Crown Forklift LP3010/3020 Series Maintenance Manual

Maintenance Manual

LP3010/3020 Series MS-LP31010/3020-GB 09/02 • Rev. B • Printed in Germany Order Number: 812521-006

This master maintenance manual is subject to continual updates.

It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.

CROWN Gabelstapler GmbH - European Headquarter Moosacher Str. 52 80809 Munich Germany Phone +49 (0)89 93 00 2 – 0 Fax +49 (0)89 93 00 2 – 133

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

Copyright 2002 CROWN Equipment Corporation

REVISION Overview of Revisions: Page 3

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

Reference to authorised service personnel added.

Page 85

Rev.1 09/02 In table E-09 battery supply changed from 48 V to 24 V.

Page 78

Rev.1 09/02 In table E-02: emergency disconnect switch test description changed.

Page 96

Rev.1 09/02 Programmer / menu structure for the steering controller corrected, missing tables (alarms etc.) inserted on the following pages.

Page 102

Rev.1 09/02 Remote control for platform: diagram and photo added to clarify application and connection. Text corrected.

Page 114

Rev.1 09/02 Diagram and description of brake corrected, as only a single stage brake is used.

Page 115

Rev.1 09/02 Diagram of brake corrected, as only a single stage brake is used.

Page 169

Rev.1 09/02 Crown abbreviations added to the wiring diagram in brackets.

Page 173 ff.

Rev. 2 09/02 Explanations in table Hyd_Dia-1-GB corrected.

Hydraulic diagram references to truck types and variants corrected.

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TABLE OF CONTENT

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TABLE OF CONTENT Table of Content ITD – INTRODUCTION

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Safety Symbols used in the Manual ................................... 3 ................................................................ Rev.1 04/00 General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair .................................................... 3 ................................................................ Rev.1 04/00 Before Leaving the Truck ................................................... 4 Before Carrying out Work on the Truck .............................. 4 Before Operating the Truck ................................................ 4 Warnings and Labels on the Truck ...................................... 4 General ................................................................................. 7 Operating Instructions ....................................................... 7 Service Training ................................................................. 7 Ordering Spare Parts ........................................................ 7 Using the Manual .............................................................. 7 Model-Number ...................................................................... 8

M1 – LUBRICATION AND ADJUSTMENT

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Jacking up the Truck ......................................................... 11 Lifting the Vehicle with a Crane ......................................... 12 Lifting the Vehicle with a Fork-Lift Truck ....................... 12 Towing the vehicle away .............................................. 12 Access to Components ................................................ 13 LP3010 Overview .............................................................. 13 LP3020 Overview .............................................................. 14 LP 3010 Overview – High Version ................................ 15 Access to Components ................................................ 17 Access to Drive Unit, Hydraulic System and Electrical Components .................................. 18 Maintenance ......................................................................... 19 Operator Involvement ........................................................ 19 Daily Maintenance Record ................................................ 19 Inspection and Maintenance Schedule ........................................................................... 19 Scheduled Replacement of High Pressure Hoses ............. 22 Monthly or Every 100 Operating Hours .............................. 23 Every 3 Months or 250 Operating Hours ........................... 25 Every 6 Months or 500 Operating Hours ........................... 27 Annually or Every 1,000 Operating Hours .......................... 29 Recommended Lubricants ................................................. 31 Lubrication Points, Overview ............................................. 33 Torques ................................................................................. 34

M2 – HYDRAULICS

PAGE

Changing Hydraulic Oil ....................................................... 37 Hydraulic Pipes and Accessories ....................................... 37 Removing the Hydraulic Unit ............................................. 38 Replacing the Hydraulic Pump .......................................... 39 Removal ...................................................................... 39 Installation ................................................................... 39 Commissioning ............................................................ 39 Pump Motor ...................................................................... 40 Replacing the Hydraulic Filter ........................................... 40 Oil Change ........................................................................ 41 Valve Block ........................................................................... 42 Pressure Relief Valves ...................................................... 42 Operation .......................................................................... 42

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TABLE OF CONTENT M2 – HYDRAULICS

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Platform Lift Pressure Relief Valve Setting ................... 42 Aux. Lift Pressure Relief Valve Setting ......................... 43 Non-Return Valve .............................................................. 43 Functional Test: ............................................................ 43 Compensation Valve ......................................................... 43 Functional Test: ............................................................ 43 Line Break Safety Device ................................................. 44 Tools Required: ............................................................ 44 Line Break Safety Device Functional Test .................... 44 Emergency Lowering Valve ............................................... 45 Tools Required: ............................................................ 45 Emergency Lowering Valve Functional Test .................. 45

M3 – DRIVE UNIT

PAGE

Drive Unit .............................................................................. 49 Preparation ....................................................................... 49 Drive Unit Removal ........................................................... 49 Gear Unit Repair ............................................................... 51 General ........................................................................ 51 Drive Unit Removal ...................................................... 51 Gear Unit Assembly .......................................................... 53 Installing the Drive Unit ..................................................... 54

M4 – ELECTRICS

PAGE

Electrical Components ........................................................ 57 AV Alarm ................................................................................ 57 CX Horn .................................................................................. 57 F1, F2, FA,FA4 Fuses ............................................................................... 57 F3, FA3 Fuses ............................................................................... 57 OPTION

F01 Aisle Recognition Sensor .................................................. 57 OPTION

F02 Aisle Recognition Sensor .................................................. 57 FE Brake ................................................................................ 57 HN3 Alarm ................................................................................ 57 K1, K2 Travel Direction Contactors ............................................... 57 K4 Main Contactor ................................................................. 57 K6 Steering Contactor ............................................................ 58 M1 Traction Motor ................................................................... 58 M2 Pump Motor ...................................................................... 58 M3 Steering Motor .................................................................. 58 MAC Chain Slack Switch ........................................................... 58 MBC ................................................................................. 58 MF Steering Limit Switch ........................................................ 58 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

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TABLE OF CONTENT M4 – ELECTRICS

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MFC Lift Limit Switch (Cabin) .................................................... 58 MFF Lift Limit Switch (Forks) .................................................... 58 OPTION

MFT Overhead Guard Monitor ................................................... 58 OPTION

MLS Lift Interruption Switch ...................................................... 58 MMI,MMA,PT Transmitter ........................................................................ 58 OPTION

MPR Door Switch ...................................................................... 59 MP1,MP3 Pallet Recognition Switch .................................................. 59 MR Lower Brake Switch .......................................................... 59 MS1, MS2 Steering: Tachogenerator ................................................... 59 MSC,MDC,PTP Cabin Lift / Lower .............................................................. 59 MV2, MV3 Lift Height Dependent Speed Reduction ............................ 59 PE Emergency Disconnect Switch ......................................... 59 PCE, PCEglf Brake Switch .................................................................... 60 PCS, PCD Fork Lift/Lower .................................................................. 60 PCS, PCSD, MCS Dead Man Switch .............................................................. 60 OPTION

PCT,MCT Aisle Guidance Two-Hand Switch ...................................... 60 PCX, PCXglf Horn Switch ...................................................................... 60 PEA Chain Slack Bypass Switch .............................................. 60 OPTION

PFA Work Lights Switch ........................................................... 60 OPTION PLS Bypass Switch .................................................................. 60 PS Pressure Switch ................................................................ 60 PTR Steering Angle Potentiometer ............................................ 61 QC Key Switch ........................................................................ 61 RL1 Trip Relay .......................................................................... 61 MK3N Traction Controller ..................................................... 62 General ............................................................................. 62 Precautionary Measures .............................................. 62 Maintenance ..................................................................... 62 Replacing the Traction Controller ....................................... 62 Settings after Replacing the Traction Controller ..................................................................... 63

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TABLE OF CONTENT M4 – ELECTRICS

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MK3N Lift Controller ............................................................ 64 General ............................................................................. 64 Precautionary Measures .............................................. 64 Maintenance ..................................................................... 64 Replacing the Lift Controller .............................................. 64 Settings after Replacing the Lift Controller ................... 65 EPS-DC Steering Controller ................................................ 66 General ............................................................................. 66 Precautionary Measures .............................................. 66 Maintenance ..................................................................... 66 Replacing the Traction Controller ....................................... 66 Settings after Replacing the Steering Controller ........... 67 Replacing Fuses .......................................................... 67 Graphic Display .................................................................... 68 General ............................................................................. 68 Precautionary Measures .............................................. 68 Maintenance ..................................................................... 68 Replacing the Graphic Display .......................................... 69 Settings after Replacing the Graphic Display ............... 69 Programmer ......................................................................... 71 General ............................................................................. 71 Connecting the programmer and the adapter ..................... 72 Data Connection to the Pump Controller: ..................... 72 Data connection to the Traction Controller: ................... 72 Data Connection to the Graphical Display .................... 73 Operating Menu ................................................................ 74 General ........................................................................ 74 Menu Functions ........................................................... 74 Graphic Display, Menu Structure .................................. 75 Graphic Display; Parameter Change Menu ......................... 76 Maximum Speed Setting ................................................... 77 Graphic Display TESTER Menu ................................................................. 78 ............................................................. Rev. 1 09/02 Graphic Display SAVE PARAMETER Menu ............................................... 79 Graphic Display ALARMS Menu ................................................................. 80 Graphic Display Language Reference List for the ALARM Menu ................ 84 Graphic Display SET OPTIONS Menu ........................................................ 85 Graphic Display ADJUSTMENTS Menu ..................................................... 86 Traction Control System, Menu Structure ..................... 87 Traction Control System, PARAMETER CHANGE Menu .... 88 Traction Control System, TESTER Menu ...................................................................... 89 Traction Control System, ALARMS Menu ..................................................................... 90 Traction Control System, SET MODEL Menu ............................................................... 91 Lift Control System, Menu Structure ................................... 92 Lift Control System, PARAMETER CHANGE Menu .............................................. 93 Lift Control System, TESTER Menu ...................................................................... 94 Lift Control System, ALARMS Menu ..................................................................... 95 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

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TABLE OF CONTENT M4 – ELECTRICS

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Steering Control System, Menu Structure .......................... 96 ............................................................. Rev. 1 09/02 Steering Control System, PARAMETER CHANGE Menu .............................................. 97 Steering Control System, TESTER menu ...................................................................... 98 Steering Control System, SET OPTIONS menu ............................................................ 99 Steering Control System, ADJUSTMENTS menu .......................................................... 100 Steering Control System, ALARM ....................................... 101 Audible Alarm ................................................................... 101 Programmer, ALARMS menu ............................................ 101 Remote Control for Platform ............................................... 102 Traction Control System Safety Test ................................... 103 Electric Motors ..................................................................... 105 General Maintenance Instructions ..................................... 105 Preparation .................................................................. 105 Important Maintenance Instructions ................................... 105 Drive Motor Maintenance ..................................................... 106 Access to Brushes ........................................................... 106 Maintenance ..................................................................... 106 Armature ...................................................................... 106 Bearings ...................................................................... 106 Pump Motor Maintenance ................................................. 107 Access to Brushes ...................................................... 107 Maintenance ................................................................ 107 Armature ...................................................................... 107 Bearings ...................................................................... 107 Steering Motor Maintenance ............................................... 108 Access to Brushes ........................................................... 108 Maintenance ..................................................................... 108 Battery .............................................................................. 109 General ............................................................................. 109 Operation .......................................................................... 109 Replacing the Battery ........................................................ 109

M-5 – BRAKE

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General Functional Description ......................................... 113 Removal ........................................................................... 113 ........................................................... Rev. 1 09/02 Assembly ......................................................................... 114 ........................................................... Rev. 1 09/02 Air Gap Setting ................................................................. 114 ........................................................... Rev. 1 09/02 Brake Moment Setting ...................................................... 114 ........................................................... Rev. 1 09/02 Brake Test ......................................................................... 114 ........................................................... Rev. 1 09/02

M6 – STEERING

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Steering ................................................................................ 119 Operation .......................................................................... 119 Steering Chain Adjustment ............................................... 119 Steering Pod Removal / Installation .................................. 120 Steering Motor Removal / Assembly ................................. 120 Steering Transmission Removal / Assembly ......................................................... 121 Potentiometer (PTR) Installation ....................................... 122 Functional Test ............................................................. 122 Steering Limit Switch (MF) ................................................ 122 Replacing the Steering Limit Switches ......................... 122 Limit Switch Test .......................................................... 123 Limit Switch Adjustment .............................................. 123 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

VII

TABLE OF CONTENT M7 – LIFTING MECHANISM

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Torques ............................................................................. 127 Fork Settings .................................................................... 127 Mast Control (Fitted) .............................................................................. 127 Flaking .............................................................................. 127 Mast Stop Buffer .............................................................. 127 Fork Carriage Stop Screws ............................................... 127 Removing the Platform without Aux. Lift (1200 mm lift height) ......................................................... 128 Removing the Platform with Aux. Lift (1200 mm lift height) ......................................................... 130 Removing Platform without Aux. Lift (1800 mm lift height) ......................................................... 133 Removing Platform with Aux. Lift (1800 mm lift height) ......................................................... 136 Mast Rollers ......................................................................... 139 Removing the Mast Rollers ............................................... 139 Fitting the Mast Rollers ..................................................... 139 Guide Rollers ....................................................................... 139 Guide Roller Removal ....................................................... 139 Guide Roller Installation .................................................... 140 Platform Installation (all variants) ...................................... 141 Fork Carriage (Aux. Lift Only) ............................................ 142 Fork Carriage Removal ................................................ 142 Removing the Fork Carriage Rollers ............................. 143 Fork Carriage Roller Installation ................................... 143 Fork Carriage Installation ............................................. 144 Tensioning the Lift Chain .............................................. 144 Lift Chains ............................................................................ 146 General ............................................................................. 146 INSPECTION .................................................................... 146 Cleaning ....................................................................... 146 Wear ............................................................................ 146 Chain Dimensions: ....................................................... 146 Freedom of Movement ................................................. 147 Chain Anchor and Pulleys ............................................ 147 Worn or Missing Plates ................................................ 147 Protruding or Turned Chain Pins ................................... 147 Corrosion ..................................................................... 148 Chain Lateral Wear ....................................................... 148 Misalignment of Lift Components ................................. 148 LIFT CHAIN LUBRICATION .............................................. 149 Fork Tine Test ................................................................... 150 General ........................................................................ 150 Fork Identification ........................................................ 150 Repairs ........................................................................ 150 Crack Inspection .......................................................... 150 Fork Blade Warping ...................................................... 151 Verticality Test ............................................................. 151 Measuring the Fork Tip Width ....................................... 152 Fork Tine Height Difference .......................................... 152 Fork Stop ..................................................................... 152 Wear ............................................................................ 153

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TABLE OF CONTENT M8 – CYLINDERS

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Cylinders .............................................................................. 157 General ............................................................................. 157 Plunger Cylinders (single-acting) .................................. 157 Piston Cylinder (Double-Acting Cylinder) ...................... 158 Maintenance ..................................................................... 160 Inspection ......................................................................... 160 Seal Installation ................................................................ 161 General ........................................................................ 161 Aux. Lift Cylinder ................................................................. 161 Removal - Preparation ...................................................... 161 Aux. Lift Cylinder Removal ................................................ 161 Repairing the Aux. Lift Cylinder ......................................... 162 Disassembly ................................................................ 162 Inspection ................................................................... 162 Assembly .................................................................... 163 Aux. Lift Cylinder Assembly .............................................. 163 Lift Cylinder .......................................................................... 163 Removal - Preparation ...................................................... 163 Lift Cylinder Removal ........................................................ 164 Repairing the Lift Cylinder ................................................. 164 Disassembly ................................................................ 164 Inspection .................................................................. 165 Lift Cylinder Assembly ...................................................... 165

DIA – ELECTRICAL DIAGRAMS

PAGE

Electrical Circuit .................................................................. 169

HYD – HYDRAULIC SCHEMATIC

PAGE

Hydraulic System ................................................................. 173 Operation .......................................................................... 173 ........................................................... Rev. 2 09/02 HLP3010, 1025 mm lift height, without aux. lift .................................. 174 ........................................................... Rev. 2 09/02 LP3020, 1845 mm lift height, with aux. lift ....................................................................... 175 ........................................................... Rev. 2 09/02 LP3010, 1620 mm lift height, without aux. lift .................................................................. 176 ........................................................... Rev. 2 09/02 LP3020, 2440 mm lift height, with aux. lift ....................................................................... 177 ........................................................... Rev. 2 09/02

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SAFETY

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SAFETY Safety Symbols used in the Manual

General Maintenance and Repair Safety Notes

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

DANGER Read the safety notices in the truck Maintenance and Operator's Manuals.

DANGER

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.

This symbol indicates life-threatening risks ● Failure to comply with this notice may result in severe or fatal injuries to yourself or other people.

Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines.

WARNING This symbol indicates the risk of serious injury and/or serious material damage.

DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels.

● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.

● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.

CAUTION This symbol indicates the risk of minor injury and/or minor material damage.

Maintenance and Repair 1.

Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices.

2.

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

3.

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

4.

To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral.

Only carry out cleaning with an oil separator.

Protect the electrical system from dampness.

5.

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

6.

Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled.

Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.

7.

Neutralise and thoroughly rinse any spilled battery fluid immediately.

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

INFORMATION Contains additional information with supplementary notes and hints.

OPTION OPTION

These items relate to optional features not supplied with the standard version.

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SAFETY 8.

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

9.

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

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

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

Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. ●

Clean any illegible labels.

●

Replace any faulty or missing labels.

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

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the truck and remove the key.

●

Block all wheels when parking on an uneven surface.

Before Carrying out Work on the Truck ●

Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.

●

Prevent the truck from rolling away.

●

Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.

●

Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes.

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INTRODUCTION

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

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

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

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

This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.

Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle.

Additional copies can be ordered as required.

With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle.

Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.

Using the Manual The manual is divided into sections. The following table shows how the manual is structured.

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

M6

Steering

M7

Mast / Lifting Mechanism

Ordering Spare Parts The maintenance manual does not cover spare parts. These are listed in a separate manual.

Spare parts can be ordered by quoting: ●

The truck specification number

●

The truck model number

M8

Cylinder

●

The truck serial number

DIA

Electrical Diagrams

HYD

Hydraulic Schematic

This information can be found on the truck's data plate.

Only if this information is provided can the order be processed quickly, correctly and reliably.

A01M-gb

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M1.0-0000-0007 7

INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions:

Model-Number LP3010

Modeldescription Mid Level Order Picker with 1.000 kg capacity

LP3020

Modeldescription Mid Level Order Picker with 1.000 kg capacity (incl. auxiliary lift)

MS-ITD-3010

88 M1.0-0000-0008

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LUBRICATION AND ADJUSTMENT

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LUBRICATION AND ADJUSTMENT Jacking up the Truck To jack up the truck, proceed as follows: The platform must be lowered (see illustration).

DANGER Always support the raised truck on square blocks or other appropriate material to relieve the trolley. Never put your hands or other parts of the body underneath a nonsupported truck.

1 Jacking Points

● Improper handling of the truck or the auxiliary equipment can result in fatal accidents.

●

Secure both loadwheels with a wedge (1).

●

Apply a jack with sufficient capacity (for LP without battery: > 1100 kg, with max. battery: > 1400 kg) at the middle of the chassis frame (2) and raise the truck (max. 20 mm).

●

Place sufficiently sized wooden blocks (hard wood) on both sides underneath the chassis and lower the truck onto the blocks (3).

●

Apply the jack to one of the outriggers.

Raise the outrigger until the loadwheel clears the floor.

Maximum loadwheel distance off the floor 20 mm.

●

Place a wooden block underneath the outrigger and lower the outrigger onto the block (4).

●

Jack up the outrigger on the other side and lower it onto a block (5).

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3

2

5

3

M1907

MS-1.0-3010

11

LUBRICATION AND ADJUSTMENT Lifting the Vehicle with a Crane Attach the chains or lifting straps as shown in Figs.

M1908 and 1909.

DANGER! Check that both the crane/lift truck and lifting equipment have sufficient lifting capacity. ● A toppling crane or fork-lift truck or a falling load can cause fatal injuries.

500

1200

700

Towing the vehicle away

M1908

M1909

Lifting the Vehicle with a Fork-Lift Truck

If the vehicle is de-energised the drive-wheel brake is active. The vehicle can be lifted and towed with a minimum 1400 kg capacity fork-lift truck. The load wheels remain on the floor. ●

Position the forks under the chassis as shown in the diagram.

●

Raise the vehicle (at the front end) approximately 20 mm off the ground.

The LP 3010 / 3020 can be raised using a fork-lift truck.

WARNING! Required capacity: for the LP without battery, 1500 kg. ●

The drive wheel must be pointing straight ahead; the platform must be fully lowered.

●

Position the fork of the lifting vehicle as shown in the diagram.

●

Secure the LP firmly to the forks of the lifting vehicle (e.g. with transport straps).

The drive wheel must no longer touch the ground. ● Otherwise you will damage the vehicle. ●

Tow the vehicle slowly forwards and only in a straight line (black arrow).

M1911 MS-1.0-3010

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LUBRICATION AND ADJUSTMENT Access to Components Components are accessed either by unscrewing covers or by unlocking and lifting the motor hood.

WARNING! The battery connector must always be pulled out before any maintenance work.

This is particularly important if plugs and sockets have to be disconnected.

LP3010 Overview

Control Panel

Mast

Dead Man Switch Strobe Light Horn Battery Compartment Operator Platform with Fork

Motor Panel

M1963

Drive Wheel (central)

Load Wheels Outrigger

OPTION

Side Casters (2x2)

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13

LUBRICATION AND ADJUSTMENT Access to Components LP3020 Overview

Mast

Basic Control Panel

Control Panel – Fork side

Dead Man Switch

Aux. Lift Cylinder Lift Chain Fork

Horn

Strobe Light

Motor Panel

Operator Platform

Battery Compartment

M1958

Drive Wheel (central) Outrigger

MS-1.0-3010

1414

Load Wheels

OPTION OPTION

Side Casters (2x2)

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Access to Components LP 3010 Overview – High Version Speed Plate (maximum possible travel speed for various platform heights)

Load Guard

Side Gates

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MS-1.0-3010

15

LUBRICATION AND ADJUSTMENT Access to Components LP 3020 Overview – High Version Speed Plate (maximum possible travel speed for various platform heights)

Overhead Guard

Side stays

M1932

MS-1.0-3010

1616

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Access to Components Main components under the motor panel

Steering control

Lifting control

Travel control Valve block

Steering motor

Pump motor Contactors Steering angle potentiometer

Hydraulic pump

Steering gear

Hydraulic tank

Steering chain

Brake Drive motor

Gear unit Drive wheel

Removable skirt

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17

LUBRICATION AND ADJUSTMENT Access to Drive Unit, Hydraulic System and Electrical Components Almost all components can be accessed under the motor panel of the vehicle.

DANGER! There is a danger of fatal accidents if you do not secure the mast and platform to prevent them being lowered while working under the raised platform or forks.

The fork carriage must also be secured or fully lowered on vehicles with an auxiliary lifting unit.

M1954

MS-1.0-3010

1818

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LUBRICATION AND ADJUSTMENT Maintenance Operator Involvement The involvement of the operator in the maintenance programme can greatly reduce the vehicle downtimes, contribute to the planning of the maintenance schedule and save money. CROWN therefore recommends that the operator performs the daily maintenance.

Daily Maintenance Record The proper performance of the daily maintenance according to the schedule must be entered in the Maintenance Record.

Inspection and Maintenance Schedule The inspection and maintenance schedule below refers to single-shift operation under normal conditions of use.

The maintenance frequency must however be adapted to the prevailing operating conditions.

In particularly dusty conditions or other extremes, the specified maintenance intervals are to be shortened. A precise schedule is to be drawn up in collaboration with a CROWN service engineer.

INFORMATION In each case, the next maintenance schedule includes all preceding schedules.

Example: In the course of a 250-hour inspection, the 8-hour and 100-hour schedules must also be performed.

When carrying out maintenance work, all parts must be routinely inspected for any wear, corrosion, damage, correct function and safety. If there is any doubt about the condition, the parts must be replaced.

WARNING The battery must be maintained exclusively according to the battery manufacturer’s instructions.

Failure to observe these instructions can damage the battery.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.1-3010

19

LUBRICATION AND ADJUSTMENT Daily or Every 8 Operating Hours, Part 1 Item

Component

Scope

Truck*

Clean as necessary

I-1

Battery and battery compartment

Check / charge battery as necessary in accordance with manufacturer's instructions.

I-2

Battery component

Check for damage, check contacts for any burning.

I-3

Leaks.

- Gear unit Check for leaks.

- Hydraulic system Check for leaks. If detected, decommission the truck.

I-4

Wheels / load wheels.

Check tyres for wear and any foreign bodies. Remove foreign bodies.

I-5

Forks

Check for damage, cracking and excessive wear.

I-6

Decals, stickers.

Make sure they are complete and legible.

I-7

Where applicable: overhead guard, gates, shields.

Make sure they are securely fastened and damage-free.

I-8

Where applicable: stepboard pallet (LP 3010 only)

Make sure it is correctly positioned, sufficiently secure and damage-free.

I-9

Key switch

Turn on and check display function.

I-10

Emergency disconnect switch.

Check operation.

I-11

Horn

Check operation.

I-12

Steering

Check operation and clearance.

I-13

Hydraulic functions.

Check all functions. The hydraulic system should cut out when the raise limit position is reached.

* Do not use high pressure cleaners and/or solvents on the truck. Do not use metallic brushes!

L02_a-GB

MS-1.1-3010

2020

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Daily or Every 8 Operating Hours, Part 2 Item

Component

Scope

I-14

Travel Functions

I-15

Hydraulic System

I-16

Palet Monitor Switch (LP 3010 with 1620 mm lift height only)

Operate the truck in both directions, slowly at first, and then at maximum speed.

The indicator should be lit during travel.

The hydraulic functions should be disabled.

Check automatic speed reduction when the steering angle is > 10° and when the platform is > 500 mm.

Raise and lower the platform. The hydraulic system should cut out when the limit positions are reached. Two-handed operation: single -hand operation should not be possible (see operatior manual).

The indicator should be lit during lifting/lowering; travel should be inhibited.

LP 3020 only: Lift and lower the fork. The hydraulic system should cut out when the limit positions are reached. Check twohanded operation (see operator manual).

Check switch operation: If the switch is not pressed down, lifting should be restricted to a lift height of 1030 mm (see operator manual).

I-17

Gate (where applicable)

Travelling, platform / fork raising and lowering should be inhibited as soon as a gate is opened.

I-18

Steering block (option)

Check operation (see operator manual); Two-handed operation!

I-19

Diagonal travel (option)

Check operation (see operator manual); Two-handed operation!

I-20

Lights (if present)

Check operation.

L02_b-GB

INFORMATION An illustrated description of the 8-hourly or daily inspection can be found in the Operator’s Manual.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

*Note on I-3: It is sufficient to check the floor beneath the vehicle for fluid leakage, without having to remove any panels.

Note on I-6: See the Operator Manual.

MS-1.1-3010

21

LUBRICATION AND ADJUSTMENT Monthly or Every 100 Operating Hours Item

Component

Scope

I-22

Hydraulic oil level

Check level, replenish as required.

I-23

Lift frame

Clean rollers and contact surfaces. Visually inspect for wear and freedom of movement. Apply more grease.

I-24

Brakes

Blast out abrasion, check air gap.

I-25

Lift chain

Clean, check for damage and grease.

I-26

Lift cylinder

Visually inspect for leaks. Check piston rod for damage. Check cylinder attachment. Check operation of lift limit switch.

I-27

Hydraulic lines.

Check hoses and lines for damage. Replace as required. Check high pressure hosing expiry date.

L-03-GB

Scheduled Replacement of High Pressure Hoses The high-pressure hoses must be replaced every six years. This period is to be calculated from the manufacture date stamped on the hose (see Fig. M1960, Item A).

DANGER! Do not exceed the expiry date of the highpressure hoses. The hoses age irrespective of the amount of use.

A

I-27

P/No. 140.../ 09-00

P/No. 140.../ 09-00

*Note on I-27: Also check hydraulik hoses in the chassis!

MS-1.1-3010

2222

M1960 M1954 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Monthly or Every 100 Operating Hours

I-23

I-26

I-25/I-26 M1942

I-23 I-23

I-27

M1958

I-22

I-24

M1927

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.1-3010

23

LUBRICATION AND ADJUSTMENT Every 3 Months or 250 Operating Hours Item

Component

Scope

I-28

Truck - battery connector

Clean contacts and check contact springs.

I-29

Frame, panels, overhead guard, forks.

Check condition of frame, panels, overhead guard and forks.

Remove any corrosion, touch-up any paint damage. In addition, check forks for wear, cracking and damage (see chapter 7).

I-30

Roller aux. lift (where applicable)

Check rollers for freedom of movement and excessive play.

I-31

Driver platform

Check rubber layer for wear and grip.

Lo4-GB

MS-1.1-3010

2424

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Every 3 Months or 250 Operating Hours

I-28

I-29 I-31 M1962

I-30 M1953

I-29

OPTION

(800 FEM) (800 x 680)

M1961

M1958

I-29

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.1-3010

25

LUBRICATION AND ADJUSTMENT Every 6 Months or 500 Operating Hours Item

Component

Scope

I-32

Drive unit attachment screws

Check torques.

I-33

Pump, drive and steering motors

Check carbon brushes for wear and freedom of movement.

I-34

Load rollers / castors

Check bearings for excessive play and wear. Replace as required. Check attachment screw / nut torques. Replace worn wheels / rollers.

I-35

Drive wheel.

Check wheel screw torques. Check tyre, replace drive wheel if the tyre is damaged or worn.

I-36

Mast and mast contact surfaces / mast rollers.

Check for wear and damage. Check the play and make sure the components are securely fastened.

I-37

Lift chain and chain anchor (where applicable)

Check the lift chain for stretch and torn plates. Replace the chain if cracking or excessive elongation is detected. Check the chain anchor and fastening bolts for damage, corrosion and cracks. Replace if damaged. Check that the chain anchor attachment is securely fastened.

I-38

Hydraulic system

Change the hydraulic oil and filter during the first service.

Thereafter every 2,000 operating hours or 2 years.

I-39

Electrical system

Check connections for corrosion, clean as required.

I-40

Electrical system

Visually inspect all switches, relays, contactors and wiring.

Blast out dust at low pressure with dry compressed air.

Check connections for corrosion, clean as required.

I-41

Steering system and steering chain

Check play and position of steering chain and check limit switch operation.

I-42

Brakes

Disassemble the brakes. Check brake lining for wear and damage. Check anchor plate and motor front flange for signs of overheating and wear. Replace damaged or worn par ts.

Lo5-GB

MS-1.1-3010

2626

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Every 6 Months or 500 Operating Hours

I-38

I-33 I-33

I-38 I-32

I-41 I-42

M1954

I-35

I-33

I-37 I-36

M1964

I-34

M1942

M1958 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.1-3010

27

LUBRICATION AND ADJUSTMENT Annually or Every 1000 Operating Hours Item

Component

Scope

I-43

Pump, traction and steering motors

Check commutator for damage and wear.

I-44

Gear unit

Change grease.

I-45

Hydraulic system

I-46

Carry out annual UVV test

Replace hydraulic oil and filter. Clean lines and connections, make sure that the system is secure and sealed. Check safety valve operation.

The UVV test is compulsory in Germany. For other countries follow national regulations, which may differ in terms of the duration and scope of the test.

L06-GB

MS-1.1-3010

2828

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Annually or Every 1,000 Operating Hours

I-45

I-45(Pump Motor) I-45 (Steering Motor)

I-44 M1954

I-45 (Drive Motor)

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.1-3010

29

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Printed in Germany

30

LUBRICATION AND ADJUSTMENT Recommended Lubricants Lubricants Only high-quality grease and oil is to be used. These lubricants are available from all oil companies. Table L01 lists current lubricants, although any equivalent lubricants can be used.

Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Type

Grease (multi purpose)

Aralube HLP-2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe E2 Retinax LX

Aral Castrol Century Esso Maxol Mobil Shell

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

Lubrication oil (chain)

Kowal 40 Essolube HDX Plus + 40 Delvac 1240

Aral Esso Mobil

053002-007

G

Low temperature lubrication oil

SHC 626

Mobil

053002-008

GG

Hydraulic oil

Vitam GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32

Aral Castrol Esso Mobil Shell

053001-003

D

Low temperature hydraulic oil

Univis J 13 Aero HFA

Aral Mobil

053001-008

DD

Transmission grease

Tribostar 2EP Lubrisint 2

Klüber Viscol

A

Low temperature transmission grease

Signal ST 150 ARCTIC 2

Viscol

AA

Special grease

MOS2 Lithium

Dow Corning

Universal lubrication oil

SAE 40

063002-022

M

C L01-gb

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-1.2-3010

M-1.2-3010-001 31

LUBRICATION AND ADJUSTMENT Lubrication points / intervals Item Component

L-1

Check hydraulic oil level and top up if necessary

Type Quantity

Every 100 hours

Every 250 hours

Every 500 hours

D

A/R

L-2 All hinges

C

A/R

L-3 Grease mast, casters and runners

B

A/R

X

L-4 Grease lift chain

B

A/R

X

L-5 Grease steering chain

G

A/R

X

L-6 Fixture piston rod

B

A/R

X

L-7 Lift cylinder

B

A/R

X

L-8 Change hydraulic oil and filtern

D

25 ltr.

After the first 500 operating hours, then every 1000 hours

L-9 Change gear grease

A

2 kg

Every 1000 hours

Every 2000 hours

X X

X

X L08-GB

MS-1.3-3010

3232

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

LUBRICATION AND ADJUSTMENT Lubrication Points, Overview

L-7

L-3

L-4 M1942

L-8

L-3 M1959

L-3

M1958

L-6 L-1/L-8

L-5 M1927

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

L-9

MS-1.3-3010

33

LUBRICATION AND ADJUSTMENT Torques

NOTE

The information contained on thise page should be used during maintenance work to determine the correct torques for standard screws and nuts.

The torques listed in the maintenance section always take precidence over those listed on this page.

Standard Screws and Nuts Grade

8 and 8.8 Thread Size

10 and 10.9

12 and 12.9

Torque (Nm)

M 5x0.8

6

8

M 6x1

10

14

M 8x1.25

24

35

M 8x1

26

37

M 10x1.5

49

70

M 10x1.25

52

73

M 12x1.75

84

110

M 12x1.5

89

125

M 16x2

200

280

M 16x1.5

215

300

M 20x2.5

390

550

M 20x1.5

430

610

M 24x3

700

980

M 24x2

735

1030

M 30x3.5

1380

1930

M 30x3

1470

2080

10 17 42 44 83 87 143 150 340 360 660 730 1170 1240 2320 2500

T02-GB MS-1.9-3010

3434

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

HYDRAULICS

Printed in Germany

35

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Printed in Germany

36M1.0-0000-00036

HYDRAULICS Changing Hydraulic Oil

3.

Hoses and pipes must not rest loosely against other components. This could result in chafing or cuts. Route lines so that they do not get jammed.

4.

All connections must be completely sealed.

5.

The elbows on suction connections must be positioned so that the suction hose has the full flow and does not collapse.

All hydraulic systems are extremely sensitive to contamination.

Therefore, the oil must be filtered through a 10 micron filter or strainer 100 before entering the system.

This is especially important if the oil comes from a barrel. The following illustration shows a compressed air pump incorporating a 10 micron filter and funnel with a strainer 100.

WARNING De-pressurise all components before carrying out maintenance work on the hydraulic system. ● High pressure hydraulic oil can cause serious injuries. ● Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction.

Physically effects will set in later. ● Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge. ● Use absorbent paper to trace leaks, never use your hands!

6459D

Hydraulic Pipes and Accessories 1.

Air blast all hoses and pipes to remove any loose dirt prior to installation. Any rubber hoses with interior wiring, thermoplastic hoses and steel tubes which are squashed together or bent are non-serviceable and must be replaced, even if no external damage is visible.

2.

Flexible thermoplatic hoses must be replaced if they distort in their normal operating position.

Rubber hoses must always be replaced if they leak.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-2.2-3310

M1.0-0000-00037 37

HYDRAULICS Removing the Hydraulic Unit WARNING

.

De-pressurise all components before carrying out maintenance work on the hydraulic system. ●

Unplug the battery connector.

●

Secure the truck from rolling away.

●

Place a tray underneath the hydraulic tank and drain the hydraulic oil from the tank.

●

Disconnect all cable connections to the pump motor and the hosing from the hydraulic pump.

●

Open clip (A, Fig. M1954) and remove the motor and pump.

●

Place the hydraulic unit on a clean workbench

B

A

M1954 MS-2.3-3310

38M1.0-0000-00038

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

HYDRAULICS Installation

Replacing the Hydraulic Pump NOTE The hydraulic pump should always be replaced and is not designed to be repaired on site.

All seals on dismantled components and filters must be replaced.

Removal ●

Remove the hydraulic unit as described in the previous section.

●

Remove the screws (4, Fig. M1969) and remove the pump (3) from the motor.

●

Clean all components (except for the motor) with a clean degreasing agent, remove the old O ring (1) and blast all components dry.

●

Apply a thin layer of oil to the new O ring (1, Fig. M1969) and insert the O ring.

●

Insert the carrier (2).

●

Place the pump on the motor (note the alignment) and secure with screws (4).

●

Refit the hydraulic unit in the reverse order as described in the Removal section.

WARNING Only use authorised lubricants (see lubricant table). ●

Fill the hydraulic container with oil in accordance with the lubricant table up to the middle of the inspection glass.

Commissioning

1

2

3

●

Never run the pump without oil.

●

Check that the system is clean and correctly assembled. All connections must be secure.

●

All components, in particular hydraulic connections, must be totally clean and dry before being used for the first time. Otherwise, it is impossible to check for leaks.

●

Apply the hydraulic functions several times. Then check the oil level and replenish if necessary.

●

Check the pressure connections and surrounding hydraulic components for leaks.

M1826

4

M1969

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-2.3-3310

M1.0-0000-00039 39

HYDRAULICS Pump Motor

●

Using pincers lift out the filter insert directly up (Fig. M1971) and remove the insert sump

Maintenance and repairs to the pump motor are described in chapter 4.

●

Remove, do not re-use, the flange seal and filter element. Clean, de-grease and dry the flange, pressure spring and filter insert.

●

Insert the filter insert. Press the new filter element into the filter insert. Put on and align the flange seal. Insert the pressure spring and flange.

Secure the flange. Tighten the fix screws crosswise and evenly.

Replacing the Hydraulic Filter ●

The hydraulic oil filter is located in the oil return flow and is fitted to the top of the hydraulic container (B, Fig. M1954).

M1970

●

Unscrew the filter flange (Fig. M1970).

M1972

●

Lift off the filter flange and pull out the filter element (Fig. M1972).

M1971 MS-2.2-3310

40M1.0-0000-00040

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

HYDRAULICS Oil Change The capacity of the hydraulic tank is approx. 18 litres of oil. The oil collecting tray must be of at least the same capacity. ●

Position the collecting tray underneath.

●

Unscrew the oil filler cap (1, Fig. M1973)

●

Remove the oil filler cap (4, Fig. M1973) and seal (3).

●

Drain the hydraulic oil until it is empty.

●

Dispose of the hydraulic oil using approved disposal methods.

●

Clean the drain plug (4) and using a new seal (3), screw in and tighten the drain plug.

●

Fill the hydraulic oil up to the middle of the inspection glass (2), screw on the filler cap (1) and bleed in accordance with the section entitled “Replacing and commissioning the hydraulic pump”.

1

2

3

M1973

4

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-2.3-3310

M1.0-0000-00041 41

HYDRAULICS Valve Block Pressure Relief Valves All models have 2 pressure relief valves in the block.

However, for trucks without auxiliary lift only pressure relief valve C (C, Fig. M1945) is active. For trucks with auxiliary lift the aux. lift pressure circuit is protected by a second pressure relief valve (E, Fig. M1945).

DANGER The two valves are designed differently.

Never put a pressure relief valve for the platform lift circuit in the aux. lift circuit or vice versa. This can cause the truck to overload and result in serious and even fatal accidents.

J

B

A

C H D M1937

Platform Lift Pressure Relief Valve Setting

G

WARNING The pressure relief valve setting is very critical. An incorrect setting can cause the truck to overload and result in serious and even fatal accidents.

E

F

M1945

Operation If the system pressure exceeds the preset value on the pressure relief valve (Fig. M1945, C / C and E), the pressure relief valve opens. Oil is channelled into the tank to preserve the max. permissible system pressure.

MS-2.4-3310

42M1.0-0000-00042

●

Prepare a test load with 30% more weight than the max. permissible load according to the capacity plate.

●

Position the forks, the load should rest against the backrest.

●

Attempt to raise the load (with platform lift)

●

The load should not rise.

If the load does rise, lower immediately and set the pressure relief valve (E, Fig. M1945). ●

Remove the lead plombing.

●

Loosen the jam nut and slightly unscrew the hex. screw.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

HYDRAULICS ●

●

●

Repeat the test with the test load. If necessary, repeat the adjustment and test until the pressure relief valve opens when the test load is raised.

Counter the set screw, repeat the test again to ensure that the set value has not been changed.

Non-Return Valve The non-return valve (J, Fig. M1937) prevents the platform / forks from accidental lowering.

Functional Test: ●

Open the motor cover.

●

Either fully raise the platform with the help of an assistant or attach the relevant remote control wiring to the “SD-M” plug and bring the platform itself up to the highest point.

●

A pressure relief valve setting is very critical. An incorrect setting can cause the truck to overload and result in serious and even fatal accidents.

Remove the brush cover on the pump motor so that the armature becomes visible.

●

Lower the platform while observing the pump motor armature. It should not turn.

●

Prepare a test load with 30% more weight than the max. permissible load according to the capacity plate.

If the armature moves, de-pressurise the hydraulic system and remove, dismantle and clean the non-return valve (J, Fig. M1937). Replace any damaged parts.

●

Fully lower the platform.

Repeat the functional test after re-assembling and fitting the valve.

●

Position the forks, the load should rest against the backrest.

Refit the lead plombing in the pressure relief valve.

Aux. Lift Pressure Relief Valve Setting DANGER

●

Attempt to raise the load with the fork lift.

●

The load should not rise.

If the load does rise, lower immediately and set the pressure relief valve (C, Fig. M1945).

Refit the motor cover.

Compensation Valve The compensation valve (A, Fig. M1945) ensures that the lifting and lowering speeds of the platform are virtually identical, both with and without load.

Functional Test:

●

Remove the lead plombing.

●

Loosen the jam nut and slightly unscrew the hex. screw.

●

●

Repeat the test with the test load. If necessary, repeat the adjustment and test until the pressure relief valve opens when the test load is raised.

●

Fully raise the platform without load.

●

Lower the platform and count the time taken for it to reach the lower stop.

●

Fully raise the platform with max. permissible load.

Lower the platform and count the time taken for it to reach the lower stop.

●

Counter the set screw, repeat the test again to ensure that the set value has not been changed.

●

●

Refit the lead plombing in the pressure relief valve.

The valve is operating correctly if the two times are virtually identical. If there is a large discrepancy, remove the compensation valve. Clean the valve and valve seat.

Replace any damaged parts.

Repeat the functional test after re-assembling and fitting the valve.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-2.4-3310

M1.0-0000-00043 43

HYDRAULICS the raised platform and fully open the ball valve in a sudden movement.

Line Break Safety Device The line break safety devices are located in the respective cylinders and are not part of the valve block.

●

The line break safety device is functioning if the cylinder to be tested lowers at max. 0.6 m/s (corresponds to 1.667 seconds at 1m lift height).

If this value is exceeded, replace the respective line break safety device.

●

Remove the test hoses and remote control wiring again.

●

Refit the pressure hose on the valve block. Clean the connections and surrounding parts of hydraulic oil. Fill hydraulic oil up to the middle of the inspection glass.

However, the functional test involves operating with the valve block and therefore we describe the procedure in this chapter.

Tools Required: To Filler Neck Hydraulic Tank Ball Valve

Fro m

Va lve B

K loc k

To Cylinder M1974

A1

B

Hose kit with high pressure ball valve (Fig. M1974)

T

Line Break Safety Device Functional Test ●

Position the forks underneath a load of 300 kg.

●

Lower platform and forks. Now press the lower switch(es) for approx. 1 minute to reduce the system pressure as far as possible. Switch off the truck.

●

Open the motor panel.

●

On the valve block, loosen the pressure hose of the cylinder to be tested (Fig. M1945: A1= platform lift B=Aux. lift, P=Pressure hose of pump, T=Return flow to tank). Collect any spilled oil.

●

Attach test hoses. Fit the pressure hose to the cylinder into the T-piece in front of the ball valve and the hose after the ball valve deep into the oil filler plug of the hydraulic tank, and ensure they cannot slide out.

●

Connect the remote control wiring to the “SD-M” plug. Ensure that nobody is standing on the platform during testing.

●

Close the ball valve, start the truck and using the remote control wiring raise the load 1m high.

●

Ensure that no persons or obstacles are below

MS-2.2-3310

44M1.0-0000-00044

P

C M1945

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

HYDRAULICS Emergency Lowering Valve The emergency lowering valve (K, Fig. M1945) enables the platform to be manually lowered if there is a power failure or the lowering valve is blocked.

Tools Required: Remote control wiring

Emergency Lowering Valve Functional Test ●

Fully lower the platform

●

Open the motor panel.

●

Connect the remote control wiring to the “SD-M” plug. Ensure that nobody is standing on the platform during testing.

●

Fully raise the platform using the remote control.

●

Ensure that no persons or obstacles are below the raised platform and fully open the emergency lowering valve (K, Fig. M1945). The platform should lower.

●

Close the emergency lowering valve again (K, Fig. M1945).

If the emergency lowering valve does not open, it must be replaced immediately. Repeat the test after replacing.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-2.2-3310

M1.0-0000-00045 45

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Printed in Germany

46

DRIVE UNIT

Printed in Germany

47

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Printed in Germany

48M1.0-0000-00048

DRIVE UNIT Drive Unit Preparation The vehicle must be raised to remove the transmission.

See Section M1 for the relevant instructions.

D

Material Required ●

Lifting gear of sufficient capacity and lift height.

●

Two hardwood blocks (minimum surface area 250 x 250 mm, 80 mm high) or other suitable solid supports for securing the vehicle.

●

B C

Suitable arrangement for holding the drive assembly when the vehicle is raised. This arrangement should also allow the assembly to be transported.

Drive Unit Removal ●

Remove battery connector and key.

●

Prevent vehicle from being switched on again.

●

Open motor compartment panels and remove skirt (A).

●

Isolate electrical connections on the motor and brake (B).

●

Open steering chain lock (16, Fig. M1753) (C) and remove steering chain.

A A

M1954

B F

●

Remove cable jacket (D) and cable.

●

Undo grub screw (28, Fig. M1753) on potentiometer. Unscrew potentiometer clamp (24, Fig. M1753) and fold it to one side with the potentiometer.

●

●

E E DANGER DO NOT WORK UNDER A SUSPENDED LOAD! ALWAYS SECURE VEHICLE AGAINST BEING LOWERED.

Remove bolt (26, Fig. M1753) and take off clamp (31, Fig. M1753). Detach microswitch for steering angle restriction (E) from its clamp.

Remove hexagon socket screw (40, Fig. M1753) in order to release the drive from the frame.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

M1926

SEVERE INJURY MAY RESULT FROM THE VEHICLE SUDDENLY BEING LOWERED.

●

Lift vehicle high enough so that the drive group is freed under the chassis and can be removed.

●

Lower vehicle onto 80 mm high hardwood blocks under the left and right sides of the frame.

●

Remove drive group and place it on a workbench.

M-3.0-3010

M1.0-0000-00049 49

DRIVE UNIT

M1753 M-3.0-3010

50M1.0-0000-00050

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

DRIVE UNIT Gear Unit Repair

●

Unscrew hexagonal socket screw (14) and remove the transmission unit cover (4) with the two alignment pins. Remove compensation ring (5).

Collect any emerging grease and dispose of according to regulations.

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Remove seal (20) and clean any residue off the seal surfaces.

Remove pinion (19) and roller bearing (18) with bolts (16, 17) and shaft (12) with O-ring (13).

WARNING THE GEAR UNIT MUST ONLY BE REPAIRED

BY AUTHORIZED PERSONNEL TRAINED BY CROWN. OTHERWISE THE MANUFACTURER’S WARRANTY IS INVALIDATED. INCORRECT SETTINGS WILL CAUSE PREMATURE GEAR UNIT FAILURE.

●

AS A RULE, THEREFORE, IT IS PREFERABLE TO FIT A REPLACEMENT GEAR UNIT.

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Apply lever below pinion (8) and remove the pinion shaft with bearing and gear.

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Remove circlip (6) from the pinion shaft.

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Extract bearing (7) with a puller. Pull off pinion (8).

Remove feather spring (11) (for subsequent replacement with new one) and extract bearing (9) from the pinion shaft with a puller.

General ●

All bearings and seals must be replaced.

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Prior to removal, clean gear unit thoroughly with a cold cleaner and blow dry gently with compressed air.

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Use assembly devices and a clean workplace.

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Undo nut (38) and remove motor pinion (36) with a puller.

All items, e.g. (06), in the following repair instructions refer to drawing M1755 on the following page unless otherwise specified.

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Remove hexagonal socket screw (21) and washers (22) and take out motor. Remove O-ring (37).

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Remove bolt (35).

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Press off drive wheel (Fig. M1923). Insert two fully threaded bolts M8 x 100 in the extraction holes and push the wheel off by alternate tightening of the bolts.

Drive Unit Removal ●

Remove key (44, Fig. M1755).

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Remove self-locking ring nut (38).

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Insert two fully threaded bolts M10 x 40 (minimum) in the extraction holes of the flange (41) (see Fig. M1924, A) and push off flange by alternate tightening of the bolts.

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Remove axial bearing (43).

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Remove hexagonal socket screw (1) and locking plate (3).

M1923

A M1924 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

M-3.1-3010

M1.0-0000-00051 51

DRIVE UNIT

M1755 M-3.1-3010

52M1.0-0000-00052

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

DRIVE UNIT Gear Unit Assembly

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Remove O-ring (26).

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Remove hexagonal socket screws (33) and flange (31).

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Remove seal (32) and O-ring (30).

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Remove lock washer (29) and force off crown gear (25) by screwing two fully threaded bolts M19 x 40 into the extraction holes of the housing (4) (Fig. M1922).

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Clean all parts thoroughly, remove residue of seals. Internal parts must be absolutely clean and free from residue. Always replace all seals and worn parts.

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Press bearing (27) and spacer sleeve (28) into crown gear (25) with a press.

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Place new seal (24) on the support surface of the crown gear (25).

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Fill bearing (27) with grease (see lubrication table).

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Place transmission housing (23) on a press bench and press the pre-assembled crown gear (25 with 27,28) into the housing until the seal (24) almost reaches the seal seating of the housing (23). Press seal (24) carefully and evenly into the seating and press the crown gear (25) fully home (see Fig. M1920).

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Insert flange (26) with attached crown gear bearing (24) into the housing. Drive the flange in

M1922

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Remove seal (24).

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Remove bearing (27) and spacer sleeve (28) with a press (see Fig. M1921).

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Check position in housing.

25

24 Tube, ext. diameter 185 mm

23

Crown gear Tube, Internal diameter 237 mm

M1920

evenly using a rubber hammer. Do not damage the O-ring.

M1921

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

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Secure the flange (25) with the bolts (33). Tighten bolts with a torque setting of 3.1 Nm.

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Press bearing (9) onto the pinion shaft (10).

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Insert spring (11) into the recess in the pinion shaft (10).

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Place pinion (8), bearing (7) and lock washer (6) on the pinion shaft (10).

M-3.1-3010

M1.0-0000-00053 53

DRIVE UNIT ●

Mount motor pinion (36) on the motor axis and tighten bolts (38) to a torque of 50 Nm.

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Place new O-ring (37) on the front flange of the motor.

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Insert drive motor into the housing (23). Rotate so that the terminal board points upward to the attachment flange of the transmission unit. Fix with the bolts (21). Torque setting: 25 Nm

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Through the bearing hole of the pinion shaft (10) in the housing (4), apply approx. 0.4 kg of grease evenly to the teeth of the crown gear (25) (see Lubrication Table).

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Carefully guide pinion shaft (10) complete with bearing and pinion (8) into the housing, ensuring correct meshing of the gear teeth with the crown gear (25).

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Insert shaft (12) into the housing (4). Fit the axial bearing (16), axial roller and cage unit (17) and cage roller bearing (18) and lightly grease.

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Install the pinion (19), axial roller and cage unit (17) and cage roller bearing (16).

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Position new O-ring (13) on the shaft (12) and fit a new housing gasket (20).

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Place compensation ring (5) on the bearing surface (7) in the housing (4).

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Apply grease (approx. 0.6 kg) evenly in the area of the crown rear inside the housing (4) according to the Lubrication Table.

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Position housing (4) on the shaft (12) and tap evenly with a rubber hammer against the gasket.

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Insert new alignment pins 5 x 20 into the recesses and secure the housing (4) with the bolts (14). Torque setting: 10 Nm

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Put the locking plate (3) in position and secure with the bolts (1). Torque setting: 6 Nm

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Place new O-ring (26) on the crown gear (25)..

Put the drive wheel (34) in position and secure with the bolts (35). Torque setting: 15 Nm

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Place the flange (47, Fig. M1753) onto the housing. Align the groove for the cable with the groove on the housing and secure the flange with the bolts (45, Fig. M1753). Torque setting: 134 Nm

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Press bearing (39, Fig. M1753) into the flange (41, Fig. M1753).

M-3.1-3010

54M1.0-0000-00054

●

Press the axial bearing ring with the ground internal surface and the ballrace facing upwards (43, Fig. M1753) into the flange (47, Fig. M1753).

Grease the ballrace, insert the ring with the ball bearings and grease. Insert the second ball cup and place shim (42, Fig. M1753) on top.

●

Insert flange (41, Fig. M1753) completely into the flange (47, Fig. M1753) using a rubber hammer and secure with a new self-locking ring nut (39, Fig. M1753). Only tighten the nut until the flange (41, Fig. M1753) has no more axial play and can still be turned freely.

Installing the Drive Unit ●

Place the drive unit on the chassis and secure with the bolts (40, Fig. M1753). Torque setting: 50 Nm

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Align the drive unit so that the drive motor is at an angle of 90 degrees to the longitudinal axis of the vehicle. Refit all other parts that were previously removed.

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Fit the steering chain again and adjust chain tension with the screw (A, Fig. 1931).

A

A

M1931

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS

Printed in Germany

55

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Printed in Germany

M1.0-0000-00056 M1.0-0000-00056 56

ELECTRICS Electrical Components

F02 Aisle Recognition Sensor OPTION

DANGER The truck must be jacked up before repairing or troubleshooting the electrical system.

AV Alarm The alarm AV (HN2) is located in the engine compartment. For operation, see pressure switch PS.

CX Horn The horn CX (HN1) is located in the engine compartment of the truck and is triggered by activating the horn switch PCX or PCXglf.

F1, F2, FA,FA4 Fuses ●

F1, 200A: Travel main fuse

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F2, 250A: Lift main fuse

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FA, 10A: Fuse for control circuits: traction control, lift control and display.

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FA4, 5A: Fuse for lift control system control circuit: the truck will still travel even if this fuse blows due to an error in the lift control system.

F3, FA3 Fuses ●

F3, 32A: Steering control main fuse

●

FA3, 3A: Steering control system control circuit

F01 Aisle Recognition Sensor OPTION

F02 (RGS2) is a reflection sensor and is only used on trucks with optional aisle guidance rollers. To enable this, two reflectors must also be fitted at the start and end of the aisle respectively. If a reflector is crossed over when entering the aisle, F01 generates a signal on Pin C6 of the traction control system. The traction control system automatically sets the mode to aisle mode.

Note: Do not use the reflectors of sensor F01.

FE Brake The electromagnetic brake FR (BR) is spring-loaded and brakes when the truck is de-energised (parking brake). When the truck is travelling, the brake is only released when the foot switch PCE or PCEglf opens or the emergency disconnect switch PE is pressed.

HN3 Alarm The alarm HN3 on the steering control system is attached to a cable tie on the wire harness.

K1, K2 Travel Direction Contactors K1: Reverse travel direction contactor (fork direction) K2: Forward travel direction contactor (drive direction)

K4 Main Contactor The K4 main contactor engages the complete power supply for the traction, pump and steering systems.

K4 is activated via the same control line as RL1, Display, Pin G3.

F01 (RGS1) is a reflection sensor and is only used on trucks with optional aisle guidance rollers. This sensor automatically sets the steering wheels straight when entering the aisle. To enable this, two reflectors must also be fitted at the start and end of the aisle respectively.

Note: Do not use the reflectors of sensor F02.

MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.2-3010

57

ELECTRICS K6 Steering Contactor Contactor K6 applies the battery (+) to the power part of the steering control system.

The coil of contactor K6 is activated by the steering control system EPS-DC via output E6.

M1 Traction Motor The traction motor M1 is a series motor with two separate field coils for forward (DR connection) and reverse travel (DL connection). For forward travel K2 closes and connection DR is set to the battery +, while for reverse travel K1 closes and connection DL is set to the battery +. The motor is controlled via connection A1.

M2 Pump Motor The pump motor M2 is a series motor. It is governed by the lift control system.

MFC Lift Limit Switch (Cabin) The lift limit switch MFC (HCS1) disconnects the pump motor M2 when the cabin's maximum lift height is reached.

MFF Lift Limit Switch (Forks) When the forks reach their maximum lift height, switch MFF (HCS2) is automatically activated, and at the same time pump motor M2 and valves ED and EDF are disconnected.

MFT Overhead Guard Monitor OPTION

Switch MFT (RCS2) is located on the overhead guard and prevents the cabin from lifting if it encounters an obstacle.

Only available on trucks with an overhead guard.

MLS Lift Interruption Switch OPTION

M3 Steering Motor The steering motor is a permanent magnetic motor. It is controlled by the EPS-DC steering control system.

MAC Chain Slack Switch Not used on the LP3010 or LP3020 (jumper on lift control system, plug C, Pin9, Pin5 and Pin6 ).

MBC Not used on the LP3010 or LP3020 (jumper on display, plug F, Pin22 and Pin10 ).

MF Steering Limit Switch Both steering limit switches MF (LMS3 and LMS4) deenergise the steering motor before the steering mechanical stop is reached. When the maximum steering angle is reached they interrupt the input signals on Pin D1 and D7 respectively of the steering control system. The switches are activated via a trip cam attached to the steering shaft.

MS-4.2-3010

58

At a given lift height the MLS (RCS1) switch prevents the cabin from lifting. The override switch PLS (ORS1) must be pressed to continue lifting.

If this option is not available, a jumper is fitted on the graphic display, plug F, between contacts 12 and 24.

MMI,MMA,PT Transmitter On the LP3010 the transmitter is on the right-hand operating handle and is activated by a cam switch. The travel speed is controlled by the traction potentiometer PT (POT1), the travel direction via switch MMI (FS1), forward = drive unit direction, and MMA (RS1), reverse = fork direction.

The LP3020 is also fitted with a second transmitter located on the right-hand side of the fork side control panel. This is designed as a twist handle.

The travel speed is controlled by the traction potentiometer PT (POT2), the travel direction via the rotary switch MMI (FS2) and MMA (RS2).

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS MPR Door Switch OPTION

Additional doors are fitted on trucks with a lift height of 1620mm (LP3010) and 2440mm (LP3020).

Each door has a door switch MPR (GTS1 and GTS2).

The truck can only be operated when both doors are closed.

MP1,MP3 Pallet Recognition Switch LP3010 with 1620mm lift height only: The switches MP1 (PLS1) and MP3 (PLS2) are located below the cabin, in the fork direction on the right-hand side and are arranged behind each other. ●

MP1: restricts the lift height of the forks to 1030mm if there is no pallet on the forks.

●

MP3: identifies if a pallet is present.

MR Lower Brake Switch The lower brake switch MR (HGTS1) is located at the rear of the driver's cabin. The lowering speed is reduced 10 cm before the cabin reaches its lowest position, ensuring smooth braking.

MS1, MS2 Steering: Tachogenerator On the LP3010 the steering wheel is mounted directly on to the tachogenerator MS1.

On the LP3020 in addition to the control panel on the fork side there is a steering wheel with tachogenerator MS2.

The tachogenerators generate a voltage proportional to the direction and speed of turn. This voltage is used to control the steering.

To ensure MS1 and MS2 work as intended, they are permanently monitored by the electronic system. A constant impulse is transmitted to the tachogenerators which creates a gentle ticker on the steering wheel.

MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MSC,MDC,PTP Cabin Lift / Lower On the LP3010 the cam switch for Lift MSC (RAS1)/ Lower MDC (LOS1) and the lift potentiometer PTP (POT3) is on the left-hand operating handle.

The LP3020 also has a rotary pushbutton for lift/lower on the left-hand side of the fork side control panel. The rotary pushbutton unit contains the switch for Lift MSC (RAS2), Lower MDC (LOS2) and the Lift Potentiometer PTP (POT4).

When the MSC and PCS lift switches are activated simultaneously (RAS1 and DMS1 or RAS2 and DMS2), pump motor M2 is activated. The lift speed is controlled by potentiometer PTP (POT3 or POT4) and proportional valve EVP (PVH).

Lowering is activated by switches MDC and PCS (LOS1 and DMS1 or LOS2 and DMS2). In the process, valve EDC (SV2) is applied in the hydraulic system. The lowering speed is controlled by proportional valve EVP (PVH).

MV2, MV3 Lift Height Dependent Speed Reduction The microswitch MV2 (LMS1) reduces the permissible travel speed to 6 km/h at a lift height of 500mm.

MV3 (LMS2) reduces the travel speed to 4 km/h at a lift height of 2500mm. Not used on the LP3010 or LP3020 (jumper to traction control system, plug C, Pin9 and Pin4).

PE Emergency Disconnect Switch On the LP3010 the emergency disconnect switch PE (EDS1) is above the right-hand operating handle.

On the LP3020 there is an additional emergency disconnect switch PE (EDS2) on the right-hand side of the fork side control panel.

Pressing the emergency switch PE (EDS1 or EDS2) interrupts the control voltage to relay RL1 and main contactor K4 (graphic display Pin G3). This serves to de-energise the entire system. The electromagnetic brake FE is engaged and the truck brakes.

MS-4.2-3010

59

ELECTRICS PCE, PCEglf Brake Switch

be pressed at the same time with PCS (RAS3) or PCD (LOS3).

PCT,MCT Aisle Guidance Two-Hand Switch OPTION

On the LP3010 the brake switch PCE (DMS4) is on the right-hand side of the base plate and is in the form of a foot switch. When the foot switch is pressed the brake is released and the truck is able to travel.

The LP3020 also contains a brake switch PCEglf (DMS5). This is on the right-hand side of the base plate on the fork side control panel and is in the form of a foot switch. A further two auxiliary switches (DMS5.1 and DMS5.2) are attached to this switch. If the truck is controlled from the mast side, DMS5.2 briefly closes the tachogenerator MS2, thereby making it hard to manoeuvre. If the truck is operated from the fork side and the foot switch PCEglf (DMS5) is operated, DMS5.2 opens and DMS5.1 closes, i.e. MS1 becomes hard to manoeuvre.

PCS, PCD Fork Lift/Lower On the LP3020 the switches for Lifting PCS (RAS3) and Lowering PCD (LOS3) are below the emergency disconnect switch on the fork side of the control panel.

Fork lifting is activated by engaging the lift switch PCS (RAS3) and switch MCS (DMS3) simultaneously. This activates the pump motor M2 and valve ED (SV1).

Lowering is activated by switch PCD (LOS3) and MCS (DMS3). Valves EDF (SV3) and EVP (PVH) are applied in the hydraulic system in the process.

The two-hand switch PCT (DMS6) must be activated in connection with the transmitter to operate the LP3010 in aisles.

On the LP3020 the two-hand switch MCT (DMS7) is incorporated in the rotary button for cabin lifting/ lowering and must be pressed down to enable travelling in the aisle.

PCX, PCXglf Horn Switch On the LP3010 the horn switch PCX (HNS1) is on the left-hand side of the base plate and is in the form of a foot switch. A horn sounds when the foot switch is pressed.

The LP3020 contains an additional horn switch PCXglf (HNS2). This is on the left-hand side of the base plate on the fork side control panel and is in the form of a foot switch.

PEA Chain Slack Bypass Switch Not used on LP3010 or LP3020 (jumper on display, plug D, Pin6 and Pin17 ).

PFA Work Lights Switch OPTION

PCS, PCSD, MCS Dead Man Switch On the LP3010 the dead man switch PCS (DMS1) is on the left-hand side next to the travel cam switch. This switch is in the form of a pushbutton and must be activated at the same time with MSC or MDC in order to activate cabin lifting or lowering.

The LP3020 also contains 2 additional dead man switches on the fork side control panel.

Dead man switch PCSD (DMS2) is integrated in the transmitter of the fork side control panel and is in the form of a pushbutton (press rotary button down). It acts as a safety switch for cabin lifting/lowering and must be activated at the same time with MSC or MDC (fork side) in order to activate cabin lifting/lowering.

Dead man switch MCS (DMS3) is located on the lefthand side below the steering wheel on the fork side control panel and is in the form of a pushbutton. It acts as a safety switch for lifting/lowering the forks and must MS-4.2-3010

60

The work lights are switched on using switch PFA (LGS1).

Available on trucks with overhead guard only.

PLS Bypass Switch OPTION

PLS (ORS1) must be pressed to continue lifting after a defined lift interruption.

PS Pressure Switch If the maximum rated load is exceeded by 20%, the pressure switch PS (make contact) engages and sets the alarm AV (HN2) to the battery negative pole.

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS PTR Steering Angle Potentiometer The steering angle potentiometer PTR (POT5) is mounted on the steering shaft of the drive wheel. It is used for the following functions: ●

Displaying the steering angle.

●

Speed reduction at a steering angle of +/- 10°

QC Key Switch The key switch QC (KYS) is located above the lefthand operating handle. Turning the key clockwise activates the control system.

RL1 Trip Relay When the key switch QC is activated the trip relay RL1 is activated via the display, Pin G3 and the power supply (battery +) for traction and pump control connected.

MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.2-3010

61

ELECTRICS MK3N Traction Controller DANGER The truck must be jacked up before repairing or troubleshooting the electrical system.

Maintenance Servicing the MK3N traction controller is limited to a dry- clean of the outer parts.

You can take this opportunity to deal with any errors identified by the programmer.

WARNING

General

The MK3N traction controller operates with high voltages. Special safety precautions therefore apply when handling the controller.

The MK3N programmable impulse controller provides effective control over the travelling pattern of the vehicle.

● Only use specially trained personnel.

Precautionary Measures ●

●

●

●

● Use non-wearying eye protection ● Do not wear loose clothing.

Do not connect the controller to any battery whose rated voltage differs from the controller's specified voltage.

A higher battery voltage can damage the MOSFETs, while a lower power supply will leave the system inoperable.

● Do not wear jewelry. ● Only use insulated tools.

Only operate the controller with special traction batteries. Do not connect it to a rectifier or to the mains!

●

Disconnect the battery.

●

Jack up the truck.

Jack up the truck when commissioning the truck or when carrying out maintenance work on the controller and electrical system, in order to prevent the truck from suddenly starting in the event of faults.

●

Discharge the traction controller capacitors by connecting BATT- and BATT+ connections via a resistance of approx. 10 Ohm, min. 5 Watt.

●

Remove the cable.

The capacitors in the controller remain charged for a few minutes after disconnecting the key switch. If you work on the controller within this period you must first disconnect the controller from the battery (remove the battery connector).

Then discharge the capacitors by short-circuiting the positive and negative connections of the power part over a resistance (10 - 100 Ohm, min.

5W) for a few seconds.

●

Remove any dirt and corroded material from the contact surfaces.

●

Wipe the traction controller with a clean, damp cloth.

●

When everything has dried, connect the cable again.

Replacing the Traction Controller

MS-4.3-3010

62

●

Disconnect the battery.

●

Jack up the truck.

●

Discharge the traction controller capacitors by connecting BATT- and BATT+ connections via a resistor (approx. 10 Ohm, min. 5 Watt).

●

Unscrew the nuts from the traction controller panel.

●

Remove the cable.

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ●

Remove the 4 screws from the corners of the controller base plate.

●

Lift out the controller and fit the new controller in the reverse order.

Settings after Replacing the Traction Controller ●

●

Connect the console (programmer) .

Enter the "SET MODEL" submenu and set the controller to "STANDARD TRACTION".

●

Change to the "PARAMETER CHANGE" submenu and set all the values to the settings as recommended in Table E-11-GB. Now check the braking distance of the vehicle and adjust the setting if necessary.

Warning: The new controller can be programmed either as a lift or traction controller and must under all circumstances be set.

Steering controller

Lift controller Traction controller

M1954 MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.3-3010

63

ELECTRICS MK3N Lift Controller DANGER The truck must be jacked up before repairing or troubleshooting the electrical system.

Maintenance Servicing the MK3N lift controller is limited to a dryclean of the outer parts.

You can take this opportunity to deal with any errors identified by the programmer.

WARNING

General

The MK3N lift controller operates with high voltages. Special safety precautions therefore apply when handling the controller.

The MK3N programmable impulse controller provides effective control over the lifting pattern of the vehicle.

● Only use specially trained personnel.

Precautionary Measures ●

●

●

●

● Use non-wearying eye protection Do not connect the controller to any battery whose rated voltage differs from the controller's specified voltage.

A higher battery voltage can damage the MOSFETs, while a lower power supply will leave the system inoperable.

Only operate the controller with special traction batteries. Do not connect it to a rectifier or to the mains!

Jack up the truck when commissioning the truck or when carrying out maintenance work on the controller and electrical system, in order to prevent the truck from suddenly starting in the event of faults.

The capacitors in the controller remain charged for a few minutes after disconnecting the key switch. If you work on the controller within this period you must first disconnect the controller from the battery (remove the battery connector).

Then discharge the capacitors by short-circuiting the positive and negative connections of the power part over a resistance (10 - 100 Ohm, min.

5W) for a few seconds.

● Do not wear loose clothing. ● Do not wear jewelry. ● Only use insulated tools.

●

Disconnect the battery.

●

Jack up the truck.

●

Discharge the lift controller capacitors by connecting BATT- and BATT+ connections via a resistance of approx. 10 Ohm, min. 5 Watt.

●

Remove the cable.

●

Remove any dirt and corroded material from the contact surfaces.

●

Wipe the lift controller with a clean, damp cloth.

●

When everything has dried, connect the cable again.

Replacing the Lift Controller

MS-4.3-3010

64

●

Disconnect the battery.

●

Jack up the truck.

●

Discharge the lift controller capacitors by connecting BATT- and BATT+ connections via a resistor (approx. 10 Ohm, min. 5 Watt).

●

Unscrew the nuts from the lift controller panel.

●

Remove the cable.

●

Remove the 4 screws from the corners of the controller base plate.

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ●

Lift out the controller and fit the new controller in the reverse order.

●

Change to the "PARAMETER CHANGE" submenu and set all the values to the settings as recommended in Table E-15-GB. Now check the braking distance of the vehicle and adjust the setting if necessary.

●

Connect the console (programmer) to the graphic display. Change to the "PARAMETER CHANGE" submenu and set all the values to the settings recommended in Table E-01-GB. Now check the lifting function and adjust the settings if necessary.

Settings after Replacing the Lift Controller ●

●

Warning: The new controller can be programmed either as a lift or traction controller and must under all circumstances be set.

Connect the console (programmer).

Enter the "SET MODEL" submenu and set the controller to "STANDARD PUMP".

Steering controller

Lift controller Traction controller

M1954 MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.3-3010

65

ELECTRICS EPS-DC Steering Controller DANGER The truck must be jacked up before repairing or troubleshooting the electrical system.

Maintenance Servicing the steering controller is limited to a dryclean of the outer parts.

You can take this opportunity to deal with any errors identified by the programmer.

WARNING

General

The steering controller operates with high voltages. Special safety precautions therefore apply when handling the controller.

The EPS-DC programmable impulse controller provides effective control over the travelling pattern of the vehicle.

● Only use specially trained personnel.

Precautionary Measures ●

●

●

●

● Use non-wearying eye protection ● Do not wear loose clothing.

Do not connect the controller to any battery whose rated voltage differs from the controller's specified voltage.

A higher battery voltage can damage the MOSFETs, while a lower power supply will leave the system inoperable.

● Do not wear jewelry. ● Only use insulated tools.

Only operate the controller with special traction batteries. Do not connect it to a rectifier or to the mains!

●

Disconnect the battery.

●

Jack up the truck.

Jack up the truck when commissioning the truck or when carrying out maintenance work on the controller and electrical system, in order to prevent the truck from suddenly starting in the event of faults.

●

Discharge the steering controller capacitors by connecting BATT- and BATT+ connections via a resistor (approx. 10 Ohm, min. 5 Watt).

●

Remove the cable.

The capacitors in the controller remain charged for a few minutes after disconnecting the key switch. If you work on the controller within this period you must first disconnect the controller from the battery (remove the battery connector).

Then discharge the capacitors by short-circuiting the positive and negative connections of the power part over a resistance (10 - 100 Ohm, min.

5W) for a few seconds.

●

Remove any dirt and corroded material from the contact surfaces.

●

Wipe the steering controller with a clean, damp cloth.

●

When everything has dried, connect the cable again.

Replacing the Traction Controller

MS-4.3-3010

66

●

Disconnect the battery.

●

Jack up the truck.

●

Discharge the steering controller capacitors by connecting BATT- and BATT+ connections via a resistance of approx. 10 Ohm, min. 5 Watt.

●

Unscrew the nuts from the controller panel.

●

Remove the cable.

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ●

Remove the 4 screws from the corners of the controller base plate.

●

Lift out the controller and fit the new controller in the reverse order.

Settings after Replacing the Steering Controller ●

Warning: The new controller must be set.

●

Connect the console (programmer) to the steering controller.

●

Change to the "PARAMETER CHANGE" submenu and set all the values to the settings as recommended in Table E-19-GB. Now check the steering of the vehicle and adjust the setting if necessary.

Replacing Fuses ●

Lever off the plastic cover from the housing.

Replace any blown fuses with fuses of the same type and current capacity.

Steering controller Lift controller Traction controller

M1954

Control circuit fuse

Power part fuse

MS-3010-069

MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.3-3010

67

ELECTRICS Graphic Display

●

Disconnect the battery.

●

Remove the console in order to access the electrical contacts of the graphic display (Fig. MS3010-066).

DANGER The truck must be jacked up before repairing or troubleshooting the electrical system.

General The graphic display does not only display the service hours. Additional settings which are passed to the traction and lift controllers during operation are programmed and stored here.

Precautionary Measures ●

Do not connect the display to any battery whose rated voltage differs from the controller's specified voltage.

A higher battery voltage can damage the MOSFETs, while a lower power supply will leave the system inoperable.

●

Only operate the display with special traction batteries. Do not connect it to a rectifier or to the mains!

●

Jack up the truck when commissioning the truck or when carrying out maintenance work on the controller and electrical system, in order to prevent the truck from suddenly starting in the event of faults.

MS-3010-066

●

Remove the plug connector, remove the console and display and place them on a clean working surface.

Maintenance Servicing the display is limited to a dry- clean of the outer parts.

WARNING MS-3010-068

Short circuit danger with electrical equipment. Special safety precautions therefore apply when working with electrical systems. ● Only use specially trained personnel.

●

Remove any dirt and corroded material from the contact surfaces.

●

Wipe the display with a clean, dry cloth and blast off any dust on the boards with low pressure dry compressed air.

●

Refit the plug connector.

● Use non-wearying eye protection. ● Do not wear loose clothing. ● Do not wear jewelry. ● Only use insulated tools.

MS-4.3-3010

68

MS-LP31010/320-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Replacing the Graphic Display ●

Disconnect the battery

●

Remove the console in order to access the electrical contacts of the graphic display (see Fig. MS-3010-066).

●

Remove the plug connector (see Fig. MS-3010066).

●

Remove nuts (A, Fig. MS-3010-067) and lift out display in full.

A

MS-3010-067

●

Fit the new display in the reverse order.

Settings after Replacing the Graphic Display ●

Warning: The new display must be set under all circumstances.

Connect the console (programmer) to the graphic display as indicated on page M-4.4-3010-002 ff.

●

Change to the "OPTIONS" submenu and set all the values according to Table E-09-GB. Now change to the "PARAMETER CHANGE" menu and set the rated values as indicated in Table E-01-GB. Now check and adjust (if necessary) the potentiometer calibration in the "ADJUSTMENTS" menu (Table E-10-GB). Now check the travel pattern, the lifting function and braking distance of the truck. Adjust the settings if necessary.

MS-GPC2000-GB 09/02 • Rev. A • Printed in Germany

MS-4.3-3010

69

Page intentionally left blank

Printed in Germany

70

ELECTRICS Programmer

The programmer is connected to the control system by a cable and an adapter (M1912).

General

CAUTION The programmer should only be connected to and disconnected from the control system when the truck is switched off.

The optional programmer (Fig. M0271-new) is used to program, test and diagnose the traction and lift control systems and the display.

JC604

PC603

PC602

M0271-new

PC601

M1912

Display Window ● ●

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

Alphanumeric LCD 2 lines with 16 characters each

Function keys

M0274 MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.4-3010

M1.0-0000-00071 71

ELECTRICS Connecting the programmer and the adapter The following items are required to communicate with the MK3N controllers and the graphic display: programmer (PN 794596), adapter (PN 810058). The controllers are located in the engine compartment. The pump controller is located on the right and the traction controller on the left.

ging the programmer. ●

Unplug the adapter and programmer.

●

Re-connect plug A to the pump controller.

Tract. controller

C

Pump Controller

B

A

C

B

A

M2050

Data Connection to the Pump Controller: ●

Power down the truck (key switch).

●

Remove plug A from the pump controller.

●

Connect PC601 of the adapter to bushing A of the pump controller.

●

Connect the programmer to plug PC602 of the adapter.

●

Power up the truck. The programmer display reads "SERIAL ERROR #1".

●

Carry out modifications as necessary.

●

Power down the truck before unplug-

MS-4.4-3010

72M1.0-0000-00072

Data connection to the Traction Controller: ●

Power down the truck (key switch).

●

Remove plug A from the traction controller.

●

Connect PC601 of the adapter to bushing A of the traction controller.

●

Connect the programmer to plug PC602 of the adapter.

●

Power up the truck. The programmer display reads "SERIAL ERROR #2".

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ●

Carry out modifications as necessary.

●

Power down the truck before unplugging the programmer.

●

Unplug the adapter and programmer.

●

Re-connect plug A to the traction controller.

Data Connection to the Graphical Display ●

Power down the truck (key switch).

●

Remove plug A from the pump controller.

●

Connect PC601 of the adapter to bushing A of the pump controller.

●

Connect the programmer to plug PC603 of the adapter

●

Connect plug A to bushing JC604 of the adapter.

●

Power up the truck (key switch).

The programmer display should not indicate any errors.

●

Carry out modifications as necessary.

●

Power down the truck before unplugging the programmer.

●

Unplug the adapter and programmer.

●

Re-connect plug A to the traction controller.

Note: If there are programmers connected to PC602 and PC603 respectively, the pump controller and the graphic display can be read and programmed simultaneously, providing PC601 & JC604 are connected.

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.4-3010

M1.0-0000-00073 73

ELECTRICS Description of Keys Key

Designation

Explanation

1

ROLL up

Selects the next sub-menu or an option.

2

ROLL down

Selects the previous sub-menu or an option.

3

ENTER

Enters the main menu. Stores the pin configuration.

4

OUT *

Quits a sub-menu or an option. Step by step return to the main menu.

5

PARAM up

Increases setting values or selects configuration.

6

SET down

Decreases setting values or selects configuration.

E05-A-gb

* You can undo a change by switching the truck off and on again. The controller will be reset to the output values.

Operating Menu General When the programmer has been connected, the truck performs an autotest start routine. The required menu can then be called using the ROLL up/down and ENTER keys.

CONFIG In the configuration menu the operation of the hourmeter can be set. In addition, the "Adjustments" sub-menu allows you to adjust for the battery voltage as measured by the controller and the actual battery voltage.

Menu Functions PARAMETER CHANGE In the PARAMETER CHANGE menu item the listed truck parameters can be read and adjusted in real time.

TESTER In the TESTER menu item the listed truck functions can be activated, checked and adjusted in real time.

ALARMS In the ALARMS menu item, error messages having arisen and been stored during truck operation can be called up and processed.

MS-4.4-3010

74M1.0-0000-00074

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Graphic Display, Menu Structure Software Ver. 1.15

Console 3 3

Main Menu

4 2

Parameter Change

3 4

1

Cutback Speed 1 Cutback Speed 2 Cutback Speed 3 Creep Speed Curve Cutback Max Speed Forw Max Speed Back Curve Time Brake Time Decel. Time Speed Coar FK. U. Speed Fine FK. U. Speed Coar FK. D. Speed Fine FK. D. Speed Coar CB. U. Speed Fine CB. U. Speed Coar CB. D. Speed Fine CB. D. Pump Creep Descent Cutback Cutback EVP Creep EVP

0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9

2

1 + 5

2

Set Model

3

Tester 4 1

2

Save Parameter 2

1

Restore Parameter 2

2

Set Options

3

1

1

Set Battery Type Curve Braking 4 Set Display Hour Check Up Done Set Aisle Cut.

24-48 ON-OFF OFF-ON OFF-ON OFF-ON

2

1

2

Adjustments 2

3 4

Min. Trac. 1 Fwd Max. Trac. 1 Fwd Min. Trac. 1 Back Max. Trac. 1 Back Min. Trac. 2 Fwd Max. Trac. 2 Fwd Min. Trac. 2 Back Max. Trac. 2 Back Min. Pump 1 Up Max. Pump 1 Up Min. Pump 1 Down Max. Pump 1 Down Min. Pump 2 Up Max. Pump 2 Up Min. Pump 2 Down Max. Pump 2 Down

V V V V V V V V V V V V V V V V

2

1

1 + 5

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

1

1

Alarms 2

V ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF V% V% V% V% V%

Not available

1

2 Battery Voltage Forward Switch Backward Switch Lifting Fork Descent Fork Lifting Cabin Descent Cabin Emergency Horn Block En. Chain Stop Cabin Enable Cabin 1 Enable Cabin 2 Enable Traction Gates Part. Stop Cabin Stop Lift Fork Enable Chain Sbl. Par. Stop C. Brake 1 Brake 2 Pallet Accelerator Aux. Pot. #1 Lifting Control Aux. Pot. #2 Temperature

Config

3 4

Errorcode, h, N, ˚C

6

1

Program VACC

3 4

Not available

1 M2052 MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00075 75

ELECTRICS Graphic Display Parameter Change Menu PARAMETER CHANGE Menu Setting Range

Recommended Setting

0-9

3

Travel speed from 500 mm lift height.

0-9

6

Travel speed from 2,500 mm lift height.

0-9

--

Void

0-9

1

Minimum travel speed.

0-9

2

Speed for steering angles > 10 degrees.

0-9

9*

Maximum forward travel speed.

0-9

9*

Maximum reverse travel speed.

CURVE TIME

0-9

9

Brake time for curve travel (steering angle > 10 degrees).

BRAKE TIME

0-9

5

Brake time when exiting from aisle or brake time triggered by aisle sensor.

0-9

5

Delay period when exiting from aisle.

0-9

3

Fork lift speed.

0-9

5

Fork lift: stopping speed

0-9

4

Fork lower speed

0-9

5

Fork lower: stopping speed

0-9

9

Cab lift speed

0-9

9

Cab lift: stopping speed

0-9

9

Cab lower speed

0-9

9

Cab lower: stopping speed

0-9

4

Minimum cab start-up speed

0-9

3

Speed reduction for lowering cab.

0-9

4

Maximum proportional valve value.

0-9

3

Minimum proportional valve value.

Menu Item CUTBACK SPEED 1 CUTBACK SPEED 2 CUTBACK SPEED 3 CREEP SPEED CURVE CUTBACK MAX SPEED FWD MAX SPEED BACK

DECEL. TIME SPEED COAR FK U SPEED FINE FK U SPEED COAR FK D SPEED FINE FK D SPEED COAR CB U SPEED FINE CB U SPEED COAR CB D SPEED FINE CN D PUMP CREEP DESENT CUTBACK CUTBACK EVP CREEP EVP

Explanation

E-01-GB

* WARNING: Do not exceed the max. permissible travel speed. See following page.

MS-4.5-3010

76M1.0-0000-00076

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Graphic Display Parameter Change Menu

Record and adjust separately for each travel direction.

Adjust the truck in such a way that it cannot travel faster than 9 km/h unladen.

DANGER The maximum speed must not exceed 10 km/h unladen and 8 km/h laden.

The "MAX SPEED FWD" and MAX SPEED BACK" values determine the maximum forward and reverse speeds respectively.

If you make any adjustment to the value, repeat the recording.

Now repeat the recording with maximum load and adjust the truck in such a way that it cannot travel faster than 7.8 km/h.

The recommended settings in table (E-01GB) are only estimates. You must always measure the actual truck speed and adjust the value so that the truck cannot travel faster than 9 km/h unladen.

Maximum Speed Setting Preliminary The traction motor brushes must be run in (minimum 10 hours operation). For new brushes set the value obtained to one level lower. This is because the performance will improve the more the brushes are run in.

Once the brushes are run in, measure and adjust the actual truck speed again.

Speed Calculation In a secure area mark a 10 m stretch. The distance must be even and have a long enough run-in zone in order to accelerate the truck beforehand to the limit speed.

Accelerate the warm truck unladen to the maximum speed and travel along the stretch.

Using a stopwatch, record the time taken to travel the distance.

Repeat this twice and calculate the mean time travelled.

Example: 3 attempts: Mean time:

(3.9 s) (4.1s) (4.0 s) 4.0 s

Speed calculation: 10 m : 4 s x 3.6 = 9 km/h

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00077 77

ELECTRICS Graphic Display TESTER Menu The Tester menu can be used to check the status of switches, the battery voltage and the display temperature in real time.

TESTER Menu Menu Item

Explanation

BATTERY VOLTAGE

Current battery voltage in volts.

Status of travel direction switch, forward: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Status of travel direction switch, reverse: BACKWARD SWITCH ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Fork lift switch status: LIFTING FORK ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Fork lower switch status: DESCENT FORK ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Cab lift switch status: LIFTING CABIN ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Cab lower switch status: DESENT CABIN ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

FORWARD SWITCH

EMERGENCY

Do not use! This test will switch off the truck.

HORN

Horn switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

BLOCK EN. CHAIN

Not used

STOP CABIN ENABLE CABIN 1 ENABLE CABIN 2 ENABLE TRACTION

Overhead guard monitor switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Cab lift safety switch (drive side) status: ON/+VB = active, switch closed. OFF/GND = inactive, switch open.

Cab and fork lift safety switch (fork side) status: ON/+VB = active, switch closed. OFF/GND = inactive, switch open.

Diagonal travel switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

For continuation of TESTER menu, p.t.o...

E-02-GB

MS-4.5-3010

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

REV. 1 09/02 78M1.0-0000-00078

ELECTRICS TESTER Menu, Continued Menu Item

GATES

PART. STOP CABIN

STOP LIFT FORK ENABLE CHAIN SBL. PAR. STOP CABIN BRAKE 1

BRAKE 2

PALLET ACCELERATOR AUX POT #1 LIFTING CONTROL AUX POT #2 TEMPERATURE

Explanation Door switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Cab lift interrupt switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Fork lift limit switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Not used Cab lift bypass switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Brake switch (drive side) status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Brake switch (fork side) status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Pallet recognition switch status: ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Drive side traction potentiometer loop voltage display: On the left, display in volts, on the right, as a percentage of the input voltage.

Fork side traction potentiometer loop voltage display: On the left, display in volts, on the right, as a percentage of the input voltage.

Drive side lift potentiometer loop voltage display: On the left, display in volts, on the right, as a percentage of the input voltage.

Fork side lift potentiometer loop voltage display: On the left, display in volts, on the right, as a percentage of the input voltage.

Graphic display temperature in degrees Celsius.

E-03-GB

Graphic Display SAVE PARAMETER Menu The SAVE PARAMETER menu allows you to store the most important truck parameters. This means you can program another truck or restore the parameters of the same truck after any amendments.

The console must be connected to the lift controller via the adapter.

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00079 79

ELECTRICS Graphic Display ALARMS Menu The traction controller can detect and save any malfunctions which occur during various operating conditions. The last five error messages are saved together with the following details: ●

Type of error

●

Frequency of error

●

Hourmeter reading

●

Power part temperature

You can use the ALARMS menu to call up and read error messages.

New error messages will always overwrite the oldest entry in the memory. Some error messages are only output to the graphic display of the truck and are not saved. Errors are output to the console in English.

The current error message is shown on the graphic display in real time and in the language programmed for the truck. An English/German/ French cross-reference list is contained at the end of this section.

ALARMS Menu Error Message

Description

Possible Cause

EMERGENCY DISCONNRCT

Emergency Disconnect Circuit status.

CONSOLE EEPROM BATTERY LOW

Storage error

1.) Emergency Disconnect Switch pressed (LP3020 has two Emergency Disconnect Switches).

2.) Error in logic part of the control system.

3.) Wire broken or plug disconnetion.

Graphic display logic part faulty.

Battery voltage too low.

SERIAL ERROR #1

Error in the serial interface of the lift control system (only shown in the truck display).

SERIAL ERROR #2

Error in the serial interface of the traction control system (only shown in the truck display).

OPEN: GATE

Door monitoring circuit open.

For continuation of ALARMS menu, p.t.o...

MS-4.5-3010

80M1.0-0000-00080

Triggered by battery voltage < 63% of the rated voltage. Further current discharge possible until the battery voltage is only 43% of the rated voltage. The output voltage is reduced proportionally up to 0 A at 43% rated voltage.

1.) Error in logic part of the lift control system.

2.) Serial cable disconnection.

3.) Voltage supply to lift controller disconnected.

4.) Incorrect battery type set for 48 volt trucks. In the OPTIONS menu of the graphic display set "Set Battery Type" to 48 V. 1.) Error in logic part of the traction control system.

2.) Serial cable connection interrupted.

3.) Voltage supply to traction controller disconnected.

4.) Incorrect battery type set for 48 volt trucks. In the OPTIONS menu of the graphic display set "Set Battery Type" to 48 V. 1.) Door(s) not locked.

2.) Error in graphic display.

3.) Broken wire.

4.) Microswitch faulty.

E-04-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ALARMS Menu, Continued Error Message

Description

Possible Cause

FAULT: AISLE GUIDE SYSTEM

Aisle system error

LIMIT SWITCH: FORKS

Aux. lift limit switch error

LIMIT SWITCH: PLATFORM

Platform lift limit switch error

SHORTED VALVE

Shor t circuit in a valve coil.

BIDIRECTIONAL REQ.: TRACTION BIDIRECTIONAL REQ.: FORKS BIDIRECTIONAL REQ.: PLATFORM INCORRECT START: TRACTION

Both travel directions requested simultaneously.

Aux. lift raising and lowering requested simultaneously.

Platform raising and lowering requested simultaneously.

Incorrect sequence in a traction request (LP3020 only).

1.) Aisle confirmation switch faulty.

2.) Graphic display faulty.

3.) Wire broken or plug disconnection.

1.) Microswitch faulty.

2.) Graphic display faulty.

3.) Wire broken or plug disconnection.

1.) Microswitch faulty.

2.) Graphic display faulty.

3.) Wire broken or plug disconnection.

Shor t circuit in a valve coil controlled by the graphic display.

Contacts jamming in one of the two travel direction switches.

Contacts jamming in one of the two aux. lift switches.

Contacts jamming in one of the two platform lift switches.

1.) Operating error. First press the deadman switch, followed by the travel switch.

2.) Contacts jamming in one of the travel direction switches.

1.) Operating error. First press the release switch, followed by the lift or lower switch.

2.) Contacts jamming in one of the lift switches for platform lift.

1.) Operating error. First press the release switch, followed by the lift or lower switch for aux. lift.

2.) Contacts jamming in one of the lift switches aupxe.rlaiftti.ng error. Only press the deadman 1fo.)r O switch on the side of the platform from which the truck is operated.

2.) Contacts jamming in one of the deadman switches.

1.) The potentiometer is incorrectly set or is faulty.

2.) The potentiometer has not been calibrated with the console (ADJUSTMENTS menu).

INCORRECT Incorrect sequence in a platform lift START: PLATFORM request (LP3020 only).

INCORRECT START: FORKS

Incorrect sequence in an aux. lift request (LP3020 only).

INCORRECT START: BRAKE

Both deadman switches pressed simultaneously (LP3020 only).

NOT IN NEUTRAL: TRACTION POT

The voltage on the traction potentiometer centre tapping deviates by more than 2 volts from the setting in the ADJUSTMENTS menu.

For continuation of ALARMS menu, p.t.o...

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

E-05-GB

MS-4.5-3010

M1.0-0000-00081 81

ELECTRICS ALARMS Menu, Continued Error Message

Description

Possible Cause

NOT IN NEUTRAL: TRACTION POT

The voltage on the platform lift potentiometer centre tapping deviates by more than 2 volts from the setting in the ADJUSTMENTS menu.

Chain slack switch circuit error.

1.) The potentiometer is incorrectly set or is faulty.

2.) The potentiometer has not been calibrated with the console (ADJUSTMENTS menu).

SLACK: IN CHAIN

PRIORITY FAULT: PLATFORM FAULT: EPS

Platform priority error.

Steering control system error (only shown on the graphic display, not the console).

FAULT: EEPROM

Error in the storage area of the traction or lift control systems (only shown on the graphic display, not the console).

NOT OK: VMN Voltage for traction or lift motor is incorrect when motors are idle (only shown on the graphic display, not the console).

FAULT: IN Voltage for traction or lift motor is > 0.5 POWERCIRCUIT volts when applied (only shown on the graphic display, not the console).

CLOSED: Travel contactor no longer opens when TRACTION truck is stationary (only shown on the CONTACTOR graphic display, not the console).

OPEN: TRACTION Travel contactor no longer closes (only CONTACTOR shown on the graphic display, not the console).

NO CURRENT: IN No output current to traction or lift motors OPERATION (only shown on the graphic display, not the console).

HIGH CURRENT: IN Output current present when truck is STBY stationary or at start, even though no current should flow (only shown on the graphic display, not the console).

TH PROTECTION The temperature of the traction or lift control systems exceeds 75 degrees Celsius. The output current is lowered in proportion to a rise in temperature until cutout at 85 degrees Celsius (only shown on the graphic display, not the console).

For continuation of ALARMS menu, p.t.o...

MS-4.5-3010

82M1.0-0000-00082

The chain slack switch is not used in the LP3000 series. In place of the switch, wire jumpers have been used at plug C, from Pin 9 to Pin 5 and Pin 6.

1.) Error in the platform lift operating sequence.

2.) Platform lift switch contacts jamming.

This is an alarm message from the steering controller. Refer to the "EPS-DC Steering Controller, ALARMS Menu" section of this chapter for the cause.

Logic part of the traction or lift control systems faulty.

1.) Error in the traction or lift control systems.

2.) Motor error.

1.) Error in the traction or lift control systems.

2.) Motor error.

Travel contactor contacts jamming.

1.) Faulty travel contactor coil.

2.) Wire broken or plug to the travel contactor coil ldisconnected.

Traction or lift control system faulty.

Traction or lift control system faulty.

1.) Excessive ambient temperature (see Operator's Manual for Specifications).

2.) Traction or lift control system faulty.

E-06-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ALARMS Menu, Continued Error Message

Description

Possible Cause

SERIAL FAULT: TRAC./HYDR.

Error in the serial transmission to the traction or lift control systems (only shown on the graphic display, not the console).

Incorrect brake operating voltage (only shown on the graphic display, not the console).

Incorrect brake operating current (only shown on the graphic display, not the console).

Short circuit in the travel contactor coil, valve coils or the horn (only shown on the graphic display, not the console).

Short circuit in the driving stage for the coils (only shown on the graphic display, not the console).

Autotest for traction and lift control systems faulty (only shown on the graphic display, not the console).

Current in proportional valve beyond the limits (only shown on the graphic display, not the console).

Voltage in proportional valve beyond the limits (only shown on the graphic display, not the console).

Logic part of traction or lift control systems faulty.

VOLTAGE FAULT: BRAKE CURRENT FAULT: BRAKE SHORTED: COIL

SHORTED: COIL DRIVER WATCHDOG

CURRENT FAULT: PROP VALVE VOLTAGE FAULT: PROP VALVE

1.) Brakes faulty.

2.) Wire broken or plug disconnection.

3.) Logic part of traction control system faulty.

1.) Brakes faulty.

2.) Wire broken or plug disconnection.

3.) Logic part of traction control system faulty.

If the error is not caused by short circuits, the traction or lift control systems are faulty.

Traction or lift control system faulty.

Traction or lift control system faulty.

1.) Proportional valve faulty.

2.) Lift control system faulty.

1.) Proportional valve faulty.

2.) Lift control system faulty.

E-07-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00083 83

ELECTRICS Graphic Display Language Reference List for the ALARM Menu The alarm messages are only displayed in English on the console. On the graphic display of the truck they always appear in the language in which the Display EEPROMS have been programmed. The following table shows the messages in English, German and French:

Englisch Emergency Disconnect EEPROM Console Battery Low Serial Error # 1 Serial Error # 2 Open: Gate Fault: Aisle Guide System Limit Switch: Forks Limit Switch: Platform Shorted: Valve Bidirectional Req.: Traction Bidirectional Req.: Forks Bidirectional Req.: Platform Incorrect Start: Traction Incorrect Start: Platform Incorrect Start: Forks Incorrect Start: Brake Not in Neutral: Traction POT Not in Neutral: Platform POT Slack: in Chain Priority Fault: Platform Fault: EPS Fault: EEPROM Not OK: VMN Fault : in Power Circuit Closed: Traction Contactor Open: Traction Contactor No Current: in Operation High Current: at STBY TH Protection Serial Fault: Trac./Hydr.

Voltage Fault: Brake Current Fault: Brake Shorted: Coil Shorted: Coil Driver WATCHDOG Current Fault: Prop Valve Voltage Fault: Prop Valve

Deutsch Not-Aus EEPROM Console Batterie leer Reihen Fehler # 1 Reihen Fehler # 2 Offene Bügel Zwangsführung Fehler Endschalter Gabel Endschalter Plattform Kurzschluss Ventile 2 Richtungen angefordert - Fahren 2 Richtungen angefordert - Gabel 2 Richtungen angefordert - Plattform Fehler Reihenfolge Fahren Fehler Reihenfolge Plattform Fehler Reihenfolge Gabel Fehler Reihenfolge Bremse POT Fahren nicht auf 0 POT Plattform nicht auf 0 Kettendurchgang Priorität Fehler Plattform EPS Fehler EEPROM Fehler VMN NOT OK Leistungskreis Fehler Fahrschütz geschlossen Fahrschütz offen Kein Strom Hoher STBY Strom Temperatur Schutz Reihenfehler Fahren/Hydraulik Spannung Fehler Bremse Strom Fehler Bremse Kurzschluss Spulen Kurzschluss Spulen Treiber WATCHDOG Strom Fehler Prop Ventile Spannung Fehler Prop Ventile

Französisch Coupure d'urgence EEPROM Console batterie basse erreur serial #1 erreur serial #2 portillons ouverts erreur auto-centrage fin course fourches fin course plate-forme court circuit valve double demande marche double demande fourches double demande plate-forme séquence erroné marche séquence erroné plate-forme séquence erroné fourches séquence erroné frein POT traction pas à 0 POT plate-forme pas à 0 chaines desserrées erreur de priorité plate-forme erreur EPS erreur EEPROM erreur VMN erreur circuit de puissance contacteur de traction fermé contacteur de traction ouvert pas de courant courant haut à repose protection thermique erreur sériel traction/hydr. erreur tension frein erreur courant frein court circuit bobines court circuit bobines actionneur WATCHDOG erreur courant valves prop. erreur tension valves prop.

E-08-D

MS-4.5-3010

84M1.0-0000-00084

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Graphic Display SET OPTIONS Menu SET OPTIONS Menu Menu item SET BATTERY TYPE CURVE BRAKING SET DISPLAY HOUR

CHECK UP DONE SET AISLE CUT

Setting Range

Recommended Description Setting

24 - 48

24

Battery voltage setting.

ON-OFF

ON

ON switches the steering angle dependent speed reduction on.

ON-OFF

OFF

When the graphic display is replaced the service hours stored in the traction and lift control systems can be transferred to the new display.

This is to preserve the actual number of service hours performed by the truck: In the ON position the service hours for the traction and lift control systems are transferred to the graphic display.

ON-OFF

OFF

ON-OFF

OFF

In the OFF position the service hours are re-stored in the traction and lift control systems. Before the transmission star ts, the display shows CHANGE CHOPPER HOUR for 10 seconds.

The setting is then automatically switched OFF. Not used.

For trucks equipped accordingly, ON switches the speed reduction off for lift heights > 500 mm.

E-09-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

REV. 1 09/02 M1.0-0000-00085 85

ELECTRICS corresponding control function by the required value in the corresponding direction.

Graphic Display ADJUSTMENTS Menu The minimum and maximum values for the lift and traction potentiometers can be set in this menu according to the position of the controls.

In order to be able to store the minimum value of a function, the control must be moved at least so far as to close the corresponding microswitch.

Press ENTER when you want to store the value.

To do this, connect the console to the lift control system via the adapter.

Move through the menu to the required value. To change a parameter, select it with ENTER and move the

ADJUSTMENTS Menu Menu Item

Value

Description

MIN TRAC 1 FWD

V

Minimum voltage, traction potentiometer on drive side, forward.

MAX TRAC 1 FWD

V

Maximum voltage, traction potentiometer on drive side, forward.

MIN TRAC 1 BACK

V

Minimum voltage, traction potentiometer on drive side, reverse.

MAX TRAC 1 BACK

V

Maximum voltage, traction potentiometer on drive side, reverse.

MIN TRAC 2 FWD

V

Minimum voltage, traction potentiometer on fork side, forward.

MAX TRAC 2 FWD

V

Maximum voltage, traction potentiometer on fork side, forward.

MIN TRAC 2 BACK

V

Minimum voltage, traction potentiometer on fork side, reverse.

MAX TRAC 2 BACK

V

Maximum voltage, traction potentiometer on fork side, reverse.

MIN PUMP 1 UP

V

Minimum voltage, lift potentiometer for platform raise on the drive side

MAX PUMP 1 UP

V

Maximum voltage, lift potentiometer for platform raise on the drive side

V

Minimum voltage, lift potentiometer for platform lower on the drive side

V

Maximum voltage, lift potentiometer for platform lower on the drive side.

MIN PUMP 2 UP

V

Minimum voltage, lift potentiometer for platform raise on the fork side

MAX PUMP 2 UP

V

Maximum voltage, lift potentiometer for platform raise on the fork side

V

Minimum voltage, lift potentiometer for platform lower on the fork side

V

Maximum voltage, lift potentiometer for platform lower on the fork side

MIN PUMP 1 DOWN MAX PUMP 1 DOWN

MIN PUMP 2 DOWN MAX PUMP 2 DOWN

E-10-D

MS-4.5-3010

86M1.0-0000-00086

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Traction Control System, Menu Structure

,

p

Console

Software Ver. 1.21

3 3

Main Menu

4 2

Parameter Change

3 4

1

Acceleration Delay Deceleration Delay Release Braking Inversion Braking Curve Braking Curve Volt TH Curve Current TH Brake Cut Back Cutb. Volt TH Cutb Curr. TH Compensation Traction I Max Coil Voltage

0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9

Battery Voltage VMN Motor Voltage Motor Current FEM Current FEM Voltage Temperature Steering Pot. Cutback Switches 2 Cutback Switches 3 Cutback Switches 4 Auxil. Cutback Enable Switches Aisle Switches Aisle Sp. Red Sw.

V V V A A V ˚C V ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF

2

1 + 5

2

Set Model

3 4

1

Standard Traction Regenerative Tr. Standard Pump

5 6

1 2

2 3

Tester 4 1

2

Save Parameter 2

Config

2

Set Options

3 4

Not available

1

2 3

Adjustments

4

Not available

1

1

Restore Parameter 2

1

Alarms 2

1 + 5 3 4

Errorcode, h, N, ˚C

6

1

Program VACC

3 4

Not available

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

1

MS-3010-063

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00087 87

ELECTRICS Traction Control System, PARAMETER CHANGE Menu PARAMETER CHANGE Menu Menu item

Setting Range

ACCELER. DELAY DECELER. DELAY RELEASE BRAKING INVERSE BRAKING CURVE BRAKING CURVE VOLT TH CURVE CURR. TH BRAKE CUTBACK CUTB. VOLT. TH CUTB. CURR. TH COMPENSATION TRACTION I MAX COIL VOLTAGE

Recommended Description Setting Acceleration until new value is reached when the traction potentiometer is taken out of the neutral position (ramp function).

Delay until new value is reached when the traction potentiometer is taken out of the neutral position (ramp function).

Amount of brake current when the traction potentiometer is taken out of the neutral position (release braking).

Amount of brake current when the traction potentiometer is taken out of one position for a travel direction and set to the opposite direction (inversion braking).

Amount of brake current for activated steering angle dependent speed reduction.

0-9

3

0-9

4

0-9

7

0-9

8

0-9

9

0-9

9

Voltage threshold for steering angle dependent speed reduction.

0-9

0

Current threshold for steering angle dependent speed reduction.

0-9

9

0-9

5

0-9

5

0-9

9

Voltage correction factor for traction motor for speed reductions.

0-9

9

Maximum permissible current for traction motor (current restriction).

0-9

7

Voltage restriction for brake coil.

Brake current on leaving aisle (rail guidance) or triggered by the aisle end cut-out (inductive guidance).

Voltage threshold for triggering speed reduction on leaving aisle (rail guidance) or triggered by the aisle end cut-out (inductive guidance).

Current threshold for triggering speed reduction on leaving aisle (rail guidance) or triggered by the aisle end cut-out (inductive guidance).

E-11-GB

MS-4.5-3010

88M1.0-0000-00088

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Traction Control System, TESTER Menu TESTER Menu Menu Item

Description

BATTERY VOLTAGE

Current battery voltage (Volts).

VM N

Current traction controller output voltage at VMN terminal.

MOTOR VOLTAGE*

Voltage display on traction motor, not available.

MOTOR CURRENT*

Current traction motor current consumptionr, not available.

FEM CURRENT*

Current brake current consumptionr, not available.

FEM VOLTAGE*

Current brake coil voltager, not available.

TEMPERATURE

Current traction controller temperature in degrees Celsius.

STEERING POT.

Displays the loop voltage on the wheel position potentiometer.

CUTBACK SWITCH 2

CUTBACK SWITCH 3

Status of MV2 switch (LMS1 = 500 mm) for lift height dependent speed reduction: ON/GND = active, switch closed.

OFF/+VB = inactive, switch open.

Status of MV3 switch (LMS2 = 2,500 mm) for lift height dependent speed reduction: ON/GND = active, switch closed.

OFF/+VB = inactive, switch open.

CUTBACK SWITCH 4 Not used AUXIL. CUTBACK

ENABLE SWITCH

AISLE SWITCH AISLE SP. RED SWITCH

Aisle sensor status: ON/+VB = active, switch applied.

OFF/GND = inactive, switch not applied.

Brake switch status (safety switch): ON/+VB = active, switch closed.

OFF/GND = inactive, switch open.

Photocell status on leaving aisle: ON/+VB = active, photocell applied.

OFF/GND = inactive, photocell not applied.

Photocell status for aisle recognition: ON/+VB = active, photocell applied.

OFF/GND = inactive, photocell not applied.

E-12-GB

* Values are not shown, if the console is connected.

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00089 89

ELECTRICS Traction Control System, ALARMS Menu The traction control can detect and store any functional errors during various operating conditions. The last five error messages are stored together with the following details: ●

Error type

●

Error frequency

●

Hourmeter status

●

Power part temperature

The corresponding error messages can be called up and read via the ALARMS menu.

New error messages always overwrite the oldest entry in the memory. However, some error messages are only displayed on the truck's graphic display and are not stored. Errors are displayed on the console in English.

On the traction controller itself a 7 segment display shows the most recent error in the form of a flashing digit. If the console is connected to the traction controller, the display disappears from the traction controller. However, the error is not lost but is simply stored in the console.

ALARMS Menu Error Code and Description 0 (THERMAL PROTECTION)

Description The temperature of the traction control system exceeds 75 degrees Celsius. The output current is lowered in proportion to a rise in temperature until cut-out at 85 degrees Celsius.

0 (INCORRECT START)

Incorrect starting sequence.

1 (EEPROM KO)

Error in the storage area of the traction control system.

1 (TIMEOUT RS232)

Error in the serial transmission from or to the traction or lift control systems.

1 (FEM NOT OK)

Brake coil voltage incorrect.

1 (WATCH DOG)

Self-monitoring failed.

Error in the serial interface of the traction control system.

1 (SERIAL ERROR #2)

2 (COIL SHORTED)

Short circuit in the travel contactor coil

2 (DRIVER SHORTED)

Short circuit in the driving stage of the travel contactor control

Possible Cause 1.) Excessive ambient temperature (see Operator's Manual for Specifications).

2.) Traction or lift control system faulty.

1.) Operating error. First press the deadman switch, followed by the travel switch.

2.) Contacts jamming in one of the travel direction switches.

Logic part of the traction or lift control systems faulty.

Error in the logic part of the traction or lift control systems has lead to the time being exceeded in the serial communication.

1.) Error in logic part of the traction control system.

2.) Faulty brake 1.) Error in logic part of the traction control system.

1.) Error in logic part of the traction control system.

2.) Serial cable connection interrupted.

3.) Voltage supply to traction controller interrupted.

4.) Incorrect battery type set for 48 volt trucks. In the OPTIONS menu of the graphic display set "Set Battery Type" to 48 V. 1.) Travel contactor coil faulty due to short circuit.

2.) Short circuit in the wiring to the travel contactor coil.

Traction control system faulty E-13-GB

For continuation of ALARMS menu, p.t.o...

MS-4.5-3010

90M1.0-0000-00090

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS

ALARMS Menu, Continued Error Code and Description 2 (VMN NOT OK) 3 (NO FULL COND.) 4 (CURRENT FEM) 5 (STBY I HIGH) 6 (CONTACTOR CLOSED) 7 (CONTACTOR OPEN) 9 (CONSOLE EEPROM) 9 (BRAKE CONT. CLOSED) 9 (I = O EVER)

Description

Possible Cause

Output voltage to motor present although no travel requested issued.

The motor voltage is greater than 0.5 volts at full throttle (measured between battery and VMN).

Electric brake current consumption beyond range.

Current flows to traction motor when truck is stationary.

1.) Traction control system power part faulty.

2.) Motor faulty.

1.) Traction control system power part faulty.

2.) Motor faulty.

1.) Brake faulty.

2.) Logic part of traction control system faulty.

Error in traction control system.

Travel contactor does not release when truck is stationary.

Travel contactor contacts jamming.

Travel contactor does not engage.

1.) Travel contactor coil faulty.

2.) Wiring to travel contactor coil interrupted.

Error in the storage unit of the traction control system.

Error in traction control system power part.

The brake does not release.

Brake relay contacts jammed.

No travel current.

Traction control system faulty.

E-14-GB

Traction Control System, SET MODEL Menu In this menu you set the controller to work either as traction controller or as lifting controller: STANDARD TRACTION = traction controller STANDARD PUMP = lifting controller

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00091 91

ELECTRICS Lift Control System, Menu Structure

Console

Software Ver. 1.21

3 3

Main Menu

4 2

Parameter Change

3 4

1

Compens Fork Compens Cabin Acceleration Soll.

Deceleration Soll.

Acceleration EVP Deceleration EVP Pump I Max

0-9 0-9 0-9 0-9 0-9 0-9 0-9

2

Config 1 + 5

1 2

Set Model

3 4

Pump Standard Standard Traction Regenerative Tr.

5 6

1 2

2

Tester

3 4

1

Battery Voltage Pump Motor Volt EVP Voltage Pump Current EVP Current Temperature Steering Pot. Lifting Cabin T Descent Cabin T Block Cabin Cutback Descent

V V V A A ˚C V ON/OFF ON/OFF ON/OFF ON/OFF

2

Set Options

3 4

Not available

1

2 3 1

Adjustments

4

Not available

2

Save Parameter 2

1

Restore Parameter 2

1

Alarms 2

1 + 5 3 4

Errorcode, h, N, ˚C

1

Program VACC

3 4

Not available

6

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

1

MS-3010-062 MS-4.5-3010

92M1.0-0000-00092

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Lift Control System, PARAMETER CHANGE Menu PARAMETER CHANGE Menu Menu Item COMPENS FORK COMPENS CABIN ACCELERATION SOLL. DECELERATION SOLL. ACCELERATION EVP DECELERATION EVP PUMP I MAX

Setting Range

Recommended Description Setting Voltage increase for an aux. lift demand proportional to the current requirements of the lift motor.

Voltage increase for a platform lift demand proportional to the current requirements of the lift motor.

0-9

9

0-9

9

0-9

7

Acceleration ramp during start-up for lifting platform.

0-9

4

Delay ramp during stop phase for lifting platform.

0-9

8

Acceleration ramp during start-up for lowering platform.

0-9

7

Delay ramp during stop phase for lowering platform.

0-9

9

Pump motor max. current setting E-15-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00093 93

ELECTRICS Lift Control System, TESTER Menu TESTER Menu Menu Item

Description

BATTERY VOLTAGE

Current battery voltage in volts.

PUMP MOTOR VOLT

Current output voltage of lift control system at VMN terminal.

EVP CURRENT*

Propor tional valve current, not displayed.*

EVP VOLTAGE*

Propor tional valve voltage, not displayed.*

PUMP CURRENT*

Current lift motor current consumtion, not displayed.*

TEMPERATURE

Current lift control system temperature in degrees Celsius.

LIFTING CABIN T.*

DESCENT CABIN T.*

BLOCK CABIN

CUTBACK DESCENT PRESSURE SWITCH*

Status of platform lift switch in Lift position, not displayed*: OFF/GND = inactive, switch open.

ON/+VB = active, switch closed.

Status of platform lift switch in Lower position, not displayed*: OFF/GND = inactive, switch open.

ON/+VB = active, switch closed.

Status of platform lift limit switch: OFF/+VB = inactive, switch not pressed.

ON/GND = active, switch pressed.

Status of speed reduction switch for platform lowering: OFF/GND = inactive, switch open.

ON/+VB = active, switch closed.

Status of load-dependent pressure switch, not displayed*: OFF/GND = inactive, switch open.

ON/+VB = active, switch closed.

E-16-GB

* Not displayed, if the console is connected to the controllers.

MS-4.5-3010

94M1.0-0000-00094

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Lift Control System, ALARMS Menu The lift control can detect and store any functional errors during various operating conditions. The last five error messages are stored together with the following details: ●

Error type

●

Error frequency

●

Hourmeter status

●

Power part temperature

The corresponding error messages can be called up and read via the ALARMS menu.

New error messages always overwrite the oldest entry in the memory. However, some error messages are only displayed on the truck's graphic display and are not stored. Errors are displayed on the console in English.

On the lift controller itself a 7 segment display shows the most recent error in the form of a flashing digit. If the console is connected to the traction controller, the display disappears from the traction controller. However, the error is not lost but is simply stored in the console.

ALARMS Menu Error Code and Description

Description

Possible Cause

0 (INCORRECT START) 1 (EEPROM KO) 1 (TIMEOUT RS232)

Incorrect lift command sequence

1.) Operating error, see Operator's Manual.

2.) Contacts jamming on one of the lift switches.

Error in storage area of lift control system.

Lift control system logic part faulty.

Error in serial transmission from or to traction / lift control systems.

1 (WATCH DOG) 1 (EVP NOT OK) 1 (SERIAL ERROR #1) 2 (COIL SHORTED)

Self-monitoring failed.

Error in the logic part of the traction or lift control system has lead to the time being exceeded in the serial communication.

1.) Error in lift control system logic part.

2 (DRIVER SHORTED) 3 (VMN NOT OK) 3 (NO FULL COND) 4 (CURRENT EVP) 5 (STBY I HIGH) 9 (CONSOLE EEPROM) 9 (I = 0 = EVER)

Proportional valve voltage error.

Error in serial interface of the lift control system.

Short circuit.

Short circuit in the driving stage of the lift control system.

Voltage at lift motor although no lift demand has been issued.

Lift motor voltage is > 0,5 volts when fully modulated.

Proportional valve incorrect current reading.

Current flowing although no lift command has been issued.

Error in non-volatile memory area of the lift control system.

No current flowing although a lift command has been issued.

1.) Proportional valve faulty.

2.) Lift control system faulty.

1.) Error in lift control system logic part.

2.) Serial cable connection interrupted.

Short circuit in a valve coil, either in a lowering valve (platform and/or aux. lift), a lift switch or the horn.

Lift control system faulty.

1.) Lift control system faulty.

2.) Pump motor faulty or not present.

1.) Lift control system faulty.

2.) Pump motor faulty or not present.

1.) Lift control system faulty.

2.) Proportional valve faulty.

Lift control system faulty.

Lift control system faulty.

Lift control system faulty.

E-17-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00095 95

ELECTRICS Steering Control System, Menu Structure

Software Ver. 1.14

Console 3 3

Main Menu

4 2

Parameter Change

3

1

Speed Limit Sensibility 4 KP KD Fwd Upp Err Ant. Fwd Low Err Ant. Rev Upp Err Ant. Rev Low Err Ant. Upp Err Pot Low Err Pot

0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9 0-9

2

Config 1 + 5

2 1

Set Model

Not available

1 2 3

Tester 4 1

Set Point Pot. Feedback Pot. Antenna Error DT MM Alarm Switch SM Alarm Switch Endstroke ACW Endstroke CW Automatic Req. Temperature Encoder Speed Debug

V V V V ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF -1 — +1 0

2

2

Set Options

3 4

1

1

Hour Counter Dir Inp Act Low Long Vehicle Stb I=0 ever Micro Check Direction Gauge Cutback Output Special Pot Adj System Config Antenna Ref Sel Auto Inp Active

KEYON/RUNNING 2 ON/OFF ON/OFF ON/OFF PRESENT/NONE OPTION #1-2 ON/OFF ON/OFF LEVEL 0 - 1 OPTION #0 - 2 1 OPTION #0 - 3

2

Adjustments

2

1

Alarms 2

Set Steer 0-Pos. Set Steer Min 4 Set Steer Max Zero Auto FB Set Battery Type

mV 2 V V V 1 V

1 + 5 3 4

Errorcode, h, N, ˚C

6

1

Program VACC

3

3 4

Not available

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

1 MS-3010-061

MS-4.5-3010

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

REV.1 09/02 96M1.0-0000-00096

ELECTRICS Steering Control System, PARAMETER CHANGE Menu PARAMETER CHANGE Menu Menu Item

Setting Range

Recommended Description Setting

SPEED LIMIT SENSIBILITY

0-9

6

Maximum turning speed of the drive wheel when steering (fastest possible turning of steering wheel).

Drive wheel turning speed setting for slow turning of steering wheel.

0-9

0

KP

0-9

5

KD

0-9

2

FWD UPP ERR ANT FWD LOW ERR ANT REV UPP ERR ANT REV LOW ERR ANT UPP ERROR POT LOW ERROR POT

0-9

-

When the steering lock is active in the aisle, this paramter affects the static accuracy of the zero position of the steering transmission.

A low value increases the tolerance range around the zero position and is therefore less precise and less sensitive. A high value will result in frequent adjustment.

When the steering lock is active in the aisle, this paramter affects the dynamic accuracy of the zero position of the steering transmission.

A low value increases the tolerance range around the zero position and is therefore less precise and less sensitive. A high value makes the control more precise and sensitive. If the value is too high, there is no further adjustment and the steering simply remains at zero.

Not used.

0-9

-

Not used.

0-9

-

Not used.

0-9

-

Not used.

0-9

-

Not used.

0-9

-

Not used.

E18-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00097 97

ELECTRICS Steering Control System, TESTER menu TESTER menu Menu item

Explanation

SET POINT POT

Not used.

FEEDBACK POT

Current voltage on feedback potentiometer loop against earth.

ANTENNA ERROR

Not used.

DT

Tachometer generator output voltage with prefix

MM ALARM SWITCH

SM ALARM SWITCH

ENDSTROKE ACW

ENDSTROKE ACW

Real time display for traction cutout contact status monitored by main processor.

OFF = Switch open ON = Switch closed.

Real time display for traction cutout contact status monitored by secondary processor.

OFF = Switch open ON = Switch closed.

Status display of steering limit switch connected to socket D, pin 7 of the main board.

OFF = Inactive, switch closed.

ON = Active, switch open.

Status display of steering limit switch connected to socket D, pin 1 of the main board.

OFF = Inactive, switch closed.

ON = Active, switch open.

AUTOMATIC REQ

Automatic mode (ON) or manual steering with tachometer generator (OFF).

TEMPERATURE

Real time display of heat dissipator temperature at end limit. An alarm is sounded if 78 degrees Celsius is exceeded.

ENCODER SPEED

Not used.

DEBUG

Not used.

E-19-GB

MS-4.5-3010

98M1.0-0000-00098

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Steering Control System, SET OPTIONS menu SET OPTIONS menu Setting Range

Recommended Setting

HOUR COUNTER DIR INP ACT LOW

RUNNING / KEY ON ON-OFF

RUNNING

LONG VEHICLE STB I=0 EVER

ON-OFF

OFF

ON-OFF

OFF

MICRO CHECK DIRECTION GAUGE CUTBACK OUTPUT

PRESENT / NONE 0-1

PRESENT

ON - OFF

OFF

SECIAL POT ADJ SYSTEM CONFIG ANTENNA REF SEL AUTO INP ACTIVE

ON - OFF

OFF

0-1

1

0-2

0

0-3

0

Menu item

OFF

0

Explanation Determines whether the hour counter counts only during operation (RUNNING) or from the moment the key switch is turned on (KEY ON).

Determines the signal range of an external travel signal assessed as being active.

ON = External travel command is LOW when active OFF = External travel command is HIGH when active Not used.

OFF = The tachometer generator is only tested when the steering is applied ON = The tachometer generator is permanently tested, even when steering is not applied.

Not used.

Not used.

Activates or cuts out the end limit if there is a fault in the end limit of the steering control system.

ON = No end limit cutout OFF = End limit cutout Not used.

0 = Tachometer generator steering controller plus wire guidance.

1 = Tachometer generator steering controller plus automatic centring.

Not used.

Sets the signal range which is assessed as being active for an external automatic request: 0 = Active is LOW (less than + 4.0 volts DC).

E-20-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-00099 99

ELECTRICS Steering Control System, ADJUSTMENTS menu ADJUSTMENTS menu Menu item

Reading

Explanation

SET STEER 0-POS

mV

Not used.

SET STEER MIN

V

SET STEER MAX

V

ZERO AUTO FB

V

Not used.

SET BATTERY TYPE

V

Selects the battery voltage for the steering controller.Must be set to 24 volts.

Sets the value of the feedback potentiometer for the steering controller to a minimum when the drive wheel is turned 90 degrees to the left.

Sets the value of the feedback potentiometer for the steering controller to a minimum when the drive wheel is turned 90 degrees to the right.

E21-GB

MS-4.5-3010

100 M1.0-0000-000100

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Steering Control System, ALARM Audible Alarm Provided fuse F1 (3A) on the logic board of the steering controller is functioning, the controller will signal errors through an audible alarm.

are made audible through a piezo electric buzzer. Here, (n) is also the number of pulses through which the alarm can be identified in the following table.

Programmer, ALARMS menu This menu displays the most recent error along with the service hours and the controller temperature at which the error occured.

The controller encodes each error through a repeating number (n) of pulses followed by an interval. The pulses

ALARMS menu Frequency and Designation 1 MICRO SLAVE KO 2 I = 0 EVER 3* STEER SENSOR KO

3* FB POT LOCKED 4 EEPROM KO 5 HIGH TEMPERATURE 6 STBY I HIGH

7 RELE KO

Description

Possible Remedy

1.) Switch the truck off and on again.

2.) If the problem remains, replace the steering controller.

End limit error or if the steering motor does 1.) Fuse F2 (32 A) blown. not receive more than 6% of the maximum 2.) Power wiring to the steering motor interrupted. current 3.) Faulty steering motor.

Tachometer generator short circuit or wiring 1.) Using the progammer check in the SET to tachometer generator interrupted.

OPTIONS menu if the reading for SYSTEM CONFIG is set to 1.

2.) Test tachometer generator wiring.

3.) Replace tachometer generator.

1.) Mechanical link from the potentiometer to the The feedback potentiometer does not steered wheel interrupted, check. change its value for steering movements.

2.) Check potentiometer wiring.

3.) Potentiometer faulty, replace.

1.) Switch truck off and on again.

Memory error in controller.

2.) If the problem persists, replace the steering controller.

1.) Allow the truck to cool down.

2.) Check steering mechanics for ease of End limit overtemperature (> 78o C) movement.

Occurs when the current sensor sees a voltage reading although the end limit is cut Replace steering controller. out when the truck is idle.

2 contacts in series are used to release the traction controller. The main processor activates the first contact, the secondary processor the second contact. Both contacts are monitored by Replace steering controller. both processors. If the main processor determines that its contact is closed when it should be open, this alarm is sounded.

The secondary processor has discovered an irregularity.

E22-GB

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.5-3010

M1.0-0000-000101 101

ELECTRICS Remot Control for Platform

MDC

Lower

WEISS/GRÜN

GRAU/GRÜN

BRAUN

ROT/SCHWARZ

ROT

MSC

Lift

SD-M AMP180901-0

Hubsteuerung

MS-3010-070

B in figure MS-3010-026

M1819-001_de

The remote control system allows the platform to be raised and lowered. You can assemble this basic equipment yourself.

A

To do this you need: ✓

1 off plug housing

✓

4-pin, AMP order no. 18090-0

✓

2.5 m oil-resistant wire, 3-pin 0.75mm²

✓

1 off housing with PG screw fitting

✓

2 off pushbuttons (make contact)

✓

Pushbutton legend

B MS-3010-026

Assemble the remote control system (A, fig. MS-3010026) in accordance with the wiring diagram (Fig. M-3010070).

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MS-4.5-3010

REV. 1 09/02 102 M1.0-0000-000102

ELECTRICS Traction Control System Safety Test

●

Connect the test lead to FR (case 2).

The safety test for the traction control system takes place in the form of a pulse monitor trip test (PMT).

●

According to EU Norm PREN 1175-1 the following test must be carried out on the traction control system to check the safety circuit.

Power up the truck.

The message VFIELD NOT OK should now appear on the programmer display. Activating the transmitter should have no effect.

●

Power down the truck, completely disconnect the test lead and remove the programmer.

The test requires a test lead, approximately 1 mm2 in diameter and a 10A fuse.

●

If the truck is now powered up again and the transmitter activated, the traction motor should start.

●

If the test fails, replace the traction controller.

●

Jack up the truck (switched off).

●

Connect one end of the test lead to -BATT.

●

Connect the other end of the test lead to VMN (Case 1 in Fig. MS-3010-064).

●

Connect the programmer to the traction controller.

●

Power up the truck.

The message CAPACITOR CHARGE should now appear on the programmer display. Activating the transmitter should have no effect.

●

Power down the truck and remove the test lead from VMN (the other end remains attached to BATT).

10 A

2

FR A

1

B

+

A1

VMN

C

Traction Controller MS-3010-064

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104

ELECTRICS probably have been thermally overloaded. Thermal overloading (temperatures >160 ºC) causes the brushes to swell up.

Brushes which jam in the brush support produce intense sparking and destroy the collector.

Electric Motors General Maintenance Instructions The following instructions apply to all motors. Details relating to specific models and designs are provided in the sub-sections (traction motor, pump motor etc.).

●

The brush edges must not be cracked. Brushes with cracking along the long edge of the surface will have been damaged by a worn collector.

If information is provided in the manual, restore the collector to the specified limits. Otherwise, replace the armature in full.

●

Loose brush connections are a clear sign of motor overload. In this case inspect the collector for burning and repair or replace as necessary.

●

When fitting the brush take care to place the spring gently on the brush. If the contact is too hard the brush will be damaged.

●

Make sure that all brushes contact the armature at the same pressure.

●

New brushes must be run in with a medium load in the first hours. Never fully charge the motor straight away.

Preparation ●

●

Disconnect the battery (= EMERGENCY DISCONNECT).

Secure the truck from rolling away.

Important Maintenance Instructions ●

Remove all carbon brushes and check for wear. If one or more carbon brushes need to be replaced, replace all brushes. In addition to the carbon brushes the pressure springs must also be replaced to ensure the correct pressure.

The length of the shortest brush determines whether the brush set needs to be replaced.

Even if the minimum length has not been reached the brushes should be replaced as the remaining useful life could be much shorter than the time until the next inspection: If a brush is too short the spring will lie on the brush support. The brush sparks during operation and burns the collector with corresponding damage.

●

Blast the motor with dry compressed air only.

●

Check the armature for uneveness, burning, grooves and cracking of the multi-plate edges.

Turn the armature if necessary. A non-oily, evenly distributed layer on the brush surfaces is normal.

●

If oil or grease is found in the motor collector compartment (usually a paste consisting of oil, oil vapour, dust and carbon particles), immediately remove the cause and clean the motor thoroughly: Oil or grease burns in the brush sparks and leaves behind a highly abrasive oil ash which can very quickly destroy the collector and the brushes.

●

The brushes must be able to move freely in the brush support (without spring tension) without tilting. Never modify brushes if one or more brushes cannot move freely.

In this case replace all brushes as they will

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MS-4.10-3010

M1.0-0000-000105 105

ELECTRICS ●

Drive Motor Maintenance

Refit the strap retainer.

Armature

Access to Brushes ●

Disconnect the battery.

●

Prevent the truck from rolling away.

●

Remove the strap retainer (A, Fig. MS-3010-060) from the motor.

●

A new armature has a 100 mm diameter.

●

The armature can be overwound, but in this case should not fall below the minimum diameter of 96 mm.

●

After overwinding, the mica must be sawed by at least 0.5 mm below the multi-plates without altering the clearance between the multi-plates.

●

Debur the multi-plate edges carefully.

Bearings ●

Both the ball bearings are maintenance-free. If the bearings are removed for repairs, they must be replaced again. The sealing elements (shaft seals etc.) must always be replaced.

●

The bearings must be replaced after 10,000 service hours.

A

MS-3010-060

Maintenance ●

Blast the motor with dry compressed air.

●

Remove all carbon brushes and check them with the armature in accordance with the specifications given in "Important Maintenance Instructions".

●

Carbon brush length, new: 32 mm

●

Carbon brush wear limit: 16 mm

MS-4.10-3010

106 M1.0-0000-000106

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS ●

Pump Motor Maintenance

Refit the strap retainer.

Armature

Access to Brushes ●

Disconnect the battery.

●

Prevent the truck from rolling away.

●

Unscrew the cover (A, Fig. MS-3010-059) from the motor.

●

A new armature has a 64 mm diameter.

●

The armature can be overwound, but in this case should not fall below the minimum diameter of 61 mm.

●

After overwinding, the mica must be sawed by at least 0.5 mm below the multi-plates without altering the clearance between the multi-plates.

●

Debur the multi-plate edges carefully.

Bearings ●

Both the ball bearings are maintenance-free. If the bearings are removed for repairs, they must be replaced again. The sealing elements (shaft seals etc.) must always be replaced.

●

The bearings must be replaced after 10,000 service hours.

MS-3010-059

Maintenance ●

Blast the motor with dry compressed air.

●

Remove all carbon brushes and check them with the armature in accordance with the specifications given in "Important Maintenance Instructions".

●

Carbon brush length, new: 20 mm

●

Carbon brush wear limit: 9 mm M1867

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.10-3010

M1.0-0000-000107 107

ELECTRICS Steering Motor Maintenance Insulation

Access to Brushes ●

Disconnect the battery.

●

Remove the strap retainer from the steering motor.

Maintenance ●

Remove all carbon brushes and check them with the armature in accordance with the specifications given in "Important Maintenance Instructions".

●

Carbon brush length, new: 22.5 mm

●

Carbon brush wear limit: 14.5 mm

●

Check the strap retainer insulation for damage.

M1866

A

MS-3010-058

Replace any damaged insulation. Refit the strap retainer.

MS-4.10-3010

108 M1.0-0000-000108

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

ELECTRICS Battery General The battery condition considerably affects the truck's performance. Proper maintenance will play a main part in maintaining the performance and service life of the battery.

Only service the battery in accordance with the battery manufacturer's instructions.

Observe the battery manufacturer's instructions when charging the battery.

Operation The battery plug is connected to the truck circuit during discharge and to the charger during charging.

Make sure that the battery connector is disconnected when the truck is not in use and that there is a fixed connection between both connectors when the truck is operating and during charging. A bad connection will cause the contacts to burn and will affect the charging and the operation of the truck.

Replacing the Battery WARNING Only use batteries which are suitable for this truck in terms of their size, weight and specifications. ● An incorrect battery type can damage the truck. ● An incorrect weight and size will alter the truck's centre of gravity. This can result in accidents.

Details of how to remove and replace the battery are contained in the truck operator's manual. Refer to this manual for further details.

MS-LP31010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-4.10-3010

M1.0-0000-000109 109

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110

BRAKE

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M1.0-0000-000112 112 M1.0-0000-000112

BRAKE Brake General Functional Description The drive motor contains the drive wheel brake which is in the form of a disk brake.

The assembly is shown on page M-5.0-3010-2.

The brake interlocks with the motor shaft. When the truck is de-energised the brake is applied: If the truck must be moved in this case the brake can be mechanically released by turning the two cheese head (fastening) screws.

Afterwards, always return them to their original position!

Test the brakes before operating the truck again.

M2019

●

Measure the thickness of the rotor (16). Replace the rotor if this thickness is less than 6.0 mm.

A new rotor is 10.0 mm thick.

●

Remove the screws from their nuts.

●

Unscrew the banjo bolts (17) from the magnetic body (3 off).

●

Remove the anchor disk (14).

Removal

●

Thoroughly clean components.

CAUTION

●

Check anchor disk (14) and rotor (16) for even wear, grooves, cracks and burning. Replace worn and damaged components.

The brake is electro-magnetically released. The axial force generated by compression springs acts on the moving anchor disk. The rotor has a friction lining on both sides and also moves axially. The force acting on the anchor disk jams the rotor between the anchor disk and the friction plate. When DC voltage is applied to the coil a magnetic force acts on the anchor disk. The anchor disk is pulled against the compression springs. The rotor is no longer jammed, i.e. the brake is released.

Do not allow the brake components to come into contact with grease or oil.

The item numbers in brackets refer to the diagram on the following page. ●

Unplug the battery connector .

●

Jack up the truck until the drive wheel is free.

Secure the truck to prevent it from rolling away.

●

Remove the panel.

●

Remove any brake dust.

●

Unplug the electric connection from the brake wiring.

●

Remove the three Allen screws.

●

Remove the magnetic body (7) from the motor (including everything connected to it).

●

Remove rotor (16) from hub (15) while taking care not to damage the toothing.

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MS-5.0-3010

M1.0-0000-000113 113

BRAKE 3

●

Attach the pre-assembled magnetic body (7) to the motor using the Allen screws (3).

●

Restore the electrical connection (20).

1 2

Air Gap Setting The operating air gap is measured between the magnetic body and the armature disk when the system is de-energised. The air gap must be set to 0.3 mm (see Fig. M1467).

7

15

●

Remove the rubber lining from the brake.

●

Check the operating air gap at several points using a feeler gauge.

●

To adjust the air gap remove the 3 mounting screws (3) and set the air gap using the banjo bolts (17). The air gap should be 0.3 mm consistently.

●

If the air gap is correctly set, torque the hex. socket screws (3) to 9.5 Nm. Refit the covering ring.

12 11

14

Brake Moment Setting Turning in the ring nut (1) increases the brake moment.

The brake setting is notched. Intermediate settings are not permitted.

17

Brake Test

16

●

The truck must be at operating temperature with a fully charged battery and on a level, dry and nonskidding concrete surface in a secure area.

Accelerate the unladen truck to maximum speed.

●

Release the deadman pedal.

●

Record the braking distance from the place where the brake was applied to the place where the truck comes to rest.

MS-3310-071

Assembly Assembly is the reverse order of disassembly. ●

●

If the thrust pieces (11) and springs (12) have fallen out of the magnetic body (7), insert them in the correct position: First the springs (12), followed by the thrust pieces (11).

Place the anchor disk (14) in the correct position on the magnetic body: Pay attention to the scribed circle.

●

Screw the banjo bolts (17) with a drop of Loctite medium into the magnetic body (7) until they reach the stop.

●

Push the rotor (16) onto the hub (15) while ensuring that the toothing is not damaged in the process.

Using the setting ring (1) adjust the brake moment until the brake test with the truck unladen shows that the braking distance in the test area corresponds to table B01-de.

Now repeat the brake test with maximum load and if necessary adjust the brake moment with the ring nut (1) until you reach the required braking distance (see Table B01-de).

Now fasten with the locking plate (2).

MS-5.0-3010

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

REV. 1 09/02 114 M1.0-0000-000114

BRAKE

Braking Distances Series LP Braking Distance (New Brake)

Braking Distance (Used Brake)

Nominal Load

Empty

Nominal Load

Empty

3m

<3m

<3m

<3m B01-GB

Inner ring

Fastening screw (3)

Outer ring

Banjo bolt (17) Operating air gap 0,3 mm Tab washer Rotor thickness

De-energised brake

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

M1467

MS-5.0-3010

REV. 1 09/02 M1.0-0000-000115 115

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STEERING

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M1.0-0000-000118 118 M1.0-0000-000118

STEERING Steering Chain Adjustment

Steering Operation The steering movement is mechanically transferred from the steering wheel (4) to a transmitter (19). The electrical output signal from the transmitter is processed by the steering control system. The control system converts the input signal of the transmitter into an output current to modulate the steering motor. The steering motor moves the drive unit in the corresponding direction via a steering chain.

A reduction in chain tension results in play in the steering. Check the chain for wear and damage before tensioning and if in doubt replace the chain. To tension, proceed as follows: ●

Disconnect the battery.

●

Open the panel.

●

Loosen the 4 mounting screws (A, Fig. M2023) of the motor retaining plate in the elongated holes.

A

M2023

●

Remove the jam nut of the tensioning screw (B, M1931).

●

Tension the chain with the screw (B).

B

M1752 M1931

●

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

Tighten the jam nut and the retaining screws of the plate.

MS-6.0-3310

M1.0-0000-000119 119

STEERING Steering Pod Removal / Installation

B

A

●

Remove the encoder from below.

●

Assembly is the reverse order.

The steering pod is attached directly below the steering wheel. ●

Disconnect the battery.

●

Unscrew the panel to which the steering wheel is attached, disconnect the plug connections and remove the panel.

●

Remove grub screw (10, Fig. M1752).

M2021

Steering Motor Removal / Assembly

M1752

●

Remove nuts (A, Abb. M2021).

(Replace the rubber buffers "B" if they are damaged or leaky).

MS-6.0-3310

120 M1.0-0000-000120

●

Disconnect the battery.

●

Open the panel.

●

Disconnect the electrical connection to the A steering motor.

●

Remove the 4 screws (2, Fig. M2025).

M2024

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

STEERING ●

Remove the motor from the top. Note the springs (4, Fig. M2025).

●

Assembly is the reverse order.

Note: Steering motor maintenance is described in Chapter 4.

Steering Transmission Removal / Assembly ●

Disconnect the battery.

●

Open the panel.

●

Remove the steering motor as described in the previous section.

●

Relieve the steering chain and remove it from the pinion (13, Fig. M2025).

●

Remove the four screws (7, Fig. M2025).

●

Remove the steering transmission (5, Fig. M2025) from the top.

●

Assembly is the reverse order.

M2025

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M1.0-0000-000121 121

STEERING Functional Test:

Potentiometer (PTR) Installation An ohmmeter is required to adjust the potentiometer (measurement range 20kOhm).

●

Connect the battery and power up the truck.

●

When the potentiometer is correctly adjusted and the drive wheel is facing straight ahead, the steering angle display must correspond to the position of the drive wheel.

●

Disconnect the battery

●

Open the panel.

●

The drive wheel must be facing straight ahead.

●

Steer to the left. The steering angle display should follow the steering movement.

●

Insert potentiometer D, Fig. M2029) in the retaining strap and insert the potentiometer axis in the carrier (B).

●

Steer to the right. The steering angle display should follow the steering movement.

●

In a secure environment, accelerate the unladen truck to max. speed and induce an abrupt left turn. The truck speed should automatically reduce beyond a 10° steering angle.

Repeat the test in the opposite direction (right).

D

Steering Limit Switch (MF) Both steering limit switches de-energise the steering motor before the drive system mechanical stop is reached. This prevents the steering motor from overheating.

C A

B M2029

●

Align the potentiometer so that the wiring runs over the retaining strap and tighten potentiometer with nut (C). Do not install the potentiometer without the torsional protection mechanism and the toothed disk.

●

Secure the wiring to the strap with cable binders.

There should be slack in the wire to the potentiometer.

●

Remove the rubber sheath from the potentiometer so that the welding points on the potentiometer are accessible.

●

Check again that the drive wheel is facing straight ahead.

●

The potentiometer has an overall resistance of 10 kOhm (measured between the blue/white and blue connecting wires).

Replacing the Steering Limit Switches

A

B

C

M2024

●

●

To adjust the centre position when the drive wheel is straight, attach the measuring lines of the potentiometer to the welding points of the blue wire (sliding contact) and the blue/white or blue/ black connecting wire.

●

Disconnect the battery.

●

Open the panel.

●

Remove the hex. socket screws (B, Abb M2024).

Using a pair of pliers turn the potentiometer axle until a reading of 5 kOhms is displayed. Use the grub screw to secure the potentiometer axis.

●

Loosen the cable binders as far as the plug connection and remove the limit switch.

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122 M1.0-0000-000122

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STEERING ●

Install in the reverse order and finally check the limit switch.

Limit Switch Adjustment The limit switches are fixed to the bearing plate. They are adjusted via the cam plate (C, Fig. M2033).

Limit Switch Test ●

Connect the battery and power up the truck.

●

Steer in one direction until the limit switch is on top of the trip cam (see item A., Fig. M2033).

●

As the steering wheel is turned further the steering motor should not run.

●

Turn the steering wheel to the right or to the left until the drive wheel is at 90 degrees to the truck longitudinal axis. The mechanical stop should not be reached. There should be a clearance of at least 2mm between the stop piece (A, Fig. M2031) and the stop cam of the cam plate.

●

Loosen the grub screw (B, Fig. M2033) and turn the cam plate (C) until the limit switch is on top of the highest point of the trip cam (see item A, Fig. M2033).

●

Check setting as described in "Limit Switch Test" and adjust if necessary.

A

C B

M2033

●

The drive group mechanical stop should not be reached. There should be a clearance of at least 2mm between the stop piece (A, Fig. M2031) and the stop cam of the cam plate.

A

B

M2031 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MS-6.0-3310

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LIFTING MECHANISM

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M1.0-0000-000126 126 M1.0-0000-000126

MAST Torques All screws and nuts must be torqued to the standard values which can be taken from the tables in section 1.

If the contact pattern is satisfactory, clean and regrease the running surfaces (see lubricant table in chapter M1).

When the mast is fully extended it should be vertical and not tilt either to the right or left. If there is any deviation, either the shims below the outer mast rollers are incorrectly fitted or the brass slide pieces are worn.

Fork Settings When the forks are fully lowered and horizontal, adjust them so that the surface of the fork tine is maximum 65 mm off the ground.

The maximum fork height (raised) must be within +/-25 mm of the fork height specified on the data plate.

For maintenance, replacement and adjustment details see the "Mast Roller" section.

Flaking A new mast can often appear to be flaking. This indicates that the rollers are entering the mast section, and is completely normal. This effect will disappear after a while. The grease applied to the section will hold the abrasion together.

Mast Control (Fitted)

Mast Stop Buffer Two rubber stop buffers act as stops for the platform's internal mast. These buffers are seldom used providing the lift limit cutout is set and operating correctly. As with all rubber parts however they wear with age. Replace any cracked or brittle buffers.

Fork Carriage Stop Screws There is a stop screw at the bottom left and right sides of the mast section respectively. These screws prevent the fork carriage from falling down in the event of excessive chain elongation or if the chain brakes. If the chain elongation is within the tolerance levels and the lift chain correctly set, the bottom rollers of the fork carriage should not touch the stop screws. To adjust, see the "Fork Carriage Roller" section.

If the screw heads are damaged, replace the stop screws. Then check the lift chain for excessive stretching and replace if necessary.

Track

MS-2920-008

Check each channel for roller tracks. The channel should not contain any grooves, notches or scoring. If any of these types of wear are visible, the mast rollers must be adjusted accordingly.

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MS-7.0-3310

127

MAST Removing the Platform without Aux. Lift (1200 mm lift height) WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly.

To remove the platform proceed as follows: ●

Disconnect the battery (remove the plug).

●

Remove the battery side panel (Fig. MS-3010-011)

●

Prevent the truck from rolling away.

MS-3010-003

1 2

MS-3010-011

3 MS-3010-006

●

Prepare the work area for collecting any spilled oil.

●

Unscrew the panel (1, MS-3010-006), cover (2) and receptacle (3).

●

Remove the plug connections to the panel.

●

Remove the wiring from the chassis (cut cable connections). Thread it through the hole (Fig. MS3010-003); unscrew the energy chain attachment MS-3010-012

MS-7.0-3310

128 128

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MAST and secure the energy chain with the wiring to the chassis so as to prevent the wire from being damaged when the mast is lifted out. ●

Remove the fastening screw connecting the lift cylinder to the upper cross member (Fig. MS3010-012).

MS-3010-014

MS-3010-014

MS-3010-007

●

Attach the load harness to the platform as indicated in Figure MS-3010-007.

Warning: The minimum capacity of the lifting gear is 500 kg!

●

Only chains whose length can be individually adjusted or adjustable belts can be used as lifting gear. Adjust the length so that the platform remains horizontal and not tilting in the mast section during lifting.

●

Slowly raise the platform, correcting any deviations if the mast rollers leave the mast section.

●

Place the platform on a secure support so that it cannot tilt (see Figs. MS-3010-014 and -015).

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129

MAST Removing the Platform with Aux. Lift (1200 mm lift height) WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly. ●

Prepare the work area for collecting any spilled oil.

●

Prevent the truck from rolling away.

●

Connect the remote control (A, Fig. MS-3010-026 to plug SD-M (B) in the motor compartment.

Remote control must be provided by the user, see Chapter 4.

MS-3010-021

A

MS-3010-022

B MS-3010-026

●

Lower the forks with the remote control and press on the lowering switch for a further 20 seconds to reduce the residual pressure in the line to the aux. lift cylinder.

●

Raise the platform until the cover for the hydraulic connections to the mast is accessible (prevent the platform from lowering!). Disconnect the battery by removing the plug and remove the cover (see Fig. MS-3010-021).

●

Remove the battery side panel (Fig. MS-3010-011)

●

Disconnect the hydraulic line to the aux. lift cylinder at its connecting point (see Fig. MS-3010022) and seal the pump side with a dummy stop (Fig. MS-310-023).

MS-3010-023

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MAST ●

Unscrew the energy chain attachment from the chassis (Fig. MS-3010-024) and attach it for the time being to the platform using a strap or a wire (Fig. MS-3010-025).

●

Unscrew panel (1, MS-3010-006), cover (2) and receptacle (3).

MS-3010-023

MS-3010-006

MS-3010-023 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

●

Remove plug connections to the panel.

●

Remove wiring from chassis (cut the cable binders). Thread it through the hole (Fig. MS-3010003); Unscrew the energy chain attachment and

MS-3010-003 MS-7.0-3310

131

MAST secure the energy chain and the wiring to the chassis so as to prevent the cable from being damaged when the platform is raised out. ●

Remove the lift cylinder mounting screw from the upper cross member (Fig. MS-3010-012).

MS-3010-014

MS-3010-012

MS-3010-014

●

Attach the load harness to the platform as shown in Fig. MS-3010-027.

Warning: The minimum capacity of the lifting gear used must be 600 kg!

●

The lifting gear used must either be individual chains with adjustable length or adjustable belts.

Adjust the length so that the platform remains horizontal when raised, not tilting in the mast section.

●

Slowly raise the platform, correct any deviations if the mast rollers jut out of the mast section.

●

Place the platform on a secure base to prevent it from tipping (see Fig. MS-3010-014 and -015).

MS-3010-027

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MAST Removing Platform without Aux. Lift (1800 mm lift height) WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly. ●

Prepare the work area for collecting any spilled oil.

●

Prevent the truck from rolling away.

●

Disconnect the battery (remove the plug).

●

Remove the battery side panel.

●

Remove the wire harness from the mast (Fig. MS3010-038) and the cable binder which secures the "P" and "Q" connectors (Fig. MS-3010-039).

MS-3010-039

●

Remove the energy chain attachment from the chassis (Fig. MS-3010-039).

MS-3010-038 MS-3010-040

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MAST ●

Attach the energy chain to the platform to prevent it from damage when the platform is raised (Fig. MS-3010-025).

MS-3010-034

●

Remove the upper mounting screws from the two lift cylinders (Fig. MS-3010-041).

MS-3010-025

●

Unscrew the microswitch from the two upper mast sections (Fig. MS-3010-034 / -035).

MS-3010-034

●

Attach the lifting mechanism (minimum capacity = 600 kg) to the overhead guard as shown in Figs.

MS-3010-042 and -043. Make sure that the chains or belts are evenly tensioned in order to raise the platform horizontally from the mast sections.

MS-3010-034

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MAST ●

Carefully raise the platform up out of the mast sections. If necessary, manually adjust the platform to prevent the mast rollers from tilting (Fig. MS-3010-036).

MS-3010-042

MS-3010-036

●

Lower the platform onto a secure wooden base (Fig. MS-3010-015).

MS-3010-0360015

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MAST Removing Platform with Aux. Lift (1800 mm lift height) WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly. ●

Prevent the truck from rolling away.

●

Disconnect the battery (remove the plug).

●

Remove "Q" and "P" wire harnesses from the lift cylinder (Fig. MS-3010-038) and disconnect the plug connector (Fig. MS-3010-039).

●

Remove the energy chain attachment from the chassis (Fig. MS-3010-039) and attach it to the platform (Fig. MS-3010-025).

MS-3010-039

MS-3010-038 MS-3010-040

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MAST

MS-3010-035

●

Attach the lifting mechanism (minimum capacity = 600 kg) to the overhead guard as shown in Figs.

MS-3010-042 and -043. Make sure that the chains or belts are evenly tensioned in order to raise the platform horizontally from the mast sections.

MS-3010-025

●

Remove the microswitches at the top left and right of the mast cross member (Figs. MS-3010-034 and -035).

MS-3010-042

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MAST

MS-3010-043

●

Carefully raise the platform up out of the mast sections. If necessary, manually adjust the platform to prevent the mast rollers from tilting (Fig. MS-3010-036).

●

Lower the platform onto a secure wooden base (Fig. MS-3010-015).

MS-3010-036

MS-3010-0360015

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MAST Mast Rollers WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly.

The mast rollers (A, Fig. MS-3010-015) and mast guide rollers (B, Fig. MS-3010-015) are only accessible when the platform has been removed. To remove the platform refer to the previous pages. Please note that the removal procedure for the platform will depend on the lift height and whether an aux. lift cylinder is fitted. ●

Remove the platform and lower it onto a secure base to prevent it from tilting.

MS-3010-016

Fitting the Mast Rollers ●

Apply a thin coat of grease to the cleaned bearing journal.

●

Push the mast roller onto the bearing journal.

●

Attach the mast roller with two screws.

Warning: Screws without a Nylstop insert must be secured with a drop of Loctite 242.

Self-locking screws must be replaced.

●

Check the fitted mast roller. The bearing should not run unevenly and the roller should be free to move.

A

1 2

B

B

Guide Rollers The guide rollers (B, Fig. MS-3010-015) compensate any lateral play in the mast section. Replace any worn or rigid guide rollers.

Guide Roller Removal 3 MS-3010-015

Removing the Mast Rollers ●

Remove the two Allen screws (Fig. MS-3010-016) from the mast roller.

●

Pull the mast roller off the bearing journal.

●

Check the mast roller for wear and make sure it can move freely. Replace any worn or uneven rollers.

●

Clean the bearing journal and replace if worn.

MS-3010-017

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MAST ●

Remove the two hex. bolts (Fig. MS-3010-017) and the shims (A, Fig. MS-3010-018) below the bearing blocks. Position or mark the shims in such a way that they can be re-installed in the same position when the guide roller is re-fitted.

Guide Roller Installation ●

Before installing the guide rollers clean and gently grease the contact surface of the bearing block and the contact surface around the mast (anticorrosion protection).

●

Secure the guide roller along with the previously removed shims using two screws (Fig. MS-3010018). Tighten the screws only so that the roller can be positioned with a rubber hammer.

Warning: Screws without a Nylstop insert must be secured with a drop of Loctite 242.

Self-locking screws must be replaced.

●

The guide rollers must be aligned at right angles.

Place a steel ruler between the two mast rollers and determine the angle between the bearing block of the guide roller and the ruler (Fig. MS3010-030). Set the bearing block to right angles and tighten the mounting screws.

A

MS-3010-018

●

Fully remove the screws and remove the guide roller together with its support.

●

Check the guide rollers for wear and make sure they can move freely. Replace any worn or damaged rollers.

A

B

MS-3010-030

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MAST Platform Installation (all variants)

●

Raise the platform and carefully insert the mast rollers into the mast section (Fig. MS-3010-031).

●

Slowly continue to lower. Thread the piston rod of the hydraulic cylinder through into its respective position. Insert and tighten the fixing screw (Figs.

MS-3010-032 and -012).

WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly.

The following steps are the same for all platform variants.

If the platform is inserted in the mast, follow the removal instructions from the previous sections in the reverse order (connecting the hydraulic system, electrical system etc.)

Requirements: ●

The battery must be disconnection (plug removed).

●

The battery side panel must be removed.

●

The truck is secured against rolling away.

●

Lifting gear with sufficient capacity, longitudinally adjustable chains or load belts and sufficient lift height available (see notes in the removal sections on the previous pages).

To install the platform proceed as follows: ●

Clean and re-grease the running surfaces of the mast sections.

●

Clean and re-grease the mast rollers and guide rollers.

●

Attach and adjust the chains or load belts in such a way that the platform can be raised horizontally.

MS-3010-031

MS-3010-031 MS-3010-031 MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

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MAST ●

Re-fit the electrical and hydraulic systems as described in the corresponding removal section, but in the reverse order.

●

Finally check the operation of the platform, once unladen and once with maximum load.

Fork Carriage (Aux. Lift Only) WARNING Carrying out assembly work on the mast can be dangerous Unsecured, non-blocked mast stages and components can sever limbs or cause fatal injuries. Always block and secure the respective components with suitable means prior to assembly.

MS-3010-049

Fork Carriage Removal ●

Connect the remote control (A, Fig. MS-3010-026) to connector SD-M (B) in the motor compartment.

A

MS-3010-044

B MS-3010-026

●

Use the remote control to lower the platform onto hard wooden blocks (see Fig. MS-3010-049).

●

Secure the truck against rolling away.

●

Remove the stop screws of the fork carriage at the bottom left and right of the section (see Fig. MS-3010-044).

●

Using a second forklift, lift the fork carriage as indicated in Fig. MS-3010-046.

●

Remove the self-locking nut of the chain anchor from the fork carriage (see Fig. MS-3010-047).

MS-3010-047

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MAST ●

Gently lower the fork carriage with the second truck (Fig. MS-3010-048). Make sure that the rollers do not tilt.

●

Remove the retaining ring from the roller axle and remove the fork carriage roller. If the roller is jammed, use an extractor (see Figs. MS-3010-053 and MS-3010-051).

MS-3010-053

MS-3010-048

●

Drive the fork carriage away and place it in such a position that the rollers are easily accessible.

Removing the Fork Carriage Rollers ●

Remove the fork carriage as described in the previous section.

●

Remove the brass slide pieces and shims (see Fig. MS-3010-052) from the roller axles. Clean and place them in such a way that they can be later inserted in the same position.

MS-3010-051

Fork Carriage Roller Installation

MS-3010-052

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●

Before installing the fork carriage check the rollers for wear, freedom of movement and evenness.

Replace any damaged rollers.

●

The brass slide pieces are subject to a certain amount of wear.

New slide pieces are 5mm thick. The wear limit is 4mm. It is advisable however to replace the slide pieces before they reach the minimum level.

●

If the old rollers, slide pieces and shims can be reused, they must be fitted in their original position.

●

Clean and re-grease all contact surfaces in the mast section. Clean and re-grease the roller axle.

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MAST ●

Push the mast roller onto the roller axle and secure it with the retaining ring.

●

Grease the cleaned brass slide piece. Slide on the previously fitted shims and fit them together into the roller axle hole. Repeat the process with all the other rollers.

●

Using a large caliper calculate the measurement A (Fig. MS-3010-055) between the upper and lower roller pairs: Rated value = 309.1 +0.1 mm

●

Gently lower the fork carriage until the lower rollers are touching the stop screws.

If necessary, add or remove shims to set measurement A. Warning: use brass slide pieces of the same thickness / number on each side of the fork carriage. The fork carriage must run parallel to the mast section and must not tilt.

MS-3010-044

MS-3010-055 MS-3010-047

Fork Carriage Installation ●

Using a second forklift carefully insert the fork carriage, without tilting, into the mast section from below. Lift it only so far so that the fork carriage rollers enter into the sections.

●

Re-fit and tighten the stop screws (see Fig. MS3010-044). If the screw heads are damaged, replace the screws.

●

Guide the chain anchor through the cross member in the fork carriage and secure it with a new selflocking nut (Fig. MS-3010-047).

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Tensioning the Lift Chain ●

Tighten the mounting nuts of the chain anchor on the fork carriage until there is approx. 2mm play between the fork carriage rollers and the stop screws of the fork carriage. The fork carriage must not rest on the stop screws.

●

Using the remote control apply the full lifting range of the forklift truck several times. Now check the distance between the lower fork carriage rollers and the stop screws, and check the chain tension.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

MAST

MS-3010-054

●

Disconnect the remote control.

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MAST Lift Chains

WARNING Do not use chemical solvents or steam to clean the chains as the lubricant applied at the factory will be removed from the inner plate surfaces.

General Lift chains are a major component of a fork lift truck.

The chain system on this mast is designed to transmit the lift force from the hydraulic cylinder to the fork reliably and efficiently. Safe, uninterrupted truck operation depends on careful servicing and maintenance of the lift chains.

Most complaints about the chain performance are due to lack of maintenance. Highly stressed precision chains require regular maintenance to ensure a long useful life.

INSPECTION The chain must be inspected every 100 hours for any signs of faults or damage. If this cannot be performed on the truck, the lift chains must be removed.

Irrespective of the result of the inspection, the lift chains, detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first.

The inspection should include the following: ●

Wear to the chain and chain elongation.

●

Pitting due to rust or corrosion, in particular on the outer surfaces of the connection plates;

●

Pins turning in or extruding from the outside plates;

●

Loss of freedom of movement

●

Damage to the anchor bolt attachment;

●

Wear and corrosion to the anchor bolt and anchor;

●

Wear between the bolts and the connection plates;

The following sections cover the above items in detail.

Cleaning The chain surface should be cleaned with parafin, a hard bristle brush and lint-free cloth.

After inspection apply another film of chain spray. The oil acts both as a lubricant and as an anti-corrosive protection.

Wear The chain bends as it passes over the chain rollers.

This leads to a gradual wearing of the joints.

Any slack a chain undergoes during its lifetime is due to wear to the links and the chain plate eyelet.

DANGER When checking for chain wear be sure to measure a part of the chain which passes over the guide pulleys. Never repair chains by cutting out the worn section and replacing it with a new section. If a chain is worn, always replace both lift chains.

The chain wear can be measured using a steel ruler.

Before testing the chain slack it is important to tension the lift chain if necessary. For non-detachable lift chains the weight of the fork carriage or mast is sufficient. If the lift chain is detached it must be kept taut during measurement.

The chain slack test must cover at least ten links over at least three different points in a section of the chain which always passes over a pulley during operation.

Chain Dimensions: New: ............................ 10 links = 154.75 mm Wear limit: ................... 10 links = 158.78 mm

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MAST DANGER

Chain Anchor and Pulleys

If just one of the faults mentioned in this chapter is detected, both chains together with their chain anchors or bolts must be immediately replaced.

In the course of checking the chain system, the chain anchors, chain bolts and pulleys must be checked for wear.

Never repair damaged chains!

This can result in fatal accidents!

On the chain anchor watch out for wear and cracking of the individual fingers. If one of the above problems occurs replace the chain anchor.

Freedom of Movement Each individual chain link must flex freely. Tight joints (Fig. 2775si) increase friction and the chain tension during lifting. Excessive chain tension in turn accelerates material wear.

Pulleys with heavily worn flanges and contact surfaces must be replaced. Worn flanges are due to misalignment. The chain tension and mast roller setting must be checked.

Worn or Missing Plates

2775si

Possible causes of stiff joints are as follows: ●

Bent pins or plates

●

Rusty joints

●

Peened plate edges

Chains which are bent or whose edges are worn must be replaced immediately.

Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (Fig. 2774si) can crack after a large number of lifting cycles with heavy loads.

Replace both chains immediately if cracking shows or plates are missing.

Protruding or Turned Chain Pins Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existant film of oil. In extreme cases the frictional torque in the joints can be such that the pins turn and gradually work out of the chain (Fig. 2776si). This can result in chain failure.

Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction.

2774si

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MAST Chains with twisted or protruding pins must be replaced immediately.

Further details on the correct lubrication and adjustments are given in the operating instructions for the particular model and at the end of this chapter.

Chain Lateral Wear Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This is caused by misalignment between the pulley and the chain anchors.

Misalignment of Lift Components ● 2776si

DANGER Never attempt to repair the chain by driving pins back into the chain. This can result in accidents with severe or even fatal injuries if the chain tears. Fit new chains.

Misalignment of the chain pinion and the chain due to the wrong number of washers on the mast or a damaged mast or cylinder components can also contribute to wearing of the chain sides.

To test whether this is the case, proceed as follows: Place the truck on a horizontal surface in the service station. Support the fork carrigae and detach both ends of the lift chain from the chain anchor and visually inspect the alignment with the anchor slots.

Corrosion The chains used on fork lift trucks are highly stressed precision components. It is particularly important to maintain the original fatigue strength throughout its useful life.

2773si

Corrosion considerably reduces the capacity of a lift or roller chain, because corrosion leads to cracking in the side plates.

It is therefore extremely important to protect lift chains from corrosion, both when operating and in storage.

The layer of grease applied at the factory is an excellent protection.

This factory lubrication is applied through a hot dip galvanizing process which ensures full penetration of all joints.

Do not steam clean or degrease new chains. After commissioning the chain supplement the factory lubrication through a regular lubrication schedule.

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MAST LIFT CHAIN LUBRICATION Lubrication is the most important factor in lift chain maintenance. It considerably affects the chain's useful life.

Highly stressed chains under constant use cannot last sufficiently long if they are not regularly lubricated within a planned maintenance schedule.

Dust will gather on oiled chains in dusty environments.

However, even in these conditions, regular lubrication can considerably reduce wear.

A paste mixture of oil and dirt will gather on the chain joints, but they will not wear as fast as they would if they were left to dry, leaving a metal to metal contact between the pins and plates.

Note: A lift chain must never be allowed to dry.

As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear.

Maintaining a lubricant film on all the chain surfaces provides the following benefits: ●

Restricts joint wear to a minimum (chain elongation)

●

Avoids corrosion

●

Reduces the risk of chain bolts turning

●

Restricts the danger of chain joints turning in to a minimum

●

Ensures an even movement of the chains and thus reduces noise levels

●

Reduces the chain tension due to less friction in the chain system

In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains.

Multi-plate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain bolt (see Fig. 2777si) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty.

Oil film

2777si

Key factors when considering which lubricant to use are as follows: ●

High degree of penetration in the narrowest of gaps

●

Maximum tolerance of pressure and shearing forces before the lubricant film comes off.

●

Suitability to the operating temperature range, especially important for cold store trucks.

In normal operating conditions the chains should be cleaned and immediately lubricated every 100 service hours.

Crown recommends the use of chain oil sprays. These have the advantage of being able to penetrate every crack at the moment of application due to low viscosity, and then to change to a high viscous state and thus resist high pressure and shearing forces. Solid lubricants have not proved as successful.

Furthermore, chain sprays are clean and uncomplicated to use.

Lubrication intervals depend on the operating conditions and the environment. Trucks parked outdoors, in cold stores or which are subjected to extreme weather conditions must be lubricated more frequently.

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MAST Fork Tine Test

DANGER

General The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see M1.2-3010-009) for cracks, damage and wear.

If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.

Fork blade Fork hanger

Forks showing signs of cracking, distortion or wear must be de-commissioned.

They endanger the life of the operator and other people as well as the general operation of the truck.

Repairs Fork repairs must only be carried out by the manufacturer / qualified personnel. When repairing supporting members always carry out a load test and check for signs of cracking.

Crack Inspection Fork shank

M0344

Curve section

Inspect all fork tine surfaces for signs of cracks (Fig. M0346) and if necessary carry out a non-rupturing crack test (magnetic particle cracking test in accordance with DIN 4113). For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam.

Fork Identification The data plate of the fork must be readable.

Cracks

M0346

M0347

Check fork hanger welding seams for any signs of cracking

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MAST If any cracking is discovered which could affect safety remove the relevant fork.

DANGER Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork.

≤ 2.5 mm

Fork Blade Warping Measure the angle deflection between the top of the fork blade and the front of the fork shank. If it is more than 91° or less than 88° (Fig. M0352) the fork must be realigned and checked before it can be used again. For measuring procedure see Fig. M0353.

M0349

Verticality Test Fork tip

Check verticality of fork shank (Fig. M0349) and fork tip (Fig.M0350/0351). If the readings illustrated below are exceeded the fork must be taken out of service.

≤ 2 mm Min. 88° Max. 91° M0350

250 mm

M0352

500 mm ≥ (x - 17 mm) ≤ (x + 8.5 mm) 500 mm Straight edge x M0351

≤ 6.0 mm

M0353

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MAST Measuring the Fork Tip Width

Fork Stop

If the fork tip width S is less than 1/6 of a (a = fork back width) do not use the fork (Fig. M0355).

Check the stop mechanism (Fig. M0356) on both fork tines. If faults or damage are discovered do not use the fork.

S≥a/6 Stop mechanism

M0355

M0356

Fork Tine Height Difference Check the height of the fork tines in relation to each other (Fig. M0354) if the fork is fixed to the fork carriage.

If the difference is greater than 3 % of the fork blade length the fork tines must be correctly aligned.

Example: If the length of the fork blade is 1150mm the maximum permissable deviation is approx. 35mm.

It is however generally advisable to align the forks if the deviation is more than 10mm.

L

3 % of L Left Fork

M0354

Right Fork

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MAST Wear Check for fork blade wear, in particular at the heel.

If the width is 90 % or less than the original value, the fork must be taken out of service. Use a caliper (Crown No. 107330) to check for wear (Fig. M0357).

Outside jaws 100% (Fork Shank)

●

Using the caliper, scan the fork blade between the taper and the curved area.

●

If the inner scan point fits 90% over the fork blade (Fig. M0360), the fork must not be used.

Inside jaws 90 % (Fork Blade)

Fork Blade Cross Section M0357

M0360

●

First caliper the outer opening 100% in the central area "a" (Figs. M0358, M0359) of the fork shank.

Caliper here the outer opening

M0358

Fork Back Section

M0359

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CYLINDERS

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M1.0-0000-000156 156 M1.0-0000-000156

CYLINDER Cylinders Piston rod

General There are two main types of hydraulic cylinder: ●

Plunger cylinders, and

●

Piston cylinders (double-acting cylinders)

Deflector Guide ring Seal

The main difference between the two types of cylinder lies in their operation as well as the sealing material design.

Guide ring

Plunger Cylinders (single-acting)

Oil

The plunger cylinder (see Fig. M1475) has only one pressurised rod surface.

The piston rod enters the cylinder via a single or several guide rings. A rod seal in the cylinder head and a dirt deflector protect the inside of the cylinder and the piston rod from external contamination.

Cylinder tube

The piston rod return movement is actuated either by the net weight of the rod or by the force acting on the piston rod from the load.

M1475

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CYLINDER Piston Cylinder (Double-Acting Cylinder) On a piston cylinder both sides of the piston are pressurised. The piston rod can therefore be moved in either direction by the oil flow.

The piston rod can produce different piston areas. This results in different forces and speeds occuring at a constant pressure and flow volume levels.

The rod of the piston cylinder has a piston at one end which enters the cylinder through a guide ring and whose piston seals protect the two oil-filled chambers against each other. The cylinder and piston rod are sealed on the outside by a rod seal in the cylinder head. An additional scraper ring protects the rod seal from external contamination.

When a piston cylinder is used as a single-acting cylinder it offers reduced operating pressure with the same cylinder tube inside diameter compared with the plunger cylinder, thanks to the larger piston surface. However, the operating speed is reduced at the same flow rate. The de-pressurised side of the cylinder must be bled.

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CYLINDER Single-Acting Cylinder

Piston Seal

Piston

Guide Ring

CylinderHead

Piston Rod Oil

Cylinder Tube

Rod Seal Deflector Ring

Return Flow to Tank

M0822

Double-Acting Cylinder

Piston Seal

Piston

Oil

Cylinder Tube

Guide Ring

Oil

Rod Seal

O Ring

Deflector Ring

Cylinder Head

Piston Rod

M0824

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CYLINDER Maintenance WARNING DE-PRESSURISE ALL HYDRAULIC SYSTEM COMPONENTS BEFORE CARRYING OUT MAINTENANCE WORK. IF PRESSURISED HYDRAULIC OIL ESCAPES FROM THE SYSTEM IT CAN RESULT IN SERIOUS INJURIES. High-pressure fluids can penetrate the skin and cause severe injuries. Reduce the pressure before disconnecting the hydraulic lines.

Tighten all connections before re-pressurising the system. Keep ands and feet away from screw holes as high-pressure fluids can emerge at these points.

Use paper or cardboard to trace leaks.

Do not use your hands.

If any high-pressure fluid penetrates the skin it should be treated as an emergency even if there are no markings to the skin at first. Pain will set in later. Damage to the tissue may result.

Inspection Before carrying out maintenance closely inspect the cylinder unit by retracting and inserting the cylinder several times. ●

Check the piston rod for scratches, nicks and other surface damage.

●

Check deflector rings and the entire cylinder head area for individual component wear and abnormal leakage.

●

If excess hydraulic oil emerges from the piston rod from at the cylinder head it may be due to a damaged rod seal. Replace the rod seal and make sure that the seal seat is clean and intact.

●

Check the pivot for signs of unusual wear or damage. When servicing the cylinder also check the condition of the other parts. Replace any parts showing signs of premature wear as well as parts which are already worn or damaged.

●

Minor irregularities on the cylinder tube surface or on the piston rod can be removed with an aluminium oxide cloth or a honing tool.

●

When all the parts have been checked clean the cylinder components in a high-grade solvent and dry with low-pressure pressurised air.

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CYLINDER Seal Installation General

1

NOTE CHECK THE SEAL GROOVE AND PISTON ROD FOR DAMAGE BEFORE FITTING A NEW SEAL. FAILURE TO DO SO COULD RESULT IN FURTHER LEAKAGE IMMEDIATELY WHEN THE SEALS HAVE BEEN REPLACED. To fit rod seals use lint-free assembly material and tools made of soft metal or a suitable plastic without sharp edges. Do not use screwdrivers or similar equipment as these could damage the seal edges.

Use appropriate protective devices if the seal is to be moved over sharp edges, cracks or curves.

Aux. Lift Cylinder

M2045

●

Pull off the drainage hose from the cylinder and blank the ports.

●

Remove the self-locking nut (1, Fig. M2043) and lift out the lift chain (2) and the chain anchor (3) over the guide pulley.

The aux. lift cylinder is a single-acting cylinder with an integrated line brake safety device.

DANGER WHEN CARRYING OUT ANY WORK ON THE MAST AND LIFT CYLINDERS THE FORK CARRIAGE AND/OR PLATFORM MUST BE PROTECTED FROM SUDDEN LOWERING USING APPROPRIATE SAFETY MECHANISMS.

2 SUDDEN LOWERING CAN RESULT IN FATAL INJURIES

Removal - Preparation ●

Fully extend the aux. lift cylinder.

●

Block the fork carriage to prevent it from lowering (support and secure with suitable mechanism).

●

Prepare a basin to collect any spilled hydraulic oil.

●

Depressurise the hydraulic system by activating the lowering switch(es) for at least one minute to reduce the system pressure as much as possible.

●

Power down the truck and disconnect the battery.

3

M2043

1

Aux. Lift Cylinder Removal ●

Carefully loosen the cylinder pressure connection (1, Fig. M2045), reduce the residual pressure, unscrew the line and blank the ports.

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CYLINDER

2

1

M2046

●

Remove the mounting screw (1, Fig. M2046) from the guide pulley bracket (2) and remove the support.

●

Remove the 2 support screws on the rear of the eye for the chain tensioner.

●

Lift out the cylinder and seal the hydraulic connections with dummy plugs.

Repairing the Aux. Lift Cylinder As with all hydraulic component work, ensure the working area is totally clean.

Disassembly Do not tension the piston / piston rod ●

Remove the cylinder nut (3, Fig. M1740).

●

Remove the seal (2) and wiper (1) from the cylinder nut (3) and take out the O ring (4).

●

Pull the piston rod (5) out of the cylinder pipe (13).

●

Remove the piston (7) together with the O ring (6) and seal (8) from the piston rod (5).

●

Remove both nuts (10) and retaining ring (9).

M1740

Inspection ●

Clean and de-grease all parts with an appropriate agent.

●

Check all parts for wear and damage: - there must be no signs of scoring on the piston rod and cylinder pipe.

Replace any parts if in doubt.

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CYLINDER Assembly ●

All seals must be replaced.

●

Assemble the seals in the reverse order of disassembly.

●

Apply a thin coat of hydraulic oil to the seals before inserting them.

●

Apply a thin film of hydraulic oil to all blank metallic parts before assembly, in particular the piston rod and the inside of the cylinder pipe.

Lift Cylinder Lift cylinders are single-acting cylinders with an integrated line brake safety device. Depending on the model, one or two lift cylinders (parallel) of varying lengths can be installed.

The procedure for disassembly, repair and assembly is the same for all cylinders. The following description for a single lift cylinder therefore applies to all variants.

DANGER WHEN CARRYING OUT ANY WORK ON THE MAST AND LIFT CYLINDERS THE FORK CARRIAGE AND/OR PLATFORM MUST BE PROTECTED FROM SUDDEN LOWERING USING APPROPRIATE SAFETY MECHANISMS.

Aux. Lift Cylinder Assembly ●

Assemble the cylinder in the reverse order of disassembly.

●

The cylinder is self-bleeding. Activate the lift functions a couple of times only. Check operation and for leaks. If necessary, replenish with hydraulic oil.

MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

SUDDEN LOWERING CAN RESULT IN FATAL INJURIES

Removal - Preparation ●

If present, fully lower the aux. lift. Fully extend the lift cylinder (fully raise the platform).

●

Block the fork carriage to prevent it from lowering (support and secure with suitable mechanism).

●

Prepare a basin to collect any spilled hydraulic oil.

●

Depressurise the hydraulic system by activating the lowering switch(es) for at least 2 one minute to reduce the system pressure as much as possible.

●

Power down the truck and disconnect the battery.

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CYLINDER Lift Cylinder Removal

Repairing the Lift Cylinder

●

Carefully loosen the cylinder pressure connection (1, Fig. M2048), reduce the residual pressure, unscrew the line and blank the ports.

●

Pull off the drainage hose from the cylinder and blank the ports.

As with all hydraulic component work, ensure the working area is totally clean.

Disassembly

1

Do not tension the piston / piston rod ●

Remove the cylinder nut (3, Fig. M2049).

●

Remove the seal (2) and wiper (1) from the cylinder nut (3) and take out the O ring (4).

●

Pull the piston rod (5) out of the cylinder pipe (11).

●

Remove the piston (7) together with the O ring (6) and seal (8) from the piston rod (5).

●

Remove both nuts (10) and retaining ring (9).

M2047

●

Remove the locking screw (1, Fig. M2047) from the upper cross member of the platform support.

●

Remove the locking screw (2, Fig. M2048) from

1

2

M2048

the lower cross member of the chassis. ●

Lift out the cylinder and seal the hydraulic connections with dummy plugs.

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MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

CYLINDER Inspection ●

Clean and de-grease all parts with an appropriate agent.

●

Check all parts for wear and damage: - there must be no signs of scoring on the piston rod and cylinder pipe.

Replace any parts if in doubt.

Assembly ●

All seals must be replaced.

●

Assemble the seals in the reverse order of disassembly.

●

Apply a thin coat of hydraulic oil to the seals before inserting them.

●

Apply a thin film of hydraulic oil to all blank metallic parts before assembly, in particular the piston rod and the inside of the cylinder pipe.

Lift Cylinder Assembly ●

Assemble the cylinder in the reverse order of disassembly.

●

The cylinder is self-bleeding. Activate the lift functions a couple of times only. Check operation and for leaks. If necessary, replenish with hydraulic oil.

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ELECTRICAL DIAGRAMS

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MS-LP3010/3020-GB 09/02 • Rev. A • Printed in Germany

169 (PVH) (SV1) (SV2) (HN2)

(RGS1)

(SV3) RED/BLACK WHITE/GREEN VIOLET

RED/BLACK

(LMS3)

BLUE

BLUE/BLACK

BLUE/GREEN

WHITE/BLACK

(HN3) RED/GREEN

(HN1)

WHITE

RED/BLUE

GREY/BLACK GREY/BLACK

YELLOW/BLACK YELLOW/BLACK

RED/WHITE RED/WHITE

WHITE/BLACK WHITE/BLACK

BROWN

BROWN

BLACK

(RCS2) (HNS1) (HNS2) (DMS5) (DMS4)(GTS) (GTS)

BLACK

BROWN

(RAS2)

BLACK

BROWN

BLACK

BROWN

BLACK

BROWN

BLACK

BROWN

BLACK

BROWN

BLACK

BROWN

BLACK

(RAS3) (LOS3)

BROWN

BLACK

BROWN

BLACK

BROWN

(LGT3)

PINK/BLACK

PINK/BLACK

BLACK

(DMS3)RED/BLACK

PINK/BLACK

PINK

BLUE/WHITE GREEN

BLUE

BLUE/BLACK YELLOW

WHITE/BLACK

VIOLET RED/BLACK

RED/BLUE

WHITE RED/BLACK

GREY

(POT2)

PINK

(KYS) (EDS1)(DMS6)(ORS1)

RED/BLUE

BROWN/BLACK YELLOW/RED

YELLOW/RED

WHITE/BLACK

BROWN

GREY

(EDS2)

GREY

RED/BLACK

BLACK

RED/GREEN

RED

RED

BLACK

RED/WHITE

GREEN

(DMS2)

RED

VIOLET

(DMS7)

RED

RED

WHITE/BLACK

WHITE

BLUE/WHITE

BLUE

(DMS5.2)

WHITE/BLACK

BROWN

RED

WHITE

BROWN

BROWN/BLACK

RED/BLACK BLUE/BLACK

(POT4)

GREEN/BLACK

BLUE

BLACK

PINK/BLACK

GREEN

WHITE

(RS2)

BLACK

(LOS1)

BROWN/WHITE

BLUE/BLACK

BROWN/BLACK

BLUE/BLACK

BLUE

GREEN

VIOLET

YELLOW

WHITE

YELLOW

RED/BLACK

BLACK

RED/BLACK

RED/BLACK

BLUE/WHITE

(POT3)

GREY

(HGTS1)

BLACK

BLUE

BLACK

(BR)

RED/BLUE

YELLOW

RED/WHITE

VIOLET

WHITE

BLUE

RED/BLUE

GREEN

RED/BLUE

WHITE/GREEN

GREY/GREEN

RED/BLACK

(HCS1)

(LMS1)

(LGT4)

RED

BROWN

PINK

(LMS2)

(RGS2)

YELLOW/RED

BROWN/BLACK

VIOLET

WHITE

YELLOW

RED/GREEN

YELLOW/BLUE

RED/YELLOW

GREEEN/BLACK

DIAGRAMS

(PLS1)

Electrical Circuit

(LOS2) (FS2) (PLS2)

Dome Light

Worklights LGT1 LGT2 (HCS2)(RCS1)

(POT1) (DMS1) (LGS1) (DMS5.1)

(FS1)

(RAS2) (RS1)

RED/GREEN

PINK/GREEN BLACK

BROWN/YELLOW

(LMS4)

(POT5)

GREEN

M1819_gb

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HYDRAULIC SCHEMATIC

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M1.0-0000-000172 M1.0-0000-000172 172

HYDRAULIC SCHEMATIC Hydraulic System Lifting:

Operation The hydraulic unit comprises the motor, pump, reservoir, all filters, valves and the lift cylinder.

The pump delivers oil from the reservoir to the lift cylinder. The lift valve opens, while the lowering valve closes.

Lowering: The lowering valve opens, while the lift valve closes. The oil flow returns from the lift cylinder to the reservoir.

M1965

1. Lowering valve

2. Adapter

3. Propor tional valve

4. Pressure switch

5. Safety valve

6. Emergency lower valve

7. Non-return valve

8. Flow control valve

9. Lowering brake

10. Test point

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HYDRAULIC SCHEMATIC Hydraulic System LP3010, 1025 mm lift height, without aux. lift Lift cylinder

M1965

1. Lowering valve

2. Adapter

3. Propor tional valve

4. Pressure switch

5. Safety valve

6. Emergency lower valve

7. Non-return valve

8. Flow control valve

9. Lowering brake

10. Test point

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Hyd_Dia-1-GB

HYDRAULIC SCHEMATIC Hydraulic System LP3020, 1845 mm lift height, with aux. lift

Lift cylinder Aux. lift cylinder

M1968

1. Lowering valve

2. Adapter

3. Propor tional valve

4. Pressure switch

5. Safety valve

6. Emergency lower valve

7. Non-return valve

8. Flow control valve

9. Lowering brake

10. Test point

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REV. 2 09/02 M1.0-0000-000175 175

HYDRAULIC SCHEMATIC Hydraulic System LP3010, 1620 mm lift height, without aux. lift Lift cylinder

Lift cylinder

M1967

1. Lowering valve

2. Adapter

3. Propor tional valve

4. Pressure switch

5. Safety valve

6. Emergency lower valve

7. Non-return valve

8. Flow control valve

9. Lowering brake

10. Test point

MS/MP-HYD-3010

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Hyd_Dia-1-GB

HYDRAULIC SCHEMATIC Hydraulic System LP3020, 2440 mm lift height, with aux. lift Lift cylinder

Lift cylinder

Aux. lift cylinder

M1966

1. Lowering valve

2. Adapter

3. Propor tional valve

4. Pressure switch

5. Safety valve

6. Emergency lower valve

7. Non-return valve

8. Flow control valve

9. Lowering brake

10. Test point

Hyd_Dia-1-GB MS/MP-HYD-3010

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