

Capacity

2.0 = 2000 kg

Model Description

WP = Electric Pedestrian Pallet Truck

Platform T ype

2335 = Fixed Platform
2330 = Folded Platform

Load Wheels

S = Single
T = Tandem

htgneLkroF

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163
2599
324
45211
564
6012184
745
806

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181
202502
304522
407672

I02a-gb

I03a-gb

MS-WP2300S-GB 05/03 • Printed in GermanyMS-ITD-1723

8M1.0-0000-00088

LUBRICATION AND ADJUSTMENT

Printed in Germany

9

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Printed in Germany

M1.0-0000-00010M1.0-0000-0001010

LUBRICATION AND ADJUSTMENT

Jacking up the Truck

CAUTION

Always support a raised truck with wooden
blocks or other suitable means to relieve
the jack.

The term "jacking up the truck" always implies that the
raised truck is lowered onto a secure base.

Raising the Truck with a Crane

Fixed Platform

Fit the chains or lifting slings as shown in the diagram:

● to each fork tip with a lifting sling tied around the
platform,

or

● with one hook on each side of the platform.

Capacity required: 600 kg for the WP 2300 S less
battery.

Jack up Points

MS1723-100

M1458-a

MS-WP2300S-GB 05/03 • Printed in Germany

MS-1.0-1723

M-1.0-0000-0001111

LUBRICATION AND ADJUSTMENT

Folding Platform

Fit the chains or lifting slings as shown in the diagram:

● to each fork tip with a lifting sling tied around the
platform.
Prevent the lifting sling from sliding off: connect it
to the forks, see dashed line S.

or

● Attach a hook to points R and L respectively on
the truck frame.
Prevent accidental sliding off: connect the two
chains or lifting slings, see dashed line H,
between the truck and the gates.

Capacity required: 570 kg for the WP 2300 S less
battery.

MS-1.0-1723

M-1.0-0000-0001212

S

R

R

L

MS-WP2300-GB 05/03 • Printed in Germany

H

L

MS-1723-101

LUBRICATION AND ADJUSTMENT

Both Platforms

It is also possible to raise the truck (with either folding
or fixed platform, after removing the panel) as shown in
the following illustration.

MS-WP2300S-GB 05/03 • Printed in Germany

MS-1723-102

MS-1.0-1723

M-1.0-0000-0001313

LUBRICATION AND ADJUSTMENT

Raising with a Forklift Truck

DANGER

Use a truck with sufficient capacity and
prevent the truck on the forks from sliding
off.

The WP 2300 S can be raised at an angle using a
forklift truck - see illustration.

Required capacity: 600 kg for the WP 2300S less
battery.

● The forks must be fully raised.

● Position the forks of the lifting truck as shown in

the illustration.

● Place a wooden block approx. 90 mm thick
between the forks of the WP 2300S and the fo rk s
of the lifting truck.

● Secure the WP 2300S on the forks of the lifting
truck (e.g. with an elastic strap).

90

600

MS-1.0-1723

M-1.0-0000-0001414

> 800

WP

2300

MS-1723-103

MS-WP2300-GB 05/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT

Component Access and Components

Removing the panel provides access to the drive unit,
hydraulic system, contactors, traction controller etc.
The panel is fixed to the frame by two screws.
Removing the screws allows you to slightly lift the
panel up out of the lower retaining lug, tilt it away and
remove it via the tiller.

Battery connector
(EMERGENCY

FU2 - FU3 F/C

FU1

DISCONNECT)

Fan

Main contactor

Pump contactor

Pump motor

Pressure switch
PS

Lowering
valve SV

Magnetic brake

Traction
controller

Horn

Lift cylinder (LH)

MS-1723-120

Hydraulic tank and
pump

MS-WP2300S-GB 05/03 • Printed in Germany

Traction motor

Drive wheel

MS-1.0-1723

M-1.0-0000-0001515

LUBRICATION AND ADJUSTMENT

Button, Horn

Travel Switch

Fast / Slow Travel Switch

Reverse Safety Switch

Lift / Lower Switch

MS1723-004

MS-1.0-1723

M-1.0-0000-0001616

MS-WP2300-GB 05/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT

Blank Page

MS-WP2300S-GB 05/03 • Printed in Germany

M-1.0-0000-0001717

LUBRICATION AND ADJUSTMENT

Maintenance

Recommended Lubricants and Oils

Lubricants

The following page lists typical lubricants which are
also used by Crown in the factory. However, any
lubricants with the same technical specifications can
be used.

Cold Store Trucks

Special hydraulic oil, lubricant oils and grease for low
temperature applications must be used for cold store
trucks (see table on following page). All screws, wash­ers, nuts, pins, retaining rings etc. must be treated
regularly with an anti-corrosion solution CROWN no.
805236-004. Electrical connections and components
must be carefully protected against corrosion. For more
details refer to chapter 4.

Maintenance intervals must be adapted to the condi­tions of use. They should be as frequent as possible to
prevent excess wear.

● Every 3 months connect the battery, carry out a
daily check and test the truck functions. Then
disconnect the battery again.

Restoring the Truck to Service

When restoring the truck to service, proceed as
follows:

● Remove any addition corrosion protection applied
(except for cold store protection)*.

● Jack up the truck, remove the wooden blocks and
lower the truck.

● Charge the battery or install a charged battery.

● Connect the batter y.

● Carry out the daily check.

*) Do not use high pressure cleaners and/or
solvents on the truck. Do not use metal brushes.
Do not wet-clean the electrical system and do not
use flammable cleaning solutions.

Truck Decommissioning

When taking the truck out of service for more than 3
months, proceed as follows:

● Disconnect the battery.

● Decommission the battery in accordance with the

manufacturer's instructions.

● Clean the tr uck*). Wipe off any grease in
accordance with the maintenance manual.

● If the truck is to be stored in hostile ambient
conditions (e.g. saline atmosphere) treat the
surfaces of the truck with a suitable solution to
prevent corrosion.

● Do not park the truck in the open air or in a
humid environment. The ideal location is a dry
room with as constant a temperature and air
humidity as possible. If the truck has to be
covered, use material through which air can
permeate rather than plastic sheets. Otherwise
condensation water may form.

● Jack up the truck. Lower the chassis onto suitable
wooden blocks in order to clear the wheels from
the ground (this prevents the wheels from
flattening under constant pressure).

M-1.0-0000-0001818

MS-WP2300S-GB 05/03 • Printed in GermanyMS-1.1-1723