Crown Forklift WD2300S SERIES Maintenance Manual

MAINTENANCE MANUAL

WD2300S SERIES Order Number: 812560-006 Revision: A • Printed in Germany

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 & Co. KG – European Headquarter – Moosacher Str. 52 80809 München 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 2005 CROWN Equipment Corporation

TABLE OF CONTENTS MA- SAFETY

PAGE

Symbols Used in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Before Parking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Before Working on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Before Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warning and Instruction Decals on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ITD- INTRODUCTION

PAGE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operator manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

M1- LUBRICATION & ADJUSTMENT

PAGE

Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting by Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting with another Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Accessing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Control handle knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Platform and side restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Recommended Lubricants and Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cold Store Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Taking the truck out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Returning the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Testing the Operation of the Safety Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Drive Wheel and Castor Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Setting the contact pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

WD2300S 09/2005 • Printed in Germany

I

M2- HYDRAULICS

PAGE

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lifting (Main Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lowering (Main Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lifting (Initial Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lowering (Initial Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Changing the Hydraulic oil and Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Motor & Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hydraulic lines and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 General Rules for Hydraulic Lines and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Replacing the relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Relief valve test and setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Testing and setting the load-sensing pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Setting the pressure switch points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pressure switch PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pressure switch PS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pressure switch PS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

M3- POWER UNIT

PAGE

Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Tools required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Gear Unit Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Preparing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Assembling the flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Pinion Shaft Aassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Adjusting the Bevel Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Checking the Flank Tooth Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

WD2300S 09/2005 • Printed in Germany

II

M4- ELECTRICAL SYSTEM

PAGE

Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Sundry Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Electrical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Traction Pod (POT, FS, RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Fast / Slow Travel Switch (HSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Safety Reverse Switch (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Brake Switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Horn Switch (HNS1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Key Switch (KYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Emergency Disconnect (BD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fuses (FU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Thermo Switch (THS, optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Diode D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Diode Block (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Platform Logic (PLM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Limit Switch (LMS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Limit Switch (LMS 2, only for masts > 1700mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Limit Switch (LMS3, only for masts > 1700mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Limit Switch LMS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Pressure Switch (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Pressure Switch (PS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Pressure Switch (PS3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Initial lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic Control Module (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Raise / Lower Switches (RAS, LOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Control Handle Main PCB (Main PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hydraulic PCB (Hydr. PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Speed Transmitter PCB (R/T PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Heating Option (F/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Battery Discharge Indicator Setting (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Calibration for Wet Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

WD2300S 09/2005 • Printed in Germany

III

SEM1 Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Precautionary Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Reduced Travel Speed Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Downhill Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Anti Roll Down Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Self-Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Monitored Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Safety Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Incorrect polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Wiring Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Protection rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Replacing the SEM1 Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Parameter Setting after Replacing the Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Travel Speed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 SEM1 Traction Controller Operating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 PARAMETER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 PROGRAM VACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Menu Structure for Folding Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Parameter Setting, Folding Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 TESTER Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Max. speed in relation to the reductionlevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 ALARMS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Traction Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Calibrating the Potentiometer, PROGRAM VACC Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 CONFIG Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SET MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SET OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Traction Controller Safety Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 WD2300S Platform Logic Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Platform Logic Controller, Part No. 816050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Checking the Platform Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 WD2300S 09/2005 • Printed in Germany

IV

Hydraulic Control Module (HCM), Part No. 816177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Calibrating the HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Important Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Traction Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Access to brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Pump Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Access to brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

M5- BRAKE

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Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Test and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Air Gap Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Braking Torque Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

M6- STEERING

PAGE

Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Control Handle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

WD2300S 09/2005 • Printed in Germany

V

Control Handle Grip Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Hand Grip Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Upper and lower shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Upper and lower shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Switch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Hydraulic PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Main board removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Safety Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Hand Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Initial Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

M7- MAST/LIFT MECHANISM

PAGE

Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Adjusting the Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Fork Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Adjusting the fork height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Lifting Gear Minimum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Fork Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Fork Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Fork Carriage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Lubricating Roller Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Mast Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Lowering Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Carrying Out The Vertical Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Lift Limit Cutout / Initial Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Lift Limit Cutout Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 LMS 2-4 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Lift Limit Cutout Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Connecting the Lift Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 WD2300S 09/2005 • Printed in Germany

VI

Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Freedom of Movement of Chain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Chain Anchor and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Worn Connection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Protruding or Turned Chain Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Chain Lateral Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Uneven Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Misaligned Lift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Fork Tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Fork Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Verticality Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Fork Blade Warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Measuring the Fork Tip Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Fork Tine Height Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Fork Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Fork Blade Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

M8- CYLINDERS

PAGE

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Safety when working on hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 General Instructions for Repairing Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Plunger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Piston Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Single-Acting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Double-Acting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Rod Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Large Rod Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Small Seal Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Rod Seal Assembly, Sealing Lip First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Initial Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Replacing the rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

WD2300S 09/2005 • Printed in Germany

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Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Installing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Cylinder Bleeding and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Free lift cylinder bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Flushing – Mast Lift Cylinders and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

M9- PLATFORM

PAGE

Mechanical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Platform Switch (PLS) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Platform Cushioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Layering the disk springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Side Restraint, Mechanical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

DIA- ELECTRICAL WIRING DIAGRAMS

PAGE

Standard Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Traffic Control Logic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Traffic Control Load Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Hydraulic Traffic Modul and Diodes Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Power Unit Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Control Handle Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Platform & Mast Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Platformmodul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Option Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Traffic Control Logic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Traffic Control Load Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Hydraulic Traffic Modul and Diodes Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Power Unit Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Control Handle Traffic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Platform & Mast Traffic circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Platformmodul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Folding platform, all versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Control Handle Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Horn Switch Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

HYD-HYDRAULIC DIAGRAMS

PAGE

Hydraulic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

WD2300S 09/2005 • Printed in Germany

VIII

SAFETY

Printed in Germany

1

Notes:

WD2300S 09/2005 • Printed in Germany

2

SAFETY Symbols Used in the Manual

Symbols Used in the Manual To provide guidance and clearly identify potential hazard points, we have used graphic illustrations in the manual:

Information This symbol is used additional information instructions.

Danger This symbol indicates a danger to life.

You or other people could be seriously or fatally injured if you fail to comply with this safetyinstruction.

with and

Option This symbol is used with text describing optional equipment.

This is not included with the standard version.

Warning This symbol representsa risk of injury and/or potentially signficant material damage.

You or other people could be seriously injured and/or significant material damage could occur if you fail to comply with this safety instruction.

Caution This symbol represents potential minor injuries and/or potential minor material damage.

You or other people could be slightly injured and/or minor material damage could occur if you fail to comply with this safety instruction.

WD2300S 09/2005 • Printed in Germany

MA-3400

3

SAFETY General Safety Instructions

General Safety Instructions

Maintenance and Repair

Maintenance and Repair Instructions

1. 1. Always carry out work in accordance with the test and maintenance schedule enclosed in these maintenance instructions and any applicable service bulletins.

Danger Observe the safety instructions in the maintenance manual and the truck operator manual.

Failure to do so could result in serious or even fatal injuries to maintenance and other personnel.

Motorised trucks can become hazardous if maintenance and servicing work are neglected. For this reason maintenance and inspections must be performed at sufficiently short intervals. There must be suitably trained personnel and proper guidelines at your place of work.

Danger Observe all relevant national and local safety regulations for maintenance and repair work.

Failure to do so could result in serious and even fatal injuries to maintenance and other personnel.

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

3. Keep fire protection equipment at hand and do not use a naked flame to check fluid levels or to test for leaks.

4. Use groundwater neutral, non-flammable solvents for cleaning. Always perform cleaning work over an oil separator. Protect the electrical system against damp.

5. Keep the work place and battery charging station clean, dry and well ventilated.

6. Do not allow oils to penetrate the ground or the drain system. Used oil must be recycled correctly.

Oil filters and dehumidifying inserts must be treated as special waste. Observe the local authority regulations.

7. Immediately neutralise and thoroughly rinse any spilled battery fluid.

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

9. Maintain the legibility of the data capacity plate and data plate, warning and instruction decals.

10. Truck modifications and additions may only be performed with Crown’s prior written approval.

11. The reliability, safety and suitability of Crown trucks can only be ensured by using original Crown parts.

MA-3400

4

WD2300S 09/2005 • Printed in Germany

SAFETY General Safety Instructions Before Parking the Truck

Before Starting the Truck

z

Brake until the truck comes to rest.

z

Test the safety mechanisms.

z

Lower the fork carriage fully.

z

Get into the travel position.

z

Apply the parking brake.

z

z

Switch off the truck and remove the key.

Test the lifting mechanism, travel direction switch, speed control, steering, warning mechanism and brakes.

z

When parking on a slope or incline always chock all wheels.

Before Working on the Truck z

Jack up the truck so that the drive wheel is clear of the ground. Apply the Emergency Disconnect and disconnect the battery.

z

Prevent the truck from rolling away and lowering.

z

When working on the mast, fork carriage or lifting mast always apply a chock to prevent accidental lowering.

z

Allow sufficient room for manoeuvre when testing the truck, to avoid endangering yourself and other people.

WD2300S 09/2005 • Printed in Germany

Warning and Instruction Decals on the Truck In the course of periodic maintenance work, check that the warning and instruction decals on the truck are complete and legible. z

Clean any dirty decals.

z

Replace any faulty or missing decals.

A description and the location of the warning and instruction decals used on the truck are given in section 10.9 of the spare parts manual.

MA-3400

5

Notes:

MA-3400

6

WD2300S 09/2005 • Printed in Germany

INTRODUCTION

Printed in Germany

7

Notes:

WD2300S 09/2005 • Printed in Germany

8

INTRODUCTION Introduction

Introduction

Ordering Spare Parts

General

The maintenance manual does not cover spare parts.

These are listed in a separate manual.

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

Spare parts can be ordered by quoting: z

The truck specification number

z

The truck model number

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

z

The truck serial number

Information

This information can be found on the truck data plate.

It is essential to provide this information to ensure accurate, fast and efficient order processing.

This book is not an operator manual. It is designed solely for specialist personnel who have been trained and authorised by Crown 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.

Operator manual

Please refer to the specification sheets for the utilisable loads, technical data and dimensions for this series.

Brochures can be obtained from your Crown dealer or from the following address: CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 80809 Munich Germany Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 or 133

This manual contains no operating instructions. An operator 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 truck.

Service Training Crown offers the appropriate truck related training for service personnel. Details of this training can be obtained from Crown on request.

WD2300S 09/2005 • Printed in Germany

ITD-3400

9

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

Maintenance manual structure Section

Description

IDX

Index

MA

Safety instructions

ITD

Introduction

1

Lubrication and Adjustment

2

Hydraulic system maintenance

3

Power unit maintenance

4

Electrical system maintenance

5

Brake system maintenance

6

Steering system maintenance

7

Mast / lift mechanism maintenance

8

Cylinder maintenance

9

Folding platform

DIA

Electrical wiring diagrams

HYD

Hydraulic diagrams

ITD-3400

10

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT

Printed in Germany

11

Notes:

WD2300S 09/2005 • Printed in Germany

12

LUBRICATION & ADJUSTMENT Lifting the Truck

Lifting the Truck

Lifting with another Forklift Truck

Danger

The WD 2300 S can be raised at an angle using a forklift truck.

Make sure the crane / truck and the lifting gear have the required capacity.

If the crane or lift truck crash or if a load falls, fatal injuries could result.

Required capacity (WD without battery): 900 kg

z

Position the forks of the truck which is doing the lifting as shown by the diagram below.

z

Place a chock approx. 90 mm thick between the outriggers of the WD 2300 S and the corresponding fork of the truck doing the lifting.

z

Secure the WS 2300 S firmly to the forks of the truck doing the lifting (e.g. with straps).

The outriggers must be fully raised and the forks fully lowered.

Lifting by Crane

800

> 800

90

Attach lifting gear as shown in the following diagram and prevent the truck from slipping (see arrow).

G_WD-on-forks

G_WD-lift-crane

WD2300S 09/2005 • Printed in Germany

M1-3400

13

LUBRICATION & ADJUSTMENT Jacking up the Truck

Jacking up the Truck

z

Place a hard wooden block underneath and lower the truck onto it (4).

Danger Always support a raised truck with wooden blocks or other appropriate equipment to relieve the jack.

Never reach your hands or other parts of your body under the truck before it has been supported, or when jacking up the truck.

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

The outriggers must be raised in full in order to jack up the truck. z

Place wedges (1) in front of both load wheels.

z

Apply a jack with sufficient capacity (>800 kg) to the centre of the skirting rail and raise the truck to a maximum of 20 mm (2).

z

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

1

4

3

3 G_WD-jack-up

z

Now raise the outriggers with the jack.

M1-3400

14

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Towing the Truck

Towing the Truck

Pull the truck slowly straight forward (as indicated by the black arrow).

When the truck is de-energised, the brake (acting on the drive wheel) is applied. To remove the truck from an aisle, for example, it can be raised and pulled by a forklift truck. Capacity required (WD 2300 S unladen): 900 kg . The load wheels remain on the ground when the truck is towed. z

Position the forks as shown in the diagram.

Take care not to damage the castor wheels on either side of the truck. z

Raise the truck (at its front) approx. 40 mm.

Caution The drive wheel must be lifted from the floor!

Otherwise the truck could be damaged.

G_WD-tow

WD2300S 09/2005 • Printed in Germany

M1-3400

15

LUBRICATION & ADJUSTMENT Accessing the Components

Accessing the Components The following is a list of covers, panels etc. which must be removed prior to carrying out repairs and / or servicing in order to access the components. Refer to the illustrations in this chapter which will help you to locate the parts.

Warning Always remove the battery connector before carrying out maintenance work. This applies in particular if the connector and electrical connections have to be separated.

z

Unigage (TT/BDI)

z

Key switch (KYS)

z

Fuse 3, FU3 (signal system)

z

Fuse 4, FU4 (signal system)

z

Platform module (PLM)

z

Pressure switches (PS1, PS2, PS3)

Control handle Provides access to: z

Horn switches (HNS1 & HNS2)

Power unit cover

z

Main Lift – lower switches (LOS1, LOS2)

Provides access to:

z

Main Lift – lift switch (RAS)

z

Traction motor ™

z

Fast / Slow Travel Switch (HSS)

z

Power unit

z

Safety Reverse Switch (SAS)

z

Brake

z

Potentiometer (POT), forward travel switch (FS), reverse travel switch (RS)

z

Pump motor (PM), lift contactor (P), lowering valve (SV1, SV2, SV3)

z

Lower switch (ILS Lower) initial lift

z

Hydraulic oil reservoir

z

Main switch (ILS Lift) initial lift

z

Horn (HN)

z

Diode block (DB)

z

Traction control module (TCM)

z

Main contactor (line)

z

Fuse FU1 (travel power fuse)

z

Fuse FU2 (raise)

z

Diagnostic LED for TCM (LED)

z

Hydraulic control module (HCM)

M1-3400

16

Control handle knuckle Provides access to: z

Brake switch (BRS)

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Accessing the Components Mast Provides access to: z

Mast switch: –

Mast 1700 mm: Speed reduction limit switch (LMS4)

–

Mast 2100 mm: Speed reduction limit switches (LMS4, LMS3, LMS2)

Platform and side restraint Provides access to: z

Travel mode switches (GCSL, GCSR, PLS)

WD2300S 09/2005 • Printed in Germany

M1-3400

17

LUBRICATION & ADJUSTMENT Accessing the Components 23 1

22

2 21 3 4 20 5 6 7

19

8 9 18

10

16 17

11

15 14

12 13 MS-3400-001

1

Lift chain

13

Castor wheel

2

Mast lift cylinder

14

Pump unit & hydraulics manifold block

3

Safety shield

15

Battery compartment

4

Control handle

16

Outrigger

5

Control handle knuckle

17

Load wheels

6

Side restraint

18

Battery / battery connector

7

Display panel

19

Outer mast

8

Drive unit / brake

20

Fork

9

Controller and contactors

21

Fork carriage

10

Platform

22

Inner mast

11

Castor wheel

23

Mast limit switch

12

Drive wheel

M1-3400

18

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Maintenance

Maintenance

z

Do not park the truck in the open air or in a humid environment. The ideal place is a dry room where the temperature and air humidity are reasonably constant. If the truck has to be covered, use an airpermeable material. Do not use plastic sheets.

Otherwise, condensation may form.

z

Jack up the truck. Lower the chassis onto suitable wooden blocks so that the wheels clear the ground (prevents the wheels from flattening from constant pressure).

z

Every 3 months connect the battery, carry out a daily inspection and activate all thetruck functions.

Finally, disconnect the battery again.

Recommended Lubricants and Oils Lubricants The next page shows typical lubricants used by Crown itself in its facilities. However, you can use any lubricants provided they meet the same technical criteria.

Cold Store Trucks Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table on following page). An anticorrosion fluid (Crown no. 805236-004) must be applied regularly to all screws, washers, nuts, pins, retaining rings etc. Carefully protect all electrical connections and components against corrosion. For detailed information, refer to chapter 4.

Service intervals must be adapted to the conditions of use. This means they must be reduced as far as possible to prevent excessive wear.

Taking the truck out of service z

If the truck is to be out of service for 3 months or more, proceed as follows:

z

Disconnect the battery.

z

De-commission the battery in accordance with the manufacturer‘s instructions.

z

Clean the truck*. Carry out lubrication in accordance with the Maintenance Manual.

z

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

WD2300S 09/2005 • Printed in Germany

Returning the Truck to Service To return the truck to service, proceed as follows: z

Remove any anti-corrosion film (apart from that provided for cold store use) *.

z

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

z

Charge the battery or fit a charged battery.

z

Connect the battery.

z

Carry out the daily inspection.

* Do not apply high pressure cleaning agents and/ or solvents to the truck. Do not use metal brushes!

Do not wet clean theelectricalsystem and do not use flammable solvents.

M1-3400

19

LUBRICATION & ADJUSTMENT Maintenance

Lubricant Type

Product Description

Manufacturer

Aralube HLP2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe EP2 Retinax LX LGWMI

Aral Castrol Century Esso Maxol Mobil Shell SKF

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

Hydraulic oil

Vitamin GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32 Hydran LZ 32 B110

Low temperature hydraulic oil Transmission oil

Grease (multipurpose)

Lowtemperature transmission oil

Lubricants

Crown Part No.

053002-001

B

053002-005

BB

Aral Castrol Esso Mobil Shell Finol Fuchs Mineralölwerke GmbH

053001-003

D

Deutz Oel HVI 32

Klockner

053001-009

DD

Hyp 85W90 GX-D 85W90 Mobilube HD85W90 Spirax MB90

Aral Esso Mobil Shell

053002-004

A

Mobil SHC 624

Mobil

053002-009

AA

Product Description

Application

Crown Part No.

Anti-corrosive agent

Tectyl

Anti-corrosive agent for cold 805236-004 store trucks.

Clearseal paint

2K clearseal paint

Acid-resistant clearseal paint 805236-003 for traction controllers used in cold stores.

M1-3400

20

Type

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

Inspection and Maintenance Schedule

When carrying out maintenance routinely check for wear, corrosion, damage, component operation and safety. If in doubt, replace components.

The following inspection and maintenance schedule assumes single-shift operation under normal conditions. The frequency of maintenance intervals must however be constantly adapted to the prevailing operating conditions. In dusty or otherwise extreme operating conditions including cold store application, the maintenance intervals specified must be reduced.

Exact details should be discussed with a Crown service engineer.

Daily Operator’s Inspection Item

Location

Action

I01

Battery

Check battery connector (Emergency Disconnect) and wires for damage, check contacts for burning.

Check battery compartment for spilled acid.

Battery safety clip and battery terminal support fitted?

Screws tight?

Catch down?

Check/charge battery in accordance with manufacturer’s instructions if necessary.

I02

Gear unit

Check for leaks: Brown oil at the bottom near the drive wheel?

If leakage is found, take the truck out of service.

I03

Hydraulics

Check for leaks: Traces of light oil on the ground beneath the truck?

If leakage is found, take the truck out of service.

I04

Steering

Check operation, ensure there is zero backlash.

I05

Platform

Test freedom of movement, automatic return and check for damage.

I06

Side restraint

Test freedom of movement and check for any damage.

I07

Forks, outriggers

Check for possible damage, cracks and excessive wear.

I08

if applicable: Load backrest

Ensure it is securely fitted and check for damage.

I09

Lift chains, chain anchor

Check for possible corrosion, cracks and any other damage.

I10

Wheels, load wheels Check tyres for wear and foreign bodies. Remove any foreign bodies.

I11

Safety shield

Securely attached, not cracked and still visible?

I12

Labels, decals

Check that they are all present, clean and legible.

I13

Key switch

Switch on and test battery discharge indicator operation.

I14

Outriggers

Raise and lower outriggers. Check operation.

WD2300S 09/2005 • Printed in Germany

M1-3400

21

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule Daily Operator’s Inspection I15

Outrigger lifting mechanism

With the outrigger raised, check for foreign bodies. Remove any foreign bodies found with a hook or similar item.

Do not use your hands to reach into the lift mechanism.

I16

Fork carriage

Raise and lower forks. Check operation. Check that the chain, inner mast and mast rollers are running correctly.

I17

Emergency Disconnect

Check operation.

I18

Horn

Check operation.

I19

Travel functions

Move the truck in both directions, first slowly and then at full speed.

Test rabbit/turtle switch operation (fast / slow) With the following settings: rider mode, side restraints folded out, outriggers down, test “rabbit” mode (fast): Speed reduction for - fork lift > 880 mm - load > 500 kg Travel inhibited for - fork lift > 1700 mm

I20

Brake

Test brakes in both directions: - by changing direction - by moving the control handle to the braking position (has the stopping distance increased since the last check?)

The control handle should automatically revert back upright when you release it from the travel position.

I21

Safety reverse switch

Test operation – see illustrations and description on following pages.

I22

Platform logic

Test operation when truck is idle (platform folded up): - Power up the truck.

- Unfold the LH side restraint - Apply travel function - Truck should not move - Unfold the RH side restraint - Apply travel function - Truck should not move - Unfold the LH and RH side restraints - Apply travel function - Truck should not move

I22

Platform logic

Test operation during travel (rider mode): - Unfold the LH side restraint - Truck should not move - Unfold the RH side restraint - Truck should not move

M1-3400

22

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

I01

,

%'

69

&$ .<6 %',

/06 30 , 69/ , 69

, , , &$ 3/0 +1 , , 70 , ,

69 ,

,

MS-3400-003

I19

I19

I21

I16

MS-3400-002

MS-3400-004

WD2300S 09/2005 • Printed in Germany

M1-3400

23

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

+16 &$

6$6

327 )6 56 ,

+16 &$

5$6 /26

,/6 /LIW /RZHU

&$ &$ &$

&$ &$ &$

,

MS-3400-005

I09

I08 I11

MS-3400-007

I14

I07

I10 I18

MS-3400-006 MS-3400-008

M1-3400

24

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Testing the Operation of the Safety Reverse Switch

Testing the Operation of the Safety Reverse Switch Danger Always test the safety reverse switch in a secure environment, free of other people and sufficiently far from obstacles.

G_WD_ARS_test

z

Set the control handle straight so that the truck can only travel in a forward direction.

z

Stand to the side with sufficient distance from the control handle.

z

Slowly move the truck forward with the control handle (walking ahead in the platform direction).

z

Make sure no one else is in the environment.

z

Apply the safety reverse switch.

The truck should stop immediately and then after a few seconds or however long the switch is held down for, move off in the opposite direction (depending on the truck pre-settings).

WD2300S 09/2005 • Printed in Germany

z

If the test does not work, the fault must be rectified before using the truck again.

The operation can be set (in the configuration menu) to either Belly (SAS operation while switch is pressed) or Timed (SAS operation cuts out after 2 seconds) .

M1-3400

25

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

Inspection and Maintenance Schedule Months: Item

Component

1

3

6

Hours: 100

250

500

I01

Travel checks

Check operation. Read the error memory log.

x

I02

Castor wheels, load wheels

Check the load wheel and castor wheel supports for clearance and wear

x

I03

Clean axles, check for wear and replace if necessary

I04

Check tyres for wear.

x

I05

Check castor wheels, adjust if necessary

x

Outriggers

Check for damage and ensure it is securely attached.

x

I07

Hydraulics

Check all hoses, lines and connections for leaks and damage

x

I08

Relief valve

Test relief valve operation and adjust setting if necessary.

I09

Pressure switch

Check operation.

x

I10

Drive wheel

Check wheel nuts are torqued correctly.

x

I12 I13

I14

Motors/Gear Unit

Check the power unit guide for clearance and wear

1000 2000

x

Check drive wheel for wear Power unit guide

x x

First gearbox oil change after the first 250 service hours, thereafter every 2000 hours.

x

Check pump and traction motor carbon brushes for wear, freedom of movement and contamination.

x

I15

Check traction and lift motor attachments

x

I16

Check gear unit for noise and leakage

x

I17

Check gear unit attachment

x

I18

Check lift and traction motor commutators for damage and wear, apply pressurized air to dust.

x

I19

Check lift motor/pump connection for damage and wear; replace if necessary.

x

M1-3400

26

24

x

I06

I11

12

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule Months: Item

Component

I20

Wiring / switches

1

3

6

Hours: 100

250

500

Check all line connections are secure Clean truck, battery and charger connector contacts and check contact springs.

I22

Check wiring, switches & connections are secure, check insulation for damage.

x

I23

Check line connections to traction controller, EMERGENCY DISCONNECT switch and main fuses FU1 & FU2 are secure

x

I24

Check power cables from traction and lift motors for damage

x

I25

Check battery cables and connectors for damage

x

Check / service battery as required in accordance with battery manufacturer's service manual.

x

Battery

Check battery condition.

x

I28

Check acid density and acid level.

x

Contactors

I30 I31

Traction controller

I32 I33

Clean and check main contactor tips, replace if necessary.

x

Clean and check pump contactor tips, replace if necessary.

x

Check operation. Read the error memory log.

x

Ensure it is securely fixed.

Brake

Blast off abrasion with pressurised air; check conical nipple for damage; check air gap and adjust if necessary.

I34

Check brake lining and friction surfaces and replace components as required.

I35

Check air gap and brake lining wear on the motor brake; clean brake linings (apply dry compressed air), and replace if necessary.

I36

Control handle

Test return spring operation.

I37

Initial lift cylinder

Check for leaks, check piston rod for wear, make sure attachment is fixed.

I38

Mast connection

Check torque.

WD2300S 09/2005 • Printed in Germany

1000 2000

x

I27 I29

24

x

I21

I26

12

x x

x x

x x x

M1-3400

27

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule Months: Item I39

Component Fork carriage

1

3

6

Hours: 100

250

500

Check for damage.

12

1000 2000

x

I40

Check forks for damage and wear.

I41

Check slack between forks and fork carriage.

x

x

x

I42

Mast

Clean bearings and contact surfaces, check for wear and replace if necessary; check mast itself for wear.

I43

Lift chains

Clean, check for wear, test elongation.

I44

Mast column and free lift cylinder chains and chain anchor

Check for wear, corrosion and damage.

x

I45

Lift chains, chain anchor

Check for possible corrosion, cracks and any other damage.

x

I46

Mast section

Check for wear.

I47

Mast rollers

Check for wear and clearance.

I48

Load backrest

Check for damage and ensure it is securely attached.

I49

Guide pulleys

Check for wear.

I50

Guide pulley yoke

Check for damage.

x

I51

Mast cylinder

Check for leaks, check piston rod for wear, make sure attachment is fixed.

x

I52

Mast switch

Check operation.

UVV testing

Germany only; other countries in accordance with national regulations.

Carry out UVV testing at specified intervals.

Annually

PMT test

Test stages in chapter 4

Annually

M1-3400

28

24

x

x x x x

x

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

, , , /06 , ,

, , , , .<6 , , , &$ 69 %' %', , , , , , , ,

30

I02 I03 I04

I10 I11

&$ 3/0 +1 ,

, , , , , ,

, , 69/ 69 69

70 , , , , ,

,

MS-3400-011

, , , MS-3400-009

I42 I44

2

1

I49 I50 I43

I46

I48

I47

I41

I44 I45

I40 I39 MS-3400-012

I51 I07 I06

1

Screw

2

Roller guide

I38

I02 I03 I04

MS-3400-010

WD2300S 09/2005 • Printed in Germany

M1-3400

29

LUBRICATION & ADJUSTMENT Inspection and Maintenance Schedule

L7

L11

/06 /06

L9 L10

L5

/06

&$ &$ &$

MS-3400-013

/

/ MS-3400-015

/

/ /

/ /

/

MS-3400-014

M1-3400

30

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Lubrication Points

Lubrication Points Item

Component

Type Quantit y

100

250

L1

Check hydraulic reservoir, top up if necessary

D

L2

Replace hydraulic oil

L3

A/R

Initial inspection

x

D

A/R

First change after 500 service hours

Battery cover hinges

B

A/R

L4

Control handle return springs

B

A/R

L5

Tie rod pintails and all lift mechanism B joints.

A/R

L6

Lift cylinder attachment

B

A/R

x

L7

Piston rod attachment

B

A/R

x

L8

Change transmission oil

A

A/R

L9

Mast sections

B

AR

x

L10

Mast & fork carriage rollers

B

AR

x

L11

Lift chains

G

AR

x

WD2300S 09/2005 • Printed in Germany

500

1000

2000

x

x x x

First change after 250 service hours

x

M1-3400

31

LUBRICATION & ADJUSTMENT Drive Wheel and Castor Wheels

Drive Wheel and Castor Wheels

z

Setting the contact pressure

To calculate the required adjustment:

The castors are located on the left and right hand sides beneath the truck. They prevent the truck from tipping over when negotiating bends.

Over time the castors apply a defined force to the ground as the articulated power unit generally compensates for the wear of the drive wheel and the castors. However, the contact pressure of the drive wheel decreases with increasing tyre wear. This extends the braking distance and on smooth surfaces will result in slipping if the truck starts with a heavy load.

New drive wheels have a 230 mm diameter.

If the diameter is only 220 mm the spring pretension of the power unit must be increased.

Otherwise the drive wheel slipping – and hence the wear – will increase disproportionately. At the same time the castor wheels will wear more than necessary due to increased contact pressure.

Procedure: z

Park the truck (unladen) on a level surface.

z

Disconnect the battery and remove the key.

z

Prevent the truck from being switched on again.

z

Remove the panel.

z

Measure and record the diameter of the drive wheel.

M1-3400

32

Measure the diameter of the castors, obtain a mean reading and record this.

New drive wheel Ø 230 mm minus current Ø of drive wheel = reading 1 New castor wheel Ø 125 mm minus current Ø of castor wheel = reading 2 Reading 1 – reading 2 = Adjustment factor Example: You have measured the actual diameter of the drive wheel to be 220 mm. Mean reading for castors 120 mm.

230 mm - 220 mm = 10 mm (reading 1) 125 mm -120 mm = 5 mm (reading 2) 10 mm -5 mm = 5 mm (adjustment factor) The bolts (B) in Fig. MS-3400-018 therefore must be screwed in 5 mm. z

Undo both counternuts (A) and turn them up by at least the adjustment factor calculated above.

z

Turn in the screws (A) alternately until you reach the adjustment factor calculated on both screws.

z

Check measurement C: rated measurement 33 mm (with new wheels)

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Drive Wheel and Castor Wheels z

Counterfix bolts (B) with nuts (A).

A

B B

C

A C

MS-3400-018

WD2300S 09/2005 • Printed in Germany

M1-3400

33

LUBRICATION & ADJUSTMENT Drive Wheel and Castor Wheels Torques The screw and nut strengths shown below are used in the manufacture of Crown trucks. The information on the page is designed to help determine the correct torque for maintenance work.

Information The torques listed in the maintenance section always supersede those shown on next page.

Screw Grade Marking

Nut Grade Markings

M1-3400

34

WD2300S 09/2005 • Printed in Germany

LUBRICATION & ADJUSTMENT Drive Wheel and Castor Wheels

Standard Screws and Nuts Grade

8 and 8.8

10 and 10.9

12 and 12.9

Thread Size

Torque (Nm)

M5 x 0.8

5-6

7-8

8-10

M6 x 1

8-10

12-14

14-16

M8 x 1.25

20-25

30-35

34-40

M10 x 1.5

40-45

60-65

70-75

M12 x 1.75

70-80

100-110

115-130

M16 x 2

170-190

240-270

280-320

M20 x 2.5

340-380

450-500

550-600

M24 x 3

580-650

800-900

900-1050

M30 x 3.5

1150-1300

1600-1800

1850-2100

Umbrako screws and nuts Grade

10 and 10.8

Thread Size

Torques (Nm)

M5 x 0.8

8

11

M6 x 1

14

19

M8 x 1.25

33

45

M10 x 1.5

63

86

M12 x 1.75

111

152

M16 x 2

270

372

M20 x 2.5

521

717

Special torques: Screws for mounting the power unit to the pivot bearing flange. 4 off M12 screws, torque 86 Nm

12 and 12.9

Screws for mounting the brake to the motor. 3 off M5 screws, torque 6 Nm Screws for mounting the mast to the chassis. 2 off M16 screws, torque 320 Nm

Screws for mounting the knuckle to the pivot bearing flange. 6 off M10 screws, torque 49 Nm

WD2300S 09/2005 • Printed in Germany

M1-3400

35

Notes:

WD2300S 09/2005 • Printed in Germany

36

HYDRAULICS

Printed in Germany

37

Notes:

WD2300S 09/2005 • Printed in Germany

38

HYDRAULICS Hydraulic Symbols

Hydraulic Symbols Symbol

Meaning Vented reservoir with lines above the fluid level

Symbol

Meaning

Electric motor with unidirectional turn and speed

Vented reservoir with lines above the fluid level

Hydraulic pump with fixed displacement and single direction of turn

Filter or strainer

Spring, (bias to normal de-energised position)

Hydraulic line with full flow

Solenoid single coil or winding

Control line or drainage withrestricted flow

Assembly housing, manifold block

Lines crossing; not connected

Throttle, adjustable

Lines crossing and connected

Throttle, fixed

Plugged port

Relief valve, adjustable

Accumulator gas charged diaphragm type

Check Valve

WD2300S 09/2005 • Printed in Germany

M2-3400

39

HYDRAULICS Hydraulic Symbols Symbol

Meaning

Symbol

Meaning

2/2 way valve (2 ways, 2 connections)

Hydraulic steer unit / 5

7 3

3/2 way valve (3 ways, 2 connections)

Torque generator 3 7

3/2 way valve (3 ways, 2 connections); Spring bias solenoid control

Shut-off valve, manual

4/2 way valve (4 ways, 2 connections)

Bypass flow control with controlled flow, pressure-regulated

4/3 way valve (4 ways, 3 connections)

Flow divider/combiner

4/3 way valve (4 ways, 3 connections); manual activation and spring centred

Single counterbalance valve assembly in manifold

Flow meter

Electric motor with unidirectional turn and variable speed

0

M2-3400

40

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Hydraulic Symbols Symbol

Meaning

Symbol

Meaning

Valve block with 3 operating units

Proportional solenoid

Shuttle valve

Dual solenoid

Relief valve, fixed setting

Solenoid valve, pilot operated

Velocity fuse

Hydraulic pilot operated

Pressure-compensated flow control with reverseflow bypass; fixed.

Manual actuator

Pressure-compensated flow control with reverseflow bypass; fixed.

Single-acting cylinder, with cushion

Pilot check valve(pilot to open)

Single-acting cylinder ram type

Manual lever actuator

Single-acting cylinder with spring returned (rod end vented)

WD2300S 09/2005 • Printed in Germany

M2-3400

41

HYDRAULICS Hydraulic Symbols Symbol

M2-3400

42

Meaning

Symbol

Meaning

Double-acting cylinder; equal area

Thermometer

Double-acting cylinder; unequal area

Pressure gauge

Pressure switch

Hydraulic motor, bidirectional

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Hydraulic Unit Removal

Hydraulic Unit Removal Warning Depressurise all components before carrying outwork 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. Physical effects may take time to set in.

Tighten all ports before reapplying system pressure.

Keep hands and body away from all ports as high pressure hydraulic oil can emerge.

Use absorbent paper to trace leaks, never use your hands!

WD2300S 09/2005 • Printed in Germany

M2-3400

43

HYDRAULICS Hydraulic System

Hydraulic System Function Lifting (Main Lift) When the “Raise” (RAS) switch is pressed down on the control handle, the pump motor is energised and starts to drive the pump. The pump initially draws oil from the reservoir via the suction filter, directing it through the internal check valve and the proportional valve which opens briefly, and back to the oil reservoir.

While the proportional valve is fully closed, the pressure builds up on the lift cylinder (softlift function).

The main lift valve is also opened to allow oil to flow into the main lift cylinder. A relief valve in the circuit keeps the pressure to the maximum permissible limit.

Lowering (Main Lift) If one of the two “Lower” switches (LOS1 or LOS2) is pressed down on the control handle, the shutoff valve opens. At the same time the proportional valve opens according to whether LOS1 or LOS2 has switched fully or partially. The main lift valve is also opened to allow oil to flow from the main lift cylinder. The hydraulic oil can now flow from the cylinder(s) via the flow restrictor back to the oil reservoir. If the proportional valve is partially open, lowering is slow. If the proportional valve is fully open, lowering is fast.

M2-3400

44

Lifting (Initial Lift) When the “Raise” (ILS Lift) switch is pressed down on the control handle, the pump motor is energised and starts to drive the pump. The pump initially draws oil from the reservoir via the suction filter, directing it through the internal check valve and the proportional valve which opens briefly, and back to the oil reservoir.

While the proportional valve is fully closed, the operating pressure builds up on the lift cylinder (soft lift). A relief valve in the circuit keeps the pressure to the maximum permissible limit. The main lift valve is also opened to allow oil to flow into the initial lift cylinders.

Lowering (Initial Lift) If the “Lower” switch (ILS Lower) is pressed down on the control handle, the shutoff valve opens. The proportionalvalve opens simultaneously. The main lift valve is also opened to allow oil to flow from the initial lift cylinder.

The hydraulic oil can now flow from the cylinder(s) via the flow restrictor back to the oil reservoir.

Note: The initial lift automatically lowers at a main lift height of 1700 mm.

WD2300S 09/2005 • Printed in Germany

Notes:

WD2300S 09/2005 • Printed in Germany

45

HYDRAULICS Hydraulic System

MS-3400-019

M2-3400

46

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Hydraulic System 1

Suction filter

2

Reservoir ventilation

3

Check valve (CV)

4

Overload valve (RV)

5

Cylinder shutoff valve (SV3)

6

Proportional valve (PV)

7

Pump & motor

8

Main lift cylinder

9

Main lift line break safety device

10

Reservoir

11

Flow restrictor

12

Initial lift cylinder

13

Main lift valve (SV1)

14

Initial lift valve (SV2)

WD2300S 09/2005 • Printed in Germany

M2-3400

47

HYDRAULICS Hydraulic System Hydraulic Reservoir Capacity Fill the hydraulic oil up to the bottom mark of the filler neck. The cylinders are lowered.

The maximum reservoir capacity is 2.0 litres.

Changing the Hydraulic oil and Hydraulic Filter z

Fully lower the forks. Retract the mast fully.

z

Fully lower the initial lift.

z

Turn the key switch OFF. Remove the key.

Disconnect the battery.

z

Attach a warning tag to the control handle to advise others that the truck is being serviced.

z

Chock the drive wheel and load wheels.

z

Remove the front cover from the power unit to access the hydraulic reservoir.

z

Separate the hydraulic lines from the hydraulic pump. Seal the hydraulic ports immediately to minimize oil loss and prevent hydraulic system contamination.

z

Disconnect all electrical wiring from the hydraulic unit. Tag out the wire ends and motor terminals to avoid any confusion when you later connect the wires.

z

Remove the retaining screws from the hydraulic unit.

z

The reservoir and motor/pump assembly can now be moved. Carefully raise the reservoir and pull it forward as far as possible. Remove the reservoir and the motor/pump assembly from the power unit frame.

z

Remove the screws securing the motor/pump assembly to the reservoir flange.

MS-3400-020 1

Reservoir cap

2

Motor

3

Filling level

Only start the truck once the reservoir has been filled with the approved hydraulic oil up to the maximum level. For the correct grade, refer to the lubricant table in Chapter 1.

The oil level should not deviate by more than +/- 5 mm from this level.

M2-3400

48

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Hydraulic System z

Remove the oil from the reservoir and any remains that have built up in the reservoir. Observe local disposal regulations.

z

Remove the retaining ring of the strainer in the filter housing of the suction line below the pump.

Replace the filter. Refit the strainer in the filter housing of the suction line. Attach the strainer and the retaining ring.

z

Fit the motor/pump assembly onto the reservoir.

z

Refit the flange and tighten the mounting screw firmly.

z

Fit the reservoir and the motor/pump assembly in the drive unit frame.

z

Refit the mounting screws and tighten them.

z

Reconnect the hydraulic supply lines and the electrical connections. Tighten the ports firmly.

z

Fill the reservoir up to the full mark (on top of the hydraulic reservoirbaffle) via a filter (at least 10 micron) using the correct hydraulic oil grade according to the operating conditions of the truck (see Chapter 1, Lubricant table).

z

Refit the front cover of the power unit, and tighten the mounting screws firmly.

z

Remove the wedge.

z

Connect the battery and remove the warning tag from the control handle.

z

Bleed the hydraulic system (see Chapter 8, Cylinder Bleeding and Flushing).

WD2300S 09/2005 • Printed in Germany

M2-3400

49

HYDRAULICS Motor & Pump Assembly

Motor & Pump Assembly Hydraulic lines and fittings

General Rules for Hydraulic Lines and Connections z

Apply pressurised air to all hoses and lines before assembling them, to remove any loose particles.

Bent steel or plastic lines will be permanently damaged. These must be replaced even if the damage is not externally visible.

z

Any hose which bends during operation in its normal assembly position must also be replaced.

z

All hoses and lines must have sufficient clearance from other surfaces or edges that could result in wear or cuts or where the hoses or lines could get caught.

z

All connections must be tight and without leaks.

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. Physical effects may take time to set in.

Tighten all ports before reapplying system pressure.

Keep hands and body away from all ports as high pressure hydraulic oil can emerge.

Use absorbent paper to trace leaks, never use your hands!

M2-3400

50

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Bleeding the Hydraulic System

Bleeding the Hydraulic System Whenever work has been performed on hydraulic components, the hydraulic system must be flushed and bled. The procedure for doing this can be found in Chapter 8 under “Cylinder Bleeding and Flushing”.

Disassembly Warning De-pressurise all components before carrying out maintenance work on the hydraulic system. High pressure hydraulic oil can cause serious injuries.

Drift Test Whenever work has been performed on hydraulic components a drift test must be carried out to ensure that certain system components are working correctly.

The procedure for doing this can be found in Chapter 8 under “Drift Test".

Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction. Physical effects may take time to set in.

Proportional function:

Tighten all ports before reapplying system pressure.

Keep hands and body away from all ports as high pressure hydraulic oil can emerge.

Whenever maintenance work has been performed on the hydraulic system.

Ensure that the load can start smoothly when the lift motor is switched on and that the load can also brake smoothly when lowering is switched off (subjective test).

The HCM (hydraulic control module) may have to be calibrated (see Electrics chapter).

WD2300S 09/2005 • Printed in Germany

Use absorbent paper to trace leaks, never use your hands! z

Fully lower the forks. Retract the mast fully.

z

Fully lower the initial lift.

z

Turn the key switch OFF. Remove the key.

Disconnect the battery.

M2-3400

51

HYDRAULICS Bleeding the Hydraulic System z

Attach a warning tag to the control handle to advise others that the truck is being serviced.

Motor

z

Chock the drive wheel and load wheels.

Refer to Chapter 4, “Electrics”, for pump motor maintenance and repair instructions.

z

Remove the front cover from the power unit to access the hydraulic components.

z

Remove the retaining screws from the hydraulic unit.

Pump The hydraulic pump cannot be serviced and can only be replaced as a complete assembly. Before fitting a new pump, make sure that the pump and all its hydraulic components are clean. Install a new suction filter (see section on changing the hydraulic oil and filter).

After replacing the pump: z

Use clean, filtered hydraulic oil (at least 10 micron) to replenish the reservoir.

z

Never run the pump without oil.

z

Start the installed pump unladen (pressure side open) and leave it to pump hydraulic fluid for max.

20 seconds. This will ensure the pump is bled and that there is sufficient lubrication. Close the pressure side again as soon as the oil emerges without bubbles. Bleed the entire system (see Chapter 8, Cylinder Bleeding and Flushing).

z

If the oil is still foaming after approx. 20 seconds, the system must be checked.

z

Check the connections again for leaks once the system has reached operating temperature.

MS-3400-021 1

Reservoir filler cap

2

Motor

3

Filling level

z

Remove the motor/pump assembly from the reservoir and take it to a suitable work area for further dismantling.

M2-3400

52

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Bleeding the Hydraulic System

3RZHU 8QLW

MP-3400-020

WD2300S 09/2005 • Printed in Germany

M2-3400

53

HYDRAULICS Bleeding the Hydraulic System

3RZHU 8QLW

MP-3400-022

M2-3400

54

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Relief Valve

Relief Valve

Relief valve setting

Replacing the relief valve

The relief valve (3) protects the hydraulic system and the lifting mechanism from overloading.

z

Remove the locking mechanism (see Fig. MP3400-022) and unscrew the relief valve (3),

z

Remove the O ring and the strainer from the valve seat if they are still in there.

z

Apply a thin coat of hydraulic oil to the new O ring and place it in the valve seat with the strainer.

z

Apply hydraulic oil to the relief valve (3), insert it into the valve seat and tighten. Tap in the new locking mechanism.

z

Refit the hydraulic unit and adjust the relief valve (3).

Model

Warning Do not let the pump unit run unless it is fixed to the chassis.

The amount of torque will twist the unit. This can result in short circuits and damage.

Capacity

Minimum test weight

Maximum test weight

Setting

WD2300S fork lift

1000 kg

1100 kg

1200 kg

180 bar

WD2300S initial lift

2000 kg

2200 kg

2300 kg

180 bar

WD2300S 09/2005 • Printed in Germany

M2-3400

55

HYDRAULICS Relief Valve Relief valve test and setting z

With the truck at operating temperature, lift a test load on the forks that corresponds to 110% of rated capacity (= minimum load). It should be easy to raise the load.

z

Now raise a test load that corresponds to 110% of rated capacity + 100 kg (=maximum load). It should not be possible to raise this load. (relief valve opens).

If necessary, adjust the relief valve so that it opens within the above mentioned tolerance range. z

z

Hold onto the setscrew and loosen the jam nut (see Fig. MS-3400-022): Turn the setscrew clockwise to increase the threshold at which the valve opens, turn it anti-clockwise to reduce the threshold.

Counter-fix the setscrew again with the nut.

M2-3400

56

MS-3400-022 1

Relief valve setscrew

WD2300S 09/2005 • Printed in Germany

HYDRAULICS Relief Valve Testing and setting the load-sensing pressure switches z

Power down the truck.

z

Remove the panel.

z

Remove the connector from the terminal lug of the load-sensing pressure switch.

z

Attach an ohmmeter or a continuity tester to the terminal lugs of the load-sensing pressure switch.

z

Power up the truck.

z

For individual test weights refer to the following page.

z

Raise the test load while observing the test item in the test menu or the ohmmeter / continuity tester.

If the pressure switch is set correctly, continuity should be displayed.

z

If this is not the case, reset the pressure switch. A setscrew is located between the terminal lugs of the pressure switch (2, Fig. MS-3400-023). Turn this until continuity is displayed.

z

If it is not possible to make the adjustment, the pressure switch is faulty and must be replaced.

Lower the load before removing the switch and depressurise the hydraulic system

2

WD2300S 09/2005 • Printed in Germany

1

MS-3400-023 1

Pressure switch

2

Setscrew

M2-3400

57

HYDRAULICS Relief Valve Setting the pressure switch points

Pressure switch PS1

The output signal of the load-sensing pressure switch PS1 lies on an input of the platform module. As soon as the raised load exceeds 500 kg, the signal is used to control speed reduction.

z

Place a load (500 kg) on the forks.

z

Set the switch so that it is activated with load.

z

Test the switch position by raising and lowering the load.

The output signal of the load-sensing pressure switch PS2 lies on an input of the hydraulic control module.

When the initial lift is raised, this is transmitted to the hydraulic control module via the switch.

Pressure switch PS2

The output signal of the load-sensing pressure switch PS3 lies on an input of the platform module. Only when the raised load exceeds 500 kg does the controller release the 2nd brake level and is used to contribute to braking.

z

Raise the initial lift without load

z

Set the switch so that it is activated (closes) with initial lift raised.

z

Set the switch so that it is not activated (open) with the initial lift lowered.

z

Test the switch position by raising and lowering the load.

The signal is also used to control speed reduction.

The correct operation of the pressure switch is therefore essential for braking with load and for the other truck functions. It also affects the maximum travel speed (see chapter 4, Speed Reduction).

Pressure switch PS3 z

Place a load (500 kg) on the initial lift.

z

Set the switch so that it is activated with load (opens).

z

Test the switch position by raising and lowering the load.

DPS1

DPS2-3

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POWER UNIT

Printed in Germany

59

Notes:

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60

POWER UNIT Gear Unit

Gear Unit

z

Raise the truck again by approx. 50 mm in order to be able to loosen the gear unit from the toothing at a later time.

z

Lower the truck onto the wooden blocks/supports.

Raise the truck approx. 500 mm to remove the gear unit.

z

Raise the device on the jack/pallet truck until it contacts the gear unit.

Tools required:

z

Remove the electrical connections from the motor.

z

Undo the six gear unit mounting screws (A) and the three motor mounting screws (B) in Fig. M1564.

Preparatory Measures

z

Forklift truck with sufficient capacity, lift height and fork length for the truck to be raised.

z

Safety mechanism for the forks of the lifting truck, required to hold the raised truck.

z

Sufficient number of wooden blocks (surface area of at least 250 x 250 mm) or suitable supports to secure the raised truck.

z

Device to carry the gear unit onto a jack or pallet truck.

Disassembly z

Disconnect the battery and remove the key.

z

Secure the truck to prevent it from being switched on again.

z

Secure the truck with a second forklift and prevent it from sliding away.

Danger Never work underneath a suspended load.

Fatal injuries could result if the truck is suddenly lowered. z

Raise the truck until you can push a jack / pallet truck underneath the truck to support it.

M1564 A

Gear unit mounting screw

B

Motor mounting screw

z

WD2300S 09/2005 • Printed in Germany

Lower the device together with the gear unit and pull it out from under the truck.

M3-XXXX-

61

POWER UNIT Gear Unit Servicing

General

Warning The gear unit must only be serviced by authorised personnel trained by Crown.

Failure to comply with this regulationwill invalidate the manufacturer’s warranty.

Correcting the flank tooth bearing and pre-tensioning the shaft support requires years of experience with gear units.

Incorrect adjustments and settings will result in premature failure of the gear unit.

It is therefore generally preferable to replace the whole gear unit.

New gear units are always supplied without oil.

Before using the gear unit for the first time, fill oil in accordance with the "Lubricant Table".

M3-XXXX-

62

z

All bearings and seals must be replaced.

z

Prior to dismantling, thoroughly clean the gear unit with a cold cleaning solution and dry with lowpressure pressurised air.

z

Use assembly equipment and a clean work area.

WD2300S 09/2005 • Printed in Germany

POWER UNIT Gear Unit

M1530A 140

Nut

190

Washer

110

Spur wheel

65

Bevel pinion shaft

230

Conical roller bearing

260

Conical roller bearing

440

Shim

70

Bevel pinion shaft

420

Shim

240

Conical roller bearing

360

Screw

160

Spacer ring

290

O-Ring

430

Shim

330

Screw

310

Retaining ring

390

Lock washer

50

Flange shaft

250

Conical roller bearing

150

Wheel bolt

100

Spur pinion

270

Shaft seal ring

130

Live ring bearing

400

Lock washer

30

Lid

350

Hex. socket screw

WD2300S 09/2005 • Printed in Germany

M3-XXXX-

63

POWER UNIT Gear Unit Disassembly / Assembly

Gear Unit Disassembly / Assembly All item numbers refer to illustration M1530A unless stated otherwise.

Disassembly z

Drain the oil.

z

Insert the gear unit with the wheel nuts into a secure device to prevent it from twisting.

z

Remove screws (330), lock washers (390) and Oring and remove lid (30).

z

Remove the hex. socket screws (350) and the lock washers (400).

z

Take off the live ring bearing (130).

z

Remove the screw (360) and washer (190).

z

Loosen the nut (140) of the bevel gear.

z

Take the gear unit out of the device.

z

Take the bevel gear (65), spacer ring (160) and adjusting shim(s) (420, 430) where applicable out of the housing.

M3-XXXX-

64

z

Extract the inner ring of the conical roller bearing (260) from the bevel gear (65).

z

Push out the flange shaft (50) using a suitable device.

z

Extract the inner ring of the conical roller bearing (250) from the flange shaft.

z

Extract the outer rings of the conical roller bearings (250, 260) from their seats in the gear unit housing.

z

Remove the rotary shaft seal and retaining ring (310) from the seat of the housing.

z

Press the bevel gear (70) down from out of the spur wheel (110) and the conical roller bearing (230).

z

Remove the conical roller bearing (230) and shim(s) (440) where applicable.

z

Extract the outer ring of the conical roller bearing (240).

z

Extract the inner ring of the conical roller bearing (240) from the bevel gear.

z

Thoroughly clean all components and remove the remains of the sealant and adhesive.

WD2300S 09/2005 • Printed in Germany

POWER UNIT Gear Unit Disassembly / Assembly Assembly

z

Information

Assembling the flange shaft All bearings and seals must be replaced.

Preparing the gear unit z

z

z

Press the outer rings of the conical roller bearings (230, 240, 250 and 260) into their respective notches in the cleaned housing. Make sure they are positioned level in the housing. Insert the retaining ring (310).

Press the inner ring of the conical roller bearing (260) onto the bevel gear (65).

Screw the wheel bolt (150) into the flange using a bolt driver.

z

Bring the housing into its subsequent assembly position.

z

Insert the inner ring of the conical roller bearing (250) in the pre-assembled outer ring (blade wheel side).

WD2300S 09/2005 • Printed in Germany

Press the rotary shaft seal (270) into the housing using a suitable tool.

Apply a thin layer of oil to the flange shaft (50) and carefully fit it in the shaft seal ring (270) and conical roller bearing (250).

Place the shim (430), spacer ring (160) and preassembled bevel gear (65) onto the flange shaft.

Information The flange shaft assembly must be tensioned with a torque wrench. z

Fit the washer (190) and screw (360) and torque the flange shaft assembly to max. 77 Nm.

z

Check the shaft can move freely and make sure there is no clearance. If necessary, reduce the torque. Note the final reading. It will be required for adjustment purposes.

z

Insert the gear unit with the wheel nuts into a secure device to prevent it from twisting.

M3-XXXX-

65

POWER UNIT Gear Unit Disassembly / Assembly Pinion Shaft Aassembly z

Press the inner ring of the conical roller bearing (240) onto the bevel gear (70).

z

Insert the pre-assembled bevel gear from the from the inside of the housing into the pre-assembled outer rings of the conical roller bearings (230, 240).

z

Push the inner ring of the conical roller bearing (230) over the shaft of the bevel gear (70) into the outer ring of the conical roller bearing (230).

Information The spur wheel nut must be tightened with a torque wrench. z

Assemble the spur wheel (110) and torque the new nut (140) to max. 100 Nm.

z

Test the freedom of movement and clearance of the bevel pinion shaft. If necessary, reduce the torque. Note the final reading. It will be required later for adjustment purposes.

Adjusting the Bevel Wheel Set Information Adjust with care. Pre-tensioning the bearings and shims will affect the tooth pattern. Do not set the pre-tension too low. it will automatically reduce during normal operation.

The correct setting can be calculated via the tooth profile pattern.

Basic Rules: z

Always adjust the bevel wheel set according to the correct flank position. The tooth ends should not form a straight line.

z

The tooth pattern must always align with the inner tooth end.

z

The tooth pattern must range from high (top edge of the tooth) to low (bottom edge of the tooth).

To adjust, add and/or remove shims (420, 430, 440) or change the pre-tension of the bearings.

Fig. M1565-1 shows the limits of the permissible tooth patterns on the bevel pinion and bevel gear.

M3-XXXX-

66

WD2300S 09/2005 • Printed in Germany

POWER UNIT Gear Unit Disassembly / Assembly Checking the Flank Tooth Bearing z

Final Assembly

Colour the tooth profiles of the bevel gear (70) with touch-up past (striking colour).

M1565-1

z

Take the gear unit out of the device.

z

Turn the bevel gear several times in one direction.

The tooth bearing will appear as a bright point (marked black in Fig. M1565-1) on the tooth flanks.

z

z

Re-assemble the bevel pinion shaft and flange shaft.

z

Clean all the components.

z

Apply a thin layer of Loctite 307 to the inside of the bearing inner rings.

z

Apply medium strength Loctite 242 (CROWN part no. 053050-006) to the threads of the nut (140) and the screw (360 ).

z

Re-assemble as described previously.

z

Manually turn the gear unit through, while checking for freedom of movement and ensure it operates without any clearance.

z

Apply a thin layer of Loctite 307 to the flat faces of the housing lid, insert the O-ring (290) and fit the lid. Tighten the screws (330) and the lock washers (390) evenly and crosswise.

z

Apply a thin layer of Loctite 307 to the flat face of the gear unit housing to the live ring bearing. Fit the live ring bearing.

Information Leave the surface and thread sealants to dry for at least 2 hours at room temperature.

Then fill with oil.

Check the tooth bearing. Remove and/or add shims (420, 430, 440) to restore the tooth bearing to the tolerance limits (Fig. M1565-1).

Warning: Torque the screw (360) and nut (140) to the previously recorded values.

Repeat the process until the tooth bearing is within the tolerance limits.

z

Set the gear unit in the assembly position.

z

Replenish with oil up to the bottom marker of the refill plug – (for the correct oil for the application temperature see the Lubrication and Adjustment chapter).

Level: 1.5 l

WD2300S 09/2005 • Printed in Germany

M3-XXXX-

67

POWER UNIT Gear Unit Disassembly / Assembly Re-Assembly z

Assembly is the reverse of disassembly. Take care not to damage the toothing of the spur pinion (100) or the spur wheel (110).

Traction motor Maintenance and servicing requirements for the traction motor are described in Chapter 4.

M3-XXXX-

68

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ELECTRICAL SYSTEM

Printed in Germany

69

Notes:

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70

ELECTRICAL SYSTEM Wire Colour Code

Wire Colour Code The wires used in the truck are colour-coded and numbered according to their function. The first digit or the first two digits indicate the wire colour while the last two digits are counter numbers.

Abbreviation

Colour

Numbera

Function

BLK

Black

0**

Digital signal

BRN

Brown

1**

Analog signal

RED

Red

2**

Positive not allowed

ORG

Orange

3**

+12 volt DC converter

YEL

Yellow

4**

Third DC converter

GRN

Green

5**

Negative not allowed

BLU

Blue

6**

Insulated negative

VIO

Violet

7**

+5 volt DC converter

GREY

Grey

8**

Fourth DC converter

WHT

White

9**

Various

RED/WHT

Red/White

29**

Positive connected

GRN/WHT

Green/White

59**

Negative connected

a. ** Numbers 01 to 99

WD2300S 09/2005 • Printed in Germany

M4-3400

71

ELECTRICAL SYSTEM Abbreviations

Abbreviations Switch Symbol Index of Abbreviationsa Abbreviation Description

Abbreviation

Description

K*

Relay

LMS

Limit switch

ACS

Travel switch

LOS

Lower switch

AXS

Auxiliary function switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Travel direction switch

RA

Raise potentiometer

DRS

Door switch

RAS

Raise switch

EDS

Emergency Disconnect

REA

Reach potentiometer

EM

Encoder module

RS

Reverse switch

ENC

Encoder

SAS

Safety reverse switch

FS

Forward switch

SDS

Start switch

HBS

Handbrake switch

SES

Seat switch

HNS

Horn switch

SSS

Side lift switch

HSS

“Rabbit/Turtle” toggle switch

THS

Thermo switch

KYS

Key switch

TLT

Tilt switch

LGS

Light switch

WAS

Walk-along / pedestrian mode switch

a.

If one of the above abbreviations is used more than once, a number suffix will be used, e.g. SV1, SV2 etc.

M4-3400

72

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Abbreviations Sundry Abbreviations Sundry Abbreviationsa Abbreviation Description

Abbreviation Description

BV(AK)

Battery voltage after the key switch

M2(PM)

Pump motor

BDI

Battery Discharge Indicator

MRC

Controller

BR

Brake

OHGD

Overhead guard display

BWI

Brush wear display

P

Pump contactor

CA

Cable connection

PC

Plug connection

F

Field coil connection

PCB

Printed circuit board

FAN

Fan

SF

Shunt field

FU

Fuse

STI

Steering wheel indicator

HN

Horn

SV

Solenoid valve

IFD

Information display

TB

Terminal block

JC

Bushing – counterpart to PC

TMM

Truck management module

LINE

Main contactor

TT

Hourmeter

M1(TM)

Traction motor

VMN

Motor driver (volt motor negative)

GCSR

RH side restraint safety switch

GCSL

LH side restraint safety switch

PLS

Platform switch

TCM

Traction motor

PS

Pressure switch

HR

Heating

a.

If one of the above abbreviations is used more than once, a number suffix will be used, e.g. SV1, SV2 etc.

WD2300S 09/2005 • Printed in Germany

M4-3400

73

ELECTRICAL SYSTEM Electrical Wiring Diagrams

Electrical Wiring Diagrams Europe

USA

Description

Europe

USA

Description

Wires joining

Switch applied manually

Wires crossing

Solenoid valve

Wire connection

Throttle / coil

Plug / socket

Resistor

Wire strap

Capacitor

Terminal board

Potentiometer

Fuse

Varistor V

M4-3400

74

Assembly

Thermal protector

Contact, normally open

Lamp

Contact, normally closed

Horn

Selective switch

Battery

Contactor / relay

Diode

Slow release contactor / relay

Breakdown diode

Time delay contactor / relay

LED

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Electrical Wiring Diagrams Europe

USA

Description

Europe

USA

Description

Switch, normally open

Transistor

Push button, mechanically actuated

MOSFET

Pushbutton, hydraulically actuated

Thyristor

Emergency Disconnect

Comparator

Motor armature

WD2300S 09/2005 • Printed in Germany

M4-3400

75

ELECTRICAL SYSTEM Electrical Components

Electrical Components Danger The truck must be jacked up prior to carrying out repair work or troubleshooting the electrical system.

Traction Pod (POT, FS, RS)

Brake Switch (BRS) The brake switch (BRS) is immediately below the control handle support. The brake switch is activated as soon as the control handle enters the upper or lower braking zone (see Fig. MS-3400-026). The PLM interrupts the power supply to the traction motor (TM) and the brake (BR) via the traction controller. The brake coil is switched off. The anchor plate is pressed against the brake through bias spring force.

The traction pod is manually actuated via thumbwheels on the control handle. The traction pod comprises a switch (FS) for forward travel, a switch (RS) for reverse travel, and a potentiometer (POT) which governs the travel speed. The signals are transmitted via drivers on the main PCB.

C

D

B

Fast / Slow Travel Switch (HSS) A

The Fast / Slow travel switch (HSS) is activated via a rotary switch (Rabbit / Turtle symbol) on the control handle. The switch signal to the traction controller is used to change between the high and slow speed ranges. However, the speed is also dependent on other factors, see PLM chapter (platform module).

Safety Reverse Switch (SAS) The safety reverse switch (SAS) is activated via the switch cap at the top of the control handle: The PLM immediately switches the traction controller from forward to reverse travel when the SAS is activated.

The signal for normal travel to the traction controller is simultaneously interrupted. Depending on the traction controller setting the truck either travels for a given time, or provided the switch is pressed, travels in reverse. The SAS function is deactivated in platform mode.

M4-3400

76

MS-3400-026

A

Lower brake zone

B

Travel zone

C

Upper brake zone

D

Neutral / rest zone

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Electrical Components Horn Switch (HNS1 & 2)

Diode D4

A buzzer sounds when the horn switch (horn symbol) is pressed.

This freewheel diode on the large brake coil (BR) protects the input on the controller against peak voltages caused when the large brake coil is switched off.

Key Switch (KYS) The key switch directs the battery supply to the traction controller and the battery discharge indicator (BDI).

Emergency Disconnect (BD) Pulling the battery connector on the red knob at the top of the truck completely disconnects the power supply to the truck.

Fuses (FU) The traction control load circuit and the control circuit are protected by FU2, the control circuit by FU3. Cold store trucks have a fuse FU4 for control handle heating. The pump load circuit is protected by FU1.

Thermo Switch (THS, optional) This switch is an electronic thermostat for cold store trucks. Located on the main PCB of the control handle and applies the heating units at temperatures below 5° and switches them off from 20°C (switch hysteresis).

WD2300S 09/2005 • Printed in Germany

Diode Block (DB) The diode block comprises diodes D1 to D3 in a single component. It acts as a freewheel diode for the small brake coil (BR) and guides the pressure switch (PS1) signal to connect the 2nd brake level.

Platform Logic (PLM) This module detects and analyses the connection status of the platform switch (PLS) and the side restraint switches (GCSR & GCSL).

Depending on the connection status an output signal is sent to the traction controller which either enables the higher travel speed or only permits the lower pedestrian speed.

The SAS and BRS signals are also connected via this module, depending on the platform switch and the side restraint switches, as well as the respective function switch.

The RAS signal (main lift) is deactivated from a main lift height of over 1700 mm plus in platform mode a height of over 1700 mm.

M4-3400

77

ELECTRICAL SYSTEM Electrical Components Limit Switch (LMS1)

Pressure Switch (PS1)

The limit switch (LMS1) interrupts the initial lift current flow when a preset maximum lift height has been reached. The limit switch is under the front panel next to the control handle support. This switch must be adjusted, see chapter 7, lift mechanism.

The pressure switch (PS1) applies when the load raised in the main lift circuit exceeds 500 kg, triggered by the rise in pressure in the hydraulic system. This reduces the maximum travel speed in platform mode to a safe level. It also applies the 2nd brake level.

Limit Switch (LMS 2, only for masts > 1700mm)

Pressure Switch (PS2)

Travel stop for lift height of 1700 mm main lift and truck in rider mode. This is controlled by the PLM. This switch must be adjusted, see chapter 7, lift mechanism.

Limit Switch (LMS3, only for masts > 1700mm) Automatic lowering of initial lift if the main lift height exceeds 1700 mm. This is controlled by the HCM.

Limit Switch LMS4 Speed reduction at a lift height of 880 mm main lift and truck in rider mode. This switch must be adjusted, see chapter 7, lift mechanism.

M4-3400

78

Indicates to the HCM that the initial lift is raised.

Applied when initial lift circuit is pressurised.

Pressure Switch (PS3) The pressure switch (PS3) applies when the load raised in the initial lift circuit exceeds 500 kg, triggered by the rise in pressure in the hydraulic system. This reduces the maximum travel speed in platform mode to a safe level. It also applies the 2nd brake level.

Initial lift Switch Lifting (ILS Lift-Initial Lift Switch) and lowering (ILS Lower-Initial Lower Switch).

The lift (ILS Lift) and lower (ILS Lower) switches are actuated as rocker switches in the lower zone of the control handle. The lift (RAS) switch activates the pump contactor (P) which is controlled by the hydraulic control module (HCM): The pump starts. The lower (ILS lower) switch applies voltage to the solenoid (SV) via the hydraulic control module (HCM). The solenoid opens.

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Electrical Components Hydraulic Control Module (HCM)

Heating Option (F/C)

This module detects and analyses the status of the hydraulic actuation switches (RAS, LOS1, LOS2, ILS Lift, ILS Lower) and some of the limit and pressure switches. Depending on the status of the switches, an output signal is transmitted to the pump contactor or one of the valves to raise or lower either one of the main or initial lift circuits.

Fitted to the Main PCB, Hydr. PCB, R/T PCB printed circuit boards as well as to an auxiliary board for traction pod heating.

Raise / Lower Switches (RAS, LOS) /06 The raise (RAS) and lower (LOS1, LOS2) switches are activated via rocker switches in the control handle. The rocker switches act on switches assembled on the circuit board of the control handle. The switches are electrically locked in pairs so that they cannot be pressed together at the same time. The raise (RAS) switch activates the pump contactor (P) which is connected via the hydraulic control module (HCM), whereby the signal is issued several times via the platform logic to prevent lifting above 1700 mm in rider mode: The pump starts. The lower (LOS) switch applies voltage to the solenoid (SV) via the hydraulic control module (HCM). The solenoid opens.

Control Handle Main PCB (Main PCB)

/06 /06

&$ &$ &$

Support for the drivers of signal transmitters Pot, RS, FS, HNS1&2, including the THS (option) and the heating.

Hydraulic PCB (Hydr. PCB) Support for signal transmitters RAS, LOS1&2, as well as the heating (option).

Speed Transmitter PCB (R/T PCB)

MS-3400-027

Support for signal transmitter HSS as well as the heating (option).

WD2300S 09/2005 • Printed in Germany

M4-3400

79

ELECTRICAL SYSTEM Electrical Components

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/06

30 +1 69/ 36 69

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MS-3400-017

M4-3400

80

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Battery

Battery

Replacing the Battery

General

Warning

The condition of the battery will affect the performance and driving characteristics of the truck. Optimal maintenance is key to maintaining the performance and useful life of the battery.

Warning The battery must be serviced solely in accordance with the battery manufacturer's instructions.

Incorrect or inadequate maintenance will initially reduce the performance of the truck and ultimately result in premature failure of the battery.

Only use batteries of the permitted size, weight and specifications for this truck.

An incorrect battery type can cause damage to the truck.

Incorrect weight and dimensions alter the truck centre of gravity. This can result in fatal accidents.

There are several different battery compartment models. Refer to the truck operator manual to battery replacement instructions.

The operator manual contains the latest safety instructions and information.

It is essential to adjust the battery discharge indicator (BDI) correctly to ensure on the one hand that the battery is not fully discharged and on the other that there is maximum battery capacity available for the task in hand.

WD2300S 09/2005 • Printed in Germany

M4-3400

81

ELECTRICAL SYSTEM Battery Discharge Indicator (BDI)

Battery Discharge Indicator (BDI)

Operation

The upper section of the unigage is a battery discharge indicator with lift cutout, while an hourmeter is located in the lower section.

The green and yellow LEDs on the battery discharge indicator show the degree of discharge on the battery.

A red flashing LED is a warning that the battery will soon be depleted. If two red LEDs are flashing, the recorder cuts out lifting. In this event the battery must be recharged or replaced with a fully charged battery to restore the truck to service.

2

1

MS-3400-028

The purpose of the lift cutout is to monitor and protect the battery and the electric components of the truck. To protect the battery the discharge cycle must not exceed 80% for a full charge (wet cell batteries).

MS-3400-029 1

Toggle switch

2

Back of recorder

Warning Greater discharge will result in permanent battery damage and can also damage the truck’s electric components.

M4-3400

82

WD2300S 09/2005 • Printed in Germany

ELECTRICAL SYSTEM Battery Discharge Indicator (BDI) General

If the lift cutout system is activated above 20% of the battery's residual capacity the battery will not be damaged, but the truck's maximum operating time under a single battery charge will not be attained.

Warning The following setting and calibration instructions for the BDI apply only to wet batteries.

If maintenance-free batteries are being used, set the toggle switch to “P”. No other settings are required. This applies only to batteries approved by Crown.

For other battery types, contact the battery manufacturer.

A battery from the factory will require approx. 5 - 10 charge and discharge cycles to reach its full capacity.

A battery is considered to be technically discharged when it has reached 20% residual capacity. For example, a battery with a 500 amp hour capacity has an actual available output of 400 amp hours.

In addition, the effective output will depend on the discharge speed, which in turn is affected by the particular truck application.

The battery discharge indicator must therefore be set in accordance with the truck's particular application conditions.

The battery discharge indicator controls the lift cutout system. The lift cutout system is designed to prevent the battery from being operated to the point where is fully discharged.

If the battery is constantly discharged to below 20% of residual capacity it will be damaged.

WD2300S 09/2005 • Printed in Germany

The lift cutout system should therefore be activated as close to 20% of the battery's residual capacity as possible. If at all, it may be slightly above 20%, but never below.

Information For new trucks, adjust the battery discharge indicator after ten discharge and charge cycles at the latest.

Battery Discharge Indicator Setting (BDI) The acid density is a very reliable indicator of the charge status of a lead acid battery. However, since it is unrealistic to continually measure the acid density of a truck battery to an industrial standard, the battery voltage is used to determine the charge status over longer journeys.

To adapt the BDI to the battery used and the truck's specific application profile, you need the battery manufacturer's data sheet. The values you require are the density of the electrolyte for an 80% discharged battery (20% battery residual capacity) and for a fully charged battery (100% battery capacity).

Finally, via the potentiometer on the back of the BDI the display is set to the actual discharge terminal voltage of the battery at 20% residual capacity. The factory default setting of the battery discharge indicator is "N" (any setting from K to U is possible).

M4-3400

83

ELECTRICAL SYSTEM Battery Discharge Indicator (BDI) Calibration for Wet Batteries z

z

Fully charge the battery as indicated by the battery manufacturer in the operating instructions.

Measure the acid density in accordance with the battery manufacturer's maintenance instructions to check if the battery is actually 100% charged.

Faulty battery cells will make calibration impossible.

Operate the truck as usual under normal operating conditions until the battery is empty: both LEDs of the BDI will flash and the lift cutout system will be triggered.

z

Leave the battery for at least 10 to12 hours (one hour at the very minimum).

z

After this interval measure the acid density on at least three different battery cells. The smallest recorded value is the one you need.

z

Compare the recorded density with the density specified by the manufacturer for an 80% discharged battery (20% residual capacity).

z

If the battery is more than 80% discharged (less than 20% residual capacity), set the potentiometer on the back of the BDI to direction K.

z

If the battery is more than 80% discharged (less than 20% residual capacity), set the potentiometer on the back of the BDI to direction U.

z

Re-charge the battery and check the calibration. If necessary, repeat this process.

Setting the discharge terminal voltage in volts/cell K

L

M

N

O

P

Q

R

S

T

U

1.57

1.63

1.68

1.73a

1.78

1.82b

1.84

1.86

1.89

1.91

1.93

a. Wet batteries b. Maintenance-free batteries

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ELECTRICAL SYSTEM Battery Discharge Indicator (BDI) Troubleshooting Connecting terminal 802833 Pin no.

5 1

8 4

NM L K

P O Q R S T U

DISCHARGE

Relay option K 1

No connection

2

+ key switch

3

Relay ARM (+) block

4

Relay N.C. (-) block

5

General (B)

6

Truck service hours

7

B+ low (24V)

8

B+ high (48V)

MS-3400-030

Symptoms:

Check:

The recorders cannot be reset.

Check the battery charge both in terms of voltage and the specific density. The settings correspond to 2.09 volts/cell. Batteries that have been charged at a battery acide temperature of 25°C/ 77°F and under max. charge current up to 1250 SG, will show this voltage. If the battery cannot be reset, the battery and/or the charger must be checked.

The truck has to be recharged too quickly Check the specific density of the battery if the red LED on the recorder is flashing. Do not turn the DISCHARGE setting to K if the specific density of the battery corresponds to a discharge of more than 80% (1150 SG for most batteries at a battery acid temperature of 25°/ 77°F at max. charge current). You can increase the operating time by turning the DISCHARE setting from N to K, provided the battery does not indicate a discharge of more than 80%.

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ELECTRICAL SYSTEM Contactors

Contactors

Inspection Contacts The contacts can blacken, swell and roughen during normal operation. This is normal, and there is no need to file or polish them. On the contrary: physically reworked contacts burn out very rapidly.

Under certain conditions the silver coating of the contacts can wander from one contact to another and collect there. This is quite harmless. The contacts must only be replaced if the silver coating has flaked off to such an extent that the supporting metal is visible.

Coils

M1480

The coil cannot be repaired. In the event of a defect, replace any coils if no resistance or an endless resistance can be measured between the connections using an ohmmeter.

Springs

Danger Disconnect the battery before working on the contactors.

Always replace the springs when fitting new contacts and whenever the contacts show signs of corrosion or discolouring due to overheating.

Important: Only use original Crown contactors as replacements, or Crown spare parts for repairs. The contactors are specially made for the truck.

Do not change the place or the angle where they are positioned, and do not change the wiring.

If dismantling a contactor for inspection or repairs, you must mark out the position of the contacts with respect to each other. It is important that contacts that are already been worked into each other are reassembled together. Otherwise, excessive wear and premature failure will result.

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ELECTRICAL SYSTEM Contactors Servicing This contactor has fixed contacts that are connected to the cover. As contacts must always be replaced in pairs, for servicing you need a complete cover, 2 moving contacts and 2 contact springs.

6

Dismantling All item numbers refer to the illustration unless stated otherwise. z

1

Unscrew two mounting screws (6) and remove the upper housing section (5).

z

Pull out the moving contact (2).

z

Unscrew the mounting nuts and take off the fixed contacts (1).

z

Clean, check and if necessary replace the components.

5

4

Assembly 2 All item numbers refer to the illustration unless stated otherwise.

3

Assembly is the reverse order of removal. z

Carefully insert the moving contact into the holes provided.

z

Screw in and tighten the mounting screws with sealant 053050-006.

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1

Contact, fixed

2

Contact, moving

3

Coil

5

Housing upper section

6

Mounting screw

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ELECTRICAL SYSTEM SEM1 Traction Controller

SEM1 Traction Controller

Precautionary Measures

Danger The truck must be jacked up prior to carrying out repair work or troubleshooting the electrical system.

z

Do not connect the controller to any battery that differs from the voltage indicated on the controller (24 - 26 volts DC). Increasing the battery voltage could damage the MOSFETs; while a lower voltage supply would fail to energise the system.

z

Only operate the controller with special traction batteries. Do not connect it to rectifiers or the mains network.

z

When starting to use the truck, jack it up to prevent it from moving without the driver in the event of possible wiring errors.

z

When the key switch has been turned off, the filter capacitors in the controller remain charged for a few minutes longer. When you work on the controller at this time, first isolate the controller from the battery (disconnect the battery). Then discharge the capacitors by shorting the positive and negative leads of the power part with each other over a resistor (10 - 100 Ohm, min. 5 W) for a few seconds.

General

Operating Characteristics M1531

The programmable impulse controller SEM1 provides effective control of the truck’s travel performance.

The truck is powered by an SEM motor (separate excited motor). With this type of motor there are two variables for controlling output: field current and armature voltage.

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Speed control Infinitely variable speed control, programmed via the handset, in both traveldirections.

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ELECTRICAL SYSTEM SEM1 Traction Controller Reduced Travel Speed Zones

Anti Roll Down Function

Several independent travel zones with reduced speed are available:

This function prevents the truck from rolling down an incline without the driver. When the key switch is switched on, the controller monitors the motor speed. If it detects a rotational movement without a travel command being issued, the truck automatically brakes.

The corresponding signals are transmitted via switches to the platform logic where they are analysed and transmitted to the controller.

Downhill Speed Control When the truck travels downhill, the controller monitors the motor armature speed, comparing it with the travel signal prescribed by the traction potentiometer. If the prescribed speed is exceeded, the truck automatically brakes electrically with energy recovery.

Regenerative Braking There are three ways of regenerative braking: z

z

z

Release braking (resetting the accelerator to neutral) Inversion braking (setting the accelerator to the opposite direction) Braking through speed restriction on inclines: The controller constantly governs the motor speed in accordance with the setpoint prescribed by the accelerator. If the setpoint is exceeded, the truck automatically brakes.

If the truck moves of its own accord on an incline, this ensures that it automatically brakes to a halt after a short time. When the truck is stationary the brake force is removed so that the truck can move again, and again braking is activated. If the brake is not applied, the truck will therefore move only very slowly down a slope.

Hourmeter An hourmeter integrated within the traction controller can be optionally set with the help of the programmer to “KEY ON” (hourmeter activated when key switch is on) or “RUNNING” (hourmeter activated only when truck is travelling).

Self-Diagnostic System The traction controller self-diagnostic system lists the five most recent error messages. These error messages can be read with the programmer. In addition to the error, the error frequency, the respective number of service hours and the traction controller temperature at the time of the error are logged and displayed.

A red LED on the traction controller also indicates the most recent error via a flashing code. The display is deleted when the controller is switched off and on again and if the error was only temporary.

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ELECTRICAL SYSTEM SEM1 Traction Controller Monitored Circuits

Safety Mechanisms

The following functions are monitored by the traction controller microprocessor, depending on the operating mode:

Incorrect polarity

z

When the truck is switched on: Control logic (hardware) and program functions (software), field current, VMN, contactor drivers, power up sequence, travel and lift switch output signals.

z

Truck on standby (key switch on): VMN, field current, contactor drivers.

z

During operation: control logic (hardware) and program functions (software), VMN, field current, contactors.

z

Permanently monitoring: traction controller temperature, battery voltage.

A main contactor controlled by the logic system separates the traction controller from the battery and thereby protects the power part from incorrect polarity.

Wiring Errors All outputs are protected against wiring errors. The outputs for the main contactor and the magnetic brake can be charged to max. 3 amps and are fitted with an overload and short circuit protection.

Temperature protection When the power part temperature exceeds 70°C, the maximum current is restricted in proportion to the rise in temperature. At 80°C the traction controller automatically cuts out.

If the temperature drops below -10° the maximum current is reduced in proportion to the ongoing battery discharge.

Start sequence A specific order must be followed for starting up the truck. Otherwise the main contact will not be activated and the truck will not operate.

Protection rating The traction controller is protected against contamination and spray water (IP 54 protection rating).

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ELECTRICAL SYSTEM SEM1 Traction Controller Maintenance Maintenance of the SEM1 traction controller is restricted to external cleaning and checking the torques of the nuts securing the power cable connecting bolts.

You should also take this opportunity to check the errors listed with the help of the programmer.

Warning The SEM1 traction controller operates at high currents.

Particular safety measures are therefore required when handling the controller.

Only use specially trained personnel.

Wipe down the traction controller with a clean, damp cloth.

z

When everything is dry, reconnect the power cable as illustrated in Fig. MS-1723-100.

z

Torque the locknut (1, Fig. MS-1723-100) to 5.5 - 8 Nm.

Important: An incorrect torque can damage the circuit board and the housing of the controller. z

Refit the control lines.

z

For cold store versions: Apply a coat of Dow Corning® 4 Compound, part no. 053051-006, to the control line connectors. Apply a layer of acidresistant clearseal paint, part no. 805236-003, to the controller.

Use non-fatigue goggles.

1

Do not wear loose clothing.

2

Do not wear jewelry.

3

Only use insulated tools.

4

z

Disconnect the battery (=EMERGENCY DISCONNECT).

z

Jack up the truck.

z

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

z

Remove the power cable: Tag out the cable if necessary. Loosen the bottom nut (1, Fig. MS1723-100).

z

z

5

MS-1723-100

Remove any dirt and corrosion from the contact surfaces.

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ELECTRICAL SYSTEM Replacing the SEM1 Traction Controller

Replacing the SEM1 Traction Controller

z

Check the contact pattern left behind by the controller back plate on the heat dissipation sheet.

The controller must lie fully flat on the heat dissipation sheet. If there are large areas with no contact to the controller, replace the heat dissipation sheet to avoid thermal problems.

z

Clean the contact surface of the traction controller on the truck chassis with a lint-free cloth and use an industry-standard silicon removal agent to remove the residue of the heat conducting paste.

z

Apply a thin and even layer of Dow Corning ® 340 heat conducting paste, part no. 053051-008 to the floorboard (= contact surface of the traction controller on the truck chassis).

z

When installing a new SEM1 traction controller in a WD2300S the controller identifies the truck model and automatically loads the correct parameters when it is switched on.

Secure the traction controller again with the 4 screws.

z

If you have changed and stored the standard configuration with the programmer, the stored parameters will be loaded the next time the controller is started.

If necessary clean the contact surfaces and refit the power cable (you must follow the instructions in the Maintenance section on the previous page) and refit the connectors for the control lines.

z

For cold store versions: Apply a coat of Dow Corning® 4 Compound, part no. 053051-006, to the control line connectors. Apply a layer of acidresistant clearseal paint to the controller.

Warning A WD2300S must only be operated with a SEM1 traction controller with the correct part number.

The use of SEM1 traction controllers with different part numbers can alter the characteristics and result in accidents.

Altered peripherals can also damage the controller.

z

Prepare to remove the traction controller as previously described in the Maintenance section.

z

Remove the 4 mounting screws and remove the traction controller.

z

When installing a new traction controller: Using the part no., check that the new traction controller is suitable for your truck

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Important: After replacing the controller check and adjust the settings. You can adjust the settings to suit the customer’s requirements. Follow the order described as follows.

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ELECTRICAL SYSTEM Replacing the SEM1 Traction Controller Parameter Setting after Replacing the Traction Controller Preparatory Measures z

Power down the truck and jack it up so that the drive wheel is free (see Chapter 1).

z

When the truck is powered down connect the programmer to the traction controller.

z

Power up the truck.

Adjustment 1. If required, change the options for the safety reverse switch and the internal service hourmeter of the controller. The standard setting is contained in the CONFIG menu table. If you have made changes, switch the truck off and on again. This will activate the changes.

2. Measure the battery voltage directly at the battery and adjust the reading measured and displayed by the traction controller (see Config menu section).

3. Using the TEST menu check the wiring and operation of the switches (see TEST menu section).

4. Re-calibrate the traction potentiometer (see “Traction pod – calibrate potentiometer, PROGRAM VACC menu).

5. Test the traction pod starting point at creep speed.

The drive wheel should start when the travel switch closes. If necessary increase the value accordingly. Repeat the test for both travel directions (see PARAMETER CHANGE menu section).

6. Jack down the truck and bring it to a secure area where you can perform test runs without endangering other people.

Warning Do not exceed the max. permissible speeds when making adjustments as described below.

7. Set the maximum “Forward” (MAX SPEED FORWARD) and “Reverse” (MAX SPEED BACK) speeds in pedestrian mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform up (PLS), side restraints folded in (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

Warning: The maximum permissible speed is 6 km/h unladen.

8. Set the maximum “Forward” (MAX SPEED FORWARD) and “Reverse” (MAX SPEED BACK) speeds in platform mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform down (PLS), side restraints folded out (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

Warning: The maximum permissible speed is 8.5 km/h unladen.

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ELECTRICAL SYSTEM Replacing the SEM1 Traction Controller 9. Set speed level 1 (CTB W C2=0, C3=0 W) in pedestrian mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform up (PLS), side restraints folded in (CSR & GSCL), rabbit/turtle switch set to slow (HSS).

13. Set speed level 3 (CTB W C2=1, C3=0 W) in pedestrian mode.

Warning: The maximum permissible speed is 6 km/h unladen.

Requirements: More than 500 kg on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform up (PLS), side restraints folded in (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

10. Set speed level 1 (CTB W C2=0, C3=0 R) in platform mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform down (PLS), side restraints folded out (CSR & GSCL), rabbit/turtle switch set to slow (HSS).

Warning: The maximum permissible speed is 6 km/h unladen.

11. Set speed level 2 (CTB W C2=0, C3=1 W) in pedestrian mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform up (PLS), side restraints folded in (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

Warning: The maximum permissible speed is 3.7 km/h unladen.

12. Set speed level 2 (CTB W C2=0, C3=1 R) in platform mode.

Requirements: No load on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform down (PLS), side restraints folded out (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

Warning: The maximum permissible speed is 2.8 km/h unladen.

14. Set speed level 3 (CTB W C2=1, C3=0 R) in pedestrian mode.

Requirements: More than 500 kg on forks (PS1), no load on initial lift (PS3), mast below 880 mm (LMS4), platform down (PLS), side restraints folded out (CSR & GSCL), rabbit/turtle switch set to fast (HSS).

Warning: The maximum permissible speed is 2.8 km/h unladen.

Warning: Note maximum capacity of truck.

Note: The relevant switches are listed in brackets.

15. Set the release brake characteristics: Set the unladen truck to maximum speed and release the travel switch. Repeat the test with the maximum permissible load. If necessary adjust the braking pattern (RELEASE BRAKING).

Warning: The maximum permissible speed is 3.7 km/h unladen.

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ELECTRICAL SYSTEM Replacing the SEM1 Traction Controller 16. Set the braking pattern for changing direction: Make this setting first in pedestrian mode and then in platform mode. Set the unladen truck to approx.

25% of maximum speed and move the travel switch in the opposite direction until it reaches the stop. Set the braking pattern so that the delay is activated gently (INVERSION BRAKING). Now repeat the test at maximum permissible speed.

Adjust the setting until the delay sets in gently in both speed ranges and the effect is ideal. Repeat the process with the maximum permissible load.

Preference should be given to the best setting for when the truck is unladen.

17. Adjust, where necessary, the time taken to change direction. To do this change the AUX TIME DELAY parameter. Both parameters, INVERSION BRAKING and AUX TIME DELAY affect the “feel” of the delay when changing direction.

Important: Power down the truck before disconnecting the programmer. Now reconnect the LEDs.

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ELECTRICAL SYSTEM Status LED

Status LED When the truck is powered up the status LED connected to terminal strip E briefly flashes. This indicates that the test program is being booted up by the controller.

The status LED is off during normal travel. When an error occurs it flashes the respective code (see following table) until the error is rectified. The programmer can be used to define the error more exactly.

Number of flashing codes

Display in programmer

Description

1

Logic failure #1

Error in current monitoring system on main contactor

1

Watch dog

Error in logic and/or program

1

EEPROM KO

Error in EEPROM range

2

INCORRECT STARTS

Start sequence error

2

FORW + BACK

Both travel directions operated simultaneously

3

CAPACITOR CHARGE

Error in power part

3

VMN NOT OK

Error during VMN test (armature current circuit)

3

VFIELD NOT OK

Error in exciting circuit

4

VACC NOT OK

Error in travel potentiometer signal

4

PEDAL WIRE KO

Error in traction pod wiring

5

NO FIELD CUR.

Error in wiring of exciting circuit or in field signal measurement

5

HIGH FIELD CUR.

Error in wiring of exciting circuit or in field signal measurement

5

STBY I HIGH

Error during armature current detection

5

I = 0 EVER

Error during armature current detection

6

CONTACTOR DRIVER

Contactor driver error

6

COIL SHORTED

Contactor coil shorted

6

CONTACTOR CLOSED

Error on contact of main contactor

7

TH. PROTECTION

Traction controller temperature too high (> 80°) or too low (< -10°)

32

BATTERY LOW

Battery discharged

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ELECTRICAL SYSTEM Travel Speed Test

Travel Speed Test

The travel speed can be tested by driving the truck over a test run of 10 m. The trucks must be operating at max. speed before they reach the test run and this speed must be maintained over the entire length of the course. The following table gives the travel speed values.

Information The travel speed must be tested when the truck is unladen. The impulse controller must be set precisely before testing the travel speed. Before starting to test the travel speed the traction motor must be at operating temperature.

To reach operating temperature, drive the truck at maximum speed over a distance of 50 m.

The WD2300S must be tested in both a laden and unladen condition.

Travel speed without load

Travel speed with rated load

Rabbit

Turtle

Rabbit

Turtle

Forks and initial lift down

5.9

3.8

5.9

3.8

Forks above 1700 mm (against overpressure) initial lift down

2.7

2.7

No Drive

No Drive

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ELECTRICAL SYSTEM Programmer

Programmer

The programmer is connected to the controller by a cable, thus powered by the controller.

General

Danger Only connect / disconnect the programmer to the controller when the truck is switched off.

The optional programmer enables programming, testing and diagnostics for the controller.

1

M0271-new

2

MS-3400-032 1

2

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Display window

z

Alphanumeric LCD display

z

2 lines with 16 characters

Function keys

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ELECTRICAL SYSTEM Programmer

Key description Key

a.

Key reference

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

OUTa

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

5

PARAM SET UP

Increases settings or selects configuration.

6

PARAM SET DOWN Decreases settings or selects configuration.

If you have not yet stored the new values you can undo a change by switching the truck on and off.

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ELECTRICAL SYSTEM SEM1 Traction Controller Operating Menu

SEM1 Traction Controller Operating Menu General When the programmer has been connected a self test start routine is performed. The software version of the controller (e.g. V2.02), the rated voltage and the rated current are now displayed.

When it is complete, use the ROLL up/down and ENTER keys to select the required menu.

ALARMS In the ALARMS menu error messages generated and stored during operation can be called up and processed.

PROGRAM VACC In the PROGRAM VACC menu item the traction potentiometer is calibrated. The traction controller reads and records the potentiometer's minimum and maximum output voltage.

CONFIG

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

TEST

The Configuration menu is used to set the operation of the hourmeter and the safety reverse switch. In addition, the "Adjustments" sub-menu allows for calibration between the battery voltage measured by the controller and the actual battery voltage.

SET MODEL is reserved for future use.

BATTERY ON/OFF must be set to OFF if a Curtis BDI is used.

In the TESTER menu the listed truck parameters can be activated, checked and set in real time.

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ELECTRICAL SYSTEM Menu Structure for Folding Platform

Menu Structure for Folding Platform STARTROUTINE

PARAMETER CHANGE

TEST

ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERSION BRAKING CTB W. C2=0, C3=0 CTB W. C2=0, C3=1 CTB W. C2=1, C3=0 MAX SPEED FORW W MAX SPEED BACK W CTB R. C2=0, C3=0 CTB R. C2=0, C3=1 CTB R. C2=1, C3=0 MAX SPEED FRW RU MAX SPEED BCK RU CREEP SPEED

BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT VMN TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH HANDLE/SEAT SWITCH QUICK INVERSION CUTBACK SWITCH WALKIE SWITCH BATTERY CHARGE

BATTERY ON/OFF

ALARMS

PROGRAM VACC

CODE H, N°, °C

VACC SETTING

CONFIG

SET MODEL

SET OPTIONS

ADJUSTMENTS

NOT AVAILABLE

HOURS: RUNNING / KEY ON QUICK INVERSION: BELLY / TIMED QUICK INVERSION ON/OFF

ADJUST BATTERY

MS-4.4-1723

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ELECTRICAL SYSTEM Parameter Setting, Folding Platform

Parameter Setting, Folding Platform The settings in this table apply only to traction controllers with software version SW # 2.01.

Warning This truck has been supplied with these values in respect of Crown safety standards.

These values must not be increased without express approval.

Exception: Tolerance compensation when installing the controller, see speed settings.

PARAMETER CHANGE menu, folding platform Menu item

Setting range

Recommend ed setting

ACC DELAY

1.15 – 3.00 sec

2

Acceleration delay: The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when travel switch suddenly set to limit).

DEC DELAY

9-0

0

Time taken to reach the new set value when the set value on the travel switch is changed. Corresponds to the braking intensity when the transmitter is returned.

RELEASE BRAKING

0-9

3

Release braking. Activated when the travel switch is released. Time taken for the motor current to fall to zero.

INVERSION BRAKING

0-9

6

Inversion braking. Activated when travel switch is set to the opposite direction. Time taken for the motor current to fall to zero.

CTB W. C2=0, C3=0

30 - 100% ACC

9

CTB W. C2=0, C3=1

30 - 100% ACC

4

CTB W. C2=1, C3=0

30 - 100% ACC

1

Maximum current (=speed) for the low speed range selected by the fast / slow speed switch (HSS) plus the preset speed reductions (in % of max. current ACC for fast speed (=normal)) in pedestrian mode. The reduction is a function of inputs C2 & C3 of the controller. CX=0 corresponds to 0 volts, CX=1 corresponds to battery positive. Again, the entire mechanical control range of the transmitter is available. Enables more sensitive travel at reduced speed.

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Description

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ELECTRICAL SYSTEM Parameter Setting, Folding Platform PARAMETER CHANGE menu, folding platform MAX SPEED FRW W

100 - 75% FCN

6

Max. speed in pedestrian mode forward: This reading determines the maximum traction current for forward travel.

When the armature voltage has been fully absorbed by the traction controller, the speed is increased by weakening the field current. If the value is set to 0 the field current will not fall below the nominal value (FCN=field current nominal) when the armature voltage is fully absorbed.

MAX SPEED BCK W

100 - 70% FCN

6

Max. speed in pedestrian mode reverse: This reading determines the maximum traction current for reverse travel.

When the armature voltage has been fully absorbed by the traction controller, the speed is increased by weakening the field current. If the value is set to 0 the field current will not fall below the nominal value (FCN=field current nominal) when the armature voltage is fully absorbed.

CTB R. C2=0, C3=0

30 - 100% ACC

8

CTB R. C2=0, C3=1

30 - 100% ACC

3

CTB R. C2=1, C3=0

30 - 100% ACC

0

Maximum current (=speed) for the low speed range selected by the fast / slow speed switch (HSS) plus the preset speed reductions (in % of max. current ACC for fast speed (=normal)) in platform mode. The reduction is a function of inputs C2 & C3 of thecontroller. CX=0 corresonds to 0 volts, CX=1 corresponds to battery positive. Again the entire mechanical control range of the transmitter is available. Enables more sensitive travel at reduced speed.

CREEP SPEED

6.5 - 11% Batt. V

2

Creep speed. Setting for the minimum voltage applied to the traction motor when the travel switch is closed. This function should be set to one level below the value at which the truck begins to travel. This ensures that the empty run of the travel switch is kept to a minimum.

MAX SPEED FRW RU

100 - 30% FCN

6

Max. speed in platform mode forward: This reading determines the maximum traction current for forward travel.

When the armature voltage has been fully absorbed by the traction controller, the speed is increased by weakening the field current. If the value is set to 0 the field current will not fall below the nominal value (FCN=field current nominal) when the armature voltage is fully absorbed.

MAX SPEED BCK RU

100 - 30% FCN

6

Max. speed in platform mode reverse: This reading determines the maximum traction current for reverse travel.

When the armature voltage has been fully absorbed by the traction controller, the speed is increased by weakening the field current. If the value is set to 0 the field current will not fall below the nominal value (FCN=field current nominal) when the armature voltage is fully absorbed.

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Notes:

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ELECTRICAL SYSTEM TESTER Menu

TESTER Menu The following table describes the various truck parameters which can be selected and checked in the TESTER menu.

TESTER Menu Menu item

Description

BATTERY VOLTAGE

Battery voltage measured at key switch input.

MOTOR VOLTAGE

Current applied to armature, measured between +BATT and VMN.

MOTOR CURRENT

Current received by motor armature.

FIELD CURRENT

Current received by field coil.

VMN

Measures the current between VMN (Volt Motor Negativ) and -BATT. The reading indicates the potential difference over the controller power part.

TEMPERATURE

Controller temperature, measured at the aluminium base plate next to the MOSFETs.

ACCELERATOR

Displays the nominal signal of the traction potentiometer. The left hand side displays the voltage reading, the right-hand side the percentage relating to the maximum operating signal calibrated via PROGRAMM VACC.

FORWARD SWITCH

Tests the operation of the “Forward” (FS) switch Displays the open (OFF) and closed (ON) status.

BACKWARD SWITCH

Tests the operation of the “Reverse” (RS) switch. Displays the open (OFF) and closed (ON) status.

HANDLE/SEAT SWITCH Tests the operation of the brake switch (BRS). Displays the open (OFF) and closed (ON) status. BRS is connected via PLM, i.e. the controller input is not pulsed in certain conditions (see PLM chapter).

QUICK INVERSION

Tests the operation of the safety reverse switch (SAS). Displays the open (OFF) and closed (ON) status. SAS is connected via PLM, i.e. the controller input is not pulsed in certain conditions (see PLM chapter).

CUTBACK SWITCH

Speed reduction functional test. The following conditions are displayed 0 –no speed reduction 1 –speed reduction 1 max. 6 Km/h 2 –speed reduction 2 max. 3.7 Km/h 3 –speed reduction 3 max. 2.8 Km/h The table on the next page shows the platform logic input signals in relation to the traction controller inputs, and the resulting speeds.

BATTERY CHARGE

Displays the battery charge status as a percentage.

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ELECTRICAL SYSTEM TESTER Menu Speed overview Max. speed in relation to the reductionlevel

Input PLM

Output PLM

PS1 Pin 18

PS3 Pin 20

HSS Pin 6

LMS 4 Pin 19

C2 Pin 15

C3 Pin 16

Speed reduction Level

Max. speed km/h

+ BV

+ BV

+ BV

0V

+ BV

+ BV

0

8.5/ 6

+ BV

+ BV

+ BV

+ BV

0V

+ BV

2

3.7

+ BV

+ BV

0V

0V

0V

+ BV

2

3.7

+ BV

+ BV

0V

+ BV

0V

+ BV

2

3.7

+ BV

+ BV

+ BV

0V

0V

0V

1

6

+ BV

0V

+ BV

+ BV

0V

+ BV

2

3.7

+ BV

0V

0V

+ BV

0V

+ BV

2

3.7

0V

0V

+ BV

0V

0V

0V

1

6

0V

+ BV

+ BV

+ BV

+ BV

0V

3

2.8

0V

+ BV

0V

0V

0V

+ BV

2

3.7

0V

+ BV

0V

+ BV

+ BV

0V

3

2.8

0V

+ BV

+ BV

0V

0V

0V

1

6

0V

0V

+ BV

+ BV

+ BV

0V

3

2.8

0V

0V

0V

0V

0V

+ BV

2

3.7

0V

0V

0V

+ BV

+ BV

0V

3

2.8

+ BV

0V

0V

0V

0V

0V

1

6

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ELECTRICAL SYSTEM ALARMS Menu

ALARMS Menu The traction controller can collect and store operational faults during operation. The last 5 error messages are stored together with the following information: z

z

Error frequency

z

Hourmeter status

z

Power part temperature

The ALARMS menu can be used to select and read the respective fault codes.

Type of error

ALARMS Menu Error message

Description

Possible Cause

LOGIC FAILURE #1

Error when testing the main contactordriver during self-diagnosis when the truck is powered up.

Control logic error.

Replace logic.

WATCH DOG

Error during self-diagnosis performed when Watchdog circuit (hardware) or program the truck is powered up, when truck is idle and (software) faulty. during travel.

Replace logic.

EEPROM KO

Error in non-volatile memory range. This is where the data for the hourmeter, error messages and truck parameters is stored.

INCORRECT START Incorrect starting sequence. The key switch, override switch (move control handle from neutral to travel position), travel switch (apply travel switch) sequence must be observed.

Turn key switch off and on again. If the error persists, replace the logic. If the error is removed make sure that allthe stored data has been deleted and reset to defaults.

- Travel switch (FS/RS) or control handle switch jammed.

- Wiring error - Incorrect starting sequence applied by user.

FORW + BACK

The test is performed permanently and checks - Wiring error if both travel directions are applied - Direction switch jammed - Incorrect starting sequence applied by simultaneously. user.

- Control handle main PCB faulty.

CAPACITOR CHARGE

- Armature power cable wiring error.

Test during self-diagnosis on power up. If 500 ms after the key switch has been activated - Controller faulty. the capacitors have not started to charge, an error message is issued and the main contactor does not close.

VMN NOT OK

- Motor cable wiring error Test when truck is idle with main contactor closed and during travel. An error message is - Motor losses to earth - Error in power part issued if VMN - is below battery voltage when the truck is idle - does not follow the specification of the driver during travel

VFIELD NOT OK

Test in idle with main contactor open. The error message is issued if approximately half the batttery voltage is not applied to the field connections.

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- Motor losses to earth - Motor field connections not connected or incorrectly connected to the controller.

- Error in field control area of power part.

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ELECTRICAL SYSTEM ALARMS Menu ALARMS Menu VACC NOT OK

Test during self-diagnosis on power up and when truck is idle. The error message is issued if the potentiometer signal deviates from the stored minimum level by more than 2 volts.

- Broken wire on potentiometer.

- Wiring error - Potentiometer faulty.

- Control handle main PCB faulty.

- PROGRAM VACC not / incorrectly calibrated.

PEDAL WIRE KO

The test is performed permanently and monitors the travel potentiometer and its wiring. Wire breakage error message.

- Potentiometer connections not wired or interrupted.

- Potentiometer faulty.

- Control handle main PCB faulty.

STBY I HIGH

Test during self-diagnosis on power up and - Current sensor faulty (replace when truck is idle. The error message is issued controller). if a current flow is detected.

- Error in back-coupling, in logic or in power part (replace component or entire controller):

I = 0 EVER

The test is performed during travel. The error - No contact with motor (check carbon message is issued if the traction current does brushes). not rise above a certain minimum level.

- Current sensor faulty (replace controller).

- Error in back-coupling, in logic or in power part (replace component or entire controller):

HIGH FIELD CURR, NO FIELD CURR

Test performed permanently and checks the field current.

-Error when measuring the field current (replace controller).

- Field cable not connected.

- Error in power part (replace controller).

CONTACT DRIVER, Test to check the main contactor circuit.

COIL SHORTED

- Contactor coil shorted, not / incorrectly connected.

- Contactor driver open or shorted (replace logic).

- Error in feedback from voltage to contactor driver (replace logic).

CONTACTOR CLOSED

Test during self-diagnosis on power up. The motor field is energised before the main contactor is pulsed. The error message is issued if the power capacitors do not discharge.

- Main contactor jammed (check contacts, replace contactor if necessary).

- Field current circuit faulty (check continuity and connections of field coil and field cable).

TH PROTECTION

- An error message is issued if the controller temperature exceeds 70°C. The maximum current is reduced in proportion to the rise in temperature. At 80°C the traction controller automatically cuts out.

- If the temperature drops below -10°C, the maximum current is reduced to 80%.

- If the error message appears in the normal temperature range, this indicates an error in the controller.

- Excessive ambient temperature.

- Thermostat faulty (replace controller).

- Logic faulty (replace logic).

- Insufficient heat dissipation (check mounting screws and rest of installation).

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ELECTRICAL SYSTEM ALARMS Menu ALARMS Menu BATTERY LOW

An error message is issued if the battery voltage drops below 63% of the rated value.

The current is reduced in proportion to the drop in voltage. The system cuts out at 43% of the rated voltage. If the error message appears when the battery voltage is above 63%, this indicates a fault in the controller or the wiring.

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- Less than 63% of the battery voltage is applied to input A2 after the key switch.

Wiring problem: poor contact, additional consumers, wire too long, small cross section etc.

- Error in microprocessor or when measuring the battery voltage (replace logic).

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ELECTRICAL SYSTEM Traction Pod

Traction Pod

z

Press ENTER. This enables you to select the calibration routine.

Calibrating the Potentiometer, PROGRAM VACC Menu

z

The display shows the stored minimum and maximum voltage of the potentiometer. An arrow in the display indicates the travel direction to which the readings are assigned. Arrow up = Forward.

Arrow down = Reverse. If you move the travel switch in the corresponding direction you can change the display accordingly.

It is always necessary to calibrate the traction pod potentiometer when: z

the traction pod potentiometer has been replaced or,

z

z

the traction controller has been replaced. With the WD2300S there is no need to physically adjust the potentiometer and the travel switch, as is the case with the WP2000S.

Press ENTER to delete the stored values. The display now shows 0.00 for the minimum and maximum values.

z

Pull the control handle towards the travel zone (brake released) and press the travel switch slowly in the forward direction until it reaches the stop.

z

The display shows the new minimum and maximum values and an arrow for the selected travel direction.

z

Pull the control handle towards the travel zone (brake released) and press the travel switch slowly in the reverse direction until it reaches the stop.

z

The display shows the new minimum and maximum values and an arrow for the selected travel direction.

z

Press OUT when you are ready.

z

The display asks “Are you sure?”. If you wish to save the new levels, press ENTER. If not, press OUT.

Preparatory Measures z

Power down the truck and jack it up so that the drive wheel is free (see Chapter 1).

z

Connect the programmer to the traction controller.

z

Power up the truck.

Calibration z

Press ENTER on the programmer.

z

Using the ROLL UP and ROLL DOWN keys scroll through to the PROGRAM VACC menu.

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ELECTRICAL SYSTEM Traction Pod z

Press OUT to quit the VACC menu.

M1610

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ELECTRICAL SYSTEM CONFIG Menu

CONFIG Menu

ADJUSTMENTS

The CONFIG menu provides access to the SET OPTIONS, ADJUSTMENTS and SET MODEL submenus.

In the ADJUST BATTERY menu item you can adapt the battery voltage measured by the controller to the actual battery voltage. Using a digital voltmeter measure the battery voltage directly on the battery.

Adjust the voltage shown in this menu until it matches the voltage measured directly on the battery.

SET MODEL No function, reserved for future use.

SET OPTIONS See table below for a description of the parameters.

The standard setting for HOUR COUNTER is “RUNNING”. For QUICK INVERSION the “BELLY” setting.

CONFIG menu Sub-menu

Option

Description

SET MODEL

NOT AVAILABLE

This parameter is reserved for future use.

HOUR COUNTER: KEY ON/ RUNNING

Determines the operation of the hourmeter contained within the traction controller. The following versions are available: - KEY ON: Counts the hours while the truck is switched on.

- RUNNING: Counts the hours while the traction motor is activated.

QUICK INVERSION: BELLY/ TIMED

Determines the operation of the safety reverse switch (belly switch): - BELLY: Truck travels in opposite direction while the safety reserve switch is pressed.

- TIMED: Truck travels in opposite direction while the safety reverse switch is pressed, but only for approx. 2 seconds.

QUICK INVERSION: ON/ OFF

Switch safety reverse switch on or off in platform mode.

ADJUST BATTERY

Adapts the battery voltage measured by the controller to the actual battery voltage. Compensates the drop in voltage through the wiring and the key switch.

SET OPTIONS

ADJUSTMENTS

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ELECTRICAL SYSTEM Traction Controller Safety Test

Traction Controller Safety Test

z

The traction controller safety test takes the form of a Pulse Monitor Trip Test (PMT).

Switch off the truck and disconnect the test lead from VMN (the other end remains connected to BATT).

z

Attach test lead to F1 (item 2).

In accordance with EU Norm PREN 1175-1 the following test must be carried out to check the fuse circuit.

z

Power up the truck. The programmer should display VFIELD NOT OK. Activating the traction pod should have no effect.

The test requires a test lead of approx. 1 mm2 cross section and a 10A fuse.

z

Switch off the truck and remove the test lead from F1 (the other end remains connected to -BATT).

z

Switch off the truck and jack it up.

z

Attach test lead to F2 (item 3).

z

Connect one end of the test lead to -BATT.

z

z

Connect the other end of the test lead to VMN (see diagram).

Power up the truck. The programmer should display VFIELD NOT OK. Activating the traction pod should have no effect.

z

Connect the programmer to the traction controller.

z

Switch off the truck, remove the test lead completely, remove the programmer.

z

Power up the truck. The programmer should display CAPACITOR CHARGE. Activating the traction pod should have no effect.

z

When the truck is switched on again and the traction pod activated, the traction motor should start.

z

If the test proves unsuccessful, replace the traction controller. a

1 2

b

+BATT

F1

VMN F2

A2

F2

FU 10A 3

-BATT

F1

A1 TM Line M1482

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ELECTRICAL SYSTEM WD2300S Platform Logic Box

WD2300S Platform Logic Box Platform Logic Controller, Part No. 816050 Platform Logic Controller, Part No.816050 Total Pins: 20 Used Pins: 18 The truck has THREE modes of operation:

Walkie Mode - Rider Mode - No Drive Mode Walkie Mode: 1. All three Inputs are low –

Input Pin 2, GCSR is low AND

–

Input Pin 3, GCSL is low AND

–

Input Pin 4, PLS is low

2. Side restrains are low and PLS is high –

Input Pin 2, GCSR is low AND

–

Input Pin 3, GCSL is low AND

–

Input Pin 4, PLS is high

Rider Mode: 1. Pin 12 is high when –

Input Pin 2, GCSR is high AND

–

Input Pin 3, GCSL is high AND

–

Input Pin 4, PLS is high

No Drive Mode: If the truck is not in Walkie or in Rider Mode, then it is NO DRIVE MODE: –

Pin 12, Rider Mode is low

–

Pin 17, BRS output (A5) is low

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ELECTRICAL SYSTEM WD2300S Platform Logic Box Platform Logic Controller, Part No.816050 SAS output: Pin 13 is only high when: –

SAS Input Pin 8 is high AND

–

Input Pin 2, GCSR is low AND

–

Input Pin 3, GCSL is low AND

–

Input Pin 4, PLS is low

BRS output (A5): Pin 17 is high when: –

BRS Input Pin 5 is high AND

–

The truck is in Walkie/ Rider Mode

LLO output (CA221-2): Pin 14 is high when: –

Input Pin 7, RAS is high

Pin 14 is low when (Low has priority over the high): –

Rider output Pin 12 high AND

–

LMS3 Input Pin 9 is high

Speed Control (Controller C2): Pin 15 is high when:

or –

Pin 6, HSS is high AND

–

Pin 18, PS1 is low AND

–

Pin 19, LMS4 is high AND

–

Pin 20, PS3 is high

–

Pin 6, HSS is high AND

–

Pin 6, HSS is high AND

–

Pin 18, PS1 is high AND

–

Pin 19, LMS4 is low AND

–

Pin 20, PS3 is high

–

Pin 6, HSS is low AND

–

Pin 18, PS1 is low AND

–

Pin 18, PS1 is low AND

–

Pin 19, LMS4 is high AND

–

Pin 19, LMS4 is high AND

–

Pin 20, PS3 is high

–

Pin 20, PS3 is low

–

Pin 6, HSS is low AND

–

Pin 18, PS1 is high AND

–

Pin 19, LMS4 is low AND

–

Pin 20, PS3 is low

or or

or

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ELECTRICAL SYSTEM WD2300S Platform Logic Box Platform Logic Controller, Part No.816050 Speed Control (Controller C3): Pin 16 is high when:

or –

Pin 6, HSS is high AND

–

Pin 18, PS1 is high AND

–

Pin 19, LMS4 is high AND

–

Pin 20, PS3 is high

–

Pin 6, HSS is low AND

Pin 18, PS1 is high AND

–

Pin 18, PS1 is high AND

–

Pin 19, LMS4 is low AND

–

Pin 19, LMS4 is high AND

–

Pin 20, PS3 is high

–

Pin 20, PS3 is high

–

Pin 6, HSS is high AND

–

Pin 6, HSS is low AND

–

Pin 18, PS1 is high AND

–

Pin 18, PS1 is high AND

–

Pin 19, LMS4 is high AND

–

Pin 19, LMS4 is high AND

–

Pin 20, PS3 is low

–

Pin 20, PS3 is low

–

Pin 6, HSS is low AND

–

Pin 6, HSS is low AND

–

Pin 18, PS1 is low AND

–

Pin 18, PS1 is low AND

–

Pin 19, LMS4 is low AND

–

Pin 19, LMS4 is low AND

–

Pin 20, PS3 is high

–

Pin 20, PS3 is low

–

Pin 6, HSS is high AND

–

Pin 18, PS1 ishigh AND

–

Pin 19, LMS4 is low AND

–

Pin 20, PS3 is high

–

Pin 6, HSS is low AND

–

or or

or or

or or

Pin 17 (BRS Output) is low when: –

Input Pin 2 AND

–

Input Pin 3 AND

–

Input Pin 4 are high (Rider Mode) AND

–

Input Pin 9, LMS2 is high

+BV (AK): Pin 1 is connected to +BV (AK) Batt NEG: Pin 10 is connected to BATT NEG

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ELECTRICAL SYSTEM WD2300S Platform Logic Box

CA 200

PLATFORM LOGIC

2942 KYS OUT

1

+BV(AK)

2916 JC103-3 GCSR

2

GCSR INPUT

2914 JC101-3 GCSL

3

GCSL INPUT

2915 JC102-3 PLS

4

PLS INPUT

2944 (2956 DIODE BLOCK-2)

5

BRS INPUT

2933 JC202-8 HSS

6

HSS INPUT

2930 PC404-4 BDI

7

RAS INPUT

2932 JC202-11 SAS

8

SAS INPUT

2918 JC107-4 LMS3

9

LMS3 INPUT

505 DIODE BLOCK-1

10

BATT NEG

UNUSED

11

UNUSED

2941 CONTROLLER A-8

12

RIDER OUTPUT

2935 CONTROLLER B-5

13

SAS OUTPUT

2926 PC221-2 HCM

14

LLO OUTPUT

2957 CONTROLLER C-2

15

SPEED OUTPUT

2928 CONTROLLER C-3

16

HSS OUTPUT

2943 CONTROLLER A-5

17

BRS OUTPUT

2901 PS1

18

PS1 INPUT

2917 JC107-3 LMS4

19

LMS4 INPUT

2927 DIODE BLOCK-3

20

PS3 INPUT

uC

MS-3400-033

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ELECTRICAL SYSTEM WD2300S Platform Logic Box Checking the Platform Logic Check the platform logic as follows: In idle –

Power up the truck.

–

Unfold the LH side restraint

–

Apply travel

–

Truck should not move

–

Unfold the RH side restraint

–

Apply travel

–

Truck should not move

–

Unfold the LH and RH side restraints

–

Apply travel

–

Truck should not move

During travel (rider mode) –

- Unfold the LH side restraint

–

Truck should not move

–

Unfold the RH side restraint

–

Truck should not move

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ELECTRICAL SYSTEM Hydraulic Control Module (HCM), Part No. 816177

Hydraulic Control Module (HCM), Part No. 816177 Operation The hydraulic control module (HCM) governs the hydraulic functions ofthe truck as a function of the limit switches and the control switches. The HCM outputs are zero active, i.e. if an output is active zero volts are applied from the module. The proportional valve is controlled with fixed defined curves.

Main Lift, Raise: Set Main Lift In input (CA221-2) to 24V: (controlled in platform logic) –

Output P Out (CA221-12) is active and

–

Output Main Lift Out (CA221-6) is active and

–

Output Prop Out (CA221-1) is energised briefly (Softlift function).

Main Lift, Lower: Set Main Lower In input (CA221-5) to 24V: –

Output Main Lift Out (CA221-6) is active and

–

Output Security Lower Valve Output (CA221-8) is active and

–

Output Prop Out (CA221-1) is semi-modulated (slow lowering).

Also activate input LOS2 In (CA222-3) to 24V: –

Output Prop Out (CA221-1) is fully modulated (fast lowering).

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Initial Lift, Raise: Input Initiallift In (CA221-12) to 24V, input LMS Main Lift (CA221-14) to 0V: –

Output P Out (CA221-12) is active and

–

Output Initiallift Out (CA221-13) is active and

–

Output Prop Out (CA221-1) is energised briefly (Softlift function).

If input LMS Lift Main Lift (CA221-14) is at 24V, there is no function.

Initial Lift, Lower: Set Initial Lift Lower In input (CA221-4) to 24V: –

Output Initiallift Out (CA221-13) is active and

–

Output Security Lower Valve Output (CA221-8) is active.

–

Proportional valve (CA221-1) is active.

Automatic initial lift lowering: Input Main Lift In (CA221-2) to 24V (controlled via platform logic) and input LMS Initial Lift In (CA221-9) to 24V and input LMS Main Lift (CA221-14) to 24V: –

Raising is terminated (as with quitting RAS) and

–

Initial Lift lower is introduced until the input LMS Initial Lift In (CA221-9) is not longer activated, or input LMS Main Lift (CA221-14) is not longer activated. If in the meantime input Main Lift In (CA221-2) is no longer activated, the current operation is terminated. Otherwise the Main Lift is automatically raised again after the Initial Lift has lowered.

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ELECTRICAL SYSTEM Hydraulic Control Module (HCM), Part No. 816177

2907 2953 2921 2904 2926 PC200-14 LLO OUT

CA 221 5902

SVL

HCM

1

PROP OUT

2

MAIN LIFT IN

2925 TCM D-4

3

2906 LMS1

4

INITIAL LIFT IN

2931 JC202-2 MAIN LOWER 2908

5

MAIN LOWER SWITCH IN

6

MAIN LIFT OUT

SV1

2909 PS1 2920 2920 SV3 2904 2952 2903 PS2 2903 LINE 2921 2934 JC202-9 INITIAL LOWER 502 PM BATT NEG 2947 LINE 2902 JC103-2 GCSR 2908 2907 2954 2950 2946 JC107-2 LMS2 2950

PS3

5904

7 5901

8

SECURITY LOWER VALVE OUTPUT

2948

9

LMS INITIAL LIFT IN

10

INITIAL LOWER IN

uC

11 P SV2

2951 DB-3

5905

12

P OUT

5903

13

INITIAL LIFT OUT

14

LMS MAIN LIFT

CA 222

UNUSED

1

UNUSED

2

2958 JC202-5 LOS2

3

UNUSED

4

UNUSED

LOS2 IN

MS-3400-034

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ELECTRICAL SYSTEM Hydraulic Control Module (HCM), Part No. 816177 Calibrating the HCM The system must be re-calibrated every time the wiring of the HCM module, the proportional valve or the hydraulic wiring is disconnected. Apply the following procedure: z

Connect the battery if it is not already connected.

z

Turn the key switch ON (lifting and lowering must be ready for operation).

z

Raise the forks to a height of approx. 1 m.

z

Disconnect the battery.

z

Depress and hold down the “Lower” switch.

z

Connect the battery.

z

Depress and hold down the “Lower” switch for 5 seconds. The forks should not lower during this period.

z

Release the lowering functions.

z

Switch the truck off and on again.

z

The procedure is complete. Check all operations in accordance with the truck’s specifications.

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ELECTRICAL SYSTEM Electric Motors

Electric Motors

z

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.).

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. z

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 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.

z

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.

z

Loose brush connections are a clear sign of motor overload. In this case inspect the collector for burning and repair or replace as necessary.

z

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.

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.

z

Make sure that all brushes contact the armature at the same pressure.

z

Blast the motor with dry compressed air only.

z

z

Check the armature for unevenness, 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.

New brushes must be run in with a medium load in the first hours. Never fully charge the motor straight away.

Preparatory Measures z

Disconnect the battery

z

Prevent the truck from rolling away.

Important Maintenance Instructions z

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:

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ELECTRICAL SYSTEM Traction Motor Maintenance

Traction Motor Maintenance Access to brushes z

Disconnect the battery

z

Prevent the truck from rolling away.

z

Remove the tensioning belt from the motor.

Maintenance z

Apply dry compressed air to the motor.

z

Remove all carbon brushes and check them with the armature in accordance with the instructions in "Important Maintenance Instructions".

z

Length of new carbon brushes: 30 mm

z

Carbon brush wear limit: 23 mm

z

Refit the tensioning belt.

1

MS-3400-036

MS-3400-037 1

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Carbon brushes

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ELECTRICAL SYSTEM Traction Motor Maintenance Armature z

A new armature has a max. diameter of 64.5 mm.

z

The armature can be overwound provided the diameter is no less than 61.5 mm

z

The armature must be replaced if its diameter is60.5 mm or less.

z

After overwinding cut the mica down to 1.5 mm below the multi-plates without changing the gap width between the multi-plates.

z

The multi-plate edges must be carefully de-burred.

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124

Bearings z

The ball bearings are maintenance-free. They must always be replaced if removed for repair work.

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ELECTRICAL SYSTEM Pump Motor Maintenance

Pump Motor Maintenance

Maintenance

Access to brushes

1

MS-3400-038 1

z

Remove the tensioning belt from the pump motor.

z

Apply low pressurised air to remove dust from the motor.

z

Remove all carbon brushes and check them with the armature in accordance with the instructions in "Important Maintenance Instructions".

z

Fit new springs.

z

Fit new brushes.

z

Check that the brushes can move freely.

z

Check that the contact pressure is the same for all springs.

z

Refit the tensioning belt.

z

Reconnect the battery.

z

Test the pump.

z

Remove the mechanism for preventing the truck from rolling away.

z

Length of new carbon brushes: 25 mm

Pump motor

z

Disconnect the battery

z

Carbon brush wear limit: 14 mm

z

Prevent the truck from rolling away.

z

Remove and discard the brushes.

z

Remove and discard the springs.

Armature

WD2300S 09/2005 • Printed in Germany

z

Turn the armature coil and check for signs of burning or other damage. Replace the armature if necessary.

z

New anchors have a 45 mm diameter. The wear limit is 44 mm.

z

The armature must not be overwound. Instead it must be replaced when the wear limit has been reached.

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125

Notes:

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126

BRAKE

Printed in Germany

127

Notes:

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128

BRAKE Brake

Brake

17

3

Hex. socket screw

7

Magnetic body

8

Screw

10

Spring

11

Pressure item

12

Spring

13

Bushing

14

Tie plate

15

Hub

16

Rotor

17

Hollow screws

18

Friction plate

20

Electric plug connection

17

M1535 3

Hex. socket screw

M0195-1

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BRAKE Brake z

Unscrew the friction plate (18) from the motor flange. A new friction plate (18) is 1.0 mm thick.

Replace if necessary.

z

Remove the screws (8) from their respective nuts.

z

Unscrew the hollow screws (17) from the magnetic body (7), (3 off).

z

Remove the tie plate (14).

z

Thoroughly clean and de-grease the components.

Warning Do not allow brake components to come into contact with oil or grease.

The item numbers in brackets refer to Figure M0195-1. z

Disconnect the battery (=EMERGENCY DISCONNECT).

z

Jack up the truck until the drive wheel is free, support the truck and prevent it from rolling away.

z

Remove the front panel.

z

Apply pressurized air to brake dust.

z

Undo the electrical connection (20) from the brake wiring (CA407).

z

Unscrew the three hex. socket screws (3).

z

Remove the magnetic body (7) from the motor (including everything connected to it).

Dismantling z

Remove the rotor (16) from the hub (15). Do not damage the toothing

z

Measure the thickness of the rotor (16). Replace the rotor (16) if the lining is less than the minimum thickness of 6.0 mm (a new rotor (16) is 10 mm thick).

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130

Test and Inspection z

Check the tie plate (14), friction plate (18) and rotor (16) for even wear, deep grooves, cracks and signs of burning. Replace any worn or damaged components.

z

Check crimp connections of the brake wiring in connector CA 407 for any loose or broken wires.

Replace any damaged crimp connectors.

z

Test the coils of the magnetic body (7) using an ohmmeter. To do this, on connector CA407 measure between ...

CA407-1 and CA407-2 (BR/1): 10.5 ± 1 ohm CA407-3 and CA407-4 (BR/2): 33 ± 3 ohm If the resistance levels of a coil are outside the tolerance range, replace the magnetic body (7). z

Check the insulating compound used to protect and secure the coils in the magnetic body (7) for cracks. Replace the magnetic body (7) if cracks are found.

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BRAKE Brake Assembly Warning Do not allow brake components to come into contact with oil or grease. z

Re-insert any pressure items (11) and springs (12) that may have fallen out of the magnetic body (7).

First the springs (12), then the pressure items (11).

z

Insert the spring (10) and bushing (13) in the magnetic body (7).

z

Place the tie plate (14) in the correct position on the magnetic body (7), while noting the hole pattern.

z

Screw the hollow screws (17) into the magnetic body (7) as far as the stop, using a medium strength sealant.

z

Insert the screws (8) into the tie plate (14) just so far that a uniform gap of 1 mm remains between the tie plate (14) and the magnetic body (7).

z

Screw the friction plate (18) onto the motor.

z

Push the rotor (16) onto the hub (15). Avoid damaging the toothing.

M1535 3

Hex. socket screw

z

Attach the pre-assembled magnetic body (7) with the hex. socket screws (3) to the motor.

z

Refit the electric plug connection (20).

Caution After assembling, it is important to set the air gap correctly, test the braking distance (see following page) and set the braking torque if necessary.

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Air Gap Setting

Braking Torque Setting

The operating air gap (A) is measured between the magnetic body (7) and the tie plate (14) when the brakes are applied.

The air gap must be set to 0.25 mm (see Fig. M1467). z

Unscrew the hollow screws (17) until they are in fixed contact the friction plate (18).

z

Torque the hex. socket screws (3) evenly to 9.5 Nm.

z

Check the operating air gap (A) along several points using a feeler gauge. The air gap (A) should be even all the way along.

z

To increase the air gap (A) unscrew the hollow screws (17) slightly. To reduce the air gap (A) screw the hollow screws (17) into the magnetic body (7). Now, measure again as described above.

z

When the air gap has been correctly set, torque the hex. socket screws (3) again to 9.5 Nm.

M1535-2 a

Inner ring

b

Outer ring

c

Safety plate

The braking torque can be set independently for the first and second stages. Turn the outer ring (b) into the magnetic body (7) to increase the torque of the first stage (BR/1). Turn the inner ring (a) to increase the torque of the second stage.

The settings are latched due to the retaining components (safety plate “c” for the first stage and safety screw for the second stage). No intermediate positions are possible, as the retaining components must work!

For the basic settings refer to the table below (screw depth A).

M1467 3

Hex. socket screw

17

Hollow screw

A

Operating air gap

B

Rotor thickness

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BRAKE Brake Brake Test

After adjusting the first stage test the brakes with maximum load.

z

Accelerate the empty truck at operating temperature with a fully charged battery on a level, dry and non-skid concrete surface to maximum speed.

z

Set the control handle to the lower braking range.

z

Measure the braking distances from the time the brakes are applied to the point where the truck comes to rest.

If necessary, remove the safety screw (4, Fig. M01951) from the inner ring (a) and using the threaded ring (6) alter the braking torque until the braking distance (see table below) with maximum capacity load is within the tolerance limits.

Now tighten the inner ring (a) again using the screw (4) and washer (5).

If necessary bend up the tappet of the safety plate (c) and alter the braking torque with the outer ring (b) until the braking distance for the empty truck is within the tolerance limit (see table below). Now secure the outer ring (b) again with the safety plate (c).

Information If the maximum travel speed is the same with or without rated load, the load-sensing pressure switch is either faulty or incorrectly set. In this case the braking distance will be too long. Check the load-sensing pressure switch before adjusting the 2nd brake stage.

(See chapter 2, Hydraulics)

WP 2300 S Rated Braking Distances and Screw Depths Model

Capacity

Screw depth A

Braking brake) With load

2330S

2000 kg

Inner ring = 7.4 mm Outer ring = 7.6 mm

distance

(new Braking brake)

rated Without load With load

1.0-1.2 m

1.0-1.1 ma 1.6-1.7 mb

distance

(used

rated Without load

1.0-1.1 m

0.9-1.0 ma 1.5-1.6 mb

a. Pedestrian mode b. Rider mode

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STEERING

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135

Notes:

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136

STEERING Control Handle Return Springs

Control Handle Return Springs

z

Tilt the control handle (8) fully down.

z

If the axle (3) still hasn’t turned, it is obviously rigid and must be assisted with the aid of the face wrench. Turn the axle (3), viewed from the LH side, anticlockwise approx. 20° from the fixed position to fully discharge the springs (4).

Caution Pre-tensioned springs!

Use care when removing them to avoid injuries.

Before carrying out any work on the control handle: z

Disconnect the battery (=EMERGENCY DISCONNECT).

z

Prevent the truck from rolling away.

Adjustment The LH side of the axle (3) is fitted as standard with a dowel pin (5). If the bias spring force reduces over time, the pre-tension of the springs (4) can be increased as follows: z

Unscrew the panel (1) and push it up.

z

Leave the control handle (8) in the neutral position (up).

z

Drive out the dowel pin (2) on the LH side.

z

Use a face wrench to turn the axle (3) a corresponding distance. Drive in the dowel pin (2) on the RH side.

z

If the spring tension is now still not sufficient to keep the control handle (8) up, replace the springs (4).

Disassembly z z

z

Unscrew the panel (1) and push it up.

Bring the control handle (8) up fully and maintain it in that position.

Mark the axle (3) position.

z

Drive out the dowel pin (2).

z

The discharged springs (4) should now turn the axle (3).

M1562 1

Panel

2

Dowel pin

3

Axle

4

Spring

5

Dowel pin

8

Control handle

z

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Drive the axle (3) out to the right so that the two springs (4) can be removed.

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137

STEERING Control Handle Return Springs Installation z

Push the springs (4) onto the axle (3). The inner, angled end should enter the groove of the axle (3) in the process. It can be useful to attach a belt around the inner end of the first inserted spring (4), in order to help line up the other springs (4).

z

Drive the axle (3) in fully.

z

Tilt the control handle (8) up as far as the stop.

z

Drive the dowel pin (2) into the LH side (RH side if necessary). To do this, turn the axle (3) sufficiently far. Lubricate the springs (4). Secure the panel (1).

Check the brakes.

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STEERING Control Handle Grip

Control Handle Grip Main Components This section contains an overview of the main components and associated terms:

MS518 a

Upper shell

b

Switch unit

c

Hand grip

d

Lower shell

e

Control handle tube

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STEERING Control Handle Grip Components

Control Handle Grip Components To access the individual components of the hand grip you will require: –

Torx® screwdriver set

–

a small screwdriver with a flat blade.

Caution Danger of electric shock De-energise the truck (disconnect the battery) and prevent it from being switched on again.

Unless otherwise stated, all screws must be torqued to the standard rating. See chapter 1 of this manual for the torque table.

MS514

Hand Grip Shells Upper and lower shell removal

B

Thumb marking

C

Thumbwheel

z

Press the thumb markings (B, Fig. MS514) on the switch unit or pull on the thumbwheels (C). The switch unit will slide up out of the bottom shell.

z

Disconnect the plug connections from the control handle wire harness and the horn switches from the switch unit printed circuit boards (arrow).

MS513 A

z

Torx screw

Remove the Torx®- screws (A) shown in Fig. MS513.

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140

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STEERING Control Handle Grip Components

MS501 MS502

z

Using a small flat bladed screwdriver lever off the cover on each hand grip (see arrow, Fig. MS502).

A

z

Torx screw

Remove the inner Torx® screws (A) shown in Fig. MS501 and pull off the grips.

MS503

z

Gently press in the horn switch and pull it out of the grip (see arrow, Fig. MS503). Disconnect the plug connection from the switch.

MS517

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B

Torx screw

C

Torx screw

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141

STEERING Control Handle Grip Components z

Remove the two Torx® screws (B) shown in Fig. MS517 and the six Torx® screws (C). Lift out the shells.

z

Remove the 4 Torx® screws (A) shown in Fig. MS513.

Upper and lower shell assembly Assembly is the reverse of disassembly. When assembling, take care not to damage thewiring.

Switch Unit Disassembly The switch unit contains the safety reverse switch, the travel switch, the “rabbit/turtle” switch, the main PC board and the pump controller PC board.

Replacing any of these components requires the switch unit to be replaced.

MS514a A

Thumb marking

B

Thumbwheel

C

Side section

z

Press the thumb markings (A) shown in Fig. MS514a on the switch unit or pull on the thumbwheels (B). The switch unit will slide up out of the bottom shell.

z

Disconnect the plug connections of the control handle wire harness and the horn from the switch unit PC boards.

MS513 A

Torx screw

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142

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STEERING Control Handle Grip Components Switch unit assembly Assembly is always the reverse of disassembly.

Make sure you re-connect the control handle wire harness and the horn wiring.

Information The connectors cannot be interchanged and are protected against incorrect polarity. z

Guide the switch unit shown in Fig. MS514a over the two side sections (C) while pushing the switch unit down and to the front.

z

Tighten the mounting screws (A) shown in Fig. MS513.

z

Test all the functions once the battery has been reconnected.

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STEERING Control Handle Grip Components “Rabbit/Turtle” Toggle Switch There are no parts on this switch module that can be repaired. It must be replaced in full.

z

Refit the switch unit (see Switch Unit section in this chapter). Test the operation.

This switch module is available in two versions: a standard and a cold store version. Make sure you use the right module!

MS504 B

Torx screw

Hydraulic PC Board MS511 A

Torx screw

Disassembly z

z

Remove the switch unit (see Switch Unit section in this chapter).

Remove the two inner Torx® screws (A) shown in Fig. MS511 and remove the toggle module.

Installation z

Insert a new toggle module and fix it with 2 Torx® screws.

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144

There are no parts on this PC board that can be repaired. It must be replaced in full.

This PC board is available in two versions: a standard and a cold store version. Make sure you use the right PC board!

Disassembly z

Remove the switch unit (see Switch Unit section in this chapter).

z

Remove the two Torx® screws (B) (see Fig. MS504) from the smaller of the two PC boards (the larger one is the main PC board). Lift out the hydraulic PC board.

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STEERING Control Handle Grip Components Installation z

Insert a new hydraulic PC board (make sure it is the right type, cold store or standard). Fix the board with 2 Torx® screws (B).

z

Refit the switch unit (see Switch Unit section in this chapter). Test the operation.

Main board removal/installation This PC board is available in two versions: a standard and a cold store version. Make sure you use the right PC board!

Information Because of its compact design, it may be difficult to use this process to reach the connector on the main PC board. If you experience difficulties replacing the PC board using the above procedure , remove the thumbwheel, the lower panel and the panel of the upper shell (see “Potentiometer Installation” in this chapter).

There are no parts on this PC board that can be repaired. It must be replaced in full. z

Remove the upper shell (see “Upper Shell” in this chapter).

z

Disconnect the potentiometer connector from the main PC board.

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10682 A

Torx screw

X

Main PC board

z

Remove the two Torx® screws (A) from the larger main PC board (X, the smaller one is the hydraulic system printed circuit board). Disconnect the wire connector of the safety reverse switch from the main PC board (X) and remove the main PC board (X).

z

Re-assemble the main PC board (X) in the reverse order.

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145

STEERING Control Handle Grip Components Potentiometer There are no parts on the potentiometer that can be repaired. It must be replaced in full.

The potentiometer is available in two versions: a standard and a cold store version. Make sure you use the right potentiometer!

MS509 C

z

Torx screw

Remove the four Torx® screws (C) shown in Fig. MS509. Remove the switch unit cover.

MS508 A

Torx screw

B

Torx screw

Disassembly z

Remove the switch unit (see Switch Unit section in this chapter).

z

Remove the two Torx® screws (A) in Fig. MS508 from the thumbwheels and disconnect the thumbwheels. Take care not to lose the plastic slide bearings (washers).

z

Remove the two Torx® screws (B) shown in Fig. MS508 holding the orange lowering switch cap. Lift out the switch cap.

MS510 D

z

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146

Torx screw

Remove the 2 Torx® screws (D) shown in Fig. MS510. Remove the connectors from the PC boards. Pull the potentiometer off the square axis.

WD2300S 09/2005 • Printed in Germany

STEERING Control Handle Grip Components Installation Before connecting the cable to the potentiometer: Fill the potentiometer bushing with grease part no.

053002-005. Do not use any other grease.

Potentiometer assembly is the reverse of disassembly.

Safety Reverse Switch Disassembly

MS509 C

z

Torx screw

Remove the two Torx® screws (B) shown in Fig. MS508 holding the orange lowering switch cap. Lift out the switch cap.

MS508 A

Torx screw

B

Torx screw

z

Remove the switch unit (see Switch Unit section in this chapter).

z

Remove the two Torx® screws (A) in Fig. MS508 from the thumbwheels and disconnect the thumbwheels. Take care not to lose the plastic slide bearings (washers).

MS500

WD2300S 09/2005 • Printed in Germany

D

Torx screw

E

Switch bypass

F

Torx screw

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147

STEERING Control Handle Grip Components z

Remove the four Torx® screws shown in Fig. MS509. Remove the switch unit cover.

z

Remove the Torx® screw (item D, Fig. MS500) and pull out the switch bypass (item E).

z

Remove the two Torx ® screws (item F).

Disconnect the microswitch from the main PC board.

Installation z

Assemble the safety reverse switch in the reverse order of disassembly.

Before connecting the microswitch to the main PC board: Lubricate the microswitch connector with grease part no. 053002-005. Do not use any other grease. z

MS502

Refit the switch unit (see Switch Unit section in this chapter) and test the operation.

Information The thumbwheels cannot be incorrectly positioned. They will only fit correctly in one position.

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STEERING Control Handle Grip Components Horn Switch

Hand Grip

Disassembly

Disassembly z

Remove the switch unit (see Switch Unit section in this chapter).

MS503

z

Remove the switch unit (see Switch Unit section in this chapter).

z

Use a small flat screwdriver to lever off the panel on the hand grip shown in Fig. MS502.

z

Gently press in the horn switch and pull it out of the grip (see Fig. MS503). Disconnect the plug connection from the switch.

MS502

Installation Information The switches on the LH and RH grips are different. If you fit the switch on the wrong side the horn symbol will be upside down!

Assemble the horn switch in the reverse order of disassembly. z

Refit the switch unit (see Switch Unit section in this chapter) and test the operation.

WD2300S 09/2005 • Printed in Germany

MS503

z

Use a small flat screwdriver to lever off the panel on the hand grip shown in Fig. MS502.

z

Gently press in the horn switch and pull it out of the grip.

z

Disconnect the plug connection from the switch (see Fig. MS503).

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149

STEERING Control Handle Grip Components z

Remove the inner Torx® screw shown in Fig. MS501 and pull off the grip.

Assemble the hand grip in the reverse order of disassembly. z

Refit the switch unit (see Switch Unit section in this chapter) and test the operation.

Initial Lift Switch

1

2

MS501

Installation Information The switches on the LH and RH grips are different. If you fit the switch on the wrong side the horn symbol will be upside down!

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150

126-2681 1

Initial lift switch

2

Shell

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STEERING Control Handle Grip Components Disassembly

Installation

z

Remove the switch unit (see Switch Unit section in this chapter).

z

z

Remove the two screws connecting the clip (1) to the shell.

Make sure the gap between the switch cap (4) and the shell (5) is even throughout its circumference. The switch cap must not jam when applied.

z

Remove the screw (2, not visible in the drawing) connecting the switch to the clip. Lift out the switch block.

z

z

Assemble the auxiliary switch in the reverse order ofdisassembly.

Refit the switch unit (see Switch Unit section in this chapter) and test the operation.

Remove the two screws (3) to remove the microswitch.

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Notes:

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152

MAST/LIFT MECHANISM

Printed in Germany

153

Notes:

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154

MAST/LIFT MECHANISM Lift Linkage

Lift Linkage

Carry out the measurement on an even surface (evenness less than or equal to 1 mm).

Adjusting the Fork Height

82 ±3mm

82 -3mm

130 ±5mm

Note: The item numbers in brackets refer to Fig. M1438 on the following page.

MS1723-701

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155

MAST/LIFT MECHANISM Lift Linkage Fork Adjustment Adjusting the fork height z

Raise the forks to gain access to the tie rods.

z

Loosen the tie rod counternut (Fig. MP-3400-005, item 17).

z

Adjust the tie rod so that the stop of the outrigger jack have evenly distributed contact to the forks when the forks are fully lowered. To do this, turn the tie rod (item 16) on the hex. nut (item A).

z

The fork height must be measured directly above the load wheels. (fork tip height): The rated value of 82 mm should not be exceeded.

z

Measure the fork carriage height from the fork tip (fork height). The rated value of 95 mm should not be exceeded.

z

Measure the fork height from the back of the fork shank. (fork shank back height): The rated value of 95 mm should not be exceeded.

z

The fork shank back height should be the same or greater than the fork tip height.

z

Tighten the tie rod counternut (Fig. MP-3400-005, item 17).

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MAST/LIFT MECHANISM Lift Linkage

6

5

7

4 3 Forke Carriage Frame

2 1

5 4

Power Unit

11

10

14

13

5 8

11

Forke Carriage Frame

9 15

5 9

A

16

17

11

12

14

20

9

18 5

9

23

13

26 25

21

11

11

Forke Carriage Frame

11

24

25 26

22 24

19 23

MP3400-005

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MAST/LIFT MECHANISM Mast

Mast

Mast Removal

Danger

Caution Risk of trapping and severing limbs!

When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally moving.

Make sure the wooden blocks and lifting gear used have sufficient capacity.

General

Always apply chocks when working on a raised mast, even when it is connected to a hoist.

1. Position truck under appropriate lifting device.

2. Lower fork carriage completely. Make certain to remove load, if applicable, from forks.

3. Fully raise the initial lift.

Torque Requirements

4. Jack up the truck: The instruction “Jack up the truck” always implies that the raised truck is lowered onto a secure base.

All screw connections on the mast must be torqued to the standard values. See Chapter 1 for these values.

5. 2 wooden blocks under the chassis, 2 under the forks. See following illustration

Please note: The mast screw connections must be torqued to 320 Nm.

6. Turn the key switch OFF. Remove the key and disconnect the battery.

Lifting Gear Minimum Capacity

7. Attach warning tag to control handle to advise others that the truck is being serviced.

Note the minimum capacity for the lifting gear whenever carrying out work on the mast. z

Mast without fork carriage: 200 kg

z

Fork Carriage: 100 kg

These figures attachments.

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158

are

excluding

forks

and

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MAST/LIFT MECHANISM Mast 11. Attach lifting device at top of all sections of the mast assembly. Then raise lifting device just enough to eliminate any slack in lifting chains/ slings.

12. Remove mast mounting nuts that secure the outer mast to the power unit. The nuts should only be used once and must then be replaced with new ones of the same type.

13. Remove mast assembly and fork carriage from truck.

G_WD-jack-up

8. Chock drive tire and load wheels.

9. Disconnect all electrical connections that may prohibit removal of the mast assembly.

10. Disconnect the hydraulic supply lines to the mast lift cylinders. Seal connections to minimize oil loss and prevent hydraulic system contamination.

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MAST/LIFT MECHANISM Mast Installation

5. Connect electrical connections between power unit and mast assembly.

Warning

6. Remove lifting device from mast assembly.

Wear appropriate safety clothing such as safety glasses and shoes, whenever performing maintenance work.

To avoid injury, do not place fingers, hands, arms or feet through mast and keep them away from pinch points.

1. Attach lifting device at top of all sections of the mast assembly.

2. Raise mast assembly and move it into position against the power unit. When attaching the outer mast to the drive unit slowly suspend the mast to avoid damaging it. Place shims between the mast and the power unit so that the mast is vertical in its longitudinal section and horizontal in its crosssection (see first diagram on last page).

7. Remove chocks.

8. Connect battery and remove warning tag from the control handle.

9. Air that may have entered the system must be bled from the system. Follow the procedure outlined under "Cylinder Bleeding and Flushing", section M8, to bleed the hydraulic circuit.

10. Carry out a lowering plumb test after attaching the mast. If the test results are outside the tolerance range, re-adjust the mast and repeat the test.

3. Secure the mast assembly to the power unit using new nuts of the same grade. Torque the screws to 320 Nm. 4. Remove any pipe plugs or caps from the hydraulic lines that were previously used to seal connections. Then connect all hydraulic lines that were previously disconnected.

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MAST/LIFT MECHANISM Mast Fork Carriage Removal

Fork Carriage Installation 1. Chock drive tire and outrigger load wheels.

Warning Wear appropriate safety clothing such as safety glasses and shoes, whenever performing maintenance work.

To avoid injury, do not place fingers, hands, arms or feet through mast and keep them away from pinch points.

1. Turn the key switch OFF. Remove the key and disconnect the battery.

2. Attach warning tag to control handle to advise others that the truck is being serviced.

2. Make certain rollers are in good condition and installed on fork carriage. Replace a worn or damaged roller.

3. Using a lifting device, raise inner mast, install the fork carriage, and lower inner mast to collapsed height.

4. Attach lifting device to fork carriage and raise carriage enough to allow chains and hydraulic supply lines, if applicable, to be connected.

5. Connect lift chain(s) to chain anchors or tensioner on fork carriage.

3. Chock drive tire and outrigger load wheels.

4. Using a lifting device, raise fork carriage until lift chains are slack.

6. Remove any pipe plugs or caps that were previously used to seal connections. Then connect all hydraulic lines that were previously disconnected.

5. Disconnect lift chain(s) from chain anchors or tensioner on fork carriage. Then lower fork carriage completely.

7. Lower fork carriage and remove lifting device.

8. Check lift chain tension and adjust if necessary.

6. Attach lifting device to top of inner mast. Then raise inner mast and remove fork carriage. Make certain rollers and shims remain in place on fork carriage.

7. Lower mast to collapsed height.

WD2300S 09/2005 • Printed in Germany

9. Remove chocks.

10. Connect battery and remove warning tag from the control handle.

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MAST/LIFT MECHANISM Mast Fork Carriage Adjustment

8. Lower fork carriage completely.

Warning

9. If clearances were acceptable, proceed to step 13.

If clearances were not acceptable, proceed to step 10.

Wear appropriate safety clothing such as safety glasses and shoes, whenever performing maintenance work.

To avoid injury, do not place fingers, hands, arms or feet through mast and keep them away from pinch points.

1. Turn the key switch OFF. Remove the key and disconnect the battery.

2. Attach warning tag to control handle to advise others that the truck is being serviced.

10. Remove fork carriage following steps 4 - 8 outlined under "Fork Carriage Removal".

11. Add shims, as necessary, to the appropriate roller locations until clearances are within the acceptable range. If more than one shim is being added at any location, it is recommended that shims be distributed evenly between right and left hand sides of the fork carriage.

12. Install fork carriage following steps 3 - 8 outlined under "Fork Carriage Installation."

3. Chock drive tire and outrigger load wheels.

13. Remove chocks.

4. Using a lifting device, raise fork carriage until the top two rollers extend above the mast channel and carriage meets the carriage stop. Then lower carriage slightly below stop to free carriage.

14. Connect battery and remove warning tag from the control handle.

5. Using a prybar, carefully force the carriage to one side until its tight against the mast channel. Retain slight pressure to hold carriage in position against mast.

6. Using a feeler gage, measure the distance between top roller and mast and record measurement. If the distance exceeds 0.5 mm place more shims on the rollers.

7. Repeat step 6 on the bottom roller.

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MAST/LIFT MECHANISM Mast Mast Maintenance Lubricating Roller Tracks 1. Lower fork carriage completely.

2. Turn the key switch OFF. Remove the key and disconnect the battery.

3. Attach warning tag to control handle to advise others that the truck is being serviced.

4. Chock drive tire and outrigger load wheels.

5. Clean roller tracks.

6. Lubricate entire roller path with a lubricant designed for the truck application (i.e., freezer/ corrosion, etc.). Refer to "Lubricant & Fluid Chart", section MS-1, for approved lubricants and recommended suppliers.

7. Remove chocks.

8. Connect battery and remove warning tag from the control handle.

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MAST/LIFT MECHANISM Mast Mast Shims Figures in brackets indicate the number of shims to be positioned.

(1)

(2)

(2)

(2)

(1)

(1)

(2)

(2)

(1)

(1)

(2)

(1)

M0382

M0381

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MAST/LIFT MECHANISM Mast A

22 Forke Carriage Frame

23 18

B

21 19 20

17

19

6

7

14 15

16

12

4

18

13

5

3

11

1 2 10 8 9 C

15

14

MP-3400-001 A

Cross-section

B

Longitudinal section

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C

Shims

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MAST/LIFT MECHANISM Lowering Plumb Test

Lowering Plumb Test Always carry out a lowering plumb test if the mast or fork carriage have been removed.

The lowering plumb test must be performed with rated load (1000 kg).

Carrying Out The Vertical Plumb Test When the above preparations have been made, extend the mast fully. Make sure that the mast does not extend as far as the stops. The plumb should not be pointing outside the square when the mast is raised.

Preparatory Measures z

Position the truck for inspection with the above test load on a level surface. The surface is level if the height difference at the wheel contact points < is 1mm.

z

Now raise the forks 300 mm.

z

Attach a plumb to the back of the fork carriage.

Once the plumb has finished oscillating, centre the middle point of the plumb on the middle point of a 20x50 mm square. The 50 mm long side should be facing the truck’s longitudinal axis.

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MAST/LIFT MECHANISM Lift Limit Cutout / Initial Lift

Lift Limit Cutout / Initial Lift

z

Check the lift height from the fork tips (see previous page). If this height is outside the tolerance range, check the mechanical setting of the lift linkage and adjust if necessary.

z

If the mechanical setting of the lift linkage is correct and the lift height is still outside the tolerance range, move the lift limit switch (LMS) into the slotted holes until the lift limit cutout (pump no longer running) takes place at a height of 130 mm ± 5 mm.

Lift Limit Cutout Setting z

Fully lower the truck.

z

Raise the forks, without rated load, from their lowest position.

1

2

4

3 M1473

1

Upper hole: Limit switch position for max. lift = 150

3

Slotted hole for lift cutout fine-tuning

2

Trail

4

Trip cam

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MAST/LIFT MECHANISM Lift Limit Cutout / Initial Lift LMS 2-4 Limit Switch Adjustment

Lift Limit Cutout Setting

The switch console can be adjusted through the slotted holes:

z

Fully lower the truck.

z

Raise the forks, without rated load, from their lowest position.

z

Check the switch points.

Check the lift height from the fork tips (see previous page). If this height is outside the tolerance range, check the mechanical setting of the lift linkage and adjust if necessary.

Mast 1700 mm:

If the lift height is still above the specified levels, move the lift limit switch console into the slotted holes until the switches apply.

*LMS4: 880 mm Mast 2100 mm: *LMS4: 880 mm *LMS3: 1700 mm *LMS2: 1700 mm

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MAST/LIFT MECHANISM Lift Limit Cutout / Initial Lift

MP-3400-019

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MAST/LIFT MECHANISM Lift Limit Cutout / Initial Lift Connecting the Lift Limit Switches Before the operation of the lift limit switches can be tested on the mast you must ensure that the switches are connected correctly. Connect the switches as follows: Mast 1700mm: LMS4: Connect JC601.

Mast 2100mm: LMS4: Connect JC601.

LMS3: Connect JC602.

LMS2: Connect JC603.

LMS

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MAST/LIFT MECHANISM Lift Chains

Lift Chains 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 used in a corrosive or dusty environment, this interval must be reduced to 50 hours. 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 every three years.

The inspection should include the following: z

Chain wear and elongation.

z

Pitting due to rust or corrosion, in particular on the outer surfaces of the connection plates.

z

Pins turning in or extruding from the outside plates.

z

Loss of freedom of movement.

z

Damage to the anchor bolt attachment

z

Wear and corrosion to the anchor bolt and anchor.

z

Wear between the bolts and the connection plates.

The following sections cover the above items in detail.

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MAST/LIFT MECHANISM Lift Chains Cleaning

Chain wear can be measured with a wear gauge (Crown No. 106440) or a steel tape measure (see Fig. 2771).

Warning Never use chemical solvents or steam to clean the chains.

The lubricant applied at the factory will be removed from the inner plate surfaces.

The chain surface should be cleaned with paraffin, a hard bristle brush and lint-free cloth.

Before testing the chain elongation 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.

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.

2771

Chain Dimensions (Dimension C in Fig. 2271).

New: 10 links = 158.75 mm Wear limit: 10 links = 163.5 mm

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.

If the chain has elongated by 3% replace the detachable chain anchors, anchor bolts and lift chains.

Danger 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.

Never repair damaged chains!

This can result in fatal accidents!

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MAST/LIFT MECHANISM Lift Chains Freedom of Movement of Chain Links

Chain Tension

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.

When installed, both lift chains should have the same chain tension to ensure even distribution of the load over the two chains when lifting.

When replacing the forks make sure that both forks lie evenly on the surface. If they are not even, compensate the chain length via the chain anchor so that both chains have the same chain tension.

After adjusting, tighten the counternuts of the chain anchor again (for correct torques see Chapter 1, Torque table).

2775si

Possible causes of stiff joints are as follows: z

Bent pins or plates

z

Rusty joints.

z

Peened plate edges.

Plate edge distortion is caused by: z

Ruptured chain pinion.

z

Constant overloading of the chain.

z

Chain striking the mast components.

Chain Anchor and Pulleys In the course of checking the chain system, the chain anchors, chain bolts and pulleys must be checked for wear.

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.

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.

Immediately replace any chains with stiff joints.

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MAST/LIFT MECHANISM Lift Chains Worn Connection Plates

Protruding or Turned Chain Pins Danger

2774si

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.

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.

2776si

Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existent 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.

Chains with twisted or protruding pins must be replaced immediately.

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MAST/LIFT MECHANISM Lift Chains Chain Lateral Wear

Corrosion

Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This can have one of two causes: uneven chain tension or misalignment between the pulleys and the chain anchors.

Uneven Chain Tension 2773si

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.

Corrosion considerably reduces the capacity of a lift chain. It results in cracking in the side plates.

Lift chains must therefore be protected from corrosion.

The layer of grease applied in the factory hot dip galvanizing process is an excellent protection and fully penetrates the joints.

Do not remove this initial layer! After commissioning the chain supplement the factory lubrication through a regular lubrication schedule.

Rust film on lift chains can be removed and neutralised by cleaning with chain oil. Always replace heavily corroded and rusting chains. The risk of cracking as a result of rust is too great.

WD2300S 09/2005 • Printed in Germany

When fitting or adjusting the chains make sure that they are evenly charged. If for example the fork heel height or the platform height are changed, the chain anchors must be loosened until both forks touch the ground. Both chains must have equal amounts of air or tension at this point. The lower chain anchor nuts must be tightened by the same number of turns. When the required height has been reached, fix the setting with the top (chain side) lock nut and its respective lock washer.

Misaligned Lift Components 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 carriage and detach both ends of the lift chain from the chain anchor and visually inspect the alignment with the anchor slots.

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MAST/LIFT MECHANISM Lift Chains 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.

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: z

Restricts joint wear to a minimum (chain elongation)

z

Avoids corrosion

z

Reduces the risk of chain bolts turning

z

Restricts the danger of chain joints turning in to a minimum

z

Ensures an even movement of the chains and thus reduces noise levels

z

Reduces the chain tension due to less friction in the chain system

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.

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.

In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains. Multiplate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain bolt (see Fig. 277si) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty.

In normal operating conditions the chains should be cleaned and immediately lubricated every 100 service hours. In extreme conditions this interval must be reduced accordingly.

Key factors when considering which lubricant to use are as follows: z

High degree of penetration in the narrowest of gaps

z

Maximum tolerance of pressure and shearing forces before the lubricant film comes off.

z

Suitability to the operating temperature range, especially important for cold store trucks.

You will find details of Crown approved chain oils in the Lubricant table in Chapter 1 of this manual.

2777si 1

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Oil film

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MAST/LIFT MECHANISM Lift Chains Separating Lift Chains

Separation

Lift chains are supplied by the meter and must be cut to the required length.

Warning

Tools and Equipment Required

Wear protective glasses.

z

A secure working plate with a hole slightly larger than the head diameter of a chain bolt. The hole must be deeper than the chain bolt length.

z

z

Carefully grind the head of the chain bolt. The inner plate surface must not be damaged.

A bearing ring (washer) with a hole slightly larger than the head diameter of a chain bolt. The bearing ring thickness must be slightlylarger than the height of the head of a chain bolt.

z

Place the bearing ring onto the hole in the working plate. The bearing ring prevents the inner plate surface from being damaged when you drive out the chain bolt.

z

A grinder.

z

Place the head of the chain bolt to be driven out into the bearing ring.

z

A hole with a diameter slightly shorter than the chain bolt and a hammer. Or a press with a suitable mandrel.

z

Make sure the chain bolt, the bearing ring and the hole are aligned in the working plate and drive the chain bolt out.

4

1

2

3

MS-7.2 1

Connecting plate

3

Backring

2

Hole in working plate

4

Grinder

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MAST/LIFT MECHANISM Fork Tines

Fork Tines

Fork Identification

General

The data plate is on the side of the fork back (Fig. 0345) and comprises the following data:

The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see chapter 1) for cracks, damage and wear.

z

Capacity

z

Load centre of gravity

If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.

z

Manufacturing Data (Month / Year)

z

Company logo

Terms

z

Manufacturing site

1

2 1 3

4 M0344 1

Fork blade

2

Fork hanger

3

Fork shank

4

Heel (curved area)

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M0345 1

Fork Identification

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MAST/LIFT MECHANISM Fork Tines Repairs

Fork Inspection

Danger

Danger Forks showing signs of cracking, distortion or wear beyond the stated tolerance levels must be decommissioned. They endanger the life of the operator and other people.

Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork.

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 Inspect all fork tine surfaces for signs of cracks.

Fatigue cracking tends to occur around the heel of the forks. Check this area with particular care. If necessary carry out a non-rupturing crack test (paint penetration process or Magnaflux).

1

M0346 1

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Cracks

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MAST/LIFT MECHANISM Fork Tines Verticality Test Check verticality of fork tip (Fig. M0350). If the tolerance level has been exceeded, de-commission the fork.

2 1 1 M0347 1

2 mm

Welding seams

For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam. If any cracking is discovered which could affect safety remove the relevant fork.

For the outrigger-overlapping version (Fig. M0348), also check for cracks on the welding seam between the fork and fork carriage/fork shank. If any cracking is discovered which could affect safety remove the relevant fork.

250 mm

M0350 1

Ruler

2

Fork tip

1

500 mm

1

max. 6 mm M0351

M0348 1

Welding seam

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1

Ruler

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MAST/LIFT MECHANISM Fork Tines Fork Blade Warping

Fork Tine Height Difference

Measure the angle deflection between the top of the fork blade and the front of the fork shank (Fig. M0353).

If dimension x is outside the tolerance range, the fork must be aligned by a specialist and re-checked.

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.

500 mm x - 17 mm x + 8,5 mm

However, this would prevent the fork from working. In practice, forks must be aligned if the deviation is max.

10 mm.

Fork Stop

x

L M0353

1

Measuring the Fork Tip Width

3

2 M0354 M0355

If the fork tip width S is less than a/6 mm (a = fork back width) do not use the fork (Fig. 0355).

1

1. Fork

2

2. Fork

3

3% of L

Check the stop mechanism (Fig. M0356) on both fork tines. The mechanism should lock securely, otherwise the fork must be de-commissioned.

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MAST/LIFT MECHANISM Fork Tines Fork Blade Wear

This calliper has 2 opposite tappets. The outer tappet is used to determine the original fork blade thickness at a section with no wear. This is the fork shank. This determines the 100% value. The inner tappets correspond to 90% of the value previously obtained. z

Scan the thickness of the fork shank using the outer tappets (Point a = 100% in Fig. MS-2232013). Fix the calliper.

z

Now use the inner tappets (90%) to scan the fork blade between the shank and the start of the curved area. If the calliper fits at any point over the fork blade, then the fork is worn. Take the fork out of service.

M0356 1

Stop mechanism

Check the fork blade for wear. The heel is particularly sensitive to wear. If the width is 90 % or less than the original value, the fork must be taken out of service. For the inspection, use the calliper with part no. 107330 (see Fig. 0357).

a=100% 1

90%

2 MS-2232-013 1

Scanning area

2

Wear limit 90%

M0357

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CYLINDERS

Printed in Germany

183

Notes:

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184

CYLINDERS Cylinders

Cylinders

General Instructions for Repairing Hydraulic Components

General

Hydraulic systems are sensitive to dirt.

Safety when working on hydraulic systems Warning Risk of serious injury from pressurized hydraulic oil.

Pressurized hydraulic oil can penetrate the skin. This must be treated as an emergency which requires immediate medical intervention.

The skin will not show any obvious initial damage and the physical effects will not be manifested immediately. Seek medical assistance if your skin has been affected by pressurized hydraulic oil.

For your personal protection: Depressurise the hydraulic system before starting assembly work on the hydraulic system.

After carrying out assembly work carefully check to see that all ports are tightened before repressurising the system.

Wear protective clothing, safety glasses and safety gloves when tracing leaks or bleeding the system.

Use a piece of absorbent paper to trace leaks, never use your hands.

Follow the hydraulic oil manufacturer’s safety instructions when handling these oils.

WD2300S 09/2005 • Printed in Germany

z

Thoroughly clean any hydraulic components that have been removed before dismantling them.

z

Always repair hydraulic components in a clean working environment.

z

Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil.

Use the same type as is used in the truck.

z

Protect all components from re-contaminating until they are installed again.

z

Immediately seal any open hydraulic ports on repaired assemblies with filler plugs. This also applies to the open ports and lines on the truck when you remove any hydraulic components.

z

Do not refinish any cylinder surfaces! Replace any damaged components.

z

When carrying out repairs always replace all the seals in the assembly. Never recycle seals which have already been used

General There are two main types of hydraulic cylinder z

Plunger cylinders

z

Piston Cylinders (Double-Acting Cylinders)

The main difference between the two types of cylinder lies in their operation as well as the sealing material design.

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185

CYLINDERS Plunger Cylinders

Plunger Cylinders The plunger cylinder (see Fig. MS-3400-080) has only one pressurised rod surface (single acting cylinder).

The piston rod (1) enters the cylinder via one or several guide rings (3,5). A rod seal (4) in the cylinder head and a dirt deflector (2) protect the inside of the cylinder and the piston rod (1) from external contamination. The piston rod return movement is actuated either by the net weight of the piston rod (1) or by the force acting on the piston rod (1) from the load.

MS-3400-080

M8-3400

186

1

Piston rod

2

Dirt deflector

3

Guide ring

4

Rod seal

5

Guide ring

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Notes:

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187

CYLINDERS Piston Cylinders

Piston Cylinders With a piston cylinder both sides (double acting cylinder) of the piston (8) are pressurized. The piston rod (1) can therefore be moved in either direction by the oil flow.

The piston rod (1) can produce different piston areas.

This results in different forces and speeds occurring at a constant pressure and flow volume levels.

The rod (1) of the piston cylinder has a piston at one end which enters the cylinder through a guide ring (5) and whose piston seals (7) protect the two oil-filled chambers against each other. The cylinder and piston rod (1) are sealed on the outside by a rod seal (4) in the cylinder head (9). An additional dirt deflector (2) protects the rod seal (4) from external contamination.

When a piston cylinder is used as a single-acting cylinder it offers reduced operating pressure with the same cylinder tube (6) 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.

M8-3400

188

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CYLINDERS Piston Cylinders Single-Acting Cylinder

MS-3400-081 1

Piston rod

6

Cylinder tube

2

Dirt deflector

7

Piston seal

4

Rod seal

8

Piston

5

Guide ring

9

Cylinder head

Double-Acting Cylinder

MS-3400-082 1

Piston rod

7

Piston seal

2

Dirt deflector

8

Piston

4

Rod seal

9

Cylinder head

5

Guide ring

10

O-Ring

6

Cylinder tube

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189

CYLINDERS Rod Seal Assembly

Rod Seal Assembly General All tools and equipment used for rod seals must be burr-free and not have sharp edges. The tools should be made either of soft metal (aluminium, brass) or a suitable plastic.

Do not use hooks to remove seals. The same rule applies: Burr-free, rounded tips and made of soft metal to avoid damaging the seal seat.

MS-3400-084 1

Insulating tape

2

Self-tapping screw

To do this, a 4 mm self-tapping screw (2) is soldered onto a screwdriver with a minimum shaft length of 150 mm and a maximum diameter of 4 mm and the solder joint sanded. The blade of the screwdriver must then be covered with an insulating tape (1) to avoid damage.

MS-3400-083

If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate protective devices.

Screwdrivers or similar tools will damage the seal seats and the seals. This will result in leaks.

To remove rod seals from lift cylinders and free-lift cylinders, you will require 2 specially produced tools (see Figure MS-3400-084).

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190

We will now demonstrate 2 procedures – depending on the seal rod diameter – for ensuring safe assembly.

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CYLINDERS Rod Seal Assembly Large Rod Seal Assembly

z

Tools required: z

Tool body (outer diameter must fit the internal diameter of the cylinder cap).

z

Three pins (1, 2 and 3). Pin (1) is fixed; pins (2) and (3) are moveable.

Now push the tool body into the cylinder cap until the rod seal is aligned with the seal seat (see Fig. MS-3400-086).

Assembly: z

Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the cylinder cap.

z

Place the rod seal over the fixed pin (1).

z

Bend the rod seal under pin (2) (see Fig. MS-3400085).

MS-3400-086 1

Pin

2

Pin

3

Pin

z

MS-2232-019 1

Pin

2

Pin

z

Pull back pin (3). A section of the rod seal jumps into the seal seat (Fig. MS-3400-087).

Bend the loop created in this way so far up that pin (3) can be pushed into the loop.

MS-3400-087

WD2300S 09/2005 • Printed in Germany

2

Pin

3

Pin

M8-3400

191

CYLINDERS Rod Seal Assembly z

Now pull back pin (2). The rod seal is now fully seated in the seal seat.

Small Seal Rod Assembly Tools required: Groove aligning arbor. The outer diameter must fit the internal diameter of the cylinder cap. The arbor should end at the bottom of the seal seat.

Arbor to drive in the seal.

MS-3400-088

z

Pull the tool body out of the cylinder cap.

z

Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the cylinder cap.

z

Place the cylinder cap onto the groove aligning arbor.

z

Gently squeeze the rod seal together.

z

Place the rod seal at one point of the seal seat.

z

Press the rod seal and the arbor into the seal seat.

MS-3400-089

M8-3400

192

WD2300S 09/2005 • Printed in Germany

CYLINDERS Rod Seal Assembly Rod Seal Assembly, Sealing Lip First The sealing lip is sensitive and must not be damaged.

You therefore require special protective sleeves (1) when pushing the seal (2) over the thread and holes.

Sealing lip assembly direction: Always to the pressure side!

1 2

MS-3400-090 1

Protective sleeve

2

Seal

WD2300S 09/2005 • Printed in Germany

M8-3400

193

Notes:

WD2300S 09/2005 • Printed in Germany

194

CYLINDERS Initial Lift Cylinder

Initial Lift Cylinder

Operation The two lift cylinders on the truck are single-acting. The piston rods are raised by the pressure of the hydraulic oil and lowered by the weight of the raised load. Figure MS-3400-080 shows the cross-section of an initial liftcylinder.

Warning De-pressurise all components before carrying out maintenance work on the hydraulicsystem. 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. Physical effects may take time to set in.

Secure all ports before reapplying 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!

WD2300S 09/2005 • Printed in Germany

MS-3400-080 1

Piston rod

2

Dirt deflector

3

Guide ring

4

Rod seal

5

Guide ring

6

Cylinder tube

M8-3400

195

CYLINDERS Initial Lift Cylinder Disassembly z

Remove the front panel.

z

Extend the piston rod (1) until the attachment of the LH piston rod (1) is positioned next to the contactors and the controller in such a way that the dowel pin can be driven out.

z

Support the fork carriage with wooden blocks or other appropriate and stable components.

z

Press the “Lower” switch for at least 10 seconds to depressurise the hydraulic system.

z

Initially, drive out the dowel pin from the attachment of the LH piston rod (1) between the contactors and the controller only so far as to see clearly that the dowel pin will not collide against a contactor or the controller when it is driven out in full.

z

Depressurise the pump motor and prevent it from beingswitched on again.

z

Protect the piston rod (1) from being scratched where it enters the truck chassis through the hole, using cardboard or similar material.

z

Fully drive out the dowel pin from the attachments of both piston rods (1).

z

Press the “Lower” switch until the piston rods (1) have been fully lowered into the initial lift cylinders through their own weight. If necessary, push the piston rods (1) in manually.

z

Undo the hydraulic connection on the initial lift cylinder. Collect any oil that emerges.

z

Remove the brackets (7) at the bottom end of each initial lift cylinder.

z

Lift the initial lift cylinders out of the truck chassis.

1

7

MS-3400-091

M8-3400

196

1

Piston rod

7

Clamp

WD2300S 09/2005 • Printed in Germany

CYLINDERS Initial Lift Cylinder Inspection

Replacing the rod seal

Before commencing repair work carry out a thorough inspection of the cylinder unit. To do this, extend and retract the cylinder several times.

Information

The item numbers refer to Figure MS-3400-080. z

Check the piston rod (1) for scratches, nicks and other surface damage.

z

Check the dirt deflectors (2) for wear and unusual leakage.

z

If excess hydraulic oil emerges from the piston rod (1) from at the cylinder head it may be due to a damaged rod seal (4). Replace the rod seal (4) and make sure that the seal seat is clean and intact.

z

When repairing the cylinder check the condition of the guide rings (3). Always replace all the seals when carrying out repairs.

z

Minor irregularities on the cylinder tube (6) surface or on the piston rod can be removed with an aluminium oxide cleaning cloth or a honing tool.

Heavily worn components must be replaced.

z

When all the parts have been checked clean the cylinder components in a high-grade solvent and dry with low-pressure pressurised air.

z

Before assembling, apply a thin layer of hydraulic oil to the cleaned components and replacement parts.

WD2300S 09/2005 • Printed in Germany

Check the seal groove and the piston rod (critical seal position) for damage before fitting a new seal. Otherwise, leakage will re-occur after the new seal has been fitted.

When fitting rod seals (6) use assembly equipment and tools made of soft metal or plastic without sharp edges.

Do not use a screwdriver or similar tools as these will damage the seal edges.

If the new rod seal (4) has to be pushed over sharp edges, cracks or nicks, use appropriate protective mechanisms.

M8-3400

197

CYLINDERS Free Lift Cylinder

Free Lift Cylinder

z

Attach warning tag to control handle to advise others that the truck is being serviced.

Seal Replacement

z

Chock drive wheel and outrigger load wheels.

z

Remove forks.

z

Using a lifting device, raise fork carriage until lift chains are slack. Then place wood blocks under each side of carriage and lower carriage onto blocks.

z

Disconnect hydraulic line to fork carriage cylinder.

Seal connections to minimize oil loss and prevent hydraulic system contamination.

z

Disconnect lift chain from tensioner on fork carriage and pull chain through yoke assembly.

z

Remove screws that secure the free lift cylinder to inner mast and carefully remove the cylinder. Make certain to save shims that were between mast and free lift cylinder.

When excessive hydraulic oil is evident on the cylinder, where the piston rod exits the cap, one or more of the seals are bad and need replaced. It is advisable to replace all the seals in the cylinder whenever the cylinder is removed and disassembled for seal replacement. Follow the procedure outlined below to remove cylinder and replace seals. z

Turn the key switch OFF. Remove the key and disconnect the battery.

MS-3400-092 1

Seal

2

Bleed screw

3

Cylinder tube

4

Piston rod

5

O-Ring

6

Backring

7

Cap

8

Guide

9

Seal

10

Dirt deflector

M8-3400

198

WD2300S 09/2005 • Printed in Germany

CYLINDERS Free Lift Cylinder z

z

Remove the retaining rings (12, 13) and piston (11) from the piston rod (4). Discard the piston (11).

z

Inspect contact surfaces on the piston rod (4) and cylinder cap (7). If slight scoring is present, sand with fine emery paper until all high surfaces have been removed. Heavily scored components must be replaced. After all parts have been disassembled and inspected, thoroughly wash all metal parts and blow dry with clean compressed air.

z

Apply a light coating of hydraulic oil (Crown P/N 063001-001) to all seals being installed.

z

Attach the retaining ring (13) to the piston rod (4).

Mount a new piston (11) to the bottom of the piston rod (4) and fix with the retaining ring (12).

z

Install piston rod (4) in cylinder tube (3). Use care when installing piston rod (4) to avoid contact with sharp edges. Make sure the piston rod (4) is positioned correctly in the cylinder tube (3).

z

Install new deflector (10), seal (9), guide (8), backring (6)and O-ring (5) in cap. Use care when installing to avoid nicking the components.

z

Mount a new seal (1) on the bleedscrew. Now screw the bleedscrew (2) into the cap (7) and tighten it.

z

Install the cap (7) on the cylinder tube (3) and tighten securely. Take care not to damage the new seals.

Remove retaining ring used to secure yoke assembly to the free lift cylinder piston rod. Then remove yoke assembly.

z

Remove cap from cylinder tube.

z

Remove bleed screw from cap. Then remove seal from bleed screw and discard seal.

z

Remove deflector (10), seal (9), guide (8), backring (6) and O-ring (5) from cap (7) and discard.

z

Carefully remove piston rod (4) from cylinder tube.

Do not allow the piston rod to come in contact with any sharp edges.

MS-3400-093 4

Piston rod

11

Piston

12

Retaining ring

13

Retaining ring

WD2300S 09/2005 • Printed in Germany

M8-3400

199

CYLINDERS Free Lift Cylinder Installing Carriage Cylinder z

Install free lift cylinder and secure it to inner mast using screws and shims previously removed.

Tighten screws securely.

z

Install yoke assembly on piston rod and secure it with retaining ring previously removed.

z

Insert lifting chain through yoke assembly and connect chain to tensioner in fork carriage. Make certain chain is not twisted.

z

Connect hydraulic supply line to free lift cylinder and tighten connections securely.

z

Using lifting device, raise fork carriage and remove blocks from under carriage. Then lower carriage completely and remove lifting device.

z

Install forks.

z

Remove chocks.

z

Connect battery and remove warning tag from the control handle.

z

Bleed the hydraulic system. See section: Cylinder Bleeding and Flushing

z

Carry out a drift test. See section: Drift Test

M8-3400

200

WD2300S 09/2005 • Printed in Germany

CYLINDERS Free Lift Cylinder Cylinder Bleeding and Flushing Hydraulic circuits need to be flushed after repair of lift cylinders and bled of all air. Before bleeding and flushing, all hydraulic ports must be checked for leaks.

In addition you must ensure that all filters, where applicable, are fitted and that there is sufficient hydraulic fluid in the reservoir for flushing and bleeding.

Hydraulic system must be pressurized during the flushing and bleeding procedures.

Flushing – Mast Lift Cylinders and Free Lift Cylinders z

Actuate control valve to raise carriage through free and stage lift and stop to hold in position.

z

When the fork carriage is raised visually inspect for leaks.

z

Actuate control valve to lower carriage through stage and free lift while visually checking operation and staging.

z

Raise and lower carriage rapidly for a minimum of 10 cycles to flush system.

Free lift cylinder bleeding Danger!

Always stay away from the operatingarea of the fork carriage while bleeding is taking place.

The fork carriage can automatically lower and result in fatal injuries.

z

Slowly extend the fork carriage to free lift. The free lift is approx. 1220 mm.

z

Slowly open fork carriage cylinder bleed screw and bleed air from cylinder until a solid stream of hydraulic fluid flows out of bleed screw hole.

z

Tighten bleed screw securely.

z

Flush cylinder following procedure outlined below.

WD2300S 09/2005 • Printed in Germany

Drift Test Danger!

Never stand or work under a suspended load If a raised load drops, fatal injuries can result.

All drift tests should be conducted with a capacity load (refer to capacity plate for the rated capacity of your truck). The material used for the test load must be evenly distributed within a 1.2 m x 0.8 m pallet and must be attached to the fork carriage. Fully extend the mast with maximum rated load. The load may not drift down more than 50 mm within 5 minutes.

Occasionally internal leaks in the cylinder may cause the fork assembly to lower slowly. However, this may also be due to leaks in the check valves, pilot valves etc. In this case flush the system by raising and lowering the fork carriage several times to remove any foreign bodies from the valve seats. Now repeat the drift test.

M8-3400

201

Notes:

WD2300S 09/2005 • Printed in Germany

202

PLATFORM

Printed in Germany

203

Notes:

Printed in Germany

204

PLATFORM Mechanical Adjustment

Mechanical Adjustment

M1550 1

Platform

11

Brake arm

3

Adjusting ring

12

Brake lining

4

Screw

21

Platform switch

10

Shaft

23

Panel

WD2300S 09/2005 • Printed in Germany

M9--XXXX-

205

PLATFORM Mechanical Adjustment Warning!

Safety-critical setting The platform should always fold up when the driver exits. The platform switch is actuated and the maximum travel speed reduced.

All item numbers relate to diagram M1550. z

Remove the panel (23).

z

The brake arm (11) and the brake lining (12) brake the platform (1) when it folds up. Turn screw (14) in to increase the friction, turn it out to reduce it.

z

Adjust the braking pattern so that the platform will automatically fold up from any position, but still cushioned. The critical point is at a platform angle of approx. 45° above the horizontal.

M9--XXXX-

206

WD2300S 09/2005 • Printed in Germany

PLATFORM Platform Switch (PLS) Adjustment

Platform Switch (PLS) Adjustment This switch transmits a signal to the traction controller.

The traction controller switches to a higher, maximum speed for platform mode if the platform is tilted down.

All item numbers relate to diagram M1550.

The control lever of the platform switch (21) is actuated by the adjusting ring (3). A screw (4) secures the adjusting ring to the shaft (10) to prevent it from twisting.

Warning!

Safety-critical setting The platform should always fold up when the driver exits. The PLS should apply within 10°. z

Remove the panel (23).

z

Loosen the screw (4).

z

With the platform lowered, turn the adjusting ring (3) until the switch is actuated. Actuation of the switch should take place between 0° (fully lowered platform) and max. 10° raised platform. The switch should not be actuated above 10°. Now tighten the screw (4) and check the setting again.

WD2300S 09/2005 • Printed in Germany

M9--XXXX-

207

PLATFORM Platform Cushioning

Platform Cushioning Layering the disk springs You can ensure maximum operational lift and spring qualities of the platform by layering the disk springs in 6 packets of 3 springs and one of 2 springs.

MS1720-101

M9--XXXX-

208

WD2300S 09/2005 • Printed in Germany

PLATFORM Side Restraint, Mechanical Adjustment

Side Restraint, Mechanical Adjustment z

Remove the panel (10).

z

The brake (5) setting determines the manual force required to fold the side restraint in and out. Turn screw (12) in to increase the force, turn it out to reduce it.

z

Adjust the brake so that the restraint can be moved with medium manual force.

M1546 5

Brake

10

Panel

12

Screw

WD2300S 09/2005 • Printed in Germany

M9--XXXX-

209

Notes:

Printed in Germany

210

ELECTRICAL WIRING DIAGRAMS

Printed in Germany

211

Notes:

WD2300S 09/2005 • Printed in Germany

212

Notes:

WD2300S 09/2005 • Printed in Germany

213

ELECTRICAL WIRING DIAGRAMS Standard Diagrams

Standard Diagrams Overview

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WD2300S 09/2005 • Printed in Germany

ELECTRICAL WIRING DIAGRAMS Standard Diagrams 1

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2

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11

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3

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12

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4

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13

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5

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14

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6

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15

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7

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16

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8

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17

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9

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WD2300S 09/2005 • Printed in Germany

DIA-3400

215

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WD2300S 09/2005 • Printed in Germany

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DIA-3400

217

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WD2300S 09/2005 • Printed in Germany

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WD2300S 09/2005 • Printed in Germany

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WD2300S 09/2005 • Printed in Germany

ELECTRICAL WIRING DIAGRAMS Standard Diagrams Platform & Mast Control Circle &$

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EDO WD2330S_7 WD2300S 09/2005 • Printed in Germany

DIA-3400

221

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WD2300S 09/2005 • Printed in Germany

Notes:

WD2300S 09/2005 • Printed in Germany

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ELECTRICAL WIRING DIAGRAMS Option Wiring Diagrams

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224

WD2300S 09/2005 • Printed in Germany

ELECTRICAL WIRING DIAGRAMS Option Wiring Diagrams 1

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10

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2

Unigage

11

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3

LMS1: Max. initial lift

12

Pedestrian mode: GCSR open & GCSL open & PLS open or GCSR open & GCSL open & PLS closed

4

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13

Diode block

5

LMS3: lift stop > 1500 mm

14

Fan

6

LMS4: Reduced travel speed > 880 mm

15

Hydraulic Control Module (HCM)

7

Reduced travel speed: HSS and/or LMS4, PS1 open

16

Platform logic

8

Active: RAS, BRS, SAS, HNS, LOS1, LOS2, ILS closed

17

Fan, HCM, DB, BDI connected to battery neg.

9

PS1: Main lift load switch 500 Kg (0 bar = closed)

18

F/C package: Active below 5°C

WD2300S 09/2005 • Printed in Germany

DIA-3400

225

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WD2300S 09/2005 • Printed in Germany

DIA-3400

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WD2300S 09/2005 • Printed in Germany

Notes:

WD2300S 09/2005 • Printed in Germany

233

ELECTRICAL WIRING DIAGRAMS Power Cables

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DIA-3400

234

WD2300S 09/2005 • Printed in Germany

ELECTRICAL WIRING DIAGRAMS Power Cables Legend Item no.

Part no.

mm2

052051-018

25

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2

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16

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16

4

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6

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16

7

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8

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1

WD2300S 09/2005 • Printed in Germany

Remarks

DIA-3400

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DIA-3400

30 '

ELECTRICAL WIRING DIAGRAMS

Main Wire Harness

Main Wire Harness

Folding platform, all versions

813845_2D

WD2300S 09/2005 • Printed in Germany

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ELECTRICAL WIRING DIAGRAMS Control Handle Wire Harness

Control Handle Wire Harness

813865_2f

DIA-3400

237

ELECTRICAL WIRING DIAGRAMS Horn Switch Wire Harness

Horn Switch Wire Harness

3&

3&

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811931_2e

Housing

Part no.

PC 413

803450-021

PC 417

803450-023

PC 419

803450-023

Item no.

Part no.

1

803450-022

DIA-3400

238

Item no.

Part no.

2

803450-024

WD2300S 09/2005 • Printed in Germany

HYDRAULIC DIAGRAMS

Printed in Germany

239

Notes:

WD2300S 09/2005 • Printed in Germany

240

Notes:

WD2300S 09/2005 • Printed in Germany

241

HYDRAULIC DIAGRAMS Hydraulic Diagrams

Hydraulic Diagrams

MS-3400-019

HYD-3400

242

WD2300S 09/2005 • Printed in Germany

HYDRAULIC DIAGRAMS Hydraulic Diagrams 1

Suction filter

2

Reservoir ventilation

3

Check valve (CV)

4

Overload valve (RV)

5

Cylinder shutoff valve (SV3)

6

Proportional valve (PV)

7

Pump & motor

8

Main lift cylinder

9

Main lift

10

Reservoir

11

Flow restrictor

12

Initial lift cylinder

13

Main lift valve (SV1)

14

Initial lift valve (SV2)

WD2300S 09/2005 • Printed in Germany

HYD-3400

243

Notes:

WD2300S 09/2005 • Printed in Germany

244