Crown Forklift WP2000S Service Manual 812535-999

Service Manual Wartungshandbuch Manuel de maintenance

WP2000S Series

U1.p65

2

04.02.00, 10:40

TABLE OF CONTENT

Printed in Germany

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Printed in Germany

TABLE OF CONTENT Table of Content MA – SAFETY

PAGE

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Safety Symbols used in the Manual ................................... M/P-MA-0000-001 .

General Maintenance and Repair Safety Notes ................... M/P-MA-0000-001 - Maintenance and Repair ................................................. M/P-MA-0000-002 - Before Leaving the Truck ................................................. M/P-MA-0000-002 - Before Carrying out Work on the Truck ............................ M/P-MA-0000-002 - Before Operating the Truck .............................................. M/P-MA-0000-002 Warnings and Labels on the Truck ...................................... M/P-MA-0000-002

ITD – INTRODUCTION

PAGE

General ................................................................................. M/P-ITD-1720-501 - Operating instruction ....................................................... M/P-ITD-1720-501 - Service training ............................................................... M/P-ITD-1720-501 - Replacement parts orders ............................................... M/P-ITD-1720-501 - Structure of the Manual .................................................. M/P-ITD-1720-501 - Page Numbers ................................................................ M/P-ITD-1720-502 Truck Data Numbering Sheet ............................................... M/P-ITD-1720-504

M1 – LUBRICATION AND ADJUSTMENT

PAGE

Component Access .............................................................. M-1.0-1720-001 Jacking up the Truck ............................................................ M-1.0-1720-001 Lifting by Crane .................................................................... M-1.0-1720-001 Lifting by Truck .................................................................... M-1.0-1720-002 .......................................... Rev.1 09/00 Components ......................................................................... M-1.0-1720-003 .......................................... Rev.1 09/00 Maintenance ......................................................................... M-1.1-1720-004 - Driver Participation ......................................................... M-1.1-1720-001 - Daily Maintenance Log .................................................... M-1.1-1720-001 - Recommended Lubricants and Oils ................................ M-1.1-1720-001 - Lubricants .................................................................. M-1.1-1720-001 - Cold Store Trucks ...................................................... M-1.1-1720-001 - Check and Maintenance Schedule .................................. M-1.2-1720-001 - Safety Reverse Switch - Functional Test ......................... M-1.2-1720-003 ---------------------------------- Rev.1 09/00 - Grease items and grease intervals .................................. M-1.2-1720-010 ---------------------------------- Rev.1 09/00 Adjustment of castor- and drivewheel pressure ................. M-1.5-1720-501 Torques ................................................................................. M-1.9-0000-001

M2 – HYDRAULICS

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Hydraulic Symbols .............................................................. M-2.0-0000-001 Hydraulic System ................................................................. M-2.1-1720-001 - Removal ......................................................................... M-2.2-1720-001 - Hydraulikpump ................................................................ M-2.3-1720-001 - Filter ............................................................................... M-2.3-1720-002 - Pressure Filter ........................................................... M-2.3-1720-002 - Suction and Return Filters ......................................... M-2.3-1720-002 - Oil Change ................................................................. M-2.3-1720-002 - Commissioning .......................................................... M-2.3-1720-002

M3 – DRIVE UNIT

PAGE

Gear Unit ............................................................................... M-3.1-1720-501 - Removal ......................................................................... M-3.1-1720-501 - Repair ............................................................................. M-3.1-1720-501 - Disassembly/Assembly ............................................. M-3.1-1720-503 - Installation ...................................................................... M-3.1-1720-505

Printed in Germany

Rev.1 09/00 M-IDX-1720-501

TABLE OF CONTENT M4 – ELECTRICS

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Electrics - General ................................................................ M-4.0-0000-001 - Wire Colour Codes .......................................................... M-4.0-0000-001 - Abbreviations .................................................................. M-4.0-0000-002 - Electrical Symbols .......................................................... M-4.0-0000-004 Electrical Components ........................................................ M-4.2-1720-500 - Transmitter (POT, FS, RS) ............................................... M-4.2-1720-500 - Fast / Slow Travel Switch (HSS) ...................................... M-4.2-1720-500 - Reverse Safety Switch (SAS) ......................................... M-4.2-1720-500 - Brake Switch (BRS) ........................................................ M-4.2-1720-500 - Override Switch (ORS) .................................................... M-4.2-1720-503 - Lift / Lower Switch (RAS, LOS) ....................................... M-4.2-1720-503 - Limit Switch (LMS) ......................................................... M-4.2-1720-503 - Horn Switch (HNS) .......................................................... M-4.2-1720-503 - Key Switch (KYS) ........................................................... M-4.2-1720-503 - Emergency Disconnect ................................................... M-4.2-1720-503 - Fuses (FU) ..................................................................... M-4.2-1720-503 - Temperature Switch (THS) (Freezer/Corrosion Truck only) M-4.2-1720-503 SEM 1 Traction Controller ................................................... M-4.3-1720-001 General ............................................................................. M-4.3-1720-001 - Precautionary Measures ............................................ M-4.3-1720-001 Operational Features ......................................................... M-4.3-1720-001 - Speed Control ............................................................ M-4.3-1720-001 - Reduced Speed Ranges ............................................ M-4.3-1720-001 - Downhill Speed Control .............................................. M-4.3-1720-001 - Regenerative Braking ................................................. M-4.3-1720-001 - Anti-Roll-Down-Function ............................................. M-4.3-1720-001 - Hourmeter .................................................................. M-4.3-1720-002 - Self Test .................................................................... M-4.3-1720-002 - Monitored Circuits ...................................................... M-4.3-1720-002 Protective Devices ............................................................ M-4.3-1720-003 - Polarity Protection ..................................................... M-4.3-1720-003 - Wiring Errors .............................................................. M-4.3-1720-003 - Temperature ............................................................... M-4.3-1720-003 - Start Sequence ......................................................... M-4.3-1720-003 - Protective Class ........................................................ M-4.3-1720-003 Maintenance ..................................................................... M-4.3-1720-003 Controller connections SEM-1 ........................................... M-4.3-1720-004 - Pin Layout SEM-1 ..................................................... M-4.3-1720-005 - Status-LED ................................................................ M-4.3-1720-006 Programmer ......................................................................... M-4.4-1720-001 General ............................................................................. M-4.4-1720-001 Operating Menu Controller SEM-1 ..................................... M-4.4-1720-002 - Operating Menu - Overview ....................................... M-4.4-1720-003 - Menu Functions ......................................................... M-4.4-1720-004 Settings and Alarms ......................................................... M-4.5-1720-001 - Menue PARAMETER CHANGE ................................. M-4.5-1720-001 - Menue TESTER ......................................................... M-4.5-1720-004 - Menue ALARMS ........................................................ M-4.5-1720-006 - Menue PROGRAM VACC .......................................... M-4.5-1720-008 - Menü CONFIG ........................................................... M-4.5-1720-009 Traction Controller Safety Test ............................................ M-4.20-1720-001 Battery ................................................................................... M-4.25-1720-001 Function ............................................................................ M-4.25-1720-001 Reading the Electrolyte Level ........................................... M-4.25-1720-001 Replacing the Battery ........................................................ M-4.25-1720-001 Removing the Battery ....................................................... M-4.25-1720-001 Charging the Battery ......................................................... M-4.25-1720-002

Printed in Germany

M-IDX-1720-502

TABLE OF CONTENT Battery Discharge Indicator (BDI) ........................................ M-4.25-1720-002 - General ........................................................................... M-4.25-1720-002 - Adjusting the Battery Discharge Indicator ....................... M-4.25-1720-002 Traction / Pump Motor Maintenance ................................... M-4.35-1720-001 - Access ........................................................................... M-4.35-1720-001 -Maintenance .................................................................... M-4.35-1720-001

M5 – BRAKE

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Brake ..................................................................................... M-5.0-1720-501 - Function ......................................................................... M-5.0-1720-501 - Removal ......................................................................... M-5.0-1720-501 - Assembly ....................................................................... M-5.0-1720-502 - Air Gap Setting ............................................................... M-5.0-1720-502 - Brake Moment Setting .................................................... M-5.0-1720-503 - Testing the Brake ............................................................ M-5.0-1720-503

M6 – STEERING

PAGE

Multitask Handle - Springs for Return Function ................ M-6.1-1720-501 - Adjustment ..................................................................... M-6.1-1720-501 - Removal ......................................................................... M-6.1-1720-501 - Assembly ....................................................................... M-6.1-1720-501

M7 – LIFTING MECHANISM

PAGE

Lift Linkage ........................................................................... M-7.0-1720-501 - Fork Height Setting ......................................................... M-7.0-1720-002

M8 – CYLINDERS

PAGE

Lift Cylinders ........................................................................ M-8.1-1720-501 - Operation ........................................................................ M-8.1-1720-501 - Removal ......................................................................... M-8.1-1720-501 - Inspection ....................................................................... M-8.1-1720-503 - Replacing the Piston Seal ............................................... M-8.1-1720-503

DIA – ELECTRICAL DIAGRAMS

PAGE

Standard Version .................................................................. M/P-DIA-1720-001 - Schematic Diagram ........................................................ M/P-DIA-1720-001 - Traction Controller ........................................................... M/P-DIA-1720-002 - Power Unit Circuit ........................................................... M/P-DIA-1720-004 - Control Handle Circuit ..................................................... M/P-DIA-1720-005 - Walkie- / Rider Circuit ..................................................... M/P-DIA-1720-006 - Power Cables .................................................................. M/P-DIA-1720-007 - Main Harness ................................................................. M/P-DIA-1720-008 - Tiller Harness .................................................................. M/P-DIA-1720-009 Freezer- / Corrosion Trucks ................................................. M/P-DIA-1720-010 - Schematic Diagram ........................................................ M/P-DIA-1720-010 - Traction Controller ........................................................... M/P-DIA-1720-011 - Power Unit Circuit ........................................................... M/P-DIA-1720-013 - Control Handle Circuit ..................................................... M/P-DIA-1720-014 - Walkie- / Rider Circuit ..................................................... M/P-DIA-1720-015 - Tiller Harness .................................................................. M/P-DIA-1720-016

HYD – HYDRAULIC SCHEMATIC

PAGE

Hydraulic Schematic ......................................................... M-HYD-1720-501

Printed in Germany

M-IDX-1720-503

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Printed in Germany

SAFETY

Printed in Germany

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Printed in Germany

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

General Maintenance and Repair Safety Notes DANGER Read the safety notices in the truck Maintenance and Operator's Manuals.

DANGER

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

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

WARNING This symbol indicates the risk of serious injury and/or serious material damage. ● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.

CAUTION This symbol indicates the risk of minor injury and/or minor material damage. ● Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage.

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

Maintenance and Repair 1.

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

2.

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

3.

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

4.

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

Only carry out cleaning with an oil separator.

Protect the electrical system from dampness.

5.

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

6.

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

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

INFORMATION Contains additional information with supplementary notes and hints.

OPTION OPTION

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

Printed in Germany

M/P-MA-0000-001

SAFETY 7.

Neutralise and thoroughly rinse any spilled battery fluid immediately.

8.

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

9.

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

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

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

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the travel switch and remove the key.

●

Block all wheels when parking on an uneven surface.

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

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

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

Clean any illegible labels.

●

Replace any faulty or missing labels.

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

Before Carrying out Work on the Truck ●

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

●

Prevent the truck from rolling away.

●

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

●

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

Printed in Germany

M/P-MA-0000-002

INTRODUCTION

Printed in Germany

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Printed in Germany

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

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

series. Brochures can be obtained from your CROWN dealer or from the following address:

CROWN Gabelstapler GmbH Kronstadter Str. 11 81677 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133

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

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

Using the Manual The Maintenance Manual is written in three independent language blocks: English, German and French.

Each language block in turn is divided into chapters and sections.

The table on the following page shows how the manual is structured.

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

Additional copies can be ordered as required.

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

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

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

Ordering Spare Parts The maintenance manual does not cover spare parts.

These are listed in a separate manual.

Spare parts can be ordered by quoting: ●

The truck specification number

●

The truck model number

M6

Steering

●

The truck serial number

M7

Mast / Lifting Mechanism

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic

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

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

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this

A01M-gb Printed in Germany

M-ITD-1720-501 1

INTRODUCTION Page Numbering in the Manual The page numbers are on the left and right-hand sides of the page footer.

If a page has been modified since the last edition, a revision number will be found in the middle of the footer: 02 REV. 2/99 means the second amendment to this page in February 1999.

The page numbers are not necessarily consecutive!

The back page of the manual contains a print number in the following form: MS-WP2000S-GB-D-F 11/99 In this example, 11/99 is the edition date.

A page beginning with M/P- is identical in both the maintenance and spare parts manuals:

M/P-1.2-1720-001 M = Maintenance Manual P = Spare Parts Manual Chapter

Page Number

Section

Truck Code

e.g. 1.2 = Test and Maintenance Schedule

(Pages which are identical for all trucks are given the code 0000 here)

A page beginning with M- is only contained in the maintenance manual:

M-1.2-1720-001 M = Maintenance Manual

Chapter

Page Number

Section

Truck Code

e.g. 1.2 = Test and Maintenance Schedule

(Pages which are identical for all trucks are given the code 0000 here) Printed in Germany

M/P-ITD-1720-502 2

INTRODUCTION A page beginning with P- is only contained in the spare parts manual:

P-1.0-1720-001 P = Spare Parts Manual

Chapter

Page Number

Section

Truck Code

e.g. 1.0 = Panels

(Pages which are identical for all trucks are given the code 0000 here)

Printed in Germany

M/P-ITD-1720-503 3

INTRODUCTION Model Number

2.0

WP

2030S

–

3

–

2

–

S

Capacity

Load Wheels

2.0 = 2000 kg

S = Single T = Tandem

Model Description WP = Electric Pedestrian Pallet Truck

Fork Length Dash

mm

1

Battery Box Size (l x w x h) 2030 = 360 Ah (288 x 624 x 627)

2

36 995

3 4

42 1125

5 6

inch

46 1210

48

7

54

8

60 I02a-gb

Fork Spread Dash

mm

1

inch 18

2

520

20

3

540

22

4

670

27 I03a-gb

Printed in Germany

M/P-IT-1720-504 4

LUBRICATION AND ADJUSTMENT

Printed in Germany

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Printed in Germany

LUBRICATION AND ADJUSTMENT Component Access For regular maintenance purposes the drive unit, hydraulic system, contactor panel etc. can be reached by removing the panel.

The panel is fixed to the chassis by three screws, (Fig. 1515),located left , right and frontside.

Remove the screws and lift the panel upward and then forward to remove it.

Use the grip in the plastic-cover on top of the panel.

Fastening screws

Jacking up the Truck CAUTION Always support a raised truck with wooden blocks or other suitable equipment, thereby relieving the jack.

The instruction "jack up the truck" always assumes that the raised truck will be lowered onto a secure surface.

M1515

Lifting with a Crane Attach the straps to the hitch points as shown and ensure they cannot slide off.

1 Jacking Points

3

2

WP 2000

4

3 M1916

M1528 Printed in Germany

Rev.1 09/00 M1.0-0000-0001 M-1.0-1720-001

LUBRICATION AND ADJUSTMENT Lifting by Truck DANGER Use a forklift with sufficient capacity and prevent the truck from sliding off the forks.

Raise the forks to their maximum height.

●

Drive the forklift sideways underneath the truck (see diagram).

●

Place hard wooden blocks under the truck.

●

Secure the truck to prevent it from sliding off the forks.

●

Raise the truck.

600

WP 2000

> 800

90

●

Printed in Germany

Rev.1 09/00 M-1.0-1720-002 M1.0-0000-0002

LUBRICATION AND ADJUSTMENT Components

Control safety device Contactor panel

Traction control system LH lift cylinder Horn

Power safety device Pump motor Pressure Switch for load-sensitive speed reduction Lowering valve Hydraulic tank and in-built pump

Magnetic brake Drive motor Drive wheel M1563

Printed in Germany

Rev.1 09/00 M1.0-0000-0003 M-1.0-1720-003

LUBRICATION AND ADJUSTMENT Fast / Slow Travel Switch

Lift / Lower Switch

Horn button

Travel Switch

M1568

Safety Reverse Switch

Model and Data Capacity Plate

Battery Box Lock Emergency DisHourmeter and Battery connect Discharge Display

Key Switch

M 1516 Printed in Germany

Rev.1 09/00 M-1.0-1720-004 M1.0-0000-0004

LUBRICATION AND ADJUSTMENT

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Printed in Germany

M1.0-0000-0005

LUBRICATION AND ADJUSTMENT Maintenance Driver Participation By involving the driver in the maintenance schedule, truck downtimes can be substantially reduced. The driver can also contribute to determining the maintenance schedule, thereby saving costs. Crown therefore recommends that the driver carry out the daily maintenance in accordance with the table on page M1.2-1720002.

Daily Maintenance Log A maintenance log is provided to keep a record of the extent and time of maintenance performed.

Recommended Lubricants and Oils Lubricants Only high grade lubricants and oils should be used.

These can be obtained from any oil manufacturer. Those listed in table on page M1.1-1720-002 are typical, and any lubricant of the same grade can be used.

Cold Store Trucks Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table on page M1.1-1720-002). An anticorrosion fluid (Crown no. 078882-002) must be applied to all screws, washers, nuts, pins, retaining rings etc.

Maintenance schedules should be kept as short as possible to prevent excessive wear of moving components.

Printed in Germany

M-1.1-1720-001 M1.0-0000-0006

LUBRICATION AND ADJUSTMENT Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Type

Grease (multi purpose)

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

Aral Castrol Century Esso Maxol Mobil Shell

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

Hydraulic oil

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

Aral Castrol Esso Mobil Shell

053001-003

D

Low temperature hydraulic oil

Univis J 13 Aero HFA

Aral Mobil

053001-008

DD

Transmission oil

Hyp 85W90 GX - D 85W90 Mobilube HD85/90 Spirax MB 90

Aral Esso Mobil Shell

053002-004

A

Low temperature transmission oil

Mobilube SHC

Mobil

053002-006

AA

Rubber and vinyl dressing

H

Special grease

MOS2 Lithium

Universal lubrication oil

SAE 40

Dow Corning

063002-022

M

C L01-gb

Printed in Germany

M1.0-0000-0007 M-1.1-1720-002

LUBRICATION AND ADJUSTMENT Check and Maintenance Schedule The following check and maintenance schedule assumes single-shift operation under normal operating conditions. The length of maintenance intervals will however depend on the particular operating conditions.

When performing maintenance work always check for wear, corrosion and damage and ensure that the parts are operating correctly and are secure. If in doubt, replace them.

In dusty or otherwise extreme environments, including cold stores, the specified maintenance intervals should be reduced. The exact periods should be established after consultation with Crown service personnel.

Daily or every 8 service hours No.

Item

Action

1

Battery

Re-charge a discharged battery. Check electrolyte level and replenish if necessary.

2

Battery Connector ( = Emergency Stop )

Check operation

3

Horn

Check operation

4

Lift / Lower rocker switch

Check operation

5

Travel switch

Check operation (both directions)

6

Safety reverse switch

Check operation

7

Brake

Check operation (both directions, both normal braking with the multi-task handle and inverse braking)

8

Steering

Check play

9

Fork

Check for visible signs of cracks and deformation

10

Wheels / Load wheels

Check tyres for wear, nails, metal splints etc.

11

Hydraulic lines and connections

Check for leaks, tighten connections if necessary

12

Platform safety switch

Check operation (platform up and platform down).

L02-S-gb

Printed in Germany

M-1.2-1720-001 M1.0-0000-0008

LUBRICATION AND ADJUSTMENT 2

9 1 10

12

13

M 1563

11

6

4

3

5, 8

M1568

7

Printed in Germany

M1.0-0000-0009 M-1.2-1720-002

LUBRICATION AND ADJUSTMENT Safety Reverse Switch – Functional Test DANGER The safety reversing switch must only be tested in a safe environment, without bystanders and sufficiently far from obstacles.

Set the tiller straight (for straight-ahead travel).

●

The truck must be ready for operation, i.e. switched on.

●

Position yourself at a sufficient distance to the side of the tiller.

●

Using the tiller, slowly move the truck forward (you walk ahead of the truck).

●

Check again for any obstacles and press the safety reversing switch.

●

The truck should stop immediately and then move back a few feet in the opposite direction.

●

If the test is not successful, the fault must be rectified before the truck can be operated again.

WP 2000

●

Printed in Germany

REV.1 09/00 M-1.2-1720-003 M-1.0-0000-00010

LUBRICATION AND ADJUSTMENT

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Printed in Germany

M1.0-0000-00011

LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours No.

Item

Action

1

Battery

Check acid density, if necessary replenish with destilled water. Check voltage of all cells, if necessary compensate; clean and grease battery terminals.

2

Contactors

Clean; check, replace if necessar y

3

Lift limit switch

Check operation

4

Electrical system

Check wires, switches and connections are secure, check insulation for damage

5

Impulse control

Check operation

6

Brake

Blast off corrosion; check seal for damage; check air gap

7

Lift cylinder

Ensure seal is tight

8

Hydraulic oil tank

Check oil level, replenish if necessary

9

Load wheels and castor bearings

Check for play, replace bearings if necessary

10

Drive wheel

Ensure wheel nuts are correctly torqued.

11

Drive unit guide

Check for play, replace rails if necessary.

L03-S-gb

Printed in Germany

Rev.1 09/00 M-1.2-1720-004 M1.0-0000-00012

LUBRICATION AND ADJUSTMENT

1

2 5

3 6 9

7

8

M1563

9 10

9 M1463

Printed in Germany

Rev.1 09/00 M1.0-0000-00013 M-1.2-1720-005

LUBRICATION AND ADJUSTMENT Every 3 months or 250 service hours No.

Item

Action

1

Truck, battery and charger connectors/plugs

Clean contacts and check contact springs

2

Connecting rods

Check for wear, ensure attachment is secure, tighten if necessary or replace connecting rods.

3

Forks

Check height setting, adjust if necessary

4

Gear unit

Initial change of gear oil after 250 hours of operation, thereafter every 2000 hours.

L04-gb

Every six months or 500 service hours No.

Item

Action

5

Tiller

Check operation and grease recuperating spring

6

Brake

Check brake lining and contact surfaces for wear, replace par ts if necessary.

Check air gap and adjust if necessary.

8

Lift mechanism

Clean bearings and striking surfaces check for wear, replace if necessary, grease

9

Load wheel and castor axles

Clean, check for wear, replace if necessary, grease

10

Hydraulic system

Change suction and return filters initially after 500 service hours, thereafter every 2000 service hours.

L05-S-gb

Printed in Germany

Rev.1 09/00 M-1.2-1720-006 M1.0-0000-00014

LUBRICATION AND ADJUSTMENT

6

1

7

2

8

11

2

11

2

5 M1563

10

10

9 9

3 M1463

4

10

Printed in Germany

Rev.1 09/00 M1.0-0000-00015 M-1.2-1720-007

LUBRICATION AND ADJUSTMENT Annually or every 1000 service hours No

Item

Action

1

Pump and drive motor

Check commutator and carbon brushes for damage, spring tension and wear; blast dust with air.

2

Gear unit

Check gear oil level, replenish if necessary

3

Brake

Check brake lining and contact surfaces for wear, replace par ts if necessary

4

Carry out UVV test

Germany only; for other countries refer to relevant regulations / laws.

L06-S-gb

Every 2 years or 2000 service hours No.

Item

Action

5

Hydraulic system

Change hydraulic oil; replace filter (initial replacement after 500 hours); Clean lines and connections, check tightness and sealing, tighten if necessary

6

Gear unit

Change gear oil L07-gb

Printed in Germany

Rev.1 09/00 M-1.2-1720-008 M1.0-0000-00016

LUBRICATION AND ADJUSTMENT

3

1

5

M1454

2, 6

Printed in Germany

Rev.1 09/00 M1.0-0000-00017 M-1.2-1720-009

LUBRICATION AND ADJUSTMENT Grease items and grease intervals Grease Items / Grease Intervals Item Component

Type

Total

100 hours X

250 hours

500 hours

1

Check hydraulic reservoir, replenish if necessary

D

A/R

2

Change hydraulic oil

D

A/R

3

Battery comp. lid hinges

B

A/R

X

4

Battery comp. lid latch

B

A/ R

X

5

Tiller: flat coil springs for return function

B

A/R

6

Connecting rod pins and all lifting mechanism joints

B

A/ R

7

Lift cylinder attachment

B

A/R

X

8

Piston rod attachment

B

A/ R

X

9

Change gearbox oil

A

A/R

1000 hours

2000 hours

X

X X

Initial change after 250 hoursof operation

X

L08-S-gb

Printed in Germany

Rev.1 09/00 M-1.2-1720-010 M1.0-0000-00018

LUBRICATION AND ADJUSTMENT

4 3 3

5

8

8 6 6 7 7 1, 2 2

9 M1464

6 6

M1463

Printed in Germany

Rev.1 09/00 M-1.2-1720-011

M1.0-0000-00019

LUBRICATION AND ADJUSTMENT Adjusting the Contact Pressure of the Castors and the Drive Wheel The castor wheels are on the left and right hand sides below the truck. They prevent the truck from tipping over when travelling around bends.

The castors apply a certain supporting force to the ground over long periods of time, as the drive unit on the slide generally compensates the drive wheel and castor wheel wear. However, the greater the tyre wear, the less the drive wheel contact pressure. This increases the braking distance and when travelling with heavy loads the truck can skid on smooth surfaces.

230 mm - 220 mm = 10 mm (A) 125 mm - 120 mm = 5 mm (B) 10 mm - 5 mm = 5 mm (Adjustment) Therefore, the screws (B) in Fig. M1519 should be tightened by 5 mm. ●

Loosen both jam nuts (A) and turn them upward by at least the calculated adjusting measurement.

●

Tighten screws (A) in turn until the calculated adjusting measurement is obtained for both screws.

●

Check dimension C: nominal measurement = 33 mm (with wheels)

●

Jam the screws (B) with nuts (A).

New drive wheels have a 230 mm diameter.

If the diameter is only 220 mm, the drive unit spring pre-tension must be increased. Otherwise the drive wheel will skid excessively, thereby also increasing the wear. The castor wheels will also wear out prematurely due to excess contact pressure.

Procedure: ●

Park the unladen truck on a level surface.

●

Remove the battery connector and the key.

●

Make sure the truck cannot be switched on.

●

Remove the panel.

●

Measure and record the drive wheel diameter.

●

Measure the diameter of the castor wheels, calculate the average diameter and record.

A

B

B

C

C

A

Calculating the Adjustment Required: New drive wheel Ø 230 mm minus current drive wheel Ø =A New castor wheel Ø 125 mm minus current castor wheel Ø=B A - B = Adjustment required Example: You record a current drive wheel diameter of 220 mm.

The average for the castor wheels is 120 mm.

M1519

Printed in Germany

M-1.5-1720-501 M1.0-0000-00020

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

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

Screw grade marking

Nut grade marking

8 .8

8 .8 8

1 2 .9 1 2 .9

graphics: m0340_1...5

T01-gb

Printed in Germany

M1.0-0000-00021 M-1.9-0000-001

LUBRICATION AND ADJUSTMENT Standard Screws and Nuts Grade

8 and 8.8

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 - 4 0

M10 x 1.5

40 - 45

60 - 65

70 - 75

M12 x 1.75

70 - 80

100 - 110

115 - 130

M 16 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 T02-gb

Umbrako Screws and Nuts Grade

10 and 10.8 Thread Size

12 and 12.9 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 T03-gb Printed in Germany

M-1.9-0000-002 M1.0-0000-00022

HYDRAULICS

Printed in Germany

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Printed in Germany

HYDRAULICS Hydraulic Symbols

Vented reservoir with lines above the fluid level

M

Electric motor with unidirectional turn and speed

M

Electric motor with unidirectional turn and variable speed

Vented reservoir with lines below the fluid level

Filter or strainer

Hydraulic line with full flow (tubing or hose)

Pilot or drain line or drainage with limited flow

Hydraulic pump with fixed displacement and single direction of turn

Hydraulic motor, bi-directional

Lines crossing; not connected Pressure gauge

Lines crossing and connected

Thermometer Plugged port (test port)

Accumulator gas charged diaphragm type Flow meter

M3559

Printed in Germany

M1.0-0000-0001 M-2.0-0000-001

HYDRAULICS

Pressure switch

Manual actuator

Double-acting cylinder; unequal area

Spring, (bias to normal deenergised position)

Double-acting cylinder; equal area Solenoid single coil or winding

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

Single-acting cylinder ram type Solenoid valve, pilot operated

Single-acting cylinder, with cushion Dual solenoid

Assembly housing, manifold block Proportional solenoid

Manual lever actuator

Pilot check valve (pilot to open)

M3560 Printed in Germany

M-2.0-0000-002 M1.0-0000-0002

HYDRAULICS

Throttle, fixed

Shuttle valve

Throttle, adjustable

Single counterbalance valve assembly in manifold Pressure-compensated flow control, fixed

Pressure-compensated flow control with reverse flow bypass; fixed.

Flow divider/combiner

Velocity fuse Bypass flow control with controlled flow, pressure-regulated

Relief valve, fixed setting

Relief valve, adjustable

Check valve

Shut-off valve, manual

P T

T P

Torque generator

L R

Hydraulic steer unit

M3561 Printed in Germany

M1.0-0000-0003 M-2.0-0000-003

HYDRAULICS

2/2 way valve (two way, two switch positions)

Valve block with 3 operating units

3/2 way valve (three way, two switch positions)

4/2 way valve (four way, two switch positions)

4/3 way valve (four way, two switch positions)

4/3 way valve (four way, two switch positions); manual activation and spring centered

3/2 way valve (three way, two switch positions); Spring bias solenoid control

M3562

Printed in Germany

M-2.0-000-004 M1.0-0000-0004

HYDRAULICS Hydraulic System Lifting:

Operation The hydraulic unit is installed next to the left hand lift cylinder and comprises the motor, pump, reservoir and all filters and valves.

The pump delivers oil from the reservoir to the two lift cylinders.

The lowering valve remains closed.

Lowering: The lowering valve opens. The oil flow returns from the two lift cylinders to the reservoir.

Lift cylinder

Lowering valve

Pressure-Switch Filter

Filter

Non-return valve Pressure relief valve

Flow reducer

145 bar Motor Vent cap Pump

Filter

Filter

Reservoir M1457-1 Printed in Germany

M/P-2.1-1720-001 M1.0-0000-0005

HYDRAULICS Removing the Hydraulic Unit WARNING De-pressurise all components before carrying out maintenance work on the hydraulic system. ● High pressure hydraulic oil can cause serious injuries. ● Whenever a high pressure fluid penetrates the skin it must be treated as an emergency, even if the skin shows no initial reaction. Physical effects set in later. ● Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge. ● Use absorbent paper to track leaks, never use your hands!

●

Unplug the battery connector (= Emergency Disconnect).

●

Secure the truck from rolling away.

●

Before commencing maintenance work place a flat container or (if necessary) a large cardboard box underneath the work surface.

●

Disconnect the wire plug connection on the lowering valve magnet (see Fig. M1523).

●

Unscrew the power connections to the pump motor (see Fig. M1522).

●

Unscrew the pressure connection (see Fig. M1522).

●

Obtain a suitable support on which to rest the hydraulic unit, e.g. a heavy iron ring.

●

Remove the hydraulic unit by removing the two fastening screws (see Fig. 1522) from the chassis.

Pressure relief valve (rear view) Connecting Cable

Pump motor

Pressure switch (loadsensitive travel speed reduction)

Screws fastening hydraulic unit to chassis

Reservoir flange

M1522

Printed in Germany

M-2.2-1720-001 M1.0-0000-0006

HYDRAULICS

Pressure port, non-return valve

Filler neck and vent cap

Lowering valve and actuating magnet

M1523

Replacing the Hydraulic Pump

●

Remove the four screws (item 26) from the reservoir flange and remove the reservoir.

●

Loosen the four screws (M6 x 50, hex. head) from the engine side of the hydraulic unit and remove the pump.

●

Loosen the filter clamps (25) and (22) and remove the filter.

●

Clean all components (except the motor) with a clean degreasing agent; remove the old seals and blow dry.

NOTE The hydraulic pump should not be replaced on site.

The pump is replaced as a complete assembly.

The seals of any disassembled parts and filters must always be replaced!

Removal ●

Remove the hydraulic unit as described in the previous section.

In the following instructions all item numbers refer to Figure M1442,. ●

Drain the oil via the filler neck.

●

Loosen the four screws (item 1).

●

Lift up the motor while ensuring that it does not fall apart.

Installation ●

Attach the new filter parts to the pump.

●

Apply a thin coat of oil to the seal (24) and insert seal.

●

Fit pump (note alignment! See Figure M1442) and fix with 4 M6 x 50 screws. Torque crossways to 18 ±2.5 Nm.

Printed in Germany

M-2.2-1720-002 M1.0-0000-0007

HYDRAULICS ●

Fit the reservoir with a new lightly oiled seal (26) and torque the flange ring with four hex. head screws (M6 x 10) to 8 ±1.2 Nm.

Filters

●

Fit the motor on the hydraulic block so that the drive shaft carrier fits into the pump shaft recess.

Align the motor and torque with the four screws (1) to 8 ±1.2 Nm.

●

●

To refit the hydraulic unit proceed in the reverse order of Removal. Note torques!

Both motor connecting cables: 4±0.5 Nm.

Replacing the Pressure Filter

Replacing the Suction and Return Filters ●

To access the suction (25) and return filter (22), the reservoir (26) must be disconnected from the pump connection plate (14). To do this, remove the 4 screws (26) from the flange (26).

●

The filters (450 µ) are integrated within the hoppershaped end piece (nozzle) of the suction (25) and return (22) lines. To disassemble, release the clamps.

Commissioning ●

Check that the system is clean and properly assembled. In particular, the pressure ports must be tightly secured.

●

Initially, fill the hydraulic oil only up to half the reservoir height (see lubricant table) using a filter with a 10 µm minimum retention rate.

●

Never operate the pump without oil.

●

All components, in particular the hydraulic ports, must be completely clean and dry prior to commissioning. Otherwise it is impossible to check whether the system is sealed.

●

Operate the lifting functions for approx. 30 seconds to bleed the system. The oil in the reservoir will foam considerably.

●

Check the pressure port and surrounding hydraulic components for leaks.

●

Park the truck and leave it to stand for approx. 20 minutes. During this interval the air will separate from the oil in the container.

●

When there is no more foam in the reservoir replenish with oil up to half the max. filling height and bleed again until no more foam is visible.

●

Now fill with hydraulic oil up to the lower mark of the filler neck.

The pressure filter (150 µ) is integrated within the pressure connection (20). When unscrewing the pressure port make sure that the ball of the nonreturn valve (21) is not lost.

Oil Change The oil reservoir (capacity 0.75 litres) does not have an oil drain plug. The used oil must therefore be suctionned off or drained from the oil reservoir.

Dispose of used oil via approved disposal methods only.

Pump Motor For maintenance and repair work to the pump motor see chapter 4, page M-4.35-1720-001 ff.

Printed in Germany

M--2.3-1720-002 M1.0-0000-0008

HYDRAULICS

Printed in Germany

M1.0-0000-0009 M--2.3-1720-003

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Printed in Germany

DRIVE UNIT

Printed in Germany

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Printed in Germany

DRIVE UNIT Gear Unit Preparatory Measures

B

For removal purposes the truck must be raised approx.

500 mm.

A

Required Tools: ●

Fork lift truck with sufficient capacity, lift height and fork length to lift the truck.

●

Safety mechanism to keep the forks of the lifting truck holding the raised truck.

●

Sufficient quantity of wooden blocks (250 x 250 mm surface area) or suitable supports to hold the raised truck.

●

Device to support the gear unit on a jack or lift truck.

Removal

M1564

Lower the mechanism with the gear unit and remove it from underneath the truck.

Remove the battery connector and key.

Make sure that the truck cannot be switched on.

Maintenance WARNING

Support the truck with a second fork lift truck and prevent it from slipping.

THE GEAR UNIT MUST ONLY BE REPAIRED

BY PERSONNEL WHO HAVE BEEN TRAINED AND AUTHORISED BY CROWN. FAILURE TO COMPLY WILL INVALIDATE THE MANUFACTURER'S WARRANTY.

DANGER NEVER WORK UNDERNEATH A SUSPENDED LOAD.

To adjust the flank tooth bearing and pre-tension the shaft bearing requires years of experience in gear units. Faulty settings will result in the premature failure of the gear unit.

Therefore it is generally preferable to replace the gear in full.

New gear units are always supplied without oil!

SEVERE INJURIES CAN RESULT IF THE TRUCK SUDDENLY FALLS. Raise the truck until a jack / lift truck with a support for the gear unit can be pushed underneath the truck.

Lift the truck by approximately another 50 mm to release the gear unit from the gear teeth.

Prior to commissioning fill with oil in accordance with the "Lubricant table".

Lower the truck onto the wooden blocks / supports.

Raise the mechanism onto the jack / lift truck until it contacts the gear unit.

General ●

All bearings and seals must be replaced.

●

Prior to disassembly thoroughly clean the gear unit with a cold-cleaning solution and blast dry with weak compressed air.

●

Use assembly equipment and a clean workbench.

Remove the electrical connections from the motor.

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

Printed in Germany

M1.0-0000-0001 M-3.1-1720-501

DRIVE UNIT

70

M1558-1

Printed in Germany

M-3.1-1720-502 M1.0-0000-0002

DRIVE UNIT Gear Unit Disassembly / Assembly

●

Thoroughly clean all components and remove any sealant and adhesive residue.

Disassembly Assembly

●

Drain the oil.

●

Place the gear unit with the wheel studs in a device which prevents it from twisting.

WARNING

●

Remove the screws (390), lock washers (330) and O ring (290) and lift off the cover (30).

●

Remove the Allen screws (350) and spring lock washers (190).

●

Remove live ring bearing (130).

●

Remove screw (360) and spacer (190).

●

Loosen bevel wheel nut (140).

●

Remove the gear unit from the device.

NOTE WHEN REMOVING THE GEAR UNIT, LABEL THE SHIMS (420, 430,440) IN ACCORDANCE WITH THEIR LOCATION. THEY WILL HAVE TO BE TEMPORARILY RE-FITTED IN THE SAME POSITION AT A LATER STAGE. ●

Remove the pinion (65), spacer ring (160) and if necessary shim(s) (420,430) from the housing.

●

Remove the bearing inner ring (260) from the bevel wheel (65).

●

Force out the flange shaft (50) using suitable tools.

●

Remove the bearing inner ring (250) from the flange shaft.

●

Pull out the bearing outer rings (250, 260) from their seats in the gearbox.

●

Remove the rotary shaft seal and the lock washer (310) from its gearbox seat.

●

Press the bevel pinion shaft (70) down and out of the drive pinion (110) and the bearing (230).

●

Remove the bearing (230) and shim(s) (440) if necessary.

●

Remove the bearing outer ring (240).

●

Remove the bearing inner ring (240) from the bevel pinion shaft.

ALL SEALS AND BEARINGS MUST BE REPLACED.

Preparing the Gear Unit ●

Fit the outer rings of the conical roller bearings (230, 240, 250 and (260) in the respective grooves of the clean gearbox. Make sure they sit evenly in the gearbox. Fit the lock washer (310).

●

Push the inner ring (260) of the conical roller bearing (260) onto the bevel wheel (65).

●

Screw the wheel stud (150) into the flange using a dynametric key.

●

Place the gearbox in its eventual assembly position.

●

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

●

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

Flange Shaft Assembly ●

Lightly grease the flange shaft (50) and carefully place it in the shaft seal (270) and the conical roller bearing (250).

●

Place the shim (430), spacer (160) and preassembled bevel wheel (65, 260) on the flange shaft.

WARNING THE FLANGE SHAFT ASSEMBLY MUST BE TENSIONED WITH A TORQUE WRENCH. ●

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

●

Check freedom of movement and play of the shaft. If necessary, reduce the torque.

Record the final reading. It will be required during calibration.

●

Insert the gear unit with wheel studs in a device which prevents it from twisting.

Printed in Germany

M1.0-0000-0003 M-3.1-1720-503

DRIVE UNIT Pinion Shaft Assembly ●

Push the bearing inner ring (240) up onto the bevel pinion shaft (70).

●

Insert the pre-assembled bevel pinion shaft from the inside of the gearbox into the pre-assembled bearing outer rings (230, 240).

●

Push the bearing inner ring (230) via the shank of the bevel pinion shaft (70) into the bearing outer ring.

Bevel pinion inner tooth end Correct tooth bearings

High

Low

High

WARNING THE SPUR PINION NUT MUST BE TIGHTENED WITH A TORQUE WRENCH. ●

●

Bevel wheel inner tooth end Correct tooth bearings

Fit the spur pinion (110) and torque new nut (140) to max. 100 Nm. Check freedom of movement and play.

If necessary, reduce the torque.

Record the final reading. It will be required during calibration.

Low

M1565-1

Checking the Flank Tooth Bearing ●

Colour the bevel wheel (70) tooth bearings with touch-up paint (marker colour).

Adjusting the Bevel Gear Assembly

●

Remove the gear unit from the device.

WARNING

●

Turn the bevel wheel several times in one direction. The tooth bearing will appear as a bright point (shown black in Fig. 1565-1) on the tooth flanks.

●

Check the tooth bearing. Set the tooth bearing to within the tolerance limits by adding and/or removing shims (420,430,440) - Fig. M1565-1.

Note: Torque screw (360) and nut (140) again to their previous values.

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

CARRY OUT ADJUSTMENT WITH CARE. BEARING AND SHIM PRE-TENSIONING AFFECT THE TOOTH BEARING. DO NOT SET THE PRE-TENSION TOO LOW AS IT AUTOMATICALLY REDUCES DURING NORMAL OPERATION. The correct setting can be determined by the flank tooth bearing.

Basic Rules: ●

Always set the bevel gear assembly in accordance with the correct flank position. The tooth ends must not form a straight line.

●

The tooth bearing must always rest on the inner tooth end.

●

The tooth bearing must lead from high (tooth upper edge) to low (tooth lower edge).

To adjust, add and/or remove compensating spacers (420, 430, 440), and/or change the bearing pre-tension.

Figure M1565-1 shows the permissible tooth bearing limits on the bevel pinion and bevel gear.

Final Assembly ●

Remove the bevel pinion shaft and flange shaft.

●

Clean the components.

●

Coat the inside of the bearing inner rings with a thin layer of Loctite 307.

●

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

●

To assemble, proceed as described previously.

●

Manually turn the gear unit while checking for freedom of movement and the absence of play during operation.

Printed in Germany

M1.0-0000-0004 M3.1-1720-004

DRIVE UNIT ●

Coat the surfaces of the gearbox cover with a thin layer of Loctite 307 surface sealant , insert the O ring (290) and fit the lid.

Evenly tighten the screws (390) and spring washers (330) crossways.

●

Coat the gearbox cover - live ring bearing contact surface with a thin layer of Loctite 307 surface sealant . Assemble the live ring bearing.

WARNING ALLOW THE CONTACT SURFACE AND THREAD SEALANT TO DRY FOR AT LEAST 2 HOURS AT ROOM TEMPERATURE BEFORE FILLING WITH OIL. ●

Place gear unit in assembly position.

●

Fill the oil up to the lower mark of the filler plug in accordance with the application temperature (see Lubrication and Adjustment chapter).

Assembly ●

Assembly is the reverse procedure of removal. Do not damage the toothing of the motor pinion (100) or the drive pinion (110).

Drive Motor For maintenance and repairs to the drive motor see the end of chapter 4, page M4.35-1720-001.

Printed in Germany

M1.0-0000-0005 M-3.1-1720-505

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Printed in Germany

ELECTRICS

Printed in Germany

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Printed in Germany

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

ABBREVIATION

COLOUR

NUMBER

FUNCTION

BLK

Black

0 **

Digital signal

BRN

Brown

1 **

Analog signal

RED

Red

2 **

Positive not connected

ORG

Orange

3 **

+12 V DC conver ter

YEL

Yellow

4 **

Third DC conver ter

GRN

Green

5 **

Negative not connected

BLU

Blue

6 **

Insulated negative

VIO

Violet

7 **

+5 V DC conver ter

GREY

Grey

8 **

Four th DC conver ter

WHT

White

9 **

Various

RED/WHT

Red/White

29 **

Positive connected

GRN/WHT

Green/White

59 **

Negative connected

** Numbers 01 to 99

E01-gb

Printed in Germany

M1.0-0000-0001 M-4.0-0000-001

ELECTRICS Abbreviations Switch Symbol Abbreviation List * Abbreviation

Component

Abbreviation

Component

K*

Relay

LMS

Limit switch

ACS

Accelerator pedal switch

LOS

Lower switch

A XS

Auxiliary function switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Direction control switch

RA

Raise potentiometer

DRS

Door switch

RAS

Raise switch

EDS

Emergency Disconnect Switch

REA

Reach potentiometer

EM

Encoder module

RS

Reverse switch

ENC

Encoder

SAS

Reverse safety switch

FS

Forward switch

SDS

Star t switch

HBS

Handbrake switch

SES

Seat switch

HSS

Fast / Slow Travel switch

SSS

Sideshifter switch

HNS

Horn switch

THS

Thermo switch

K YS

Key switch

TLT

Tilt switch

LGS

Light switch

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

E02-gb

Printed in Germany

M-4.0-0000-002 M1.0-0000-0002

ELECTRICS

Sundry Abbreviations * Abbreviation

Description

Abbreviation

Description

BV(AK)

Battery Voltage after key

M2 (PM)

Pump motor

BDI

Battery discharge indicator

MRC

Controller

BR

Brake

OHGD

Overhead guard display

BWI

Brush wear indicator

P

Pump contactor

CA

Cable connection

PC

Plug connector (fitting JC)

F

Connection field coils

PCB

Printed circuit board

FAN

Fan

SF

Shunt field

FU

Fuse

STI

Steering wheel indicator

HN

Horn

SV

Solenoid valve

I FD

Information display

TB

Terminal board

JC

Jack connector (fitting PC)

TMM

Truck management module

LINE

Line contactor

TT

Hourmeter

M1 (TM)

Traction motor

VMN

Chopper (Negative voltage motor)

* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2etc.

E03-gb

Printed in Germany

M1.0-0000-0003 M-4.0-0000-003

ELECTRICS Other Abbreviations* Abréviation

Désignation

Abréviation

Désignation

GCSR

Gate Closed Switch Right

GCSL

Gate Closed Switch Left

PLS

Platformswitch

TCM

Traction Motor

PS

Pressure Switch

HR

Heater

* If an abbreviation is used more than one time, a index number is added. E.g.PLS1, PLS2 etc.

E12-S-GB

Electrical Symbols EUROPE

1 2 3 4 5 6

USA

1 2 3 4 5 6

DESCRIPTION

EUROPE

DESCRIPTION

Wires joining

Hand operated maintained contact

Wires crossing

Solenoid valve

Wire connection

Inductor

Plug / socket

Resistor

Wire strap

Capacitor

Terminal board

Potentiometer

Fuse J

T

Thermal protector

Contact, normally open

Lamp

Contact, normally closed

Horn

Contact double throw

Battery

Operating device

Diode

Operating devices, slow releasing Operating device, slow operating Hand operated push button

Breakdown diode LED Transistor

c

Mechanically actuated

MOSFET

c

Hydraulically actuated

Thyristor

Emergency disconnect

Comparator

c

.

Varistor

U

Assembled unit

NO

USA

Motor armature

.

M0056-gb Printed in Germany

M-4.0-0000-004 M1.0-0000-0004

ELECTRICS Electrical Components DANGER Jack up the truck before carrying out repair work or troubleshooting the electrical system.

Transmitter (POT, FS, RS) The transmitter is manually activated via a rocker switch in the multitask handle head. The transmitter comprises a switch (FS) for forward travel, a switch (RS) for reverse travel, and a potentiometer (POT) which governs the travel speed.

Fast / Slow Travel Switch (HSS)

Safety Reverse Switch (SAS) The push button at the end of the multitask handle head is used to activate the safety reverse switch (SAS).

A sudden change from forward to reverse travel is achieved via the traction controller. As long as the push button is pressed (e.g. by the stomach), the truck reverses. This normally lasts for a brief moment.

Brake Switch (BRS) The brake switch (BRS) is immediately below the multitask handle attachment. As soon as the multitask handle reaches the upper or lower braking zone (see Fig. M1559-1) the brake switch is activated. The traction controller interrupts the power supply to the traction motor (TM) and the brake (BR). The brake magnet releases the anchor disk which in turn, spring powered, brakes the truck.

The Fast / Slow travel switch (HSS) is activated via a toggle switch (Rabbit / Turtle & Rabbit symbol) on the multitask handle head. The switch signal to the traction controller is used to change between the high and slow speed ranges.

Upper brake zone

Neutral / Idle Position

Travel zone

Lower brake zone

Reverse

Forward

M1559-1

Printed in Germany

M1.0-0000-0005 M-4.2-1720-500

ELECTRICS

Printed in Germany

M-4.2-1720-001 M1.0-0000-0006

ELECTRICS

Printed in Germany

M1.0-0000-0007 M-4.2-1720-002

ELECTRICS Lift / Lower Switch (RAS, LOS) The lift (RAS) and lower (LOS) switches are manually activated via a rocker switch in the multitask handle head.

The lift (RAS) switch operates the pump contactor (P) and causes the pump to start.

The lower (LOS) switch energises the solenoid valve (SV), causing the magnetic valve to open.

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

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

Fuses (FU)

Limit Switch (LMS) The limit switch (LMS) interrupts the pump contactor current flow when a preset maximum lift height has been reached. The limit switch is under the front panel next to the multitask handle support.

Fig. 1473 shows the position of the limit switch after lift cut-out.

Horn Switch (HNS) A buzzer sounds when the horn button is pressed.

Limit switch fitted for lift cut-out at 130 mm

The entire truck circuit is protected by fuse FU1, the control circuit by fuse FU2.

OPTION

Cold store trucks have a fuse FU3 for multitask handle heating.

OPTION

Temperature Switch (THS)

Only for cold store trucks. The temperature switch switches off the multitask handle heating at ambient temperatures over 10 °C.

Upper hole: Limit switch location for max. lift = 150 mm

Trip cam

Track

M1473

Elongated hole for fine adjustment of lift cut-out point Printed in Germany

M-4.2-1720-003 M1.0-0000-0008

ELECTRICS SEM 1 Traction Controller

Operational Features Speed Control

DANGER Jack up the truck before carrying out repair work or troubleshooting the electrical system.

General The programmable ZAPI SEM Zero impulse controller provides effective control over the driving behaviour of the truck.

The truck is powered by a separate excited motor (SEM). This version has two variables for governing the motor output: field and armature current.

Precautionary Measures ●

●

Do not attach the controller to a battery with a different rated voltage to that of the controller (24 - 36 VDC).

A higher battery voltage may destroy the MOSFETs, while a lower power supply will result in system failure.

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

●

When commissioning jack up the truck to prevent it from starting suddenly if there is a wiring error.

●

When the key switch has been turned off the filter capacitors in the controller remain charged for a few minutes. If work is performed on the controller during this time it must be disconnected from the battery (disconnect battery). Finally, to discharge the capacitors short-circuit the positive and negative terminals of the power part together over a resistance (10 - 100 Ohm, min. 5 W) for a few seconds.

Stepless, handset programmable speed control in both directions.

Reduced Speed Range Two travel speed ranges can be chosen using the rabbit/ turtle toggle switch HSS in the multitask handle.

Reduced speeds can be programmed between 30 % and 100 % of normal travel speed by using the handset.

Downhill Speed Control When travelling downhill the controller monitors and compares the motor anchor current with the drive signal from the traction potentiometer. When the motor anchor current decreases, electrical braking with energy retention is introduced.

Regenerative Braking Three forms of regenerative braking are available: ●

Deceleration braking by setting the travel switch to an smaller value, but still > 0, without changing the drive direction.

●

Inversion braking (quick inversion): travel switch set in opposite direction.

●

Release braking: travel switch set to neutral.

Anti - Roll Down Function This function prevents the truck from accidentally rolling down a slope. When the key switch is on the controller monitors anchor current of the traction motor. If the truck starts to roll down the slope without a travel comand, the controller detects the change in the achor current and braking is automatically activated. After this, the monitoring cycle starts over again.

Such, if the brake is not applied manually, the truck will therefore move down the slope very slowly.

Printed in Germany

M1.0-0000-0009 M-4.3-1720-001

ELECTRICS Hourmeter An hourmeter is integrated within the traction controller which can be set via the programmer either to "KEY ON" (hourmeter activated when key switch on) or "RUNNING" (hourmeter activated only during travel).

Self Test The traction controller self-test system lists up to five different error messages which can be called up via the programmer. The type of fault as well as the frequency, number of service hours and the controller temperature at the time of the error are stored and displayed.

In addition, a red LED on the controller flashes a code for the most recent error.

Monitored Circuits See the following diagram for a explanation:

SELF DIGNOSTICS Executed In Four Conditions

ALLWAYS Contin. Test By Key On

KEY ON One Time Test By Key On

STAND BY Contin. As Long As Key Is On

TRACTION Contin. Test During Traction

BATTERY VOLTAGE TEMPERATURE

START UP SEQUENCE

VACC NOT OK

CONTACTOR DRIVER

NO FIELD CURRENT

COIL SHORTED

CAPACITOR CHARGE

I FIELD HIGH

FORW + BACK

I = 0 EVER

WATCHDOG

V FIELD NOT OK

I HIGH AT STAND

VMN NOT OK

INCORRECT START

PEDAL WIRE KO

CONTACTOR DRIVER

Note:Text in the white boxes shows the messages of the programmer.

See table E-13-S-GB for a description of the monitored components.

Printed in Germany

M-4.3-1720-002 M1.0-0000-00010

ELECTRICS Protective Devices Polarity Protection A general protection controlled by the logic system separates the traction controller from the battery and thus protects the power part from incorrect polarity.

Maintenance Maintenance of the SEM-1 controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.

WARNING

Wiring Errors

The SEM -1 controller operates with high throughputs. Special safety measures are therefore required.

All outputs are protected against wiring errors. The outputs for the general protection and the magnetic brake can be charged with max. 3 A and are fitted with both an overload and a short circuit protection.

● Only properly trained personnel must carry out maintenance work. ● Use non-wearying eye protection.

Temperature

● Do not wear loose clothing.

From a power part temperature of 80°C upwards the maximum current is limited in proportion to the rise in temperature. At 90°C the traction controller automatically cuts out.

At temperatures below -10°C the maximum current is reduced in proportion to the ongoing battery discharge.

● Do not wear jewelry. ● Use insulated tools only.

●

Disconnect the battery (= emergency disconnect).

●

Jack up the truck.

To start the truck there is a specific start sequence which must be observed. Otherwise the line contactor will not be activated and the truck will not function:

●

Discharge the controller capacitors by connecting for a short time BATT- and BATT+ of the controller via a cable including a resistor of about 10 Ohm.

1.

Key "ON"

●

Remove cables.

2.

Guide tiller out of brake zone into drive zone (this opens the brake switch BRS)

●

Remove contamination and corrosion from the contact surfaces.

3.

choose your direction and speed

●

Wipe the controller with a clean, damp cloth.

●

Before connecting the cables make sure that the controller is completely dry.

Start Sequence

This means, the usual behavior of some operators leads to an error. This operators normaly take down the tiller first and then start the truck. This is not possible with this truck.

Safety Class The traction controller is protected against dust and spray water (IP54)

Printed in Germany

M1.0-0000-00011 M-4.3-1720-003

ELECTRICS Traction Controller, Diagnostic Sheet The follwing table assist in tracking down errors in the traction controller. ●

Do all measurements with fully loaded battery.

●

Always jack up the truckto prevent it from moving!

WP2000-S CONTROLLER DIAGNOSTICS LIST KEY ON, STANDBY PIN

RESULTS

A1 A2 A3

+BV +BV 40% +BV +BV +BV 0V +BV 0V 0V +BV 0V +BV ACC V 0.5V 12V +BV 0V +BV 0V +BV 0V

A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 C1 C2 C3 D1 D2 D3 D4 D5 D6 E1-8:

+BV 0V +BV +BV 0V

COMMENTS

TRACTION RESULTS

COMMENTS

TILLER IN TRAVEL ZONE TILLER IN BRAKE ZONE TILLER IN TRAVEL ZONE TILLER IN BRAKE ZONE

PLS, GCSL & GCSR CLOSED PLS, GCSL & GCSR OPEN

0V +BV 40% +BV +BV 0V 0V +BV 0V 0V +BV 0V +BV

PLS, GCSL & GCSR CLOSED PLS, GCSL & GCSR OPEN

POT WIPER POT LOW POT HIGH REVERSE SWITCH CLOSED REVERSE SWITCH OPEN SAFETY (SAS) SWITCH CLOSED SAFETY (SAS) SWITCH OPEN FORWARD SWITCH CLOSED FORWARD SWITCH OPEN

ACC V 0.5V 12V +BV 0V +BV 0V +BV 0V

POT WIPER POT LOW POT HIGH REVERSE SWITCH CLOSED REVERSE SWITCH OPEN SAFETY (SAS) SWITCH CLOSED SAFETY (SAS) SWITCH OPEN FORWARD SWITCH CLOSED FORWARD SWITCH OPEN

MAIN CONTACTOR CLOSED MAIN CONTACTOR OPEN TILLER IN TRAVEL ZONE TILLER IN BRAKE ZONE TILLER IN TRAVEL ZONE TILLER IN BRAKE ZONE

IF THE LOAD IS ≥ 1.2 t IF THE LOAD < 1.2 t HSS (R/T) CLOSED HSS (R/T) OPEN

UNUSED +BV HNS CLOSED 0V (SEE 2) HNS OPEN BATT NEG +BV RAS & LMS CLOSED 0V RAS OR LMS OPEN BATT NEG +BV LOS SWITCH CLOSED 0V LOS SWITCH OPEN

+BV 0V +BV +BV 0V +BV 0V BATT NEG +BV 0V BATT NEG +BV 0V

IF THE LOAD IS ≥ 1.2 t IF THE LOAD < 1.2 t HSS (R/T) CLOSED HSS (R/T) OPEN UNUSED HNS CLOSED HNS OPEN RAS & LMS CLOSED RAS OR LMS OPEN LOS SWITCH CLOSED LOS SWITCH OPEN

Do not measure, used by handheld programmer console

1) To measure the above, connect the common lead of the voltmeter to BATT NEG and the positive lead to the pin.

2) 0V –1 minute after opening HNS. 3) All connections as per electrical drawing.

Printed in Germany

M-4.3-1720-004 M1.0-0000-00012

ELECTRICS ZAPI SEM-1 Traction Controller Connections

F1

F2

6

D

1

8

E

1

3 C1 6

B

1

8

A

1

VMN

M1531

Power Connections

Control Connections A

Connection for: Key switch, battery discharge indicator (+ hourmeter), main contactor, brake, brake and override switch

Traction motor driver (negative)

B

Transmitter and reverse safety switch connection

Connections to tractionmotor field coils

C

Speed reduction switch connection

D

Connection for: horn and switch, pump contactor and lowering valve and switches

E

Programmer connection

BATT+

Positive battery supply

BATT-

Negative battery supply

VMN F1, F2

Printed in Germany

M1.0-0000-00013 M-4.3-1720-005

ELECTRICS SEM-1 Pin Layout A1 Hourmeter output A2 Key switch input (positive battery voltage after key switch: BV (AK)

D1 Not used

A3 Main contactor output, negative

D2 Horn switch (HNS) input; simultaneously positive horn supply

A4 Magnetic brake output, negative

D3 Negative horn supply

A5 Special travel zone override switch input; function is active when battery voltage supplied; simultaneously positive magnetic brake output

D4 Lift switch (RAS) input; simultaneously pump contactor (P) positive supply

A6 Negative battery voltage

D5 Pump contactor (P) and lowering valve (SV) negative supply

A7 Positive main contactor output; simultaneously BV(AK) for all switches

D6 Lower switch (LOS) input; simultaneously lowering valve (SV) positive supply

A8 Brake switch (BRS) input

B1 Loop potentiometer input; Working signal from 0 V (minimum speed) to 10 V (max. speed) B2 Negative potentiometer output B3 Positive potentiometer output B4 Reverse travel switch (RS) input; function is active when battery voltage is applied.

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

The status LED is off during normal travel. When an error occurs it flashes the respective code (see table E13-S-GB) until the error is rectified.

The programmer can be used to define the error more exactly.

B5 Reverse safety switch (SAS) input; function is active when battery voltage is applied.

The reverse safety switch is only active, when the truck is in pedestrian mode. However, the switch can be activated for rider mode by using the handset.

B6 Forward travel switch (FS) input; function is active when battery voltage is applied.

C1 BV (AK); not used. Connected to C2 instead C2 Not used. Connected to C1 instead C3 Fast / slow travel switch (HSS) input; function is active (slow travel) when no battery voltage is applied.

Printed in Germany

M-4.3-1720-006 M1.0-0000-00014

ELECTRICS Description of Alarms, shown by Diagnostic-LED Flashes

Failure

Alarm

1

Logic

WATCHDOG

Logic board and/or software failure

EEPROM KO

Memory fault

2

Starting Sequence

INCORRECT START

FORW + BACK

3

4

5

6

Starting Current

Accelerator

Current Sensor

Line Contactor

CAPACITOR CHARGE

Possible Cause

Brake Override Switch failure Error in star ting sequence Incorrect wiring Double direction, FORW/BACK, requested Charging of power unit capacitors is slower than 2sec.

VMN NOT OK

Motor power circuit Motor frame fault Faulty controller

VFIELD NOT OK

Field voltage failure

VACC NOT OK

POT wiper is interrupted Incorrect calibration of the POT switch Faulty POT

PEDAL WIRE KO

POT wires High and/or Low are interrupted

NO FIELD CUR.

Failure of the current transducer Field cable disconnected Failure in field power unit

HIGH FIELD CUR.

Failure of the current transducer Field cable disconnected Failure in field power unit

STBY I HIGH

Current sensor failure Logic failure

I = 0 EVER

Current sensor failure

COIL SHORTED

Contactor coil is shor ted Logic failure

DRIVER SHORTED

Contactor driver is open or shor ted Logic failure

7

Temperature

TH. PROTECTION

Thermal sensor failure Logic board failure

32

Batterie Voltage

BATTERY LOW

Discharged battery Note: This is an Option E13-S-GB

Printed in Germany

M1.0-0000-00015 M-4.3-1720-009

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

Programmer General

CAUTION

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

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

M0271-neu

Display Window ● ●

1

3

5

ROLL ROLL

ENTER OUT

PARAM SET

2

4

6

Alpha-numeric LCD display 2 lines @ 16 characters

Operating Keys

M0274 Printed in Germany

M-4.4-1720-001 M1.0-0000-00016

ELECTRICS Description of Keys Key

Designation

Explanation

1

ROLL up

Selects the next sub-menu or an option.

2

ROLL down

Selects the previous sub-menu or an option.

3

ENTER

Enters the main menu. Stores the pin configuration.

4

OUT *

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

5

PARAM up

Increases setting values or selects configuration.

6

SET down

Decreases setting values or selects configuration.

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

E05-gb

Operating Menu ZAPI SEM 1 Controller General When the programmer has been connected a self test start routine is performed. When it is complette, use the ROLL up/down and ENTER keys to select the required menu.

Printed in Germany

M1.0-0000-00017 M-4.4-1720-002

ELECTRICS Operating Menu - Overview ACCELER DELAY 0-9 DECELER DELAY 0-9 RELEASE BRAKING 0-9 INVERS. BRAKING 0-9 CUTBACK SPEED 0-9 MAX SPEED FORW W 0 - 9 MAX SPEED BACK W 0 - 9 CUTBACK SPEED 1 0-9 MAX SPEED FORW RU 0 - 9 MAX SPEED BACK RU 0 - 9 CREEP SPEED 0-9

CROWN CONSOLE V. 1.0 SEM1 CROWN 1.03 24V 300A HM

MAIN MENU PARAMETER CHANGE

MAIN MENU TESTER

MAIN MENU ALARMS

CODE hr, NO.,˚C

MAIN MENU PROGRAM VACC

VACC SETTING MIN MAX

BATTERY VOLTAGE V MOTOR VOLTAGE V MOTOR CURRENT A A FIELD CURRENT V VMN ˚C TEMPERATURE V% ACCELERATOR FORWARD SWITCH ON/OFF BACKWARD SWITCHON/OFF HANDLE SWITCH ON/OFF QUICK INVERSION ON/OFF LOW PERF. SWITCH ON/OFF CUTBACK SWITCH ON/OFF ON/OFF BRS SWITCH BATTERY CHARGE %

MIN VACC MAX 0.0 UP/DOWN 0.0

MAIN MENU CONFIG. MENU

CONFIG. MENU SET MODEL

CONFIG. MENU SET OPTIONS

CONFIG. MENU ADJUSTMENTS

NOT AVAILABLE

HOUR COUNTER KEY ON/RUNNING QUICK INVERSION BLLY/TIMED QUICK INVERSION ON/OFF

ADJUST BATTERY

M1606 Printed in Germany

M-4.4-1720-003 M1.0-0000-00018

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

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

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

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

CONFIG The Configuration menu is used to set the operation of the hourmeter and the safety reverse switch.

In addition, the "Adjustments" sub-menu allows for calibration between the battery voltage measured by the controller and the actual battery voltage.

Printed in Germany

M1.0-0000-00019 M-4.4-1720-004

ELECTRICS Settings PARAMETER CHANGE Menu Menu item

Setting range

ACCELER DELAY

1.15 - 3.00 sec

DECELER DELAY

0-9

Recommended setting

Description

2

Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when transmitter (rocker switch) suddenly set to limit). Higher values give longer delay.

0

Time taken to reach the new set value when the set value on the transmitter is changed. Corresponds to the braking intensity when the transmitter is returned.Higher values take more time to reach the new value.

RELEASE BRAKING

0-9

3

Release braking. Activated when the accelerator pedal is released or when it returns to neutral. Time taken for the motor current to fall to zero.Ahigher values result in shorter braking distance.

INVERSE BRAKING

0-9

6

Inversion braking. Activated when transmitter (rocker switch) is set to the opposite direction. Time taken for the motor current to fall to zero.Ahigher values result in shorter braking distance.

E06-S-gb

Printed in Germany

M-4.5-1720-001 M1.0-0000-00020

ELECTRICS Settings Menü PARAMETER CHANGE Menu Item

MAX SPEED FRW W

MAX SPEED BCK W

Setting range

Recommended setting

Description

0-9

Maximum forward speed in pedestrian mode: This value determines the maximum traction motor current during forward travel.

When the armature voltage has been fully absorbed by the controller, See warning! the speed is increased weakening the field current. If the value is set to 6 0 the field current will not fall below the nominal value (FCN = field current nominal) when the armature voltage is fully fully absorbed.

A higher value increases the maximum forward speed in walky mode.

0-9

Maximum rverse speed in pedestrian mode: This value determines the maximum traction motor current during reverse travel.

When the armature voltage has been fully absorbed by the controller, See warning! the speed is increased weakening the field current. If the value is set to 6 0 the field current will not fall below the nominal value (FCN = field current nominal) when the armature voltage is fully fully absorbed.

A higher value increases the maximum freverse speed in walky mode.

E06-S-Part3-gb

DANGER! The maximum speed in walkie-mode must not exceed 6 km/h!

The setting of "MAX SPEED FRW W" und "MAX SPEED BCK W" determine the speed.

The values suggested in table E06-S-gb are to be seen as initial settings. You must measure the speed of the truck and adjust the controller to meet this limit!

Adjustment of "MAX SPEED FRW W" and "MAX SPEED BCK W" Presets The brushes of the motor must have run for a mimmum of 10 hours totaly. With new brushes installed, reduce the measured setting by one and set this reduced value.

The reason for this is a constantly increasing maximum speed during the initial run in of new brushes.

After the brushes have run in, you must measure the maximum speed of the truck again and correct the speed accordingly.

Measuring the speed

before should be available to accelerate the truck to maximum speed before reaching the mark.

Drive through the zone with maximum speed and without load.

Use a stop-watch to measure the time needed for the distance of 10 meters.

Carry out three test drives in total and calculate the average of the results.

Example: 3 Time values: (16.2 s) (16.4 s) (16.8s) Average: 16.467 s Calculate the speed: 16,467 s / 10 m * 3,6 = 5,928 km/h Repeat the test run for the opposit travel direction.

Adjust the value to meet the requirement of a max. speed of 6 km/h in walky mode for each travel direction. After changing a value you must verify the setting by a new test run.

In a safe zone mark a distance of 10 meters on the floor. The surface must be level an a sufficent distance Printed in Germany

M1.0-0000-00021 M-4.5-1720-002

ELECTRICS Settings PARAMETER CHANGE Menu Menu item

MAX SPEED FRW RU

MAX SPEED BCK RU

CREEP SPEED

Setting range

0-9

0-9

0-9

Recommended setting

Description

See warning!

6

Max. forward speed in rider mode, truck without load: this value determines the maximum traction motor current during forward travel.

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

See warning!

6

Max. reverse speed in rider mode, truck without load: this value determines the maximum traction motor current during reverse travel.

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

3

Creep speed: setting for the minimum voltage applied to the traction motor when the travel switch is closed.

This function should be set to one level below the value at which the truck begins to travel.

This ensures that the empty run of the transmitter (rocker switch) is kept to a minimum.

E06-S-Part2-gb

Printed in Germany

M-4.5-1720-003 M1.0-0000-00022

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

TESTER Menu Menu Item

Description

BATTERY VOLTAGE

Battery voltage measured at key switch input.

MOTOR VOLTAGE

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

MOTOR CURRENT

Current received by motor armature.

FIELD CURRENT

Current received by field coil.

VMN

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

TEMPERATURE

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

ACCELERATOR

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

FORWARD SWITCH

Tests the operation of the "Forward" (FS) switch.

Displays the open (OFF) and closed (ON) status.

BACKWARD SWITCH

Tests the operation of the "Reverse" (RS) switch.

Displays the open (OFF) and closed (ON) status.

HANDLE SWITCH

Tests the operation of the "Override" (ORS) switch.

Displays the open (OFF) and closed (ON) status.

QUICK INVERSION

Tests the operation of the "Safety Reverse" (FS) switch.

Displays the open (OFF) and closed (ON) status.

LOW PERF. SWITCH

Zero function, as the switch is not present on the truck.

Control logic input is bridged.

CUTBACK SWITCH

Tests the operation of the "Fast / Slow" (FS) switch.

Displays the open (OFF) and closed (ON) status.

BRS SWITCH

Tests the operation of the "Brake" (BRS) switch.

Displays the open (OFF) and closed (ON) status.

BATTERY CHARGE

Displays the battery charge status as a percentage.

E07-gb

Printed in Germany

M1.0-0000-00023 M-4.5-1720-004

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

Type of error

●

Error frequency

●

Hourmeter status

●

Power part temperature

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

ALARMS Menu Error Message

Description

Possible Cause

LOGIC FAILURE #1

Main contactor drive test error during autodiagnostic function on truck power-up.

Control logic error.

Replace logic system.

WATCH-DOG

Error in auto-diagnostic function performed during truck power-up, when parked and during travel.

Watchdog circuit (hardware) or program (software) faulty. Replace logic system.

EEPROM KO

Error in non-volatile memory area where hourmeter, error message and truck parameter data is stored.

Turn key switch off and on again. If the error persists, replace the logic system. If the error is removed, make sure that all the stored data is deleted and reset to a default value.

INCORRECT START

Start sequence incorrect. The following sequence must be maintained: Override switch (by moving the multitask handle from idle to travel position), followed by travel switch (by pressing the transmitter (rocker switch)).

- Travel direction switch (FS/RS) or multitask handle switch jammed - Wiring error - Incorrect start sequence entered by user

FORW + BACK

Test is performed constantly and checks whether both travel directions are applied simultaneously.

- Wiring error - Travel direction switch jammed - Incorrect start sequence entered by user

CAPACITOR CHARGE

Test during auto-diagnostic function on power-up. If the capacitors have not started to charge 500 metres after turning the key switch, an error message appears and the main contactor does not close.

Power part faulty.

Replace logic system.

E08-gb

Printed in Germany

M-4.5-1720-006 M1.0-0000-00024

ELECTRICS ALARMS Menu (Contd.)

Error Message

Description

Possible Cause

VMN NOT OK

Test performed in idle mode with the main contactor closed and during travel.

The error message appears when VMN - is below the battery voltage when truck is idle - does not comply with power when truck is travelling

- Motor cable wiring error - Motor loss to earth - Power part error

VFIELD NOT OK

Test performed when truck is idle and main contactor open. The error message appears if approx. 50% of the battery voltage is not applied to the field connections.

- Motor loss to earth - Motor field connections not connected or incorrectly connected to controller - Error in power part field controller range

VACC NOT OK

Test performed during auto-diagnostic function on power-up and when truck is idle. The error message appears if the potentiometer signal deviates by more than 2 volts from the stored minimum value.

- Potentiometer cable broken - Wiring error - Potentiometer faulty - PROGRAM VACC not performed or incorrectly performed.

PEDAL WIRE KO

Test performed constantly and monitors the traction potentiometer and its wiring. Error message appears for broken wires.

Potentiometer connections not wired or interrupted.

STBY I HIGH

Test performed during auto-diagnostic function on power-up and when truck is idle. The error message appears if a current flow is detected.

- Faulty current sensor (replace controller) - Back coupling, logic system or power part error (replace component or entire controller)

Test performed during travelling. The error message appears if the traction current does not exceed a given minimum value.

- Insufficient motor contact (check carbon brushes) - Faulty current sensor (replace controller) - Back coupling, logic system or power part error (replace component or entire controller)

Test performed constantly and checks the field current.

- Field current measuring error (replace controller) - Field cable not connected - Power part error (replace component or entire controller)

Tests the main contactor circuit.

- Contactor coil short-circuited, not connected or incorrectly connected - Contactor drive opened or shortcircuited (replace logic system) - Voltage feedback errorto contactor driver (replace logic system)

I = 0 EVER

HIGH FIELD CURR, NO FIELD CURR

CONTACTOR DRIVER; COIL SHORTED

E09-gb

Printed in Germany

M1.0-0000-00025 M-4.5-1720-007

ELECTRICS ALARMS Menu (contd.)

Error Message

Description

Possible Cause

CONTACTOR CLOSED

Test performed during auto-diagnostic function on power-up.

The motor field is energised before the main contactor is applied. The error message appears if the power capacitors do not discharge.

- Main contactor jammed (check contacts, if necessary replace contactor) - Faulty field circuit (check field coil and field cable operation and connections)

TH PROTECTION

- An error message appears if the controller temperatue exceeds 80°C. The maximum current is reduced in proportion to the rise in temperature.

At 90°C the system automatically cuts out.

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

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

- Temperature sensor faulty (replace controller) - Faulty logic (replace logic system) - Insufficient heat transfer (check mounting bolts and the rest of the system)

BATTERY LOW

An error message appears if thebattery voltage falls below 63% of the nominal value.The ccurrent is reduced in proportion to the potential difference.

At 43% of the nominal value the system automatically cuts out.

- If the error message appears at a battery voltage above 63%, this indicates an error in the controller or the wiring.

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

Wiring problem: poor contact, additional consumer, cable too long, small diameter etc.

- Microprocessor error or battery current measurement error (replace logic system) E10-gb

PROGRAM VACC Menu The PROGRAM VACC sub-menu enables each traction potentiometer to be calibrated individually for each truck by taking and storing the minimum and maximum output voltages of the traction potentiometer.

The minimum output voltage is read as the travel switch is closed, the maximum output voltage when the travel switch is fully applied (rocket switch at limit). This ensures that the full physical path of the potentiometer is used.

Approx. 14V is applied to the travel switch via the traction controller. The signal range used by the potentiometer is from 0V (minimum speed) to 10V (maximum speed).

Printed in Germany

M-4.5-1720-008 M1.0-0000-00026

ELECTRICS CONFIG Menu The CONFIG menu provides access to the SET OPTIONS and ADJUSTMENTS sub-menus. The SET MODEL sub-menu is blocked (NOT AVAILABLE).

CONFIG Menu Sub-Menu SET MODEL

Option

Description ---

Not available

HOUR COUNTER: KEY ON / RUNNING

Determines the operation of the hourmeter in the traction controller. The following options are available: - KEY ON: Counts the hours while the truck is switched on - RUNNING: Counts the hours while the traction motor is applied

QUICK INVERSION: BELLY / TIMED

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

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

ADJUST BATTERY

Adjusts the battery current measured by the controller to the actual battery current. This can be necessary for example in the event of a relatively high voltage potential on the key switch.

SET OPTIONS

ADJUSTMENTS

E11-gb

Printed in Germany

M1.0-0000-00027 M-4.5-1720-009

ELECTRICS Traction Controller Safety Test

●

Power up the truck.

The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.

●

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

●

Attach test lead to F2 (item 3).

●

Power up the truck.

The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.

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

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

The test requires a test lead of approx. 1 mm2 diameter and a 10A fuse. ●

Switch off the truck and jack it up.

●

Connect one end of the test lead to -BATT.

●

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

●

Connect the other end of the test lead to VMN (item 1 in Fig. 805980_6).

●

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

●

If the test proves unsuccessful, replace the traction controller.

●

Connect the programmer to the traction controller.

●

Power up the truck.

The programmer should display CAPACITOR CHARGE. Activating the transmitter should have no effect.

●

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

●

Attach test lead to F1 (item 2).

Test lead 1

FU 10A 2

3

Traction Controller +BATT

F1

VMN F2

A2

F2

-BATT

F1

A1 TM Line +

PM

FU1 125A BD:1

24V BATT.

P

BD:2 805980_6 Printed in Germany

M-4.20-1720-001 M1.0-0000-00028

ELECTRICS Battery

Replacing the Battery WARNING

General

Only use batteries which comply with the dimension, weight and capacity requirements for this truck.

The condition of the battery considerably affects the output and behaviour of the truck. Proper maintenance enhances the performance and service life of the battery.

● An incorrect battery can damage the truck. ● Incorrect weight and dimensions alter the truck centre of gravity. This can result in accidents and will invalidate the warranty.

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

The respective manufacturer's maintenance manual is provided with all batteries supplied by Crown.

Operation During discharge the battery connector is connected to the truck circuit. During charging, it is connected to the charger.

Make sure that the battery connector is not disconnected when the truck is in use and that there is a fixed connection between the connector halves during truck operation and when the battery is being charged. A poor connection will cause the contacts to burn and damage the operation and charging capacity of the battery.

Reading the Electrolyte Level Check the electrolyte level on the surface of the battery fluid before adding destilled water.

The electrolyte density is the most reliable indicator of the battery's condition. When checking it, make sure that sufficient electrolyte is suctionned into the glass tube so that the floating body can swim freely when the acid tester is held vertically.

To replace the battery use either a battery trolley or a crane with sufficient capacity.

Removing the Battery ●

Apply the handbrake.

The multitask handle is vertical.

●

Switch off the truck and remove the key.

●

Open the battery compartment lid (see Fig. M1461).

●

Remove the battery connection and put the battery cable in a safe place.

●

Securely fit the appropriate lifting equipment.

●

Using an appropriate lifting mechanism lift the battery out of the truck and rest it securely.

●

Install the charged battery in the reverse order.

To compensate for loss of electrolyte use destilled water only. Replenish at regular intervals irrespective of the ambient temperature (see maintenance schedule in Section M1.2).

The battery plates must be covered. Never overfill the battery as wet and dirty cell lids lead to leak current and can thus reduce battery power. Overfilling can also lead to corrosion of the battery terminals and damage to the battery housing.

Excessive loss of electrolyte indicates a faulty battery, e.g. due to over-charging, total discharge, leak current from individual battery cells etc.

M1461

Printed in Germany

M1.0-0000-00029 M-4.25-1720-001

ELECTRICS Charging the Battery

Battery Discharge Indicator (BDI)

DANGER

General

Hydrogen is released during charging which can ignite and explode. It is a lifethreatening danger! ● Always keep the battery compartment lid open when charging a fixed battery. ● Make sure the charging area is well ventilated. ● The charging area must be free from naked flames and sparks.

CAUTION Before commissioning the charger make sure that it is suitable for the battery voltage and size.

A battery from the factory requires between 5 - 10 discharge cycles before it reaches its full capacity.

A battery is considered to be discharged when it has a residual capacity of 20 %. For example, a battery with a capacity of 500 Ah has an actual available output of 400 Ah. In addition the usable output depends on the discharge rate which in turn is governed by the particular truck application. For this reason the battery discharge indicator must be set in accordance with the conditions of use of the truck. An incorrectly set battery discharge indicator can result in total discharge or complete failure of the battery.

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

READ the instructions of the charger manufacturer.

Connect the battery to the charger. Make sure that the connection is secure.

After charging, make sure that all insulators between the cell connections and the battery lid are correctly positioned before using the truck again.

Adjusting the Battery Discharge Indicator The standard factory setting for the battery discharge indicator is "N" (selector at the back of the BDI module).

To adjust this setting proceed as follows:

DANGER Never travel without a side battery compartment panel or with an open battery compartment lid.

This can result in accidents.

●

Measure the electrolyte density on the fully charged battery.

●

The density should be measured on three different battery cells and should be at least 1.27 - 1.28 or 1.29 - 1.30 for high density batteries (consult battery manufacturer for exact values).

●

Measure the acid density again as soon as two red LEDs on the battery discharge indicator flash and lifting is automatically interrupted. Take the reading as before. The reading should not be less than 1.12- 1.13.

●

For higher readings change the battery discharge indicator setting to "K", for lower readings change to "U".

●

Make a test measurement with the battery charged and discharged.

Printed in Germany

M-4.25-1720-002 M1.0-0000-00030

ELECTRICS Traction / Pump Motor Maintenance Access ●

Unplug battery connector (=Emergency Disconnect).

●

Prevent truck from rolling away.

Carbon Brush

M1570

Maintenance ●

Remove all carbon brushes and check for wear (Fig. M1460). If carbon brushes need to be replaced, always replace all the carbon brushes together. It is advisable to replace the pressure springs at the same time.

●

Traction motor: Carbon brush min. length is 16 mm

●

Pump motor: Carbon brush min. length is 10 mm

●

Apply pressurised air to the motor.

●

Turn the armature to check for irregularities or other damage. An evenly distributed layer on the brush contact surfaces is normal.

●

Make sure that all brushes exert a uniform pressure on the armature.

●

Traction motor: refit the strap retainer.

●

Pump motor: refit the insulation cap.

Screw on the commutator cap.

Attach the hydraulic unit onto the chassis.

M1519

●

Traction motor: Remove strap retainer from upper section of motor.

●

Pump motor: Unbolt hydraulic unit from chassis.

Unscrew commutator cap. Remove insulation protective cap.

Printed in Germany

M4.35-1720-001

M1.0-0000-00031

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Printed in Germany

BRAKE

Printed in Germany

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Printed in Germany

BRAKE Brake Drive motor brake fastening screws (3 off)

General Functional Description The drive motor contains the drive wheel brake which is in the form of a disk brake.

The assembly is shown on page M5.0-1720-502.

The brake interlocks with the motor shaft. When the truck is de-energised the brake is applied: If the truck must be moved in this case the brake can be mechanically released by turning the two cheese head (fastening) screws.

Afterwards, always return them to their original position!

Test the brakes before operating the truck again.

The brake is electro-magnetically released. The axial force generated by compression springs acts on the moving anchor disk. The rotor has a friction lining on both sides and also moves axially. The force acting on the anchor disk jams the rotor between the anchor disk and the friction plate. When DC voltage is applied to the coil a magnetic force acts on the anchor disk. The anchor disk is pulled against the compression springs.

The rotor is no longer jammed, i.e. the brake is released.

Removal CAUTION Do not allow the brake components to come into contact with grease or oil.

M1462

The item numbers in brackets refer to the diagram on the following page. ●

Remove the battery connector (=Emergency Disconnect).

●

Jack up the truck until the drive wheel is free.

Secure the truck to prevent it from rolling away.

●

Remove the front panel.

●

Remove any brake dust.

●

Unplug the electric connection from the brake wiring (20).

●

Remove the three Allenscrews.

●

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

●

Remove rotor (16) from hub (15) while taking care not to damage the toothing.

●

Measure the thickness of the rotor (16). Replace the rotor if this thickness is less than 6.0 mm.

A new rotor is 10.0 mm thick.

●

Remove the friction plate (18) from the motor flange. New friction plates are 1.0 mm thick.

Replace if necessary.

●

Remove the screws from their nuts.

●

Unscrew banjo bolts (17) from the magnetic body (3 off).

●

Remove anchor disk (14).

●

Thoroughly clean components.

●

Check anchor disk (14), friction plate (18) and rotor (16) for even wear, grooves, cracks and burning. Replace worn and damaged components.

Printed in Germany

M1.0-0000-0001 M-5.0-1720-501

BRAKE by the thrust piedes (11). ●

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

●

Place the anchor disk (14) in the correct position on the magnetic body: Pay attention to the scribed circle.

●

Screw the banjo bolts (17) with a drop of Loctite medium into the magnetic body (7) until they reach the stop.

●

Insert the screws (8) into the anchor plate so that there is a minimum gap of 1 mm between the anchor plate and the magnetic body. Secure screws (8) with muts (9) in the anchorplate.

●

Screw the friction plate (18) onto the motor.

●

Push the rotor (16) onto the hub (15) while ensuring that the toothing is not damaged in the process.

●

Attach the pre-assembled magnetic body (7) to the motor using the Allen screws (3).

●

Restore the electrical connection (20).

Air Gap Setting The operating air gap is measured between the magnetic body and the anchor disk when the truck is braked. The air gap should be set to 0.2 mm (see Fig. M1467).

17

●

Unscrew the banjo bolts (3) until they reach the fixed position on the friction plate (18).

●

Torque the Allen screws (3) evenly to 9.5 Nm.

●

Check the operating air gap at several points along the length using a feeler gauge. The air gap must be even throughout.

●

To increase the air gap slightly unscrew the banjo bolts (17). To reduce the air gap screw the banjo bolts (17) into the magnetic body. Now measure again as described above.

●

When the air gap is correctly set torque the Allen screws (3) again to 9.5 Nm.

17

M0195-1

Assembly Assembly is the reverse order of disassembly. ●

If the thrust pieces (11) and springs (12) have fallen out of the magnetic body (7), insert them in the correct position: First the springs (12), followed Printed in Germany

M-5.0-1720-502 M1.0-0000-0002

BRAKE Change the brake moment with the adjusting ring (1) to fit the tolerances specified in Table B01S-gb.

Brake Moment Setting Different brake moments can be set for the first and second stages. To increase the moment of the first stage screw the adjusting ring (1) into the magnetic body.The adjustment must be done in steps, enshuring that the threadring could be secured with the lap of the locking plate (2). Start with the basic setting according Table B01S-gb, Screw Depth A. To increase the moment of the second stage screw the thread ring (6).

Secure the adjusting ring (1) with the locking plate (6).

Now repeat the brake test with maximum load. adjust the brake moment if necessary with the the thread ring (6) to the specified range (see Table B01S-gb). Secure the thread ring (6) with screw (4) and washer (5) when done.

Brake Test ●

Accelerate to max. speed the empty truck (no load on the forks!) at operating temperature with a fully charged battery on a level, dry and non-skidding concrete surface in a secure area.

●

Set the control handle to the lower braking zone.

●

Record the braking distance from the time of application of the brakes to the time the truck comes to a halt.

WP2000S Nominal Braking Distances and Screw Depth Model

2020

Capacity

2.000 kg

Screw Depth A

Inner ring = 4 mm Outer ring = 4.6 mm

Braking Distance (new brake)

Braking Distance (used brake)

Laden (nominal load)

Unladen

Laden (nominal load)

Unladen

1.95 - 2.05 m

1.85 - 1.95 m

1.85 - 1.95 m

1.75 - 1.85 m B01-S-GB

Inner ring

Outer ring

Fastening screw Banjo bolt Operating air gap

Tab washer Rotor thickness

M1467

De-energised brake

Printed in Germany

M1.0-0000-0003 M-5.0-1720-503

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Printed in Germany

M5.0-1720-004

STEERING

Printed in Germany

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Printed in Germany

STEERING Multitask Handle - Springs for Return Function 1

CAUTION Pre-tensioned springs!

When removing, take care to avoid injury.

8 2

Before carrying out any work on the tiller: ●

Remove the battery connector (EMERGENCY STOP).

●

Block the truck.

3

7

4

Adjustment

5

The axle (4) is fitted as standard on the left hand side with a tensioning pin (5). If the spring pressure reduces over time the spring pre-tension (2) can be increased as follows: ●

Unscrew the panel (1) and push it up.

●

Leave the tiller (8) in the rest position (up).

●

Drive out the tensioning pin (2) on the left-hand side.

●

Using a face spanner (3) turn the axle (3) as far as necessary. Drive in the tensioning pin (2) on the right-hand side.

●

6

M1562

If the spring tension is still not sufficient to keep the tiller up, replace the springs.

Removal ●

Unscrew the panel (1) and push it up.

●

Bring the tiller (8) to its highest position and keep it there.

●

Mark the position of the axle (3).

●

Drive out the tensioning pin (2).

The relieved springs should now turn the axle.

●

Tilt the tiller down to its lowest position.

●

If the axle (3) has still not turned, it is clearly fixed in its position and must be moved with the aid of a face spanner. To fully relieve the springs, rotate the axle (3), seen from the left hand side, approx.

20° anticlockwise from the fixed position.

●

Drive the axle (3) as far out to the right hand side so that the 2 springs (4) can be removed.

Assembly ●

Push the springs (4) onto the axle (3). The inner, offset end must insert into the axle (3) groove. A strap wrapped around the inner end of the first spring to be inserted can prove useful when inserting the other springs.

●

Drive the axle (3) into position.

●

Set the tiller (8) to the upper limit.

●

Drive in the tensioning pin on the left-hand side (if necessary on the right). Turn the axle as far as necessary. Grease the springs. Fasten the panel.

Check the brakes.

Printed in Germany

M1.0-0000-0001 M-6.1-1720-501

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Printed in Germany

LIFTING MECHANISM

Printed in Germany

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Printed in Germany

LIFTING MECHANISM Lift Linkage Fork Height Setting Note: The item numbers in brackets refer to the lifting equipment diagram in section 7.8 of the spare parts manual. ●

Lower the fork fully. The lifting joint (25) stop should match the fork tines (see Fig. M1468).

If not, adjust fork height as desribed:

●

Raise lifting equipment.

●

Measure fork height above lift joint swivel point (left-hand measurement point in Fig. M1465).

The height should be between 82 and 85 mm.

●

Measure fork height at the fork carriage back (right-hand measurement point in Fig. M1465).

The height should be between 82 and 88 mm.

WARNING The forks must be supported with wooden blocks or other suitable devices before carrying out work on or below raised forks. ●

Unscrew counternuts (14) from connecting rod.

●

Turn connecting rod (13) on hex. head.

●

Lower lifting equipment and check lifting joint stop.

●

Repeat the above steps until the stop setting is right when the fork is lowered.

●

Tighten counternuts (14).

●

Repeat procedure on second fork tine.

M1468

Lift joint stop (both sides)

Stop points

Lift 130 mm 85-3 mm

M1465 Printed in Germany

M1.0-0000-0001 M-7.0-1720-501

LIFTING MECHANISM

M1438 Printed in Germany

M-7.0-1720-002 M1.0-0000-0002

CYLINDERS

Printed in Germany

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Printed in Germany

CYLINDERS Lift Cylinders Operation The two lift cylinders are single-acting. The piston rods are raised by the hydraulic oil pressure and lowered by the weight of the raised load. Fig. M1475 shows a cylinder cross-section.

Piston Rod

Removal ●

Remove the front panel.

●

Extend the piston rods until the left piston rod attachment comes to rest next to the contactors and controller so that the dowel pin can be driven out.

●

Support the fork carriage with wooden blocks or other suitable parts.

●

Press the "Lower" switch for at least 10 seconds to de-pressurise the hydraulic system.

Scraper Guide Ring Seal Guide Ring Oil

WARNING

Cylinder Tube

De-pressurise all hydraulic system components before carrying out maintenance work. ● If pressurised hydraulic oil escapes from the system it can result in serious injuries. ● If any high-pressure fluid penetrates the skin it should be treated as an emergency even if there are no markings to the skin at first. Pain will set in later. Damage to the tissue may result.

M1475

● Tighten all connections before re-pressurising the system. Keep hands and feet away from screw holes as high-pressure fluids can emerge at these points. ● Use paper or cardboard to trace leaks.

Do not use your hands.

Printed in Germany

M1.0-0000-0001 M-8.1-1720-501

CYLINDERS ●

First drive out the dowel from the left-hand piston rod attachment between the contactors and controller so far as to be able to check whether the pin collides with the contactor or controller when it is fully driven out.

●

De-energise the pump motor and prevent it from being switched on again.

●

Protect the piston rods from scratches where they have been introduced into the chassis through the hole by using cardboard or similar material.

●

Drive out the dowel pins from the attachments of both piston rods.

●

Keep pressing on the "Lower" switch until the piston rods have been lowered into the lift cylinders by their own weight.

●

Unscrew the hydraulic connection to the lift cylinder, collecting any spilled oil.

●

Remove the brackets at the lower end of the lift cylinders.

●

Lift out the lift cylinders from the chassis.

M1474

Bracket

Printed in Germany

M-8.1-1720-502 M1.0-0000-0002

CYLINDERS Inspection Carefully examine the cylinder unit prior to carrying out repair work. To do this, extend and retract the cylinder several times. ●

Check the piston rods for signs of nicks, scratches or other damage to the surface.

●

Check the scraper rings for wear and unusual leakage.

●

If any excess hydraulic oil is leaking from the piston rod this may be due to a damaged rod seal. Replace the rod seal and make sure that the seal seat is clean and intact.

●

When repairing the cylinder check the condition of the guide rings. Ideally, all seal components should be replaced, not just worn or damaged seals.

●

Minor irregularities on the cylinder tube surface or the piston rod can be removed with an aluminium oxide cloth or a honing tool.

●

After inspection, clean all cylinder components in a high grade solvent and dry with a weak stream of compressed air.

●

Gently oil the clean parts and replacement parts with hydraulic oil before fitting them.

Replacing the Piston Seal NOTE Check the seal groove and piston rod (critical seal location) for damage before fitting a new seal.

Failure to do so will otherwise result in repeated leakage.

Use burr-free assembly tools and equipment made of soft metal or a suitable plastic without sharp edges to replace piston seals. Do not use a screw driver or similar tools as these could damage the seal edges.

If a new seal must be inserted over sharp edges, slots or corners, take appropriate protective measures.

Printed in Germany

M1.0-0000-0003 M-8.1-1720-003

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Printed in Germany

ELECTRICAL DIAGRAMS

Printed in Germany

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Printed in Germany

DIAGRAMS

COM

WP 2000-S STANDARD SCHEMATIC DIAGRAM

RAS

LMS

BRS

PS

2

5

3

COM

COM

COM

COM

COM

COM

COM

5 SAS

HSS

HNS

LOS

6

4

5

5

RS FS BRK SMALL COIL

2

POT

3

DIODE BLOCK

CURTIS 803 "COMBI"

LARGE COIL

BRK

LINE

1

TT 1 KYS 2

P

SV

3 5

UNUSED

6

BDI

7

UNUSED

8

COM

4 BATT NEG

GCSR HN

COM

1 PLS

COM

1 GCSL

5

6

7

8

3

4

2

1

3

C

6

B

A

2

1

6

5

4

3

2

1

7

8

6

5

4

3

2

1

1

D

BATT -

5

4

3

2

E 1

F2

F1

VMN

BATT +

TCM (SEM 1)

CONSOLE / ZAPI INSTRUMENT COM

KYS

A2

F1

F2

A1 TM

FU2 10A

LINE

+

P PM

FU1 125A

+ BD:1

BATTERY 24Volt

BD:2

NOTE: 1 Walkie Mode: GCSR, PLS & GCSL open.

2 Forks lower then 130mm: LMS closed.

3 Load is less then 1200kg: PS closed, 2/3 brake.

4 Reduce speed: HSS is open.

5 Funct. active, when: RAS, BRS, HNS or LOS closed.

6 Wired to normally closed, held open

M1595 Printed in Germany

M/P-DIA-1720-001 1

DIAGRAMS WP 2000-S STANDARD TRACTION CONTROLLER - LOGIC SIDE

TCM SEM1 2901 PC404-2 INSTR.

A 1

5900 PC 404-1 TT

2 3

2902 5903

4

5902

5

2923 PC 407-1 BRK (large coil) 001 BLK (2 CORE) JC 406-3 BRS INPUT 500 PC 404-5 BATT NEG 2904 JC 103-2 +BV (AK) GCSR 002 BLK (2 CORE) PC 406-2 BRS 2920 JC 102-2 PLS

8

COM

202 FU2 OUT +BV

PC 407-2 BRK NEG (large coil)

5901 PC 407-4

1

2924 PC 407-3

2

B 011 BLK PC411-5 POT NEG +0,5V

3

009 BLK PC411-3 POT HIGH +12V

4

007 BLK PC411-1 RS

5

005 BLK PC410-6 SAS

6

008 BLK PC411-2 FS

C

2908 JC202-3 +BV (AK)

1

2909

LINE COM

PS

2

2921

3

006 BLK PERFORMANCE 1/2 (R/T)

2913 JC 202-4

D 1

2911

1 2

2910

POT CIRCUIT & DRIVER

3

010 BLK PC411-4 POT WIPER

DIODE BLOCK

7

203 JC404-7 INSTR.

5904

6

KYS

2915 PC404-4 +BV

UNUSED

2

2912

3

501

4

2914

5

502

6

2918

HN

P SV

503

2919 JC202-2

M1596 Printed in Germany

2 M/P-DIA-1720-002

DIAGRAMS WP 2000-S STANDARD TRACTION CONTROLLER - POWER SIDE

202 KYS COM

FU2 10A

FU1 125A

TCM SEM1 LINE

201

A 1

KYS +BV IN TO THE LOGIC

2

LINE CONTACTOR NEG

3

BRK NEG (large coil)

4

BRS INPUT

5

BATTERY NEG

6

BATTERY POS (AK)

7

WALKIE/RIDER MODE

8

+ BATT

A1 BD:1

A2

B

POT WIPER

1

POT LOW +0,5V

2

POT HIGH +12V

3

RS - REVERSE SWITCH IN

4

1

SAS SAFETY SWITCH IN

5

FS - FORWARD SWITCH IN

6

BATTERY POS (AK)

C 1

PERF. CUT FOR 1200KG OR MORE

2

3

PERF. 1/2, HSS (R/T) INPUT

3

4

VMN

+ 24V BATTERY

HOUR METER OUTPUT

TM F1

F1 D UNUSED

BD:2

F2

1

HN - HORN HIGH

2

HN - HORN LOW

3

P - PUMP CONTACTOR HIGH

4

P & SV CONTACTORS LOW

5

SV - LOWERING VALVE HIGH

6

F2

E POSITIVE SERIAL RECEPTION

1

NEGATIVE SERIAL RECEPTION

2

POSITIVE SERIAL TRANSMISSION

3

NEGATIVE SERIAL TRANSMISSION

4

BATT NEG

5

BATTERY POS (AK)

6

UNUSED

7

UNUSED

8

2

- BATT NOTES: 1 VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED 0.5V = NO COMMAND

2 CONNECTOR "E" COULD BE USED: a- CONSOLE b- ZAPI'S INSTRUMENT

3 Load ≥ 1200kg 0V Load <1200kg + BV

4 HSS (R/T) closed +BV HSS (R/T) open

0V

M1597

Printed in Germany

M/P-DIA-1720-003 3

DIAGRAMS WP 2000-S STANDARD POWER UNIT CIRCUIT

JC 202

PC 202

2916 PC404-3

COM

002 BLK PC410-2

1

1

2917

003 BLK PC410-3

2

2

2919 SV

HIGH

001 BLK PC410-1

3

3

2908 C1

+BV (AK)

004 BLK PC410-5

4

4

2913 HN

HIGH

UNUSED

5

5

2922 THS

UNUSED

6

6

504

2926 LMS Opt.

LMS

P-

2925 LMS Opt.

BATT NEG

JC 404 PC404

CURTIS 803 "COMBI" 1

1

TT

2901 KYS NO +BV

2

2

KYS (+BV)

2916 LMS NC +BV

3

3

2915 P HIGH +BV

4

4

500

5

5

BATT NEG

UNUSED

6

6

UNUSED

KYS COMM +BV

7

7

BDI

UNUSED

8

8

UNUSED

5900 A1

203

A6

TT

BATT NEG

PC 406

JC 406

UNUSED

1

1

RED

002

BLK(2) A7 +BV (AK)

2

2

BLK

001

BLK(2) A5 BRS INPUT

3

3

WHT

UNUSED

4

4

UNUSED

COM

BRS

JC 407

PC 407

LARGE COIL

2923 A5 BRS INPUT

1

1

BLK

5902 A4 BRK NEG

2

2

BLU

2924 DIODE BLOCK (2)

3

3

BLK

5901 DIODE BLOCK (1)

4

4

BLK

SMALL COIL

BRK

M1599 Printed in Germany

4 M/P-DIA-1720-004

DIAGRAMS WP 2000-S STANDARD CONTROL HANDLE CIRCUIT

JC 410

PC 410

001 BLK PC202-3

1

1

BLU

002 BLK PC202-1

2

2

PINK

003 BLK PC202-2

3

3

RED

UNUSED

4

4

5

5

BLK

005 BLK B5 SAS INPUT

6

6

WHT

7

7

BRN

8

8

BLU

006 BLK C3 PERF. 1/2

007 BLK B4 REVERSE IN

1

1

ORN

008 BLK B6 FORWARD IN

2

2

YEL

009 BLK B3 POT HIGH

3

3

VIO

010 BLK B1 POT WIPER

4

4

BRN

011 BLK B2 POT LOW

5

5

WHT

COM

HNS

COM

COM

HSS

6

6

RS

COM

FS

COM

POT

UNUSED

PC 412

NO

LOS

JC 411

PC 411

SAS NC

COM

83019

004 BLK PC202-4

UNUSED

RAS

JC 412

GRAY

1

1

WHT

BLK

2

2

BLU

BLU

3

3

UNUSED

GRAY

4

4

BRN

COM

1

1 Wired to normally closed, held open

M1600

Printed in Germany

M/P-DIA-1720-005 5

DIAGRAMS WP 2000-S STANDARD WALKIE / RIDER CIRCUIT

JC 101

UNUSED

PC 101

RED

1

1

2906

2

2

BLK

2903

3

3

WHT

4

4

UNUSED

JC 102 UNUSED 2920 A8

UNUSED

1

1

RED

2

2

BLK

3

3

WHT

4

4

PLS

COM

1

Platform Switch

PC 103

UNUSED

1

1

RED

2904 A7 +BV (AK)

2

2

BLK

3

3

WHT

4

4

NOTE: 1 GCSL, PLS & GCSR are shown in walkie mode.

1

Side Restraint Left

PC 102

JC 103

UNUSED

GCSL

COM

GCSR

COM

1

Side Restraint Right

M1598 Printed in Germany

6 M/P-DIA-1720-006

DIAGRAMS Power-Cables

M1609 Printed in Germany

M/P-DIA-1720-007 7

2919

2908

2913

2922

504

1

1

1

1

1

2

3

4

5

6

THS

HN

D

Controller

205

2922

6+4

6+4

2913

2912

501

6+4

6+4

2917

1

1

JC202

2911

2921

2902

2901

2912

501

2914

502

2918

3

3

3

3

3

2

3

4

5

6

1

3 2

3 1

3 4

3 5

3 6

Controller

3 3

3 7

2

3

2921

A

1

3

2909

3

2

C

203 3 8

2 3

1

2903 4

3

2

1

GCSR

803450-006

PC 407

803450-017 803450-016

C

803450-018

803450-002

D

JC 103 A

803450-002

803450-002

JC 406

JC 102

803450-008

PC 404

803450-002

803450-003

JC 202

JC 101

CROWN NO

HOUSING

JC406

803450-013

3

5+4

504

6+4

6+4

6+4

6+4

6+4

6+4

Wire Bundle with Protective Cover

Wire Bundle

Lead

Branch Point

Terminal

62007-005

LEGENDS:

4,3mm U Shape

62007-068

503

2 3

4 4

16

2

18

15

10

14

USED

2919

2918

2911

2910

5904

2910

10

6,3mm Insolation

d = 8,4

2915 2909

P+

Faston 6,3 CuZn/Sn

Spring Terminal

Female Terminal

Male Terminal

COMMENTS

SV

PS

LINE

503

8 9

62007-43 803448-2

803448-003

803678-006

P9

502

Faston 4.8 CuZn/Sn 4,3mm Insolation Flag Recep. Insu.

7

6

5

62007-021

116858

2 4

803450-010

CROWN NO.

BRAKE SWITCH

4

3

2

1

TYPE

SHRINKING TUBE

30

002BLK(2) 1 001BLK(2) 1

1

Main Harness - 807 634 Standard - 807 877 F/C

JC103

1

2904

PC407

Controller

2 4

5901

BRAKE

2 2

2 1

2924

2908

8 9

2914

7

FU3 6+4

205

7+8

DIODE BLOCK

(pin 3)10

2924

(pin 2)10

203

5901 5903 5904

2

2

2

2

6

1

1 3

PLS

1 2

4

FU2

2917

JC102

1 3

1 2

4

5+4

LMS

GCSL

204

201

JC101 1

6+4

201

7+8

202

(pin 1)10

2

5

4

3

2

2901

5903

2916

5902 001BLK(2) 2923

2915

500

500 002BLK(2) 2904

6+4

2926

Curtis 803 "Combi"

2923

7+8

FU1

2925

PC404 1

5900

5900

2902

5902

6+4

204 2920

6+4

202 2906

8 M/P-DIA-1720-008 2920

2925 2906

6+4

2916 2903

7+8

2926

KYS

DIAGRAMS

Main-Harness

HANDLE HARNESS

M1602

Printed in Germany

Do not mount these connectors

NOTE:

2

2

2

2

3

4

6

5

2

1

004

001

- YEL/GRN wire should be cut from both branch points.

803450-017

B

116858 803450-013

2 3

Spring terminal

Female terminal

COMMENTS

803450-007

PC 411

CROWN NO.

803450-008

803450-007 PC 410

PC 202

NO.s 7

19

011

010

003

2

2

2

2

008 009

2

2

2

007

002

TYPE

3

6

CROWN NO.

008

3

5

HOUSING

005

3

4

PC 202

007

3

3

30mm

009 006

005

011

3

2

2

2

003

004

2

002

3

300mm Cable Protection tube

30mm Shrinking tube

2

001

1

006

010

B

3

HANDLE HARNESS 807 633

6

5

4

3

2

1

PC 411

8

7

6

5

4

3

2

1

PC 410

DIAGRAMS

Tiller-Harness

M1608

Printed in Germany

M/P-DIA-1720-09 9

DIAGRAMS WP 2000-S OPTIONS F/C

COM

SCHEMATIC DIAGRAMM

RAS

COM

COM

COM

COM

COM

COM

COM

5

LMS

BRS

PS

SAS

HSS

HNS

LOS

2

5

3

8

4

5

5

1

TT 1 KYS 2

RS FS

BRK SMALL COIL

2

POT

3

DIODE BLOCK

CURTIS 803 "COMBI"

LARGE COIL

BRK

LINE

P

SV

3 5

UNUSED

6

BDI

7

UNUSED

8

COM

4 BATT NEG

GCSR HN

COM

1 F/C Option

PLS

1 COM

7

GCSL

5

6

7

8

3

4

2

1

3

C

6

B

A

2

1

6

5

4

3

2

1

7

8

6

5

4

3

2

1

1

D

BATT -

5

4

3

2

E 1

F2

F1

VMN

BATT +

TCM (SEM 1)

CONSOLE / ZAPI INSTRUMENT

6

KYS

A2

COM

COM

THS

F1

F2

A1 TM

FU3 2A

FU2 10A

LINE

+

P PM

FU1 125A

+

BD:1

BATTERY 24 Volt

BD:2

NOTE: 1 Walkie Mode: GCSR, PLS & GCSL open.

2 Forks lower then 130mm: LMS closed.

3 Load < 1200kg: PS closed, 2/3 brake.

4 Reduce Speed: HSS open.

5 Funct. activ, when: RAS, BRS, SAS, HNS or LOS closed.

6 Temperatur < 0˚C: THS closed.

7 Activ: F/C-Option < 0˚C. 8 Wired to normally closed, held open

M1601 Printed in Germany

10 M/P-DIA-1720-010

DIAGRAMS WP 2000-S OPTIONS TRACTION CONTROLLER - SEM1 LOGIC SIDE

TCM SEM1 2901 PC404-2 INSTR.

A 1

5900 PC 404-1 TT

2 3

2902 5903

4

5902

5

2923 PC 407-1 BRK (large coil) 001 BLK (2 core) JC 406-3 BRS INPUT 500 PC 404-5 BATT NEG 2904 JC 103-2 +BV (AK) GCSR 002 BLK (2 core) PC 406-2 BRS 2920 JC 102-2 PLS

8

PC 407-2 BRK NEG (large coil)

5901 PC 407-4

1

2924 PC 407-3

2

B 010 BLK PC411-4 POT WIPER 011 BLK PC411-5 POT NEG +0,5V

3

009 BLK PC411-3 POT HIGH +12V

4

007 BLK PC411-1 RS

5

005 BLK PC410-6 SAS

6

008 BLK PC411-2 FS

2911

1 2

LINE COM

PS 2910

POT CIRCUIT & DRIVER

3

5904

7

202 FU2 OUT +BV COM

DIODE BLOCK

6

203 JC404-7 INSTR.

KYS

C

2908 JC202-3 +BV (AK)

1

2909

2

2921

3

006 BLK PERFORMANCE 1/2 (R/T)

2913 JC 202-4

D 1

UNUSED

2

2912

3

501

4

2914

5

502

6

2918

2915 PC404-4 +BV HN

P SV

503

2919 JC202-2

M1591 Printed in Germany

M/P-DIA-1720-011 11

DIAGRAMS WP 2000 -S OPTIONS TRACTION CONTROLLER - ZAPI POWER SIDE

202 KYS COMM

205 THS COMM

TCM SEM1

FU2 10A

FU3 2A 201

A LINE

FU1 125A

1

KYS +BV IN TO THE LOGIC

2

LINE CONTACTOR LOW

3

BRK NEG (large coil)

4

BRS INPUT

5

BATTERY NEG

6

BATTERY POS (AK)

7

WALKIE/RIDER MODE

8

+ BATT

A1

B

BD:1

A2

POT WIPER

1

POT LOW +0,5V

2

POT HIGH +12V

3

RS - REVERSE SWITCH IN

4

SAS SAFETY SWITCH IN

5

FS - FORWARD SWITCH IN

6

1

VMN

+ 24V BATTERY

HOUR METER OUTPUT

C

TM F1

BATTERY POS (AK)

1

PERF. CUT FOR 1200KG OR MORE

2

3

PERF. 1/2, HSS (R/T) INPUT

3

4

F1 D

BD:2

F2

UNUSED

1

HN - HORN HIGH

2

HN - HORN LOW

3

P - PUMP CONTACTOR HIGH

4

P & SV CONTACTORS LOW

5

SV - LOWERING VALVE HIGH

6

F2

E POSITIVE SERIAL RECEPTION NEGATIVE SERIAL RECEPTION

1

POSITIVE SERIAL TRANSMISSION

3

NEGATIVE SERIAL TRANSMISSION

4

BATT NEG

5

BATTERY POS (AK)

6

UNUSED UNUSED

7

2

2

8

- BATT

NOTES: 1 VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED 0.5V = NO COMMAND

2 CONNECTOR "E" COULD BE USED: a- CONSOLE b- ZAPI'S INSTRUMENT

3 Load ≥ 1200kg 0V Load <1200kg + BV

4 HSS (R/T) closed +BV HSS (R/T) open

0V

M1592 Printed in Germany

12 M/P-DIA-1720-012

DIAGRAMS WP 2000-S OPTIONS POWER UNIT CIRCUIT

PC 202

LMS1

JC 202

COM

2926 UNUSED

2925

LMS NOT MOUNTED

002 BLK PC410-2

1

1

2917

003 BLK PC410-3

2

2

2919 SV HIGH

001 BLK PC410-1

3

3

2908 C1 +BV (AK)

004 BLK PC410-5

4

4

2913 HN HIGH

012 BLK PC410-4

5

5

2922

2916 PC404-3

COM

205 FU3 OUT +BV THS

013 BLK PC411-6

6

6

504

P- BATT NEG

JC 404 PC404 CURTIS 803 "COMBI"

1

1

TT

2901 KYS NO + BV

2

2

KYS (+BV)

2916 LMS NC +BV

3

3

2915 P HIGH +BV

4

4

500

5

5

BATT NEG

UNUSED

6

6

UNUSED

203

7

7

BDI

8

8

UNUSED

5900 A1

A6

TT

BATT NEG

KYS COMM +BV

UNUSED

JC 406

PC 406

UNUSED

1

1

RED

002

BLK(2) A7 +BV (AK)

2

2

BLK

001

BLK(2) A5 BRS INPUT

3

3

WHT

4

4

UNUSED

UNUSED

COM

BRS

JC 407

PC 407

LARGE COIL

2923 A5

BRS INPUT

1

1

BLK

5902 A4

BRK NEG

2

2

BLU

2924 DIODE BLOCK (2)

3

3

BLK

5901 DIODE BLOCK (1)

4

4

BLK

SMALL COIL

BRK

M1594

Printed in Germany

M/P-DIA-1720-013 13

DIAGRAMS WP 2000-S OPTIONS CONTROL HANDLE CIRCUIT

JC 410

PC 410

001 BLK PC202-3

1

1

BLU

002 BLK PC202-1

2

2

PINK

003 BLK PC202-2

3

3

RED

012 BLK PC202-5

4

4

RED/WHT

004 BLK PC202-4

5

5

BLK

005 BLK B5 SAS IN

6

6

WHT

UNUSED

7

7

BRN

8

8

BLU

006 BLK C3 PERF. 1/2

1

1

83019 HNS COM

COM

HSS

COM

FS

COM

2

YEL

009 BLK B3 POT HIGH +12

3

3

VIO

010 BLK B1 POT WIPER

4

4

BRN

011 BLK B2 POT LOW +0,5V

5

5

WHT

013 BLK PC202-6

6

6

BLK

POT

GRN PC 412

NO

COM

RS

2

F/C Package

JC 412

GRAY

1

1

WHT

BLK

2

2

BLU

BLU

3

3

UNUSED

GRAY

4

4

BRN

COM

LOS

ORN

008 BLK B6 FORWARD IN

SAS NC

COM

JC 411

PC 411 007 BLK B4 REVERSE IN

RAS

1

1 Wired to normally closed, held open

M1590 Printed in Germany

14 M/P-DIA-1720-014

DIAGRAMS WP 2000-S OPTIONS WALKIE / RIDER CIRCUIT

PC 101

JC 101

1

1

RED

2906

2

2

BLK

2903

3

3

WHT

4

4

UNUSED

UNUSED

JC 102 UNUSED 2920 A8

UNUSED

1

PC 102

1

1

RED

2

2

BLK

3

3

WHT

4

4

COM

1

PLS Platform Switch

PC 103

JC 103

UNUSED

1

1

RED

2904 A7 +BV (AK)

2

2

BLK

3

3

WHT

4

4

UNUSED

GCSL Side Restraint Left

1

GCSR Side Restraint Right

NOTE: 1 GCSL, PLS & GCSR are shown in walkie mode.

M1593 Printed in Germany

M/P-DIA-1720-015 15

16 M/P-DIA-1720-016

Do not mount these connectors

TYPE

008

3

6

NOTE:

005

3

5

CROWN NO.

007

3

4

HOUSING

009

3

3

2

2

2

2

2

2

1

2

3

4

5

6

PC 202

005

3

2

013

803450-017

B

116858 803450-013

2 3

Spring terminal

Female terminal

COMMENTS

803450-007

PC 411

CROWN NO.

803450-008

PC 410

803450-007

7

19

NO.s

013

004

PC 202

011

001

- YEL/GRN wire should be cut from both branch points.

010

003

012

009

2

2

2

2

2

002

2 008

2

2

2

007

006

004

30

2

003

2

2 012

2 002

011

300mm Cable Protection tube

30mm Shrinking tube

001

010

006

3

3

1

B

Controller C-3

HANDLE HARNESS F/C 805 938

6

5

4

3

2

1

PC 411

8

7

6

5

4

3

2

1

PC 410

DIAGRAMS

M1603

Printed in Germany

HYDRAULIC SCHEMATIC

Printed in Germany

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Printed in Germany

HYDRAULIC SCHEMATIC

145 bar

M1457-1 Printed in Germany

M/P-HYD-1720-501 1

Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany

CROWN Gabelstapler GmbH Moosacher Straße 52 80806 München Germany Telefon +49 (0)89 93 00 2 – 0 Telefax +49 (0)89 93 00 2 – 175 und 133

MS-WP2000S-GB • Rev.1 09/00 • Printed in Germany