Crown Forklift WP2300 Series Maintenance Manual

Maintenance Manual

WP2300 Series MS-WP2300 04/03 • Printed in Germany Order Number: 812528-006

This master maintenance manual is subject to continual updates.

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

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

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

Copyright 2002 CROWN Equipment Corporation

REVISION Overview of Revisions: Page 3

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

Reference to authorised service personnel added.

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TABLE OF CONTENT

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TABLE OF CONTENT Table of Content ITD – INTRODUCTION

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

M1 – LUBRICATION AND ADJUSTMENT

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Component Access ............................................................. 11 Jacking up the Truck ........................................................... 11 Lifting by Crane ................................................................... 11 Lifting by Truck ................................................................. 12 Components ........................................................................ 13 Maintenance ........................................................................ 16 Recommended Lubricants and Oils ................................. 16 Lubricants ................................................................... 16 Cold Store Trucks ........................................................ 16 Truck Decommissioning ..................................................... 16 Restoring the Truck to Service ........................................... 16 Check and Maintenance Schedule ..................................... 18 Safety Reverse Switch – Functional Test .......................... 20 Grease items and grease intervals .................................... 28 Castors ................................................................................. 30 Torques ................................................................................ 31

M2 – HYDRAULICS

PAGE

Hydraulic Symbols .............................................................. 35 Hydraulic System ................................................................ 39 Operation ......................................................................... 39 Removing the Hydraulic Unit ............................................ 40 Replacing the Hydraulic Pump ......................................... 41 Removal ...................................................................... 41 Installation ................................................................... 41 Commissioning and Bleeding the System ........................ 41 Filters ............................................................................... 43 Replacing the Pressure Filter ...................................... 43 Replacing the Suction and Return Filters .................... 43 Oil Change ....................................................................... 43 Replacing the Safety Valve ............................................... 44 Safety Valve Setting ......................................................... 44 Safety Valve Test and Setting ...................................... 44

M3 – DRIVE UNIT

PAGE

Gear Unit .............................................................................. 47 Drive Unit, General .............................................................. 48 Removing the Drive Unit ..................................................... 48

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TABLE OF CONTENT M3 – DRIVE UNIT

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Traction Motor Removal ................................................... 48 Dismantling the Motor ...................................................... 49 Assembling the Motor ...................................................... 49 Traction Motor Assembly .................................................. 51 Gear Unit Disassembly .................................................... 52 General ....................................................................... 52 Preparation ................................................................. 52 Draining the oil ............................................................ 52 Removing the drive unit .............................................. 52 Dismantling the gear unit lid ........................................ 52 Dismantling the gear unit ............................................ 53 Gear Unit Assembly .................................................... 53 Installing the gear unit lid ............................................ 55 Adding Oil ................................................................... 55 Installing the drive unit ..................................................... 55

M4 – ELECTRICS

PAGE

Electrics - General ............................................................... 59 Wire Colour Codes ........................................................... 59 Abbreviations ................................................................... 60 Electrical Symbols ............................................................ 62 Electrical Components ....................................................... 63 Transmitter (POT, FS, RS) ................................................ 63 Fast / Slow Travel Switch (HSS) ....................................... 63 Reverse Safety Switch (SAS) ........................................... 63 Brake Switch (BRS).......................................................... 63 Override Switch (ORS) ..................................................... 63 Raise / Lower Switch (RAS, LOS) .................................... 64 Limit Switch (LMS) ........................................................... 64 Horn Switch (HNS) ........................................................... 64 Key Switch (KYS) ............................................................. 64 Emergency Disconnect .................................................... 64 Fuses (FU) ....................................................................... 64 OPTION

Thermal Switch (THS) ........................................... 65 Battery .................................................................................. 67 General ............................................................................ 67 Replacing the battery ....................................................... 67 Battery Discharge Indicator (BDI) ...................................... 67 General ............................................................................ 67 Battery Discharge Indicator Setting (BDI) ........................ 68 Calibration ........................................................................ 68 SEM0 Traction Controller .................................................... 67 General ............................................................................ 67 Precautionary Measures ............................................. 67 Operational Features ....................................................... 67 Speed Control ............................................................. 67 Reduced Speed Ranges ............................................. 67 Downhill Speed Control ............................................... 67 Regenerative Braking .................................................. 67 Anti - Roll Down Function ............................................ 67 Hourmeter ................................................................... 68 Self Test ...................................................................... 68 Monitored Circuits ....................................................... 68 Protective Devices ............................................................ 68 Polarity Protection ....................................................... 68 Wiring Errors ............................................................... 68 Temperature ................................................................ 68 Start Sequence ........................................................... 68 MS-WP2300-GB 04/03 • Printed in Germany

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TABLE OF CONTENT M4 – ELECTRICS

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Safety Class ................................................................ 68 Maintenance .................................................................... 69 Replacing the SEM0 Traction Controller........................... 70 Parameter Setting after Replacing the Traction Controller ............................. 70 Preparatory Measures ................................................ 70 Setting ......................................................................... 70 Status LED .................................................................. 72 Programmer ......................................................................... 73 General ............................................................................ 73 Operating SEM0 Controller Menu .................................... 74 General ....................................................................... 74 Operating Menu - Overview ........................................ 75 Menu Functions .......................................................... 75 PARAMETER CHANGE .............................................. 75 Settings and Alarms............................................................ 76 TESTER Menu ................................................................. 77 ALARMS Menu ................................................................ 78 PROGRAM VACC Menu .................................................. 79 Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu .................................................. 81 Preparatory Measures ................................................ 81 Calibration ................................................................... 81 CONFIG Menu ...................................................................... 82 SET MODEL .................................................................... 82 SET OPTIONS ................................................................. 82 Adjustments ..................................................................... 82 Traction Controller Safety Test ........................................... 83 Battery .................................................................................. 85 General ............................................................................ 85 Replacing the battery ....................................................... 85 Battery Discharge Indicator (BDI) ...................................... 85 General ............................................................................ 85 Battery Discharge Indicator Setting (BDI) ........................ 86 Calibration ........................................................................ 86 On Board Charger ............................................................... 87 General ............................................................................ 87 Battery Charging Phases ............................................ 87 Special Charging Phases ............................................ 87 Charging Errors ................................................................ 88 Green LED is not lit ..................................................... 88 Green LED flashing ..................................................... 88 Important Technical Data ................................................. 89 Replacing the Charger ..................................................... 89 Removal / Installation .................................................. 89 Electric Motors .................................................................... 91 General Maintenance Instructions ................................... 91 Preparation ................................................................. 91 Important Maintenance Instructions ............................ 91 Traction Motor Maintenance ............................................... 92 Access to Brushes ........................................................... 92 Maintenance .................................................................... 92 Armature ..................................................................... 92 Bearings ...................................................................... 92 Pump Motor Maintenance ................................................... 93 Access to brushes ............................................................ 93 Maintenance .................................................................... 93 Armature ..................................................................... 93 MS-WP2300-GB 04/03 • Printed in Germany

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TABLE OF CONTENT M5 – BRAKE

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Brake .................................................................................... 97 Operation ......................................................................... 97 Removal ........................................................................... 97 Assembly .......................................................................... 99 Air Gap Setting ................................................................. 99 Brake Moment Setting ...................................................... 99 Testing the Brakes ............................................................ 99

M6 – STEERING

PAGE

Live Ring Bearing ................................................................ 103 Disassembly ..................................................................... 103 Installation ........................................................................ 103 Multitask Handle - Springs for Return Function ............... 104 Adjustment ....................................................................... 104 Removal ........................................................................... 104 Assembly .......................................................................... 104 Tiller Handle ......................................................................... 105 Main Components ............................................................ 105 Tiller Handle Component Removal / Installation .............. 106 Tiller Handle Shells .......................................................... 106 Removing the Upper and Lower Shells ....................... 106 Fitting the Upper and Lower Shells ............................. 107 Switch Unit ....................................................................... 108 Removal ...................................................................... 108 Switch Unit Installation ................................................ 108 "Fast/Slow" Toggle Switch ................................................ 109 Removal ...................................................................... 109 Installation ................................................................... 109 Hydraulic Board ................................................................ 109 Removal ...................................................................... 109 Installation ................................................................... 109 Potentiometer ................................................................... 110 Removal ...................................................................... 110 Installation ................................................................... 110 Safety Reverse Switch ..................................................... 111 Removal ...................................................................... 111 Installation ................................................................... 111 Horn Switch ...................................................................... 112 Removal ...................................................................... 112 Installation ................................................................... 112 Handle .............................................................................. 113 Removal ...................................................................... 113 Installation ................................................................... 113

M7 – LIFTING MECHANISM

PAGE

Lift Linkage .......................................................................... 117 Fork Height Setting .......................................................... 117

M8 – CYLINDERS

PAGE

Lift Cylinders ....................................................................... 121 Operation ......................................................................... 121 Removal ........................................................................... 121 Inspection ......................................................................... 123 Replacing the Piston Seal ................................................ 123

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TABLE OF CONTENT DIA – ELECTRICAL DIAGRAMS

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Overall Wiring Diagram, Standard Version ........................ 127 Overall Wiring Diagram with Options ................................ 128 Wire harness overview, all versions .................................. 129

HYD – HYDRAULIC SCHEMATIC

PAGE

Hydraulic Schematic ........................................................... 133

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SAFETY

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SAFETY Safety Symbols used in the Manual

General Maintenance and Repair Safety Notes

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

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

DANGER

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

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

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

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

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

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

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

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

Maintenance and Repair 1.

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

2.

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

3.

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

4.

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

Only carry out cleaning with an oil separator.

Protect the electrical system from dampness.

5.

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

6.

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

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

7.

Neutralise and thoroughly rinse any spilled battery fluid immediately.

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

INFORMATION Contains additional information with supplementary notes and hints.

OPTION OPTION

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

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SAFETY 8.

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

9.

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

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

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

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

Clean any illegible labels.

●

Replace any faulty or missing labels.

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

Before Leaving the Truck ●

Stop the truck.

●

Lower the fork carriage fully.

●

Apply the parking brake.

●

Turn off the truck and remove the key.

●

Block all wheels when parking on an uneven surface.

Before Carrying out Work on the Truck ●

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

●

Prevent the truck from rolling away.

●

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

●

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

Before Operating the Truck ●

Check the safety devices.

●

Get into the driver's seat.

●

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

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INTRODUCTION

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

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

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

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

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

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

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

Additional copies can be ordered as required.

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

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

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

These are listed in a separate manual.

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

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

Spare parts can be ordered by quoting: ●

The truck specification number

M6

Steering

●

The truck model number

M7

Mast / Lifting Mechanism

●

The truck serial number

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic A01M-gb

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

1.6

WP

2015

–

3

–

2

–

S

Capacity

Load Wheels

1.6 = 1600 kg 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) 2315 = 150 Ah (146 x 660 x 604) 2320 = 240 Ah (212 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

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LUBRICATION AND ADJUSTMENT Component Access

Lifting by Crane

Lifting off the panel will provide access to the drive unit, hydraulic system, contactors, traction controller etc.

The panel is fixed to the chassis via two screws.

By removing the screws you can lift up the panel from the lower lugs, tilt and lift it out over the tiller.

Attach the straps to the hitch points as shown and prevent them from sliding off.

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

Please follow the instruction "Jack up the truck" in this manual by jacking up the truck and supporting it with wooden blocks.

MS1723-005

Jacking Points

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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

●

MS-1723-002

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LUBRICATION AND ADJUSTMENT Components

Battery Connector (Emergency Disconnect)

Control fuse (Power) Fuse

FU3 F/C

Traction Controller

Lift Cylinder RH

Main Contactor

Pump Contactor

Lift Cylinder LH Pump Motor

Lowering Valve

Hydraulic Reservoir with Integrated Pump

Horn Magnetic Brake Drive Motor

Drive Wheel M1454-new

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LUBRICATION AND ADJUSTMENT Fast / Slow Travel Switch

Button, Horn

Travel Switch

Reverse Safety Switch

Socket for storing Charger Plug

MS1723-004

Lift / Lower Switch

Battery Monitor Displays Key Switch

Hourmeter and Battery Discharge Display

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LUBRICATION AND ADJUSTMENT Maintenance Recommended Lubricants and Oils Lubricants The following page lists typical lubricants which are also used by Crown in the factory. However, any lubricants with the same technical specifications can be used.

Cold Store Trucks Special hydraulic oil, lubricant oils and grease for low temperature applications must be used for cold store trucks (see table on following page). All screws, washers, nuts, pins, retaining rings etc. must be treated regularly with an anti-corrosion solution CROWN no.

805236-004. Electrical connections and components must be carefully protected against corrosion. For more details refer to chapter 4.

Maintenance intervals must be adapted to the conditions of use. They should be as frequent as possible to prevent excess wear.

●

Every 3 months connect the battery, carry out a daily check and test the truck functions. Then disconnect the battery again.

Restoring the Truck to Service When restoring the truck to service, proceed as follows: ●

Remove any addition corrosion protection applied (except for cold store protection)*.

●

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

●

Charge the battery or install a charged battery.

●

Connect the battery.

●

Carry out the daily check.

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

Do not wet-clean the electrical system and do not use flammable cleaning solutions.

Truck Decommissioning When taking the truck out of service for more than 3 months, proceed as follows: ●

Disconnect the battery.

●

Decommission the battery in accordance with the manufacturer's instructions.

●

Clean the truck*). Wipe off any grease in accordance with the maintenance manual.

●

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

●

Do not park the truck in the open air or in a humid environment. The ideal location is a dry room with as constant a temperature and air humidity as possible. If the truck has to be covered, use material through which air can permeate rather than plastic sheets. Otherwise condensation water may form.

●

Jack up the truck. Lower the chassis onto suitable wooden blocks in order to clear the wheels from the ground (this prevents the wheels from flattening under constant pressure).

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LUBRICATION AND ADJUSTMENT Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Grease (multi purpose)

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

Aral Castrol Century Esso Maxol Mobil Shell SKF

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

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

Aral Castrol Esso Mobil Shell Finol Fuchs Minralölwerke GmbH

053001-003

D

Low temperature hydraulic oil

Deutz Oel HVI 32

Klockner

053001-009

DD

Transmission oil

Hyp 85W90 GX - D 85W90 Mobilube HD85/90 Spirax MB90

Aral Esso Mobil Shell

053002-004

A

Low temperature transmission oil

Mobil SHC 624

Mobil

053002-009

AA

Hydraulic oil

Type

L01_lubricants_wp-GB

Product

Product Name

Application

Crown Part No.

Anti-corrosive agent

Tectyl

Anti-corrosive agent for cold store trucks

805236-004

2K transparent coating

Acid resistant transparent coating for traction controllers for cold store applications.

805236-003

Elring Dirko

Jointing compound for gear unit lid (liquid seal).

310 ml cartridge: 805236-002 100 g Tube: 805236-001

Transparent coating

Jointing compound

L01_adjuvants_WP-GB

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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

Fast / Slow travel switch

Check operation

7

Reverse safety switch

Check operation

8

Brake

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

9

Steering

Check play

10

Fork

Check for visible signs of cracks and deformation

11

Wheels / Load wheels

Check tyres for wear, nails, metal splints etc.

12

Hydraulic lines and connections

Check for leaks, tighten connections if necessary

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LUBRICATION AND ADJUSTMENT

2

8 1

MS1723-011

9 10

11

12 MS1723-012 MS1723-014

6

4 3

5, 8

7 MS1723-004

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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

●

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LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours No.

Item

Action

1

Battery

According to instructions of battery fabricant

2

Contactors

Clean; check, replace if necessary

3

Lift limit switch

Check operation

4

Electrical system

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

5

Controller

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.

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LUBRICATION AND ADJUSTMENT

1

5

4 3

2

7

7 8 6

MS1723-016

10 MS1723-015

MS1723-013

9

9

MS1723-011 MS-WP2300-GB 04/03 • Printed in Germany

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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

Carbon brushes Pump and drive motor

Check for wear, ease of motion and contamination

3

Connecting rods

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

4

Forks

Check height setting, adjust if necessary

5

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

6

Tiller

Check operation and grease flat coil springs for return function

7

Brake

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

8

Lift cylinder

Clean attachments of cylinder (bottom) and piston rods (top), check for wear, replace if necessary, grease

9

Lift mechanism

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

10

Load wheel and castor axles

Clean, check for wear, replace if necessary, grease

11

Hydraulic system

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

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LUBRICATION AND ADJUSTMENT

1

8 8 5

6 11 7 2

MS1723-016

4

10

9

9 3

MS1723-011

MS1723-011

MS-WP2300-GB 04/03 • Printed in Germany

MS-1.2-1723

M-1.0-0000-00025 25

LUBRICATION AND ADJUSTMENT Annually or every 1000 service hours No

Item

Action

1

Pump and drive motor

Check commutator for damage 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

L06-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

MS-1.2-1723

26M-1.0-0000-00026

MS-WP2300-GB 04/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT

1

5 3

MS1723-016

2, 6 1

MS-WP2300-GB 04/03 • Printed in Germany

MS-1.2-1723

M-1.0-0000-00027 27

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

X

6

Connecting rod pins and all lifting mechanism joints

B

A/R

X

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

Initial change after 250 hoursof operation

X

L08-gb

MS-1.2-1723

28M-1.0-0000-00028

MS-WP2300-GB 04/03 • Printed in Germany

LUBRICATION AND ADJUSTMENT

4 3 3

8

7

8 9 1, 2 7

MS1723-016

5

6

MS1723-011 MS-WP2300-GB 04/03 • Printed in Germany

MS-1.2-1723

M-1.0-0000-00029 29

LUBRICATION AND ADJUSTMENT Castors The castors are on the left and right-hand sides under the truck. They prevent the truck from tilting when travelling around bends. The supporting force can be adjusted with a adjusting screw. This screw pushes the wheel bracket down around the bracket rotary axle via a plate and two spring units.

●

Manually screw in the adjusting screw on both castors as far as possible. Now continue to screw half a turn using a wrench.

●

Completely unscrew the adjusting screw on both castors again.

If the truck wheels are heavily worn or if they have been replaced, both castors must be adjusted.

●

Again, manually screw in the adjusting screw on both castors as far as possible. Now continue to screw three quarters of a turn using a wrench.

●

Set the adjustment with a jam nut.

●

Park truck (unladen) on an even surface.

●

Remove battery connection (=Emergency Stop).

●

Remove the jam nut on both castors.

●

Completely unscrew the adjusting screw on both castors.

The supporting force of each castor should now be 500 N, the equivalent of a 50 kg load.

Jam nut

Adjusting screw

Rotary axle bracket

M1470

Plate MS-1.5-1723

30M-1.0-0000-00030

Wheel

Wheel bracket MS-WP2300-GB 04/03 • Printed in Germany

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

MS-WP2300-GB 04/03 • Printed in Germany

T01-gb

MS-1.9-1723

M-1.0-0000-00031 31

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 - 40

M10 x 1.5

40 - 45

60 - 65

70 - 75

M12 x 1.75

70 - 80

100 - 110

115 - 130

M16 x 2

170 - 190

240 - 270

280 - 320

M20 x 2.5

340 - 380

450 - 500

550 - 600

M24 x 3

580 - 650

800 - 900

900 - 1050

M30 x 3.5

1150 - 1300

1600 - 1800

1850 - 2100 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

MS-1.9-1723

32M-1.0-0000-00032

MS-WP2300-GB 04/03 • Printed in Germany

HYDRAULICS

Printed in Germany

33

Page intentionally left blank

Printed in Germany

34M1.0-0000-00034

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

MS-WP2000-GB 02/03 • Printed in Germany

MS-2.0-0000

M-1.0-0000-00035 M1.0-0000-00035 35

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 MS-2.0-0000

36M1.0-0000-00036 M-1.0-0000-00036

MS-WP2000-GB 02/03 • Printed in Germany

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 MS-WP2000-GB 02/03 • Printed in Germany

MS-2.0-0000

M-1.0-0000-00037 M1.0-0000-00037 37

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

MS-2.0-0000

38M1.0-0000-00038 M-1.0-0000-00038

MS-WP2000-GB 02/03 • Printed in Germany

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 Filter

Filter

Non-return valve Pressure relief valve

Flow reducer

150 bar bis 170 bar* Motor Vent cap Pump

Filter

Filter

Reservoir * abhängig von Modell und Einstellung des Sicherheitsventills MS-WP2000-GB 02/03 • Printed in Germany

M1457-1 MS-2.1-1723

M-1.0-0000-00039 M1.0-0000-00039 39

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.

Safety pressure relief valve (rear view) Connecting Cable

Pump motor

Pressure switch (loadsensitive travel speed reduction)

Screws fastening hydraulic unit to chassis

Reservoir flange

MS-2.2-1723

40M1.0-0000-00040 M-1.0-0000-00040

M1522

MS-WP2000-GB 02/03 • Printed in Germany

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.

MS-WP2000-GB 02/03 • Printed in Germany

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.

MS-2.2-1723

M-1.0-0000-00041 M1.0-0000-00041 41

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.

●

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.

●

Pump Motor For maintenance and repair work to the pump motor see chapter 4.

Filters Replacing the Pressure Filter ●

Commissioning and Bleeding the System ●

●

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.

Replacing the Suction and Return Filters 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.

●

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

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.

●

Lower the forks fully.

MS-2.2-1723

42M1.0-0000-00042 M-1.0-0000-00042

●

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 hopper-shaped end piece (nozzle) of the suction (25) and return (22) lines. To disassemble, release the clamps.

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.

MS-WP2000-GB 02/03 • Printed in Germany

HYDRAULICS

MS-WP2000-GB 02/03 • Printed in Germany

MS-2.2-1723

M-1.0-0000-00043 M1.0-0000-00043 43

HYDRAULICS ●

Replacing the Safety Valve

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

●

Remove the hydraulic unit as described in the previous section "Removing the Hydraulic Unit".

●

Remove the locking mechanism (4, Fig. MS1723007) and unscrew the safety valve (3),

lf necessary adjust the safety valve so that it opens within the above-mentioned tolerance range:

●

Remove the O-ring and the filter from the valve seat if they are still located there.

●

Remove the hydraulic unit as described in the previous section "Removing the Hydraulic Unit".

●

Apply a thin coat of hydraulic oil to the new Oring and position it together with the filter in the valve seat.

●

●

Apply a thin coat of hydraulic oil to the safety valve and screw it in securely to the valve seat.

Insert the new locking mechanism.

Using a large screwdriver hold the setscrew securely (1, Fig. MS1723-007) and with a fork wrench undo the jam nut (2, Fig. MS1723-007): Turn the setscrew clockwise to increase the limit at which the valve opens, turn it anticlockwise to reduce the limit.

●

Re-fit the hydraulic unit and adjust the safety valve.

Note: 1/8 turn ~ 200 kg

Safety Valve Setting The safety valve (15, Fig. M1542 previous page and 1 to 3, Fig. MS1723-007 ) protects the hydraulic system and the lifting mechanisms against overloading.

●

Fix the setscrew (1) again using the nut (2).

●

Refit the hydraulic unit and repeat the test.

Repeat the setting until the safety valve opens within the tolerance range.

WARNING Do not run the pump unit unless it is fixed to the chassis ● The torque is so great that the unit will twist. This may result in short circuits and cause damage.

The safety valve is not accessible when the pump unit is installed. First remove the pump unit before making adjustments.

Safety Valve Test and Setting 3 ●

With the truck at operating temperature raise a test load positioned in the centre of the forks which corresponds to 110% of the rated capacity (= minimum load). It should be possible to raise this load safely.

Model

Rated Capacity

Minimum Maximum Load Load

WP2315

1,600 kg

1,760 kg

1,860 kg

WP2320

2,000 kg

2,200 kg

2,300 kg

2

1

MS1723-007

4

H01-GB MS-2.2-1723

44M1.0-0000-00044 M-1.0-0000-00044

MS-WP2000-GB 02/03 • Printed in Germany

DRIVE UNIT

Printed in Germany

45

Page intentionally left blank

Printed in Germany

46M1.0-0000-00046

DRIVE UNIT Gear Unit Drive unit attachment to knuckle flange

Vent filter

Drive wheel

Drive motor (drive pinion disassembled)

M1471

Gear unit lid

Pinion shaft and gear wheel

Oil filler plug (6 Nm)

Oil level

Driven shaft and gear wheel

Oil drain plug (6 Nm) MS-WP2000-GB 04/03 • Printed in Germany

M1472 MS-3.1-1723

M-1.0-0000-00047 M1.0-0000-00047 47

DRIVE UNIT Drive Unit, General

●

Prevent the drive unit from tipping and remove the 4 mounting screws (1, Fig. MS1723-031) connecting the drive unit to the knuckle.

●

Either jack up the truck so that the drive unit can be removed from under it or raise the truck using a crane with sufficient capacity (see Chapter 1 for instructions and safety guidelines),

●

Place the drive unit in a secure device.

The drive unit comprises the gear unit and the traction motor.

The traction motor can be removed without having to remove the drive unit or the gear unit. It is not necessary to drain the oil when the drive is upright.

WARNING The drive unit is heavy.

Traction Motor Removal

● When removing the drive unit use an appropriate mechanism to prevent it from tipping. ● It is easiest to lift the truck away from the drive unit using a crane. ● If you need to jack up the truck to release the drive unit, secure the truck using secure supports.

Note: If you are removing the traction motor with the drive unit still installed, ensure that the motor does not get caught in the bearing cage of the drive unit when removed.

Set the drive unit at an angle so that the motor can be freely removed. ●

Disconnect the battery and prevent the truck from being switched on again.

●

Disconnect the electrical wiring from the motor.

●

Remove the two mounting screws connecting the motor (A, Fig. MS1723-021) to the gear unit.

Removing the Drive Unit ●

●

Disconnect the battery and prevent the truck from being switched on again.

Disconnect the electrical wiring from the motor.

A 1

MS1723-031 MS1723-021 MS-3.1-1723

48M1.0-0000-00048 M-1.0-0000-00048

MS-WP2300-GB 04/03 • Printed in Germany

DRIVE UNIT C

B

MS1723-024

MS1723-022

●

●

●

Unscrew both screws (B, Fig. MS1723-022) by approx. 2 turns.

Using a plastic hammer tap alternately on the screw heads (B) to drive the motor from the centering flange. Do not damage the screws.

Fully remove the screws (B) and take out the motor. Note: Do not damage the gear teeth in the process (C, Fig. MS1723-024) and D, Fig. MS1723-023)

●

Remove the motor as described in the previous section.

●

Dismantle the brake (see “BRAKE” chapter)

●

Remove the retaining ring (40).

●

Using an extractor, remove the pinion (1) via the bushing (11).

●

Remove the seal (29).

●

Force out the rotary shaft seal (32).

●

Remove the bearing (20) and the inner raceway (12).

Assembling the Motor

Dismantling the Motor Note: If no other figure number is indicated, all reference numbers in the following sections refer to Figure MS-1723-027-A on the next page.

D

B

●

Press the bearing (20) onto the rotor shaft while holding up the opposite shaft end.

●

Apply Loctite® 601 to the inner raceway (12).

●

Insert the seal (29) into the bushing (11) and press the rotary shaft seal (32) in. Now insert the ball bearing compensating shim (33) into the bushing (11).

●

Fit the complete bushing onto the motor rotor.

●

Insert the key (50) and press on the pinion (1).

●

Put the retaining ring (40) in position.

●

Attach the brake (see “BRAKE” chapter)

●

Attach the motor as described below.

MS1723-023 MS-WP2000-GB 04/03 • Printed in Germany

MS-3.1-1723

M-1.0-0000-00049 M1.0-0000-00049 49

DRIVE UNIT

5 59 29

11

33

32 1

40 50 12

58 20 6

22

21

70

30 51 3 24 61 62

31 2

7 45 48/49 4

60 43

9

23

44

MS1723-027A

MS-3.1-1723

50M1.0-0000-00050 M-1.0-0000-00050

MS-WP2300-GB 04/03 • Printed in Germany

DRIVE UNIT Traction Motor Assembly A

Auxiliary Tools Required: 2 x M6 threaded rods, approx. 100 mm long. ●

To aid assembly screw 2 M6 threaded rods, approx. 100 mm long, into two opposite threaded holes on the motor (E, MS1723-023)

●

Slide the motor into the gear unit with the mounting aids facing forward and slide it into position. Do not damage the gear teeth in the process.

E

MS1723-021

MS1723-023

●

Re-insert the two mounting screws for the motor (A, Fig. MS1723-021) on the gear unit. Tighten the two screws alternately in small increments.

This will bring the motor fully into alignment and will prevent it from tipping in this position.

●

Re-insert the screws (B, Fig. MS1723-022).

●

Torque the screws A, Fig. MS1723-021 and B, Fig. MS1723-022 to 10 Nm.

●

Refit the electrical connections to the motor and brake.

●

Test the operation of the motor.

B

MS1723-022

MS-WP2000-GB 04/03 • Printed in Germany

MS-3.1-1723

M-1.0-0000-00051 M1.0-0000-00051 51

DRIVE UNIT Draining the oil

Gear Unit Disassembly

●

General Note: It is not necessary to dismantle the motor if you are disassembling the gear unit and then reassembling it.

Place a container underneath the drain plug (G, Fig. MS1723-029) of the gear unit and drain the oil. Unscrew the control plug (F) to drain the oil more quickly.

Removing the drive unit Always replace all the bearings and seals when dismantling the gear unit. Worn seals and bearings will result in premature failure of the unit.

Preparation ●

Disconnect the battery and prevent the truck from being switched on again.

●

If necessary, remove the motor as described in the previous section.

●

Unscrew and remove the drive wheel.

●

Now remove the drive unit for disassembly. Refer to the “REMOVING THE DRIVE UNIT” section at the beginning of this chapter.

●

Remove both screws (58, Fig. MS1723-027) together with the 10 screws (60) securing the housing lid.

Dismantling the gear unit lid WARNING Do not damage the contact surfaces of the gear unit housing and the gear unit lid. ● Do not use a thick tool (screwdriver or similar). This will damage the contact surfaces. ●

Tap a burr-free, thin tool around the circumference of the sealing gap until the housing lid can be easily lifted off (see Fig. MS1723-030).

F

G

MS1723-029

● MS1723-028

MS-3.1-1723

52M1.0-0000-00052 M-1.0-0000-00052

Using a scraper carefully remove the sealant compound residue from the contact surfaces of the gear unit housing and the gear unit lid. Now thoroughly clean the contact surfaces with a MS-WP2300-GB 04/03 • Printed in Germany

DRIVE UNIT ●

Place the bushing (9) onto the rollers of the bearing (24) and press the bearing (23) into the gear unit housing and insert the retaining ring (44).

Note: If no other figure number is indicated, all reference numbers in the following sections refer to Figure MS-1723-0027-A on the next page.

●

Place the wheel (4) in position and guide the driven shaft carefully into the shaft seal, threading in the bushing in the process.

●

Remove the retaining ring (61, Fig. MS1723027A) and the supporting ring (62).

●

Thread the wheel (4) onto the external spline of the driven shaft (7).

●

Remove the wheel (2) using a suitable extractor.

●

Support the wheel (4) with a suitable bushing and press the driven shaft (7) into the wheel (4).

●

Remove the retaining ring (45) and the two shims (48, 49).

●

Using a suitable number of shims (49) between the two shims (48) separate the driven shaft (7) so that it is free of play and insert the retaining ring (45).

●

Press the bearing (22) onto the pinion shaft (3).

●

Hold up the inner raceway of the bearing (21) and fit the pinion shaft (3). Insert the retaining ring (42).

●

The contact surfaces on the lid and the gear unit housing must be clean and free of oil.

If necessary clean the surfaces as described in DISMANTLING THE GEAR UNIT LID.

suitable cleaning agent (e.g. Loctite® 7063 Cleaner).

Dismantling the gear unit

●

Press out the driven shaft (7) towards the drive wheel. This will damage the bearing (23).

●

Remove the retaining ring (44) and pull out the bearing (23). The bearing is no longer useable.

●

Remove the retaining ring (43) and pull the bearing (24) out via the outer ring.

●

Now press out the rotary shaft seal (31).

●

Remove the retaining ring (42) and the locking lid (30).

●

Press out the pinion shaft (3) towards the gear unit lid (6). Both bearings (21 and 22) will remain on the pinion shaft.

●

Apply Dirko® sealant paste around the contact surface of the gear unit lid (see chapter 1, table adjuvants).

●

Pull both bearings (21 and 22) off the pinion shaft (3).

●

Place the key (51) in the pinion shaft (3).

●

Hold up the inner raceway of the bearing (21) and press the wheel (2) onto the pinion shaft (3).

●

Thread the supporting ring (62) into the pinion shaft (3) and insert the retaining ring (61).

●

Press the locking lid (30) into the housing.

Note: The driven pinion is a component of the motor.

The pinion and bearing removal process is described above in the TRACTION MOTOR section.

Gear Unit Assembly Always replace all the bearings and seals when dismantling the gear unit. Worn seals and bearings will result in premature failure of the unit. ●

Press the bearing (21) into the housing via the outer ring.

●

Press the inner raceway of the roller bearing (24) onto the driven shaft (7).

●

Press the shaft seal (31) from the outside into the gear unit housing seat.

●

Fit the outer ring of the roller bearing (24) and insert the retaining ring (43).

MS-WP2000-GB 04/03 • Printed in Germany

MS-3.1-1723

M-1.0-0000-00053 M1.0-0000-00053 53

DRIVE UNIT

5 59 29

11

33

32 1

40 50 12

58 20 6

22

21

70

30 51 3 24 61 62

31 2

7 45 48/49 4

60 43

9

23

44

MS1723-027A

MS-WP2300-GB 04/03 • Printed in Germany

54M1.0-0000-00054 M-1.0-0000-00054

DRIVE UNIT Installing the gear unit lid ●

Place the gear unit lid onto the housing and gently press against it.

●

Insert all 10 mounting screws (M8x16 Tuflock A) of the lid and torque them evenly and alternately to 25 Nm.

●

If you have removed the motor, install it again as described in TRACTION MOTOR ASSEMBLY.

●

With the drive unit vertical, fill the specified amount of gear oil up to the bottom mark of the control screw (B) via the hole for the vent filter (A).

●

Screw in the vent filter (A) and the control screw (B) again once the correct oil level is reached.

The torque for the filter and the control screw is 6 Nm.

Installing the drive unit

Adding Oil

●

Fit the drive unit in the reverse order of removal (see DRIVE UNIT REMOVAL in this chapter.

●

Test the truck’s operation and then check the gear unit for leaks.

You require approx. 0.7 litres of gear oil (see LUBRICANT TABLE IN CHAPTER 1 to make a selection which is appropriate to

your conditions of use). ●

Unscrew the vent filter (A, Fig. MS1723-026) and remove the control screw (B). New gear units are supplied with a lock screw instead of a vent filter.

This prevents oil from spilling during transport.

Make sure a vent filter is fitted (A, Fig. MS1723026) if the gear unit is fitted in the truck.

A

B

MS1723-026

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ELECTRICS

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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

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ELECTRICS Abbreviations Switch Symbol Abbreviation List * Abbreviation

Component

Abbreviation

Component

K*

Relay

LMS

Limit switch

ACS

Accelerator pedal switch

LOS

Lower switch

AXS

Auxiliary function switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Direction control switch

RA

Raise potentiometer

DRS

Door switch

RAS

Raise switch

E DS

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

KYS

Key switch

TLT

Tilt switch

LGS

Light switch

WAS

Walk along switch

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

MS-4.0-0000

60M1.0-0000-00060

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MS-WP2300-GB 04/03 • Printed in Germany

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

IFD

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.

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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 MS-4.0-0000

62M1.0-0000-00062

MS-WP2300-GB 04/03 • Printed in Germany

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

Reverse Safety Switch (SAS) The safety reverse switch (SAS) is activated via the switch cap at the end of the tiller head: the traction controller immediately changes from forward to reverse travel when the SAS is activated. The signal for normal travel to the traction controller is simultaneously interrupted. Depending on the traction controller setting the truck either travels for a given time, or provided the switch is pressed, travels in reverse.

Transmitter (POT, FS, RS) The travel switches are activated via the butterfly switches on the tiller. The transmitter comprises a switch (FS) for forward travel, a switch (RS) for reverse travel, and a potentiometer (POT) which governs the travel speed. For cold store versions the potentiometer is heated.

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

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. M1476) 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.

Override Switch (ORS) The override switch (ORS) is immediately below the multitask handle attachment. As soon as the multitask handle reaches the special travel zone (see Fig. M1476) the override switch (ORS) sends a signal to the traction controller with the resulting slow travel option (by pressing the travel switch). This provides better shunt operation in restricted conditions.

Upper brake zone

Special travel zone

Neutral / Idle Position

Travel zone

Lower brake zone

Reverse

Forward

M1476

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ELECTRICS Raise / Lower Switch (RAS, LOS) The raise (RAS) and lower (LOS) switches are activated via rocker switches in the tiller head. The rocker switches act on switches fitted on the tiller hydraulic PCB. The switches are physically locked in pairs so that they cannot be pressed together at the same time.

The raise (RAS) switch activates the pump contactor (P), which cause the pump to start.

The lower (LOS) switch applies voltage to the solenoid (SV) which causes the solenoid to open.

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.

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.

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.

Limit switch fitted for lift cut-out at 130 mm

Fuses (FU)

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

Trip cam

Track

M1473

Elongated hole for fine adjustment of lift cut-out point MS-4.3-1723

64M1.0-0000-00064

MS-WP2300-GB 04/03 •Printed in Germany

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

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

SAS

CA 419 (RHS)

OPTION

POT, FS, RS HNS

OPTION

CA 417 (LHS)

Thermal Switch (THS)

This switch is an electronic thermostat for cold store trucks. It is located on the main tiller PCB and switches the heating units on when the temperature falls below 0°C.

HNS

RAS / LOS HSS CA 410 CA 411

CA 414 CA 415 CA 412 CA 413

ORS KYS BRS

CA 404 BDI

FU3 FU2 FU1

CA 403

CA A, B, C, D, and E TCM

BD LMS/LMS1

Main Harness

CA 402

P

Onboard Charger

Line PM SV HN

Handle Harness Plug Holder

BR

TM

CA 202

BATT CA 406

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66

ELECTRICS 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.

SEM0 Traction Controller DANGER Jack up the truck before carrying out any repair work or troubleshooting the electrical system.

Operational Features Speed Control Stepless, handset programmable speed control in both directions.

General

Reduced Speed Ranges Two reduced speed ranges are available: slow travel (via a HSS rotary switch contained in the tiller handle) and the special travel range (dependent on the tiller position, activated via a ORS microswitch contained in the tiller).

Downhill Speed Control When travelling downhill the controller monitors the motor anchor speed via the drive signal from the traction potentiometer. When the set speed is exceeded, electrical braking with energy retention is introduced.

M1478

Regenerative Braking The programmable SEM0 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.

Three forms of regenerative braking are available: ●

Release braking (travel switch or multitask handle return to neutral)

●

Inversion braking (travel switch set in opposite direction)

●

Braking by reducing speed on a slope: the controller constantly regulates the engine speed according to the set value prescribed by the travel switch. Braking is automatically activated when the set value is exceeded.

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.

Anti - Roll Down Function

●

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

This function prevents the truck from accidentally rolling down a slope. When the key switch is on the controller monitors the engine speed. If it detects a turning movement without a travel command, braking is automatically activated.

●

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

If the truck automatically starts to move on a slope, it therefore brakes after a short period. When the truck stops braking is released causing the truck to move again, followed by further braking. If the brake is not applied the truck will therefore move down the slope very slowly.

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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-diagnostic system lists the five most recent error messages. These error messages can be called up via the programmer. As well as the error, the system stores and displays the error frequency, the respective number of service hours and the temperature of the traction controller at the time the error was recorded.

In addition a red LED on the traction controller indicates the last recorded error via a flashing code.

The display is deleted when the controller is switched off and on again, and if the error was only temporary.

Temperature 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.

Start Sequence To start the truck there is a specific start sequence which must be observed. Otherwise the general protection will not be activated and the truck will not function.

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

Monitored Circuits The following functions are monitored by the traction controller microprocessor depending on the operating mode: ●

Starting the truck: control logic system (hardware) and program functions (software), field current, VMN, contactor drivers, switch order sequence, traction and lift switch output signal.

●

Standby mode (key switch on): VMN, field current, contactor drivers.

●

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

●

Continual monitoring: Traction controller temperature, battery voltage.

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.

Wiring Errors 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.

MS-4.3-1723

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ELECTRICS Maintenance Maintenance of the SEM0 controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.

WARNING The SEM0controller operates with high current. Special safety measures are therefore required. ● Only properly trained personnel must carry out maintenance work.

Note: The lower nut secures the connection bolt to the power part board and the plastic housing. If this nut is insufficiently torqued (less than 6 Nm), excessive transition resistances will occur between the board and the bolt. The resultant heat may damage the controller and melt the cover around the connection bolts.

If the torque is too high (more than 7 Nm) the power part board and the housing may suffer physical damage. ●

● Wear safety glasses.

Using a torque wrench check the torque for the fastening nut (2, Fig. MS519) of the connection bolt. The rated value is 6 – 7 Nm.

Important: An incorrect torque may damage the controller board and housing.

● Do not wear any loose clothing. ● Do not wear any jewelry. ● Use insulated tools only.

●

Disconnect the battery (= emergency disconnect).

●

Jack up the truck.

●

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, 5 W.

●

Remove the power cable: mark the cable if necessary. Secure the lower nut (2, Fig. MS519) with a fork wrench. Undo the upper nut (1, Fig. MS519).

●

Remove any dirt and corroded material from the contact surfaces.

●

Wipe the traction controller with a clean, damp cloth.

●

When everything is dry connect the power cable again. To do so, secure the lower nut (2, Fig. MS519) with a fork wrench and only tighten the upper nut (1, Fig. MS519). Connect the control lines.

●

For cold store versions: coat the control line connectors with Dow Corningâ 4 Compound, part no. 053051-006.

1

2

MS519

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M1.0-0000-00069 69

ELECTRICS no. 053051-006. Paint the controller with an acidresistant clearseal paint.

Replacing the SEM0 Traction Controller WARNING The WP2300 must only be operated with the SEM0 traction controller (Part No. 813096001). ● The use of SEM0 traction controllers with different part numbers can change the characteristics and result in accidents.

When fitting a new SEM0 traction controller with part no. 813096-001 on a WP2300, the controller recognises the truck model and automatically loads the standard parameters for the WP2300 when it is powered up.

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

Remove the 4 mounting screws and remove the traction controller.

●

Check the contact pattern left behind by the controller back plate on the heat dissipation sheet. The controller must lie fully flat on the heat dissipation sheet.

If there are large areas with no contact to the controller, replace the heat dissipation sheet to avoid thermal problems.

●

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

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

●

Secure the traction controller again with the 4 screws.

●

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

●

Parameter Setting after Replacing the Traction Controller Preparatory Measures ●

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

●

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

●

Power up the truck.

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

●

●

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

For cold store versions: coat the control line connectors with Dow Corningâ 4 Compound, part

MS-4.3-1723

70M1.0-0000-00070

1.

If required, change the options for the safety reverse switch and the internal service hourmeter of the controller. The standard setting is contained in Table 11-GB. When you have made the changes, switch the truck off and on again to activate the changes.

2.

Measure the battery voltage directly at the battery and adjust the reading measured and displayed by the traction controller (see CONFIG MENU section).

3.

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

4.

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

5.

Test the traction pod starting point at creep speed. The drive wheel should start when the travel switch closes. If necessary increase the value accordingly. Repeat the test for both travel directions (see PARAMETER CHANGE menu section).

6.

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

7.

Set the maximum speed to slow travel if necessary (CUTBACK SPEED). Repeat the test with maximum load (see PARAMETER CHANGE menu section).

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS 8.

Set the maximum speed to the special range if necessary (OVERRIDE). Repeat the test with maximum load (see PARAMETER CHANGE menu).

9.

Set the maximum speed “Forward” (MAX SPEED FORWARD) and “Reverse” (MAX SPEED BACK).

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

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

11. Set the braking pattern for changing direction: Set the unladen truck to approx. 25% of maximum speed and move the travel switch in the opposite direction until it reaches the stop.

Set the braking pattern so that the delay sets in gently (INVERSION BRAKING).

Now repeat the test at maximum permissible speed. Adjust the setting until the delay sets in gently in both speed ranges and the effect is ideal. Preference should be given to the best setting for when the truck is unladen.

Repeat the process with the maximum permissible load.

12. Adjust, where necessary, the time taken to change direction. To do this change the AUX TIME DELAY parameter.

Both parameters, INVERSION BRAKING and AUX TIME DELAY affect the “feel” of the delay when changing direction.

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

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ELECTRICS 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.

No of Flashes

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

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

Console Display

Notes

1

Logic failure #1:

Line contactor voltage control error

1

Watch dog:

Logic or software error

1

EEPROM KO:

EEPROM error

2

INCORRECT STARTS:

Star ting sequence for travel not correct

2

FORW + BACK:

Forward and backward simultaneously requested

3

CAPACITOR CHARGE

Problem with power block

3

VMN NOT OK

Problem with chopper; armature voltage not correct

3

VFIELD NOT OK

Field voltage not correct

4

VACC NOT OK

Signal from traction potentiometer not correct

4

PEDAL WIRE KO

Traction pod wiring not correct

5

NO FIELD CUR.

No field current: Field wiring not correct or field current sensor error

5

HIGH FIELD CUR.

High field current: Field wiring not correct or field current sensor error

5

STBY I HIGH

High current: Armature current sensor error

5

I = 0 EVER

No current: Armature current sensor error

6

CONTACTOR DRIVER

Contactor driver error

6

COIL SHORTED

Contactor coil shor ted

6

CONTACTOR CLOSED

Line contactor contact faulty

7

TH. PROTECTION

Temperature of control unit too high (> 80°C) or too low (< -10°C)

32

BATTERY LOW

Battery voltage too low E04-gb

MS-4.4-1723

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

Programmer General

CAUTION

The optional programmer, Crown P/N 793548, 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-neu MS-WP2300-GB 04/03 • Printed in Germany

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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 SET UP

Increases setting values or selects configuration.

6

PARAM 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, as long as you have not safed the settings before.

E05-GB

Operating SEM0 Controller Menu General When the programmer has been connected a self test start routine is performed. The software version of the controller (e.g. V2.02), the rated voltage and the rated current are now displayed.

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

MS-4.4-1723

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ELECTRICS Operating Menu - Overview STARTROUTINE

PARAMETER CHANGE

TEST

ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERSION BRAKING CUTBACK SPEED OVERRIDE MAX SPEED FORW MAX SPEED BACK CREEP SPEED

BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT VMN TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH HANDLE/SEAT SWITCH QUICK INVERSION LOW PERF. SWITCH CUTBACK SWITCH BRS SWITCH BATTERY CHARGE

ALARMS

PROGRAM VACC

CODE H, N°, °C

VACC SETTING

CONFIG

SET MODEL

SET OPTIONS

ADJUSTMENTS

SX YES/NO

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

ADJUST BATTERY

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

TEST In the TEST 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.

The SX parameter in the SET MODEL sub-menu is reserved for future use and must remain set on SX = NO.

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ELECTRICS Settings and Alarms PARAMETER CHANGE Menu Setting range

Recommended setting

ACCELER DELAY

1.15 - 3.00 sec

0

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

DECELER DELAY

9-0

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.

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.

INVERSE BRAKING

0-9

9

Inversion braking. Activated when transmitter (butterfly switch) is set to the opposite direction. Time taken for the motor current to fall to zero.

AUX TIME DELAY

0-9

1

A lower value reduces the time taken for inverse braking to activate when changing from one direction to the opposite direction.

Menu item

Description

CUTBACK SPEED

30 - 100 % ACC

7

Maximum current (= speed) for the low speed range selected by the fast / slow speed switch (HSS) (in % of max. current ACC for fast speed (= normal)). Again, the entire mechanical control range of the transmitter is available. Enables more sensitive travelling at reduced speed.

OVERRIDE

10 - 50 % ACC

2

Max. travel current (= speed) in special travel zone (see section M4.2).

6

Max. forward speed: 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.

6

Max. reverse current: 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 (butterfly switch) is kept to a minimum.

MAX SPEED FORW

MAX SPEED BACK

CREEP SPEED

100 - 58 % FCN

100 - 58 % FCN

5 - 14 % V Batt.

E06-GB MS-4.5-1723

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MS-WP2300-GB 04/03 •Printed in Germany

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/SEAT 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

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.4-1723

M1.0-0000-00077 77

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 butterfly 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.

- Tiller main board faulty.

CAPACITOR CHARGE

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

E08-GB

MS-4.5-1723

78M1.0-0000-00078

MS-WP2300-GB 04/03 •Printed in Germany

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 ear th.

- Power par t 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 ear th.

- Motor field connections not connected or incorrectly connected to controller.

- Error in power par t 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.

- Broken potentiometer cable.

- Wiring error.

- Potentiometer faulty.

- Tiller main board 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.

- Tiller main board faulty.

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 par t 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 par t error (replace component or entire controller).

I = 0 EVER

PROGRAM VACC Menu

E09-GB

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).

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.5-1723

M1.0-0000-00079 79

ELECTRICS ALARMS Menu (contd.)

Error Message

Description

Possible Cause

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

CONTACTOR CLOSED 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 propor tion 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.

- Excessive ambient temperature.

- 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 propor tion 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).

Test performed constantly and checks the field current.

- Field current measuring error (replace controller).

- Field cable not connected.

- Power par t error (replace component or entire controller).

Tests the main contactor circuit.

- Contactor coil shor t-circuited, not connected or incorrectly connected - Contactor drive opened or shor tcircuited (replace logic system).

- Voltage feedback error to contactor driver (replace logic system).

HIGH FIELD CURR, NO FIELD CURR

CONTACTOR DRIVER; COIL SHORTED

E10-GB

MS-4.5-1723

80M1.0-0000-00080

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu

●

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

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

●

Press OUT when you are ready.

●

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

●

Press OUT to quit the VACC menu.

●

the traction pod potentiometer has been replaced or,

●

the traction controller has been replaced.

With the WP2300 there is no need to physically adjust the potentiometer and the travel switch as is the case with the WP2000.

Preparatory Measures ●

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

●

Connect the programmer to the traction controller.

●

Power up the truck.

Calibration ●

Press ENTER on the programmer.

●

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

●

Press ENTER to select the calibration routine.

●

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

If you move the travel switch in the corresponding direction you can change the display accordingly.

●

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

●

Pull the tiller to the travel range (brake released) and press the travel switch slowly in the forward direction until it reaches the stop.

●

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

●

Pull the tiller to the travel range (brake released) and press the travel switch slowly in the reverse direction until it reaches the stop.

MS-WP2300-GB 04/03 • Printed in Germany

M1610

MS-4.5-1723

M1.0-0000-00081 81

ELECTRICS ADJUSTMENTS

CONFIG Menu The CONFIG menu provides access to the SET OPTIONS, ADJUSTMENTS and SET MODEL sub-menus.

SET MODEL WARNING This menu item provides options for future use. Do not change the default settings (SX = NO).

In the menu item ADJUST BATTERY you can adjust the battery voltage measured by the controller to give the actual battery voltage.

Using a digital voltmeter measure the battery voltage directly at the battery. Adjust the voltage shown in this menu until it matches the voltage measured directly at the battery.

● This would result in incorrect standard settings being loaded. This would change the truck operating characteristics and could cause accidents.

SET OPTIONS See Table E11-GB for a description of the parameters.

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

CONFIG Menu Sub-Menu SET MODEL

Option SX YES/NO

Description This parameter is reserved for future use. Do not change this parameter. SX = NO must be set.

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

MS-4.5-1723

82M1.0-0000-00082

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS ●

Attach test lead to F1 (item 2).

●

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).

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

●

Attach test lead to F2 (item 3).

●

Switch off the truck and jack it up.

●

●

Connect one end of the test lead to -BATT.

Power up the truck.

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

●

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

●

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

●

Connect the programmer to the traction controller.

●

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

●

Power up the truck.

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

●

If the test proves unsuccessful, replace the traction controller.

Traction Controller Safety Test 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.

●

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

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

MS-WP2300-GB 04/03 • Printed in Germany

M4.20-1720-001

MS-4.6-1723

M1.0-0000-00083 83

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MS-WP2300-GB 10/02 • Printed in Germany

84

ELECTRICS Battery

Battery Discharge Indicator (BDI) WARNING

General

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

The battery condition has a considerable impact on the performance of the truck. Effective maintenance will maintain the performance levels and lifespan of the battery.

● For maintenance-free batteries follow the manufacturer's instructions regarding the discharge terminal voltage.

WARNING The battery must be serviced solely in accordance with the battery manufacturer's instructions. ● Incorrect or inadequate maintenance will initially reduce the performance of the truck and ultimately result in premature failure of the battery.

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

Replacing the battery

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

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

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

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

WARNING Only use batteries of the permitted size, weight and specifications for this truck. ● An incorrect battery type can cause damage to the truck. ● An incorrect weight and size will alter the centre of gravity of the truck, potentially resulting in accidents.

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

The operator manual contains the latest safety instructions and information.

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

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

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

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

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

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.25-1723

M1.0-0000-00085 85

ELECTRICS to check if the battery is actually 100% charged.

Faulty battery cells will make calibration impossible.

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

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

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

●

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

●

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

●

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

●

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

●

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

●

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

●

Charge the battery again and then check the calibration.

The factory default setting of the battery discharge indicator is "N" (any setting from K to U is possible).

Calibration ●

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

Measure the acid density in accordance with the battery manufacturer's maintenance instructions

Discharge Terminal Voltage Setting in Volts/Cell K

L

M

N

O

P

Q

R

S

T

U

1.57

1.63

1.68

1.73

1.78

1.82

1.84

1.86

1.89

1.91

1.93 E20-GB

MS-4.25-1723

86M1.0-0000-00086

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS On Board Charger Note: This charger is intended solely for use with open lead acid batteries (wet batteries).

WARNING The charger cannot be repaired in the field.

Attempting to make repairs can result in accidents caused by electric shock and fire. ● Replace the charger where necessary with an original Crown replacement charger.

General Please read this paragraph carefully. It contains important information on the operation of the charger. You must understand how the charger operates in order to correctly assess any problems which may occur when charging the battery.

This charger is an "intelligent" device. A microprocessor controls the charging by taking into account the charge status of the battery.

A complete charge cycle consists of several phases, indicated by a yellow LED. A green LED indicates the presence of the mains supply.

Both LEDs are located on the instrument panel next to the socket to protect the mains lead.

Battery Charging Phases The charge cycle begins with connection to the mains supply. The green LED is permanently lit.

First Phase (I1) The first phase (I1) is a charge with constant (maximum possible) current. This phase lasts until the battery voltage > 24 volts. (The yellow LED is permanently lit.)

Second Phase (P) In the second phase (P) the charging capacity (product of charging current and charging voltage) is kept constant. In addition the charging current is reduced in proportion to the increasing battery voltage. This phase ends when the battery voltage reaches a certain level.

(The yellow LED is permanently lit.)

MS-WP2300-GB 04/03 • Printed in Germany

Third Phase (U) In the third phase (U) the charging current is kept constant. The output voltage of the charger is restricted to 29 volts. During this phase the charging current drops increasingly. (The yellow LED flashes rapidly.)

Fourth Phase (I2) The fourth and for normal charges last phase (I2) is again a charge with constant current until the gassing voltage stage is reached. The amount of constant current used to charge is calculated from the charge consumed by the battery during the first two phases (I1 and P).

The duration of this phase is set to reach 17% of capacity (= Boost - factor 1.15) consumed by the battery during the first three phases (I1, P and U). The charging voltage is restricted to 34 volts. (The yellow LED flashes slowly.)

End of Normal Charging Normal charging is completed at the end of the fourth phase. (The yellow LED is off) The battery is now fully charged and the total battery capacity can be used.

Special Charging Phases Compensating Charge For instructions on compensating charging, in particular charging intervals, please refer to the battery manufacturer's documentation If the charger remains connected to the mains at the end of a normal charge, 15 minutes after Phase I2 a compensating charge will begin with half the constant current used during phase I2. (The yellow LED flashes either regularly or intermittently.)

The compensating charge reduces the problem of sulphating and the cell voltage of the 12 battery cells is compensated to 2 volts / cell.

This phase ends when the battery voltage is stable, i.e. changes by less than 60 mV/h.

MS-4.8-1723

M1.0-0000-00087 87

ELECTRICS Float Charge

Charging Errors

If the charger remains connected to the mains after the compensating charge, 48 hours later the charge recommences with the first phase (I1). As the battery however is still full, the individual charging cycles are severely reduced, and the first phase (I1) is even bypassed if the battery voltage has not fallen below 24 volts.

Green LED is not lit Possible Causes: Socket does not conduct mains voltage Check whether the socket conducts voltage by plugging in an item of equipment (e.g. lamp etc.) which you know is working.

The float charge ensures that the battery can be used even after long periods of inactivity. (The yellow LED flashes regularly or intermittently.)

Faulty mains lead to charger Temporarily replace the mains lead to the charger with one which you know is ok. When you finally replace the mains lead avoid damaging the lead when fitting the clamp.

Partial Charging The charger is designed to adapt to all discharge conditions of the battery and all typical partial charge cycles. It uses an "occasional charging" feature. The electronic system takes into account these partial charges and adjusts the current in the fourth phase (I2) accordingly.

Faulty Charger Replace the charger.

Green LED flashing In this case an error has occurred during charging. The charging time in phase I1 or P is too long (time limit exceeded).

If charging is interrupted by the user (mains connector removed) and if the mains connector is re-inserted within 13 minutes, it then continues at the point at which it was interrupted.

The charger stores the capacity charged into the battery up to the interruption for 13 minutes and calculates a correction value which ensures that the capacity subsequently removed from the battery is recharged.

Possible Causes: One or more battery cells faulty Repair the battery in accordance with the battery manufacturer's instructions.

If the mains interruption lasts for more than 13 minutes, the charging process will start again with phase 1.

The ambient temperature is too high. The charger automatically reduces the output capacity in order to avoid a thermal overload. When the ambient temperature is too high the charging current is reduced, which can lead to time limits being exceeded.

Also check whether the fan starts up when the mains lead is connected. The air inlet and outlet of the charger must not be covered.

Error in charger microprocessor. Reset the microprocessor as follows:

Charging Phases Phases

I1 and P

U1

I2

Tstop= 15 Min

Compensating Charge

Tstop= 48 h

Float Charge

Error

On

Fan Green LED

Off

On

Off

Permanently on PermanenIntermittent Rapid flash Slow flash tly on flash

Off

As for I2 and U2

Stop

Disconnected

Mains plug connected

Mains

Yellow LED

U2

Off

On

Undefined

Off

Flashes

Off

Undefined

Off E21-GB

MS-4.10-1723

88M1.0-0000-00088

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS ●

Remove the mains plug and disconnect the battery.

●

Disconnect the charger connections to the earth contact or the pump contactor and fuse F1 and short-circuit the two leads of the charger.

Alternatively, wait 10 minutes. Then re-connect the charger lead to the battery.

Charger safety class: IP20 Ambient temperature: 0 °C to +40 °C Air humidity: 90% relative, not condensing

Replacing the Charger WARNING

●

Re-connect the mains plug.

●

Check that the green LED is permanently lit and the charger fan is running.

●

Do not reverse the battery connection wires ● If you reverse connect the charger wires to a battery, the minimum damage you will incur is a blown internal fuse.

This fuse can only be replaced by the manufacturer. Replace the charger where necessary with an original Crown replacement charger.

If the green LED is not lit and/or the fan is not running, replace the charger.

Important: Before replacing a charger, always check whether the malfunction is due to a temperature problem or the battery.

Faulty battery cells of poorly serviced batteries or charger ambient temperatures above 40 °C are typical causes of faults.

Take into account the fact that the charger emits heat (the temperature of the airflow extracted by the on-board fan is 20 °C above ambient temperature). This heat loss also heats up the environment if the ventilation is inadequate.

If the temperature and battery can both be safely ruled out as possible causes, reset the microprocessor and check if it is possible to charge.

Removal / Installation ●

Remove the mains plug and disconnect the battery.

●

Undo the mains supply lock on the charger and remove the connector.

●

Disconnect the charger connections to the earth contact of the pump contactor and fuse F1.

●

Disconnect the plug connection of the 3 wire lead to the LEDs.

●

Remove the 4 screws which attach the charger to the retaining plate and remove the charger.

●

Installation is the reverse order of removal.

Important Technical Data Mains voltage: 230 V +10% / -15% Mains frequency: 50 - 60 Hz + /-1% Output capacity: 720 W + /-3% ●

Can be used for open lead acid batteries with 12 cells and a cell voltage of 2 volts (24 volt battery)

●

Minimum battery capacity 160 Ah

●

Maximum battery capacity 300 Ah

The maximum charging time at room temperature for an 80% discharged battery is: ●

15 h for a 300 Ah battery

●

12 h for a 240 Ah battery

●

8 h for a 160 Ah battery

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.10-1723

M1.0-0000-00089 89

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Printed in Germany

90

ELECTRICS In this case replace all brushes as they will probably have been thermally overloaded.

Thermal overloading (temperatures >160 ºC) causes the brushes to swell up.

Brushes which jam in the brush support produce intense sparking and destroy the collector.

Electric Motors General Maintenance Instructions The following instructions apply to all motors. Details relating to specific models and designs are provided in the sub-sections (traction motor, pump motor etc.).

●

The brush edges must not be cracked. Brushes with cracking along the long edge of the surface will have been damaged by a worn collector.

If information is provided in the manual, restore the collector to the specified limits. Otherwise, replace the armature in full.

●

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

●

When fitting the brush take care to place the spring gently on the brush. If the contact is too hard the brush will be damaged.

●

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

●

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

Preparation ●

Disconnect the battery (= EMERGENCY DISCONNECT).

●

Secure the truck from rolling away.

Important Maintenance Instructions ●

Remove all carbon brushes and check for wear.

If one or more carbon brushes need to be replaced, replace all brushes. In addition to the carbon brushes the pressure springs must also be replaced to ensure the correct pressure.

The length of the shortest brush determines whether the brush set needs to be replaced.

Even if the minimum length has not been reached the brushes should be replaced as the remaining useful life could be much shorter than the time until the next inspection: If a brush is too short the spring will lie on the brush support. The brush sparks during operation and burns the collector with corresponding damage.

●

Blast the motor with dry compressed air only.

●

Check the armature for uneveness, burning, grooves and cracking of the multi-plate edges.

Turn the armature if necessary. A non-oily, evenly distributed layer on the brush surfaces is normal.

●

If oil or grease is found in the motor collector compartment (usually a paste consisting of oil, oil vapour, dust and carbon particles), immediately remove the cause and clean the motor thoroughly: Oil or grease burns in the brush sparks and leaves behind a highly abrasive oil ash which can very quickly destroy the collector and the brushes.

●

The brushes must be able to move freely in the brush support (without spring tension) without tilting. Never modify brushes if one or more brushes cannot move freely.

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.10-1723

M1.0-0000-00091 91

ELECTRICS Traction Motor Maintenance Access to Brushes Battery connector

M1460

Carbon brush

Armature MS1723-016

Traction Motor Tensioning Belt ●

Disconnect the battery

●

Prevent the truck from rolling away.

●

Remove the tensioning belt from the motor.

Maintenance ●

Apply dry compressed air to the motor.

●

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

●

A new carbon brush is 28 mm long

●

Carbon brush wear limit: 15 mm

●

Refit the tensioning belt.

●

A new armature has a max. diameter of 53.3 mm.

●

The armature can be overwound provided the diameter is no less than 51.8 mm.

●

The armature must be replaced if the diameter is 49.5 mm or less.

●

After overwinding cut the mica down to at least 0.5 mm below the multi-plates without changing the gap width between the multi-plates.

●

The multi-plate edges must be carefully deburred.

Bearings ●

MS-4.10-1723

92M1.0-0000-00092

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

MS-WP2300-GB 04/03 •Printed in Germany

ELECTRICS Maintenance

Pump Motor Maintenance Access to brushes

●

Apply dry compressed air to the motor.

●

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

●

A new carbon brush is 20 mm long

●

Carbon brush wear limit: 10 mm

Battery Connector

Armature ●

A new armature has a diameter of 40 mm. The wear limit is 38.3 mm.

●

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

Refit the hydraulic unit as described in CHAPTER 2.

MS1723-016

Pump motor commutator bearing lid Hydraulic unit attachment ●

Disconnect the battery

●

Prevent the truck from rolling away.

●

Remove the hydraulic unit as described in CHAPTER 2.

●

Unscrew the commutator bearing lid and remove the insulating protective cap.

MS-WP2300-GB 04/03 • Printed in Germany

MS-4.10-1723

M1.0-0000-00093 93

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94

BRAKE

Printed in Germany

95

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M1.0-0000-00096 96 M1.0-0000-00096

BRAKE Brake Operation The drive motor contains the drive wheel brake in the form of a disk brake.

The assembly is shown on page 5.6-1720-001 in the spare parts manual.

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 screws.

However, afterwards you must always return them to their original position! Before operating the truck again, make sure that it cannot be moved.

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

M1462

Mounting screws (hex. head)

Screws for mechanical releasing of brake (cheese head screws)

●

Remove magnetic body (3) from motor (including everything connected to it).

●

Remove rotor (7) from hub (5) while taking care not to damage the toothing.

●

Measure the thickness of the rotor. Replace the rotor if the minimum thickness of 5.5 mm is exceeded.

The item numbers in brackets refer to Figure M1441 on the next page. ●

Unplug the battery connector (=Emergency Disconnect).

●

Secure the truck to prevent it from rolling away.

●

Remove the friction plate (9).

●

Remove the front panel.

●

Unscrew the chees head screws (see Fig. M1462) from their nuts.

●

Remove the rubber cover ring (8) from the groove in the magnetic body.

●

Unscrew banjo bolts (2) from the magnetic body (3 off).

●

Remove anchor disk (6).

●

Thoroughly clean components.

●

Check anchor disk (6), friction plate (9) and rotor (7) for even wear, grooves, cracks and burning, if necessary replace components.

●

Remove any abrasion dust.

●

Unplug the electric connections from the magnetic body (3).

●

Loosen the three mounting screws (see Fig. M1462).

CAUTION Do not allow the striking surfaces to come into contact with grease or oil.

MS-WP2300-F 04/03 • Printed in Germany

MS-5.0-1723

M1.0-0000-00097 97

BRAKE

M1441

MS-5.0-1723

98M1.0-0000-00098

MS-WP2300-F 04/03 •Printed in Germany

BRAKE throughout.

Assembly To assemble, proceed in the reverse order. ●

●

If any thrust members (for the three internal compression springs) have fallen out of the magnetic body, insert them correctly with the end face facing the spring.

Place the anchor disk correctly on the magnetic body: thefriction plate must lie on the side facing away from the magnetic body.

●

Screw the banjo bolts into the magnetic body as far as the stop.

●

Screw the cylinder bolts into their nuts so that there is a gap of at least 1mm between the anchor disk and the magnetic body.

●

Place the friction plate on the motor.

●

Push the rotor onto the hub while taking care not to damage the toothing.

●

Attach the magnetic body and everything connected to it to the motor with the hex. bolts.

Air Gap Setting The working air gap is measured between the magnetic body and the anchor disk while the brake is applied.

It should be set to 0.2 mm.

The max. permissible setting is 0.55 mm. ●

Unscrew the banjo bolts as far as the fixed stop on the friction plate.

●

Tighten the hex. bolts evenly.

●

Using a feeler gauge measure the working air gap at several points. It must be uniform

●

To increase the air gap slightly unscrew the hex. bolts. To reduce the air gap slightly screw the banjo bolts into the magnetic body. Then proceed as described above.

●

When the air gap has been correctly set, torque the hex. bolts to 6 Nm using a torque wrench.

Brake Moment Setting The brake moment can be increased by screwing the adjusting ring (1) into the magnetic body. The setting is notched.

Testing the Brakes ●

Accelerate the unladen truck with completely loaded battery at operating temperature on an even, dry concrete surface until it reaches maximum speed.

●

Set multi-task handle to lower brake zone.

●

Measure the braking distance from the time of application of the brakes to the time the truck halts.

Nominal Braking Distance (unladen) Model

New Rotor

Used (braked) Rotor

2320

0.6 to 0.7 m

0.5 to 0.6 m

2315

0.5 to 0.6 m

0.45 to 0.55 m B01-gb

Mounting screw Banjo bolt Working air gap Rotor thickness

Brake de-energized

MS-WP2300-F 04/03 • Printed in Germany

M1467

MS-5.0-1723

M1.0-0000-00099 99

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100

STEERING

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101

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M1.0-0000-000102 102 M1.0-0000-000102

STEERING Live Ring Bearing The multitask handle is connected to the drive unit via the knuckle and a flange. The live ring bearing is located between the flange and the truck chassis and acts as a twin conical roller bearing. It is maintenancefree and contains lubricant for lifetime. Fig. M1477 shows a cross-section of the live ring bearing with the drive unit disassembled.

●

Using a rubber hammer gently knock the flange (17) and the drive unit down out of the chassis.

The lower conical roller bearing together with the inner ring and the seal (14) remain on the flange.

●

Remove the lower conical roller bearing to-gether with the inner ring and the seal (14) from the flange.

●

Lift out the upper conical roller bearing together with the inner ring and the seal (14).

●

Drive out the outer rings (16) of both bearings from the chassis.

Disassembly The item numbers in brackets refer to the graphics of the knuckle in section 3.3 of the spare parts manual. ●

Disconnect the battery (emergency disconnect).

●

Jack up the truck.

●

Remove the front panel and knuckle panels.

●

Remove all 6 mounting screws (12) of the knuckle (6) and remove the multitask handle and its support. Make sure that no wires are damaged in the process.

●

Installation ●

Prior to installation make sure that the surfaces are clean and burr-free.

●

Refit all wire connections without twisting them.

●

Torque the knuckle mounting screws (12) to 49 Nm.

Disconnect the drive unit wires.

Multitask Handle

Screws (12)

Knuckle (6) Upper Conical Roller Bearing

Seal (14)

Conical Rollers with Inner Ring

Outer Ring (16)

Lower Conical Roller Bearing

Flange (17)

Truck Chassis M1477

MS-WP2300-GB 04/03 • Printed in Germany

MS-6.1-1723

M1.0-0000-000103 103

STEERING Multitask Handle - Springs for Return Function The 3 springs for return function are located on the rotary axle of the multitask handle. The inner, offset end of the springs fits in the longitudinal slot of the axle.

The external end which is also offset exerts upward pressure on the multitask handle.

The springs can be easily accessed for lubrication by removing the panel from the knuckle.

Adjustment The axle (4) is fixed on the left hand side as standard with a roll pin (5). If the spring pressure reduces with time, the springs (2) can be re-tensioned as follows: ●

Set multitask handle (1) to zero/rest position (1).

●

Drive out the dowel pin on the left hand side.

●

Drive in the dowel pin on the right hand side by rotating the axle as far as possible using a face spanner.

CAUTION

Removal Do not place your hands inside the multitask handle near the rotary axle while the springs are tensioned.

●

Multitask handle (1) in zero position.

●

Record the position of the axle.

To prevent injury caused by the vehicle suddenly moving, in particular when working on the multitask handle support:

●

Drive out the roll pin.

The de-pressurised springs should rotate the axle.

●

Disconnect the battery (emergency disconnect).

●

Set the multitask handle to the lowest position.

●

Secure the truck to prevent it from rolling away.

●

If the axle has still not turned, it is clearly fixed in its position and must be moved with the aid of a face spanner. Rotate the axle, seen from the left hand side, approx. 20° anticlockwise from the fixed position.

●

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

The item numbers in brackets refer to the graphic M1491.

Roll Pin (5) R.H. Side

L.H. Side

Assembly ●

Push the 3 springs onto the axle. The inner, offset end must insert into the axle 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 into position.

●

Set the multitask handle to the upper limit.

●

Using a roll pin fix the axle to the left hand side (right hand side if necessary). To do this, rotate the axle as far as necessary.

Knuckle (6)

Axle (4)

Control Handle (1)

Springs (2) MS-6.1-1723

104 M1.0-0000-000104

M1491 MS-WP2300-GB 04/03 • Printed in Germany

STEERING Tiller Handle Main Components This is an overview of the main components and their associated terms:

Upper Shell

Tiller Tube

Switch Unit

Handle MS518

Lower Shell

MS-6.2-1723

MS-WP2300-GB 04/03 • Printed in Germany

M

1

.

0

-

0

0

0

0

-

0

0

0

1

0

105 5

STEERING Tiller Handle Shells

Tiller Handle Component Removal / Installation

Removing the Upper and Lower Shells

To access the various components of the tiller handle you will need: A 2, 3, 5, 8 mm Torx® screwdriver and a small screwdriver with a flat blade.

CAUTION Danger of short circuiting!

De-energise the truck (disconnect the battery) and prevent it from being switched on again.

Unless otherwise stated, all screws must be tightened with a standard torque. A torque table can be found in chapter 1 of this manual.

A ●

MS513

Remove the four M5 Torx® screws (A, Fig. MS513).

B

MS503

A

MS514

●

Press on the thumb markings (A, Fig. MS514) of the switch unit or pull on the butterfly switches (B).

The switch unit will slide up out of the lower shell.

●

Remove the plug connector of the tiller wire harness and the horn switch from the switch unit boards.

MS-6.2-1723

M 106

1

MS-WP2300-GB 04/03 • Printed in Germany

.

0

-

0

0

0

0

-

0

0

0

1

0

6

STEERING

MS501

●

Remove the internal M5 Torx® screws and pull the handles off (see Fig. MS501).

MS502

●

Using a small flat screwdriver lever out the protective cap from each tiller handle (see Fig. MS502).

M8

M8 MS503

●

Gently press the horn switch inward and pull it out of the handle (see Fig. MS503). Disonnect the plug connector from the switch.

MS517

M5 ●

Remove the two M5 Torx® screws and the six M8 Torx® screws (see Fig. MS517). Remove the shells.

Fitting the Upper and Lower Shells Installation is the reverse of removal. When installing, take care not to damage the wiring.

MS-6.2-1723

MS-WP2300-GB 04/03 • Printed in Germany

M

1

.

0

-

0

0

0

0

-

0

0

0

1

0

107 7

STEERING ●

Switch Unit Removal The switch unit contains the safety reverse switch, the travel switch, the "Fast/Slow" toggle switch, the main board and the pump controller board.

To replace any one of these components you have to disassemble the entire switch unit.

Remove the plug connector of the tiller wire harness and the horn switch from the switch unit boards.

Switch Unit Installation Installation is essentially the reverse order of removal.

Ensure you re-connect the tiller wire harness and the horn wiring. The connectors cannot be interchanged and are reverse battery protected.

Guide the switch unit over the two side sections (C, Fig. MS514), pushing the switch unit downward and forward in the process.

Tighten the mounting screws (M5).

After re-connecting the battery test all functions.

A

●

MS513

Remove the 4 M5 Torx® screws (A, Fig. MS513).

B

C

A

MS514

●

Press on the thumb markings (A, Fig. MS514) of the switch unit or pull on the butterfly switches (B).

The switch unit will slide up out of the lower shell.

MS-6.2-1723

M 108

1

MS-WP2300-GB 04/03 • Printed in Germany

.

0

-

0

0

0

0

-

0

0

0

1

0

8

STEERING "Fast/Slow" Toggle Switch

Hydraulic Board

There are no parts in this switch module which can be repaired. The entire module must be replaced.

There a no parts in this board which can be repaired. It must be replaced in full.

The switch module comes in two variants: a standard version (812943-001) and a cold store version (812274-001). Make sure you use the right module!

The board comes in two variants: a standard version and a cold store version. Make sure you use the right board!

Removal Removal ●

●

Remove the switch unit (see SWITCH UNIT section in this chapter).

Remove the switch unit (see SWITCH UNIT section in this chapter).

MS504

● MS511 ●

Remove the two M3 Torx® screws (see Fig. MS511) and remove the toggle module.

Remove the two M3 Torx® screws (see Fig. MS504) from the smaller of the two boards (the larger one is the main board). Remove the hydraulic board.

Installation Installation ●

Fit the new toggle module and fix it with two M3 Torx® screws.

●

Re-install the switch unit (see SWITCH UNIT section in this chapter).Carry out a functional test.

●

Fit a new hydraulic board (ensuring it is the right version, cold store or standard!) and fix it with two M3 Torx® screws.

●

Re-install the switch unit (see SWITCH UNIT section in this chapter).Carry out a functional test.

MS-6.2-1723

MS-WP2300-GB 04/03 • Printed in Germany

M

1

.

0

-

0

0

0

0

-

0

0

0

1

0

109 9

STEERING Potentiometer There are no parts in the potentiometer which can be repaired. It must be replaced in full. The potentiometer comes in two variants: a standard version and a cold store version. Make sure you use the right potentiometer!

Removal ●

Remove the switch unit (see SWITCH UNIT section in this chapter).

MS510

MS508

●

Remove the two M3 Torx® screws which secure the orange lower switch cap. Remove the switch cap.

●

Remove the four M5 Torx® screws shown in Fig. MS509. Remove the switch unit cover.

●

Remove the two M3 Torx® screws shown in Fig. MS510. Remove the connectors from the boards.

Remove the potentiometer from the square axle.

Installation ●

●

Remove the two M3 Torx® screws (see Fig. MS508) from the butterfly switches and pull the butterfly switches off. Take care not to lose the plastic slide bearings (washers).

Before connecting the wire to the potentiometer, pack the potentiometer bushing with grease (part no. 053002-005). Do not use any other grease.

Installation of the potentiometer is the reverse of removal.

Note: The butterfly switches cannot be fitted incorrectly. They will only fit properly in a single position.

MS509

MS-6.2-1723

110 M1.0-0000-000110

MS-WP2300-GB 04/03 • Printed in Germany

STEERING Safety Reverse Switch Removal ●

Remove the switch unit (see SWITCH UNIT section in this chapter).

A

B C MS500

MS508

●

●

Remove the two M3 Torx® screws (see Fig. MS508) from the butterfly switches and pull the butterfly switches off. Take care not to lose the plastic slide bearings (washers).

Remove the two M3 Torx® screws which secure the orange lower switch cap. Remove the switch cap.

●

Remove the M3 Torx® screw (item A, Fig. MS500) and pull out the switch jumper (item B).

●

Remove the two M2 Torx® screws (item C).

Remove the microswitch connector from the main board.

Installation Installation of the safety reverse switch is the reverse of removal. ●

Before connecting the microswitch to the main board, lubricate the microswitch connector with grease (part no. 053002-005).

Do not use any other grease.

●

Re-install the switch unit (see SWITCH UNIT section in this chapter) and carry out a functional test.

Note: The butterfly switches cannot be fitted incorrectly. They will only fit properly in a single position.

MS509

●

Remove the four M5 Torx® screws shown in Fig. MS509. Remove the switch unit cover.

MS-WP2300-GB 04/03 • Printed in Germany

MS-6.2-1723

M1.0-0000-000111 111

STEERING Installation

Horn Switch Removal ●

Remove the switch unit (see SWITCH UNIT section in this chapter).

Note: The switches for the left and right handles are different. If you fit the switch on the wrong side the horn symbol will be upside down!

Fit the horn switch in the reverse order of removal. ●

Re-install the switch unit (see SWITCH UNIT section in this chapter) and carry out a functional test.

MS502

●

Using a small flat screwdriver lever out the handle protective cap (see Fig. MS502)

MS503

●

Simply press the horn switch inward and pull it out of the handle (see Fig. MS503). Disconnect the plug connector from the switch.

MS-6.2-1723

112 M1.0-0000-000112

MS-WP2300-GB 04/03 • Printed in Germany

STEERING Handle Removal ●

Remove the switch unit (see SWITCH UNIT section in this chapter).

MS501

●

Unscrew the internal M5 Torx® screw (see Fig. MS501) and pull off the handle.

Installation

MS502

Note: The switches for the left and right handles are different. If you fit the switch on the wrong side the horn symbol will be upside down!

Fit the horn switch in the reverse order of removal.

●

Using a small flat screwdriver lever out the handle protective cap (see Fig. MS502)

●

Re-install the switch unit (see SWITCH UNIT section in this chapter) and carry out a functional test.

MS503

●

Simply press the horn switch inward and pull it out of the handle (see Fig. MS503). Disconnect the plug connector from the switch (see Fig. MS503).

MS-WP2300-GB 04/03 • Printed in Germany

MS-6.2-1723

M1.0-0000-000113 113

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114

LIFTING MECHANISM

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115

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MM 116

11

. .

00

--

00

00

00

00

--

00

00

00

11

1

6

LIFTING MECHANISM Lift Linkage

●

Repeat procedure on second fork tine.

●

Measure the fork height above the lift joint pivot point (left hand measuring point in Fig. M1465).

The height should not exceed 83mm.

●

Measure the fork height at the fork carriage rear wall (right and measuring point in Fig. M1465).

The height should not exceed 89mm.

The measurement on the fork carriage rear wall must be equal to or greater than that at the fork tip.

Fork Height Setting Note: The item numbers in brackets refer to Figure M1438 on the following page.

Carry out the measurement on a level surface (level to 1mm). ●

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.

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).

M1468

Lift joint stop (both sides)

Stop points

Lift 130 mm 85-3 mm

+3

85 -3 mm

M1465 MS-WP2300-GB 04/03 • Printed in Germany

MS-7.1-1723

M1.0-0000-000117 117

LIFTING MECHANISM

Loadwheel, tandem

M1438 MS-7.1-1723

118 M1.0-0000-000118

MS-WP2300-GB 04/03 • Printed in Germany

CYLINDERS

Printed in Germany

119

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M1.0-0000-000120 120 M1.0-0000-000120

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.

MS-WP2300-GB 04/03 • Printed in Germany

MS-8.1-1723

M1.0-0000-000121 121

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

MS-8.1-1723

122 M1.0-0000-000122

MS-WP2300-GB 04/03 • Printed in Germany

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.

MS-WP2300-GB 04/03 • Printed in Germany

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.

MS-8.1-1723

M1.0-0000-000123 123

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124

ELECTRICAL DIAGRAMS

Printed in Germany

125

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126

+ PM

P

FU2 10A

F2

A2

202 KYS COMM +BV

LINE

A1

TM

F1

+BATT

VMN

F1

F2

-BATT

2

POT CIRCUIT & DRIVER

TCM SEM0

Overall Wiring Diagram, Standard Version

FU1 125A

BD:1

24V BATTERY

BD:2

Key:

MS-WP2300-GB 04/03 • Printed in Germany

3 = An SAS signal is required for a travel signal from the FS and RS drivers.

2 = The BRS signal to release the brake is transmitted via a diode in the traction controller.

1 = Diagnostics LED. Remove to connect the programmer.

201

2901+BV (AK)

5900 PC404-1 NOT USED

A 1 101 5901 BATT NEG

2 4

3 5 7

6

103 JC406-3 ORS SIG 102 +BV(AK) 501 PC404-5 BATT NEG 2907 +BV(AK) 2908 JC406-1 +BV (AK) 2909 JC406-2 BRS SIG

KYS C

+

2902 PC404-2 +BV (AK) 203 JC404-7 BDI +BV 202 KYS COMM +BV

-

3

2

1

013 PC415-7 NOT USED

005 PC410-10 HNS SIGN

004 PC415-2 +BV (AK)

003 PC415-5 LOS SIG

002 PC415-4 RAS SIG

CA 202

2914 LOS SIG

4

UNUSED

LMS

2910 +BV (AK)

5

2913 PC404-3 RAS SIG

2906 HNS SIG

6

2912

UNUSED

2913 RAS SIG

2902 +BV (AK)

5900 NOT USED

4

3

2

1

501

701

2901

UNUSED

1

WHT

WHT

BLK

1

3

2

4

+BV

BATT NEG

UNUSED

KYS

RED (unused)

BLK

SAS

2

CA 417

1

2

CA 419

1

BRS

ORS

127

MS-DIA-1723

DIAGRAMS

813200-complete

HNS2 PN 811932-002

HNS2

HNS1 PN 811932-001

HNS1

SAS PN 811935

ACS PN 813533

CURTIS 900R "BDI"

UNUSED

2915 RAS SIG

5

BR

501 A6 BATT NEG

CA 404

006 PC410-7 POT SIG

201

UNUSED

-

LINE +

007 PC410-8 POT LOW

6

8

1

UNUSED

7

2910 PC 202-3 +BV (AK)

2 008 PC410-5 POT HIGH

8

B

3

203 KYS COMM +BV

UNUSED UNUSED

2908 A7 +BV (AK)

2

2

1

FS

3

CA 410

4

RS

2909 A8 BRS SIG

1

5

103 A5 ORS SIG

RED (unused)

001 BATT NEG

2

6

BLK

010 B-5 SAS SIG

3

7

CA 412

3

POT

011 B-6 FS SIG

4

CA 411

009 B-4 RS SIG

5

3

008 B-3 POT HIGH

6

4

CA 406

009 PC410-4 RS SIG

2911+BV (AK)

010 PC410-2 SAS SIG

2915 PC404-4 RAS SIG

4

-

504

-

011 PC410-3 FS SIG

+BV (AK)

+

SV -

2906 JC 202-4 HNS SIG

012 PC414-3 R/T (HSS) SIG

UNUSED

HN

+

P

5

+

6

C 1 2 3

1

D 2903 HNS SIG

2904 RAS SIG

502 BATT NEG 4

503 BATT NEG

2

5

2905 LOS SIG

3

6

2914 JC202-2 LOS SIG

3 5961 PC415-8 NOT USED

GRAY

7

BLU

006 B-1 POT SIG

8

1

+ RXD

007 B-2 POT LOW

2

RXD NEG

E 1

2904

2902

2903

5

2901

3

6

4

CA 413

2

2

+

1

-

9 TXD NEG

2962 PC415-1 +BV(AK)

3

+ TXD 4

BATT NEG

10 +BV (AK)

005 PC202-4 R/T (HNS) SIG

MAIN PCB PN 812941

LOS

11

5

12

2

6

5962 PC414-4 NOT USED

3

UNUSED

004 PC202-3 +BV(AK)

7

2963 PC414-1 +BV(AK)

4

UNUSED

CA 414

5

8

1

002 PC202-1 RAS SIG

6

1

CA 415

2963 PC415-3 +BV(AK)

2

003 PC202-2 LOS SIG

7

2962 PC410-9 +BV(AK)

UNUSED

3

261 PC410-11 NOT USED

HYDRAULIC PCB PN 812942-001

RAS

261 PC415-6 NOT USED

1

HSS 012 C-3 R/T (HSS) SIG

013 PC202-5 NOT USED

8

4

7

R/T SWITCH PN 811941

2

5961 PC410-6 NOT USED

5962 PC410-12 NOT USED

1

DIAGRAMS

_

FU3 2A

+ PM

_ P

FU2 10A LINE

A1

TM

F1

F2

A2

202 KYS COMM +BV

205 +BV F/C HR

201

+BATT

VMN

F1

F2

-BATT

7 = HR POT F/C is part of the ACS module

2

POT CIRCUIT & DRIVER

TCM SEM0

6 = Mains plug socket, for "installed charger" option only

5 = "Charger installed" option.

4 = Electronic thermo switch, switches ground for F/C HR at ambient temperature < +5 °C.

6 2901+BV (AK)

5900 PC404-1 TT

2 5901 BATT NEG

101

1

A

3 103 JC406-3 ORS SIG 102 +BV(AK) 501 PC404-5 BATT NEG 2907 +BV(AK) 2908 JC406-1 +BV (AK) 2909 JC406-2 BRS SIG

4 5 6 7 8

-

KYS

BR

C

+

CA 202

002 PC415-4 RAS SIG

2918

003 PC415-5 LOS SIG

LMS1

1

004 PC415-2 +BV (AK)

2902 PC404-2 +BV (AK)

2

005 PC410-10 HNS SIG

2916 UNUSED

3

2912

2914 LOS SIG

4

013 CA415-7 +BV F/C HR

2913 PC404-3 RAS SIG

2910 +BV (AK)

UNUSED

203 JC404-7 BDI +BV

2906 HNS SIG

5

202 KYS COMM +BV

-

6

TT

2908 A7 +BV (AK)

2

1

WHT

WHT

BLK

RED (unused)

2903

2904

2902

3

5

2901

4

6

2

CA 417

1

2

CA 419

RED

ORS

ACS PN 8135334

SAS PN 811935

HNS1

HNS PN 811933

HNS2

HNS PN 811933

16 x //R

7

813201-complete-_Opt

BLK

1

BRS

205 +BV F/C HR

+BV (AK)

2909 A8 BRS SIG

3

BLK

RED (unused)

UNUSED

+

1

103 A5 ORS SIG

4

LOS

MAIN PCB F/C PN 812272

RAS

1

CA 416

SAS

LINE

2

2910 PC 202-3 +BV (AK)

5900 A1 TT

3

CA 404 CURTIS 803 "COMBI" 006 PC410-7 POT SIG

2902 +BV (AK)

B 1 007 PC410-8 POT LOW

BATT NEG

2

UNUSED

4

5

BDI +BV

2913 RAS SIG

501 A6 BATT NEG

6

CA 406

UNUSED

2915 RAS SIG

-

2906 JC 202-4 HNS SIG

+

UNUSED

008 PC410-5 POT HIGH

UNUSED HN

7

009 PC410-4 RS SIG

2903 HNS SIG

504

8

3

1

502 BATT NEG

SV -

203 KYS COMM +BV

4

2

2904 RAS SIG +

UNUSED

010 PC410-2 SAS SIG

2915 PC404-4 RAS SIG

2911 +BV (AK)

5

3

503 BATT NEG

012 PC414-3 R/T (HSS) SIG

4

2905 LOS SIG

-

011 PC410-3 FS SIG

1

C 2 3

5

D

6

2

1

FS

4

POT

CA 410

4

RS

CA 411

1

5

2914 JC202-2 LOS SIG

001 P BATT NEG

2

6

5

2

HR POT F/C PN 812315

MS-WP2300-GB 04/03 • Printed in Germany

HYDRAULIC PCB F/C PN 812273-001

15 x //R

BLK

GRAY

7

BLU

006 B-1 POT SIGN

8

2

1

1

007 B-2 POT LOW

9

002 PC202-1 RAS SIG

6

CA 413 2962 PC415-1 +BV(AK)

10

11

12

1

CA 415

003 PC202-2 LOS SIG

7

2

261 PC410-11 +BV F/C HR

8

004 PC202-3 +BV(AK)

013 CA202-5 +BV F/C HR

3

5961 PC410-6 COMM F/C HR

2963 PC414-1 +BV(AK)

2962 PC410-9 +BV(AK)

5962 PC414-4 COMM F/C HR

261 PC415-6 +BV F/C HR

005 PC202-4 HNS SIG

2

3

CA 412

7

3

010 B-5 SAS SIG

3 1

+ TXD

E

3

011 B-6 FS SIG 2

TXD NEG

+ RXD

3

4 4

BATT NEG

009 B-4 RS SIG +

15 x //R

RXD NEG

5

+BV (AK)

8

4

5

6

UNUSED

UNUSED

-

P

6

+BV (AK)

+

HSS

008 B-3 POT HIGH

7

2

R/T PCB F/C PN 812877

2 x //R

6

1

CA 414 1

3

2963 PC415-3 +BV(AK)

4

UNUSED 012 C-3 R/T (HSS) SIG

2

5962 PC410-12 GND F/C

1

5961 PC415-8 COMM F/C HR

8

3 = An SAS signal is required for a travel signal from the FS and RS drivers.

2 = The BRS signal to release the brake is transmitted via a diode in the traction controller.

1 = Diagnostics LED. Remove to connect the programmer.

Key:

BD:2

24V BATTERY

BD:1

FU1 125A

Overall Wiring Diagram with Options

+

5

MS-DIA-1723

128

204

102 5901

PC 404 5900 2903

1

502

2 3

2 4

2 2

2902

2 5

2905

503

7 8

3 3 3 3 3

D 1 2 3 4 5 6

2

6

2904

2913

BDI

2915

2 2

3

3

2

4

5 6

1

PC419

1010 1010 PC413

3

HANDLE MAIN PCB

1 2

2

1

11 11

1

2

11 11

2

PC417 2 1

HNS HNS

3

FU1 2

204

FU3

4

LMS

Part No.

129

MS-DIA-1723

Harness_Complete

E99-GB

803450-010 116858 116858 803450-010 116858 803450-022 116858 116858 803450-024 803450-024 803450-019 803450-019 803450-019 803450-019

5

DIAGRAMS

6+4 6+4

1

JC 202-5

4 F/C auxiliary wire harness 812961-001

Contact Type

5 F/C adapter wiring LMS 812961-002

Part No.

204

7+8

202 203

501

203

3

4

3

3

2901

2901 2902

201

3

5

3

4

2903

7+8 6+4

5900

3

6

006

3

5

2902

2901

KYS

FU2

2901

3

7

501

1 101

3

A

5901

3

8

103 102

3

2907 2908 2909

007

3

6

2904

Housing

2912

1 Main wire harness 808276 2 2 Tiller wire harness 811953

SV

3 3 Horn switch wire harness 811931

6+4

HN

008

3

205

205

1 2 2 1 2 10 2 2 11 11 3 3 3 3

10+11 6+4

202

201

1

504

6+4

6+4

2906 2903

2914 2905

502

009

3

2

6+4

010

1

B

011

3

3

2

3

803450-003 803450-007 803450-008 803450-002 803450-015 803450-021 803450-020 803450-008 803450-023 803450-023 803450-018 803450-017 803450-016 803450-017

2913

6+4

FU1 5+4

2911 2908

001 010 011 009 008

2961

3

1 2961

C 012

5961

007

P-

006

2962

9

005 001

261 5962

2902

2903

Wire harness overview, all versions

4 BR 4

1

JC406 1 103

2909

P

2 2 2 2 2 2 2 2 2 11 2

10 2

9

8

7

6

5

4

3

2

1

PC 410

504

12 2

2

2904

JC202 PC202 PC404 JC406 PC410 PC413 PC414 PC415 PC417 PC419 A B C D

10+11 6+4

RED/WHT

7+8

RED/WHT

7+8

1 2911

503

6+4

1

2904

HANDLE MAIN PCB

1

LINE

2915

6+4

4

1

6

JC 202

5

4

1

3

PC 202

1

2

2907

4 5 6 2 2

1

1

3 2

2910

6+4

BRS 2 ORS 3

LMS 2 2

2

8

2

7

2

6

2

5

2

HANDLE HYDRAULIC PCB

4

2

9

3

2

2

HANDLE R/T PCB

1

2

2

5961

1

2

013

1 2

PC 415

2

261

1

003

101

6+4

Key: PC 414

2

002

3

2963

4

004

013

R/T PCB = "Fast/Slow" changeover module (all PCBs/modules are located in the tiller)

2962

2906

005

2912

Terminal Type Par t No.

E100-GB

062007-021 803678-006 803448-003 062007-043 803448-002 062007-054 803448-004 803448-005

2963

2910

004

6+4

4 5 6 7 8 9 10 11

012

2914

003

2913

MS-WP2300-GB 04/03 • Printed in Germany

5962

2912

002

6+4

TCM SEM0

130

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MS-WP2000-GB 12/02 • Printed in Germany

HYDRAULIC SCHEMATIC

Printed in Germany

131

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Printed in Germany

MM 132

11

. .

00

--

00

00

00

00

--

00

00

00

11

3

2

HYDRAULIC CIRCUIT

Lift cylinder

Lowering valve Filter

Filter

Non-return valve Pressure relief valve

Flow reducer

150 bar to 170 bar* Motor Vent cap Pump

Filter

Filter

Reservoir * depending on model and setting of the pressure relef walve

MS-WP2300-GB 04/03 • Printed in Germany

M1457-1

MS-HYD-1723

M1.0-0000-000133 133

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134