Crown Forklift WI 2300 Series Maintenance Manual 812585-006

WI 2300 SERIES MAINTENANCE MANUAL

M Order number: 812585-006 Revision: A • Printed in Germany

This master manual is subject to continual updates.

It is intended solely for companies authorised by CROWN. The distribution of its content or copies thereof to third parties is prohibited.

CROWN Gabelstapler GmbH & Co. KG - European Headquarters Moosacher Str. 52 80809 Munich Germany Tel: +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 2009 CROWN Equipment Corporation

TABLE OF CONTENTS

I

Notes:

II

TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting the truck by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Placing the Truck in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Testing Trucks in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Restoring the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Accessing the Motor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Motor compartment components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Accessing the Back of the Motor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Components on the back of the motor compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Accessing the Control Handle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Control handle components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Accessing the Distributor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Recommended Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cold Store Truck Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Abbreviations used in the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Annual Inspection in Accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Terms and Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

WI 2300

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TABLE OF CONTENTS Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Entire Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Removed Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Load and Castor Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the load wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Castor Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Castor wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Castor wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the position of the pivoting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Castor Wheel Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Castor wheel suspension removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Castor wheel suspension assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 30 31 31 31 31 31 31 31 32 32 32 33 33 33 33 33 33 33 33 34 35 35 35

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Lines and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulics manifold ports and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Diagram - TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Diagram - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Diagram - TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminology Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Lift, Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Lift, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Lift, Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Lift, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Lift Lowering and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing the Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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IV

39 39 39 39 39 39 40 41 42 43 44 44 44 44 44 44 44 45 46 46 46 47 48 48 48 48 49 50

TABLE OF CONTENTS DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Drive Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Drive Wheel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Replacing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Replacing the Drive Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Drive Gear Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Drive Gear Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Repairing the Drive Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Drive Gear Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Drive Gear Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Adjusting the bevel gear set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Changing the Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Adding Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Repairing the Live Ring Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Removing the Live Ring Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Installing the Live Ring Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (ALM) Travel alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (ARB) Anti roll back module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (BBD) Battery connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (BDI) Unigage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (BRK) Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (BRS) Brake switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (EDS) Emergency Disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (F/R Contactor) Direction contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (FU) Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (HCM) Hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (HM) Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (HNS1 & HNS2) Horn switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (HSS) “Rabbit/Turtle” toggle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (HYD PCB) Hydraulic printed circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (ILS Lift & ILS Lower) Initial lift switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 (KYS) Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (LMS - initial) Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (LMS - 1700 mm) Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (LOS1, LOS2) Lower switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (MAIN PCB) Main circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (ORS) Override switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (PM / M2) Pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (P) Pump contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (PCB) Distributor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (POT, FS, RS) Traction pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (PV) Proportional valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 (RAS) Raise switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 (SAS) Safety reverse switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

WI 2300

V

TABLE OF CONTENTS (THS) Thermal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(THS1) Motor thermal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(TM / M1) Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Component Assembly Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributor PCB components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Controller 1207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overtemperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance reduction for low voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Controller Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Potentiometer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status LED Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Controller Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PMT Test Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1307 Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCROLL DISPLAY keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHANGE VALUE keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MORE INFO key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAM key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSTIC key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL DIAGNOSTIC menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the SPECIAL DIAGNOSTIC menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL PROGRAM Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting the SPECIAL PROGRAM menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1311 Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programmer menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitor menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PROGRAM Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSTICS and SPECIAL DIAGNOSTICS menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL PROGRAM menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Controller Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WI 2300

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67 67 67 68 70 71 71 71 71 71 71 71 71 72 72 72 72 73 74 75 75 76 77 78 78 78 79 79 79 79 79 79 80 80 80 80 80 81 81 82 82 82 82 82 82 82 83 83 83 84 84 85

TABLE OF CONTENTS Replacing the Display Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Display Instrument Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Display Instrument Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Battery Discharge Indicator (BDI) Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Lift cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Battery Discharge Indicator (BDI) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Wet cell battery calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Replacing the Key Switch (KYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Key Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Key Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Replacing the LMS-Initial Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Limit Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Limit Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Replacing the LMS-1700 mm Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Limit Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Limit Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Replacing the Override Switch (ORS) and the Brake Switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Override Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Replacing the Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Replacing the Emergency Disconnect Switch (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Emergency Disconnect Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Emergency Disconnect Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 General Motor Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Repairing the Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Traction Motor Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Checking the Traction Motor Components for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Traction Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Repairing the Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Pump Motor Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Checking the Pump Motor Components for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Pump Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Repairing the Direction Contactor (F/R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Direction Contactor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Direction Contactor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Wear Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Direction Contactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Direction Contactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Repairing the Pump Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Pump Contactor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Pump Contactor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Wear Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Checking the contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Pump Contactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Pump Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

WI 2300

VII

TABLE OF CONTENTS Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 101 101 102

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 General Brake Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Electromagnetic Brake Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Repairing the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Brake Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Adjusting the Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Setting the Braking Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Checking the Braking Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Reducing the Stopping Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Repairing Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Return Spring Pre-Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Replacing the Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Return spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Return spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Repairing the Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Steering Column Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Steering Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Replacing the Steering Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Steering Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Steering Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Adjusting the Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Repairing the Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Replacing the Control Handle Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Replacing the Switch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Switch unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Replacing the “Rabbit/Turtle” Toggle Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Toggle module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Toggle module assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Replacing the Control Handle Grip PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Hydraulic PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Hydraulic PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Main PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Main PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Replacing the Traction Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Traction potentiometer removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Traction potentiometer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

WI 2300

VIII

TABLE OF CONTENTS Replacing the Safety Reverse Switch (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Safety reverse switch (SAS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Safety reverse switch (SAS) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Replacing the Grips and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Replacing the Initial Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Initial lift switch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Initial lift switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Repairing the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Repairing the TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Replacing the Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Mast Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Replacing the Mast Rollers and Adjusting the Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Assembling the Remaining Attachments and Mast Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Preparing the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Lowering Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Repairing the Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Replacing the Fork Carriage Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Checking the Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Periodic inspection of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Periodic replacement of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Inspecting Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Checking the service hours for the lift chains and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Checking the lift chain for elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Worn or missing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Turned pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Chain lateral wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Checking chain supports and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Checking the chain pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Checking and adjusting the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Checking the lifting components for misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Lubricating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Lubrication intervals and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Tools and equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Lift Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Outrigger Lift Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Fork Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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TABLE OF CONTENTS CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Outer Lift Cylinders on the TL and TT Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer lift cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Outer Lift Cylinders on TF Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer lift cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outer lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Free Lift Cylinders on the TT and TF Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Free Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Free lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Initial Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial lift cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Cylinders Before Starting Repair Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Rod Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Lift Cylinders on the TL and TT Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Lift Cylinder on the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Free Lift Cylinders on the TF and TT Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Free Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Free Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Initial Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Lift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding and Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding the Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the Lift and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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155 155 155 156 156 156 156 156 157 157 158 158 158 158 159 159 160 160 161 162 163 163 163 164 164 165 166 166 166 167 167 167 168 169 169 170 171 171 172 173 173 174 175 175 176 176 176 176 177

TABLE OF CONTENTS SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Distributor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Traction Controller - Drive Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Instrument & HCM Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Control Handle Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Lift Limit Switches and Temperature Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Anti Roll Back (ARB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Limit Switch Cables (LMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Horn Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Plug Connector Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Contact Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Control Handle and Horn Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Control Handle, Sideshift/Initial Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Control Handle Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Plug Connector Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Strobe and Alarm Signal Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Plug Connector Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Cable Lugs and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Hydraulic Diagram - TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Hydraulic Diagram - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Hydraulic Diagram - TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

WI 2300

XI

Notes:

XII

INTRODUCTION

1

Notes:

2

INTRODUCTION Important Information

Important Information

Service personnel qualification

This maintenance manual details the maintenance and repair work to be carried out on the following truck models:

To maintain the safety and functionality of the truck, maintenance and repair work must only be performed by service engineers who have been authorised by Crown.

•

WI 2300

Contact Crown if you wish to have your engineers trained.

Manual structure The manual is divided into the following sections:

Ordering Spare Parts

Section

To order spare parts, use the spare parts catalog supplied separately. Always quote the following numbers when ordering spare parts:

Index

•

Specification number

Introduction

•

Model number

Safety

•

Serial number

These numbers can be found on the truck data plate.

For details of your truck's technical specifications refer to the Technical Specifications chapter in the operator manual.

Lubrication & Adjustment Hydraulic System Drive Unit

Note: Always use original Crown spare parts.

Electrics

Ordering documentation

Brake System

Spare parts catalogs, operator manuals, specification sheets etc. can be obtained from:

Steering Lift Mechanism

CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY

Cylinders Wiring Diagrams Hydraulic Diagrams

Text mark-ups in the manual The following symbols and mark-ups are used in the manual:

Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 or 133 www.crown.com

1., 2., 3. denote work steps to be taken. Ö This arrow indicates the consequences of an action. ¾ This arrow indicates action to be taken to avoid hazards contained in a warnings.

(1), (2), (3) etc. indicate text references to item numbers in illustrations.

•

Indicates the first level in a list.

– Indicates the second level in a list.

Note: Where the word "Note" appears before text, this indicates important additional information.

WI 2300

Rev.2 02/2009

3

Notes:

4

SAFETY

5

Notes:

6

SAFETY Safety Notices

Safety Notices The following symbols will help you to assess the risk to yourself, other people and materials should you fail to comply with a safety notice:

DANGER This symbol warns of immediate danger to the life and health of personnel.

Severe injury or death will result. ¾ Follow all instructions indicated by this symbol in order to avoid injury or death.

WARNING This symbol warns of potential danger to the life and health of personnel.

Severe injury or death may result. ¾ Follow all instructions indicated by this symbol in order to avoid injury or death.

CAUTION This symbol warns of possible danger to the health of personnel.

Injury may result. ¾ Follow all instructions indicated by this symbol in order to avoid injury.

CAUTION This signal word without a symbol warns of material damage.

Damage to the truck, tools and mechanisms may result. ¾ Follow all instructions indicated by this signal word in order to avoid damage.

WI 2300

Rev.1 04/2009

7

SAFETY Basic Safety Notices

Basic Safety Notices

•

Organisational measures

Service personnel must stop work immediately if any unauthorised persons enter the hazardous area. These persons must be removed immediately.

•

Repair work must only be carried out by service engineers approved by Crown.

•

Work on electrical equipment must only be carried out by specialist electricians in accordance with electrical regulations.

•

High pressure hydraulic oil can cause severe injuries. Depressurise the hydraulic system before opening any sections of it.

•

Note the basic and action-specific safety notices in the respective chapters of this manual. Refer also to the truck operator manual, in particular the Safety chapter.

•

A 15 minute discharge time must be observed for the electrical energy stored in the capacitors and coils. Alternatively, these components can undergo a controlled discharge through an electrical resistor.

•

Service personnel must also observe statutory and other binding accident and environmental protection regulations.

•

•

The legal minimum age for performing repair work must be observed.

When carrying out work near the battery, always cover the battery terminals with a suitable insulating material (e.g. plywood board) to prevent short circuits.

•

Before carrying out work underneath and on raised components (e.g. fork carriages, extended mast stages, the truck itself), attach suitable safety devices and supports with sufficient capacity.

•

Springs and gas pressure dampers must be checked and slowly discharged before removing them.

•

Service personnel must be trained and authorised to operate industrial trucks and must be able to demonstrate their competence.

Personal safety equipment •

•

Always wear safety equipment such as safety shoes and goggles when carrying out maintenance and repairs. Depending on requirements you may also need to wear safety gloves and ear muffs.

Repair work

When carrying out work on the hydraulic system, e.g. bleeding the system, wear suitable protective clothing such as safety gloves, goggles or a face mask.

•

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

•

Long hair, loose clothing and jewellery are prohibited. They could get caught or drawn in, resulting in injury. Do not wear jewellery especially when working on electrical systems, as a short circuit could cause burning.

•

Always use insulated tools when working on electrical systems.

Protecting the hazardous area •

•

When carrying out repair work that could be hazardous to yourself and other people, seal off a large part of the hazardous area with suitable marker tape.

Before carrying out repair work, service personnel must ensure that there is no one in the hazardous area.

Rev.1 04/2009

8

Hazards from stored energy

•

Always carry out repair work in accordance with the test and maintenance schedule contained in this manual and any applicable service bulletins.

•

Before carrying out repair work prepare the truck as follows: – Park the truck on a level surface – Lower the forks to the ground – Switch off the truck and prevent it from being switched on again – Disconnect the battery and prevent the connector from being attached by unauthorised personnel.

•

When carrying out work that requires battery supply, jack up the truck until the drive wheel is clear of the ground.

•

Do not use a naked flame near the truck or to check fluid levels or for leaks.

•

Always have suitable fire protection equipment to hand when carrying out work.

•

Keep the truck clean; this makes it easier to find loose or missing components.

•

Welding work must only be carried out after prior consultation with Crown.

WI 2300

SAFETY Basic Safety Notices •

Keep the work area clean and well lit. An untidy or poorly lit work area can lead to accidents.

•

Always charge batteries in designated charging areas and make sure the area is well ventilated.

•

Modifications to the original condition of the truck must be examined and approved in writing by Crown beforehand.

•

Remove battery acid stained clothing immediately.

•

If acid comes into contact with the skin, rinse immediately with plenty of clean water. If it comes into contact with the eyes, rinse immediately with clean water for several minutes and then seek medical attention.

•

Immediately neutralize and thoroughly rinse any spilled battery fluid.

•

Only use original Crown spare parts and accessories.

•

Never install or commission damaged components.

Restoring the truck to service after repair work •

After carrying out repairs refit any safety mechanisms that have been removed and make sure they are working correctly.

•

The truck may only be restored to service after repair work once all the truck functions have been successfully tested, in particular on the following components: – Brakes – Direction switches

•

Always use suitable hoist devices and lifting gear with sufficient capacity.

•

Attach lifting gear to the designated strap points and prevent it from slipping. Make sure the lifting gear cannot touch other components during lifting.

•

Do not stand under a swinging load.

•

Repair work can only be performed under a raised truck if the truck has been protected against accidental lowering.

•

Work may only be performed on the chassis, fork carriage or mast if they have also been protected against accidental lowering.

•

Lifting gear such as load slings routed around sharp edges must be protected from cuts.

To avoid endangering other people, always test the truck in an open area where there are no other people or obstacles.

Handling batteries

• •

Clean any dirty decals and replace any damaged or missing ones.

Lifting gear and slings

Particular care is required when cleaning the truck and components that have been removed. See page 31.

•

•

– Lifting mechanism

Cleaning work

•

In accordance with the test and maintenance intervals check that the warning and instruction decals on the truck are complete and legible.

– Steering – Warning devices (horn, warning indicator)

•

•

Note: The spare parts manual gives details of the labelling and position of the warning and instruction decals on the truck.

– Speed control

•

Warning and instruction decals on the truck

Batteries may only be charged, serviced or replaced by trained personnel. Observe the instructions contained in the operator manual, as well as the instructions of the battery and charger manufacturers.

The charger must be appropriate to the battery voltage and capacity. First connect the battery, then switch the charger on.

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

Do not use a naked flame and do not smoke when handling batteries.

Do not touch battery terminals with metal objects.

Cover the battery terminals with a suitable insulation (such as a plywood board) if you have to work in this area.

Environmental protection •

•

Any work that involves environmentally hazardous substances being released must only be performed in designated areas, to allow hazardous chemicals and oils to be separated.

All substances released during maintenance and repair work must be collected in the proper manner and disposed of in accordance with national regulations. Oil filters and dehumidifying inserts must be treated as special waste.

•

Always act responsibly when carrying out repairs to avoid damaging the environment.

WI 2300

Rev.1 04/2009

9

Notes:

10

LUBRICATION & ADJUSTMENT

11

Notes:

12

LUBRICATION & ADJUSTMENT Transport and Storage

Transport and Storage

Lifting the truck by crane

CAUTION Battery acid can scald Battery acid will spill if a filled battery tips over during transport. This can cause injury to bystanders and damage the truck and transportation equipment.

1

¾ Always remove the battery before transporting the truck.

Lifting the Truck WARNING Falling loads are hazardous Fatal injuries can result if the truck or crane crash or if a load falls. ¾ Make sure the crane, lifting truck and the load handling equipment used have the required capacity.

Information on the required capacity can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.

Fig. 1 Lifting the truck by crane

1. Fully lower the forks.

2. Fully raise the outriggers.

3. Attach the lifting slings as shown in the illustration.

4. Attach the lifting gear as shown in Fig. 3.

5. Wedge a board (1) between the slings to act as an anti-slip device.

6. Carefully lift the truck with the crane.

WI 2300

13

LUBRICATION & ADJUSTMENT Transport and Storage Lifting the truck with a forklift truck

2 1

Fig. 2 Lifting the truck with a forklift truck

1. Fully lower the forks.

2. Fully raise the outriggers.

3. Position the forks (1) of the truck that is doing the lifting under the chassis of the truck.

4. Compensate for the difference in height between the chassis and the outriggers: to do this, lay a sufficiently thick beam (2) onto a fork of the truck that is doing the lifting. Ö This will ensure that the weight is equally distributed over both forks when the truck is raised.

5. Attach the truck securely to the mast of the truck doing the lifting (e.g. with a tensioning belt).

6. Raise the truck only as far as is necessary for transporting.

WI 2300

14

LUBRICATION & ADJUSTMENT Towing the Truck

Towing the Truck A de-energised truck can be towed over short distances using a second truck without having to release the drive wheel brake. This might be necessary for example if it has been left in an aisle.

WARNING Tipovers can result in fatal accidents A truck tipover can result in fatal injuries. ¾ Make sure the towing truck has sufficient capacity.

Information on the capacity required can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.

1

¾ Make sure the drive and castor wheels of the broken down truck do not get damaged by the forks of the towing truck. ¾ Make sure the broken down truck does not slide off the forks of the towing truck.

Fig. 3 Towing the truck

1. Position the forks (1) of the towing truck under the truck (see Fig. 3).

CAUTION Avoid damaging the drive wheel When the truck is de-energised the brakes are applied to the drive wheel. If it drags along the ground while the truck is being towed it will get damaged.

2. Raise the motor compartment side of the truck by approx. 20 mm.

3. Pull the truck slowly and in a forward direction only (see arrow).

¾ Make sure the drive wheel does not touch the ground as the truck is being towed.

WI 2300

15

LUBRICATION & ADJUSTMENT Jacking up the Truck

Jacking up the Truck

4. Place the jack under the centre of the truck's chassis at the contact point (2) and raise the truck by no more than 20 mm.

5. Place hard wooden blocks (3) underneath the chassis and lower the truck onto them.

WARNING Tipovers can result in fatal accidents ¾ Make sure the jack has sufficient capacity. Information on the capacity required can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.

6. Place a jack underneath an outrigger at the contact point (4) and raise the truck until it is horizontal.

7. Place a hard wooden block (5) under both outriggers and lower the truck onto it.

WARNING Incorrect jacking procedures can cause fatal accidents Improper handling of the truck or the tools can result in fatal accidents. ¾ Never place your hands or other parts of your body under the truck before it has been supported. ¾ Always support a raised truck with wooden blocks or other suitable equipment to relieve the jack. ¾ Only jack up the truck so far as to raise the wheels off the ground. Any further lifting will increase the risk of tipover.

1

4

5

3 2 3

Fig. 4 Jacking up the Truck

1. Fully lower the forks.

2. Fully raise the outriggers.

3. Chock the load wheels with wedges (1).

WI 2300

16

LUBRICATION & ADJUSTMENT Placing the Truck in Storage

Placing the Truck in Storage

Restoring the Truck to Service

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

Carry out the following steps to restore the truck to service after a period of storage:

1. Disconnect the battery from the truck's circuit.

1. Remove any anti-corrosion film that may have been applied.

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

3. Clean the truck (see page 31) and then lubricate it.

2. Jack up the truck, remove the hard wooden blocks and lower the truck.

4. Lubricate the truck in accordance with the maintenance schedule.

3. Charge the battery or install a charged battery.

4. Connect the battery.

5. Store the truck in a dry room with constant temperature and air humidity. Do not park the truck in the open air or in a humid environment.

5. Carry out the safety inspection.

6. The surfaces of trucks subjected to hostile ambient conditions such as saline atmosphere must be treated with suitable preservatives to prevent corrosion.

7. Cover the truck with an air-permeable material to protect against dust. Do not use plastic sheets as condensation could form.

Battery Maintenance The condition of the battery has a considerable impact on the performance of the truck. Optimum maintenance (regular acid density and level checks, cleaning the cell covers) maintains the battery's performance and useful life.

Always service the battery in accordance with the battery manufacturer's instructions.

8. Jack up the truck (see page 49) to prevent the wheels from flattening.

Testing Trucks in Storage CAUTION Long periods of inactivity can damage the hydraulic system If the hydraulic system is unused for too long, the hydraulic cylinders may suffer corrosion damage. ¾ Every 3 months test the hydraulic system on trucks placed in storage.

1. Connect the battery.

2. Check the battery charge and re-charge the battery if required.

3. Check the hydraulic oil level. Top up if required.

4. Apply all hydraulic functions.

Note: Approach all limit positions at least once to coat the whole of the cylinder surfaces with oil.

5. Check the hydraulics and gear unit for leaks.

6. Check the corrosion protection and replace if necessary.

7. After inspection disconnect the battery.

WI 2300

17

LUBRICATION & ADJUSTMENT Component Access

Component Access WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Accessing the Motor Compartment

1

2 Fig. 5 Removing the front panel 1

Front panel

2

Screws

1. Loosen the screws (2).

2. Remove the front panel (1).

WI 2300

18

LUBRICATION & ADJUSTMENT Component Access Motor compartment components 1

2

3

4

5

6 7

23

8

9

10

11

12

20

22

21

13 19

14

18 17

16 15

Fig. 6 Motor compartment components 1

Brake

13

Pump motor

2

Horn

14

Pilot-operated load hold valve (SVCL)

3

Brake switch (BRS)

15

Main lift lowering valve (PV)

4

Override switch (ORS)

16

Hydraulic Control Module (HCM)

5

Battery discharge indicator (BDI)

17

Anti-rollback module (ARB)

6

Key switch (KYS)

18

Traction control module (TCM)

7

Distributor PCB with FU2, FU4 and FU5

19

Direction contactor (F/R)

8

Hydraulic oil reservoir

20

Fuse FU1 (travel)

9

Fuse FU3 (raise)

21

Gear unit

10

Emergency Disconnect

22

Drive wheel

11

Pump contactor

23

Traction motor

12

Thermal switch (THS1)

WI 2300

19

LUBRICATION & ADJUSTMENT Component Access Accessing the Back of the Motor Compartment 5

WARNING

6

Incorrect handling of the lifting gear and slings can cause injury You can be injured if a component falls on you.

3

¾ Always use lifting gear and slings with sufficient capacity. ¾ Attach the slings securely to the component to be lifted. ¾ Watch out for your hands as there is a risk of trapping.

Fig. 8 Lifting the battery out of the truck 5

Lifting bar

6

Lifting slings or chains

3. Strap the battery (3) to a lifting bar (5) using lifting slings or chains (6).

1

CAUTION Risk of damaging the battery container ¾ Make sure the battery is raised vertically out of the battery container, perpendicular to the lifting gear.

2 4. Lift the battery (3) carefully out of the truck.

4 3 Fig. 7 Accessing the back of the motor compartment 1

Battery connector

2

Receptacle lugs

3

Battery

4

Battery cover

1. Open the battery cover (1).

2. Remove the battery connector (1) and place it on the battery (3).

WI 2300

20

LUBRICATION & ADJUSTMENT Component Access Components on the back of the motor compartment

Accessing the Control Handle Components Details of how to access the control handle components can be found starting on page 119.

Control handle components

1

2

3 4 5

3 7 8

1 2

1

Initial lift cylinder

2

Limit switch (LMS - initial)

3

Manifold

6

Fig. 10 Control handle components

Fig. 9 Back of the motor compartment 1

7

1

Initial lift switch (lower)

2

Initial lift switch (raise)

3

Travel switch (HSS)

4

Main lift – lower switches (LOS1, LOS2)

5

Main lift – raise switch (RAS)

6

Horn switches (HNS1, HNS2)

7

Travel switch potentiometer (POT), forward travel switch (FS), reverse travel switch (RS)

8

Safety reverse switch (SAS)

WI 2300

21

LUBRICATION & ADJUSTMENT Component Access Accessing the Distributor PCB 1

2

Fig. 11 Accessing the distributor PCB 1

Screw

2

Bracket

1. Move the front panel out.

2. Loosen the screws (1).

3. Lift out the cover (2).

3

Fig. 12 Distributor PCB 3

Distributor PCB

WI 2300

22

LUBRICATION & ADJUSTMENT Recommended Lubricants and Consumables

Recommended Lubricants and Consumables

Carefully protect all electrical connections and components against corrosion. For detailed information, refer to the Electrical System chapter.

The following tables list lubricants and consumables that Crown uses in its factory. However, you can use any lubricants provided they meet the same technical criteria.

Service intervals (see page 32) must be adapted to the conditions of use.

Cold Store Truck Requirements Special hydraulic oils, lubricants and grease must be used for cold store applications (cold store trucks).

Abbreviations used in the Table The lubricant type is indicated by letters. Individual letters (A, B, ...) denote lubricants for normal temperature ranges, double letters (AA, BB, ...) for low temperature ranges.

An anti-corrosion fluid (Crown no. 805236-004) must be applied to all machine parts such as screws, washers, nuts, pins, retaining rings etc.

Model

Lubricant Type

Product

Manufacturer

A

Transmission oil

Hyp 85W90

Aral

GX-D 85W90

Esso

Mobilube HD85W90

Mobil

Spirax MB90

Shell

AA

Low temperature transmission oil

Mobil SHC 624

Mobil

B

Grease (Multi-Purpose)

Aralube HLP2

Aral

LM Grease

Castrol

Regulus A2

Century

Beacon EP2

Esso

EP2

Maxol

Mobiluxe EP2

Mobil

Retinax LX

Shell

LGWMI

SKF

Aralube SKL2

Aral

Unirex Lotemp EP

Mobil

Vitam G 32

Aral

Hyspin AWS-32

Castrol

Nuto H32

Esso

DTE 24

Mobil

Tellus 32

Shell

Hydran LZ 32

Finol

Rendin B10

Fuchs

Deutz Oel HVI 32

Klockner

BB D

DD

Low temperature grease Hydraulic oil

Hydraulic oil (low temp)

Crown Part Number

053002-004

053002-009

053002-005

053002-005

053001-003

053001-009

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23

LUBRICATION & ADJUSTMENT Recommended Lubricants and Consumables Model

Lubricant Type

Product

Manufacturer

G

Lubrication oil

Essolube HDX+40

Esso

Kowal 40

Aral

Delvac 1240

Mobil

GG

Low temperature lubrication SHC 626 oil

Mobil

M

Special grease

Dow Corning

Molycote® BR-2 Plus

Crown Part Number

053002-008

053002-008 -----------------

Lubricants

Product

Application

Crown Part No.

Anti-corrosive agent

Tectyl

Corrosion inhibitor for cold store trucks

805236-004

Rubber & Vinyl Dressing

Commercial

Rubber Components, Plastic Pan- ------------els

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24

LUBRICATION & ADJUSTMENT Planned Maintenance

Planned Maintenance Maintenance Schedule This maintenance schedule assumes single shift operation under normal conditions.

The maintenance intervals must however always be adapted to the prevailing operating conditions. In extreme conditions (dust, dirt, humidity etc.) and in cold stores the maintenance intervals should be reduced. Exact details should be discussed with a Crown service engineer.

Routinely check for wear, corrosion, damage, and test component operation and safety when carrying out maintenance work. If in doubt, replace components.

Planned maintenance must be performed either after a certain number of service hours or a certain period of time (whichever is reached first).

The next higher inspection interval includes the previous intervals.

For example: The 1000 hour service also includes the inspection and lubrication items lists specified under 500 hours and 250 hours.

Annual Inspection in Accordance with FEM 4.004 Guideline FEM 4.004 “Regular Inspection of Industrial Trucks” requires the truck to be inspected by an expert.

This inspection must be carried out annually or in intervals as specified by the owner's risk analysis.

National regulations must be taken into account.

Exact details of intervals should be discussed with a Crown service engineer.

Terms and Abbreviations used The following terms and abbreviations are used in the subsequent tables: M

Months

h

Service hours

X

Perform on standard trucks

C

Perform on cold store trucks

I

Inspection item

L

Lubrication item

The lubricant type is indicated by letters. Individual letters (A, B, ...) denote lubricants for normal temperature ranges, double letters (AA, BB, ...) for low temperature ranges.

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LUBRICATION & ADJUSTMENT Planned Maintenance

I-5

I-6

L-1 L-2

I-7

L-5 I-13

L-3

I-8 I-4

I-9

I-12

I-10 I-1 I-2

I-11

I-3 I-2

I-1

I-2

L-4

Fig. 13 Maintenance schedule

6M Position Lubricant

Action

Check the clearance and wear levels on the load wheel and casX/C tor wheel supports.

I-2

Check the load wheels, castors and drive wheel for wear.

X/C

I-3

Clean the initial lift guide contact surfaces and check for wear.

X/C

I-4

Check the fork carriage and outriggers for cracks.

Check the fork carriage rollers for slack.

X/C

I-5

Carry out a lowering plumb test on the mast.

X/C

I-6

Check the chain anchors and lift chains for damage, corrosion and wear (cracks) (see Chain anchors and lift chains, page 144).

X/C Replace the chain anchors and lift chains after 6000 hours or 3 years.

G / GG

Lubricate the lift chains (see Chain anchors and lift chains, page 144).

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26

24 M

250 h 500 h 1000 h

I-1

L-1

12 M

X/C

LUBRICATION & ADJUSTMENT Planned Maintenance 6M Position Lubricant L-2

H

Action

250 h 500 h 1000 h

Lubricate the hose rollers.

X/C

Lubricate the lift chain pulleys.

X/C

I-8

Check the mast rollers for wear and slack.

X/C

I-9

Check the screw locking devices on the top mast attachment.

Note: Only perform a visual inspection on the bottom mast attachment screws as these are secured by a tightening torque and X / C Loctite. Tightening the screws further would damage the screw locking device.

I-10

Check the load backrest for damage and ensure it is securely fitted.

I-11

Check the forks for damage and wear.

L-4

Lubricate the pintles, tie rod and all lift mechanism joints.

X/C

I-12

Check the hydraulic cylinder piston rods for damage and ensure cylinder is sealed.

Check the cylinder attachment fuses.

X/C

I-13

Clean the mast contact surfaces and check for wear.

X/C

Lubricate the mast contact surfaces.

X/C

L-5

24 M

Check the pulleys, pulley yoke, hose rollers and mast limit cushX/C ioning for wear, damage and slack.

I-7 L-3

12 M

G / GG

B / BB

X/C X/C

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LUBRICATION & ADJUSTMENT Planned Maintenance

I-16

I-17

I-18

I-19

I-15

I- 20

I-14

I- 21

I- 24

L-7

L-6

I- 23

I- 22

I- 25

I-15

I-18

I- 26

I- 31 I- 32

I- 27 I- 30

I- 28

L-10 L-9

I- 29

L-8

Fig. 14 Maintenance schedule (continued)

6M Item

Lubricant

Action

24 M

250 h 500 h 1000 h

I-14

Tighten the traction motor attachments.

I-15

Check the carbon brushes and commutator of pump and traction motors for wear.

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28

12 M

X/C X/C

LUBRICATION & ADJUSTMENT Planned Maintenance 6M Item

Lubricant

12 M

24 M

Action

250 h 500 h 1000 h

I-16

Apply weak pressurized air to the brake.

Check the conical nipple for damage.

Check the brake air gap.

X/C

I-17

Dismantle and clean the brake.

Check all components for wear and damage. Replace any worn or damaged components.

X/C

I-18

Torque all power cable connections.

X/C

I-19

Check the restoring force of the control handle springs.

X/C

I-20

Read the traction controller error log.

Torque the traction controller attachment.

X/C

I-21

Carry out a PMT test (safety test) on the traction controller (see page 76)

Annually

I-22

Check the steering chain tension.

I-23

Torque the gear unit attachment and check the gear unit oil level.

L-6

A / AA

Check the gear unit oil level and replenish as required.

L-7

A / AA

Replace the transmission oil.

X/C X/C X/C X/C

I-24

Tighten the drive wheel nuts after 50 hours for a new truck or after removal/assembly. Thereafter tighten the wheel nuts every X/C 500 hours or every 12 months.

I-25

Check the pump contactor contacts for wear.

X/C

I-26

Check the entire hydraulic system for leaks.

X/C

I-27

Check the pump motor coupling for damage and wear.

X/C

I-28

Check the pump motor attachment clamp for damage and replace if necessary. Make sure the pump motor is secure and fix the attachment clamp if required.

X/C

I-29

Check the settings of the relief valves RV1 and RV2.

X/C

L-8

D / DD

Replace hydraulic oil.

L-9

D / DD

Check the hydraulic oil level and replenish if necessary

X/C

I-30

Check the direction contactor contacts for wear.

X/C

I-31

Check the insulation of the electric wires for damage.

Make sure the switches and connections are fitted securely and check for corrosion.

L-10 I-32

B / BB

X/C

X/C

Lubricate the hinges and battery panel lock.

X/C

Check the battery cables and connectors for damage.

X/C

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LUBRICATION & ADJUSTMENT Torques

Torques Standard torques Note: The torques listed in the manual always take precedence over standard torques.

Standard screws and nuts Grade:

8 and 8.87

10 and 10.9

Thread size

12 and 12.9

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 10.9

Thread size

Torque (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

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12 and 12.9

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components

Cleaning the Truck and Components

Cleaning the Entire Truck 1. Park the truck at an approved washing site.

2. Switch off the truck, disconnect the battery and prevent it from being switched on again.

CAUTION

CAUTION

Health risk Cleaning agents, lubricants and consumables can damage your health.

Do not steam-clean the truck and do not use metal brushes to clean it.

¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Cleaning the truck surface 3. Dry clean the truck. To do this use cloths, soft brushes and if necessary weak, dry compressed air.

Effects of incorrect cleaning Electrical components Electrical components such as connectors, contacts, distributor boards, controllers and wiring can be damaged by water, cleaning agents and solvents.

Mineral and chemical residue that automatically remain on or in components after cleaning, are a cause of corrosion. This corrosion results in malfunctions and premature failure.

Roller and slide bearings Steam cleaning and solvents damage the lubricant film on bearing surfaces. This results in dry running and rapid damage to the bearing elements.

Corrosion-protected surfaces

Note: Local contamination that cannot be removed by dry cleaning can be treated with a damp cloth and a neutral cleaning agent. Make sure that neither water nor cleaning agent get into electrical components or bearings.

Cleaning lift chains 4. See page 32.

Cleaning electrical components 5. Clean electrical components only with weak, dry compressed air and a dry cloth.

Interior cleaning 6. Clean detachable rubber mats with water and a neutral cleaning agent.

The brake lines, screw connections and shiny metal surfaces in particular on cold store trucks are factorytreated with an anti-corrosive agent (Anticorit BW 366®). This protection can be washed off by solvents and steam cleaning. The above-mentioned components will corrode as a result.

7. Allow the rubber mats to dry out fully before returning them to the truck.

Environmental Protection

9. Wipe down the truck.

Cleaning must only be performed in specially designated areas to enable hazardous chemicals and oils to be separated.

8. Damp-wipe plastic parts with a neutral cleaner.

Note: If necessary use a standard commercial plastic cleaning agent to remove obstinate dirt.

After cleaning the truck 10. Remove any paint damage.

11. Add anti-corrosion agent if necessary.

Collect any waste (such as oily cleaning cloths) and dispose of them in accordance with local regulations.

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Rev. 1, Feb 09

31

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components Cleaning Removed Components

5. Re-lubricate, paint or apply anti-corrosion agent to the components as required.

Cleaning lift chains

6. Refit the components.

7. For cold store trucks apply Anticorit BW 366® as an anti-corrosion agent for screw connections and shiny metal surfaces.

WARNING Improper cleaning can cause chains to crack!

A cracked chain can result in fatal injuries.

Never clean lift chains with steam cleaners, cold cleaning agents or corrosive, acid-based agents. This can cause direct chain damage through hydrogen embrittlement. ¾ Clean the chain surfaces only with paraffin derivatives such as cleaning petroleum or cleaning petrol. ¾ Apply an approved chain oil immediately after cleaning or inspection (see page 23).

1. Remove persistent dirt with cleaning petroleum or cleaning petrol. Apply a thin layer of the cleaning agent with a hard bristle brush and wipe with a lintfree cloth.

2. Apply an approved chain oil immediately after cleaning (see page 23).

Cleaning other mechanical components With the exception of lift chains, components that have been removed can be steam-cleaned under certain conditions.

CAUTION Mechanical components may only be steam-cleaned if no electrical components or bearings are affected.

1. Components that have been removed should be cleaned by hand, ideally with warm water and a mild neutral cleaning agent.

2. If steam-cleaning cannot be avoided, it should be done without a cleaning agent. If grease needs to be removed, use a mild neutral cleaning agent.

Note: Steam-cleaning can remove anti-corrosion agent and paint from surfaces.

3. If a neutral cleaning agent has been used, rinse the components thoroughly with clear water.

4. Leave the cleaned components to dry thoroughly.

Note: Cleaned components must be dry and free of cleaning agent residue before being refitted, lubricated or painted.

Rev. 1, Feb 09

32

WI 2300

LUBRICATION & ADJUSTMENT Replacing the Load and Castor Wheels

Replacing the Load and Castor Wheels

Load wheel assembly Note: Assembly is the reverse of disassembly. Check the bushings (23) for wear and replace if necessary.

1. After assembly carry out a lowering plumb test and make sure the mast tilt is within the permissible range.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

Replacing the Castor Wheel 12 9

¾ Lower the forks to the ground. ¾ Switch the truck off.

11

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again.

11

¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

10

12

Replacing the Load Wheels

13

19 22

Fig. 16 Replacing the castor wheel

Castor wheel removal 23

7

1. Remove the screws (12).

25

2. Remove the cotter pins (11) and take off the axle (10).

3. Remove the castor wheels (13).

23 21

21

24 26

24 26

Castor wheel assembly Note: Assembly is the reverse of disassembly. Always replace the self-locking nuts (12).

1. After assembly carry out a lowering plumb test and make sure the mast tilt is within the permissible range.

27

25

Lowering Plumb Test

Fig. 15 Replacing the load wheels

Removing the load wheels 1. Remove the dowel pins (21).

2. Raise the outrigger and move the rockers (26) up.

3. Remove the axles (25) and take off the load wheels (27).

4. Remove the rockers (26).

5. Loosen the screws (7) and remove the bushings (23).

A lowering plumb test checks the permissible mast tilt and should always be carried out if there have been changes made to the drive and castor wheels. The lowering plumb test must be performed with rated truck load (see capacity plate).

1. Park the truck on a level surface with the test load.

Note: The surface is level if the height difference at the wheel contact points is less than 1 mm.

2. Raise the forks to a height of 300 mm.

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LUBRICATION & ADJUSTMENT Replacing the Load and Castor Wheels 3. Attach the lowering plumb to the back of the fork carriage.

4. Drop the lowering plumb.

5. Plot the middle of a 20 x 50 mm square, e.g. cardboard, under the plumb. The long side of the square should be facing the longitudinal axis of the truck.

1 2

6. Attach the square you have drawn to the floor using adhesive tape.

7. Extend the mast until it is just before the limit stops.

8. Extend the string of the lowering plump until it is just above the ground.

3

1

9. Drop the lowering plumb. Ö The lowering test is successful if the lowering plumb is within the square you have drawn.

Note: If the lowering plumb is outside of the square, the mast tilt must be adjusted by changing the position of the pivoting carriage. Now carry out another lowering plumb test and make sure the permissible mast tilt is not exceeded.

Adjusting the position of the pivoting carriage WARNING A truck tipover can result in accidents Changing the position of the pivoting carriage can cause the truck to tipover while travelling or when lifting or lowering loads.

2

Fig. 17 Pivoting carriage

1. Remove the front panel.

2. Loosen the nut (2) and adjust the position of the pivoting carriage (3) with the screws (1) so that the lowering plump is within the square you have drawn.

3. After adjusting, fix the screws (1) with the nuts (2).

¾ The pivoting carriage should only be adjusted by trained personnel.

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LUBRICATION & ADJUSTMENT Replacing the Load and Castor Wheels Replacing the Castor Wheel Suspension

Castor wheel suspension assembly Note: Assembly is the reverse of disassembly. Note the following: 1. Lubricate the bearing (7) with grease (part no.

053002-001).

1

2. Use threadlocker (part no. 053050-006) to fix the screws (3).

2 3 4 5 6

7 8 12 9 11

11

10 12 13 Fig. 18 Castor wheel

Castor wheel suspension removal 1. Remove the screws (3) and take the entire castor wheel out of the truck.

2. Remove the retaining ring (1) and press the castor wheel out of its housing (2).

3. Remove the seal (8), bearing (7) and spacer washers (6).

4. Undo the retaining ring (5) and press the bearing (4) out of the bearing housing (2).

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35

Notes:

36

HYDRAULIC SYSTEM

37

Notes:

38

HYDRAULIC SYSTEM General Instructions

General Instructions

Note: Whenever the hydraulic control module (HCM) or the lowering valve of the main lift (PV) is replaced, the hydraulic system must be calibrated (see page 102).

WARNING High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency.

Seek medical assistance even if the skin appears normal at first.

To avoid accidents:

Hydraulic Unit Components The hydraulic unit consists of the following components:

1

¾ Depressurise the hydraulic system before opening any sections of it.

9

¾ Tighten all connections before pressurising the system.

2

¾ Keep hands and body away from pressurized fluid.

3

¾ Only trace leaks with a piece of paper or cardboard.

8

Hydraulic Lines and Ports •

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

•

Once a steel or plastic line has been bent, it is permanently damaged. It must be replaced even if the damage is not externally visible.

•

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

•

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

•

All connections must be tight and without leaks.

4

7

5 6

Fig. 19 Hydraulic unit

Bleeding the Hydraulic System Whenever work has been performed on hydraulic components, the hydraulic system must be flushed and bled (see page 176).

Drift Test Always perform a drift test after carrying out any work on hydraulic components (see the Cylinders chapter on page 177).

1

Thermal switch (THS)

2

Pump motor

3

Pilot-operated load hold valve (SVCL)

4

Pressure relief valve (RV1)

5

Pump and valve block

6

Main lift lowering valve (PV)

7

Hydraulic oil reservoir

8

Hydraulic Control Module (HCM)

9

Filler neck

Lift Operation Test Whenever work has been performed on hydraulic components, the truck's lift system must be tested. It is important to establish that a load can be raised and lowered smoothly.

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HYDRAULIC SYSTEM General Instructions Hydraulics manifold ports and valves 2

3

4

5

1

9 8

7

6

Fig. 20 Manifold 1

Main lift shutoff valve (SV3)

2

Mast port

3

Pressure line from hydraulic unit port

4

Initial lift port

5

Reservoir return line from hydraulic unit port

6

Initial lift lowering valve (SV2)

7

Pressure relief valve (RV2)

8

Initial lift shutoff valve (SV1)

9

Hydraulics manifold

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HYDRAULIC SYSTEM Hydraulic Diagram - TL Mast

Hydraulic Diagram - TL Mast 8

9

7

10 11

6

12

13

5

14 3 4 2

15

M 1

Fig. 21 Hydraulic Diagram - TL Mast 1

Suction filter

9

Initial lift cylinder

2

Motor and pump

10

Initial lift shutoff valve (SV1)

3

Check valve (CV)

11

Initial lift lowering valve (SV2)

4

Pressure relief valve (RV1)

12

Orifice (ORF1)

5

Pilot-operated load hold valve (SVCL)

13

Pressure relief valve (RV2)

6

Main lift shutoff valve (SV3)

14

Main lift lowering valve (PV)

7

Main lift line break safety valve

15

Lowering brake valve

8

Main lift cylinder

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HYDRAULIC SYSTEM Hydraulic Diagram - TT Mast

Hydraulic Diagram - TT Mast 9 8

8

10

7

7

11

12

13

6

14

15

5

16

3 4

2

17

M 1

Fig. 22 Hydraulic Diagram - TT Mast 1

Suction filter

10

Free lift cylinder line break safety valve

2

Motor and pump

11

Initial lift cylinder

3

Check valve (CV)

12

Initial lift shutoff valve (SV1)

4

Pressure relief valve (RV1)

13

Initial lift lowering valve (SV2)

5

Pilot-operated load hold valve (SVCL)

14

Orifice (ORF1)

6

Main lift shutoff valve (SV3)

15

Pressure relief valve (RV2)

7

Main lift line break safety valve

16

Main lift lowering valve (PV)

8

Main lift cylinder

17

Lowering brake valve

9

Free lift cylinder

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HYDRAULIC SYSTEM Hydraulic Diagram - TF Mast

Hydraulic Diagram - TF Mast 11

9

9

10 8

8

7

7 12

13 14

6

15

16

5

17

3 2

4

18

M 1

Fig. 23 Hydraulic Diagram - TF Mast 1

Suction filter

10

Free lift cylinder line break safety valve

2

Motor and pump

11

Free lift cylinder

3

Check valve (CV)

12

Initial lift cylinder

4

Pressure relief valve (RV1)

13

Initial lift shutoff valve (SV1)

5

Pilot-operated load hold valve (SVCL)

14

Initial lift lowering valve (SV2)

6

Main lift shutoff valve (SV3)

15

Orifice (ORF1)

7

Main lift line break safety valve

16

Pressure relief valve (RV2)

8

Main lift cylinder

17

Main lift lowering valve (PV)

9

Free lift cylinder line break safety valve

18

Flow controller

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HYDRAULIC SYSTEM Functional Description

Functional Description

Initial Lift Lowering and Blocking If the outriggers are fully raised and the forks fully extended, the outriggers (initial lift) lower automatically when the forks are raised to 1900 mm. The forks should brake gently automatically just before the maximum height. Initial lift should be inhibited while the forks are above 1700 mm.

Terminology Explanation •

SV1 = Initial lift shutoff valve

•

SV2 = Initial lift lowering valve

•

SV3 = Main lift shutoff valve

•

SVCL = Pilot-operated load hold valve

•

RV1 = Relief valve, protects the hydraulic circuit from overload

•

RV2 = Second relief valve to restrict the pressure in the Main Lift

•

PV = Main Lift lowering valve

Main Lift, Raise When the raise button (RAS) on the control handle is pressed, the pump contactor engages and the pump delivers oil. Initially the oil is directed back towards the reservoir via the lowering valve (PV) which remains temporarily open. To guide the oil to the Main Lift cylinder, the Main Lift shutoff valve (SV 3) is energized simultaneously with the lowering valve (PV). As the lowering valve (PV) closes, an operating pressure builds up on the Main Lift cylinder (soft lift).

Main Lift, Lower When the lower button is pressed, switches LOS 1 and LOS 2 are applied in turn. This opens the load hold valve (SVCL) and the shutoff valve (SV 3). The lowering speed is governed by the lowering valve (PV) which is simultaneously controlled by the Hydraulic Control Module (HCM). If only the LOS 1 switch is applied, the lowering valve (PV) opens approximately half way. If both LOS 2 and LOS 1 are applied, the lowering valve (PV) opens fully.

Initial Lift, Raise When the initial lift button (ILS Lift) on the control handle is pressed, the pump contactor engages and the pump delivers oil. Initially the oil is directed back towards the reservoir via the lowering valve (PV) which remains temporarily open. To guide the oil to the initial lift cylinders, the initial lift lowering valve (SV 2) is energized simultaneously with the lowering valve (PV). As the lowering valve (PV) closes, an operating pressure builds up on the initial lift cylinders (soft lift).

Initial Lift, Lower When the initial lift lower (ILS Lower) button is pressed, the initial lift lowering valve SV 2 opens and the initial lift cylinders lower.

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HYDRAULIC SYSTEM Repairing the Hydraulic Unit

Repairing the Hydraulic Unit

Fig. 24 Hydraulic unit overview

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HYDRAULIC SYSTEM Repairing the Hydraulic Unit Hydraulic Unit Removal

5. Attach the new suction line (22) to the pump flange with the collar.

6. Insert the flange (18) with the new seals (17, 20) and fix them with the screws (19).

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

Replacing the flow controller 7. Unscrew the flow controller (21) from the pump flange (4) and replace it with a new flow controller.

Replacing the hydraulic oil reservoir 8. Loosen the screw (16) and remove the collar (15).

¾ Lower the forks to the ground.

9. Remove the hydraulic oil reservoir (30).

¾ Switch the truck off.

10. Drain the hydraulic oil via the filler neck (24) into a suitable oil tray.

¾ Disconnect the battery.

11. Dispose of the old hydraulic oil reservoir and hydraulic oil in accordance with environmental regulations.

¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground. Refer to the operator manual instructions (“Transport and Storage” chapter - Jacking up the Truck).

12. Insert new seals and attach the new hydraulic oil reservoir to the hydraulic unit with the collar (15).

13. Add hydraulic oil (see page 47).

Note: The following item numbers refer to Fig. 24 on page 45.

Hydraulic Unit Assembly

1. Depressurise the hydraulic system by following lowering the forks and the initial lift.

Note: Assembly is the reverse of disassembly. Note the following:

2. Depress and hold down the “Lower” button for approx. 10 seconds to relieve the hydraulic pressure.

1. After assembling, bleed and flush the hydraulic system (see page 176).

3. Open the front cover.

2. Perform the drift test (see page 177).

4. Disconnect the hydraulic lines from the manifold.

5. Seal the ports with filler plugs.

6. Disconnect the electrical wires.

7. Loosen all the screws connecting the hydraulic unit to the chassis.

8. Loosen and remove the terminal (1).

9. Take off the entire hydraulic unit including the reservoir.

Hydraulic Unit Servicing The following components can be replaced during servicing.

•

Suction filter

•

Flow controller

•

Hydraulic oil reservoir

1. Loosen the screws (19).

2. Remove the flange (18) and seals (17, 20).

Replacing the suction filter 3. Remove the collars from the suction line (22).

4. Remove the suction line (22) and the filter.

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HYDRAULIC SYSTEM Replacing the Hydraulic Oil

Replacing the Hydraulic Oil To replace the hydraulic oil the reservoir must be removed or the oil drained.

3

1 2

Fig. 25 Replacing the hydraulic oil 1

Hydraulic oil reservoir

2

Level markers

3

Filler neck cap

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

1. Disassemble the entire hydraulic unit (see page 46).

2. Disassemble the hydraulic oil reservoir (1) (see page 46).

3. Add hydraulic oil while observing the level markers (2).

Note: The reservoir capacity is approx. 8.0 litres. Make sure you use the correct oil grade (see page 23).

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47

HYDRAULIC SYSTEM Relief Valve Replacement and Adjustment

Relief Valve Replacement and Adjustment

Relief Valve Assembly

The relief valve (RV1) protects the lifting mechanism from overload; it opens at a pressure of 215 bar.

The valve block relief valve is has a precise factory setting. The valve must be set accordingly if replaced.

Note: In order to set the relief valve, there must be sufficient hydraulic oil in the reservoir.

Note: Assembly is the reverse of disassembly. Note the following: 1. Apply a thin coat of hydraulic oil to the new O ring and position it with the strainer (1) in the valve seat.

2. Apply hydraulic oil to the new relief valve (2), insert it into the valve seat and tighten.

Relief Valve Adjustment

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

4

¾ Lower the forks to the ground.

3

¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Fig. 27 Relief valve adjustment

1. Block the relief valve (2) on the hex. bolt (3) with the screwdriver and loosen the nut (4).

Relief Valve Disassembly

1 2

3 Fig. 26 Relief valve disassembly

1. Disassemble the hydraulic unit (see page 46).

2. Position the screwdriver on the hex. bolt (3) and unscrew the relief valve (2).

3. Remove the filter (1).

5

Fig. 28 Relief valve adjustment

2. Using the hex. key wrench set the required pressure by turning the setscrew (5).

– To increase the pressure: turn the setscrew (5) clockwise.

– To reduce the pressure: turn the setscrew (5) anti-clockwise.

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HYDRAULIC SYSTEM Relief Valve Replacement and Adjustment Note: A quarter turn of the setscrew (5) will reduce or increase the pressure by approx. 15 bar. For the required pressure setting refer also to the next section Testing the Relief Valve.

Note: The rated capacity can be found on the truck's capacity data plate. Make sure that the relief valve setting is within the tolerance range. Reset the relief valve in the event of deviations.

5 4

Fig. 29 Relief valve adjustment

3. When the required pressure has been set, hold the setscrew (5) in place with the hex. key wrench and torque the nut (4) to 9 Nm. 4. Refit the hydraulic unit (see page 46) check the relief valve setting (see following section).

Testing the Relief Valve WARNING Risk of injury and pump damage Non-secured pump units can twist and injure you. The pump and neighbouring components can also be seriously damaged, resulting in short circuits. ¾ Attach the pump unit securely to the chassis before operating it.

1. Raise the forks.

2. With the truck at operating temperature place a test load of 110% of the rated capacity of the initial lift on the outriggers. Ö The load should lift easily.

3. Now place a test load of 110% of the rated capacity of the initial lift +100 kg. Ö It should not be possible to raise this load as the relief valve should open.

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HYDRAULIC SYSTEM Hydraulic System Troubleshooting

Hydraulic System Troubleshooting Symptom

Probable Cause

Remedy

Noisy pump

- Oil level too low.

- Incorrect oil viscosity (e.g. standard oil used in cold store environment).

- Leak in suction pipe union (pump suctions air).

- Filter in suction pipe partly clogged.

- Check oil level.

- Use correct hydraulic oil.

- Check suction pipe connection to pump.

- Replace filter.

Foaming hydraulic oil

- Air in system - Water in oil

- Check oil level.

- Check suction pipe connection to pump.

- Clean reservoir and replace hydraulic oil.

Pump or oil overheating - Incorrect oil viscosity (e.g. cold store oil - Drain oil completely and add oil depending on the application conditions. used at normal temperature).

- Drain oil completely, clean reservoir and - Oil contaminated with water. fill with clean oil.

- Pressure relief valve permanently open - Check oil level.

- Check suction pipe / pump connection (see “Foaming hydraulic oil” symptom).

- Check setting and operation of relief valve (see pages 48 and 49).

Low flow rate

- Air in system.

- See “Foaming hydraulic oil” remedy.

- Pressure relief valve leaky or set too low. - See “Pump or oil overheating” remedy.

- Check setting and operation of relief - Oil too hot. valve (see pages 48 and 49).

No build up of pressure

- Faulty relief valve - Oil level low

- Test relief valve (see pages 48 and 49), replace if faulty.

- Add hydraulic oil.

Lifting delay

- Air in manifold

- Flush the lift cylinders (see page 176).

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DRIVE UNIT

51

Notes:

52

DRIVE UNIT Drive Unit Components

Drive Unit Components The drive unit consists of the following components:

1

4

2

3 Fig. 30 Drive unit components 1

Brake

2

Drive transmission unit

3

Drive wheel

4

Traction motor

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DRIVE UNIT Replacing the Drive Wheel

Replacing the Drive Wheel WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again.

2

1

Fig. 31 Replacing the drive wheel 1

Drive wheel

2

Wheel nut

Drive Wheel Disassembly 1. Loosen the wheel nuts (2).

2. Jack up the truck until the drive wheel is clear of the ground.

3. Remove the wheel nuts (2).

4. Pull the drive wheel (1) off the bolts.

5. Fit the new drive wheel (1).

Drive Wheel Assembly Note: Assembly is the reverse of disassembly. Torque the wheel nuts (2) to 130 Nm.

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DRIVE UNIT Replacing the Drive Unit

Replacing the Drive Unit

WARNING

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

The weight of the drive unit can cause injury The drive unit is heavy, therefore proceed with caution to avoid injury. ¾ Always use a suitable mechanism to remove the drive unit. ¾ Always use two people when removing the drive unit.

¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery.

WARNING

¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground.

Incorrect handling of the lifting gear and slings can cause injury You can be injured if a component falls on you.

Drive Unit Removal

¾ Always use lifting gear and slings with sufficient capacity. ¾ Attach the slings securely to the component to be lifted. ¾ Watch out for your hands as there is a risk of trapping.

4. Place a suitable mechanism under the drive unit (e.g. lift truck with a supporting device) to hold the drive unit.

3

5. Remove all the screws (1) and place the entire drive unit (3) on the device.

1

6. Remove the entire drive unit (3) from the side of the truck.

Drive Unit Assembly 2

Note: Assembly is the reverse of disassembly. Note the following: 1. Apply threadlocker order no. 053050-006 to the screws (1) and torque them to 50 Nm.

1

2. Remove the steering chain (2) and adjust the control handle (see page 118).

Fig. 32 Drive unit 1

Screw

2

Steering chain

3

Drive unit

1. Remove the steering chain (2) (see page 117).

2. Remove the brake connector.

3. Unscrew the electrical wires from the drive motor.

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DRIVE UNIT Replacing the Drive Gear Unit

Replacing the Drive Gear Unit 4

Note: The gear unit must only be repaired by trained and authorised Crown personnel. Failure to do so will invalidate the warranty.

5

CAUTION Incorrect adjustment can damage the gear unit Correcting the tooth flank bearing and pre-tensioning the shaft bearing requires years of experience with gear units.

6

¾ It is preferable to replace the gear unit!

Drive Gear Unit Removal 1. Disassemble the drive wheel (see page 54).

2. Drain the gear oil (see page 61).

3. Remove the entire drive unit (see page 55).

4. Use a suitable device to secure the drive unit and place it on a workbench.

Fig. 34 Drive gear unit

1

3

4

Screw

5

Live ring bearing

6

Gear ring

7. Remove the screws (4) and take off the live ring bearing (5).

8. Take off the gear ring (6).

Drive Gear Unit Assembly CAUTION

2

The gear can be damaged if it is allowed to run dry New drive gear units are supplied without gear oil. ¾ Always add gear oil to new drive gear units.

Note: Assembly is the reverse of disassembly. Note the following:

Fig. 33 Drive unit 1

Screw

2

Drive gear unit

3

Traction motor

1. Add gear oil (see page 61).

2. Assemble the entire gear unit (see page 55).

3. Assemble the drive wheel (see page 54).

5. Remove the screws (1).

6. Lift the traction motor (3) carefully out of the toothing of the drive gear unit (2).

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DRIVE UNIT Repairing the Drive Gear Unit

Repairing the Drive Gear Unit !

'

&

$ %

' "

&

! !

'

!

& "

"

! !

!

# $ $ #

% %

! !

#

Fig. 35 Drive gear unit overview

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DRIVE UNIT Repairing the Drive Gear Unit Drive Gear Unit Disassembly

5. Remove the bevel gear (10).

Note: The gear unit must only be repaired by trained and authorised Crown personnel. Failure to do so will invalidate the warranty.

6. Remove the nut (9).

7. Remove the bevel pinion shaft (5) with an appropriate tool.

8. Remove the ball races of the bearings (2, 3, 12) with an appropriate tool.

CAUTION

9. Remove the shaft seal (15).

Incorrect adjustments and settings will result in premature failure of the gear unit Correcting the tooth flank bearing and pre-tensioning the shaft bearing requires years of experience with gear units.

10. Clean all components, check them for wear and damage and replace them as required.

Drive Gear Unit Assembly The following item numbers refer to Fig. 35, page 57.

¾ It is preferable to replace the gear unit!

Repairing the drive gear unit generally involves the following:

CAUTION

•

Replacing all seals such as shaft seals and O rings.

•

Replacing all bearings.

Used seals cause leaks and bearings can be damaged when removed

•

Cleaning all components of the drive gear unit and removing the remains of the sealant and adhesive.

¾ Replace all bearings and seals.

•

Checking all components for wear and damage and replacing them as required.

1. Remove the cups of the bearings (2, 3, 12) with an appropriate tool.

The following item numbers refer to Fig. 35, page 57.

CAUTION

2. Attach and calk the thread shield ring (4).

3. Insert the oil drain plug (23) with a new seal in the cover and tighten it.

4. Attach a new O ring (21) to the cover.

Bearing and pinion shaft assembly

Health risk Cleaning agents, lubricants and consumables can damage your health.

5. Apply a thin layer of Loctite 307 to where the bearing (3) sits on the pinion shaft (5) and press on the bearing (3) using an appropriate tool.

¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

6. Fit the shim (7) and spacer sleeve (6) onto the pinion shaft (5).

Preparation

7. Insert the pinion shaft (5) from below into the housing (1).

1. Disassemble the drive wheel (see page 54).

8. Insert the second bearing (3) and spur wheel (8).

2. Remove the entire drive unit (see page 55).

9. Screw on the nuts (9) and torque them to 160 Nm.

3. Disassemble the drive gear unit (see page 56).

Assembling the flange shaft with bearing and gear wheels

Removing the ball bearings and shaft seals 1. Remove the screws (33) and take off the gear unit cover (24).

10. Insert the wheel bolt (17) into the flange shaft (16).

11. Place the bearing (2) in its respective ball race.

2. Remove the screws (22) and take off the cover (20).

12. Apply a thin layer of Loctite 307 to the outside diameter of the rotary shaft seal (15) and fit the seal.

3. Remove the screw (19) and take off the washer (18).

13. Apply a thin coat of oil to the sealing lip of the rotary shaft seal (15).

4. Press out the flange shaft (16) with an appropriate tool.

14. Press the shim (11) onto the bevel gear (10) and press on the bearing (12) using an appropriate tool.

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DRIVE UNIT Repairing the Drive Gear Unit 15. Place the shim (14) and the spacer bushing (13) onto the flange shaft (16).

1

16. Insert the flange shaft (16) from below into the housing (1).

2 3

17. Insert the bevel gear (10) and washer (18) and secure them with the screw (19).

18. Adjust the bevel gear set (see next section).

Adjusting the bevel gear set Note: Carry out the checks and adjustments with care as the pre-tension on the bearings and shims will affect the tooth flank bearing. Do not set the pre-tension too low. It will automatically reduce during normal operation.

6

4

Checking the tooth flank bearing The correct setting can be calculated via the permissible tooth flank bearing. Figure 36 shows the limits of the permissible tooth flank bearings on the bevel pinion and bevel gear.

Fig. 36 Permissible tooth flank bearings

Note the following: •

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

•

The tooth flank bearing must always align with the inner tooth end.

•

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

1. Colour the tooth flanks of the bevel gear (10) with touch-up paste (striking colour) or a light oil colour.

5

1

High tooth flank bearing on bevel pinion

2

Bevel pinion

3

Bevel gear

4

Low tooth flank bearing on bevel gear

5

High tooth flank bearing on bevel gear

6

Low tooth flank bearing on bevel pinion

Checking the tooth flank bearing To adjust, add and/or remove shims and/or change the pre-tension of the bearings.

3. Bring the pattern within the tolerance levels (see Fig. 36): – Remove and/or add shims (14, 11, 7).

2. Turn the bevel gear several times in one direction. Ö The tooth flank bearing will appear as a bright point (marked black in Fig. 36) on the tooth flanks.

– Set the bearing pre-tension by changing the torque of the screw (19). The gear unit must be able to turn freely without backlash.

Take care not to exceed the maximum torque of 300 Nm. Note: After adjusting, record the torque level.

4. After adjusting the bevel gear set, remove the screw (19) and apply a coat of Delo 187 threadlocker.

5. Tighten the screw (19) to the previously recorded torque.

6. Replace the nut (9) and torque it to 160 Nm. Ö The bevel gear set is now fully adjusted. The drive gear unit can now be assembled in full.

Assembling the drive gear unit in full 1. Apply a thin layer of oil to the O ring (21) and insert it in the cover (20).

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DRIVE UNIT Repairing the Drive Gear Unit 2. Apply a thin layer of Loctite 307 to the contact surfaces of the housing (1) and the gear unit cover (24).

3. Torque the gear unit cover (24) to the standard rating crosswise.

WARNING Accidents can result if the steering jams Unsuitable greases can jam the steering. ¾ Use low temperature grease for the live ring bearings on cold store trucks.

4. Remove the old grease and clean the live ring bearing.

5. Lubricate / fill the live ring bearing with grease (order no. 053002-005).

Note: On cold store trucks use grease order no.

053002-005.

6. Insert the gear ring (27).

7. Insert the live ring bearing (28) and fix it with the screws (29).

8. Remove any excess grease and clean the entire area.

CAUTION A leaky gear unit can cause accidents Leave the sealing compound and threadlocker to dry for at least 2 hours at room temperature before adding gear oil.

9. Open the oil refill plug (30).

10. Add gear oil (order no. 053002-004) until the oil has reached the thread of the filler port (approx. 1.5 litres).

Note: For cold store versions use gear oil with order no. 53002-009.

11. Fit the bleed cap (26).

12. Insert the oil filler plug (30) with a new seal and tighten it.

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DRIVE UNIT Changing the Gear Oil

Changing the Gear Oil

3. Add gear oil (order no. 053002-004) until the oil has reached the thread of the filler port (approx. 1.5 litres).

Note: For cold store versions use gear oil with order no. 53002-009.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

4. Insert the oil filler plug (30) with a new seal and tighten it.

¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Draining the Oil The item numbers refer to Fig. 35, page 57.

1. Open the front panel of the truck.

2. Turn the control handle to the left as far as the stop.

3. Remove the oil refill plug (30).

4. Turn the control handle to the right as far as the stop.

5. Place a container under the drain plug (23) to collect the gear oil.

6. Remove the drain plug (23) and collect the oil in the container.

7. Dispose of the oil in accordance with environmental regulations.

Adding Gear Oil 1. Clean the oil drain plug (23).

2. Insert the oil drain plug (23) with a new seal and tighten it.

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DRIVE UNIT Repairing the Live Ring Bearing

Repairing the Live Ring Bearing

Installing the Live Ring Bearing

Removing the Live Ring Bearing WARNING

1. Remove the entire drive unit (see page 55).

2. Disassemble the drive gear unit (see page 56).

Accidents can result if the steering jams Unsuitable greases can jam the steering. ¾ Use low temperature grease for the live ring bearings on cold store trucks.

1

2

1. Remove the old grease and clean the live ring bearing.

2. Lubricate / fill the live ring bearing with grease (order no. 053002-005).

3

Note: On cold store trucks use grease order no.

053002-005.

3. Insert the gear ring (3).

4. Insert the live ring bearing (2) and fix it with the screws (1).

5. Remove any excess grease and clean the entire area.

Fig. 37 Live ring bearing 1

Screw

2

Live ring bearing

3

Gear ring

3. Remove the screws (1) and take off the live ring bearing (2).

4. Take off the gear ring (3).

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ELECTRICAL SYSTEM

63

Notes:

64

ELECTRICAL SYSTEM Electrical Components

Electrical Components

•

FU1 protects the power circuit of the traction motor.

•

FU2 protects the control circuit and options.

Brief Description

•

(ALM) Travel alarm

FU3 protects the power circuit of the hydraulic pump.

•

FU4 protects the unigage (BDI).

The travel alarm (alarm transmitter) is activated by the travel alarm driver (DR) when the travel switch is pressed.

•

FU5 protects the cold store options (F/C).

(ARB) Anti roll back module

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.

The ARB module prevents the truck from rolling back on a ramp. If the direction switch is released when the truck is travelling on a ramp, the truck stops and the brake applies. The brake requires a ramp descent of at least 10 impulses on the motor speed sensor (approx.

10 to 20 mm) for it to apply.

(BBD) Battery connector The power supply to the truck is disconnected by pulling the battery connector.

(BDI) Unigage The unigage incorporates the battery discharge indicator and the hourmeter. If the battery voltage is too low there is a lift cutout (for setting, see Electrical chapter).

(BRK) Brake The override switch (ORS) or brake switch (BRS) transmit a positive signal to the traction controller. The traction controller then releases the brake.

(BRS) Brake switch The brake switch (BRS) is immediately below the control handle support. As soon as the control handle reaches the upper braking zone (3, see page 66) or lower braking zone (1, see page 66), the brake switch is activated. The traction controller interrupts the power supply to the traction motor (TM) and the brake (BR).

The brake coil is switched off and the anchor plate is pressed against the brake through bias spring force.

(EDS) Emergency Disconnect switch Pushing the Emergency Disconnect switch disconnects vehicle power.

(F/R Contactor) Direction contactor The direction contactor changes the polarity of the power circuit current to the traction motor anchor coil.

It is governed by the traction control module.

(FU) Fuses

(HCM) Hydraulic control module

(HM) Horn The horn is activated via horn switches HNS1 / HNS2 via the drivers on the main circuit board.

(HNS1 & HNS2) Horn switches A buzzer sounds when the horn button is pressed.

(HSS) “Rabbit/Turtle” toggle switch The toggle switch for the travel speed levels (rabbit/turtle symbol) is located on the control handle. The switch signal to the traction controller is used to change between the high and slow speed ranges. The switch is connected in series to the limit switch (LMS).

(HYD PCB) Hydraulic printed circuit board The hydraulic printed circuit board contains the raise (RAS) and lower (LOS1, LOS2) switches. The hydraulic printed circuit board also distributes positive supply to the heating resistors / thermostat.

On the cold store version the hydraulic printed circuit board is equipped with heating resistors.

(ILS Lift & ILS Lower) Initial lift switches The initial lift-lift (ILS Lift) and initial lift-lower (ILS Lower) switches are located in the lower part of the control handle. They are actuated via a common rocker.

The initial lift-lift switch energises the pump motor (PM) via the pump contactor (P) and the pump starts. The pump contactor is connected via the hydraulic control module (HCM).

The initial lift-lower switch applies voltage to the solenoid (SV) via the hydraulic control module (HCM) and the solenoid opens.

The entire truck circuit is protected by the following fuses: WI 2300

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ELECTRICAL SYSTEM Electrical Components (KYS) Key switch The key switch directs the battery supply to the traction controller and the battery discharge indicator (BDI).

3

(LMS - initial) Limit switch

4

If the initial lift reaches the LMS - initial limit switch at 130 mm, the initial lift is cut off by interrupting the power circuit.

2

(LMS - 1700 mm) Limit switch If the main lift reaches the LMS - 1700 mm limit switch at 1700 mm, the initial lift is automatically lowered. This is controlled by the hydraulic control module (HCM).

The lift and travel speeds are also reduced.

1

(LOS1, LOS2) Lower switches The 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 (LOS) and (RAS) are electrically locked in pairs so that they cannot both apply at the same time.

The initial lift-lower switch (LOS) applies voltage to the solenoid (SV) via the hydraulic control module (HCM) and the solenoid opens.

(MAIN PCB) Main circuit board The main circuit board contains driver connections for switches SAS, FS, RS, POT, HNS1 and HNS2 and a thermostat switch (THS). On cold store trucks the thermal switch connects the control handle heaters when the temperature drops below 5°C, and switches them off when the temperature exceeds 15°C.

(ORS) Override switch The override switch (ORS) is immediately below the control handle support. As soon as the control handle enters the brake override zone (4) the override switch (ORS) sends a signal to the traction controller with the resulting slow travel option (by pressing the traction pod). This provides better shunt operation in restricted conditions.

(PM / M2) Pump motor The pump motor drives the hydraulic pump. It is controlled by the hydraulic control module (HCM) via the pump contactor (P).

Fig. 38 Control handle positions 1

Brake zone

2

Drive zone

3

Brake position, parking brake

4

Brake override zone

(P) Pump contactor The pump contactor connects positive power supply to the truck's pump motor. It is governed by the hydraulic control module (HCM).

(PCB) Distributor PCB The distributor PCB receives control signals which are used to control the drivers for the horn, pump, brake and lowering valve. The distributor PCB also receives control signals which are transmitted directly to the control module. For access to the distributor PCB and components see page 22.

(POT, FS, RS) Traction pod The traction pod is manually actuated via the 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. On cold store versions the potentiometer (POT) is heated.

(PV) Proportional valve The proportional valve opens temporarily on lifting to reduce overpressure (soft lift). It opens half-way or fully on lowering, depending on the lowering speed selected (LOS1, LOS2).

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ELECTRICAL SYSTEM Electrical Components (RAS) Raise switch The raise (RAS) switch is activated via a rocker switch in the control handle. The rocker switches act on the switch which is assembled on the circuit board of the control handle. The switches (LOS) and (RAS) are electrically locked in pairs so that they cannot both apply at the same time.

The lift (RAS) switch activates the pump contactor (P) which is controlled by the hydraulic control module (HCM). The pump starts.

(SAS) Safety reverse switch The safety reverse switch (SAS) is activated via the switch cap at the top of the control handle. When this is applied, the truck changes from forward to reverse travel. The signal for normal travel to the traction controller is simultaneously interrupted. Depending on the traction controller setting the truck reverses either for a given time, or for as long as SAS is applied.

(THS) Thermal switch The thermal switch is an electronic thermostat for cold store trucks. It is located on the main PCB of the control handle and applies the heaters at temperatures below 5°C and switches them off at 15°C.

(THS1) Motor thermal switch If the pump motor reaches a temperature of 170°C, the motor thermal switch turns the pump motor off. The pump motor starts again when the temperature reaches approx. 140°C.

(TM / M1) Traction motor The traction motor is a compound motor and is governed by the traction controller.

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ELECTRICAL SYSTEM Electrical Component Assembly Location

Electrical Component Assembly Location

LMS - 1700

LMS - Speed Fast/Slow

EDS

BDI (CA405) + TT

LMS1 Initial

KYS

MAIN PCB (CA410, CA411, CA412, CA413, CA414, CA415, CA416, THS)

BATT

HYD PCB

HSS (CA414)

LOS1, LOS2 CA415 RAS HNS1 (CA417) HNS2 (CA419) SAS (CA412) POT PCB F/C (CA416)

POT, FS, RS (CA411)

Fig. 39 Electrical component assembly location

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ELECTRICAL SYSTEM Electrical Component Assembly Location

BRS (CA406) ILS - Lift/Lower (CA420)

HN

BRK (CA402)

ORS (CA407)

Distribution Panel SF (CA401) TM / M1 TCM (CA403) F/R Contactor

FU1 ALM FU3

P

THS1

PM / M2

SVCL

PV

ARB

HCM (CA221) Fig. 40 Electrical component assembly location

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ELECTRICAL SYSTEM Electrical Component Assembly Location Distributor PCB components

7

8

6

1

5

2 4

3

Fig. 41 Distributor PCB 1

CA204

2

CA205

3

CA203

4

CA202

5

CA201

6

Fuse FU4

7

Fuse FU2

8

Fuse FU5

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ELECTRICAL SYSTEM Traction Controller 1207

Traction Controller 1207

Error Logging

The following is a list of the most important traction controller functions.

Errors are logged in the controller memory. It contains all the errors that have occurred since the last time the diagnostic history was cleared. Multiple occurrences of an individual error are recorded as a single event.

Key switch The key switch input energises the logic part of the controller and starts the power-up diagnostics. In conjunction with the brake input the key switch input releases all the logic functions of the controller.

The error logging function can be loaded via the SPECIAL DIAGNOSTICS menu in the programmer.

Current limit The current limit function reduces the PWM signal (PWM = pulse width modulation) to the controller power part until the motor current falls below the value of the current limit.

Overvoltage protection In the event of overvoltage the pulse width modulation (PWM) cuts out and opens the contactors. When the permissible voltage has been reached the controller resumes operation.

Overtemperature protection From a power stage temperature of 85°C the output current is linearly reduced until it is zero at 95°C.

Performance reduction for low voltage If the battery voltage drops below a defined level, the controller proportionally reduces the output current, This reduces the maximum speed (which is current-dependent).

If the battery voltage rises back over the defined low voltage level, the controller proportionally increases the output current. This ensures that the output, as a produce of current and voltage, remains constant.

Fault identification The internal microprocessor monitors the controller.

When a fault is identified, the status LED on the controller flashes a fault code.

If it is a critical error, the controller cuts out. For transient errors such as a low voltage error, the error message automatically goes out when the error no longer applies.

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ELECTRICAL SYSTEM Traction Controller Operator Panel

Traction Controller Operator Panel

Connecting the Programmer The connecting cable of the programmer is attached to the socket (5).

Note: If the parameters are changed via the programmer the potentiometers must be set to OFF.

1

Status LED Display During normal operation the status LED (4) flashes approximately every second. If there is a fault, the status LED flashes a two-digit code continually until the fault is rectified. The status LED (4) always shows the most recent fault on the controller. An overview of the possible status LED displays can be found on page 73.

2

Fig. 42 Traction controller 1

Traction controller

2

Panel

The operator panel is located under the removable panel (2).

3

MAIN

PLUG

4

CREEP ACCEL.

CURRENT LIMIT

LOW

STATUS

SPEED LIMIT

5 Fig. 43 Traction controller operator panel 3

Potentiometer

4

Status LED

5

Programmer socket

Potentiometer Adjustment The potentiometers (3) can be used to adjust: •

Maximum travel current (MAIN)

•

Maximum plugging current (PLUG)

•

Acceleration time (ACCEL.)

•

Maximum creep speed

•

Maximum slow travel speed (LOW).

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ELECTRICAL SYSTEM Traction Controller Operator Panel Status LED Display Overview

Description of symbols used:

Note: During normal operation the status LED flashes approximately every second. The status LED always shows the most recent fault on the controller.

⊗ Ο ∗

LED off.

–

Flashing signal interval.

LED permanently lit.

LED flashes once.

Status LED

Programmer Display

Description

Probable Cause

⊗

None

Traction controller not active

Power supply interrupted or traction controller faulty

Ο

Unspecified

Traction module faulty

-

∗_∗∗

HW FAILSAFE

Hardware fault

Controller faulty

∗_∗∗∗

M- FAULT

M- output shorted

M- output frame leakage.

Short circuit in motor.

Direction contactor not closed.

Direction contactor not closed fast enough.

Short circuit between motor and housing.

∗_∗∗∗∗

SRO

Power-up sequence error.

Incorrect power-up sequence of key switch, brake and direction switch.

Wrong SRO type selected.

Brake or wiring of travel direction switch disconnected.

Sequencing delay too short.

∗∗_∗

THROTTLE FAULT 1

Traction potentiometer malfunction.

Potentiometer wire disconnected.

Potentiometer input shorted to B -.

Travel switch potentiometer faulty.

Incorrect travel switch type selected.

∗∗_∗∗

BB WIRING CHECK

Safety reverse switch circuit check failed.

Safety reverse switch (SAS) wiring faulty.

∗∗_∗∗∗

HPD

Travel switch applied when truck switched on.

Incorrect starting sequence.

Incorrect HPD type selected.

∗∗_∗∗∗∗

THROTTLE FAULT 2

Traction potentiometer malfunction.

Earth wire shorted.

Potentiometer wiring disconnected.

Incorrect travel switch type selected.

∗∗∗_∗

CONT DRVR OC

Overcurrent in contactor driver. Short circuit in direction contactor coil.

Short circuit in motor shunt coil or wiring.

∗∗∗_∗∗

DIR CONT WELDED

Direction contacts are welded. Direction contactor contacts are welded or jamming.

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ELECTRICAL SYSTEM Traction Controller Operator Panel Status LED

Programmer Display

Description

∗∗∗_∗∗∗

MISSING CONTACTOR

Wiring to direction contactor or Direction contactor coil is open. shunt field open.

Direction contactor coil missing.

Shunt coil connection is open.

Direction contactor wiring disconnected.

∗∗∗∗_∗

LOW BATTERY VOLT- Battery voltage too low.

AGE

Battery voltage below 16 V

∗∗∗∗_∗∗

OVERVOLTAGE

Overvoltage

Battery voltage above 16 V

∗∗∗∗_∗∗∗

THERMAL CUTBACK

Reduction in travel speed due Traction controller temperature to traction controller high or low above +85 °C or below -25 °C. temperature.

Truck overloaded.

Controller fitted incorrectly.

Extreme ambient conditions.

Troubleshooting

Probable Cause

The exceptions are:

Most faults can be rectified by resetting the controller by switching the truck off and on with the key switch or by activating and deactivating the brake.

Fault

Remedy

Contactor coil overvoltage

Automatic as soon as the current drops to normal levels.

Safety reverse switch

Apply safety reverse switch or brake.

Travel switch collision protection

Pull back the travel switch until it is below the limit.

Overvoltage

Automatic as soon as the battery voltage drops below the limit.

Travel direction switch start-up protec- Keep the correct power-up sequence. tion Overtemperature

Automatic when the temperature drops again.

Travel switch error

On attaining the normal travel switch signal.

Low voltage

Automatic as soon as the battery voltage rises above the limit.

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ELECTRICAL SYSTEM Traction Controller Servicing

Traction Controller Servicing WARNING Short circuits can cause fires The traction controller operates with high currents. Particular safety measures are therefore required when handling the controller. ¾ You must be trained to carry out this work. ¾ Wear close-fitting clothing and goggles. ¾ Do not wear jewellery or other metal objects. ¾ Always use insulated tools.

Service work on the traction controller is restricted to: •

External cleaning.

•

Checking any errors logged using the programmer.

Cleaning the Traction Controller WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Discharging the capacitors 1. Short the positive and negative terminals of the traction control module over a resistor (10 - 100 Ω, min. 5 W) for a few seconds.

Cleaning the traction controller 2. Remove the power cable.

3. Remove any dirt and corrosion from the contact surfaces.

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

5. Dry the traction controller.

6. Refit the power cables to the traction controller and torque the nuts to 5 Nm. WI 2300

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ELECTRICAL SYSTEM PMT Test

PMT Test

7. Apply the brake switch.

EN 1175-1 requires regular inspection of the safety circuits of electronic control modules in electric lift trucks, which is known as the PMT test (Pulse Monitor Trip Test).

We recommend that this test be carried out at least annually as part of planned maintenance (see page 25) on the traction control module (TCM).

Ö The status LED on the traction controller (see page 72) flashes as follows: ∗_∗∗∗ (see table on page 73). Ö The programmer display shows M- FAULT (see table on page 73).

8. Select forward or reverse with the direction switch.

Note: The PMT test is successful if the traction motor does not start now.

WARNING

WARNING

Accident risk from accidental start-up during test If a safety circuit is faulty, the truck or parts of it can suddenly move. Fatal accidents may result.

Accident risk from traction controller malfunctions Traction controllers that have failed the PMT test have a fault in their safety circuits.

¾ Before carrying out the safety test jack up the truck so that the drive wheel is clear of the ground.

¾ Replace any traction controllers that have failed their PMT test.

¾ Insert wedges under the load wheels.

¾ Repeat the PMT test on the new traction controller.

WARNING Risk of scalding and injury to eyes The power fuse can burn, causing burning metal particles to explode. These particles can cause serious eye injuries and scald the skin. ¾ Always wear protective glasses and appropriate protective clothing. ¾ Only use encapsulated power fuses. With these fuses, the fuse strip is covered to prevent liquid metal particles from spraying.

Preparing the test wire 1. Prepare a test wire > 1.5 mm2, with a 10 A fuse and an insulated clip at each end.

Preparing the truck 2. Switch the truck off 3. Jack up the truck until the drive wheel is clear of the ground.

PMT Test 4. Attach the test wire (2) to B- and M- of the traction controller (see Fig. 44).

5. Connect the programmer to the traction controller.

6. Power up the truck.

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ELECTRICAL SYSTEM PMT Test Wiring Diagram

PMT Test Wiring Diagram

B+ A2 FU4 2A

FU2 10A

EDS

FU1 D1 125A

D2

F D2 A2 F TM R A1 R

1

MB-

2

PC 1:1

24V

PC 1:2

Fig. 44 PMT test wiring diagram 1

Traction controller

2

Test wire

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ELECTRICAL SYSTEM 1307 Programmer

1307 Programmer The programmer 1307 enables the traction controller to be programmed and tested. A diagnosis of the traction controller can also be produced.

The programmer is connected to the traction controller via a cable. The programmer is powered via the traction controller.

Operation

The display screen (7) contains a 4-row LCD display.

The display contrast can be adjusted in the SPECIAL PROGRAM MODE menu.

The display shows four lines of a menu at the same time. Use the SCROLL DISPLAY keys (5) to display the other lines.

The PROGRAM (6), TEST (1) and DIAGNOSTIC (2) keys allow the function menu to be selected.

Use the SCROLL DISPLAY keys (5) to scroll up and down the display in the window.

The CHANGE VALUES keys (3) change the value of the parameter selected.

7 1 2 6 3

The MORE INFO key (4) provides further information on the row selected in the three menus. Pressing the MORE INFO key (4) and the PROGRAM (6) or DIAGNOSTICS key (2) simultaneously brings you to the Special Program menu or the Special Diagnostics menu.

If you wish to select a specific menu item it must be displayed in the top row. The menu item selected is highlighted in programming mode by a flashing arrow (= cursor). Only in this position can a parameter be changed or information relating to the parameter retrieved.

All keys, with the exception of the SCROLL DISPLAY keys (5), contain an LED. When the key is pressed the LED illuminates and shows the menu being used.

5

The LED in the CHANGE VALUE keys (3) is permanently lit when you reach the limit and cannot be further adjusted.

4

Connecting the Programmer WARNING

Fig. 45 1307 programmer

Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

1

TEST key

¾ Lower the forks to the ground.

2

DIAGNOSTIC key

3

CHANGE VALUE key

¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

4

MORE INFO key

5

SCROLL DISPLAY key

6

PROGRAM key

7

Display screen

1. Connect the programmer to the traction controller socket (see Fig. 43, page 72).

Note: Make sure the brake switch is not applied when you connect the programmer to the controller.

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ELECTRICAL SYSTEM 1307 Programmer When all the data has been read from the controller, the programmer will show the model number of the controller, the manufacturing date and the software version. After these displays the programmer will request further entries.

More information on the various parameters is available in all the programmer menus. To return to the list, press the MORE INFO key (4) again.

PROGRAM key

Key Function Description SCROLL DISPLAY keys Use the SCROLL DISPLAY keys (5) to scroll up and down the menu. The keys can be pressed repeatedly or held down.

If one of the keys is held down, the display will scroll with increasing speed until you let go of the key.

Fig. 47 Programming mode

The PROGRAM key (6) switches programming mode on.

The display screen shows a menu in list form for all the adjustable parameters and functions of the controller, with the current settings. Use the SCROLL DISPLAY keys (5) to scroll through the list.

8

Fig. 46 Scroll bar in the PROGRAM menu

A small scroll bar (8) shows the current position in the four menu items displayed. When the scroll bar (8) is at the top border the start of the menu is displayed. As you scroll through the menu the scroll bar moves down.

When the scroll bar is at the bottom border you have reached the end of the menu.

CHANGE VALUE keys Use the CHANGE VALUE keys (3) to increase or reduce the value of the parameter selected in the menu.

The keys can be pressed repeatedly or held down. The longer a key is pressed, the faster the parameter value will change. An LED on each key indicates the activity status of that key. When a parameter is changed the LED on the key remains illuminated until the maximum value for this parameter is reached. If the LED goes out this indicates that the parameter cannot be changed any further.

Fig. 48 Extended display

The MORE INFO key (4) provides an extended display of the selected parameter with a bar graph, the current value as well as the minimum and maximum values for this parameter.

Parameters can be changed either directly in the list or, after pressing the MORE INFO key, in the extended display.

Note: The setting range for a particular parameter depends on other parameters.

For example the controller will not permit the traction current limit to be less than the present setting for the collision protection current limit. If you try to set the traction current limit less, a display message will refer you to the dependency.

TEST key

MORE INFO key •

To display more information about the menu item selected.

•

To start specific special functions (e.g. self test).

Pressing the TEST key (1) activates Test mode. The test menu is used for testing after installation and for troubleshooting. The display provides information in real time on the status of the inputs and outputs as well as the controller temperature.

•

To select the SPECIAL-PROGRAM or SPECIALDIAGNOSTIC menus (when pressed in conjunction with the PROGRAM (6) or DIAGNOSTICS (2) keys).

The required menu item does not have to be in the top row of the display in the test menu list. It only has to be in the 4 rows shown in the display. The SCROLL DISPLAY keys (5) can also be used to scroll.

The MORE INFO key (4) has three functions:

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ELECTRICAL SYSTEM 1307 Programmer Pressing the MORE INFO key (4) while the programmer is in test mode provides more information. Abbreviations are then explained in detail. The parameter in question must be selected, i.e. must be in the top row.

1. Set the programmer to the SPECIAL-PROGRAM mode.

DIAGNOSTIC key

Copying controller settings

Pressing the DIAGNOSTIC key (2) brings up current errors. Pressing the MORE INFO key (4) menu mode brings up details on abbreviations.

The menu items of the special program Save Controller Settings in Programmer and Load Programmer Settings into Controller allow you to copy controllers.

SPECIAL DIAGNOSTIC menu

To do this simply program a controller with the required parameters and save the settings in the programmer (Save Controller Settings in Programmer). Now load the program into another controller with the same model number (Load Programmer Settings into Controller).

This mode shows the controller's error log. It contains all the faults that have occurred since the last time the error log was cleared. If the same fault has occurred several times, it is only logged once.

The controller's maximum and minimum temperatures can be seen in the TEST menu.

Selecting the SPECIAL DIAGNOSTIC menu 2. Press the LED on the DIAGNOSTICS key (2). Ö The LED on the DIAGNOSTICS key illuminates as if the programmer were in diagnostic mode.

More information on the item selected can be viewed by pressing the MORE INFO key (4). The error log can only be cleared in the SPECIAL PROGRAM menu.

A number of tasks can be performed in the SPECIAL PROGRAM menu: •

Copy settings, load them into new controllers and clear the logs.

Immediately after the programmer is connected to a controller the controller's program is read and stored in the programmer's memory.

To restore the original settings in the Revert to Previous Settings row, press the MORE INFO key and follow the instructions. All the previous settings will be overwritten.

Programmer self-test

SPECIAL PROGRAM Menu Revert to original settings after changes.

Reverting to original settings

While the truck is switched on and the programmer connected to the controller, you can access the original settings at any time during programming via the SPECIAL PROGRAM menu.

1. Press and hold down the MORE INFO key (4).

•

2. Select the "Clear Diagnostic History" menu item and press the MORE INFO key (4).

The programmer is checked by means of two test screens. Proceed as follows: 1. Switch off the truck and connect the programmer to the controller.

2. Press the MORE INFO key as you turn the key switch on.

Selecting the SPECIAL PROGRAM menu

3. Use the SCROLL DISPLAY keys (5) to select the first test display.

1. Hold down the MORE INFO key.

Ö Each LCD segment is switched on.

2. Press the PROGRAM key.

4. Use the SCROLL DISPLAY keys (5) to select the second test display.

Ö The LED on the PROGRAM key illuminates as if the programmer were in diagnostic mode.

Selecting a menu item (the first row is always the one selected) with the SCROLL DISPLAY keys and pressing the MORE INFO key (4) again opens up a submenu. Here you can change the function selected.

Pressing the MORE INFO key (4) again returns you to the selection menu.

Ö All the characters used in the menus are displayed.

Note: To test the keys, the LEDs in the respective keys should illuminate during the self test. To end the selftest turn the key switch off.

Clearing the error log Clearing the log also deletes the maximum and minimum temperature values in the test menu.

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ELECTRICAL SYSTEM 1311 Programmer

1311 Programmer The 1311 programmer is the successor to the 1307 model. It is available under part no. 130475 and comes with connection cables part no.130480 (4 pin Molex connector) and part no. 130481 (RJ11 connector).

Program Monitor Faults Functions Information Programmer Setup

The 1311 programmer can be used for the following Curtis traction controllers: •

Model 1207

•

Model 1214

•

Model 1703

Fig. 50 Main menu

The programmer is powered via the traction controller.

Operation

You are at the highest level of the main menu. A flashing rectangle on the left border shows the cursor position. Use the navigation keys (4) to move the cursor up and down.

Menus without entries are not displayed.

The right arrow key of the navigation key (4) opens an entry in the main menu. A right-indented sub-menu is displayed.

1

Program Max Speed Acceleration Monitor Faults Functions Information

4

2

92% 1.2s

Fig. 51 Sub-menu display

Details can be viewed in a sub-menu of the programmer menu. Press the right arrow key of the navigation key (4) to display more information and a bar chart.

3 Fig. 49 1311 programmer 1

Display screen

2

Data+/- key

3

Highlighter keys 1 to 3

4

Navigation key

Program Max Speed

92% Min 10

Note: The following is a description of how to operate the programmer with the programming menu. The navigation description also applies to all the other menus.

When the programmer is connected it shows the controller's model number, manufacturing date and software version. The display then shows the main menu.

Max 100

Fig. 52 Bar chart

Use the data +/- key (2) to change the setting of the parameter displayed. Press the left arrow key of the navigation key (4) to switch back to the next highest menu level.

To highlight an item in the menu, press down on one of the highlighter keys (3). After 3 seconds this highlight

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ELECTRICAL SYSTEM 1311 Programmer will be confirmed on the display screen. To move to a set highlighted item, press the appropriate highlighter key (3).

Note: The highlights are not stored permanently.

The highlights are deleted if: •

The programmer is disconnected from the controller.

•

The truck is switched off.

Adjusting the programmer Various configurations and information can be accessed via the PROGRAM menu. The following shows the structure of the PROGRAM menu: PROGRAM – LCD CONTRAST – LANGUAGE – INFORMATION

Menus

– OEM INFO – RECONFIGURED

Main menu The main menu is displayed when the programmer is connected. All the basic functions can be selected from the main menu.

– MODEL NUMBER – SERIAL NUMBER – MANUFACTURING DATE – SOFTWARE VERSION

Programmer menu The programming menu can contain several submenus with parameters. This menu is used to adapt the truck to the operating conditions and the application.

– HARDWARE VERSION – MC-PROTOCOL VER – ES-PROTOCOL VER – S-PROTOCOL VER – DEVICE TYPE

Monitor menu The monitor menu contains a list of all the variables that can be read and displayed.

Fault menu The fault menu shows the current faults. It can also be used to clear the fault history. It contains the sub-items: – SYSTEM FAULTS – FAULT HISTORY – CLEAR FAULT HISTORY

Functions The 1311 programmer can also be used to copy data between similar models, to reset data and for other model-specific functions. The following shows the structure of the SETTING menu: SETTINGS – GET SETTINGS FROM CONTROLLER – WRITE SETTINGS TO CONTROLLER – RESET ALL SETTINGS

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ELECTRICAL SYSTEM 1311 Programmer Menu Terms PROGRAM Menu Display

Meaning

MAIN C / L

Traction current limit

L / S MAIN C / L

Traction current limit, at low speed

PLUG C / L

Plugging current limit

L / PLUG C / L

Plugging current limit, at low speed

EMR REV C / L

Safety reverse switch current limit

L / S EMR REV C / L

Safety reverse switch current limit, at low speed

RAMP C / L

Ramp start current limit

L / S RAMP C / L

Ramp start current limit, at low speed

ACCEL RATE

Acceleration rate in seconds

THROTTLE TYPE

Travel switch type

RAMPE SHAPE

Ramp shape

CREEP SPEED

Creep speed as a % of maximum speed

LOW SPEED

Low speed as a % of maximum speed

EMR REV SPEED

Safety reverse switch speed as a % of maximum speed

SEQUENCING DLY

Delay in checking the power-up sequence

VARIANBLE PLUG

Varying the brake current with the travel switch

HIGH PEDAL DIS

Travel switch start up protection (potentiometer)

SRO

Direction switch start up protection (SRO)

ANTI - TIEDOWN

Anti-tie down: on or off

QUICK START

Quick start rate

TEST menu Display

Meaning

FORWARD INPUT

Forward switch: on / off

REVERSE INPUT

Reverse switch on / off

BRAKE INPUT

Brake switch: on / off

THROTTLE %

Travel switch signal as a % of maximum speed

SPEED IN

Rapid travel switch: on / off

EMR. REV INPUT

Safety reverse switch: on / off

MAIN CONTACTOR

Main contactor: on / off

FWD CONTACTOR

Forward contactor: on / off

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ELECTRICAL SYSTEM 1311 Programmer Display

Meaning

REV CONTACTOR

Reverse contactor: on / off

BATT VOLTAGE

Battery voltage

HEATSINK °C

Heatsink temperature

MAX TEMP °C

Max. recorded heatsink temperature (cannot be used)

MIN TEMP °C

Minimum recorded heatsink temperature

DIAGNOSTICS and SPECIAL DIAGNOSTICS menus Display

Meaning

WIRING CHECK

Error checking the safety reverse switch

CONT DRVR OC

Current through contactor driver too high

DIR CONT WELDED

Direction contactor contacts jammed

HPD

Travel switch start up protection activated

HW FAILSAFE

Hardware safety device activated

LOW BATTERY VOLTAGE

Battery voltage too low (< 16 V)

M - SHORTED

Short circuit on M- output to B-

MISSING CONTACTOR

Contactor control circuit cutout

NO KNOW FAULTS

Controller has not detected any errors

OVERVOLTAGE

Battery voltage too high (> 45 V)

SRO

Direction switch start up protection activated

THERMAL CUTBACK

Reduction due to overtemperature or low temperature

THROTTLE FAULT 1

Travel switch error (incorrect value)

THROTTLE FAULT 2

Travel switch error (wire disconnected)

SPECIAL PROGRAM menu Display

Meaning

RESET ALL SETTINGS

Revert to initial settings

CONT SETTING-> PROG

Store controller settings in programmer

PROG SETTINGS-> CONT

Load settings from programmer into controller

CLEAR DIAG HISTORY

Clear error log

CONTRAST ADJUSTMENT

Adjust the contrast display

LANGUAGE SELECTION

Select display language

PROGRAMMER INFO

View programmer information

CONTROLLER INFO

View controller information

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ELECTRICAL SYSTEM Traction Controller Settings

Traction Controller Settings Program Menu Menu item

Setting range

Setting

Description

MAIN C / L

20 - 250 A

180

Traction current limit

PLUG C / L

20 - 250 A

110

Plugging current limit

ACELL RATE

0-3s

1,0

Acceleration

CREEP SPEED

0 - 25 %

0

Creep speed

LOW SPEED

40 - 100 %

40

Low speed

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ELECTRICAL SYSTEM Replacing the Display Instrument

Replacing the Display Instrument The display instrument consists of the battery discharge indicator (1) and the hourmeter (2).

1

Glass panel

2

Display instrument

3

Screw

4

Mount

1. Move the front panel out.

2. Remove the dashboard.

1

3. Remove connector CA405 from the display instrument.

4. Loosen the screws (3) and take off the mount (4).

5. Remove the glass panel (1) and display instrument (2).

Note: The display instrument cannot be repaired.

Record the elapsed service hours when replacing the display instrument.

Display Instrument Assembly 2

Note: Assembly is the reverse of disassembly.

Battery Discharge Indicator (BDI) Information

Fig. 53 Display instrument 1

Battery discharge indicator (BDI)

2

Hourmeter (TT)

Display Instrument Removal 1 2 4

3

Note: The following information applies to wet cell batteries only. Note that only wet cell batteries can be used for this truck.

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 effective output of 400 amp hours.

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

The battery discharge indicator must therefore be set according to the truck's particular application conditions.

Lift cutout 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 become damaged.

Fig. 54 Display instrument removal

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.

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ELECTRICAL SYSTEM Replacing the Display Instrument The lift cutout should therefore be activated as close to 20% of the battery's residual capacity as possible. It may be slightly above 20% but never below this level.

Finally, via the potentiometer (1) on the back of the BDI the display is set to the actual discharge terminal voltage of the battery at 20% residual capacity.

Note: For new trucks the battery discharge indicator should be set at the latest after ten discharge and charge cycles.

The standard factory setting for the battery discharge indicator is "N".

Battery Discharge Indicator (BDI) Adjustment

1. Fully charge the battery according to the battery manufacturer’s service instructions.

Wet cell battery calibration

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

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.

3. Operate the truck in its normal environment until the battery is empty. Ö Both LEDs of the BDI will flash and the lift cutout system will be activated.

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

4. Leave the battery if possible for 10 to 12 hours (one hour at least!).

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

6. Compare the density recorded with the density specified by the battery manufacturer for an 80% discharged battery (20% residual capacity): Note: If the battery is more than 80% discharged (less than 20% residual capacity), set the potentiometer (1) to direction U. If the battery is less than 80% discharged (less than 20% residual capacity), set the potentiometer (1) to direction K. 7. Recharge the battery and check the calibration.

Repeat the calibration as required.

1 Fig. 55 Potentiometer on BDI

Discharge terminal voltage setting in volts/cell K

L

M

N

O

P

Q

R

S

T

U

1.57

1.63

1.68

1.73

1.78

1.82

1.84

1.86

1.89

1.91

1.93

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ELECTRICAL SYSTEM Replacing the Key Switch (KYS)

Replacing the Key Switch (KYS)

Key Switch Assembly Note: Assembly is the reverse of disassembly.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

1

Fig. 56 Replacing the key switch 1

Key switch

Key Switch Removal 1. Move the front panel out.

2. Remove the dashboard.

3. Remove both plug connectors from the key switch (1).

4. Unscrew the ring nut and remove the shim.

5. Take out the key switch (1).

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ELECTRICAL SYSTEM Replacing the LMS-Initial Limit Switch

Replacing the LMS-Initial Limit Switch

Limit Switch Removal 1. Disconnect PC422 from the main wire harness.

2. Loosen the screws (2) and remove the limit switch (1).

Limit Switch Assembly Note: Assembly is the reverse of disassembly. Note the following:

1

1. After assembling, adjust the limit switch (1) via the slotted holes so that the initial lift automatically cuts out at an initial lift height of 130 mm.

Fig. 57 LMS-initial limit switch assembly location 1

LMS - initial limit switch (viewed from above)

1

2

Fig. 58 LMS-Initial limit switch 2

Screw

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ELECTRICAL SYSTEM Replacing the LMS-1700 mm Limit Switch

Replacing the LMS-1700 mm Limit Switch

Limit Switch Removal 1. Disconnect PC421 from the main wire harness.

If the main lift reaches the LMS - 1700 mm limit switch at 1700 mm, the initial lift is automatically lowered. This is controlled by the hydraulic control module (HCM).

The lift and travel speeds are also reduced.

2. Loosen the screws (2) and remove the limit switch (1).

Limit Switch Assembly Note: Assembly is the reverse of disassembly.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

1 2

Fig. 59 LMS-1700 limit switch 1

LMS-1700 mm limit switch

2

Screw

WI 2300

90

ELECTRICAL SYSTEM Replacing the Override Switch (ORS) and the Brake Switch (BRS)

Replacing the Override Switch (ORS) and the Brake Switch (BRS) For more information on the override switch (ORS) see page 66 and for the brake switch (BRS) see page 65.

Override Switch Assembly 1. Connect CA407 to the main wire harness.

2. Insert the override switch (1) and sleeves (2).

3. Fix the override switch (1) with the screws (3) and nuts.

4. After assembly, carry out a functional test.

Replacing the Brake Switch

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

Note: The brake switch (connector CA406) is removed and assembled in the same way. After assembly, carry out a functional test.

¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

4

1

2

3

Fig. 60 Override and brake switches 1

Override switch (ORS)

2

Sleeve

3

Screw

4

Brake switch (BRS)

1. Disconnect CA407 from the main wire harness.

2. Loosen the screws (3) and remove the override switch (1).

WI 2300

91

ELECTRICAL SYSTEM Replacing the Emergency Disconnect Switch (EDS)

Replacing the Emergency Disconnect Switch (EDS)

Emergency Disconnect Switch Removal 1. Loosen the nuts (13) and disconnect the electrical supply.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off.

2. Loosen the screws (4) and (8) and remove the Emergency Disconnect switch (10).

Emergency Disconnect Switch Assembly Note: Assembly is the reverse of disassembly. After assembly carry out a functional test and make sure the Emergency Disconnect switch is working correctly.

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Fig. 61 Replacing the Emergency Disconnect switch

WI 2300

92

ELECTRICAL SYSTEM General Motor Maintenance Instructions

General Motor Maintenance Instructions

•

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

Note: These maintenance instructions apply to all DC motors with brushes.

•

Place the pressure springs carefully on the brush before fitting the brush. Otherwise the brush could be damaged.

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

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

•

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

Motor

¾ Lower the forks to the ground. ¾ Switch the truck off.

CAUTION

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Brushes •

Remove all brushes and check for wear. The length of the shortest brush determines whether the brush set needs to be replaced.

•

If one or more brushes need to be replaced, replace all brushes and their pressure springs at the same time. This will ensure the correct contact pressure.

•

If the minimum brush length has not been reached, the brushes should still be replaced as they could wear fully before the time of the next inspection.

Note: If a brush is too short the pressure spring will lie on the brush support and there will be no pressure. The brush will spark during operation, burning the collector.

•

The brushes must be able to move freely in the brush support, without spring tension and without twisting. Never modify the brushes if one or more cannot move freely. In this case replace all brushes as they will probably have been thermally overloaded.

Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

•

Blast the motor with dry compressed air only.

•

If oil or grease is found in the motor collector compartment (usually a paste consisting of oil, oil vapor, dust and carbon particles), immediately remove the cause and clean the motor thoroughly:

Note: 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.

Armature •

Check the armature for unevenness, burning, grooves and cracking of the multi-plate edges. Turn the armature if necessary.

Note: A non-oily, evenly distributed layer on the brush surfaces is normal.

Note: Thermal overloading causes the brushes to swell up. Brushes which jam in the brush support produce intense sparking and destroy the collector.

•

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.

Note: If information is provided in the manual, restore the collector to the specified limits. Otherwise, replace the armature in full.

WI 2300

93

ELECTRICAL SYSTEM Repairing the Traction Motor

Repairing the Traction Motor

Fig. 62 Traction motor overview

WI 2300

94

ELECTRICAL SYSTEM Repairing the Traction Motor Traction Motor Removal and Disassembly

Checking the Traction Motor Components for Wear

WARNING

CAUTION

Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

¾ Lower the forks to the ground. ¾ Switch the truck off.

1. Clean all components thoroughly using a suitable solvent.

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

2. Check for motor, brush and armature wear as detailed on page 93.

Brush check 3. Check the length of the brushes (14).

The following item numbers refer to Fig. 62, page 94.

Note: New brushes (14) are 30 mm long. The wear limit is 23 mm.

1. Open the front cover.

Armature check

2. Remove and fit the drive unit (see page 55).

4. Check the wear level of the armature (22).

3. Remove and fit the drive gear unit (see page 56).

Note: The armature (22) can be turned off. The minimum rated diameter of the armature is 61.5 mm. After turning off the armature undercut the insulation between the commutator sections by 0.5 mm.

4. Disassemble the brake (see page 106).

5. Remove the steering chain (see page 117).

6. Remove the grille (4).

7. Remove the brushes (14).

Field coil check

8. Remove the retaining rings (5) and take off the shims (7, 6).

5. Check the field coils for damage.

9. Remove the Woodruff key (21).

6. Check all components for wear and damage and replace them as required.

Note: If a field coil is damaged replace the motor.

10. Press the armature (22) out of the bearing plate (8).

11. Remove the wire from the terminal board (17).

12. Remove the screws (9) and washers (10).

13. Remove the brush plate mounting screws (13).

14. Remove the retaining ring (5) and shim (27).

15. Remove the retaining ring (12) and bearing (25).

16. Extract the bearing sleeve (24).

Traction Motor Assembly Note: Assembly is the reverse of disassembly. Note the following: 1. Bearings that have been pulled off during disassembly must be replaced by new ones.

2. Replace the shaft seal (23) and O ring (26).

17. Remove the radial shaft seal (23) from the bearing sleeve.

WI 2300

95

ELECTRICAL SYSTEM Repairing the Pump Motor

Repairing the Pump Motor 4. Lift out the pump motor (3).

WARNING

5. Remove the tensioning belt (2).

Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground.

6. Remove the brushes (19) and pressure springs.

Checking the Pump Motor Components for Wear 1. Remove any dust from the motor with weak compressed air.

¾ Disconnect the battery.

2. Check for motor, brush and armature wear as detailed on page 93.

¾ Prevent the truck from being switched on again.

Brush check

¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

3. Check the length of the brushes.

Pump Motor Removal and Disassembly

Armature check

¾ Switch the truck off.

Note: New brushes are 23 mm long. The wear limit is 15 mm.

4. Check the armature wear; rotate the armature and check for burning and damage.

1

Note: New armatures have a 48.5 mm diameter. The wear limit is 47.5 mm. Do not over tighten the armature. Replace the armature if the wear limit has been reached.

Field coil check

2

5. Check the field coils for damage.

Note: If a field coil is damaged replace the motor.

5 3

6. Check all components for wear and damage and replace them as required.

Pump Motor Assembly 4

Note: Assembly is the reverse of disassembly. Note the following: 1. Bearings that have been pulled off during disassembly must be replaced by new ones.

2. Replace all conical nipples.

Fig. 63 Pump motor removal 1

Screw

2

Tensioning belt

3

Pump motor

4

Attachment clamp

5

Power cable

1. Disconnect the power cable (5) and all other electrical connections from the motor.

2. Remove the attachment clamp (4).

3. Remove the screws (1).

WI 2300

96

ELECTRICAL SYSTEM Repairing the Direction Contactor (F/R)

Repairing the Direction Contactor (F/R)

1. Open the front panel of the truck.

2. Loosen the screws (1), remove the power cable and other electrical wires from the direction contactor (3).

3. Remove the screws (2) on either side and take off the direction contactor.

CAUTION The use of other manufacturers' contactors can damage the truck The original contactors are designed for Crown trucks.

Direction Contactor Disassembly

¾ Only use original Crown contactors as replacements.

1 8

¾ Do not change the place or the angle where they are positioned and do not change the wiring.

1

1

Direction Contactor Removal

8 7

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

6

6

2

2

¾ Lower the forks to the ground.

1

¾ Switch the truck off. ¾ Disconnect the battery.

5

¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

9

4 4

1

3

2

3 Fig. 65 Direction contactor

Fig. 64 Direction contactor removal 1

Screw

2

Screw

3

Direction contactor

WI 2300

Rev.1 04/2009

97

ELECTRICAL SYSTEM Repairing the Direction Contactor (F/R) Wear Test

1

Contact (fixed)

2

Contact (moving)

Checking contacts

3

Coil

1. Check the silver coating of the contacts (1, 2).

4

Pin

5

Twin contact

6

Spring

Ö If the silver coating has worn to the extent that the support material is visible, both contacts (1, 2) must be replaced.

7

Housing

8

Screw

9

Insulation

Note: The contacts (1, 2) are subject to natural wear during operation. Blackened, tarnished or scarified contacts must not be treated, as this would cause them to wear even faster.

Checking the coils

CAUTION The incorrect assembly of contacts can result in failure and excess wear Contacts already worked in with each other must be placed together again on assembly. ¾ Mark the contacts (1, 2) when disassembling the contactor.

1. Loosen the screws (8) and lift them off with the housing (7).

1. Using an ohmmeter measure the resistance between the connections on the coil (3). Ö If either an endless resistance or no resistance are recorded, the coil (3) is faulty and must be replaced.

Note: If there is a freewheel diode between the connections, desolder it on one side and then test the coil.

Otherwise the results will be false.

Checking the springs 1. Check the springs (6) for corrosion or discolouring caused by heat. Ö Replace any corroded or discoloured springs (6).

2

Direction Contactor Assembly Note: Assembly is the reverse of disassembly. Note the following: 1. Insert the fixed contacts (1) according to their markings.

2. When inserting the springs (6) make sure they are fully positioned in their seats.

3. Insert the pins (4) into the coil (3).

4. Place the insulation (9) on the coil (3).

7

6

Fig. 66 Removing moving contacts

2. Mark the contacts that are placed together (1, 2).

3. Use your thumbs to lift the moving contact (2) slightly.

4. Using a small, flat screwdriver push the springs (6) down and remove the moving contact (2).

5. Take the springs (6) out.

6. Clean all the components.

Rev.1 04/2009

98

5. Place the twin contact (5) on the pins (4).

6. Place the housing (7) on the coil body.

Note: When placing the housing (7) make sure the spring-loaded contact actuators are fully positioned in the coil body holes. The housing (7) should lie flush against the coil body when pressed gently by hand.

7. Insert the screws (8) and tighten them evenly with threadlocker (053050-006) starting from the centre and working out.

Direction Contactor Assembly Note: Assembly is the reverse of disassembly (see page 97).

WI 2300

ELECTRICAL SYSTEM Repairing the Pump Contactor

Repairing the Pump Contactor

1

CAUTION The use of other manufacturers' contactors can damage the truck The original contactors are designed for Crown trucks. ¾ Only use original Crown contactors as replacements. ¾ Do not change the place or the angle where they are positioned and do not change the wiring.

Pump Contactor Removal

Pump contactor

2

Nut

3

Mount

4

Screw

1. Open the front panel of the truck.

2. Loosen the nuts (2) and remove the power cable and fuse mount.

3. Remove all electrical wires from the pump contactor (1).

4. Loosen both screws (4) and remove the pump contactor (1) from the mount (3).

Pump Contactor Disassembly

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

6

1

¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery.

5

¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

7 4

1 2

2

3

4 3

Fig. 68 Pump contactor

Fig. 67 Pump contactor removal WI 2300

Rev.1 04/2009

99

ELECTRICAL SYSTEM Repairing the Pump Contactor 1

Nut

2

Contact (moving)

3

Coil

4

Spring

5

Housing

6

Screw

7

Contact (fixed)

Checking the springs 1. Check the spring (4) for corrosion or discolouring caused by heat. Ö Replace any corroded or discoloured springs (4).

Pump Contactor Assembly 1. Insert the fixed contacts (7) according to their markings.

2. Insert the washers and nuts (1) and fasten them.

Take care not to damage the housing (5) when fastening them.

CAUTION The incorrect assembly of contacts can result in failure and excess wear Contacts already worked in with each other must be placed together again on assembly.

3. Insert the moving contact (2) into the markings in the coil (3).

4. Fit the housing (5).

5. Insert the screws (6) with washers and apply threadlocker (053050-006).

¾ Mark the contacts (2, 7) when disassembling the contactor.

Pump Contact Assembly

1. Loosen and remove the screws (6).

Note: Assembly is the reverse of disassembly (see page 99).

2. Remove the housing (5).

3. Mark the contacts that are placed together (2, 7).

4. Remove the moving contact (2).

5. Unscrew the nuts (1) and remove the contacts (7).

6. Clean all the components.

Wear Test Checking the contacts 1. Check the silver coating of the contacts (2, 7). Ö If the silver coating has worn to the extent that the support material is visible, both contacts (2, 7) must be replaced.

Note: The contacts (2, 7) are subject to natural wear during operation. Blackened, tarnished or scarified contacts must not be treated, as this would cause them to wear even faster.

Checking the coils 1. Using an ohmmeter measure the resistance between the connections on the coil (3). Ö If either an endless resistance or no resistance are recorded, the coil (3) is faulty and must be replaced.

Note: If there is a freewheel diode between the connections, desolder it on one side and then test the coil.

Otherwise the results will be false.

Rev.1 04/2009

100

WI 2300

ELECTRICAL SYSTEM Battery Information

Battery Information The condition of the battery has a considerable impact on the performance of the truck. Optimum maintenance is key to maintaining the performance and useful life of the battery.

Note: Note that only wet cell batteries can be used for this truck.

Charging the Battery CAUTION The battery must be serviced and charged strictly in accordance with the battery and charger manufacturers' instructions.

Unsuitable chargers and incorrect maintenance will result in reduced truck performance in the short term.

In the medium term it will lead to premature battery failure.

Replacing the Battery WARNING Incorrect battery sizes and weights can result in fatal accidents Incorrect weight and size affect the truck’s centre of gravity which can result in accidents.

Only use batteries with the right dimensions, weight and capacity requirements for this truck.

1. Replace the battery as outlined in the truck operator manual.

WI 2300

101

ELECTRICAL SYSTEM Hydraulic System Calibration

Hydraulic System Calibration The hydraulic system must be re-calibrated every time the wiring is disconnected or one of the following components is replaced: •

Hydraulic control module - HCM (see page 69)

•

Proportional valve - PV (see page 69)

To calibrate the hydraulic system, proceed as follows: 1. Connect the battery.

2. Turn the key switch ON (lifting and lowering must be operational).

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

4. Disconnect the battery.

5. Depress and hold down the “Lower forks” switch.

6. Connect the battery.

7. Depress the “Lower forks” switch for five seconds. Ö The forks should not lower during the five seconds.

8. Release the "Lower forks" switch.

9. Switch the truck off and on again.

Note: The calibration is now complete. Now carry out a test on all the hydraulic functions.

WI 2300

102

BRAKE SYSTEM

103

Notes:

104

BRAKE SYSTEM General Brake Information

General Brake Information

Electromagnetic Brake Operating Principle

1

2

Fig. 69 Brake and traction motor 1

Brake

2

Traction motor

The brake (1) interlocks with the motor shaft of the traction motor (2).

Fig. 70 Electromagnetic brake

In order to generate the turning moment or brake torque, the coil of the magnetic body (1) is energised with DC voltage. This produces a magnetic field. The magnetic attraction pulls the armature disk (10) of the armature component against the force of the pre-tensioned spring (4) over the air gap to the friction surface of the brake magnetic body or rotor (7), producing the brake torque.

WI 2300

105

BRAKE SYSTEM Repairing the Brake If the power supply is interrupted, the magnetic field collapses and the pre-tensioned ring spring pulls the armature disk back to its original position.

Repairing the Brake WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Fig. 71 Electromagnetic brake

Brake Removal 1. Open the front panel of the truck.

2. Remove the electric wires from the brake.

3. Remove the cover (10).

4. Remove the screws (9).

5. Remove the magnetic body (1) and all its associated parts from the traction motor.

WI 2300

106

BRAKE SYSTEM Repairing the Brake Brake Disassembly

Brake Installation

CAUTION

WARNING

Health risk Cleaning agents, lubricants and consumables can damage your health.

An altered brake torque can result in accidents The brake friction lining and friction surfaces must not come into contact with oil or grease. Even the smallest amounts can reduce the brake torque significantly.

¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

¾ Keep oil and grease away from the friction lining and friction surfaces.

1. Remove the screws (6) from the magnetic body.

2. Remove the armature disk (2).

1. Insert the springs (4) into the magnetic body (1).

3. Remove the rotor (7) from the hub (8).

2. Place the thrust pieces (3) onto the springs (4).

Note: The hub (8) can remain on the motor shaft. If the hub (8) needs to be replaced, remove its retaining ring.

3. Position the hub (8) onto the motor shaft and attach it with the retaining ring.

4. Remove the friction plate (11) from the motor shaft.

4. Insert the friction plate (11) into the correct position while observing the hole pattern.

Checking the brake components 5. Thoroughly clean all components with a brake solvent.

6. Check the armature disk (2), friction plate (11) and rotor (7) for uneven wear, deep grooves, cracks and signs of burning.

5. Push the rotor (7) onto the hub (8).

6. Torque the magnetic body (1) to the traction motor using the screws (9) to 9.5 Nm. 7. Attach the electric wires.

8. Adjust the brake air gap (see next chapter).

7. Measure the thickness of the rotor (7) along several points. Ö If the rotor (7) is less than 7.3 mm thick, the friction lining is worn and the rotor must be replaced.

8. Test the coil of the magnetic body (1) using an ohmmeter. To do this measure the resistance at CA402-1 and CA402-2. Ö If the coil is intact you should obtain a reading of approx. 15.2 Ω. Ö If the coil resistance reading differs significantly, replace the magnetic body (1).

9. Replace all worn and faulty brake components.

Brake Assembly 1. Insert the thrust pieces (3) and compression springs (4) into the magnetic body (1).

2. Place the armature disk (2) on the magnetic body (1).

3. Insert the screws (6) into the magnetic body (1) as far as the stop using a medium strength threadlocker.

Note: Insert the screws into the nuts only so far that a uniform gap of at least 1 mm remains between the armature disk (2) and the magnetic body (1).

WI 2300

107

BRAKE SYSTEM Brake Air Gap Adjustment

Brake Air Gap Adjustment

WARNING

Adjusting the Air Gap The brake air gap is measured between the magnetic body and the armature disk when the brake is applied (brake de-energised).

An altered brake torque can result in accidents The brake friction lining and friction surfaces must not come into contact with oil or grease. Even the smallest amounts can reduce the brake torque significantly, resulting in serious injuries. ¾ Keep oil and grease away from the friction lining and friction surfaces.

1 4

2 3 Fig. 72 Brake air gap adjustment 1

Magnetic body

2

Armature disk

3

Screw

4

Screw

Measuring the air gap 1. Remove all the screws (3) until they are in contact with the friction plate.

2. Torque all screws (4) evenly to 9.5 Nm. 3. Measure the air gap between the magnetic body (1) and armature disk (2) along several places using a feeler gauge.

Note: The air gap should be between 0.25 mm and 0.35 mm. It should be even all the way along.

Adjusting the air gap Note: Unscrew the screws (3) to increase the air gap, turn the screws (3) in to reduce it.

4. Depending on the size of the air gap insert or remove the screws (3) and using a feeler gauge check that the air gap is even all the way along (0.25 mm to 0.35 mm).

5. If the air gap is set correctly, torque all the screws (4) again evenly to 9.5 Nm.

WI 2300

108

BRAKE SYSTEM Setting the Braking Distance

Setting the Braking Distance 1

A

1

2

2

Fig. 73 Pre-setting the brake 1

Setscrew

2

Magnetic body

Fig. 74 Adjusting the braking distance

Pre-setting the braking distance

1

Setscrew

2

Magnetic body

1. Insert the setscrew (1) until dimension "A" is 10 mm.

3. Insert or remove the setscrew (1) depending on the result of the brake test (see page 110).

Note: Note that the setscrew must be secured with the safety plate. The setscrew must therefore be positioned so that the tappet of the safety plate can engage.

Note: Note that the setscrew must be secured with the safety plate. The setscrew must therefore be positioned so that the tappet of the safety plate can engage.

2. After carrying out the pre-setting, check the truck's braking distance (see Checking the Braking Distance, page 110).

4. After adjusting, secure the setscrew (1) with the safety plate.

Adjusting the braking distance Note: Remove the setscrew (1) to extend the truck's braking distance, insert it to reduce the braking distance.

WI 2300

109

BRAKE SYSTEM Setting the Braking Distance Checking the Braking Distance Note: The brake test is performed first with maximum load and then with an unladen truck.

7. Apply the brakes fully when it reaches the brake marker.

8. Measure the braking distance.

9. Repeat the test three times and obtain the average braking distance.

10. Compare the braking distance recorded with the values on the following table.

WARNING Risk of serious accidents involving third parties People suddenly stepping onto the test route can be fatally injured. ¾ Make sure there is nobody near the test route.

Note: The braking distances should be within the specified ranges. Note that there are different braking distances for new and "used" brakes. A brake is deemed to be new if it has complete less than ten full braking operations.

¾ If necessary use assistants to prevent unauthorised access.

11. Now repeat the brake test in the same way with an unladen truck.

¾ Use suitable equipment to block the test route.

Reducing the Stopping Distance

Preparing the test route 1. Clean the test route and prevent unauthorised personnel from accessing it.

2. Attach a brake marker with adhesive tape to the floor of the test route.

Note: The truck should be travelling at maximum speed by the time it reaches this marker.

3. Attach a marker with adhesive tape to the floorboard of the truck.

Brake test 4. Raise the maximum permissible load (see data plate).

The following measures can reduce the braking distance of the truck: •

Continue insert the brake screw (see Adjusting the Braking Distance, page 109).

•

Check the brake air gap and adjust as required (see page 108).

•

Check the thickness of the rotor's friction lining (see Brake Disassembly, page 107), at replace the rotor as required.

•

Clean the brake, check for wear and replace components as required.

Note: Perform a brake test each time you re-adjust the brake.

5. Lower the forks down to the outriggers.

6. With the truck at operating temperature, increase the speed to maximum.

Permissible Braking Distances New brake

“Used brake”

Truck model

With max. load

No load

With max. load

No load

WI2300

1.0 - 1.1 m

0.6 - 0.7 m

0.95 - 1.05 m

0.55 - 0.65 m

WI 2300

110

STEERING

111

Notes:

112

STEERING Repairing Control Handle Return Springs

Repairing Control Handle Return Springs

Return Spring Pre-Tension Adjustment

If the return spring bias spring force reduces over time, the pre-tension can be adjusted in several stages. Return springs whose pre-tension cannot be increased any further must be replaced.

Note: The axle (6) contains 2 holes for the dowel pin which are offset by 90 degrees. This allows you to adjust the pre-tension of the return springs by 90 degrees respectively by turning the axle.

7

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

6

¾ Lower the forks to the ground. ¾ Switch the truck off.

4

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Panel Removal 5 Fig. 76 Pre-tension adjustment

1

4

Return spring

5

Spacer ring

6

Axle

7

Dowel pin

4. Set the control handle upright.

5. Fix the axle (6) using a fork wrench.

3

Ö This prevents the return springs (4) from discharging when the dowel pin (7) is deflected.

2

6. Remove the dowel pin (7).

7. Turn the axle (6) 90 degrees with the fork wrench.

Fig. 75 Panel removal

Ö This will tension the springs.

1

Panel

8. Strike the dowel pin (7) in.

2

Panel

3

Screw

Ö This increases the pre-tension of the return springs (6).

1. Open the front panel of the truck.

2. Remove both panels (1).

3. Loosen two screws (3) and remove the panel (2).

Note: Assembly is the reverse of disassembly.

9. Make sure the return springs have sufficient pretension. The control handle should move automatically to the horizontal position.

10. If necessary increase the pre-tension of the return springs further.

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STEERING Repairing Control Handle Return Springs 11. After adjusting, grease the return springs (for lubricant see page 23).

12. Assemble all the panels.

13. Test the truck's brakes.

Replacing the Return Springs

Tools required: Shortened axle (8) on which the return springs can be pre-assembled. The axle must be shorter than 119 mm so that it can be inserted with the control handle in the control handle knuckle (9).

Pre-assembling the return springs

WARNING Risk of injury from pre-tensioned springs Pre-tensioned springs can snap off with extreme force.

1. Push the return springs (4) with the spacer ring (5) onto the shortened axle (8). The inner, angled end of the return springs should enter the groove of the shortened axle (8) in the process.

¾ Be particularly careful when handling springs and wear protective goggles.

Note: Note that the shortened axle (8) moves with the axle (6). The return springs are pushed onto the axle (6) at the same time. When inserting the axles make sure the grooves are positioned accordingly (see Fig. 77).

Return spring removal

Return spring assembly

1. Remove the panels (see page 113).

2. Insert the pre-assembled return springs (4) with the control handle into the control handle knuckle (9).

2. Set the control handle upright.

3. Remove the dowel pin (7). Ö The axle (6) turns and the return springs (4) are discharged.

4. Set the control handle all the way down to fully discharge the return springs (4).

Note: If the axle is jammed, turn it approx. 20 degrees clockwise with a fork wrench in order to discharge the return springs.

3. Insert the axle (6) from the left hand side and make sure that the position of the groove corresponds to the groove of the shortened axle (8).

4. Strike in the axle (6) carefully and drive out the axle (8). Ö The return springs are pushed onto the axle (6) in the process.

5. Drive out the axle (6) from the right hand side.

Return spring pre-tension adjustment

6. Remove the return springs (4).

5. Set the control handle upright.

6. Starting from the neutral position of the return springs, turn the axle (6) 90 degrees using a fork wrench and increase the pre-tension of the return springs.

Return spring assembly 4

7

7. Strike the dowel pin (7) in.

8. Make sure the return springs have sufficient pretension.

8

6

Ö The control handle should move automatically to the upright position.

9. If necessary increase the pre-tension of the return springs further.

10. After adjusting, grease the return springs (for lubricant see page 23).

11. Assemble all the panels.

9

12. Test the truck's brakes.

Fig. 77 Return spring assembly 8

Shortened axle

9

Control handle knuckle

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STEERING Repairing the Steering Column

Repairing the Steering Column WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Steering Column Removal 4 1

2 14

Fig. 78 Remove the bracket 1

Screw

2

Bracket

1. Move the front panel out.

15

2. Undo the screws (1).

Fig. 79 Steering column removal

3. Lift out the bracket (2).

4. Mark the assembly position of the tiller support with reference to the chassis.

5. Mark the assembly position of the chain wheel (6) with reference to the chain tensioning block (11).

Cardan joint removal 6. Remove the bottom screw (4) from the Cardan joint (3) and push the chain wheel (6) down.

7. Remove the top screw (4) from the Cardan joint.

8. Remove the Cardan joint (3) from the steering pivot.

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STEERING Repairing the Steering Column Note: If the Cardan joint (3) has too much slack, it must be replaced.

9. If necessary remove the retaining rings (1) and the faulty bearings (2).

10. If necessary remove the slide bearings (9) and (10).

Steering Column Assembly Note: Assembly is the reverse of disassembly. Note the assembly position markings.

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STEERING Replacing the Steering Chain

Replacing the Steering Chain

Note: The steering chain tension should yield approx.

3 - 5 mm when you push your thumb onto the middle of the steering chain.

7. Check the truck's straight travel and adjust as required (see following chapter).

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Steering Chain Removal 1. Turn the control handle until the chain lock (14) is at the front.

2. Mark the position of the drive wheel with reference to the chassis.

3. Mark the assembly position of the pinion (6) with reference to the chain tensioning block (11).

4

4. Remove the screw (12).

5. Insert a suitable tool in the hole (15) and push the chain tensioning block (11) against the compression spring (13).

14

6. Secure the tensioned compression spring (13) with a wooden wedge.

7. Open the chain lock (14) and remove the steering chain.

Steering Chain Assembly 1. Check the tooth flanks of the two pinions and replace if necessary.

2. Guide the steering chain around the pinion of the gear unit.

3. Align the pinion (6) and drive wheel with the markings.

4. Insert the steering chain in the pinion (6) and connect both ends to the chain lock (14).

5. Insert the screw (12) and remove the wooden wedge.

15 Fig. 80 Replacing the steering chain

6. Adjust the chain tension with the screw (12).

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STEERING Adjusting the Control Handle

Adjusting the Control Handle For straight travel the control handle should be in line with the truck. If not, adjust the control handle.

Note: The following item numbers refer to Figure 80.

1. Loosen the screws (7) on the pinion (6).

2. Set the control handle to the centre position.

3. Fix the pinion (6) with the screws (7).

4. Check the straight travel again and adjust as required.

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STEERING Repairing the Control Handle

Repairing the Control Handle 5

4 1

2

3 Fig. 81 Main control handle components 1

Switch unit

4

Control handle tube

2

Hand grip

5

Upper shell

3

Lower shell

Note: A brief description of the electronic components of the control handle grip can be found on page 65. For more information on the assembly location of the electronic components refer to page 68.

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STEERING Repairing the Control Handle Replacing the Control Handle Shells 2

2

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

3

¾ Lower the forks to the ground. ¾ Switch the truck off.

3

¾ Disconnect the battery. ¾ Prevent the truck from being switched on again. ¾ Jack up the truck until the drive wheel is clear of the ground (see page 16).

Shell removal Fig. 83 Switch unit disassembly

2. Press the thumb markings (3) or pull on the thumbwheels (2). Ö The switch unit will slide up out of the bottom shell.

3. Remove the control handle wire harness plug connections and the horn buttons from the PC boards.

1

1

5

Fig. 82 Shell removal

1. Remove the screws (1).

Fig. 84 Cover removal

4. Lever off the covers (5) on each hand grip.

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STEERING Repairing the Control Handle

5

7

8 7 Fig. 85 Horn switch disassembly

9

5. Carefully push the horn switch (5) in and pull it off the grip.

6. Remove the connector (5) from the horn switch.

Fig. 87 Shell removal

8. Remove the screws (7) and (9).

9. Remove the shells (8).

Shell assembly Note: Assembly of the shells is the reverse order of disassembly. Take care not to damage the wiring.

1. After assembly, connect the battery and test all the functions of the control handle.

6 Fig. 86 Grip removal

7. Remove the screws (6) and pull off the grips.

Replacing the Switch Unit The switch unit contains the: •

Safety reverse switch

•

Travel switch / traction potentiometer

•

“Rabbit/Turtle” toggle module

•

Main PC board Hydraulic PCB (Lift / lower switches)

•

Initial lift switch

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

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STEERING Repairing the Control Handle Switch unit removal

Switch unit assembly Note: Assembly is the reverse of disassembly. Note the following: 1. Re-connect the control handle wire harness and horn wiring to the PC boards.

2. After assembly, connect the battery and test all the functions of the control handle.

Replacing the “Rabbit/Turtle” Toggle Module 1

There are no parts of the toggle module (HSS) that can be repaired. It must be replaced as a complete unit.

CAUTION Use of the wrong toggle module can damage the truck The module is available as either a standard or a cold store version.

1

¾ Make sure you use the right module.

Fig. 88 Shell removal

1. Remove the screws (1).

2

Toggle module removal 2

3

1

3

2 Fig. 90 “Rabbit/Turtle” toggle module

1. Disassemble the switch unit (see page 122).

2. Remove the screws (2) and take off the toggle module (1).

Fig. 89 Switch unit removal

2. Press the thumb markings (3) or pull on the thumbwheels (2).

Toggle module assembly

Ö The switch unit will slide up out of the bottom shell.

3. Remove the control handle wire harness plug connections and the horn buttons from the PC boards.

Note: Assembly is the reverse of disassembly. Note the following: 1. Re-fit the switch unit (see page 122).

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STEERING Repairing the Control Handle 2. After assembly, connect the battery and test all the functions of the control handle.

Main PC board removal

Replacing the Control Handle Grip PC Boards The main PC board (Main PCB) and the hydraulic PC board (HYD PCB) are located in the control handle grip. The main PC board is the larger of the two. Neither of the PC boards contains components that can be repaired; they must be replaced as complete units.

CAUTION Use of the wrong PC board can damage the truck This hydraulic and main PC boards are available as either standard or cold store versions. ¾ Make sure you use the right PC boards.

Hydraulic PC board removal

2

1

Fig. 92 Main PC board removal

1. Remove the switch unit (see page 122).

2. Remove the connector of the potentiometer from the main PC board.

3. Remove the screws (1).

4. Remove the connector of the safety reverse switch from the main PC board (2).

5. Remove the main PC board.

Note: If you cannot reach the connector on the main PC board, remove the thumbwheels, the bottom cover and the upper shell cover (see "Replacing the Traction Potentiometer" on page 123).

1 2

Main PC board assembly

Fig. 91 Hydraulic PC board removal

Note: Assembly is the reverse of disassembly. Note the following:

1. Remove the switch unit (see page 122).

1. Re-fit the switch unit (see page 122).

2. Remove the screws (2) from the hydraulic PC board.

2. After assembly, connect the battery and test all the functions of the control handle.

3. Remove the hydraulic PC board (1).

Hydraulic PC board assembly Note: Assembly is the reverse of disassembly. Note the following: 1. Re-fit the switch unit (see page 122).

2. After assembly, connect the battery and test all the functions of the control handle.

Replacing the Traction Potentiometer There are no parts of the traction potentiometer (POT travel switch) that can be repaired. It must be replaced as a complete unit.

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STEERING Repairing the Control Handle CAUTION 6

Use of the wrong potentiometer can damage the truck The traction potentiometer is available as either a standard or a cold store version. ¾ Make sure you use the right potentiometer.

Traction potentiometer removal 1

7

1

2

3 7 5

Fig. 94 Cover removal

6. Remove the screws (7).

7. Remove the cover (6).

4 Fig. 93 Thumbwheel removal

11

1. Remove the switch unit (see page 122).

2. Remove the screws (3).

8

Note: Take care not to lose the slide bearings (2) when removing the thumbwheels (1).

10

3. Extract the thumbwheels (1).

4. Remove the screws (4) while holding on to the lowering switch cap (5).

5. Remove the lowering switch cap (5).

9 Fig. 95 Traction potentiometer removal

8. Remove the screws (11).

9. Remove the connectors from the PC boards.

10. Remove the traction potentiometer (8) from the square axle.

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STEERING Repairing the Control Handle Traction potentiometer assembly Note: Assembly is the reverse of disassembly. Note the following:

6

1. Fill the socket (10) with grease (part no. 053002005).

Note: The socket (10) must only be filled with grease (part no. 053002-005). Do not use any other types of grease.

2. Re-fit the switch unit (see page 122).

3. After assembly, connect the battery and test all the functions of the control handle.

7

Replacing the Safety Reverse Switch (SAS) Safety reverse switch (SAS) removal 1

1

2

7 Fig. 97 Cover removal

6. Remove the screws (7).

7. Remove the cover (6).

3 5

9 10 4

8

Fig. 96 Thumbwheel removal

1. Remove the switch unit (see page 122).

2. Remove the screws (3).

11

Note: Take care not to lose the slide bearings (2) when removing the thumbwheels (1).

12

3. Extract the thumbwheels (1).

4. Remove the screws (4) while holding on to the lowering switch cap (5).

5. Remove the lowering switch cap (5).

Fig. 98 Safety reverse switch removal

8. Remove the screw (8).

9. Remove the switch bypass (12).

10. Remove the screws (11).

11. Disconnect the micro switch (9) from the main PC board.

12. Take out the safety reverse switch (10).

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STEERING Repairing the Control Handle Safety reverse switch (SAS) assembly

1. Remove the switch unit (see page 122).

Note: Assembly is the reverse of disassembly. Note the following:

2. Remove the screws (2).

1. Fill the socket of the micro switch cable (9) with grease (part no. 053002-005).

4. Remove the screws (4) and take off the switch block.

Note: The socket (10) must only be filled with grease (part no. 053002-005). Do not use any other types of grease.

5. Remove the screws (3) and take off the initial lift switch (1).

2. Re-fit the switch unit (see page 122).

3. Remove the electrical connectors.

Initial lift switch assembly Note: Assembly is the reverse of disassembly. Make sure the gap between the switch cap and the shell is uniformly even. The switch cap must not jam when applied.

3. After assembly, connect the battery and test all the functions of the control handle.

Replacing the Grips and Horn Switch

1. Re-fit the switch unit (see page 122).

Note: Refer to page 120 for the removal and assembly of the grips and horn switch.

2. After assembly, connect the battery and test all the functions of the control handle.

Replacing the Initial Lift Switch Initial lift switch removal 2 1

3 4 3

4 2

Fig. 99 Replacing the initial lift switch 1

Initial lift switch

2

Screw

3

Screw

4

Screw

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LIFTING MECHANISM

127

Notes:

128

LIFTING MECHANISM Repairing the Mast

Repairing the Mast

TL Mast

Repairs to the various mast types are restricted to replacing the mast rollers and repairing the chain anchors and lift chains (see page 144).

The TL mast consists of a static outer mast which also contains an inner mast. They are supported by two embedded mast rollers. The inner mast is raised by two mast cylinders. The fork carriage is mounted on four rollers and mounted to the internal mast.

The truck can be equipped with the following masts: •

TT mast (Triplex)

•

TF mast (Duplex)

•

TL mast (Simplex)

Because of the shortened inner mast, the mast does not extend immediately beyond the retracted height during lifting. This means that free lift is more restricted.

TT Mast The TT mast configuration consists of a static outer mast and two inner masts mounted on the inside. They are supported by embedded mast rollers. The first inner mast is raised directly by two mast cylinders. The second inner mast is raised automatically by chains.

The chains are attached at the top to the static outer mast and at the bottom of the second inner mast. The twin chain design creates a first to second mast lift ratio of 2:1. The fork carriage is mounted on four rollers; the free lift cylinder is connected to the inner mast.

The fork carriage is raised indirectly by chains running on rollers secured to the inner mast. The twin chain design creates a fork carriage to internal mast lifting ratio of 2:1.

The fork carriage is raised by a chain running across the free lift cylinder in a return roller. Because of the large diameter of the lift cylinder, initially only the fork carriage is raised in the inner mast. The overall height remains unchanged when the fork carriage is raised within free lift. Once the free lift cylinder has extended as far as the stop, the mast cylinders take over the task of completing the lifting operation.

TF Mast The TF mast configuration consists of a static outer mast which also contains an inner mast. They are supported by embedded mast rollers. The inner mast is raised by two mast cylinders. The fork carriage is mounted on four rollers; the free lift cylinder is connected to the inner mast.

The fork carriage is raised by a chain running across the free lift cylinder in a return roller. Because of the large diameter of the lift cylinder, initially only the fork carriage is raised in the inner mast. The overall height remains unchanged when the fork carriage is raised within free lift. Once the free lift cylinder has extended as far as the stop, the mast cylinders take over the task of completing the lifting operation.

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LIFTING MECHANISM Repairing the TT Mast

Repairing the TT Mast

Inner mast 1

Outer mast

Fig. 100 Overview of TT mast, outer mast and inner mast 1

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LIFTING MECHANISM Repairing the TT Mast

Inner mast 2

Fig. 101 Overview of TT mast, inner mast 2

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LIFTING MECHANISM Replacing the Mast Rollers

Replacing the Mast Rollers The following outlines the replacement of all the mast rollers on a TT mast. The individual steps for replacing the rollers are: •

Remove the fork carriage

•

Remove the entire mast unit

•

Remove the outer mast

•

Remove inner mast 1

•

Replace the mast rollers and adjust the clearance with shims

•

Assembly is the reverse order

WARNING Risk of trapping and severing limbs Unsecured components can sever limbs and cause fatal injuries.

When carrying out work on the mast and the attachments: ¾ Always block the mast stages and attachments to prevent them from moving accidentally. ¾ Make sure the equipment used has sufficient strength.

Note: The mast rollers for the TF and TL masts are replaced in a similar manner. Note that the hydraulic lines and connections differ slightly from this description (see lift cylinder overviews on pages 160 and 163).

WARNING

¾ Disconnect the battery.

High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency.

Seek medical assistance even if the skin appears normal at first.

To avoid accidents: • Depressurise the hydraulic system before opening any sections of it.

• Tighten all connections before pressurising the system.

• Keep hands and body away from pressurized fluid.

¾ Prevent the truck from being switched on again.

•

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off.

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

Only trace leaks with a piece of paper or cardboard.

Mast Roller Removal Note: – Weight of mast with fork carriage: approx.

1000 kg – Weight of fork carriage: approx. 200 kg Fork carriage removal 1. Lower the forks to the ground.

2. Depressurise the hydraulic system.

3. Remove the battery.

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LIFTING MECHANISM Replacing the Mast Rollers 7. Using a crane, raise inner mast 1 approx. 300 mm until the fork carriage rollers are located outside inner mast 2.

8. Pull the fork carriage out to the front and using a crane or a forklift truck lower it onto a suitable base.

Removing the entire mast unit 1. Remove the side panels from the chassis.

1 4

Fig. 102 Mast guard

4. Remove the mast guard (1).

Fig. 104 Limit switch

2. Unplug the connector of the "fast/slow travel speed” limit switch (4).

3

3. If applicable, remove the cable from the “LMS1700” limit switch (see page 68).

2

5

Fig. 103 Yoke assembly

5. Remove the bolts (2) from the chain anchor.

6. Lift out the entire yoke assembly (3) from the top.

CAUTION

Fig. 105 Lifting the mast unit

Raising the inner mast too far can damage the lift chains and hydraulic hoses ¾ Raise inner mast 1 no further than approx. 300 mm.

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LIFTING MECHANISM Replacing the Mast Rollers 8. Place the entire mast unit on a secure work base.

WARNING

Outer mast removal

Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

8

4. Attach load slings (5) to the entire mast unit as shown in Fig. 105 and attach it to the crane.

8

6

Fig. 108 Hydraulic connections

1. Place a container under the hydraulic connections (8) of the outer lift cylinders to collect the hydraulic oil.

Fig. 106 Hydraulic adapter

CAUTION

5. Remove the hydraulic adapter (6).

Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

2. Undo the hydraulic connections (8) from the outer lift cylinders.

7 7

9

Fig. 107 Mast assembly removal

6. Remove the four screws (7) from the mast attachment.

7. Lift the entire mast unit out of the truck with the crane. Take care not to damage the cable and connector of the "fast/slow travel speed" limit switch (4).

Fig. 109 Retaining rings

3. Remove both retaining rings (9) from the outer lift cylinders.

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LIFTING MECHANISM Replacing the Mast Rollers CAUTION The weight of the lift cylinders can cause injury ¾ Use 2 people to remove the lift cylinders.

11

4. Remove the outer lift cylinder attachment clamps and take off both lift cylinders.

12

10

Fig. 110 Hydraulic connections

5. Undo the hydraulic connections (10) from the top hydraulic lines of the free lift cylinder.

6. Strike out the cotter pins from the lift chain anchors.

13 Fig. 111 Stops

7. Loosen the screws (11) of the stops (12) between the outer mast and inner mast 1 on either side.

8. Remove the stops (12) above the recess (13).

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LIFTING MECHANISM Replacing the Mast Rollers

18 14

15 Fig. 114 Manifold block

3. Remove all hydraulic lines and connections from the manifold block (18) and remove the manifold block.

Fig. 112 Extracting the outer mast

9. Hang load slings around the outer mast (14) and using a crane carefully pull it out of inner mast 1 (15) and put it down.

20

Inner mast 1 removal

19

16

Fig. 115 Pulleys

17

Fig. 113 Hose rollers

1. Remove the retaining rings (16) from the hose rollers (17).

4. Remove the retaining rings from the pulleys and strike out the bolts (19).

5. Push inner mast 1 forward and remove the pulleys (20).

6. Hang load slings around inner mast 1 and using a crane carefully pull it out of inner mast 2 and put it down.

7. Remove all the mast rollers from the outer mast and inner masts 1 and 2.

2. Remove both hose rollers (17).

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LIFTING MECHANISM Replacing the Mast Rollers Replacing the Mast Rollers and Adjusting the Slack WARNING

3

Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

Slack on the mast rollers is compensated by using shims. Shims come in 0.5 mm, 1.0 mm and 1.5 mm thicknesses.

Note: Try to use as few shims as possible. Several thin shims should be replaced by one thick one. Note that the number of shims required on the left and right mast rollers should be the same for each mast stage. Refer to Figure 123 on page 140.

2. Place the wooden strip (3) on the top end of the inner mast.

Adjusting the slack on the mast rollers between inner masts 1 and 2

Ö This prevents the hydraulic lines from being trapped when inner mast 2 is inserted.

Fig. 117 Wooden strip

1

4 2 5

Fig. 116 Mast rollers

Fig. 118 Inserting inner mast 1

1. Insert one 1.5 mm thick shim and one mast roller (1) respectively onto the receptacles (2) of inner masts 1 and 2.

3. Hang load slings around inner mast 1 (4) and using a crane insert it into inner mast 2 (5).

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LIFTING MECHANISM Replacing the Mast Rollers 10. If necessary, remove inner mast 2 and re-adjust the slack.

11. If the slack has been set correctly, install the pulleys, hose rollers, manifold ports and manifold in reverse order of removal (see "Removing inner mast 1" on page 136).

12. Apply a layer of grease to the entire length of the mast running surfaces along which the rollers move.

1

Adjusting the slack on the mast rollers between the outer mast and inner mast 1 Note: Adjust the slack in the same way as in the previous chapter "Adjusting the slack of the mast rollers between inner masts 1 and 2".

Fig. 119 Moving inner mast 2

4. Place screwdrivers by the top and bottom mast rollers (1) and push inner mast 2 against the opposite side of inner mast 1.

1. If the slack has been set correctly, refit the stops, lift chains, free lift cylinder hydraulic connections and outer lift cylinder in reverse order of removal (see "Removing the outer mast" on page 134).

Assembling the Remaining Attachments and Mast Unit Note: Assembly of the remaining attachments and mast unit is the reverse of disassembly (see previous page). Note the following: 1. Apply a layer of grease to the entire length of all the mast running surfaces along which the mast rollers move.

6

Fig. 120 Determining the slack

1

5. Use shims (6) of various thicknesses to determine the amount of slack.

Note: Adjust so that there is as little slack as possible.

When you move the masts manually there should be no point at which they move sluggishly.

6. Hang load slings around inner mast 1 and using a crane carefully pull it out of inner mast 2 and put it down.

Fig. 121 Replacing the rubber buffer

7. Use the same number of shims on either side of inner masts 1 and 2 (see Fig. 123).

2. Replace any rubber buffers (1) that have been damaged or are missing.

8. Hang load slings around inner mast 1 and using a crane insert it into inner mast 2.

3. When inserting the outer lift cylinder make sure the vent screws are facing outwards.

9. Check that the slack is as low as possible by manually moving the mast along its entire length.

4. Proceed with caution when inserting the entire mast unit and take particular care not to damage

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LIFTING MECHANISM Replacing the Mast Rollers the cable and connector of the "fast/slow travel speed" limit switch (see Fig. 104, page 133) or the bottom hydraulic lines.

2

Fig. 122 Aligning the mast unit

5. Before bolting the mast unit, ensure that it is aligned centrally in the chassis. Make sure that the left and right gaps (2) between the chassis and the outer masts are uniform.

6. Torque the mast attachment screws (see Fig. 107, page 134) to 110 Nm.

Preparing the Hydraulic System 1. Bleed the hydraulic system.

2. Carry out a drift test.

3. Check the hydraulic operations.

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LIFTING MECHANISM Replacing the Mast Rollers

(1)

(2)

(1)

(2)

(1)

(1)

(2)

(2)

(2) (1)

(1)

(2)

(1)

(2)

Figures in brackets indicate the number of shims to be positioned.

Note that the same number of shims must be used on either side of the mast Fig. 123 Distributing the shims on the mast rollers

Lowering Plumb Test The lowering plumb test checks the permissible mast tilt. Always carry out a lowering plumb test when the mast or fork carriage has been removed. The lowering plumb test must be performed with rated truck load (see capacity plate).

5. Plot the middle of a 20 x 50 mm square, e.g. cardboard, under the plumb. The long side of the square should be facing the longitudinal axis of the truck.

6. Attach the square you have drawn to the floor using adhesive tape.

1. Park the truck on a level surface with the test load.

7. Extend the mast until it is just before the limit stops.

Note: The surface is level if the height difference at the wheel contact points is less than 1 mm.

8. Extend the string of the lowering plump until it is just above the ground.

2. Raise the forks to a height of 300 mm.

9. Drop the lowering plumb.

3. Attach the lowering plumb to the back of the fork carriage.

Ö The lowering test is successful if the lowering plumb is within the square you have drawn.

4. Drop the lowering plumb.

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LIFTING MECHANISM Replacing the Mast Rollers Note: If the lowering plumb is outside of the square, the mast tilt must be adjusted by adding or removing shims. Now carry out another lowering plumb test and make sure the permissible mast tilt is not exceeded.

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LIFTING MECHANISM Repairing the Fork Carriage

Repairing the Fork Carriage Replacing the Fork Carriage Rollers Checking the clearance 1. Raise the fork carriage as far as the stop.

2. Lower the fork carriage approx. 50 mm.

3. Using a mounting iron push the top fork carriage roller against the inner mast.

1

4. Using shims with different thicknesses check for slack. See also the chapter entitled Replacing the Mast Rollers and Adjusting the Slack on page 137. Ö If the slack is too great, remove the fork carriage and compensate with shims.

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

Fig. 124 Mast guard

4. Remove the mast guard (1).

¾ Lower the forks to the ground.

3

¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again.

WARNING

2

Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

Fork carriage removal 1. Lower the forks to the ground.

2. Depressurise the hydraulic system.

3. Remove the battery.

Fig. 125 Yoke assembly

5. Remove the bolts (2) from the chain anchor.

6. Lift out the entire yoke assembly (3) from the top.

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

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LIFTING MECHANISM Repairing the Fork Carriage CAUTION

WARNING

Raising the inner mast too far can damage the lift chains and hydraulic hoses ¾ Raise inner mast 1 no further than approx. 300 mm.

7. Using a crane, raise inner mast 1 approx. 200 mm until the fork carriage rollers are located outside inner mast 2.

8. Pull the fork carriage out to the front and using a crane or a forklift truck lower it onto a suitable base.

Defective forks can cause fatal accidents They endanger the life of the operator and other people. ¾ Decommission any forks with signs of cracks or deformation, for example. ¾ Defective forks must be repaired by the manufacturer or by authorised and qualified personnel.

Adjusting the slack Note: See also the chapter entitled Replacing the Mast Rollers and Adjusting the Slack on page 137.

1

1. Insert the shims at the top right-hand roller of the fork carriage.

2. Insert the same number of shims at the bottom right-hand roller of the fork carriage.

3. Assemble the fork carriage in reverse order of disassembly.

4. Check the slack again.

Note: When checking the slack make sure the fork carriage does not jam at the highest point of the mast.

Fig. 126 Fork carriage visual inspection

Checking the Fork Carriage

1

The fork carriage must be inspected periodically by trained personnel for cracks, damage and wear (see Maintenance Schedule on page 25).

1. Visually inspect all fork carriage surfaces for signs of cracks.

If the fork carriage is to be used in extreme operating conditions such as frequent load transporting, the inspection must be carried out at shorter intervals.

WARNING

Welding seam

2. If necessary carry out a non-rupturing crack test (e.g. paint penetration process or Magnaflux®).

Note: With fork over versions, check the welding seam (1) between the fork and the fork carriage or the fork shank for cracks. Replace the fork carriage if any cracks are detected.

Improper repairs can cause fatal accidents Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork. ¾ Repairs must always be carried out by the manufacturer or by authorised and qualified personnel.

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LIFTING MECHANISM Chain Supports and Lift Chains

Chain Supports and Lift Chains

Cleaning lift chains

General Lift chains are safety components. Careful maintenance and repairs are a prerequisite for safe truck operation and long uptime.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

WARNING Improper cleaning can cause chains to crack A cracked chain can result in fatal injuries.

Never clean lift chains with steam cleaners, cold cleaning agents or corrosive, acid-based agents. This can cause direct chain damage through hydrogen embrittlement. ¾ Clean the chain surfaces only with paraffin derivatives such as cleaning petroleum or cleaning petrol.

Apply a thin layer of the cleaning agent with a hard bristle brush and wipe with a lint-free cloth.

¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

¾ Apply an approved chain oil again after cleaning or immediately after the inspection (see Lubricants and Consumables chart on page 23). The oil acts as an anti-corrosion agent.

Periodic inspection of chain supports and lift chains CAUTION Lift chains and chain supports must be periodically cleaned, inspected and lubricated (see Planned Maintenance, page 25).

The interval must be adapted for corrosive or dusty environments, i.e. reduced accordingly so that safety is not affected.

Periodic replacement of chain supports and lift chains For safety reasons chain supports, lift chains, anchor bolts and attachment items must be replaced periodically irrespective of their external condition.

Irrespective of the condition and inspection results you must replace the following components after every 6000 service hours or 3 calendar years at the latest: •

Lift chains

•

Chain supports and their attachment items

•

Anchor bolts and their attachment items

Note: Chain supports are marked with the date of manufacture / assembly (week/year).

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WI 2300

LIFTING MECHANISM Inspecting Chain Supports and Lift Chains

Inspecting Chain Supports and Lift Chains CAUTION If damage is detected on the lift chains during inspection, replace the lift chains and the chain supports, chain bolts and attachment items before returning the truck to service. If 2 chains are used paired, replace in pair.

supports, anchor bolts and lift chains together with all their attachments.

Checking the lift chain for elongation General The chain bends as it passes over the chain rollers.

This gradually causes the chain links and the chain plate eyelets to wear. The chain therefore elongates over time.

Preparatory measures 1. Remove the lift chain if it cannot be fully inspected when installed.

WARNING Crashing loads can cause injury Lift chains, chain supports, chain bolts and their attachments are safety components. Their failure can cause the load to crash, resulting in fatal injuries.

2. Clean the lift chain (see page 144).

Tools required: •

Wear gauge (see Fig. 127) or steel ruler

¾ Never repair lift chains, chain supports or chain bolts - always replace them with original spare parts.

The inspection covers the following points: Checking the service hours for the chain supports and lift chains.

•

Checking the lift chain for elongation.

•

Checking for wear on the edges of the chain connection plates.

•

Checking for pitting due to corrosion, in particular on the outer surfaces of the connection plates.

•

Checking for twisted and protruding pins.

•

Checking for loss of freedom in the chain links.

•

Checking for damage to the anchor bolts and their attachments.

•

Checking for wear and corrosion of the chain supports and anchor bolts.

Checking the service hours for the lift chains and anchor bolts 1. Check the chain support date of manufacture (see engraving on chain support): If the chain supports are 3 years or older, replace the chain supports, anchor bolts and lift chains together with all their attachments.

2. Check the number of service hours since the chain support and lift chains were last replaced: If the chain supports or lift chains have been in service for 6000 hours or more, replace the chain

ROLLER AND LEAF CHAIN WEAR SCALE

•

Fig. 127 Crown wear gauge

The chain wear can be measured using a wear gauge (part no. 106440) or a steel tape measure.

The Crown wear gauge (see Fig. 127) has two scales: •

Scale “A” is used for 19.05 mm (0.75 inch) and 25.4 mm (1 inch) pitch chains.

•

Scale “B” is used for 15.88 mm (0.625 inch) pitch chains.

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Replace lift chains, chain supports, anchor bolts and attachments if the chain has elongated by more than 3 %!

Checking the chain for elongation 1. Raise the fork carriage to tension the lift chain.

(Pull removed lift chains taut in order to measure them.)

Note: For twin chains always replace the second lift chain with the chain support and anchor bolts.

Checking the lift chains This section lists the inspection items that can be performed in one step: •

Check for loss of freedom in the chain links.

•

Check for worn or missing plates.

•

Check for twisted and protruding pins.

•

Check for lift chain lateral wear.

•

Check for lift chain corrosion.

Freedom of movement Each individual chain link must flex freely. Tight joints (see Fig. 129) increase friction and the chain tension during lifting. Excessive chain tension in turn accelerates material wear.

A

Fig. 128 Measurement section (A) on the lift chain

Fig. 129 Tight joints

Possible causes of stiff chain links are as follows:

CAUTION Make sure you measure a part of the chain that passes over a pulley.

•

Bent pins or plates

•

Rusty chain links

•

Peened plate edges.

Plate edge distortion is caused by:

2. With taut lift chain check section (A) either in front or rear of pulley for elongation.

– Ruptured chain pinion.

3. Repeat the measurement on 3 parts of the chain that always pass over a pulley during operation.

– Chain striking the mast components.

– Constant overloading of the chain.

Note: If you are using a steel ruler, the measurement must include at least 10 links. See following table: Pitch

No. of chain links

Length new

Wear limit

25.4 mm 1 inch

12

305 mm 12 inch

314 mm 12.375 inch

19.05 mm 0.75 inch

16

305 mm 12 inch

314 mm 12.375 inch

15,88 mm 0.625 inch

20

318 mm 12.5 inch

327 mm 12.875 inch

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Worn or missing plates Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (see Fig. 130) can crack after a high number of lifting cycles with heavy loads.

Fig. 130 Worn connection plate WI 2300

LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Turned pins 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 (see Fig. 131). The chain can break as a result.

Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction.

nizing process is an excellent protection and fully penetrates the joints. Do not remove this layer of grease!

Checking lift chains for rust, rust marks and cracking caused by corrosion 1. If you have not already done so, with the mast fully lowered undo the lift chain bolts from the top chain supports (remove the anchor bolts) and thread them out so that they can accessed along their whole length.

2. Check the chain links for corrosion and corrosion damage (marks, pitting).

3. Rust film on lift chains can be removed with chain oil. Now check again for rust marks.

4. Immediately replace any chains with rust marks or pitting along with the chain supports, anchor bolts and attachments. Chains used in pairs must also be replaced in pairs.

Chain lateral wear 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: Fig. 131 Turned pin

•

Checking chain links for freedom of movement, worn connection plates and turned pins

Uneven chain tension (see Checking and adjusting the chain tension, page 148).

•

Misalignment between the pulleys and the chain anchors (see Checking the lifting components for misalignment, page 148).

1. With the mast fully lowered, undo the lift chain bolts from the top chain supports (remove the anchor bolts) and thread them out far enough that they can accessed along their whole length.

2. Check the chain links for freedom of movement, worn connection plates and turned pins.

Immediately replace any damaged chains along with the chain supports, anchor bolts and attachments. Chains used in pairs must also be replaced in pairs.

Checking chain supports and anchor bolts Checking chain supports 1. Check the chain supports for: – Assembly period expiry (max. 6000 hours or 3 years, see date on chain support head)

Corrosion

– Cracks

Corrosion considerably reduces the capacity of a lift chain. It results in cracking in the side plates.

– Corrosion – Finger wear 2. Replace any damaged or worn chain supports.

Checking the anchor bolts – Check the anchor bolts for: – Cracks – Corrosion, – Wear

Fig. 132 Cracking caused by corrosion

Lift chains must therefore be protected from corrosion.

The layer of grease applied in the factory hot dip galva-

3. Replace any damaged anchor bolts.

4. Check the condition of the anchor bolt retaining element.

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Replace any corroded or missing retaining elements.

Checking the chain pulleys 1. Check the chain pulleys for: – Wear in the flange area – Running surface wear Worn flanges are due to misalignment. If the pulleys are worn: 2. Check or adjust the chain tension and mast roller setting.

Checking and adjusting the chain tension When installed, both outer lift chains should be equally tensioned to ensure even distribution of the load over the two chains during lifting operations.

The forks on the fork carriage should lie evenly on the ground. If they are not even, compensate the chain length via the chain anchor so that both chains have the same tension.

After adjusting the chain length, tighten the chain anchor counternuts again.

Checking the lifting components for misalignment 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: 1. Park the truck on a level surface.

2. Support the fork carriage and disassemble the anchor bolts on both ends of the lift chains.

3. Visually inspect the alignment with the anchor slots.

If the chain ends are not aligned with the chain support slots: – Check the mast, cylinder and piston rams for damage.

– Check the alignment of the mast stages.

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LIFTING MECHANISM Lubricating Lift Chains

Lubricating Lift Chains

CAUTION

General information

A lift chain must never be allowed to dry.

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.

As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear.

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. 133) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty.

The key thing is that the lubricant oil can penetrate into the chain bolts. This is impossible if the chains are covered in grease and dirt.

1

Maintaining a lubricant film on all the chain surfaces provides the following benefits: •

Restricts joint wear to a minimum (chain elongation).

•

Avoids corrosion.

•

Reduces the risk of chain bolts turning.

•

Restricts the danger of chain links turning in to a minimum.

•

Ensures an even movement of the chains and thus reduces noise levels.

•

Reduces the chain tension due to less friction in the chain system.

Key factors when considering which lubricant to use are as follows: •

High degree of penetration in the narrowest of gaps

•

Maximum tolerance of pressure and shearing forces before the lubricant film comes off.

•

Suitability to the operating temperature range, especially important for cold store trucks.

Fig. 133 Oil film (1) in a multi-plate chain

Lubrication intervals and lubricants Under normal operating conditions the chains should be cleaned according to the intervals specified in the maintenance schedule (see page 25), and then lubricated with an approved chain lubricant (see page 23).

In extreme conditions this interval must be reduced accordingly.

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 links, 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.

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149

LIFTING MECHANISM Separating Lift Chains

Separating Lift Chains

Cutting the lift chain

Lift chains are supplied by the meter and must be cut to the required length.

WARNING

Tools and equipment required •

Risk of eye damage Splinters can fly off during grinding operations.

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.

•

¾ Wear goggles to avoid eye injuries.

A backring (washer) with a hole slightly larger than the head diameter of a chain bolt. The backring thickness must be slightly larger than the height of the head of a chain bolt. The backring prevents the inner plate surface from being damaged when you drive out the chain bolt.

1. Carefully grind the head of the chain bolt, taking care not to damage the chain plate eyelet.

2. Place the backring onto the hole in the working plate.

•

A grinder.

•

A hammer and hole with a diameter slightly shorter than the chain bolt. Or a press with a suitable mandrel.

3. Insert the head of the chain bolt to be driven out into the backring. Ö Align the chain bolt, backring and hole in the working plate.

4. Drive out the chain bolt.

1

4

3

1

2

1

Chain plate eyelet

3

Backring

2

Hole in working plate

4

Grinder

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LIFTING MECHANISM Lift Height Adjustment

Lift Height Adjustment

(2, Fig. 134) make slight contact with the stop points when the outriggers are fully lowered (1, Fig. 134).

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery.

Max. 75 mm

¾ Prevent the truck from being switched on again.

Outrigger Lift Height Adjustment

Fig. 135 Initial lift height adjustment

5. Tighten the nuts (16) on the tie rods (15).

6. Measure the outrigger height when the outriggers are fully lowered on the load wheels. Ö The height should not exceed 75 mm.

Note: The maximum outrigger height is 215 mm.

Fork Height Adjustment 1. Fully lower the outriggers and forks.

2 1 Fig. 134 Lift height adjustment 1

Riser stop

2

Outrigger stop point

Max. 92 mm

1. Fully lower the outriggers. Ö The stop points of the outriggers (2) should just make contact with the stop points (1).

If this is not the case, adjust the outrigger height as follows: Note: The following item numbers refer to Figure 137 on page 152.

2. Raise the outriggers so that the tie rods (15) can be removed.

Fig. 136 Lift height adjustment

2. Measure the height at the fork tips and the fork shank when the forks are fully lowered. Ö The height should not exceed 92 mm.

3. Loosen the nuts (16) on the tie rods (15).

Note: The fork shank height should be the same or greater than the fork tip height. The lift chains should be tensioned at a lift height of 92 mm.

4. Adjust the tie rods (15) by turning the hex. bolts on the tie rods so that the stop points of the outriggers

3. If there is any deviation, use the chain anchor to adjust the fork height.

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LIFTING MECHANISM Lift Height Adjustment

Fig. 137 Lifting mechanism overview

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CYLINDERS

153

Notes:

154

CYLINDERS General

General

Hydraulic System Repair Instructions

Safety Notices CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

WARNING High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency.

Seek medical assistance even if the skin appears normal at first.

To avoid accidents: • Depressurise the hydraulic system before opening any sections of it.

• Tighten all connections before pressurising the system.

• Keep hands and body away from pressurized fluid.

•

•

Hydraulic systems are sensitive to dirt.

•

Thoroughly clean disassembled hydraulic components before dismantling them.

•

Always repair hydraulic components at a clean workstation.

•

Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil.

•

Protect components against re-contamination before assembling them.

•

Immediately seal open hydraulic ports on repaired assemblies with dummy plugs. This also applies to open ports and lines on the truck.

•

Do not refinish any cylinder surfaces. Replace any damaged parts.

•

Always replace all the seals on the assembly. Used seals can cause leaks.

Always use a piece of paper or cardboard to trace leaks.

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CYLINDERS Tools

Tools

Producing extractors 1. Hard solder a self-tapping 4 mm screw (3) onto the shaft (min. 150 mm, long, max. Ø 4 mm) of a screwdriver (1).

CAUTION

2. Sand the soldering joint.

Cylinder surfaces can be damaged through the use of unsuitable tools.

3. Wrap insulating tape (1) around the shaft and soldering joint of the screwdriver.

¾ Do not use a screwdriver or similar tools. ¾ Use burr-free tools made of soft metal (brass, aluminium) without sharp edges or a suitable plastic.

Groove aligning arbor for small rod seals

You must produce the following tools yourself:

The outer diameter of the groove aligning arbor must fit the internal diameter of the cylinder cap.

Small hook

The arbor should end flush with the bottom of the seal seat.

Use small hooks to remove small seals (see Fig. 138).

1

2

3 Fig. 140 Groove aligning arbor in a cylinder cap 1

Cylinder cap

Fig. 138 Hook

2

Seal seat

Extractor

3

Groove aligning arbor

Two extractors to remove rod seals (see Fig. 139) .

1

3

2

Fig. 139 Extractor

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CYLINDERS Tools Assembly devices for large rod seals Produce a tool body (12, Fig. 141) with a diameter to match the internal diameter of the cylinder caps.

1 2

3 4

Fig. 141 Assembly device for large rod seals 1

Tool body

2

Fixed pin

3

Rod seal (shown for illustration purposes only)

4

Axial moving pins

Protective mechanisms If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate plastic protective mechanisms.

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157

CYLINDERS Rod Seal Removal and Assembly

Rod Seal Removal and Assembly

1

Removing a large rod seal

2 3

1. Turn one extractor (see Fig. 139) respectively into the opposite parts of the rod seal.

4

2. Pull the seal out of its seat using the grips of the tools.

3. Dispose of the rod seal.

Removing a small rod seal

5

1. Using a small hook (see Fig. 138) pull the rod seal out of the seal seat.

6

2. Dispose of the rod seal.

Inserting a large rod seal 1. Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the cylinder cap.

2. Place the rod seal over the fixed pin (1, Fig. 142).

3. Bend the rod seal under the pin (2).

4. Now bend the resultant loop up so that the pin (3) can be moved into the loop.

Fig. 143 Wound rod seal

5. Push the tool body (1, Fig. 5) into the cylinder cap (2) until the rod seal (6) is aligned with the seal seat in the cylinder cap.

6. Pull the pin (1, Fig. 144) back. Ö One segment of the rod seal jumps into the seal seat.

1

1

2

2 Fig. 142 Threading the rod seal

Fig. 144 The first rod seal segment is located in the seal seat.

7. Retract the pin (2, Fig. 144). Ö The rod seal is now fully located in the seal seat (see Fig. 145)

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CYLINDERS Rod Seal Removal and Assembly Rod seal assembly, sealing lip first The sealing lip is sensitive and must not be damaged.

Special protective sleeves (1) are required when pushing the seal (2, Fig. 147) over the thread and holes.

CAUTION Incorrectly assembled rod seals will leak ¾ Fit the rod seal with the sealing lip facing the pressure side.

1

3

2

Fig. 145 Rod seal fully inserted in seal seat

4

8. Pull the tool body out of the cylinder cap.

Fitting a small rod seal 6 1

5 2 3 Fig. 147 Sealing lip facing the pressure side

4

1

Cylinder tube

2

Inner thread

3

Protective sleeve for assembly

4

Rod seal

5

Sealing lip

6

Backring

Fig. 146 Small rod seal assembly

•

Apply a thin coating of hydraulic oil to the rod seal (2, Fig. 146) and the seal seat (3) in the cylinder cap (1).

•

Place the cylinder cap on the groove aligning arbor (4).

•

Gently bend the rod seal (2) together.

•

Place one part of the rod seal into the seal seat (3).

•

Press the rod seal into the seal seat using a burrfree aluminium or plastic arbor (1).

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159

CYLINDERS Replacing the Lift Cylinders

Replacing the Lift Cylinders

Replacing the Outer Lift Cylinders on the TL and TT Masts

WARNING High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency.

Seek medical assistance even if the skin appears normal at first.

To avoid accidents: • Depressurise the hydraulic system before opening any sections of it.

• Tighten all connections before pressurising the system.

• Keep hands and body away from pressurized fluid.

•

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck: ¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again.

Always use a piece of paper or cardboard to trace leaks.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

WARNING Risk of trapping and severing limbs Unsecured mast stages and attachments can sever limbs or even cause fatal injuries. ¾ Before starting assembly always block and secure the relevant components with equipment with sufficient strength and stability.

Fig. 148 TL mast lift cylinder

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CYLINDERS Replacing the Lift Cylinders

1

Fig. 150 LMS 1700 connector

2. If applicable, remove the connector of the “LMS 1700” limit switch (1) to prevent it from being damaged.

2

Fig. 149 TT mast lift cylinder

Outer lift cylinder removal 1. Depressurise the hydraulic system.

Fig. 151 Retaining rings

3. Remove both retaining rings (2) from the top of the lift cylinders.

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

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CYLINDERS Replacing the Lift Cylinders CAUTION Raising the inner mast too far can damage the lift chains and hydraulic hoses

5

¾ Raise inner mast 1 no further than approx. 300 mm.

4. Strap belts around the centre of inner mast 1 and using a crane raise it by approx. 200 mm.

5. Use suitable wooden blocks to prevent inner mast 1 from lowering.

Fig. 154 Hydraulic lines

9. Undo the hydraulic line union (5) from the two lift cylinders.

3

CAUTION The weight of the lift cylinders can cause injury ¾ Use 2 people to remove the lift cylinders.

Fig. 152 Attachment clamps

6. Remove the attachment clamps (3) on either side.

10. Get two people to raise the lift cylinder out of the truck and place it down on a suitable support.

Outer lift cylinder assembly Note: Assembly of the outer lift cylinders is the reverse order of disassembly. Note the following:

4

•

When inserting the lift cylinders make sure the bleed screws are facing outwards.

•

If the piston ram of the lift cylinder is retracted it cannot be secured. The piston ram will then have to be pressurised and extended until the retaining rings can be fitted.

Fig. 153 Cover plates

7. Remove the cover plates (4) on either side.

8. Place a container under the lift cylinders to collect the hydraulic oil.

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CYLINDERS Replacing the Lift Cylinders Replacing the Outer Lift Cylinders on TF Masts

1

2

Fig. 156 Top hydraulic lines

1. Extend inner mast 1 slightly to gain access to the top hydraulic lines (1,2).

2. Use suitable wooden blocks to prevent inner mast 1 from lowering.

3. Remove the left hydraulic line (1) in full.

4. Loosen the unions on the right hydraulic line (2).

Outer lift cylinder assembly Note: The outer lift cylinders are assembled in the same way as for the TL and TT mast lift cylinders. In addition, the following steps must be carried out:

Fig. 155 TF mast lift cylinders

•

Extend inner mast 1 slightly to gain access to the top hydraulic lines (1,2).

•

Use suitable wooden blocks to prevent inner mast 1 from lowering.

•

When inserting the lift cylinders make sure the bleed screws are facing outwards.

•

The piston ram may have to be extended manually until the retaining rings can be fitted.

Outer lift cylinder removal Note: The outer lift cylinders are removed in the same way as for the TL and TT mast lift cylinders. In addition, the following steps must be carried out:

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CYLINDERS Replacing the Lift Cylinders Replacing the Free Lift Cylinders on the TT and TF Masts

3

WARNING Accidental truck movement can cause injury A powered up truck with a connected battery can move suddenly when you are working on it.

You should therefore carry out the following safety procedures before starting any operations on the truck:

2

¾ Lower the forks to the ground. ¾ Switch the truck off. ¾ Disconnect the battery. ¾ Prevent the truck from being switched on again.

Fig. 158 Yoke assembly

3. Remove the bolts (2) of the chain anchor.

4. Lift out the entire yoke assembly (3) from the top.

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

Free Lift Cylinder Removal

WARNING Lifting gear failure can cause accidents Note the minimum capacity for the lifting gear whenever carrying out work on the mast.

Fork carriage removal 1. Depressurise the hydraulic system.

CAUTION Raising the inner mast too far can damage the lift chains and hydraulic hoses ¾ Raise inner mast 1 no further than approx. 300 mm.

5. Using a crane, raise inner mast 1 approx. 200 mm until the fork carriage rollers are located outside inner mast 2.

1

6. Pull the fork carriage out to the front and using a crane or a forklift truck lower it onto a suitable base.

Free lift cylinder removal 7. If necessary, push the piston ram of the free lift cylinder down manually as far as the stop.

8. Using a crane, carefully raise inner mast 1 by approx. 200 mm.

9. Use suitable wooden blocks to prevent inner mast 1 from lowering.

Fig. 157 Mast guard

2. Remove the mast guard (1).

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164

CYLINDERS Replacing the Lift Cylinders

8

4

6

5 Fig. 161 Attachment clamp

13. Remove the attachment clamp (8).

Fig. 159 Hydraulic line

CAUTION

10. Undo the unions (4) and (6) from the bottom hydraulic line.

The weight of the lift cylinders can cause injury

11. Remove the union (5).

¾ Use 2 people to remove the lift cylinders.

14. Get two people to raise the free lift cylinder out of the truck and place it down on a suitable support.

Note: Take care not to lose the knob (see Fig. 162) of the free lift cylinder.

7

Free lift cylinder assembly Note: Assembly of the free lift cylinder is the reverse order of disassembly. Note the following:

1

Fig. 160 Free lift cylinder

12. Remove the screws (7) from the bottom of the free lift cylinder.

Fig. 162 Knob assembly

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165

CYLINDERS Replacing the Lift Cylinders •

Insert the knob (1) in the correct position underneath the free lift cylinder.

8. Immediately seal ports with dummy plugs.

•

When attaching the free lift cylinder secure first the attachment clamp (see Fig. 161) followed by the screws underneath the free lift cylinder. This prevents the cylinder from buckling.

10. Lift the initial lift cylinder out of the truck.

9. Remove the bottom clamps (1).

Initial lift cylinder assembly Note: Assembly is the reverse of disassembly.

Replacing the Initial Lift Cylinder Initial lift cylinder removal 1

3

2

1

3

2

1

1

Fig. 163 Initial lift cylinder 1

Clamp

2

Initial lift cylinder

3

Hydraulic union

1. Raise the initial lift cylinder so that the clamps (1) can be removed.

2. Support the forks with suitable wedges.

3. Press the "Outrigger lower" switch on the control handle for at least 10 seconds to reduce the hydraulic pressure.

4. Remove the top clamp (1) from the initial lift cylinder.

5. Press the “Outrigger lower” switch on the control handle until the cylinders have lowered down into the limit position through their own weight. If necessary, push the cylinder down manually.

6. Disconnect and remove the battery.

7. Undo the hydraulic unions (3) and collect any escaping hydraulic oil in a suitable container.

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166

CYLINDERS Repairing Lift Cylinders

Repairing Lift Cylinders CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health. ¾ Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Checking Cylinders Before Starting Repair Work After removal from the truck: •

Check the piston rams for nicks, scratches, corrosion and other surface damage. Replace any damaged piston rams.

•

Check the dirt deflectors for wear and unusual leakage.

•

If excess hydraulic oil emerges from the ram it may be due to a damaged rod seal.

After dismantling: •

Clean the individual parts in a clean solvent and dry them with weak compressed air.

•

Before assembling, apply a thin layer of hydraulic oil to the cleaned components and replacement parts.

•

Replace all backrings and seals.

Replacing the Rod Seals CAUTION Damaged or contaminated seal seats and piston rams will result in immediate leaks, even with new seals. The same applies to the use of unsuitable tools for seal removal and fitting. ¾ Before fitting a new seal check the seal seats and piston rams for damage and make sure they are clean. ¾ When replacing rod seals use assembly equipment and tools made of soft metal or plastic without sharp edges. Suitable tools and assembly procedures are described starting on page 155.

WI 2300

167

CYLINDERS Repairing the Lift Cylinders on the TL and TT Masts

Repairing the Lift Cylinders on the TL and TT Masts

12 9 2 5

11 3 11 10

6

12 4

9

2 3 4

10

1

5

8

6

7 8

4 8 7

1

1

Velocity fuse

2

Deflector

3

Seal

4

Guide ring

5

Cylinder cap

6

O-ring

7

Piston

8

Guide ring

9

Piston ram

10

Cylinder tube

11

Bleed screw

12

Conical nipple

Fig. 164 Lift Cylinders on the TL and TT Masts WI 2300

168

CYLINDERS Repairing the Lift Cylinders on the TL and TT Masts Lift Cylinder Disassembly 1. Carefully check the cylinder before starting repair work (see page 167).

CAUTION

2. Replace all the seals and apply a thin coat of hydraulic oil to the new seals and shiny metal surfaces.

3. Insert the half shells of the piston (7) in the groove of the piston ram (9).

4. Pull new guide rings (8) onto the piston (7).

The cylinder tube can become damaged when you clamp the cylinder.

5. Push the pre-assembled piston ram (9) into the cylinder tube (10).

¾ Tighten the tensioner very slightly and use prismshaped braces.

6. Insert the deflector (2), seals (3), guide rings (4) and O ring (6) into the cylinder cap (5).

2. Tension the cylinder tube (10) to prevent the cylinder from twisting.

7. De-grease the threads of the cylinder cap (5) and the cylinder tube (10), taking care not to degrease the seals.

3. Unscrew the cylinder cap (5) from the cylinder tube (10).

4. Pull the cylinder tube (10) down from off the ram (9). Take care not to damage it.

5. Remove the deflector (2), seal (3), guide rings (4) and O ring (6).

6. Remove the half shells of the piston (7) from the piston ram (9).

7. Remove the guide rings (8).

8. Check the piston ram (9) and cylinder cap (5) for deep grooves.

Note: Minor grooves can be rectified with fine sandpaper. Replace any components with deep grooves.

9. Remove the bleed screw (11) and conical nipple (12).

10. If required, unscrew the velocity fuse (1) from the hydraulic port on the cylinder tube.

8. Push the cylinder cap (5) carefully over the lubricated piston ram (9), taking care not to oil the thread.

9. Apply Loctite 242 to the start of the thread of the cylinder cap (5).

10. Screw the cylinder cap (5) a few turns onto the cylinder tube (10). Now grease the other thread pitches, screw on the cylinder cap (5) fully and torque it to 120 - 140 Nm. 11. Insert the bleed screw (11) with a new conical nipple (12) and torque it to 5 - 6 Nm. 12. Insert the velocity fuse (1) and torque it to 8 - 9 Nm. 13. Re-fit the lift cylinder back in the truck (see page 160).

14. Bleed the hydraulic system (see page 176).

15. Perform the drift test (see page 177).

Lift Cylinder Assembly CAUTION Incorrect handling during assembly can result in cylinder leaks ¾ Take care not to damage the piston rod and the new seals during assembly. ¾ Use burr-free tools without sharp edges. ¾ Apply a thin coating of hydraulic oil to all seals and components prior to assembly. ¾ Observe the general instructions on assembling seal rods starting on page 155.

1. Wash all the metal components that have been removed and clean with dry compressed air.

WI 2300

169

CYLINDERS Repairing the Lift Cylinder on the TF Mast

Repairing the Lift Cylinder on the TF Mast

12

1

9

1

2

11

3 5

12

4

11

2

6

3 4 5

10 9

8 7 8

7

8

1

1

Velocity fuse

2

Deflector

3

Seal

4

Guide ring

5

Cylinder cap

6

O-ring

7

Piston

8

Guide ring

9

Piston ram

10

Cylinder tube

11

Bleed screw

12

Conical nipple

Fig. 165 TF mast lift cylinder

WI 2300

170

6 4

10

1

CYLINDERS Repairing the Lift Cylinder on the TF Mast Lift Cylinder Disassembly 1. Carefully check the cylinder before starting repair work (see page 167).

CAUTION

2. Replace all the seals and apply a thin coat of hydraulic oil to the new seals and shiny metal surfaces.

3. Insert the half shells of the piston (7) in the groove of the piston ram (9).

4. Pull new guide rings (8) onto the piston (7).

The cylinder tube can become damaged when you clamp the cylinder.

5. Push the pre-assembled piston ram (9) into the cylinder tube (10).

¾ Tighten the tensioner very slightly and use prismshaped braces.

6. Insert the deflector (2), seals (3), guide rings (4) and O ring (6) into the cylinder cap (5).

2. Tension the cylinder tube (10) to prevent the cylinder from twisting.

7. De-grease the threads of the cylinder cap (5) and the cylinder tube (10), taking care not to degrease the seals.

3. Unscrew the cylinder cap (5) from the cylinder tube (10).

4. Pull the cylinder pipe (10) down from off the ram (9). Take care not to damage it.

5. Remove the deflector (2), seal (3), guide rings (4) and O ring (6).

6. Remove the half shells of the piston (7) from the piston ram (9).

7. Remove the guide rings (8).

8. Check the piston ram (9) and cylinder cap (5) for deep grooves.

Note: Minor grooves can be rectified with fine sandpaper. Replace any components with deep grooves.

9. Remove the bleed screw (11) and conical nipple (12).

10. Remove the velocity fuses (1) if required.

8. Push the cylinder cap (5) carefully over the lubricated piston ram (9), taking care not to oil the thread.

9. Apply Loctite 242 to the start of the thread of the cylinder cap (5).

10. Screw the cylinder cap (5) a few turns onto the cylinder tube (10). Now grease the other thread pitches, screw on the cylinder cap (5) fully and torque it to 120 - 140 Nm. 11. Insert the bleed screw (11) with a new conical nipple (12) and torque it to 5 - 6 Nm. 12. Insert the velocity fuses (1) and torque them to 8 9 Nm. 13. Re-fit the lift cylinder back in the truck (see page 163).

14. Bleed the hydraulic system (see page 176).

15. Perform the drift test (see page 177).

Lift Cylinder Assembly CAUTION Incorrect handling during assembly can result in cylinder leaks ¾ Take care not to damage the piston rod and the new seals during assembly. ¾ Use burr-free tools without sharp edges. ¾ Apply a thin coating of hydraulic oil to all seals and components prior to assembly. ¾ Observe the general instructions on assembling seal rods starting on page 155.

1. Wash all the metal components that have been removed and clean with dry compressed air.

WI 2300

171

CYLINDERS Repairing the Free Lift Cylinders on the TF and TT Masts

Repairing the Free Lift Cylinders on the TF and TT Masts 9 2 5

9

3 11 12

4

6 12

2 3

10

4

11

5

6

7

4

8

10 8

1

7 8 1

Velocity fuse

2

Deflector

3

Seal

4

Guide ring

5

Cylinder cap

6

O-ring

7

Piston

8

Guide ring

9

Piston ram

10

Cylinder tube

11

Bleed screw

12

Conical nipple

Fig. 166 Free lift cylinders on the TF and TT masts WI 2300

172

1

CYLINDERS Repairing the Free Lift Cylinders on the TF and TT Masts Free Lift Cylinder Disassembly 1. Carefully check the cylinder before starting repair work (see page 167).

CAUTION

2. Replace all the seals and apply a thin coat of hydraulic oil to the new seals and shiny metal surfaces.

3. Insert the half shells of the piston (7) in the groove of the piston ram (9).

4. Pull new guide rings (8) onto the piston (7).

The cylinder tube can become damaged when you clamp the cylinder.

5. Push the pre-assembled piston ram (9) into the cylinder tube (10).

¾ Tighten the tensioner very slightly and use prismshaped braces.

6. Insert the deflector (2), seals (3), guide rings (4) and O ring (6) into the cylinder cap (5).

2. Tension the cylinder tube (10) to prevent the cylinder from twisting.

7. De-grease the threads of the cylinder cap (5) and the cylinder tube (10), taking care not to degrease the seals.

3. Unscrew the cylinder cap (5) from the cylinder tube (10).

4. Pull the cylinder pipe (10) down from off the ram (9). Take care not to damage it.

5. Remove the deflector (2), seal (3), guide rings (4) and O ring (6).

6. Remove the half shells of the piston (7) from the piston ram (9).

7. Remove the guide rings (8).

8. Check the piston ram (9) and cylinder cap (5) for deep grooves.

Note: Minor grooves can be rectified with fine sandpaper. Replace any components with deep grooves.

9. Remove the bleed screw (11) and conical nipple (12).

10. If required, unscrew the velocity fuse (1) from the hydraulic port on the cylinder tube.

8. Push the cylinder cap (5) carefully over the lubricated piston ram (9), taking care not to oil the thread.

9. Apply Loctite 242 to the start of the thread of the cylinder cap (5).

10. Screw the cylinder cap (5) a few turns onto the cylinder tube (10). Now grease the other thread pitches, screw on the cylinder cap (5) fully and torque it to 120 - 140 Nm. 11. Insert the bleed screw (11) with a new conical nipple (12) and torque it to 5 - 6 Nm. 12. Insert the velocity fuse (1) and torque it to 8 - 9 Nm. 13. Re-fit the free lift cylinder back in the truck (see page 165).

14. Bleed the hydraulic system (see page 176).

15. Perform the drift test (see page 177).

Free Lift Cylinder Assembly CAUTION Incorrect handling during assembly can result in cylinder leaks ¾ Take care not to damage the piston rod and the new seals during assembly. ¾ Use burr-free tools without sharp edges. ¾ Apply a thin coating of hydraulic oil to all seals and components prior to assembly. ¾ Observe the general instructions on assembling seal rods starting on page 155.

1. Wash all the metal components that have been removed and clean with dry compressed air.

WI 2300

173

CYLINDERS Repairing the Initial Lift Cylinder

Repairing the Initial Lift Cylinder

2 3

1

4 2

5 3 1

3 4 5

6

3

6

1

Piston ram

2

Deflector

3

Guide ring

4

Backring

5

Seal

6

Cylinder tube

Fig. 167 Initial lift cylinder overview

WI 2300

174

CYLINDERS Repairing the Initial Lift Cylinder Initial Lift Cylinder Disassembly 1. Carefully check the cylinder before starting repair work (see page 167).

2. Remove the piston ram (1) from cylinder tube (6).

Take care not to damage it.

3. Remove the deflector (2), guide rings (3), backrings (4) and seals (5).

Initial Lift Cylinder Assembly CAUTION Incorrect handling during assembly can result in cylinder leaks ¾ Take care not to damage the piston rod and the new seals during assembly. ¾ Use burr-free tools without sharp edges. ¾ Apply a thin coating of hydraulic oil to all seals and components prior to assembly. ¾ Observe the general instructions on assembling seal rods starting on page 155.

1. Wash all the metal components that have been removed and clean with dry compressed air.

2. Replace all the seals and apply a thin coat of hydraulic oil to the new seals and shiny metal surfaces.

3. Insert the deflector (2), guide rings (3), backrings (4) and seals (5).

4. Carefully insert the piston ram (1) into the cylinder tube (6).

5. Re-fit the initial lift cylinder back in the truck (see page 166).

6. Bleed the hydraulic system (see page 176).

7. Perform the drift test (see page 177).

WI 2300

175

CYLINDERS Bleeding and Flushing the System

Bleeding and Flushing the System

Bleeding the Lift Cylinders 1. Raise the forks to a height of approx. 1,220 mm.

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, check that all filters are fitted and that there is sufficient hydraulic oil in the reservoir (see page 47).

Now carry out a drift test as described on page 177.

2. Slowly open the R.H. mast lift cylinder bleed screw and bleed air from cylinder until bubble-free hydraulic fluid flows out of bleed screw hole.

3. Tighten the bleed screw.

4. Bleed the L.H. lift cylinder in the same way.

Bleeding the Free Lift Cylinder 1. Slowly extend the forks to free lift.

WARNING

2. Slowly open the free lift cylinder bleed screw and bleed air from the system until bubble-free hydraulic fluid flows out of bleed screw hole.

High pressure hydraulic system High-pressure hydraulic oil can cause injury!

3. Tighten the bleed screw securely.

¾ Wear safety gloves and goggles or a face mask when depressurising the system.

Flushing the Lift and Free Lift Cylinders Note: The lift and free lift cylinders must be bled.

WARNING

1. Raise the forks above free lift height.

Lowering forks can cause injury The forks can automatically lower when the hydraulic system is being depressurised and during the drift test.

2. With the forks raised visually check for leaky cylinders.

¾ Never stand underneath a raised fork.

3. Extend and retract the mast at maximum speed to the maximum lift height at least 10 times to flush the entire hydraulic system.

¾ Seal off the hazardous area to prevent other people from entering and standing under a raised fork.

Ö Repair any leaky cylinders.

WI 2300

176

CYLINDERS Drift Test

Drift Test When all the work has been carried out on the hydraulic components, e.g. repairing and replacing hydraulic cylinders or valves, a drift test must be performed. The drift test checks for leaks in the hydraulic system components.

•

All drift tests must be performed with maximum rated load. The truck's rated capacity is shown on the capacity data plate.

•

The material used for the test load must be evenly distributed on a pallet and must be attached to the fork carriage.

•

The forks must be spread to the maximum width.

•

Whenever you carry out a drift test the hydraulic oil temperature must be 30 - 40°. Measure the temperature in the hydraulic reservoir before carrying out the drift test.

WARNING Standing under a raised load can cause fatal injuries Fatal injuries could result if the forks of the truck suddenly lower or if a load falls. ¾ Never stand underneath raised forks or loads. ¾ Seal off the hazardous area to prevent access.

1. Flush the lift and free lift cylinders (see page 176).

2. Raise the maximum rated load and secure it on the forks to prevent it from sliding and falling.

3. Attach the lowering plumb to the fork tip.

4. Fully extend the mast with maximum rated load.

The lowering plumb should be approx. 100 mm above the ground.

5. Measure the distance from the lowering plumb to the ground and record the measurement.

6. After 10 minutes measure the distance from the lowering plumb to the ground again.

Note: The extended mast should not lower more than 100 mm within 10 minutes. If the mast has lowered further, this indicates that some of the hydraulic system components are faulty and must be replaced.

WI 2300

177

Notes:

178

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179

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WI 2300

181

WIRING DIAGRAMS Distributor PCB Distributor PCB

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WI 2300

182

WIRING DIAGRAMS Traction Controller - Drive Side Traction Controller - Drive Side

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WI 2300

183

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WI 2300

184

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WI 2300

185

WIRING DIAGRAMS Control Handle Control Circuit Control Handle Control Circuit

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WI 2300

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*#

",+

5.53%$

7(4

0# (#-

,-3 ).)4)!,

#!

4(3 INSIDE 0-

#! "$)

7(4

#! (#-

7(4 "?

Fig. 174 Lift limit switches and temperature switches

WI 2300

187

WIRING DIAGRAMS Anti Roll Back (ARB) Anti Roll Back (ARB)

#! !.4) 2/,, "!#+ !2" 0# 0#"

"6

3)'.!, " 3%.3/2 "%!2).'

0# 0#"

"!#+7!2$ 37)4#(

3)'.!, ! 3%.3/2 "%!2).'

0# 0#"

0/4

0# 0#"

"23

0# 0#"

&/27!2$ 37)4#(

*# "2+

"2+ '.$

"6 3%.3/2 "%!2).'

5.53%$

5.53%$

5.53%$

'.$ 3%.3/2 "%!2).'

0# 0#"

'.$ 0.

#!

2%$

7(4

",5

",+

3%.3/2 "%!2).'

0.

"?

Fig. 175 Anti Roll Back (ARB)

WI 2300

188

*#

0 3

#

*#

&!.

#

*# ,-3 )NITIAL

$

36

36

36

+

+ 2ELAY 3OCKET

'2.?

9%,?

#/.42/,,%2

0 #/.4!#4/2

+93

0# * !.4) 2/,, "!#+ 0#

& 2

#/.4!#4/2

2 & "

*#

$ ,-3

MM

& (!.$,% " 0#"

*# 0#

' '2.?

) ).3425-%.4 0#

9%,?

*# $ %#2

7(4?

(/2.

'2.?

*#

!,-

# 3TROBE ,IGHT

7(4?

"2.?

0# ( 3&

*# % "2+

0#

0#"

!

0#

"

06 36#,

*#

% 4(3

(#-

0# !

0#"

" 0#" 0#

'

*#

9%,?

$ /23

*#

"2.?

$ "23

#ONTACTS

#OIL

7(4?

'2.?

"2.?

9%,?

"2.?

7(4?

%$3 /54 ).

WIRING DIAGRAMS Main Harness

Main Harness

Fig. 176 Main Harness

WI 2300

189

WIRING DIAGRAMS Main Harness Plug connector housing

Replacement Parts

Mod

Housing

Part No.

Description

Part No.

Description

A

PC 201, PC 203

803452-002

Connector

811996-003

Pedestal relay

824206

Harness, complete

B

PC 202, PC 205

803452-002

Connector

C

JC 207, JC 208, JC 209

803452-002

Connector

JC 406, JC 407, JC 421, JC 422, JC 424

803452-002

E

JC 402, JC 408

803450-001

Connector

F

JC 210

803450-003

Connector

G

PC 221, PC 403

116851

H

PC 401

I Y

Wire connections Wire No.

Connection

2900

EDS OUT PC201-1 PCB

2901

PC201-2 PCB KYS IN

2902

KYS OUT PC201-3 PCB

2903

PC205-2 PCB JC207-1 Alarm

Connector

2904

JC207-1 Alarm JC208-1 FAN

803450-005

Connector

2905

PC 405

803450-008

Connector

PC202-1 PCB PC401-1 SF

PC 200

803450-044

Connector

2906

PC201-6 PCB PC405-2 BDI

Contact pins

2907

PC202-7 PCB JC402-1 BRK

Item No.

Part No.

2908

PC200-9 AntiRollBack JC424-1 Sensor

1

803452-005

2909

2

803452-006

PC200-1 AntiRollBack PC203-16 PCB

3

803450-010

2910

4

803450-087

PC200-6 AntiRollBack PC203-15 PCB

5

116858

2911

JC422-2 LMS Initial JC210-6 HANDLE

6

803450-049

2912

10

813444-001

JC406-1 BRS JC407-2 ORS

2913

JC208-3 Fan JC209-3 Power S.

2914

PC201-7 PCB Traction Contactor (R)

2915

Traction Contactor (R) Traction Contactor (F)

D

Connector

Cable lugs and rings Mod

Part No.

Description

---

816812-004

Plat-pin plug

---

816812-001

Plat-pin plug

---

816812-018

Insulation

WI 2300

190

WIRING DIAGRAMS Main Harness Wire No.

Connection

Wire No.

Connection

2916

PC201-11 PCB PC405-6 BDI

2937

PC203-12 PCB PC403-12 Controller

2917

PC203-15 PCB PC403-15 Controller

2938

PC203-13 PCB PC403-13 Controller

2918

PC203-16 PCB PC403-16 Controller

2939

PC203-11 PCB JC207-4 Alarm

2919

PC201-16 PCB SV2

2940

PC203-12 PCB JC207-3 Alarm

2920

SV2 SV1

2941

PC203-14 PCB PC403-14 Controller

2921

SV1 SV3

2942

PC203-1 PCB PC403-1 Controller

2922

SV3 P Contactor

2943

PC401-2 SF PC202-2 PCB

2923

P Contactor PV

2944

PC221-16 PCB K1 - Pin 86

2924

PV SVCL

BRN_2

2925

SVCL PC221-7 HCM

PC202-3 PCB JC407-1 ORS

WHT_2

2926

PC205-1 PCB HORN

PC202-6 PCB JC407-3 ORS

YEL_2

2927

JC210-5 Handle PC221-4 HCM

PC202-4 PCB JC406-2 BRS

GRN_2

2928

JC422-1 LMS Initial PC221-5 HCM

PC202-5 PCB JC406-3 BRS

GRN_1

2929

JC210-4 Handle PC405-4 BDI

K1 - Pin 30 PC205-7 PCB

YEL_1

2930

JC210-3 Handle PC221-9 HCM

K1 - Pin 87 PC205-8 PCB

WHT_1

2931

JC210-2 Handle PC221-10 HCM

JC421-2 LMS 1700mm PC221-16 HCM

BRN_1

2932

JC408-1 THS PC405-3 BDI

JC421-3 LMS 1700mm PC202-4 PCB

2933

JC408-2 THS PC221-2 HCM

100

PC200-4 AntiRollBack JC424-2 Sensor

2934

---

101

2935

---

PC200-2 AntiRollBack JC424-3 Sensor

2936

PC403-11 Option PC203-11 HCM

102

PC200-3 AntiRollBack PC203-2 PCB

WI 2300

191

WIRING DIAGRAMS Main Harness Wire No.

Connection

Wire No.

Connection

103

PC200-7 AntiRollBack PC203-3 PCB

5913

PC200-13 AntiRollBack JC424-4 Sensor

104

PC200-5 AntiRollBack PC203-6 PCB

500

200

EDS IN PC201-4 PCB

PC201-14 PCB B- Controller

501

201

PC201-5 PCB PC405-7 BDI

PC201-15 PCB JC209-2 Power S.

502

300

PC203-5 PCB PC403-5 Controller

PC201-15 PCB JC208-2 Fan

503

301

PC203-6 PCB PC403-6 Controller

JC208-1 Fan JC207-2 Alarm

504

302

PC203-7 PCB PC403-7 Controller

B- Controller PC221-11 HCM

505

PC201-13 PCB PC405-5 BDI

506

PC221-11 HCM K1 - Pin 85

5900

PC200-8 AntiRollBack JC402-2 BRK

5901

PC201-8 PCB Traction Contactor (R)

5902

PC201-9 PCB Traction Controller (F)

5903

PC203-2 PCB PC403-2 Controller

5904

PC203-3 PCB PC403-3 Controller

5905

SV2 PC221-6 HCM

5906

P Contactor PC221-12 HCM

5907

PV PC221-1 HCM

5908

SVCL PC221-8 HCM

5909

SV3 PC221-14 HCM

5910

SV1 PC221-13 HCM

5911

HORN PC205-3 PCB

5912

PC200-14 AntiRollBack PC202-8 PCB

WI 2300

192

WIRING DIAGRAMS Limit Switch Cables (LMS) Limit Switch Cables (LMS)

0#

"

#ONNECT TO -AIN (ARNESS 0.

*# #ONNECT TO ,-3 ",+ MM 0.

"2.

!

",+ "2.

!

Fig. 177 Limit switch (LMS) cables

Plug connector housing Mod

Housing

Part No.

Description

A

JC 423

803450-002

Connector

B

PC 421

803450-006

Socket

Contact pins Item No.

Part No.

1

803450-010

2

116858

Replacement Parts Part No.

Description

824207

Harness, complete

WI 2300

193

WIRING DIAGRAMS Horn Wire Harness Horn Wire Harness

0#

0#

0#

% Fig. 178 Horn wire harness

Plug Connector Housing Housing

Part No.

Description

PC 413

803450-021

Housing

PC 419

803450-023

Housing

PC 417

803450-023

Housing

Contact Pins Item No.

Part No.

1

803450-022

2

803450-024

Replacement Parts Part No.

Description

811931

Harness, complete

WI 2300

194

WIRING DIAGRAMS Control Handle and Horn Switch Assembly Control Handle and Horn Switch Assembly

*# *#

$ Fig. 179 Control handle and horn switch assembly

Replacement Parts Part No.

Description

811933

Harness, complete

WI 2300

195

WIRING DIAGRAMS Control Handle, Sideshift/Initial Lift Assembly Control Handle, Sideshift/Initial Lift Assembly

",5% ",!#+ ",5%

",!#+

*#

$ Fig. 180 Control handle, sideshift/initial lift assembly

Replacement Parts Part No.

Description

812895

Harness, complete

WI 2300

196

WIRING DIAGRAMS Control Handle Wire Harness Control Handle Wire Harness

0#

0#

'2.

7(4 '2.

2%$ '2%9 0).+ 9%, ",+

'2%9 ",5 "2.

2%$ ",5

WHT (004)

0#

'2.

'2%9 0).+ 9%, ",+ 2%$ ",5

"2. ",5

'2%9

7(4

6)/ 0).+ "2. '2.

2%$

0#

0#

BRN / GRN (013) PINK (003) VIO (002) 7(4 9%, 9%, "2.

7(4 '2.

0#

7(4 9%, YEL / BRN (016)

# Fig. 181 Control handle wire harness

Plug Connector Housing

Mod

Housing

Part No.

Description

Mod

Housing

Part No.

Description

E

PC 210

803450-007

Connector

A

PC 410

803450-009

Connector

819279-003

Seal

819279-006

Seal

803452-002

Connector

803450-020

Connector

819279-002

Seal

803450-008

Connector

819279-004

Seal

803450-006

Connector

819279-002

Seal

B C D

PC 414 PC 415 PC 420

F

PC 204

WI 2300

197

WIRING DIAGRAMS Control Handle Wire Harness Contact pins Item No.

Part No.

1

116858

2

803450-048

3

803452-005

Replacement Parts Part No.

Description

813426

Harness, complete

WI 2300

198

WIRING DIAGRAMS Strobe and Alarm Signal Wire Harness Strobe and Alarm Signal Wire Harness

0# *#

#

!

30

30

0#

"/44/-

4/0

0#

%

!,!2$2)6%2

$

!,!2-

"

*#

0/7%2 3500,9 8#

Fig. 182 Strobe and alarm signal wire harness (optional equipment)

Plug Connector Housing

Replacement Parts

Mod

Housing

Part No.

Description

Part No.

Description

A

JC 245

803450-001

Housing

818947

Harness, complete

B

PC 207

803450-006

Connector

C

PC 245

803450-005

Connector

D

PC 246

803450-007

Connector

E

JC 240

---

Connector

Contact pins Item No.

Part No.

1

803450-010

2

116858

Cable Lugs and Rings Mod

Part No.

Description

5

062007-032

Ring Terminal

WI 2300

199

WIRING DIAGRAMS Power Cables Power Cables

6 "!44% 29

"!44 $)3#/..%#4 0#

0#

TO +93 TO &5

).

%$3

0 0-

/54

$ %

$ %

&5 !

$ &5 !

!

& 2

4$

!

!

"

5

-

"

" Fig. 183 Power cables

WI 2300

200

HYDRAULIC SCHEMATIC

201

Notes:

202

HYDRAULIC DIAGRAMS Hydraulic Symbols

Hydraulic Symbols Icon

Meaning

Icon

Vented reservoir with lines above the fluid level

Meaning

Electric motor unidirectional single speed

Vented reservoir with lines above the fluid level

Hydraulic pump fixed displacement unidirectional

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

Component enclosure manifold block

Lines crossing; not connected

Resistor orifice throttle (adjustable)

Lines crossing and connected

Throttle, fixed

Plugged port

Relief valve adjustable

Accumulator gas charge diaphragm type

Check valve

WI 2300

Rev.1 02/2009

203

HYDRAULIC DIAGRAMS Hydraulic Symbols Icon

Meaning

Icon

Meaning

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

Hydraulic steer unit L R

T P

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

Torque generator P T

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 pre-tension valve assembly in manifold

Flow meter

Electric motor unidirectional variable speed

Rev.1 02/2009

204

WI 2300

HYDRAULIC DIAGRAMS Hydraulic Symbols Icon

Meaning

Icon

Meaning

Valve block with 3 operating units

Proportional solenoid

Shuttle valve

Dual solenoid

Relief valve, fixed setting

Hydraulic pilot operated solenoid valve

Velocity fuse

Hydraulic pilot operated hydraulic valve

Pressure-compensated flow control with reverseflow bypass; fixed.

Manual actuator

Pressure-compensated flow control, 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)

WI 2300

Rev.1 02/2009

205

HYDRAULIC DIAGRAMS Hydraulic Symbols Icon

Rev.1 02/2009

206

Meaning

Icon

Meaning

Double-acting cylinder; equal area

Thermometer

Double-acting cylinder; unequal area

Pressure gauge

Pressure switch

Hydraulic motor, bidirectional

WI 2300

HYDRAULIC DIAGRAMS Hydraulic Diagram - TL Mast Hydraulic Diagram - TL Mast

8

9

7

10 11

6

12

13

5

14 3 4 2

15

M 1

Fig. 184 Hydraulic Diagram - TL Mast 1

Suction filter

9

Initial lift cylinder

2

Motor and pump

10

Initial lift shutoff valve (SV1)

3

Check valve (CV)

11

Initial lift lowering valve (SV2)

4

Pressure relief valve (RV1)

12

Orifice (ORF1)

5

Pilot-operated load hold valve (SVCL)

13

Pressure relief valve (RV2)

6

Main lift shutoff valve (SV3)

14

Main lift lowering valve (PV)

7

Main lift line break safety device

15

Lowering brake valve

8

Main lift cylinder

WI 2300

207

HYDRAULIC DIAGRAMS Hydraulic Diagram - TT Mast Hydraulic Diagram - TT Mast

9 8

8

10

7

7

11

12

13

6

14

15

5

16

3 4

2

17

M 1

Fig. 185 Hydraulic Diagram - TT Mast 1

Suction filter

10

Free lift cylinder line break safety valve

2

Motor and pump

11

Initial lift cylinder

3

Check valve (CV)

12

Initial lift shutoff valve (SV1)

4

Pressure relief valve (RV1)

13

Initial lift lowering valve (SV2)

5

Pilot-operated load hold valve (SVCL)

14

Orifice (ORF1)

6

Main lift shutoff valve (SV3)

15

Pressure relief valve (RV2)

7

Main lift line break safety device

16

Main lift lowering valve (PV)

8

Main lift cylinder

17

Lowering brake valve

9

Free lift cylinder

WI 2300

208

HYDRAULIC DIAGRAMS Hydraulic Diagram - TF Mast Hydraulic Diagram - TF Mast

11

9

9

10 8

8

7

7 12

13 14

6

15

16

5

17

3 2

4

18

M 1

Fig. 186 Hydraulic Diagram - TF Mast 1

Suction filter

10

Free lift cylinder line break safety valve

2

Motor and pump

11

Free lift cylinder

3

Check valve (CV)

12

Initial lift cylinder

4

Pressure relief valve (RV1)

13

Initial lift shutoff valve (SV1)

5

Pilot-operated load hold valve (SVCL)

14

Initial lift lowering valve (SV2)

6

Main lift shutoff valve (SV3)

15

Orifice (ORF1)

7

Main lift line break safety device

16

Pressure relief valve (RV2)

8

Main lift cylinder

17

Main lift lowering valve (PV)

9

Free lift cylinder line break safety valve

18

Flow controller

WI 2300

209

Notes:

210