Crown WI 2300 Pedestrian Powered Stacker Service Manual
224 pages · Publication 812585-006
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- Models
- WI 2300
- Manual type
- Service Manual
- Pages
- 224
- Publication
- 812585-006
- Condition
- Brand new
What's inside
From the manual's own table of contents: 394 sections, 403 entries. See sample pages (PDF, 662 KB)
General1 topic
- TABLE OF CONTENTS INTRODUCTION
Important Information
Manual structure
Text mark-ups in the manual
Service personnel qualification
Ordering Spare Parts
Ordering documentation
SAFETY
Safety Notices
Basic Safety Notices
Organisational measures
Personal safety equipment
Protecting the hazardous area
Hazards from stored energy
Repair work
Restoring the truck to service after repair work
Cleaning work
Handling batteries
Warning and instruction decals on the truck
Lifting gear and slings
Environmental protection
LUBRICATION & ADJUSTMENT
Transport and Storage
Lifting the Truck
Show all 395 sections
Lifting the truck by crane
Lifting the truck with a forklift truck
Towing the Truck
Jacking up the Truck
Placing the Truck in Storage
Testing Trucks in Storage
Restoring the Truck to Service
Battery Maintenance
Component Access
Accessing the Motor Compartment
Motor compartment components
Accessing the Back of the Motor Compartment
Components on the back of the motor compartment
Accessing the Control Handle Components
Control handle components
Accessing the Distributor PCB
Recommended Lubricants and Consumables
Cold Store Truck Requirements
Abbreviations used in the Table
Planned Maintenance
Maintenance Schedule
Annual Inspection in Accordance with FEM 4.004
Terms and Abbreviations used1 topic
- TABLE OF CONTENTS Torques
Standard torques
Cleaning the Truck and Components
Effects of incorrect cleaning
Electrical components
Roller and slide bearings
Corrosion-protected surfaces
Cleaning the Entire Truck
Cleaning Removed Components
Cleaning lift chains
Cleaning other mechanical components
Replacing the Load and Castor Wheels
Replacing the Load Wheels
Removing the load wheels
Load wheel assembly
Replacing the Castor Wheel
Castor wheel removal
Castor wheel assembly
Lowering Plumb Test
Adjusting the position of the pivoting carriage
Replacing the Castor Wheel Suspension
Castor wheel suspension removal
Castor wheel suspension assembly
HYDRAULIC SYSTEM
General Instructions
Hydraulic Lines and Ports
Bleeding the Hydraulic System
Drift Test
Lift Operation Test
Hydraulic Unit Components
Hydraulics manifold ports and valves
Hydraulic Diagram - TL Mast
Hydraulic Diagram - TT Mast
Hydraulic Diagram - TF Mast
Functional Description
Terminology Explanation
Main Lift, Raise
Main Lift, Lower
Initial Lift, Raise
Initial Lift, Lower
Initial Lift Lowering and Blocking
Repairing the Hydraulic Unit
Hydraulic Unit Removal
Hydraulic Unit Servicing
Hydraulic Unit Assembly
Replacing the Hydraulic Oil
Relief Valve Replacement and Adjustment
Relief Valve Disassembly
Relief Valve Assembly
Relief Valve Adjustment
Testing the Relief Valve
Hydraulic System Troubleshooting1 topic
- TABLE OF CONTENTS DRIVE UNIT
Drive Unit Components
Replacing the Drive Wheel
Drive Wheel Disassembly
Drive Wheel Assembly
Replacing the Drive Unit
Drive Unit Removal
Drive Unit Assembly
Replacing the Drive Gear Unit
Drive Gear Unit Removal
Drive Gear Unit Assembly
Repairing the Drive Gear Unit
Drive Gear Unit Disassembly
Adjusting the bevel gear set
Changing the Gear Oil
Draining the Oil
Adding Gear Oil
Repairing the Live Ring Bearing
Removing the Live Ring Bearing
Installing the Live Ring Bearing
ELECTRICAL SYSTEM
Brief Description
(ALM) Travel alarm
(ARB) Anti roll back module
(BBD) Battery connector
(BDI) Unigage
(BRK) Brake
(BRS) Brake switch
(EDS) Emergency Disconnect switch
(F/R Contactor) Direction contactor
(FU) Fuses
(HCM) Hydraulic control module
(HM) Horn
(HNS1 & HNS2) Horn switches
(HSS) “Rabbit/Turtle” toggle switch
(HYD PCB) Hydraulic printed circuit board
(ILS Lift & ILS Lower) Initial lift switches
(KYS) Key switch
(LMS - initial) Limit switch
(LMS - 1700 mm) Limit switch
(LOS1, LOS2) Lower switches
(MAIN PCB) Main circuit board
(ORS) Override switch
(PM / M2) Pump motor
(P) Pump contactor
(PCB) Distributor PCB
(POT, FS, RS) Traction pod
(PV) Proportional valve
(RAS) Raise switch
(SAS) Safety reverse switch1 topic
- TABLE OF CONTENTS (THS) Thermal switch
(THS1) Motor thermal switch
(TM / M1) Traction motor
Electrical Component Assembly Location
Distributor PCB components
Traction Controller 1207
Key switch
Current limit
Overvoltage protection
Overtemperature protection
Performance reduction for low voltage
Fault identification
Error Logging
Traction Controller Operator Panel
Potentiometer Adjustment
Connecting the Programmer
Status LED Display
Status LED Display Overview
Troubleshooting
Traction Controller Servicing
Cleaning the Traction Controller
PMT Test
PMT Test Wiring Diagram
Programmer
Operation
Key Function Description
SCROLL DISPLAY keys
CHANGE VALUE keys
MORE INFO key
PROGRAM key
TEST key
DIAGNOSTIC key
SPECIAL DIAGNOSTIC menu
Selecting the SPECIAL DIAGNOSTIC menu
SPECIAL PROGRAM Menu
Selecting the SPECIAL PROGRAM menu
Programmer
Menus
Main menu
Programmer menu
Monitor menu
Fault menu
Functions
Adjusting the programmer
Menu Terms
PROGRAM Menu
TEST menu
DIAGNOSTICS and SPECIAL DIAGNOSTICS menus
Traction Controller Settings1 topic
- TABLE OF CONTENTS Replacing the Display Instrument
Display Instrument Removal
Display Instrument Assembly
Battery Discharge Indicator (BDI) Information
Lift cutout
Battery Discharge Indicator (BDI) Adjustment
Wet cell battery calibration
Replacing the Key Switch (KYS)
Key Switch Removal
Key Switch Assembly
Replacing the LMS-Initial Limit Switch
Limit Switch Removal
Limit Switch Assembly
Replacing the LMS-1700 mm Limit Switch
Replacing the Override Switch (ORS) and the Brake Switch (BRS)
Override Switch Assembly
Replacing the Brake Switch
Replacing the Emergency Disconnect Switch (EDS)
Emergency Disconnect Switch Removal
Emergency Disconnect Switch Assembly
General Motor Maintenance Instructions
Brushes
Motor
Armature
Repairing the Traction Motor
Traction Motor Removal and Disassembly
Checking the Traction Motor Components for Wear
Traction Motor Assembly
Repairing the Pump Motor
Pump Motor Removal and Disassembly
Checking the Pump Motor Components for Wear
Pump Motor Assembly
Repairing the Direction Contactor (F/R)
Direction Contactor Removal
Direction Contactor Disassembly
Wear Test
Checking contacts
Checking the coils
Checking the springs
Direction Contactor Assembly
Repairing the Pump Contactor
Pump Contactor Removal
Pump Contactor Disassembly
Checking the contacts
Pump Contactor Assembly
Pump Contact Assembly1 topic
- TABLE OF CONTENTS Battery Information
Charging the Battery
Replacing the Battery
Hydraulic System Calibration
BRAKE SYSTEM
General Brake Information
Electromagnetic Brake Operating Principle
Repairing the Brake
Brake Removal
Brake Disassembly
Brake Assembly
Brake Installation
Brake Air Gap Adjustment
Adjusting the Air Gap
Setting the Braking Distance
Checking the Braking Distance
Reducing the Stopping Distance
STEERING
Repairing Control Handle Return Springs
Panel Removal
Return Spring Pre-Tension Adjustment
Replacing the Return Springs
Return spring removal
Return spring assembly
Repairing the Steering Column
Steering Column Removal
Steering Column Assembly
Replacing the Steering Chain
Steering Chain Removal
Steering Chain Assembly
Adjusting the Control Handle
Repairing the Control Handle
Replacing the Control Handle Shells
Shell removal
Shell assembly
Replacing the Switch Unit
Switch unit removal
Switch unit assembly
Replacing the “Rabbit/Turtle” Toggle Module
Toggle module removal
Toggle module assembly
Replacing the Control Handle Grip PC Boards
Hydraulic PC board removal
Hydraulic PC board assembly
Main PC board removal
Main PC board assembly
Replacing the Traction Potentiometer
Traction potentiometer removal
Traction potentiometer assembly1 topic
- TABLE OF CONTENTS Replacing the Safety Reverse Switch (SAS)
Safety reverse switch (SAS) removal
Safety reverse switch (SAS) assembly
Replacing the Grips and Horn Switch
Replacing the Initial Lift Switch
Initial lift switch removal
Initial lift switch assembly
LIFTING MECHANISM
Repairing the Mast
TT Mast
TF Mast
TL Mast
Repairing the TT Mast
Replacing the Mast Rollers
Mast Roller Removal
Replacing the Mast Rollers and Adjusting the Slack
Assembling the Remaining Attachments and Mast Unit
Preparing the Hydraulic System
Repairing the Fork Carriage
Replacing the Fork Carriage Rollers
Checking the Fork Carriage
Chain Supports and Lift Chains
General
Periodic inspection of chain supports and lift chains
Periodic replacement of chain supports and lift chains
Inspecting Chain Supports and Lift Chains
Checking the service hours for the lift chains and anchor bolts
Checking the lift chain for elongation
Preparatory measures
Freedom of movement
Worn or missing plates
Turned pins
Corrosion
Chain lateral wear
Checking chain supports and anchor bolts
Checking the chain pulleys
Checking and adjusting the chain tension
Checking the lifting components for misalignment
Lubricating Lift Chains
General information
Lubrication intervals and lubricants
Separating Lift Chains
Tools and equipment required
Lift Height Adjustment
Outrigger Lift Height Adjustment
Fork Height Adjustment1 topic
- TABLE OF CONTENTS CYLINDERS
Hydraulic System Repair Instructions
Tools
Small hook
Extractor
Producing extractors
Groove aligning arbor for small rod seals
Assembly devices for large rod seals
Protective mechanisms
Rod Seal Removal and Assembly
Removing a large rod seal
Removing a small rod seal
Inserting a large rod seal
Fitting a small rod seal
Rod seal assembly, sealing lip first
Replacing the Lift Cylinders
Replacing the Outer Lift Cylinders on the TL and TT Masts
Outer lift cylinder removal
Outer lift cylinder assembly
Replacing the Outer Lift Cylinders on TF Masts
Replacing the Free Lift Cylinders on the TT and TF Masts
Free Lift Cylinder Removal
Free lift cylinder assembly
Replacing the Initial Lift Cylinder
Initial lift cylinder removal
Initial lift cylinder assembly
Repairing Lift Cylinders
Checking Cylinders Before Starting Repair Work
Replacing the Rod Seals
Repairing the Lift Cylinders on the TL and TT Masts
Lift Cylinder Disassembly
Lift Cylinder Assembly
Repairing the Lift Cylinder on the TF Mast
Repairing the Free Lift Cylinders on the TF and TT Masts
Free Lift Cylinder Disassembly
Repairing the Initial Lift Cylinder
Initial Lift Cylinder Disassembly
Bleeding and Flushing the System
Bleeding the Lift Cylinders
Bleeding the Free Lift Cylinder
Flushing the Lift and Free Lift Cylinders1 topic
- TABLE OF CONTENTS SCHEMATIC DIAGRAMS
Electrical Diagram
Distributor PCB
Traction Controller - Drive Side
Brake Circuit
Instrument & HCM Circuit
Control Handle Control Circuit
Lift Limit Switches and Temperature Switches
Anti Roll Back (ARB)
Main Harness
Plug connector housing
Contact pins
Cable lugs and rings
Limit Switch Cables (LMS)
Horn Wire Harness
Control Handle and Horn Switch Assembly
Replacement Parts
Control Handle, Sideshift/Initial Lift Assembly
Control Handle Wire Harness
Strobe and Alarm Signal Wire Harness
Power Cables
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Inside this manual
Real pages from this service manual (224 pages). Open the sample pages (PDF, 662 KB)
- Repair procedure, page 44: LUBRICATION & ADJUSTMENT
- Specifications, page 101: Replacing the Display Instrument
- Diagram, page 212: WIRING DIAGRAMS
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 224 pages
Quantity one is the manual described above.
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