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Crown WS2000 Series Forklift Service Repair Manual.pdf

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Service and Parts Manual Wartungs- und Ersatzteilhandbuch Manuel de maintenance et de pièces detachées Series WE/WS
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 001 IDX - 4220 - 001 X X. X X ..................................... Introduction .............................................................................................................................. ITD-0000-001 X X. X X ..................................... General maintenance instruction ........................................................................................ MA-0000-001 SECTION M1 LUBRICATION AND ADJUSTMENT X X. X X ..................................... Component access ................................................................................................................ M1.0-4220-001 X X. X X ............................................ Raising the truck ................................................................................................................... M1.0-4220-002 X X. X X ..................................... Inspection and maintenance plan ....................................................................................... M1.1-4220-001 X X. X X ............................................ Service scope ....................................................................................................................... M1.1-4220-001 X X. X X ............................................ Inspection and maintenance plan 8 hrs. ............................................................................. M1.1-4220-002 X X. X X ............................................ Inspection and maintenance plan 100 hrs. ......................................................................... M1.1-4220-004 X X. X X ............................................ Inspection and maintenance plan 250/500 hrs. .................................................................. M1.1-4220-006 X X. X X ............................................ Inspection and maintenance plan 1000 hrs. ....................................................................... M1.1-4220-008 X X. X X ..................................... Lubrication ................................................................................................................................ M1.2-4220-001 X X. X X ............................................ General.................................................................................................................................. M1.2-4220-001 X X. X X ............................................ Lubrication points ................................................................................................................. M1.2-4220-006 X X. X X ..................................... Lubricants and oil recommendations table ..................................................................... M1.3-0000-001 X X. X X ..................................... Torque values .......................................................................................................................... M1.9-0000-001 SECTION M2 HYDRAULIC MAINTENANCE X X. X X ..................................... Hydraulic schematic symbols .............................................................................................. M2.0-0000-001 X X. X X ..................................... Hydraulic system ..................................................................................................................... M2.1-4220-001 X X. X X ............................................ General.................................................................................................................................. M2.1-4220-001 X X. X X ............................................ Hydraulic oil tank ................................................................................................................... M2.1-4220-002 X X. X X ............................................ Valve block ............................................................................................................................ M2.1-4220-005 X X. X X ............................................ Hydraulic oil pump ................................................................................................................. M2.1-4220-006 X X. X X ............................................ Hydraulic system/softlift ....................................................................................................... M2.1-4220-025 X X. X X ..................................... Hydraulic system ..................................................................................................................... M2.7-4220-001 X X. X X ............................................ Ventilate TL/TF and TT Mast ................................................................................................. M2.7-4220-001 SECTION M3 DRIVE UNIT MAINTENANCE X X. X X ..................................... Drive Unit ................................................................................................................................... M3.0-4220-001 X X. X X ............................................ Drive wheel ........................................................................................................................... M3.0-4220-001 X X. X X ............................................ Gearbox ................................................................................................................................ M3.0-4220-003 X X. X X ............................................ Gearbox/Repair..................................................................................................................... M3.0-4220-004 X X. X X .................................................. Turntable bearing ........................................................................................................... M3.0-4220-008 X X. X X ..................................... Pivoting carriage...................................................................................................................... M3.9-4220-001 X X. X X ............................................ General.................................................................................................................................. M3.9-4220-001 X X. X X ..................................... Wheels and Tyres.................................................................................................................... M3.9-4220-003 X X. X X ............................................ General.................................................................................................................................. M3.9-4220-003 X X. X X ............................................ Load wheel, single axle ........................................................................................................ M3.9-4220-003 X X. X X ............................................ Load wheel, tandem axle ..................................................................................................... M3.9-4220-004 X X. X X ............................................ Support wheel mounting....................................................................................................... M3.9-4220-005 SECTION M4 ELECTRICAL MAINTENANCE X X. X X ..................................... Basic electrics .......................................................................................................................... M4.0-0000-001 X X. X X ............................................ Wiring colour code ................................................................................................................ M4.0-0000-001 X X. X X ............................................ Colour coding in accordance with DIN 47100...................................................................... M4.0-1710-002
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 002 IDX - 4220 - 002 X X. X X ............................................ Index of abbreviations switch symbols ............................................................................... M4.0-0000-003 X X. X X ............................................ Typical electrical symbols ..................................................................................................... M4.0-0000-005 X X. X X ............................................ Transistor control with pulse width modulation ................................................................... M4.0-4220-006 X X. X X ..................................... Electrical components ........................................................................................................... M4.2-4220-001 X X. X X ............................................ Switches ............................................................................................................................... M4.2-4220-001 X X. X X ..................................... Controller ................................................................................................................................. M4.3-1710-001 X X. X X ............................................ General.................................................................................................................................. M4.3-1710-001 X X. X X ............................................ Explanation of function ......................................................................................................... M4.3-1710-002 X X. X X ............................................ Pilot wire pins ........................................................................................................................ M4.3-1710-007 X X. X X ............................................ Adjustment panel .................................................................................................................. M4.3-1710-008 X X. X X ............................................ LED Codes ............................................................................................................................ M4.3-1710-009 X X. X X ............................................ Maintenance .......................................................................................................................... M4.3-1710-011 X X. X X ............................................ Removal / installation ............................................................................................................ M4.3-1710-012 X X. X X ............................................ Safety instruction ................................................................................................................. M4.3-1710-013 X X. X X ............................................ Controler check..................................................................................................................... M4.3-1710-014 X X. X X ..................................... Programmer ............................................................................................................................. M4.4-1710-001 X X. X X ............................................ General.................................................................................................................................. M4.4-1710-001 X X. X X ............................................ Keypad definition .................................................................................................................. M4.4-1710-002 X X. X X ............................................ Operationg modes ................................................................................................................ M4.4-1710-006 X X. X X ..................................... Values and fault codes for Controller ................................................................................ M4.5-4220-001 X ..... X................................................ Controller settings ................................................................................................................. M4.5-4220-001 .. X..... X ............................................ Controller settings ................................................................................................................. M4.5-4220-003 X X. X X ............................................ Program menu ....................................................................................................................... M4.5-1710-005 X X. X X ............................................ Test menu .............................................................................................................................. M4.5-1710-006 X X. X X ............................................ Diagnostic and special diagnostic menu .............................................................................. M4.5-1710-007 X X. X X ............................................ Special program menu .......................................................................................................... M4.5-1710-008 X X. X X ............................................ Trouble shooting chart .......................................................................................................... M4.5-1710-009 X X. X X ............................................ Fault recovery ....................................................................................................................... M4.5-1710-012 X X. X X ..................................... Battery level indicator/Operationg hours counter........................................................... M4.6-4220-001 X X. X X ..................................... Key Switch ................................................................................................................................ M4.8-4220-001 X X. X X ............................................ Disassembly/Assembly ........................................................................................................ M4.8-4220-001 X X. X X ............................................ Reverse safety switch ......................................................................................................... M4.8-4220-002 X X. X X ............................................ Drive switch .......................................................................................................................... M4.8-4220-002 X X. X X ............................................ Switch raise/lower ............................................................................................................... M4.8-4220-005 X X. X X ............................................ Horn switch .......................................................................................................................... M4.8-4220-006 X X. X X ............................................ Speed limiter switch .............................................................................................................. M4.8-4220-006 X X. X X ............................................ Brake switch ......................................................................................................................... M4.8-4220-007 X X. X X ............................................ Override switch .................................................................................................................... M4.8-4220-009 X X. X X ............................................ Emergency off switch .......................................................................................................... M4.8-4220-010 X X. X X ............................................ Distributor board .............................................................................................................. M4.9-4220-001 X X. X X ............................................ Motor ................................................................................................................................... M4.10-4220-001 X X. X X .................................................. General ........................................................................................................................... M4.10-4220-001 X ..... X...................................................... Pump motor ..................................................................................................................... M4.10-4220-002 X X. X X ........................................................ Disassembly/Assembly ........................................................................................... M4.10-4220-002 X X. X X ........................................................ Maintenance/Repair ................................................................................................. M4.10-4220-003 .. X..... X ........................................................ Pump motor............................................................................................................... M4.10-4220-006 X X. X X .................................................. Drive motor ..................................................................................................................... M4.10-4220-008 X X. X X ........................................................ Disassembly ............................................................................................................. M4.10-4220-006 X X. X X ........................................................ Repair ....................................................................................................................... M4.10-4220-007 X X. X X ........................................................ Assembly ................................................................................................................. M4.10-4220-009 X X. X X ........................................................ Maintenance ............................................................................................................. M4.10-4220-009 X X. X X ............................................ Electrics panel ................................................................................................................... M4.11-4220-001 X X. X X .................................................. General ........................................................................................................................... M4.11-4220-001
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t X X. X X ..................................... Direction of contactor ............................................................................................................. M4.11-4220-002 X X. X X ............................................ General.................................................................................................................................. M4.11-4220-002 X X. X X ............................................ Disassembly .......................................................................................................................... M4.11-4220-002 X X. X X ............................................ Repairs .................................................................................................................................. M4.11-4220-003 X X. X X ..................................... Pump contactor ....................................................................................................................... M4.11-4220-004 X X. X X ............................................ General.................................................................................................................................. M4.11-4220-004 X X. X X ............................................ Disassembly .......................................................................................................................... M4.11-4220-004 X X. X X ............................................ Repairs .................................................................................................................................. M4.11-4220-004 X X. X X ..................................... Battery ........................................................................................................................................ M4.12-4220-001 X X. X X ............................................ General.................................................................................................................................. M4.12-4220-001 X X. X X ............................................ Checking the electrolyte level ............................................................................................... M4.12-4220-001 X X. X X ............................................ Charging the battery ............................................................................................................. M4.12-4220-002 X X. X X ............................................ Maintenance .......................................................................................................................... M4.12-4220-004 X X. X X ..................................... Battery connections ............................................................................................................... M4.12-4220-005 X X. X X ............................................ General.................................................................................................................................. M4.12-4220-005 X X. X X ............................................ Disassembly .......................................................................................................................... M4.12-4220-005 X X. X X ............................................ Repairs .................................................................................................................................. M4.12-4220-005 X X. X X ............................................ Assembly .............................................................................................................................. M4.12-4220-006 X X. X X ..................................... Test procedures (PMT) .......................................................................................................... M4.20-4220-001 X X. X X ............................................ General.................................................................................................................................. M4.20-4220-001 SECTION M5 BRAKE MAINTENANCE X X. X X ..................................... Brakes system ........................................................................................................................ M5.0-4220-001 X X. X X ............................................ Genral.................................................................................................................................... M5.0-4220-001 X X. X X ............................................ Setting ................................................................................................................................... M5.0-4220-003 SECTION M6 STEERING MAINTENANCE X X. X X ..................................... Steering ..................................................................................................................................... M6.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M6.0-4220-001 X X. X X ............................................ Removal of control handle .................................................................................................... M6.0-4220-002 X X. X X .................................................. Cross joint ....................................................................................................................... M6.0-4220-004 X X. X X ............................................ Chain tensioning device ........................................................................................................ M6.0-4220-005 X X. X X ............................................ Steering chain ....................................................................................................................... M6.0-4220-006 SECTION M7 MAST MAINTENANCE X X. X X ..................................... Mast ............................................................................................................................................ M7.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TL Mast.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TF Mast.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TT Mast.................................................................................................................................. M7.0-4220-002 X X. X X ............................................ Mast disassembly/assembly ................................................................................................ M7.0-4220-002 X X. X X ............................................ Fork carriage disassembly/assembly .................................................................................. M7.0-4220-003 X X. X X ............................................ Mast maintenance ................................................................................................................. M7.0-4220-004 X X. X X .................................................. Greasing roller tracks ..................................................................................................... M7.0-4220-004 X X. X X .................................................. Roller disassembly ......................................................................................................... M7.0-4220-005 X X. X X ..................................... Lift chain inspection ............................................................................................................... M7.5-0000-001 X X. X X ............................................ General.................................................................................................................................. M7.5-0000-001 X X. X X ............................................ Lubrication ............................................................................................................................ M7.5-0000-001 X X. X X ............................................ Identifying damages .............................................................................................................. M7.5-0000-002 X X. X X ..................................... Gabelzinkenprüfung ............................................................................................................... M7.8-0000-001 X X. X X ............................................ General.................................................................................................................................. M7.8-0000-001 X X. X X ............................................ Fork identification .................................................................................................................. M7.8-0000-001 IDX - 4220 - 003 IDX - 4220 - 003
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 004 IDX - 4220 - 004 X X. X X ............................................ Repairs .................................................................................................................................. M7.8-0000-002 SECTION M8 CYLINDER MAINTENANCE X X. X X ..................................... Cylinder ..................................................................................................................................... M8.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M8.0-4220-001 X X. X X ............................................ Simplex mast cylinder ........................................................................................................... M8.0-4220-001 X X. X X ............................................ Lifting cylinder ....................................................................................................................... M8.0-4220-002 SECTION M9 COVERS X X. X X ..................................... Panels/Covers .......................................................................................................................... M9.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M9.0-4220-001 X X. X X ............................................ Protective cover.................................................................................................................... M9.0-4220-001 X X. X X ............................................ Battery cover ........................................................................................................................ M9.0-4220-001 X X. X X ............................................ Nuckle cover ......................................................................................................................... M9.0-4220-002 SECTION DIA WIRING DIAGRAMS X X. X X ..................................... Electrical diagrams ................................................................................................................. DIA-4220-001X X X. X X ............................................ Schematic ............................................................................................................................. DIA-4220-001X X X. X X ............................................ Distribution panel................................................................................................................... DIA-4220-002X X X. X X ............................................ Handle and BDI ...................................................................................................................... DIA-4220-003X X X. X X ............................................ Traction controller ................................................................................................................. DIA-4220-004X X X. X X ............................................ Brake/Option: charger .......................................................................................................... DIA-4220-005X X X. X X ..................................... Electrical diagrams ................................................................................................................. DIA-4220-025X X X. X X ............................................ Schematic ............................................................................................................................. DIA-4220-025X X X. X X ............................................ Distribution panel................................................................................................................... DIA-4220-026X X X. X X ............................................ Handle and BDI ...................................................................................................................... DIA-4220-027X X X. X X ............................................ Traction controller ................................................................................................................. DIA-4220-028X X X. X X ............................................ Brake/Option: charger .......................................................................................................... DIA-4220-029X X X. X X ............................................ Propotional electronic ........................................................................................................... DIA-4220-030X SECTION HYD HYDRAULIC SCHEMATICS X X. X X ..................................... Hydraulck Schematic .............................................................................................................. HYD-4220-001 X X. X X ............................................ Simplex .................................................................................................................................. HYD-4220-001 X X. X X ............................................ Duplex ................................................................................................................................... HYD-4220-002 X X. X X ............................................ Triplex.................................................................................................................................... HYD-4220-002 X X. X X ............................................ Simplex .................................................................................................................................. HYD-4220-003 X X. X X ............................................ Duplex ................................................................................................................................... HYD-4220-004 X X. X X ............................................ Triplex.................................................................................................................................... HYD-4220-004 SECTION WZ TOOLS X X. X X ..................................... Tools ........................................................................................................................................... WZ -4220-001
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t SECTION 1 POWER UNIT PARTS / COVERS X X.............................................. Frame with pivoting carriag ........................................................................................................ 1.0-4220-002 ....... X X ..................................... Frame with pivoting carriag ........................................................................................................ 1.0-4220-050 X X. X X ..................................... Wheels ......................................................................................................................................... 1.5-4220-002 SECTION 2 HYDRAULIC PARTS X ..... X......................................... Hydraulic power unit ................................................................................................................... 2.1-4220-002 X ..... X......................................... Hydraulic power unit (Softlift)..................................................................................................... 2.1-4220-025 .. X..... X ..................................... Hydraulic power unit ................................................................................................................... 2.1-4220-050 .. X..... X ..................................... Hydraulic power unit (Softlift)..................................................................................................... 2.1-4220-075 X X. X X ..................................... Hydraulic tank .............................................................................................................................. 2.2-4220-001 X X. X X ..................................... Hydraulic tank . (Softlift) .............................................................................................................. 2.2-4220-025 X ..... X......................................... Control valve ............................................................................................................................... 2.3-4220-002 .. X..... X ..................................... Control valve ............................................................................................................................... 2.3-4220-050 X ..... X......................................... Hydraulic TL Mast ........................................................................................................................ 2.4-4220-002 .. X..... X ..................................... Hydraulic TL Mast ........................................................................................................................ 2.4-4220-050 X ..... X......................................... Hydraulic TF Mast ........................................................................................................................ 2.6-4220-002 .. X..... X ..................................... Hydraulic TF Mast ........................................................................................................................ 2.6-4220-050 .. X..... X ..................................... Hydraulic TT Mast ........................................................................................................................ 2.8-4220-002 X ..... X......................................... Pump and Motor ........................................................................................................................... 2.9-4220-002 .. X..... X ..................................... Pump and Motor ........................................................................................................................... 2.9-4220-050 SECTION 3 DRIVE UNIT PARTS X X. X X ..................................... Drive unit ...................................................................................................................................... 3.0-4220-002 X X. X X ..................................... Gearbox ....................................................................................................................................... 3.1-4220-002 X X. X X ..................................... Drive motor .................................................................................................................................. 3.2-4220-002 X X. X X ..................................... Knuckel ........................................................................................................................................ 3.3-4220-002 X X. X X ..................................... Knuckel .... (Platform) .................................................................................................................. 3.3-4220-025 SECTION 4 ELECTRICAL PARTS X X. X X ..................................... Electrical parts ............................................................................................................................. 4.0-4220-002 .............................................................................................................................................................12/96 X X. X X ..................................... Electrical parts ...............................................................................01/97 ................................... 4.0-4220-025 X X. X X ..................................... Electrical parts ............................................................................................................................. 4.0-4220-050 .............................................................................................................................................................12/96 X X. X X ..................................... Electrical parts ...............................................................................01/97 ................................... 4.0-4220-075 X X. X X ..................................... Pump contactor ........................................................................................................................... 4.4-4220-002 X X. X X ..................................... Contactor ..................................................................................................................................... 4.4-2130-050 X X. X X ..................................... Control handle ............................................................................................................................. 4.5-1710-002 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle ...............................................................................09/98 ................................... 4.5-1710-025 X X. X X ..................................... Control handle (Grip) .................................................................................................................. 4.5-1710-050 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Grip) ....................................................................09/98 ................................... 4.5-1710-075 X X. X X ..................................... Control handle (Hup cap) ........................................................................................................... 4.5-1710-100 X X. X X ..................................... Control handle (Freezer/Corrosion) .......................................................................................... 4.5-1710-125 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Freezer/Corrosion) ............................................09/98 ................................... 4.5-1710-150 X X. X X ..................................... Control handle (Grip/Freezer) .................................................................................................... 4.5-1710-175 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Grip/Freezer) ......................................................09/98 ................................... 4.5-1710-200 X X. X X ..................................... Control handle (Hup cap/Freezer) ............................................................................................. 4.5-1710-225 X X. X X ..................................... Powerpack .................................................................................................................................. 4.8-4220-002 .............................................................................................................................................................W-5-3411 X X. X X ..................................... Powerpack ....................................................................................W-5-3412 ............................ 4.8-4220-025 X X. X X ..................................... Emergency Stop .......................................................................................................................... 4.9-4220-002 IDX - 4220 - 005 IDX - 4220 - 005
Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t SECTION 5 BRAKE PARTS X ..... X......................................... Brake ........................................................................................................................................... 5.3-4220-004 .. X..... X ..................................... Brake ........................................................................................................................................... 5.3-4220-006 SECTION 6 STEERING X X. X X ..................................... Drive unit parts ............................................................................................................................ 6.0-4220-004 SECTION 7 MAST / LIFT STRUCTURE PARTS X ..... X......................................... TL Mast ........................................................................................................................................ 7.1-4220-002 .. X..... X ..................................... TL Mast ........................................................................................................................................ 7.1-4220-052 X ..... X......................................... TF Mast ........................................................................................................................................ 7.3-4220-002 .. X..... X ..................................... TF Mast ........................................................................................................................................ 7.3-4220-050 .. X..... X ..................................... TT Mast ........................................................................................................................................ 7.5-4220-002 ....... X......................................... Fork Carriage ............................................................................................................................... 7.6-4220-002 ........... X ..................................... Fork Carriage ............................................................................................................................... 7.6-4220-050 X .................................................. Fork Carriage ............................................................................................................................... 7.6-4220-100 .. X.............................................. Fork Carriage ............................................................................................................................... 7.6-4220-102 X X. X X ..................................... Load backrest ............................................................................................................................. 7.9-4220-002 SECTION 8 CYLINDER PARTS X ..... X......................................... Lift Cylinder TL Mast.................................................................................................................... 8.1-4220-001 .............................................................................................................................................................12/97 X ..... X......................................... Lift Cylinder TL Mast......................................................................01/98 ................................... 8.1-4220-025 .. X..... X ..................................... Lift Cylinder TL/TT Mast .............................................................................................................. 8.1-4220-050 .............................................................................................................................................................12/97 .. X..... X ..................................... Lift Cylinder TL/TT Mast ................................................................01/98 ................................... 8.1-4220-075 X ..... X......................................... Lift Cylinder TF Mast.................................................................................................................... 8.2-4220-002 .............................................................................................................................................................12/97 X ..... X......................................... Lift Cylinder TF Mast......................................................................01/98 ................................... 8.2-4220-025 .. X..... X ..................................... Lift Cylinder TF Mast.................................................................................................................... 8.2-4220-050 .............................................................................................................................................................12/97 .. X..... X ..................................... Lift Cylinder TF Mast......................................................................01/98 ................................... 8.2-4220-075 X ..... X......................................... Free lift cylinderTF Mast .............................................................................................................. 8.3-4220-002 X ..... X......................................... Free lift cylinderTF Mast .............................................................................................................. 8.3-4220-050 .. X..... X ..................................... Free lift cylinderTF/TT Mast ......................................................................................................... 8.4-4220-002 .............................................................................................................................................................12/97 X X..... X ..................................... Free lift cylinderTF/TT Mast ...........................................................01/98 ................................... 8.4-4220-050 SECTION 9 CABIN/PLATFORM X X..................................................... Platform .... (Option) .............................................................................................................. 9.0-4220-001 X X. X X ............................................ Covers................................................................................................................................... 9.3-4220-002 X X.....................................................Covers...... (Platform/Option)................................................................................................ 9.3-4220-025 SECTION 10 MISCELLANEOUS SERVICE INFORMATION X X. X X ..................................... Labels and Decals....................................................................................................................... 10.9-4220-002 X X.............................................. Labels and Decals (Platform/Option) .......................................................................................... 10.9-4220-025 IDX - 4220 - 006 IDX - 4220 - 006
Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 001 IDX - 4220 - 001 X .X X.X ...........................................Einleitung ............................................................................................................................ ITD-0000-001 X .X X.X ...........................................Allgemeine Wartungsanweisung ................................................................................. MA-0000-001 ABSCHNITT M1 Schmierung & Einstellung X .X X.X ...........................................Komponentenzugang ...................................................................................................... M1.0-4220-001 X .X X.X ................................................. Aufbocken des Fahrzeuges .......................................................................................... M1.0-4220-002 X .X X.X ...........................................Prüf- und Wartungsplan .................................................................................................. M1.1-4220-001 X .X X.X ................................................. Wartungsumfang ............................................................................................................ M1.1-4220-001 X .X X.X ................................................. Prüf-u. Wartungsplan 8Std. ............................................................................................ M1.1-4220-002 X .X X.X ................................................. Prüf-u. Wartungsplan 100Std. ........................................................................................ M1.1-4220-004 X .X X.X ................................................. Prüf-u. Wartungsplan 250/500 Std. ............................................................................... M1.1-4220-006 X .X X.X ................................................. Prüf-u. Wartungsplan 1000 Std. ..................................................................................... M1.1-4220-008 X .X X.X ...........................................Schmieren .......................................................................................................................... M1.2-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M1.2-4220-001 X .X X.X ................................................. Schmierpunkte ................................................................................................................ M1.2-4220-004 X .X X.X ...........................................Schmiermittel und Ölempfehlungen ........................................................................... M1.3-0000-001 X .X X.X ...........................................Anzugsmomente .............................................................................................................. M1.9-0000-001 ABSCHNITT M2 WARTUNG HYDRAULIK X .X X.X ...........................................Hydraulik Funktions- und Schaltzeichen ..................................................................... M2.0-0000-025 X .X X.X ...........................................Hydraulik System .............................................................................................................. M2.1-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M2.1-4220-001 X .X X.X ................................................. Hydrauliköltank ............................................................................................................... M2.1-4220-002 X .X X.X ................................................. Ventilblock ....................................................................................................................... M2.1-4220-005 X .X X.X ................................................. Hydraulikölpumpe ........................................................................................................... M2.1-4220-006 X .X X.X ................................................. Hydraulik System/Softlift ................................................................................................ M2.1-4220-025 X .X X.X ...........................................Hydraulikanlage ................................................................................................................. M2.7-4220-001 X .X X.X ................................................. Entlüften TL/TF und TT Mast .......................................................................................... M2.7-4220-001 ABSCHNITT M3 WARTUNG ANTRIEBSEINHEIT X .X X.X ...........................................Antriebseinheit ................................................................................................................. M3.0-4220-001 X .X X.X ................................................. Antriebsrad ..................................................................................................................... M3.0-4220-001 X .X X.X ................................................. Getriebe .......................................................................................................................... M3.0-4220-003 X .X X.X ................................................. Getriebe/ Instandsetzung ............................................................................................... M3.0-4220-004 X .X X.X ....................................................... Drehkranzlager ........................................................................................................ M3.0-4220-008 X .X X.X ...........................................Pendelschwinge ............................................................................................................... M3.9-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M3.9-4220-001 X .X X.X ...........................................Räder und Reifen .............................................................................................................. M3.9-4220-003 X .X X.X ................................................. Allgemeines .................................................................................................................... M3.9-4220-003 X .X X.X ................................................. Lastrad Singelachse ...................................................................................................... M3.9-4220-003 X .X X.X ................................................. Lastrad Tandemachse .................................................................................................... M3.9-4220-004 X .X X.X ................................................. Stützradlagerung ............................................................................................................ M3.9-4220-005 ABSCHNITT M4 WARTUNG ELEKTRIK X .X X.X .................................... Elektrische Grundlagen ......................................................................................................... M4.0-0000-001 X .X X.X ........................................... Farbschlüssel für Leitungen ................................................................................................ M4.0-0000-001 X .X X.X ........................................... Farbcode nach DIN 47100 .................................................................................................... M4.0-1710-002
Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM WE 1.25t WE 1.6t WS 1.35t WS 1.8t INHALTSVERZEICHNIS X .X X.X ........................................... Abkürzungsverzeichnis Schaltsymbole .............................................................................. M4.0-0000-003 X .X X.X ........................................... Elektrische Schaltsymbole .................................................................................................... M4.0-0000-005 X .X X.X ........................................... Motorsteuerung mit Pulsweitemodulation ............................................................................. M4.0-4220-006 X .X X.X .................................... Elektrische Komponenten .................................................................................................... M4.2-4220-001 X .X X.X ...........................................Schalter ................................................................................................................................. M4.2-4220-001 X .X X.X .................................... Fahrsteuerung ......................................................................................................................... M4.3-1710-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M4.3-1710-001 X .X X.X ........................................... Erklärung der einzelenen Funktionen ................................................................................... M4.3-1710-002 X .X X.X ........................................... Steuerleitungsanschlüsse .................................................................................................... M4.3-1710-007 X .X X.X ........................................... Bedienfeld ............................................................................................................................. M4.3-1710-008 X .X X.X ........................................... LED Codes ............................................................................................................................ M4.3-1710-009 X .X X.X ...........................................Wartung ................................................................................................................................ M4.3-1710-011 X .X X.X ........................................... Ausbau/Einbau ...................................................................................................................... M4.3-1710-012 X .X X.X ...........................................Sicherheitshinweise ............................................................................................................. M4.3-1710-013 X .X X.X ........................................... Prüfung Fahrsteuerung ........................................................................................................ M4.3-1710-014 X .X X.X .................................... Programmiergerät .................................................................................................................. M4.4-1710-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M4.4-1710-001 X .X X.X ........................................... Tastenerklärung .................................................................................................................... M4.4-1710-002 X .X X.X ........................................... Betriebsmenüs ...................................................................................................................... M4.4-1710-006 X .X X.X .................................... Einstellwerte und Fehlermeldungen für Fahrsteuerung .............................................. M4.5-4220-001 X ..... X................................................ Einstellwerte Fahrsteuerung ................................................................................................ M4.5-4220-001 ...X .....X ........................................... Einstellwerte Fahrsteuerung ................................................................................................ M4.5-4220-003 X .X X.X ........................................... Menüs Programmiergeräte.................................................................................................... M4.5-1710-005 X .X X.X ........................................... Testmenü ............................................................................................................................... M4.5-1710-006 X .X X.X ........................................... Diagnosemenü und Spezial Diagnosemenü ......................................................................... M4.5-1710-007 X .X X.X ........................................... Spezial Programmenü ........................................................................................................... M4.5-1710-008 X .X X.X ........................................... Fehlersuchanleitung ............................................................................................................. M4.5-1710-010 X .X X.X ........................................... Fehlerrückstellung ................................................................................................................ M4.5-1710-012 X .X X.X .................................... Batterieentladeanzeige/Betriebsstundenzähler ............................................................. M4.6-4220-001 X .X X.X .................................... Schlüsselschalter ................................................................................................................... M4.8-4220-001 X .X X.X ........................................... Ausbau/Einbau ...................................................................................................................... M4.8-4220-001 X .X X.X ...........................................Umkehrschutzschalter .......................................................................................................... M4.8-4220-002 X .X X.X ...........................................Fahrschalter .......................................................................................................................... M4.8-4220-002 X .X X.X ........................................... Schalter Heben/Senken ........................................................................................................ M4.8-4220-005 X .X X.X ...........................................Signalhornschalter ................................................................................................................ M4.8-4220-006 X .X X.X ...........................................Geschwindigkeitsbegrenzungsschalter .............................................................................. M4.8-4220-006 X .X X.X ...........................................Bremsschalter ....................................................................................................................... M4.8-4220-007 X .X X.X ...........................................Overrideschalter ................................................................................................................... M4.8-4220-009 X .X X.X ........................................... Not-Aus Schalter .................................................................................................................. M4.8-4220-010 X .X X.X .................................... Verteilerplatine ........................................................................................................................ M4.9-4220-001 X .X X.X .................................... Motoren ..................................................................................................................................... M4.10-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.10-4220-001 X ..... X................................................ Pumpenmotor ........................................................................................................................ M4.10-4220-002 X .X X.X ................................................. Aus-/Einbau .................................................................................................................... M4.10-4220-002 X .X X.X ................................................. Wartung/Instandsetzung ................................................................................................ M4.10-4220-003 X ..... X................................................ Pumpenmotor ........................................................................................................................ M4.10-4220-006 X .X X.X ........................................... Fahrmotor .............................................................................................................................. M4.10-4220-008 X .X X.X ................................................. Ausbau ........................................................................................................................... M4.10-4220-006 X .X X.X ................................................. Instandsetzung ............................................................................................................... M4.10-4220-007 X .X X.X ................................................. Einbau ............................................................................................................................. M4.10-4220-009 X .X X.X ................................................. Wartung .......................................................................................................................... M4.10-4220-009 X .X X.X .................................... Elektrotafel ............................................................................................................................... M4.11-4220-001 IDX - 4220 - 002 IDX - 4220 - 002
Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 003 IDX - 4220 - 003 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-001 X .X X.X .................................... Fahrrichtungsschütz .............................................................................................................. M4.11-4220-002 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-002 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.11-4220-002 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.11-4220-003 X .X X.X .................................... Hubschütz ................................................................................................................................. M4.11-4220-004 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-004 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.11-4220-004 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.11-4220-004 X .X X.X .................................... Baterrie ...................................................................................................................................... M4.12-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.12-4220-001 X .X X.X ........................................... Elektrolytstand (prüfen) ........................................................................................................ M4.12-4220-001 X .X X.X ........................................... Baterrie laden ........................................................................................................................ M4.12-4220-002 X .X X.X ...........................................Wartung ................................................................................................................................ M4.12-4220-004 X .X X.X .................................... Baterriesteckverbindung ...................................................................................................... M4.12-4220-005 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.12-4220-005 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.12-4220-005 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.12-4220-005 X .X X.X ...........................................Einbau.................................................................................................................................... M4.12-4220-006 X .X X.X .................................... Testverfahren (PMT) .............................................................................................................. M4.20-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.20-4220-001 ABSCHNITT M5 WARTUNG BREMSE X .X X.X .................................... Bremssystem .......................................................................................................................... M5.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M5.0-4220-001 X .X X.X ........................................... Einstellungen ......................................................................................................................... M5.0-4220-003 ABSCHNITT M6 WARTUNG LENKUNG X .X X.X .................................... Lenkung .................................................................................................................................... M6.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M6.0-4220-001 X .X X.X ........................................... Ausbau Lenkeinheit .............................................................................................................. M6.0-6220-002 X .X X.X ................................................. Kreuzgelenk .................................................................................................................... M6.0-4220-004 X .X X.X ...........................................Kettenspanner ...................................................................................................................... M6.0-4220-005 X .X X.X ........................................... Lenkkette ............................................................................................................................... M6.0-4220-006 ABSCHNITT M7 WARTUNG MAST X .X X.X .................................... Hubgerüst ................................................................................................................................. M7.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.0-4220-001 X .X X.X ........................................... Hubgerüst TL ........................................................................................................................ M7.0-4220-001 X .X X.X ........................................... Hubgerüst TF ........................................................................................................................ M7.0-4220-001 X .X X.X ........................................... Hubgerüst TT ........................................................................................................................ M7.0-4220-002 X .X X.X ...........................................Hubgerüstausbau/-einbau .................................................................................................... M7.0-4220-002 X .X X.X ...........................................Gabelträgerausbau/-einbau ................................................................................................. M7.0-4220-003 X .X X.X ........................................... Wartung/Mast ........................................................................................................................ M7.0-4220-004 X .X X.X ................................................. Rollbahnen fetten ........................................................................................................... M7.0-4220-004 X .X X.X ................................................. Rollen ausbau ................................................................................................................. M7.0-4220-005 X .X X.X .................................... Hubkettenprüfung .................................................................................................................. M7.5-0000-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.5-0000-001 X .X X.X ........................................... Schmieren ............................................................................................................................. M7.5-0000-001 X .X X.X ........................................... Schäden erkennen ............................................................................................................... M7.5-0000-002 X .X X.X .................................... Gabelzinkenprüfung ............................................................................................................... M7.8-0000-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.8-0000-001 X .X X.X ........................................... Gabelkennzeichnung ............................................................................................................ M7.8-0000-001
Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM WE 1.25t WE 1.6t WS 1.35t WS 1.8t INHALTSVERZEICHNIS X .X X.X ........................................... Reperaturen .......................................................................................................................... M7.8-0000-002 ABSCHNITT M8 WARTUNG ZYLINDER X .X X.X .................................... Zylinder...................................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Simplexzylinder ..................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Hubzylinder ........................................................................................................................... M8.0-4220-002 X .X X.X ........................................... Ausbau / Einbau von Stangendichtungen ............................................................................ M8.0-0000-003 ABSCHNITT M9 WARTUNG VERKLEIDUNGEN X .X X.X .................................... Verkleidungen ......................................................................................................................... M9.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M9.0-4220-001 X .X X.X ...........................................Abdeckhaube ........................................................................................................................ M9.0-4220-001 X .X X.X ........................................... Batteriedeckel ....................................................................................................................... M9.0-4220-001 ABSCHNITT DIA SCHALTPLAN X .X X.X .................................... Schaltplan .................................................................................................................................. DIA-4220-001X X .X X.X ........................................... Blockdiagramm ...................................................................................................................... DIA-4220-001X X .X X.X ........................................... Verteilerplatine ...................................................................................................................... DIA-4220-002X X .X X.X ........................................... Deichsel- und Kombiinstrument ............................................................................................ DIA-4220-003X X .X X.X ........................................... Fahrsteuerung Curtis ............................................................................................................ DIA-4220-004X X .X X.X ........................................... Bremse und Ladegerät ......................................................................................................... DIA-4220-005X X .X X.X .................................... Schaltplan Softlift .................................................................................................................... DIA-4220-025X X .X X.X ........................................... Blockdiagramm ...................................................................................................................... DIA-4220-025X X .X X.X ........................................... Verteilerplatine ...................................................................................................................... DIA-4220-026X X .X X.X ........................................... Deichsel- und Kombiinstrument ............................................................................................ DIA-4220-027X X .X X.X ........................................... Fahrsteuerung Curtis ............................................................................................................ DIA-4220-028X X .X X.X ........................................... Bremse und Ladegerät ......................................................................................................... DIA-4220-029X X .X X.X ........................................... Proportional-Steuerung ......................................................................................................... DIA-4220-030X ABSCHNITT HYD HYDRAULIK SCHEMA X .X X.X .................................... Hydraulik Schema.................................................................................................................... HYD-4220-001 X .X X.X ...........................................Simplex .................................................................................................................................. HYD-4220-001 X .X X.X ........................................... Duplex ................................................................................................................................... HYD-4220-002 X .X X.X ........................................... Triplex.................................................................................................................................... HYD-4220-002 X .X X.X ...........................................Simplex .................................................................................................................................. HYD-4220-003 X .X X.X ........................................... Duplex ................................................................................................................................... HYD-4220-004 X .X X.X ........................................... Triplex.................................................................................................................................... HYD-4220-004 ABSCHNITT WZ WERKZEUGE X .X X.X .................................... Werkzeug .................................................................................................................................. WZ-4220-001 IDX - 4220 - 004 IDX - 4220 - 004
Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t ABSCHNITT 1 RAHMEN- / ABDECKUNGSTEILE X .X ............................................. Rahmen mit Pendelschwinge ...................................................................................................... 1.0-4220-002 ....... X.X .................................... Rahmen mit Pendelschwinge ...................................................................................................... 1.0-4220-050 X .X X.X .................................... Räder ........................................................................................................................................... 1.5-4220-002 ABSCHNITT 2 HYDRAULIKTEILE X ..... X......................................... Hydraulikaggregat ....................................................................................................................... 2.1-4220-002 X ..... X......................................... Hydraulikaggregat (Softlift) ......................................................................................................... 2.1-4220-025 ...X .....X .................................... Hydraulikaggregat ....................................................................................................................... 2.1-4220-050 ...X .....X .................................... Hydraulikaggregat (Softlift) ......................................................................................................... 2.1-4220-075 X .X X.X .................................... Hydrauliktank ............................................................................................................................... 2.2-4220-001 X .X X.X .................................... Hydrauliktank .. (Softlift) .............................................................................................................. 2.2-4220-025 X ..... X......................................... Steuerventil .................................................................................................................................. 2.3-4220-002 ...X .....X .................................... Steuerventil .................................................................................................................................. 2.3-4220-050 X ..... X......................................... Hydraulik TL Mast ........................................................................................................................ 2.4-4220-002 ...X .....X .................................... Hydraulik TL Mast ........................................................................................................................ 2.4-4220-050 X ..... X......................................... Hydraulik TF Mast ........................................................................................................................ 2.6-4220-002 ...X .....X .................................... Hydraulik TF Mast ........................................................................................................................ 2.6-4220-050 ...X .....X .................................... Hydraulik TT Mast ........................................................................................................................ 2.8-4220-002 X ..... X......................................... Pumpmotor ................................................................................................................................... 2.9-4220-002 ...X .....X .................................... Pumpmotor ................................................................................................................................... 2.9-4220-050 ABSCHNITT 3 TEILE DER ANTRIEBSEINHEIT X .X X.X .................................... Antriebseinheit ............................................................................................................................ 3.0-4220-002 X .X X.X .................................... Getriebe ....................................................................................................................................... 3.1-4220-002 X .X X.X .................................... Fahrmotor .................................................................................................................................... 3.2-4220-002 X .X X.X .................................... Deichsellagerung ......................................................................................................................... 3.3-4220-002 X .X X.X .................................... Deichsellagerung (Plattform) ....................................................................................................... 3.3-4220-025 ABSCHNITT 4 ELEKTROTEILE X .X X.X .................................... Elektrik .......................................................................................................................................... 4.0-4220-002 .............................................................................................................................................................12/96 X .X X.X .................................... Elektrik ............................................................................................01/97 ................................... 4.0-4220-025 X .X X.X .................................... Elektrik .......................................................................................................................................... 4.0-4220-050 .............................................................................................................................................................12/96 X .X X.X .................................... Elektrik ............................................................................................01/97 ................................... 4.0-4220-075 X .X X.X .................................... Pumpschütz ................................................................................................................................. 4.4-4220-002 X .X X.X .................................... Fahrschütz .................................................................................................................................. 4.4-4220-050 X .X X.X .................................... Deichsel ....................................................................................................................................... 4.5-1710-002 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel .........................................................................................09/98 ................................... 4.5-1710-025 X .X X.X .................................... Deichsel ... (Griff) ....................................................................................................................... 4.5-1710-050 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Griff) .........................................................................09/98 ................................... 4.5-1710-075 X .X X.X .................................... Deichsel ... (Kappe) .................................................................................................................... 4.5-1710-100 X .X X.X .................................... Deichsel ... (Kühlhaus)................................................................................................................ 4.5-1710-125 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Kühlhaus)..................................................................09/98 ................................... 4.5-1710-150 X .X X.X .................................... Deichsel ... (Griff/Kühlhaus) ....................................................................................................... 4.5-1710-175 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Griff/Kühlhaus) .........................................................09/98 ................................... 4.5-1710-200 X .X X.X .................................... Deichsel ... (Kappe/Kühlhaus) .................................................................................................... 4.5-1710-225 X .X X.X .................................... Batterie/Ladegerät ....................................................................................................................... 4.8-4220-002 .............................................................................................................................................................W-5-3411 X .X X.X .................................... Batterie/Ladegerät .........................................................................W-5-3412 ............................ 4.8-4220-025 X .X X.X .................................... Not-Aus ....................................................................................................................................... 4.9-4220-002 IDX - 4220 - 005 IDX - 4220 - 005
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf
Crown WS2000 Series Forklift Service Repair Manual.pdf

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Crown WS2000 Series Forklift Service Repair Manual.pdf

  • 1. Service and Parts Manual Wartungs- und Ersatzteilhandbuch Manuel de maintenance et de pièces detachées Series WE/WS
  • 2. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 001 IDX - 4220 - 001 X X. X X ..................................... Introduction .............................................................................................................................. ITD-0000-001 X X. X X ..................................... General maintenance instruction ........................................................................................ MA-0000-001 SECTION M1 LUBRICATION AND ADJUSTMENT X X. X X ..................................... Component access ................................................................................................................ M1.0-4220-001 X X. X X ............................................ Raising the truck ................................................................................................................... M1.0-4220-002 X X. X X ..................................... Inspection and maintenance plan ....................................................................................... M1.1-4220-001 X X. X X ............................................ Service scope ....................................................................................................................... M1.1-4220-001 X X. X X ............................................ Inspection and maintenance plan 8 hrs. ............................................................................. M1.1-4220-002 X X. X X ............................................ Inspection and maintenance plan 100 hrs. ......................................................................... M1.1-4220-004 X X. X X ............................................ Inspection and maintenance plan 250/500 hrs. .................................................................. M1.1-4220-006 X X. X X ............................................ Inspection and maintenance plan 1000 hrs. ....................................................................... M1.1-4220-008 X X. X X ..................................... Lubrication ................................................................................................................................ M1.2-4220-001 X X. X X ............................................ General.................................................................................................................................. M1.2-4220-001 X X. X X ............................................ Lubrication points ................................................................................................................. M1.2-4220-006 X X. X X ..................................... Lubricants and oil recommendations table ..................................................................... M1.3-0000-001 X X. X X ..................................... Torque values .......................................................................................................................... M1.9-0000-001 SECTION M2 HYDRAULIC MAINTENANCE X X. X X ..................................... Hydraulic schematic symbols .............................................................................................. M2.0-0000-001 X X. X X ..................................... Hydraulic system ..................................................................................................................... M2.1-4220-001 X X. X X ............................................ General.................................................................................................................................. M2.1-4220-001 X X. X X ............................................ Hydraulic oil tank ................................................................................................................... M2.1-4220-002 X X. X X ............................................ Valve block ............................................................................................................................ M2.1-4220-005 X X. X X ............................................ Hydraulic oil pump ................................................................................................................. M2.1-4220-006 X X. X X ............................................ Hydraulic system/softlift ....................................................................................................... M2.1-4220-025 X X. X X ..................................... Hydraulic system ..................................................................................................................... M2.7-4220-001 X X. X X ............................................ Ventilate TL/TF and TT Mast ................................................................................................. M2.7-4220-001 SECTION M3 DRIVE UNIT MAINTENANCE X X. X X ..................................... Drive Unit ................................................................................................................................... M3.0-4220-001 X X. X X ............................................ Drive wheel ........................................................................................................................... M3.0-4220-001 X X. X X ............................................ Gearbox ................................................................................................................................ M3.0-4220-003 X X. X X ............................................ Gearbox/Repair..................................................................................................................... M3.0-4220-004 X X. X X .................................................. Turntable bearing ........................................................................................................... M3.0-4220-008 X X. X X ..................................... Pivoting carriage...................................................................................................................... M3.9-4220-001 X X. X X ............................................ General.................................................................................................................................. M3.9-4220-001 X X. X X ..................................... Wheels and Tyres.................................................................................................................... M3.9-4220-003 X X. X X ............................................ General.................................................................................................................................. M3.9-4220-003 X X. X X ............................................ Load wheel, single axle ........................................................................................................ M3.9-4220-003 X X. X X ............................................ Load wheel, tandem axle ..................................................................................................... M3.9-4220-004 X X. X X ............................................ Support wheel mounting....................................................................................................... M3.9-4220-005 SECTION M4 ELECTRICAL MAINTENANCE X X. X X ..................................... Basic electrics .......................................................................................................................... M4.0-0000-001 X X. X X ............................................ Wiring colour code ................................................................................................................ M4.0-0000-001 X X. X X ............................................ Colour coding in accordance with DIN 47100...................................................................... M4.0-1710-002
  • 3. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 002 IDX - 4220 - 002 X X. X X ............................................ Index of abbreviations switch symbols ............................................................................... M4.0-0000-003 X X. X X ............................................ Typical electrical symbols ..................................................................................................... M4.0-0000-005 X X. X X ............................................ Transistor control with pulse width modulation ................................................................... M4.0-4220-006 X X. X X ..................................... Electrical components ........................................................................................................... M4.2-4220-001 X X. X X ............................................ Switches ............................................................................................................................... M4.2-4220-001 X X. X X ..................................... Controller ................................................................................................................................. M4.3-1710-001 X X. X X ............................................ General.................................................................................................................................. M4.3-1710-001 X X. X X ............................................ Explanation of function ......................................................................................................... M4.3-1710-002 X X. X X ............................................ Pilot wire pins ........................................................................................................................ M4.3-1710-007 X X. X X ............................................ Adjustment panel .................................................................................................................. M4.3-1710-008 X X. X X ............................................ LED Codes ............................................................................................................................ M4.3-1710-009 X X. X X ............................................ Maintenance .......................................................................................................................... M4.3-1710-011 X X. X X ............................................ Removal / installation ............................................................................................................ M4.3-1710-012 X X. X X ............................................ Safety instruction ................................................................................................................. M4.3-1710-013 X X. X X ............................................ Controler check..................................................................................................................... M4.3-1710-014 X X. X X ..................................... Programmer ............................................................................................................................. M4.4-1710-001 X X. X X ............................................ General.................................................................................................................................. M4.4-1710-001 X X. X X ............................................ Keypad definition .................................................................................................................. M4.4-1710-002 X X. X X ............................................ Operationg modes ................................................................................................................ M4.4-1710-006 X X. X X ..................................... Values and fault codes for Controller ................................................................................ M4.5-4220-001 X ..... X................................................ Controller settings ................................................................................................................. M4.5-4220-001 .. X..... X ............................................ Controller settings ................................................................................................................. M4.5-4220-003 X X. X X ............................................ Program menu ....................................................................................................................... M4.5-1710-005 X X. X X ............................................ Test menu .............................................................................................................................. M4.5-1710-006 X X. X X ............................................ Diagnostic and special diagnostic menu .............................................................................. M4.5-1710-007 X X. X X ............................................ Special program menu .......................................................................................................... M4.5-1710-008 X X. X X ............................................ Trouble shooting chart .......................................................................................................... M4.5-1710-009 X X. X X ............................................ Fault recovery ....................................................................................................................... M4.5-1710-012 X X. X X ..................................... Battery level indicator/Operationg hours counter........................................................... M4.6-4220-001 X X. X X ..................................... Key Switch ................................................................................................................................ M4.8-4220-001 X X. X X ............................................ Disassembly/Assembly ........................................................................................................ M4.8-4220-001 X X. X X ............................................ Reverse safety switch ......................................................................................................... M4.8-4220-002 X X. X X ............................................ Drive switch .......................................................................................................................... M4.8-4220-002 X X. X X ............................................ Switch raise/lower ............................................................................................................... M4.8-4220-005 X X. X X ............................................ Horn switch .......................................................................................................................... M4.8-4220-006 X X. X X ............................................ Speed limiter switch .............................................................................................................. M4.8-4220-006 X X. X X ............................................ Brake switch ......................................................................................................................... M4.8-4220-007 X X. X X ............................................ Override switch .................................................................................................................... M4.8-4220-009 X X. X X ............................................ Emergency off switch .......................................................................................................... M4.8-4220-010 X X. X X ............................................ Distributor board .............................................................................................................. M4.9-4220-001 X X. X X ............................................ Motor ................................................................................................................................... M4.10-4220-001 X X. X X .................................................. General ........................................................................................................................... M4.10-4220-001 X ..... X...................................................... Pump motor ..................................................................................................................... M4.10-4220-002 X X. X X ........................................................ Disassembly/Assembly ........................................................................................... M4.10-4220-002 X X. X X ........................................................ Maintenance/Repair ................................................................................................. M4.10-4220-003 .. X..... X ........................................................ Pump motor............................................................................................................... M4.10-4220-006 X X. X X .................................................. Drive motor ..................................................................................................................... M4.10-4220-008 X X. X X ........................................................ Disassembly ............................................................................................................. M4.10-4220-006 X X. X X ........................................................ Repair ....................................................................................................................... M4.10-4220-007 X X. X X ........................................................ Assembly ................................................................................................................. M4.10-4220-009 X X. X X ........................................................ Maintenance ............................................................................................................. M4.10-4220-009 X X. X X ............................................ Electrics panel ................................................................................................................... M4.11-4220-001 X X. X X .................................................. General ........................................................................................................................... M4.11-4220-001
  • 4. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t X X. X X ..................................... Direction of contactor ............................................................................................................. M4.11-4220-002 X X. X X ............................................ General.................................................................................................................................. M4.11-4220-002 X X. X X ............................................ Disassembly .......................................................................................................................... M4.11-4220-002 X X. X X ............................................ Repairs .................................................................................................................................. M4.11-4220-003 X X. X X ..................................... Pump contactor ....................................................................................................................... M4.11-4220-004 X X. X X ............................................ General.................................................................................................................................. M4.11-4220-004 X X. X X ............................................ Disassembly .......................................................................................................................... M4.11-4220-004 X X. X X ............................................ Repairs .................................................................................................................................. M4.11-4220-004 X X. X X ..................................... Battery ........................................................................................................................................ M4.12-4220-001 X X. X X ............................................ General.................................................................................................................................. M4.12-4220-001 X X. X X ............................................ Checking the electrolyte level ............................................................................................... M4.12-4220-001 X X. X X ............................................ Charging the battery ............................................................................................................. M4.12-4220-002 X X. X X ............................................ Maintenance .......................................................................................................................... M4.12-4220-004 X X. X X ..................................... Battery connections ............................................................................................................... M4.12-4220-005 X X. X X ............................................ General.................................................................................................................................. M4.12-4220-005 X X. X X ............................................ Disassembly .......................................................................................................................... M4.12-4220-005 X X. X X ............................................ Repairs .................................................................................................................................. M4.12-4220-005 X X. X X ............................................ Assembly .............................................................................................................................. M4.12-4220-006 X X. X X ..................................... Test procedures (PMT) .......................................................................................................... M4.20-4220-001 X X. X X ............................................ General.................................................................................................................................. M4.20-4220-001 SECTION M5 BRAKE MAINTENANCE X X. X X ..................................... Brakes system ........................................................................................................................ M5.0-4220-001 X X. X X ............................................ Genral.................................................................................................................................... M5.0-4220-001 X X. X X ............................................ Setting ................................................................................................................................... M5.0-4220-003 SECTION M6 STEERING MAINTENANCE X X. X X ..................................... Steering ..................................................................................................................................... M6.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M6.0-4220-001 X X. X X ............................................ Removal of control handle .................................................................................................... M6.0-4220-002 X X. X X .................................................. Cross joint ....................................................................................................................... M6.0-4220-004 X X. X X ............................................ Chain tensioning device ........................................................................................................ M6.0-4220-005 X X. X X ............................................ Steering chain ....................................................................................................................... M6.0-4220-006 SECTION M7 MAST MAINTENANCE X X. X X ..................................... Mast ............................................................................................................................................ M7.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TL Mast.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TF Mast.................................................................................................................................. M7.0-4220-001 X X. X X ............................................ TT Mast.................................................................................................................................. M7.0-4220-002 X X. X X ............................................ Mast disassembly/assembly ................................................................................................ M7.0-4220-002 X X. X X ............................................ Fork carriage disassembly/assembly .................................................................................. M7.0-4220-003 X X. X X ............................................ Mast maintenance ................................................................................................................. M7.0-4220-004 X X. X X .................................................. Greasing roller tracks ..................................................................................................... M7.0-4220-004 X X. X X .................................................. Roller disassembly ......................................................................................................... M7.0-4220-005 X X. X X ..................................... Lift chain inspection ............................................................................................................... M7.5-0000-001 X X. X X ............................................ General.................................................................................................................................. M7.5-0000-001 X X. X X ............................................ Lubrication ............................................................................................................................ M7.5-0000-001 X X. X X ............................................ Identifying damages .............................................................................................................. M7.5-0000-002 X X. X X ..................................... Gabelzinkenprüfung ............................................................................................................... M7.8-0000-001 X X. X X ............................................ General.................................................................................................................................. M7.8-0000-001 X X. X X ............................................ Fork identification .................................................................................................................. M7.8-0000-001 IDX - 4220 - 003 IDX - 4220 - 003
  • 5. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 004 IDX - 4220 - 004 X X. X X ............................................ Repairs .................................................................................................................................. M7.8-0000-002 SECTION M8 CYLINDER MAINTENANCE X X. X X ..................................... Cylinder ..................................................................................................................................... M8.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M8.0-4220-001 X X. X X ............................................ Simplex mast cylinder ........................................................................................................... M8.0-4220-001 X X. X X ............................................ Lifting cylinder ....................................................................................................................... M8.0-4220-002 SECTION M9 COVERS X X. X X ..................................... Panels/Covers .......................................................................................................................... M9.0-4220-001 X X. X X ............................................ General.................................................................................................................................. M9.0-4220-001 X X. X X ............................................ Protective cover.................................................................................................................... M9.0-4220-001 X X. X X ............................................ Battery cover ........................................................................................................................ M9.0-4220-001 X X. X X ............................................ Nuckle cover ......................................................................................................................... M9.0-4220-002 SECTION DIA WIRING DIAGRAMS X X. X X ..................................... Electrical diagrams ................................................................................................................. DIA-4220-001X X X. X X ............................................ Schematic ............................................................................................................................. DIA-4220-001X X X. X X ............................................ Distribution panel................................................................................................................... DIA-4220-002X X X. X X ............................................ Handle and BDI ...................................................................................................................... DIA-4220-003X X X. X X ............................................ Traction controller ................................................................................................................. DIA-4220-004X X X. X X ............................................ Brake/Option: charger .......................................................................................................... DIA-4220-005X X X. X X ..................................... Electrical diagrams ................................................................................................................. DIA-4220-025X X X. X X ............................................ Schematic ............................................................................................................................. DIA-4220-025X X X. X X ............................................ Distribution panel................................................................................................................... DIA-4220-026X X X. X X ............................................ Handle and BDI ...................................................................................................................... DIA-4220-027X X X. X X ............................................ Traction controller ................................................................................................................. DIA-4220-028X X X. X X ............................................ Brake/Option: charger .......................................................................................................... DIA-4220-029X X X. X X ............................................ Propotional electronic ........................................................................................................... DIA-4220-030X SECTION HYD HYDRAULIC SCHEMATICS X X. X X ..................................... Hydraulck Schematic .............................................................................................................. HYD-4220-001 X X. X X ............................................ Simplex .................................................................................................................................. HYD-4220-001 X X. X X ............................................ Duplex ................................................................................................................................... HYD-4220-002 X X. X X ............................................ Triplex.................................................................................................................................... HYD-4220-002 X X. X X ............................................ Simplex .................................................................................................................................. HYD-4220-003 X X. X X ............................................ Duplex ................................................................................................................................... HYD-4220-004 X X. X X ............................................ Triplex.................................................................................................................................... HYD-4220-004 SECTION WZ TOOLS X X. X X ..................................... Tools ........................................................................................................................................... WZ -4220-001
  • 6. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDON NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t SECTION 1 POWER UNIT PARTS / COVERS X X.............................................. Frame with pivoting carriag ........................................................................................................ 1.0-4220-002 ....... X X ..................................... Frame with pivoting carriag ........................................................................................................ 1.0-4220-050 X X. X X ..................................... Wheels ......................................................................................................................................... 1.5-4220-002 SECTION 2 HYDRAULIC PARTS X ..... X......................................... Hydraulic power unit ................................................................................................................... 2.1-4220-002 X ..... X......................................... Hydraulic power unit (Softlift)..................................................................................................... 2.1-4220-025 .. X..... X ..................................... Hydraulic power unit ................................................................................................................... 2.1-4220-050 .. X..... X ..................................... Hydraulic power unit (Softlift)..................................................................................................... 2.1-4220-075 X X. X X ..................................... Hydraulic tank .............................................................................................................................. 2.2-4220-001 X X. X X ..................................... Hydraulic tank . (Softlift) .............................................................................................................. 2.2-4220-025 X ..... X......................................... Control valve ............................................................................................................................... 2.3-4220-002 .. X..... X ..................................... Control valve ............................................................................................................................... 2.3-4220-050 X ..... X......................................... Hydraulic TL Mast ........................................................................................................................ 2.4-4220-002 .. X..... X ..................................... Hydraulic TL Mast ........................................................................................................................ 2.4-4220-050 X ..... X......................................... Hydraulic TF Mast ........................................................................................................................ 2.6-4220-002 .. X..... X ..................................... Hydraulic TF Mast ........................................................................................................................ 2.6-4220-050 .. X..... X ..................................... Hydraulic TT Mast ........................................................................................................................ 2.8-4220-002 X ..... X......................................... Pump and Motor ........................................................................................................................... 2.9-4220-002 .. X..... X ..................................... Pump and Motor ........................................................................................................................... 2.9-4220-050 SECTION 3 DRIVE UNIT PARTS X X. X X ..................................... Drive unit ...................................................................................................................................... 3.0-4220-002 X X. X X ..................................... Gearbox ....................................................................................................................................... 3.1-4220-002 X X. X X ..................................... Drive motor .................................................................................................................................. 3.2-4220-002 X X. X X ..................................... Knuckel ........................................................................................................................................ 3.3-4220-002 X X. X X ..................................... Knuckel .... (Platform) .................................................................................................................. 3.3-4220-025 SECTION 4 ELECTRICAL PARTS X X. X X ..................................... Electrical parts ............................................................................................................................. 4.0-4220-002 .............................................................................................................................................................12/96 X X. X X ..................................... Electrical parts ...............................................................................01/97 ................................... 4.0-4220-025 X X. X X ..................................... Electrical parts ............................................................................................................................. 4.0-4220-050 .............................................................................................................................................................12/96 X X. X X ..................................... Electrical parts ...............................................................................01/97 ................................... 4.0-4220-075 X X. X X ..................................... Pump contactor ........................................................................................................................... 4.4-4220-002 X X. X X ..................................... Contactor ..................................................................................................................................... 4.4-2130-050 X X. X X ..................................... Control handle ............................................................................................................................. 4.5-1710-002 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle ...............................................................................09/98 ................................... 4.5-1710-025 X X. X X ..................................... Control handle (Grip) .................................................................................................................. 4.5-1710-050 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Grip) ....................................................................09/98 ................................... 4.5-1710-075 X X. X X ..................................... Control handle (Hup cap) ........................................................................................................... 4.5-1710-100 X X. X X ..................................... Control handle (Freezer/Corrosion) .......................................................................................... 4.5-1710-125 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Freezer/Corrosion) ............................................09/98 ................................... 4.5-1710-150 X X. X X ..................................... Control handle (Grip/Freezer) .................................................................................................... 4.5-1710-175 .............................................................................................................................................................08/98 X X. X X ..................................... Control handle (Grip/Freezer) ......................................................09/98 ................................... 4.5-1710-200 X X. X X ..................................... Control handle (Hup cap/Freezer) ............................................................................................. 4.5-1710-225 X X. X X ..................................... Powerpack .................................................................................................................................. 4.8-4220-002 .............................................................................................................................................................W-5-3411 X X. X X ..................................... Powerpack ....................................................................................W-5-3412 ............................ 4.8-4220-025 X X. X X ..................................... Emergency Stop .......................................................................................................................... 4.9-4220-002 IDX - 4220 - 005 IDX - 4220 - 005
  • 7. Printed in Germany REVISION DESCRIPTION SERIAL NUMBER PAGE OF UNITS IDENTIFICATION USEDFOR NUMBER NUMBER FROM: DATE DATE TO: DATE INDEX WE 1.25t WE 1.6t WS 1.35t WS 1.8t SECTION 5 BRAKE PARTS X ..... X......................................... Brake ........................................................................................................................................... 5.3-4220-004 .. X..... X ..................................... Brake ........................................................................................................................................... 5.3-4220-006 SECTION 6 STEERING X X. X X ..................................... Drive unit parts ............................................................................................................................ 6.0-4220-004 SECTION 7 MAST / LIFT STRUCTURE PARTS X ..... X......................................... TL Mast ........................................................................................................................................ 7.1-4220-002 .. X..... X ..................................... TL Mast ........................................................................................................................................ 7.1-4220-052 X ..... X......................................... TF Mast ........................................................................................................................................ 7.3-4220-002 .. X..... X ..................................... TF Mast ........................................................................................................................................ 7.3-4220-050 .. X..... X ..................................... TT Mast ........................................................................................................................................ 7.5-4220-002 ....... X......................................... Fork Carriage ............................................................................................................................... 7.6-4220-002 ........... X ..................................... Fork Carriage ............................................................................................................................... 7.6-4220-050 X .................................................. Fork Carriage ............................................................................................................................... 7.6-4220-100 .. X.............................................. Fork Carriage ............................................................................................................................... 7.6-4220-102 X X. X X ..................................... Load backrest ............................................................................................................................. 7.9-4220-002 SECTION 8 CYLINDER PARTS X ..... X......................................... Lift Cylinder TL Mast.................................................................................................................... 8.1-4220-001 .............................................................................................................................................................12/97 X ..... X......................................... Lift Cylinder TL Mast......................................................................01/98 ................................... 8.1-4220-025 .. X..... X ..................................... Lift Cylinder TL/TT Mast .............................................................................................................. 8.1-4220-050 .............................................................................................................................................................12/97 .. X..... X ..................................... Lift Cylinder TL/TT Mast ................................................................01/98 ................................... 8.1-4220-075 X ..... X......................................... Lift Cylinder TF Mast.................................................................................................................... 8.2-4220-002 .............................................................................................................................................................12/97 X ..... X......................................... Lift Cylinder TF Mast......................................................................01/98 ................................... 8.2-4220-025 .. X..... X ..................................... Lift Cylinder TF Mast.................................................................................................................... 8.2-4220-050 .............................................................................................................................................................12/97 .. X..... X ..................................... Lift Cylinder TF Mast......................................................................01/98 ................................... 8.2-4220-075 X ..... X......................................... Free lift cylinderTF Mast .............................................................................................................. 8.3-4220-002 X ..... X......................................... Free lift cylinderTF Mast .............................................................................................................. 8.3-4220-050 .. X..... X ..................................... Free lift cylinderTF/TT Mast ......................................................................................................... 8.4-4220-002 .............................................................................................................................................................12/97 X X..... X ..................................... Free lift cylinderTF/TT Mast ...........................................................01/98 ................................... 8.4-4220-050 SECTION 9 CABIN/PLATFORM X X..................................................... Platform .... (Option) .............................................................................................................. 9.0-4220-001 X X. X X ............................................ Covers................................................................................................................................... 9.3-4220-002 X X.....................................................Covers...... (Platform/Option)................................................................................................ 9.3-4220-025 SECTION 10 MISCELLANEOUS SERVICE INFORMATION X X. X X ..................................... Labels and Decals....................................................................................................................... 10.9-4220-002 X X.............................................. Labels and Decals (Platform/Option) .......................................................................................... 10.9-4220-025 IDX - 4220 - 006 IDX - 4220 - 006
  • 8. Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 001 IDX - 4220 - 001 X .X X.X ...........................................Einleitung ............................................................................................................................ ITD-0000-001 X .X X.X ...........................................Allgemeine Wartungsanweisung ................................................................................. MA-0000-001 ABSCHNITT M1 Schmierung & Einstellung X .X X.X ...........................................Komponentenzugang ...................................................................................................... M1.0-4220-001 X .X X.X ................................................. Aufbocken des Fahrzeuges .......................................................................................... M1.0-4220-002 X .X X.X ...........................................Prüf- und Wartungsplan .................................................................................................. M1.1-4220-001 X .X X.X ................................................. Wartungsumfang ............................................................................................................ M1.1-4220-001 X .X X.X ................................................. Prüf-u. Wartungsplan 8Std. ............................................................................................ M1.1-4220-002 X .X X.X ................................................. Prüf-u. Wartungsplan 100Std. ........................................................................................ M1.1-4220-004 X .X X.X ................................................. Prüf-u. Wartungsplan 250/500 Std. ............................................................................... M1.1-4220-006 X .X X.X ................................................. Prüf-u. Wartungsplan 1000 Std. ..................................................................................... M1.1-4220-008 X .X X.X ...........................................Schmieren .......................................................................................................................... M1.2-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M1.2-4220-001 X .X X.X ................................................. Schmierpunkte ................................................................................................................ M1.2-4220-004 X .X X.X ...........................................Schmiermittel und Ölempfehlungen ........................................................................... M1.3-0000-001 X .X X.X ...........................................Anzugsmomente .............................................................................................................. M1.9-0000-001 ABSCHNITT M2 WARTUNG HYDRAULIK X .X X.X ...........................................Hydraulik Funktions- und Schaltzeichen ..................................................................... M2.0-0000-025 X .X X.X ...........................................Hydraulik System .............................................................................................................. M2.1-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M2.1-4220-001 X .X X.X ................................................. Hydrauliköltank ............................................................................................................... M2.1-4220-002 X .X X.X ................................................. Ventilblock ....................................................................................................................... M2.1-4220-005 X .X X.X ................................................. Hydraulikölpumpe ........................................................................................................... M2.1-4220-006 X .X X.X ................................................. Hydraulik System/Softlift ................................................................................................ M2.1-4220-025 X .X X.X ...........................................Hydraulikanlage ................................................................................................................. M2.7-4220-001 X .X X.X ................................................. Entlüften TL/TF und TT Mast .......................................................................................... M2.7-4220-001 ABSCHNITT M3 WARTUNG ANTRIEBSEINHEIT X .X X.X ...........................................Antriebseinheit ................................................................................................................. M3.0-4220-001 X .X X.X ................................................. Antriebsrad ..................................................................................................................... M3.0-4220-001 X .X X.X ................................................. Getriebe .......................................................................................................................... M3.0-4220-003 X .X X.X ................................................. Getriebe/ Instandsetzung ............................................................................................... M3.0-4220-004 X .X X.X ....................................................... Drehkranzlager ........................................................................................................ M3.0-4220-008 X .X X.X ...........................................Pendelschwinge ............................................................................................................... M3.9-4220-001 X .X X.X ................................................. Allgemeines .................................................................................................................... M3.9-4220-001 X .X X.X ...........................................Räder und Reifen .............................................................................................................. M3.9-4220-003 X .X X.X ................................................. Allgemeines .................................................................................................................... M3.9-4220-003 X .X X.X ................................................. Lastrad Singelachse ...................................................................................................... M3.9-4220-003 X .X X.X ................................................. Lastrad Tandemachse .................................................................................................... M3.9-4220-004 X .X X.X ................................................. Stützradlagerung ............................................................................................................ M3.9-4220-005 ABSCHNITT M4 WARTUNG ELEKTRIK X .X X.X .................................... Elektrische Grundlagen ......................................................................................................... M4.0-0000-001 X .X X.X ........................................... Farbschlüssel für Leitungen ................................................................................................ M4.0-0000-001 X .X X.X ........................................... Farbcode nach DIN 47100 .................................................................................................... M4.0-1710-002
  • 9. Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM WE 1.25t WE 1.6t WS 1.35t WS 1.8t INHALTSVERZEICHNIS X .X X.X ........................................... Abkürzungsverzeichnis Schaltsymbole .............................................................................. M4.0-0000-003 X .X X.X ........................................... Elektrische Schaltsymbole .................................................................................................... M4.0-0000-005 X .X X.X ........................................... Motorsteuerung mit Pulsweitemodulation ............................................................................. M4.0-4220-006 X .X X.X .................................... Elektrische Komponenten .................................................................................................... M4.2-4220-001 X .X X.X ...........................................Schalter ................................................................................................................................. M4.2-4220-001 X .X X.X .................................... Fahrsteuerung ......................................................................................................................... M4.3-1710-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M4.3-1710-001 X .X X.X ........................................... Erklärung der einzelenen Funktionen ................................................................................... M4.3-1710-002 X .X X.X ........................................... Steuerleitungsanschlüsse .................................................................................................... M4.3-1710-007 X .X X.X ........................................... Bedienfeld ............................................................................................................................. M4.3-1710-008 X .X X.X ........................................... LED Codes ............................................................................................................................ M4.3-1710-009 X .X X.X ...........................................Wartung ................................................................................................................................ M4.3-1710-011 X .X X.X ........................................... Ausbau/Einbau ...................................................................................................................... M4.3-1710-012 X .X X.X ...........................................Sicherheitshinweise ............................................................................................................. M4.3-1710-013 X .X X.X ........................................... Prüfung Fahrsteuerung ........................................................................................................ M4.3-1710-014 X .X X.X .................................... Programmiergerät .................................................................................................................. M4.4-1710-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M4.4-1710-001 X .X X.X ........................................... Tastenerklärung .................................................................................................................... M4.4-1710-002 X .X X.X ........................................... Betriebsmenüs ...................................................................................................................... M4.4-1710-006 X .X X.X .................................... Einstellwerte und Fehlermeldungen für Fahrsteuerung .............................................. M4.5-4220-001 X ..... X................................................ Einstellwerte Fahrsteuerung ................................................................................................ M4.5-4220-001 ...X .....X ........................................... Einstellwerte Fahrsteuerung ................................................................................................ M4.5-4220-003 X .X X.X ........................................... Menüs Programmiergeräte.................................................................................................... M4.5-1710-005 X .X X.X ........................................... Testmenü ............................................................................................................................... M4.5-1710-006 X .X X.X ........................................... Diagnosemenü und Spezial Diagnosemenü ......................................................................... M4.5-1710-007 X .X X.X ........................................... Spezial Programmenü ........................................................................................................... M4.5-1710-008 X .X X.X ........................................... Fehlersuchanleitung ............................................................................................................. M4.5-1710-010 X .X X.X ........................................... Fehlerrückstellung ................................................................................................................ M4.5-1710-012 X .X X.X .................................... Batterieentladeanzeige/Betriebsstundenzähler ............................................................. M4.6-4220-001 X .X X.X .................................... Schlüsselschalter ................................................................................................................... M4.8-4220-001 X .X X.X ........................................... Ausbau/Einbau ...................................................................................................................... M4.8-4220-001 X .X X.X ...........................................Umkehrschutzschalter .......................................................................................................... M4.8-4220-002 X .X X.X ...........................................Fahrschalter .......................................................................................................................... M4.8-4220-002 X .X X.X ........................................... Schalter Heben/Senken ........................................................................................................ M4.8-4220-005 X .X X.X ...........................................Signalhornschalter ................................................................................................................ M4.8-4220-006 X .X X.X ...........................................Geschwindigkeitsbegrenzungsschalter .............................................................................. M4.8-4220-006 X .X X.X ...........................................Bremsschalter ....................................................................................................................... M4.8-4220-007 X .X X.X ...........................................Overrideschalter ................................................................................................................... M4.8-4220-009 X .X X.X ........................................... Not-Aus Schalter .................................................................................................................. M4.8-4220-010 X .X X.X .................................... Verteilerplatine ........................................................................................................................ M4.9-4220-001 X .X X.X .................................... Motoren ..................................................................................................................................... M4.10-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.10-4220-001 X ..... X................................................ Pumpenmotor ........................................................................................................................ M4.10-4220-002 X .X X.X ................................................. Aus-/Einbau .................................................................................................................... M4.10-4220-002 X .X X.X ................................................. Wartung/Instandsetzung ................................................................................................ M4.10-4220-003 X ..... X................................................ Pumpenmotor ........................................................................................................................ M4.10-4220-006 X .X X.X ........................................... Fahrmotor .............................................................................................................................. M4.10-4220-008 X .X X.X ................................................. Ausbau ........................................................................................................................... M4.10-4220-006 X .X X.X ................................................. Instandsetzung ............................................................................................................... M4.10-4220-007 X .X X.X ................................................. Einbau ............................................................................................................................. M4.10-4220-009 X .X X.X ................................................. Wartung .......................................................................................................................... M4.10-4220-009 X .X X.X .................................... Elektrotafel ............................................................................................................................... M4.11-4220-001 IDX - 4220 - 002 IDX - 4220 - 002
  • 10. Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t IDX - 4220 - 003 IDX - 4220 - 003 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-001 X .X X.X .................................... Fahrrichtungsschütz .............................................................................................................. M4.11-4220-002 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-002 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.11-4220-002 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.11-4220-003 X .X X.X .................................... Hubschütz ................................................................................................................................. M4.11-4220-004 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.11-4220-004 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.11-4220-004 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.11-4220-004 X .X X.X .................................... Baterrie ...................................................................................................................................... M4.12-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.12-4220-001 X .X X.X ........................................... Elektrolytstand (prüfen) ........................................................................................................ M4.12-4220-001 X .X X.X ........................................... Baterrie laden ........................................................................................................................ M4.12-4220-002 X .X X.X ...........................................Wartung ................................................................................................................................ M4.12-4220-004 X .X X.X .................................... Baterriesteckverbindung ...................................................................................................... M4.12-4220-005 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.12-4220-005 X .X X.X ...........................................Ausbau.................................................................................................................................. M4.12-4220-005 X .X X.X ...........................................Instandsetzung ..................................................................................................................... M4.12-4220-005 X .X X.X ...........................................Einbau.................................................................................................................................... M4.12-4220-006 X .X X.X .................................... Testverfahren (PMT) .............................................................................................................. M4.20-4220-001 X .X X.X ........................................... Allegmeines ........................................................................................................................... M4.20-4220-001 ABSCHNITT M5 WARTUNG BREMSE X .X X.X .................................... Bremssystem .......................................................................................................................... M5.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M5.0-4220-001 X .X X.X ........................................... Einstellungen ......................................................................................................................... M5.0-4220-003 ABSCHNITT M6 WARTUNG LENKUNG X .X X.X .................................... Lenkung .................................................................................................................................... M6.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M6.0-4220-001 X .X X.X ........................................... Ausbau Lenkeinheit .............................................................................................................. M6.0-6220-002 X .X X.X ................................................. Kreuzgelenk .................................................................................................................... M6.0-4220-004 X .X X.X ...........................................Kettenspanner ...................................................................................................................... M6.0-4220-005 X .X X.X ........................................... Lenkkette ............................................................................................................................... M6.0-4220-006 ABSCHNITT M7 WARTUNG MAST X .X X.X .................................... Hubgerüst ................................................................................................................................. M7.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.0-4220-001 X .X X.X ........................................... Hubgerüst TL ........................................................................................................................ M7.0-4220-001 X .X X.X ........................................... Hubgerüst TF ........................................................................................................................ M7.0-4220-001 X .X X.X ........................................... Hubgerüst TT ........................................................................................................................ M7.0-4220-002 X .X X.X ...........................................Hubgerüstausbau/-einbau .................................................................................................... M7.0-4220-002 X .X X.X ...........................................Gabelträgerausbau/-einbau ................................................................................................. M7.0-4220-003 X .X X.X ........................................... Wartung/Mast ........................................................................................................................ M7.0-4220-004 X .X X.X ................................................. Rollbahnen fetten ........................................................................................................... M7.0-4220-004 X .X X.X ................................................. Rollen ausbau ................................................................................................................. M7.0-4220-005 X .X X.X .................................... Hubkettenprüfung .................................................................................................................. M7.5-0000-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.5-0000-001 X .X X.X ........................................... Schmieren ............................................................................................................................. M7.5-0000-001 X .X X.X ........................................... Schäden erkennen ............................................................................................................... M7.5-0000-002 X .X X.X .................................... Gabelzinkenprüfung ............................................................................................................... M7.8-0000-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M7.8-0000-001 X .X X.X ........................................... Gabelkennzeichnung ............................................................................................................ M7.8-0000-001
  • 11. Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM WE 1.25t WE 1.6t WS 1.35t WS 1.8t INHALTSVERZEICHNIS X .X X.X ........................................... Reperaturen .......................................................................................................................... M7.8-0000-002 ABSCHNITT M8 WARTUNG ZYLINDER X .X X.X .................................... Zylinder...................................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Simplexzylinder ..................................................................................................................... M8.0-4220-001 X .X X.X ........................................... Hubzylinder ........................................................................................................................... M8.0-4220-002 X .X X.X ........................................... Ausbau / Einbau von Stangendichtungen ............................................................................ M8.0-0000-003 ABSCHNITT M9 WARTUNG VERKLEIDUNGEN X .X X.X .................................... Verkleidungen ......................................................................................................................... M9.0-4220-001 X .X X.X ........................................... Allgemeines ........................................................................................................................... M9.0-4220-001 X .X X.X ...........................................Abdeckhaube ........................................................................................................................ M9.0-4220-001 X .X X.X ........................................... Batteriedeckel ....................................................................................................................... M9.0-4220-001 ABSCHNITT DIA SCHALTPLAN X .X X.X .................................... Schaltplan .................................................................................................................................. DIA-4220-001X X .X X.X ........................................... Blockdiagramm ...................................................................................................................... DIA-4220-001X X .X X.X ........................................... Verteilerplatine ...................................................................................................................... DIA-4220-002X X .X X.X ........................................... Deichsel- und Kombiinstrument ............................................................................................ DIA-4220-003X X .X X.X ........................................... Fahrsteuerung Curtis ............................................................................................................ DIA-4220-004X X .X X.X ........................................... Bremse und Ladegerät ......................................................................................................... DIA-4220-005X X .X X.X .................................... Schaltplan Softlift .................................................................................................................... DIA-4220-025X X .X X.X ........................................... Blockdiagramm ...................................................................................................................... DIA-4220-025X X .X X.X ........................................... Verteilerplatine ...................................................................................................................... DIA-4220-026X X .X X.X ........................................... Deichsel- und Kombiinstrument ............................................................................................ DIA-4220-027X X .X X.X ........................................... Fahrsteuerung Curtis ............................................................................................................ DIA-4220-028X X .X X.X ........................................... Bremse und Ladegerät ......................................................................................................... DIA-4220-029X X .X X.X ........................................... Proportional-Steuerung ......................................................................................................... DIA-4220-030X ABSCHNITT HYD HYDRAULIK SCHEMA X .X X.X .................................... Hydraulik Schema.................................................................................................................... HYD-4220-001 X .X X.X ...........................................Simplex .................................................................................................................................. HYD-4220-001 X .X X.X ........................................... Duplex ................................................................................................................................... HYD-4220-002 X .X X.X ........................................... Triplex.................................................................................................................................... HYD-4220-002 X .X X.X ...........................................Simplex .................................................................................................................................. HYD-4220-003 X .X X.X ........................................... Duplex ................................................................................................................................... HYD-4220-004 X .X X.X ........................................... Triplex.................................................................................................................................... HYD-4220-004 ABSCHNITT WZ WERKZEUGE X .X X.X .................................... Werkzeug .................................................................................................................................. WZ-4220-001 IDX - 4220 - 004 IDX - 4220 - 004
  • 12. Printed in Germany KORREKTURSTAND BESCHREIBUNG SERIENNUMMER SEITEN DES IDENTIFIKATIONS GERÄTES NUMMER NUMMER VON: DATUM DATUM BIS: DATUM INHALTSVERZEICHNIS WE 1.25t WE 1.6t WS 1.35t WS 1.8t ABSCHNITT 1 RAHMEN- / ABDECKUNGSTEILE X .X ............................................. Rahmen mit Pendelschwinge ...................................................................................................... 1.0-4220-002 ....... X.X .................................... Rahmen mit Pendelschwinge ...................................................................................................... 1.0-4220-050 X .X X.X .................................... Räder ........................................................................................................................................... 1.5-4220-002 ABSCHNITT 2 HYDRAULIKTEILE X ..... X......................................... Hydraulikaggregat ....................................................................................................................... 2.1-4220-002 X ..... X......................................... Hydraulikaggregat (Softlift) ......................................................................................................... 2.1-4220-025 ...X .....X .................................... Hydraulikaggregat ....................................................................................................................... 2.1-4220-050 ...X .....X .................................... Hydraulikaggregat (Softlift) ......................................................................................................... 2.1-4220-075 X .X X.X .................................... Hydrauliktank ............................................................................................................................... 2.2-4220-001 X .X X.X .................................... Hydrauliktank .. (Softlift) .............................................................................................................. 2.2-4220-025 X ..... X......................................... Steuerventil .................................................................................................................................. 2.3-4220-002 ...X .....X .................................... Steuerventil .................................................................................................................................. 2.3-4220-050 X ..... X......................................... Hydraulik TL Mast ........................................................................................................................ 2.4-4220-002 ...X .....X .................................... Hydraulik TL Mast ........................................................................................................................ 2.4-4220-050 X ..... X......................................... Hydraulik TF Mast ........................................................................................................................ 2.6-4220-002 ...X .....X .................................... Hydraulik TF Mast ........................................................................................................................ 2.6-4220-050 ...X .....X .................................... Hydraulik TT Mast ........................................................................................................................ 2.8-4220-002 X ..... X......................................... Pumpmotor ................................................................................................................................... 2.9-4220-002 ...X .....X .................................... Pumpmotor ................................................................................................................................... 2.9-4220-050 ABSCHNITT 3 TEILE DER ANTRIEBSEINHEIT X .X X.X .................................... Antriebseinheit ............................................................................................................................ 3.0-4220-002 X .X X.X .................................... Getriebe ....................................................................................................................................... 3.1-4220-002 X .X X.X .................................... Fahrmotor .................................................................................................................................... 3.2-4220-002 X .X X.X .................................... Deichsellagerung ......................................................................................................................... 3.3-4220-002 X .X X.X .................................... Deichsellagerung (Plattform) ....................................................................................................... 3.3-4220-025 ABSCHNITT 4 ELEKTROTEILE X .X X.X .................................... Elektrik .......................................................................................................................................... 4.0-4220-002 .............................................................................................................................................................12/96 X .X X.X .................................... Elektrik ............................................................................................01/97 ................................... 4.0-4220-025 X .X X.X .................................... Elektrik .......................................................................................................................................... 4.0-4220-050 .............................................................................................................................................................12/96 X .X X.X .................................... Elektrik ............................................................................................01/97 ................................... 4.0-4220-075 X .X X.X .................................... Pumpschütz ................................................................................................................................. 4.4-4220-002 X .X X.X .................................... Fahrschütz .................................................................................................................................. 4.4-4220-050 X .X X.X .................................... Deichsel ....................................................................................................................................... 4.5-1710-002 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel .........................................................................................09/98 ................................... 4.5-1710-025 X .X X.X .................................... Deichsel ... (Griff) ....................................................................................................................... 4.5-1710-050 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Griff) .........................................................................09/98 ................................... 4.5-1710-075 X .X X.X .................................... Deichsel ... (Kappe) .................................................................................................................... 4.5-1710-100 X .X X.X .................................... Deichsel ... (Kühlhaus)................................................................................................................ 4.5-1710-125 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Kühlhaus)..................................................................09/98 ................................... 4.5-1710-150 X .X X.X .................................... Deichsel ... (Griff/Kühlhaus) ....................................................................................................... 4.5-1710-175 .............................................................................................................................................................08/98 X .X X.X .................................... Deichsel ... (Griff/Kühlhaus) .........................................................09/98 ................................... 4.5-1710-200 X .X X.X .................................... Deichsel ... (Kappe/Kühlhaus) .................................................................................................... 4.5-1710-225 X .X X.X .................................... Batterie/Ladegerät ....................................................................................................................... 4.8-4220-002 .............................................................................................................................................................W-5-3411 X .X X.X .................................... Batterie/Ladegerät .........................................................................W-5-3412 ............................ 4.8-4220-025 X .X X.X .................................... Not-Aus ....................................................................................................................................... 4.9-4220-002 IDX - 4220 - 005 IDX - 4220 - 005