Maintenance Manual
WP2300S Series Printed in Germany ● Revision Level B Order Number: 812529-006
This master 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 A
Rev.1 04/00 General corrections and additions to the text. Reference to authorised service personnel added.
Page 63
Rev.2 05/05 General corrections and additions to text. Additions to Safety Reverse Switch (SAS) Used from serial no. 5A336576, except for 5A337937. Additions to Brake Switch (BRS) Used from serial no. 5A336576, except for 5A337937.
Page 64
Rev.2 05/05 Additions to Platform Control Switches (GCSR, GCSL, PLS) Used from serial no. 5A336576, except for 5A337937.
Page 64_A
Rev.2 05/05 Additions to Platform Logic (PLM) Used from serial no. 5A336576, except for 5A337937.
Page 65_A
Rev.2 05/05 Updated diagram, addition to PLM.
Page 66_A
Rev.2 05/05 WP2340S diagram included.
Page 80_A
Rev.2 05/05 Parameter setting for trucks with folded platform. Parameter setting for trucks with fixed platform.
Page 88_A
Rev.2 05/05 Troubleshooting addition.
from page 102 Rev.2 05/05 General text corrections. Updates and additions: Control handle grip, up to page 112 Switch unit, fast/slow toggle switch, hydraulic PCB, main PCB removal/ installation, potentiometer, safety reverse switch, horn switch, hand grip. from page 131 Rev.2 05/05 Corrections to diagrams and WP2340S addition. from page 136 Rev.2 05/05 Wiring diagram updates. WP2340S addition.
WP2300S 05/2005 • Printed in Germany
MS-REV-1723
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TABLE OF CONTENT
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M1.0-0000-000II II M1.0-0000-000II
TABLE OF CONTENT Table of Content REV– OVERVIEW OF REVISIONS
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Overview of Revisions: ....................................................... A .......................................................... Rev.2 05/2005
ITD – INTRODUCTION
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Safety Symbols used in the Manual .................................. 3 ............................................................... Rev.1 04/00 General Maintenance and Repair Safety Notes ................ 3 Maintenance and Repair .................................................. 3 ............................................................... Rev.1 04/00 Before Leaving the Truck .................................................. 4 Before Carrying out Work on the Truck ............................ 4 Before Operating the Truck ............................................... 4 Warnings and Labels on the Truck ..................................... 4 General ................................................................................. 7 Operating Instructions ...................................................... 7 Service Training ................................................................ 7 Ordering Spare Parts ....................................................... 7 Using the Manual ............................................................. 7 Model-Number ..................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT
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Jacking up the Truck ........................................................... 11 Raising the Truck with a Crane ........................................... 11 Fixed Platform .................................................................. 11 Folding Platform ............................................................... 12 Both Platforms .................................................................. 13 Raising with a Forklift Truck ............................................... 14 Component Access and Components .............................. 15 Maintenance ........................................................................ 18 Recommended Lubricants and Oils ................................. 18 Lubricants ................................................................... 18 Cold Store Trucks ........................................................ 18 Truck Decommissioning ................................................... 18 Restoring the Truck to Service ........................................... 18 Check and Maintenance Schedule .................................. 20 Safety Reverse Switch – Functional Test ................................................................... 22 Grease items and grease intervals .................................. 30 Adjusting the Contact Pressure of the Castors and the Drive Wheel ............................................................ 32 Torques ................................................................................ 33
M2 – HYDRAULICS
PAGE
Hydraulic Symbols .............................................................. 37 Hydraulic System ................................................................ 41 Operation ......................................................................... 41 Removing the Hydraulic Unit ............................................ 42 Replacing the Hydraulic Pump ......................................... 43 Removal ...................................................................... 43 Installation ................................................................... 43 Commissioning and Bleeding the System ........................ 43 Filters ............................................................................... 45 Replacing the Pressure Filter ...................................... 45 Replacing the Suction and Return Filters .................... 45 Oil Change ....................................................................... 45 Replacing the Safety Valve ............................................... 46 Safety Valve Setting ......................................................... 46 Safety Valve Test and Setting ...................................... 46 WP2300S 05/2005 • Printed in Germany
III
TABLE OF CONTENT Testing and Setting the LoadDependent Pressure Switch ............................................. 47
M3 – DRIVE UNIT
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Gear Unit .............................................................................. 51 Preparatory Measures ..................................................... 51 Removal ........................................................................... 51 Maintenance .................................................................... 51 General ....................................................................... 51 Gear Unit Disassembly / Assembly .................................. 53 Disassembly ................................................................ 53 Assembly .................................................................... 53 Preparing the Gear Unit .............................................. 53 Flange Shaft Assembly ............................................... 53 Pinion Shaft Assembly ................................................ 54 Adjusting the Bevel Gear Assembly ............................ 54 Final Assembly ............................................................ 54 Assembly .................................................................... 55
M4 – ELECTRICS
PAGE
Electrics - General ............................................................... 59 Wire Colour Codes ........................................................... 59 Abbreviations ................................................................... 60 Electrical Symbols ............................................................ 62 Electrical Components ....................................................... 63 Travel Switch (POT, FS, RS) ............................................. 63 Fast/Slow Switch (HSS) ................................................... 63 Safety Reverse Switch (SAS) ........................................... 63 Safety Reverse Switch (SAS) ........................................... 63 .................. Used from serial no. 5A336576, ................................................................................................................. except for 5A337937. .......................... ........................................................................................................................................................ Rev.2 05/2005 Brake Switch (BRS).......................................................... 63 Brake Switch (BRS).......................................................... 63 .................. Used from serial no. 5A336576, ................................................................................................................. except for 5A337937. .......................... ........................................................................................................................................................ Rev.2 05/2005 Raise/Lower Switch (RAS, LOS) ...................................... 64 Pressure Switch (PS) ....................................................... 64 Platform Control Switches (GCSR, GCSL, PLS) .............. 64 Platform Control Switches (GCSR, GCSL, PLS) .............. 64 .................. Used from serial no. 5A336576, ................................................................................................................. except for 5A337937. .......................... ........................................................................................................................................................ Rev.2 05/2005 Lift Limit Switch (LMS) ..................................................... 64 Horn Switch (HNS) ........................................................... 64 Foot Switch (FTS) ............................................................ 64 Key Switch (KYS) ............................................................. 64 Emergency Disconnect (BD) ............................................ 64 Fuses (FU) ....................................................................... 64 OPTION
Thermal Switch (THS) ........................................... 64 Filter (WP2340S only) ...................................................... 64 ......................................................... Rev.2 05/2005 Diode D4 .......................................................................... 64 ......................................................... Rev.2 05/2005 Diode block (DB) .............................................................. 64 ......................................................... Rev.2 05/2005 Platform Logic (PLM) ....................................................... 64_A .............. Used from serial no. 5A336576, ................................................................................................................. except for 5A337937. .......................... ........................................................................................................................................................ Rev.2 05/2005 WP2330S ......................................................................... 65 WP2330S ......................................................................... 65_A ..................................................... Rev.2 05/2005 WP2335S ......................................................................... 66_A ..................................................... Rev.2 05/2005 WP2340S ......................................................................... 66_A ..................................................... Rev.2 05/2005 Battery .................................................................................. 67 WP2300S 05/2005 • Printed in Germany
IV
TABLE OF CONTENT General ............................................................................ 67 Replacing the battery ....................................................... 67 Battery Discharge Indicator (BDI) ...................................... 67 General ............................................................................ 67 Battery Discharge Indicator Setting (BDI) ........................ 68 Calibration ................................................................... 68 SEM1 Traction Controller .................................................... 69 General ................................................................................. 69 Precautionary Measures ............................................. 69 Operational Features ....................................................... 69 Speed Control ............................................................. 69 Reduced Speed Ranges ............................................. 69 Downhill Speed Control ............................................... 69 Regenerative Braking .................................................. 69 Anti - Roll Down Function ............................................ 69 Hourmeter ................................................................... 70 Self Test ...................................................................... 70 Monitored Circuits ....................................................... 70 Protective Devices ............................................................ 70 Polarity Protection ....................................................... 70 Wiring Errors ............................................................... 70 Temperature ................................................................ 70 Start Sequence ........................................................... 71 Safety Class ................................................................ 71 Maintenance .................................................................... 71 Replacing the SEM1 Traction Controller ........................... 72 Parameter Setting after Replacing the Traction Controller 72 Preparatory Measures ................................................ 72 Setting ......................................................................... 72 Status LED .................................................................. 74 Programmer ......................................................................... 75 General ............................................................................ 75 Operating SEM1 Controller Menu .................................... 76 General ....................................................................... 76 Menu Functions .......................................................... 76 PARAMETER CHANGE .............................................. 76 Menu Structure for Folded Platform ............................ 77 Menu Structure for Fixed Platform .............................. 78 Parameter Setting, Folded Platform ................................... 79 Parameter Setting, Folded Platform ................................... 80 Parameter Setting, Folded or Fixed Platform .................... 80_A .................................................... Rev.2 05/2005 Parameter Setting, Fixed Platform ..................................... 80 TESTER Menu ................................................................. 82 ALARMS Menu ................................................................ 83 Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu .................................................. 86 Preparatory Measures ................................................ 86 Calibration ................................................................... 86 CONFIG Menu ...................................................................... 87 SET MODEL .................................................................... 87 SET OPTIONS ................................................................. 87 Adjustments ..................................................................... 87 Traction Controller Safety Test .......................................... 88 Troubleshooting Platform Logic, Controller PN 815144 .... 88_A ..................................................... Rev.2 05/2005 Electric Motors .................................................................... 89 General Maintenance Instructions ................................... 89 Preparation ................................................................. 89 Important Maintenance Instructions ............................ 89 Traction Motor Maintenance ............................................... 90 Access to Brushes ........................................................... 90 WP2300S 05/2005 • Printed in Germany
V
TABLE OF CONTENT Maintenance .................................................................... 90 Armature ..................................................................... 90 Bearings ...................................................................... 90 Pump Motor Maintenance ................................................... 91 Access to brushes ............................................................ 91 Maintenance .................................................................... 91 Armature ..................................................................... 91
M5 – BRAKE
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Brake .................................................................................... 95 Removal ........................................................................... 95 Disassembly ................................................................ 96 Test and Inspection ..................................................... 96 Assembly .................................................................... 96 Assembly .......................................................................... 97 Air Gap Setting ................................................................. 97 Brake Moment Setting ...................................................... 98 Testing the Brakes ....................................................... 98
M6 – STEERING
PAGE
Multitask Handle - Springs for Return Function .................................................................. 101 Adjustment ....................................................................... 101 Removal ........................................................................... 101 Assembly .......................................................................... 101 Tiller Handle ......................................................................... 103 Main Components ............................................................ 103 Tiller Handle Component Removal / Installation ......................................................... 104 Tiller Handle Shells .......................................................... 104 Removing the Upper and Lower Shells ....................... 104 Fitting the Upper and Lower Shells ............................. 105 Switch Unit ....................................................................... 106 Removal ...................................................................... 106 Switch Unit Installation ................................................ 106 "Fast/Slow" Toggle Switch ................................................ 107 Removal ...................................................................... 107 Installation ................................................................... 107 Hydraulic Board ................................................................ 107 Removal ...................................................................... 107 Installation ................................................................... 107 Main PC Board Removal/Installation ................................ 107_B ................................................... Rev.2 05/2005 Potentiometer ................................................................... 108 Removal ...................................................................... 108 Installation ................................................................... 108 Safety Reverse Switch ..................................................... 109 Removal ...................................................................... 109 Installation ................................................................... 109 Horn Switch ...................................................................... 110 Removal ...................................................................... 110 Installation ................................................................... 110 Handle .............................................................................. 111 Removal ...................................................................... 111 Installation ................................................................... 111
M7 – LIFTING MECHANISM
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Lift Linkage .......................................................................... 115 Fork Height Setting .......................................................... 115 Lift Limit Cutout ................................................................... 117 Lift Limit Cutout Setting .................................................... 117 WP2300S 05/2005 • Printed in Germany
VI
TABLE OF CONTENT M8 – CYLINDERS
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Lift Cylinders ....................................................................... 121 Operation ......................................................................... 121 Removal ........................................................................... 121 Inspection ......................................................................... 123 Replacing the Piston Seal ................................................ 123
M9 – PLATFORM
PAGE
Folding Platform .................................................................. 127 Mechanical Setting ........................................................... 127 Platform Switch Setting (PLS) .......................................... 128 Platform Suspension ........................................................ 129 Plate Spring Layers ..................................................... 129 Side Gates, Mechanical Setting ....................................... 130 Fixed Platform WP2335S ..................................................... 131 Replacing the Savety Switch ............................................ 131 Fixed Platform WP2340S ..................................................... 131_A .................................................. Rev.2 05/2005 Replacing the Savety Switch ............................................ 131_A ................................................... Rev.2 05/2005 Fixed Platform WP2340S ..................................................... 132_A .................................................. Rev.2 05/2005 Replacing Switches below the Entry Bars (FPS 1 & FPS 2)132_A ................................................... Rev.2 05/2005
DIA – ELECTRICAL DIAGRAMS
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Notes to overall wiring diagram, standard version, folded platform, WP2330S .............................................................. 136 ....................................................... Rev.2 05/2005 Overall Wiring Diagram, Standard, Folded Platform, WP2330S .............................................................................. 137 ....................................................... Rev.2 05/2005 SCHEMATIC DIAGRAM ................................................... 138 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 138 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 139 ....................................................... Rev.2 05/2005 PLATFORM CIRCUIT ...................................................... 139 ....................................................... Rev.2 05/2005 POWER UNIT CIRCUIT ................................................... 140 ....................................................... Rev.2 05/2005 CONTROL HANDLE CIRCUIT ......................................... 140 ....................................................... Rev.2 05/2005 PLATFORM LOGIC .......................................................... 141 ....................................................... Rev.2 05/2005 Notes to overall wiring diagram, with Options, folded platform, WP2330S .............................................................. 142 ....................................................... Rev.2 05/2005 Overall Wiring Diagram, with Options, Folded Platform, WP2330S .............................................................................. 143 ....................................................... Rev.2 05/2005 SCHEMATIC DIAGRAM ................................................... 144 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 144 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 145 ....................................................... Rev.2 05/2005 PLATFORM CIRCUIT ...................................................... 145 ....................................................... Rev.2 05/2005 POWER UNIT CIRCUIT ................................................... 146 ....................................................... Rev.2 05/2005 CONTROL HANDLE CIRCUIT ......................................... 146 ....................................................... Rev.2 05/2005 PLATFORM LOGIC .......................................................... 147 ....................................................... Rev.2 05/2005 Notes to overall wiring diagram, standard version, fixed platform, WP2335S ..................................................... 148 ....................................................... Rev.2 05/2005 Overall Wiring Diagram, Standard Version, Fixed Platform, WP2335S .................................................... 149 ....................................................... Rev.2 05/2005 Notes to overall wiring diagram, with Options, fixed platform, WP2335S ..................................................... 150 ....................................................... Rev.2 05/2005 Overall Wiring Diagram, with Options, Fixed Platform, WP2335S .............................................................................. 151 ....................................................... Rev.2 05/2005 Diagrams, Standard Version, Fixed Platform, WP2340S ... 152 ....................................................... Rev.2 05/2005 SCHEMATIC DIAGRAM ................................................... 152 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 152 ....................................................... Rev.2 05/2005 POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 153 ....................................................... Rev.2 05/2005 PLATFORM CIRCUIT ...................................................... 153 ....................................................... Rev.2 05/2005 POWER UNIT CIRCUIT ................................................... 154 ....................................................... Rev.2 05/2005 CONTROL HANDLE CIRCUIT ......................................... 154 ....................................................... Rev.2 05/2005 Diagrams, with Options, Fixed Platform, WP2340S .......... 155 ....................................................... Rev.2 05/2005 WP2300S 05/2005 • Printed in Germany
VII
TABLE OF CONTENT SCHEMATIC DIAGRAM ................................................... 155 ....................................................... Rev.2 05/2005 TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 155 ....................................................... Rev.2 05/2005 POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 156 ....................................................... Rev.2 05/2005 PLATFORM CIRCUIT ...................................................... 156 ....................................................... Rev.2 05/2005 POWER UNIT CIRCUIT ................................................... 157 ....................................................... Rev.2 05/2005 CONTROL HANDLE CIRCUIT ......................................... 157 ....................................................... Rev.2 05/2005 Wire harness overview, folded platform, WP2330S all versions ......................................................... 158 ....................................................... Rev.2 05/2005 Main Harness, Folded Platform, WP2330S, All Versions .. 159 ....................................................... Rev.2 05/2005 Control Handle - Wire Harness Folded Platform, WP2330S, All Versions ........................................................ 160 ....................................................... Rev.2 05/2005 Horn Switch - Wire Harness, Folded Platform, WP2330S, All Versions ........................................................ 161 ....................................................... Rev.2 05/2005 Wire harness overview, Fixed Platform, WP2340S, All Versions ....................................................... 162 ....................................................... Rev.2 05/2005 Wire harness overview, Fixed Platform, WP2340S, All Versions ....................................................... 163 ....................................................... Rev.2 05/2005 Control Handle - Wire Harness FFixed Platform, WP2340S, All Versions ........................................................ 164 ....................................................... Rev.2 05/2005 Horn Switch - Wire Harness Fixed Platform, WP2340S, All Versions ........................................................ 165 ....................................................... Rev.2 05/2005 Cables, Platform, Fixed Platform, WP2340S, All Versions .......................................................................... 166 ....................................................... Rev.2 05/2005 Power Cables ....................................................................... 167
HYD – HYDRAULIC SCHEMATIC
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Hydraulic Schematic ........................................................... 171
WP2300S 05/2005 • Printed in Germany
VIII
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
Maintenance and Repair
This symbol indicates the risk of minor injury and/or minor material damage.
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.
MS-0000-MA
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INTRODUCTION
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M1.0-0000-0006 6 M1.0-0000-0006
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
MS-WP2300S-GB 05/03 • Printed in Germany
MS-ITD-1723
M1.0-0000-0007 7
INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions:
2.0
WP
2335S –
3
–
2
–
S
Capacity
Load Wheels
2.0 = 2000 kg
S = Single T = Tandem
Model Description WP = Electric Pedestrian Pallet Truck
Fork Length Dash
mm
1 2 Platform Type 2335 = Fixed Platform 2330 = Folded Platform
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
MS-ITD-1723
88 M1.0-0000-0008
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LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT Jacking up the Truck
Raising the Truck with a Crane
CAUTION
Fixed Platform
Always support a raised truck with wooden blocks or other suitable means to relieve the jack.
Fit the chains or lifting slings as shown in the diagram: ●
The term "jacking up the truck" always implies that the raised truck is lowered onto a secure base.
to each fork tip with a lifting sling tied around the platform, or
●
with one hook on each side of the platform.
Capacity required: 600 kg for the WP 2300 S less battery.
Jack up Points MS1723-100
M1458-a
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MS-1.0-1723
M-1.0-0000-00011 11
LUBRICATION AND ADJUSTMENT Folding Platform Fit the chains or lifting slings as shown in the diagram: ●
to each fork tip with a lifting sling tied around the platform. Prevent the lifting sling from sliding off: connect it to the forks, see dashed line S.
or ●
Attach a hook to points R and L respectively on the truck frame. Prevent accidental sliding off: connect the two chains or lifting slings, see dashed line H, between the truck and the gates.
Capacity required: 570 kg for the WP 2300 S less battery.
S
H L R
R
L MS-1723-101
MS-1.0-1723
12M-1.0-0000-00012
MS-WP2300-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT Both Platforms It is also possible to raise the truck (with either folding or fixed platform, after removing the panel) as shown in the following illustration.
MS-1723-102
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M-1.0-0000-00013 13
LUBRICATION AND ADJUSTMENT Raising with a Forklift Truck DANGER Use a truck with sufficient capacity and prevent the truck on the forks from sliding off. The WP 2300 S can be raised at an angle using a forklift truck - see illustration. Required capacity: 600 kg for the WP 2300S less battery. The forks must be fully raised.
●
Position the forks of the lifting truck as shown in the illustration.
●
Place a wooden block approx. 90 mm thick between the forks of the WP 2300S and the forks of the lifting truck.
●
Secure the WP 2300S on the forks of the lifting truck (e.g. with an elastic strap).
600
WP 2300
> 800
90
●
MS-1723-103
MS-1.0-1723
14M-1.0-0000-00014
MS-WP2300-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT Component Access and Components Removing the panel provides access to the drive unit, hydraulic system, contactors, traction controller etc. The panel is fixed to the frame by two screws. Removing the screws allows you to slightly lift the panel up out of the lower retaining lug, tilt it away and remove it via the tiller.
FU2 - FU3 F/C
FU1
Battery connector (EMERGENCY DISCONNECT)
Fan
Magnetic brake Traction controller Main contactor
Horn
Pump contactor Lift cylinder (LH) Pump motor Pressure switch PS
Lowering valve SV Hydraulic tank and pump
MS-1723-120
Traction motor
MS-WP2300S-GB 05/03 • Printed in Germany
Drive wheel
MS-1.0-1723
M-1.0-0000-00015 15
LUBRICATION AND ADJUSTMENT Fast / Slow Travel Switch
Button, Horn
Travel Switch
Reverse Safety Switch
MS-1.0-1723
16M-1.0-0000-00016
Lift / Lower Switch
MS1723-004
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LUBRICATION AND ADJUSTMENT
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M-1.0-0000-00017 17
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).
MS-1.1-1723
18M-1.0-0000-00018
MS-WP2300S-GB 05/03 • Printed in Germany
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 Klarlack
Acid resistant transparent coating for traction controllers for cold store applications.
805236-003
Transparent coating
L01_adjuvants_WPS-GB
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.1-1723
M-1.0-0000-00019 19
LUBRICATION AND ADJUSTMENT Check and Maintenance Schedule The following check and maintenance schedule assumes single-shift operation under normal operating conditions. The length of maintenance intervals will however depend on the particular operating conditions.
When performing maintenance work always check for wear, corrosion and damage and ensure that the parts are operating correctly and are secure. If in doubt, replace them.
In dusty or otherwise extreme environments, including cold stores, the specified maintenance intervals should be reduced. The exact periods should be established after consultation with Crown service personnel.
Daily or every 8 service hours No.
Item
Action
1
Battery
Re-charge a discharged battery. Check electrolyte level and replenish if necessary.
2
Battery Connector ( = Emergency Stop )
Check operation
3
Horn
Check operation
4
Lift / Lower rocker switch
Check operation
5
Travel switch
Check operation (both directions)
6
Safety reverse switch
Check operation
7
Brake
Check operation (both directions, both normal braking with the multi-task handle and inverse braking)
8
Steering
Check play
9
Fork
Check for visible signs of cracks and deformation
10
Wheels / Load wheels
Check tyres for wear, nails, metal splints etc.
11
Hydraulic lines and connections
Check for leaks, tighten connections if necessary
12
Platform safety switch
Check operation (platform up and platform down).
L02-S-GB
MS-1.2-1723
20M-1.0-0000-00020
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
8 2 7
1
10 11
12
MS1723-200
9
3 10
6
4 3
5, 8
7 MS1723-004
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00021 21
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
●
MS-1.2-1723
22M-1.0-0000-00022
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
Blank Page
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00023 23
LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours No.
Item
Action
1
Battery
Check acid density, if necessary replenish with destilled water. Check voltage of all cells, if necessary compensate; clean and grease battery terminals.
2
Contactors
Clean; check, replace if necessary
3
Lift limit switch
Check operation
4
Electrical system
Check wires, switches and connections are secure, check insulation for damage
5
Impulse control
Check operation
6
Brake
Blast off corrosion; check air gap
7
Lift cylinder
Ensure seal is tight
8
Hydraulic oil tank
Check oil level, replenish if necessary
9
Load wheels and castor bearings
Check for play, replace bearings if necessary
10
Drive wheel
Ensure wheel nuts are correctly torqued.
11
Drive unit guide
Check for play, replace rails if necessary. Lubricate.
L03-S-GB
MS-1.2-1723
24M-1.0-0000-00024
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
2 6
5 1
4
7 3 11 8
MS1723-200
10
MS1723-013
9
9
MS1723-011
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00025 25
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. L05-gb
MS-1.2-1723
26M-1.0-0000-00026
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
6 1
7
2
11
4
10
9
9 3
MS1723-011
MS1723-011
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00027 27
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
28M-1.0-0000-00028
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
1 5
2 MS1723-200
MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00029 29
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
A/R = As required
MS-1.2-1723
30M-1.0-0000-00030
1000 hours
2000 hours
X
Initial change after 250 hoursof operation
X L08-S-gb
MS-WP2300S-GB 05/03 • Printed in Germany
LUBRICATION AND ADJUSTMENT
5 4 3
8
7 1,2
9
6
MS1723-011 MS-WP2300S-GB 05/03 • Printed in Germany
MS-1.2-1723
M-1.0-0000-00031 31
LUBRICATION AND ADJUSTMENT Adjusting the Contact Pressure of the Castors and the Drive Wheel
Example: You record a current drive wheel diameter of 220 mm. The average for the castor wheels is 120 mm.
The castor wheels are on the left and right hand sides below the truck. They prevent the truck from tipping over when travelling around bends.
230 mm - 220 mm = 10 mm (A) 125 mm - 120 mm = 5 mm (B) 10 mm - 5 mm = 5 mm (Adjustment)
The castors apply a certain supporting force to the ground over long periods of time, as the drive unit on the slide generally compensates the drive wheel and castor wheel wear. However, the greater the tyre wear, the less the drive wheel contact pressure. This increases the braking distance and when travelling with heavy loads the truck can skid on smooth surfaces.
Therefore, the screws (B) in Fig. M1519 should be tightened by 5 mm. ●
Loosen both jam nuts (A) and turn them upward by at least the calculated adjusting measurement.
●
Tighten screws (A) in turn until the calculated adjusting measurement is obtained for both screws.
●
Check dimension C: nominal measurement = 33 mm (with wheels)
●
Jam the screws (B) with nuts (A).
New drive wheels have a 230 mm diameter. If the diameter is only 220 mm, the drive unit spring pre-tension must be increased. Otherwise the drive wheel will skid excessively, thereby also increasing the wear. The castor wheels will also wear out prematurely due to excess contact pressure. Procedure: ●
Park the unladen truck on a level surface.
●
Remove the battery connector and the key.
●
Make sure the truck cannot be switched on.
●
Remove the panel.
●
Measure and record the drive wheel diameter.
●
Measure the diameter of the castor wheels, calculate the average diameter and record.
A
B
B
C
C
A
Calculating the Adjustment Required: New drive wheel Ø 230 mm minus current drive wheel Ø=A New castor wheel Ø 125 mm minus current castor wheel Ø = B A - B = Adjustment required
M1519
MS-1.5-1723
32M-1.0-0000-00032
MS-WP2300S-GB 05/03 • 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-WP2300S-GB 05/03 • Printed in Germany
T01-gb
MS-1.9-1723
M-1.0-0000-00033 33
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
34M-1.0-0000-00034
MS-WP2300S-GB 05/03 • Printed in Germany
HYDRAULICS
Printed in Germany
35
Blank Page
Printed in Germany
36M1.0-0000-00036
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-WP2300S-GB 05/03 • Printed in Germany
MS-2.0-0000
M-1.0-0000-00037 M1.0-0000-00037 37
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
38M1.0-0000-00038 M-1.0-0000-00038
MS-WP2300S-GB 05/03 • 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-WP2300S-GB 05/03 • Printed in Germany
MS-2.0-0000
M-1.0-0000-00039 M1.0-0000-00039 39
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
40M1.0-0000-00040 M-1.0-0000-00040
MS-WP2300S-GB 05/03 • 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 and the check valve remain closed.
Lowering: The lowering valve opens. The oil flow returns from the two lift cylinders to the reservoir.
Lift cylinder
Pressure-Switch Lowering valve Filter
Filter
Non-return valve Pressure relief valve
Flow reducer
150 bar to 170 bar* Motor Vent cap Pump
Filter
Filter
Reservoir M1457-2
* depending on truck model and setting of the pressure relef walve MS-WP2300S-GB 05/03 • Printed in Germany
MS-2.1-1723
M-1.0-0000-00041 M1.0-0000-00041 41
HYDRAULICS Removing the Hydraulic Unit ●
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 connections (see Fig. M1522).
● Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge.
●
Unscrew the power connections to the pump motor (see Fig. M1522).
●
Unscrew the pressure connection.
● Use absorbent paper to track leaks, never use your hands!
●
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. M11522) from the chassis.
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.
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
42M1.0-0000-00042 M-1.0-0000-00042
M1522 MS-WP2300S-GB 05/03 • Printed in Germany
HYDRAULICS Replacing the Hydraulic Pump
●
NOTE The hydraulic pump should not be replaced on site. The pump is replaced as a complete assembly.
To refit the hydraulic unit proceed in the reverse order of Removal. Note torques! Both motor connecting cables: 4±0.5 Nm.
Commissioning and Bleeding the System ●
Check that the system is clean and properly assembled. In particular, the pressure ports must be tightly secured.
●
Initially, fill the hydraulic oil only up to half the reservoir height (see lubricant table) using a filter with a 10 µm minimum retention rate.
●
Never operate the pump without oil.
●
All components, in particular the hydraulic ports, must be completely clean and dry prior to commissioning. Otherwise it is impossible to check whether the system is sealed.
●
Operate the lifting functions for approx. 30 seconds to bleed the system. The oil in the reservoir will foam considerably.
●
Check the pressure port and surrounding hydraulic components for leaks.
●
Park the truck and leave it to stand for approx. 20 minutes. During this interval the air will separate from the oil in the container.
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.
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.
●
Now fill with hydraulic oil up to the lower mark of the filler neck.
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 on next page: ●
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.
●
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.
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.
●
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.
MS-WP2300S-GB 05/03 • Printed in Germany
MS-2.2-1723
M-1.0-0000-00043 M1.0-0000-00043 43
HYDRAULICS
M1442
MS-2.2-1723
44M1.0-0000-00044 M-1.0-0000-00044
MS-WP2300S-GB 05/03 • Printed in Germany
HYDRAULICS Pump Motor For maintenance and repair work to the pump motor see chapter 4.
Filters Replacing the Pressure Filter ●
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 ●
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-WP2300S-GB 05/03 • Printed in Germany
MS-2.2-1723
M-1.0-0000-00045 M1.0-0000-00045 45
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.
3 2
Safety Valve Test and Setting ●
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). See capacity data plate for this value. It should be possible to raise this load safely.
Model
Rated Capacity
Minimum Load
Maximum Load
WP2330S
2.000 kg
2.200 kg
2.300 kg
WP2335S
2.000 kg
2.200 kg
2.300 kg
1
MS1723-007
4
H01-GB
MS-2.2-1723
46M1.0-0000-00046 M-1.0-0000-00046
MS-WP2300S-GB 05/03 • Printed in Germany
HYDRAULICS Testing and Setting the LoadDependent Pressure Switch The output signal of the load-dependent pressure switch (1, Fig. MS-1723-400) is applied to an input of the traction controller. Only when the load on the forks is greater than 900 - 1,000 kg does the controller release the 2nd brake stage and the 2nd brake stage is then also used for braking. The correct operation of the pressure switch is therefore essential for braking with a load. It also affects the maximum travel speed of the truck (see Chapter 4, Speed Reduction). ●
Place a test load of 900 to 1,000 kg on the forks. Fully lower the forks so that the test load rests on the ground.
●
Switch off the truck.
●
Remove the panel.
●
Remove the connector from the connecting lugs of the load-dependent pressure switch.
●
Connect the programmer (see CHAPTER 4, PROGRAMMER, TEST MENU, PRESSURE SWITCH). Alternatively, connect an ohmmeter or a continuity tester to the connecting lugs of the load-dependent pressure switch.
●
Switch on the truck.
●
Raise the test load while at the same time observing the test item in the test menu or the ohmmeter / continuity tester. Continuity should be indicated if the pressure switch is correctly set.
●
If this is not the case, adjust the pressure switch. There is a setscrew (2, Fig. MS-1723-400) between the connecting lugs of the pressure switch. Turn the setscrew until continuity is indicated.
●
If it is not possible to adjust, this means that the pressure switch is faulty and must be replaced. Lower the load before removing the switch and depressurise the hydraulic system.
2
1
MS-1723-400
MS-WP2300S-GB 05/03 • Printed in Germany
M-1.0-0000-00047 M1.0-0000-00047 47
Blank Page
Printed in Germany
48
DRIVE UNIT
Printed in Germany
49
Blank Page
Printed in Germany
50M1.0-0000-00050
DRIVE UNIT Gear Unit Preparatory Measures
B
For removal purposes the truck must be raised approx. 500 mm.
A
Required Tools: ●
Fork lift truck with sufficient capacity, lift height and fork length to lift the truck.
●
Safety mechanism to keep the forks of the lifting truck holding the raised truck.
●
Sufficient quantity of wooden blocks (250 x 250 mm surface area) or suitable supports to hold the raised truck.
●
Device to support the gear unit on a jack or lift truck.
Removal
M1564
Lower the mechanism with the gear unit and remove it from underneath the truck.
Remove the battery connector and key. Make sure that the truck cannot be switched on.
Maintenance WARNING
Support the truck with a second fork lift truck and prevent it from slipping.
THE GEAR UNIT MUST ONLY BE REPAIRED BY PERSONNEL WHO HAVE BEEN TRAINED AND AUTHORISED BY CROWN. FAILURE TO COMPLY WILL INVALIDATE THE MANUFACTURER'S WARRANTY.
DANGER NEVER WORK UNDERNEATH A SUSPENDED LOAD.
To adjust the flank tooth bearing and pretension the shaft bearing requires years of experience in gear units. Faulty settings will result in the premature failure of the gear unit. Therefore it is generally preferable to replace the gear in full. New gear units are always supplied without oil!
SEVERE INJURIES CAN RESULT IF THE TRUCK SUDDENLY FALLS. Raise the truck until a jack / lift truck with a support for the gear unit can be pushed underneath the truck. Lift the truck by approximately another 50 mm to release the gear unit from the gear teeth.
Prior to commissioning fill with oil in accordance with the "Lubricant table".
Lower the truck onto the wooden blocks / supports. Raise the mechanism onto the jack / lift truck until it contacts the gear unit.
General ●
All bearings and seals must be replaced.
●
Prior to disassembly thoroughly clean the gear unit with a cold-cleaning solution and blast dry with weak compressed air.
●
Use assembly equipment and a clean workbench.
Remove the electrical connections from the motor. Loosen the six gear unit fastening screws (A) and the three motor fastening screws (B) in Fig. M1564.
WP2300S 05/2005 • Printed in Germany
MS-3.1-1723
M-1.0-0000-00051 M1.0-0000-00051 51
DRIVE UNIT
70
M1530A
MS-3.1-1723
52M1.0-0000-00052 M-1.0-0000-00052
WP2300S 05/2005 • Printed in Germany
DRIVE UNIT Gear Unit Disassembly / Assembly All item numbers refer to Figure M1530A unless otherwise stated.
●
Remove the bearing inner ring (240) from the bevel pinion shaft.
●
Thoroughly clean all components and remove any sealant and adhesive residue.
Disassembly Assembly
●
Drain the oil.
●
Place the gear unit with the wheel studs in a device which prevents it from twisting.
NOTE
●
Remove the screws (390), lock washers (330) and O ring (290) and lift off the cover (30).
●
Remove the Allen screws (350) and spring lock washers (190).
●
Remove live ring bearing (130).
●
Remove screw (360) and spacer (190).
●
Loosen bevel wheel nut (140).
●
Remove the gear unit from the device.
NOTE WHEN REMOVING THE GEAR UNIT, LABEL THE SHIMS (420, 430,440) IN ACCORDANCE WITH THEIR LOCATION. THEY WILL HAVE TO BE TEMPORARILY RE-FITTED IN THE SAME POSITION AT A LATER STAGE. ●
Remove the pinion (65), spacer ring (160) and if necessary shim(s) (420,430) from the housing.
●
Remove the bearing inner ring (260) from the bevel wheel (65).
●
Force out the flange shaft (50) using suitable tools.
●
Remove the bearing inner ring (250) from the flange shaft.
●
Pull out the bearing outer rings (250, 260) from their seats in the gearbox.
●
Remove the rotary shaft seal and the lock washer (310) from its gearbox seat.
●
Press the bevel pinion shaft (70) down and out of the drive pinion (110) and the bearing (230).
●
Remove the bearing (230) and shim(s) (440) if necessary.
●
Remove the bearing outer ring (240).
WP2300S 05/2005 • Printed in Germany
ALL SEALS AND BEARINGS MUST BE REPLACED.
Preparing the Gear Unit ●
Fit the outer rings of the conical roller bearings (230, 240, 250 and (260) in the respective grooves of the clean gearbox. Make sure they sit evenly in the gearbox. Fit the lock washer (310).
●
Push the inner ring (260) of the conical roller bearing (260) onto the bevel wheel (65).
●
Screw the wheel stud (150) into the flange using a dynametric key.
●
Place the gearbox in its eventual assembly position.
●
Insert the conical roller bearing inner ring (250) in the pre-assembled outer ring (trail wheel side).
●
Press the shaft seal (270) into the gearbox using a suitable tool.
Flange Shaft Assembly ●
Lightly grease the flange shaft (50) and carefully place it in the shaft seal (270) and the conical roller bearing (250).
●
Place the shim (430), spacer (160) and preassembled bevel wheel (65, 260) on the flange shaft.
NOTE THE FLANGE SHAFT ASSEMBLY MUST BE TENSIONED WITH A TORQUE WRENCH. ●
Arrange the shim (190) and screw (360) and torque the flange shaft assembly to max. 77 Nm.
●
Check freedom of movement and play of the shaft. If necessary, reduce the torque. Record the final reading. It will be required during calibration.
●
Insert the gear unit with wheel studs in a device which prevents it from twisting. MS-3.1-1723
M-1.0-0000-00053 M1.0-0000-00053 53
DRIVE UNIT Pinion Shaft Assembly ●
Checking the Flank Tooth Bearing
Push the bearing inner ring (240) up onto the bevel pinion shaft (70).
●
Insert the pre-assembled bevel pinion shaft from the inside of the gearbox into the pre-assembled bearing outer rings (230, 240).
●
Push the bearing inner ring (230) via the shank of the bevel pinion shaft (70) into the bearing outer ring.
Bevel pinion inner tooth end Correct tooth bearings
High
Low
NOTE THE SPUR PINION NUT MUST BE TIGHTENED WITH A TORQUE WRENCH. ●
Fit the spur pinion (110) and torque new nut (140) to max. 100 Nm.
●
Check freedom of movement and play. If necessary, reduce the torque. Record the final reading. It will be required during calibration.
Adjusting the Bevel Gear Assembly
Low
High
Bevel wheel inner tooth end Correct tooth bearings M1565-1
●
Colour the bevel wheel (70) tooth bearings with touch-up paint (marker colour).
●
Remove the gear unit from the device.
●
Turn the bevel wheel several times in one direction. The tooth bearing will appear as a bright point (shown black in Fig. 1565-1) on the tooth flanks.
●
Check the tooth bearing. Set the tooth bearing to within the tolerance limits by adding and/or removing shims (420,430,440) - Fig. M1565-1. Note: Torque screw (360) and nut (140) again to their previous values. Repeat the process until the tooth bearing lies within the tolerance limits.
NOTE CARRY OUT ADJUSTMENT WITH CARE. BEARING AND SHIM PRE-TENSIONING AFFECT THE TOOTH BEARING. DO NOT SET THE PRE-TENSION TOO LOW AS IT AUTOMATICALLY REDUCES DURING NORMAL OPERATION. The correct setting can be determined by the flank tooth bearing. Basic Rules: ●
Always set the bevel gear assembly in accordance with the correct flank position. The tooth ends must not form a straight line.
●
The tooth bearing must always rest on the inner tooth end.
●
The tooth bearing must lead from high (tooth upper edge) to low (tooth lower edge).
Final Assembly ●
Remove the bevel pinion shaft and flange shaft.
●
Clean the components.
●
Coat the inside of the bearing inner rings with a thin layer of Loctite 307.
●
Apply medium strength nut locking solution Loctite 242 (Crown part no. 053050-006) to the threads of the nut (140) and screw (360).
●
To assemble, proceed as described previously.
●
Manually turn the gear unit while checking for freedom of movement and the absence of play during operation.
To adjust, add and/or remove compensating spacers (420, 430, 440), and/or change the bearing pretension. Figure M1565-1 shows the permissible tooth bearing limits on the bevel pinion and bevel gear.
MS-3.1-1723
54M1.0-0000-00054 M-1.0-0000-00054
WP2300S 05/2005 • Printed in Germany
DRIVE UNIT ●
Coat the surfaces of the gearbox cover with a thin layer of Loctite 307 surface sealant , insert the O ring (290) and fit the lid. Evenly tighten the screws (390) and spring washers (330) crossways.
●
Coat the gearbox cover - live ring bearing contact surface with a thin layer of Loctite 307 surface sealant . Assemble the live ring bearing.
NOTE ALLOW THE CONTACT SURFACE AND THREAD SEALANT TO DRY FOR AT LEAST 2 HOURS AT ROOM TEMPERATURE BEFORE FILLING WITH OIL. ●
Place gear unit in assembly position.
●
Fill the oil up to the lower mark of the filler plug in accordance with the application temperature (see Lubrication and Adjustment chapter).
Assembly ●
Assembly is the reverse procedure of removal. Do not damage the toothing of the motor pinion (100) or the drive pinion (110).
Drive Motor For maintenance and repairs to the drive motor see the end of chapter 4, page M4.35-1720-001.
WP2300S 05/2005 • Printed in Germany
M-1.0-0000-00055 M1.0-0000-00055 55
Blank Page
Printed in Germany
56
ELECTRICS
Printed in Germany
57
Blank Page
Printed in Germany
58 M1.0-0000-00058 M1.0-0000-00058
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
MS-WP2300S-GB 05/03 • Printed in Germany
E01-gb
MS-4.0-1723
M1.0-0000-00059 59
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
EDS
Emergency Disconnect Switch
REA
Reach potentiometer
EM
Encoder module
RS
Reverse switch
EN C
Encoder
SAS
Reverse safety switch
FS
Forward switch
SDS
Star t switch
H BS
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-4.0-1723
60M1.0-0000-00060
E02-gb
MS-WP2300S-GB 05/03 • 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.
MS-WP2300S-GB 05/03 • Printed in Germany
E03-gb
MS-4.0-1723
M1.0-0000-00061 61
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-4.0-1723
62M1.0-0000-00062
MS-WP2300S-GB 05/03 • Printed in Germany
ELECTRICS Safety Reverse Switch (SAS) Used from serial no. 5A336576, except for 5A337937.
Electrical Components DANGER Jack up the truck before carrying out repairs or troubleshooting the electrical system.
Travel Switch (POT, FS, RS) The travel switch is manually activated via the butterfly switch on the control handle cap. The travel switch consists of a switch (FS) for forward travel, another switch (RS) for reverse travel, and a potentiometer (POT) to control the travel speed.
Fast/Slow Switch (HSS) A rotary button (rabbit//turtle & rabbit symbol) activates the Slow/Fast switch (HSS) on the control handle cap. The switch signal to the traction controller operates the change between the fast and slow speed zones.
Safety Reverse Switch (SAS) The safety reverse switch (SAS) is activated via the switch cap at the end of the control handle 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 reverses either for a certain period of time or for as long as the switch is pressed.
The safety reverse switch (SAS) is activated via the switch cap at the end of the control handle head. The PLM changes the traction controller immediately 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 reverses either for a certain period of time or for as long as the switch is pressed.
Brake Switch (BRS) The brake switch (BRS) is located directly below the control handle suspension. As soon as the control handle reaches the upper or lower brake zone (see Fig. M1559-2), the brake switch is activated. The power supply to the traction motor (TM) and the brakes (BR) is cut off via the traction controller. The brake magnet releases the armature plate which causes the truck to brake through spring tension.
Brake Switch (BRS) Used from serial no. 5A336576, except for 5A337937. The brake switch (BRS) is located directly below the control handle suspension. As soon as the control handle reaches the upper or lower brake zone (see Fig. M1559-2), the brake switch is activated. The power supply to the traction motor (TM) and the brakes (BR) is cut off by the traction controller via the PLM. The brake magnet releases the armature plate which causes the truck to brake through spring tension.
Upper brake zone Neutral / Idle Position
C
Travel zone
B
Lower brake zone
A
M1559-2
WP2300 05/2005 • Printed in Germany
MS-4.2-1723
63
ELECTRICS Raise/Lower Switch (RAS, LOS)
Key Switch (KYS)
The raise (RAS) and lower (LOS) switches are activated by cams in the control handle cap. The cams act on switches mounted on the hydraulic PCB of the control handle. The switches are mutually and mechanically locked so that they cannot be pressed at the same time. The raise (RAS) switch activates the pump contactor (P), causing the pump to start. The lower (LOS) switch supplies the solenoid (SV) with current, causing the solenoid to open.
Pressure Switch (PS)
The key switch activates the power supply to the traction controller and the battery discharge indicator (BDI).
Emergency Disconnect (BD) Pull the battery connector on the red handle at the top of the truck to fully disconnect the truck's power supply.
Fuses (FU) The entire truck circuit is protected by the FU1 fuse and the control circuit is protected by FU2. Cold store trucks have an additional fuse, FU3, for control handle heating. OPTION
The pressure switch is applied if the load raised is more than 900 kg to 1,000 kg and causes the pressure to rise in the hydraulic system. This reduces the maximum travel speed in rider mode to a safe level.
Platform Control Switches (GCSR, GCSL, PLS) Folded platform only. These three switches are arranged in series. The chain controls the position of the gate and the platform. When all the switches are closed, the traction controllers changes to the higher platform speed.
Platform Control Switches (GCSR, GCSL, PLS) Used from serial no. 5A336576, except for 5A337937.
OPTION
Thermal Switch (THS)
This is an electronic thermostat for cold store trucks. It is located on the main PCB of the control handle and applies the heating units when the temperature falls below 0°C.
Filter (WP2340S only) When jolts are caused by travelling on uneven surfaces, switches FPS1 & FPS2 – actuated by the side entry bars – can briefly open and inhibit travel. The filter delays the signal to inhibit travel by approx. 1s. This avoids accidental travel cut-out.
Diode D4 This freewheel diode on the large brake coil (BR) protects the input on the controller against peak voltages caused when the large brake coil is switched off.
Folded platform only. These three switches are signal transmitters for the platform logic and enable slow / fast travel. When all the switches are closed, the traction controller changes to the higher platform speed.
Lift Limit Switch (LMS)
Diode block (DB) The diode block comprises diodes D1 to D3 in a single component. It acts as a freewheel diode for the small brake coil (BR) and guides the pressure switch (PS) signal to connect the 2nd brake level.
The limit switch (LMS) cuts out the pump contactor circuit when the preset maximum height is reached. The limit switch is located under the front panel next to the knuckle. This switch must be adjusted, see Chapter 7, LIFTING MECHANISM.
Horn Switch (HNS) The horn is sounded when the horn switch (horn symbol) is pressed.
Foot Switch (FTS) Only available with fixed platforms. When pressed it releases the travel signal via the traction controller. MS-4.2-MS-1723
WP2300 05/2005 • Printed in Germany
02 Rev. 05/05
64
ELECTRICS Platform Logic (PLM) Used from serial no. 5A336576, except for 5A337937. This module detects and analyses the connection status of the platform switch (PLS) and the side gate switch (GCSR & GCSL). Depending on the connection status an output signal is sent to the traction controller which either enables the higher travel speed or only permits the lower walkie speed. The SAS and BRS signals are also connected via this module, depending on the platform switch and the side gate switch, as well as the respective function switch.
WP2300 05/2005 • Printed in Germany
MS-4.2-1723
64_A
ELECTRICS WP2330S
PC/JC 415 PC/JC 414 PC/JC 413 PC/JC 412 PC/JC 411 PC/JC 410
BATTERY TRAY
HSS (R/T) RAS/LOS
FU3 (Option F/C)
HNS POT,FS,RS BD BB (SAS)
LMS PC/JC 203 P LINE BUSBAR PC/JC 101 GCSL
813507
CA 419 (HNS2) CA 417 (HNS1)
HANDLE HARNESS PC/JC 406 BRS PC/JC 407 BR
INSTRUMENT PC/JC 404 KYS MAIN HARNESS
FU2 DB PC/JC 202 A,B,C,D AND E
FU1 PM SV PS PLS PC/JC 102
TCM HN
TM PC/JC 103 GCSR
MS-4.2-MS-1723
65
WP2300 05/2005 • Printed in Germany
ELECTRICS WP2330S BATT FU3 AND FU3 HOLDER OPT.
PC / JC 415 PC / JC 414 PC / JC 413 PC / JC 412 PC / JC 411 PC / JC 410
HSS (R/ T) RAS / LOS HNS POT, FS, RS
BD BB (SAS)
PLM PC / JC 200
PC / JC 416
PLM Used from S/No. 5A336576 on, but not on S/No. 5A337937
LMS P LINE
813507_2B
BUSBAR PC / JC 101 GCSL
FAN CA 419 (RHS)
HANDLE HARNESS
CA 417 (LHS)
PC / JC 4065 BRS PC / JC 407 BR INSTRUMENT PC / JC 404
KYS MAIN HARNESS FU2 AND FU2 HOLDER
DB
FU1 AND FU1 HOLDER
PC / JC 202 A, B, C, D AND E
PM SV PS PLS PC / JC 102
TCM HN
TM PC / JC 103 GCSR
WP2300 05/2005 • Printed in Germany
MS-4.2-1723
02 Rev. 05/05 65_A
ELECTRICS WP2335S
CA 419 (HNS2) CA 417 (HNS1)
HANDLE HARNESS
PC/JC 406 BRS PC/JC 407 BR INSTRUMENT PC/JC 404 KYS DB MAIN HARNESS PC/JC 202 A,B,C,D AND E
FU2
TCM
FU1
HN
PM SV PS
TM PC/JC 415 PC/JC 414 PC/JC 413 PC/JC 412 PC/JC 411 PC/JC 410
BATTERY TRAY
813508
HSS (R/T) RAS/LOS HNS POT,FS,RS
FU3 (Option F/C)
BB (SAS)
BD
LMS
P LINE BUSBAR PC/JC 101 MS-4.2-MS-1723
66
FTS
WP2300 05/2005 • Printed in Germany
ELECTRICS WP2340S CA 419 (RHS) CA 417 (LHS)
HANDLE HARNESS PC/JC 406 BRS PC/JC 407 BR
FU2 AND FU2 HOLDER
INSTRUMENT PC/JC 404 KYS DB MAIN HARNESS PC/JC 202 A, B, C, D AND E TCM
PM FU1 AND FU1 HOLDER SV PS
HN
TM FPS FILTER
BATTERY TRAY
PC/JC 415 PC/JC 414 PC/JC 413 PC/JC 412 PC/JC 411 PC/JC 410
813509
HSS (R/T) RAS/LOS HNS
FU3 AND FU3 HOLDER OPT.
BD POT, FS, RS BB (SAS)
LMS P LINE BUSBAR PC / JC 101
FTS
WP2300 05/2005 • Printed in Germany
MS-4.2-1723
02 Rev. 05/05 66_A
Blank Page
MS-4.2-MS-1723
66_B
WP2300 05/2005 • Printed in Germany
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-WP2300S-GB 05/03 • Printed in Germany
MS-4.25-1723
67
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
68
MS-WP2300S-GB 05/03 •Printed in Germany
ELECTRICS Operational Features
SEM1 Traction Controller
Speed Control DANGER Jack up the truck before carrying out any repair work or troubleshooting the electrical system.
Infinately variable handset programmable speed control in both directions.
Reduced Speed Ranges There are several interdependent travel ranges with reduced speed available: slow travel (via a rotary switch contained in the tiller handle HSS), slow travel when the platform is not folded out (via the GCSR, GCSL and PLS switches) in walkie mode and an automatically reduced travel speed for loads in excess of 1,000 kg.
General
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.
M1531
Regenerative Braking Three forms of regenerative braking are available:
The programmable SEM1 impulse controller provides effective control over the driving behaviour of the truck. The truck is powered by a separate excited motor (SEM). This version has two variables for governing the motor output: field and armature current.
Precautionary Measures ●
Do not attach the controller to a battery with a different rated voltage to that of the controller (24 - 36 VDC). A higher battery voltage may destroy the MOSFETs, while a lower power supply will result in system failure.
●
Only operate the controller with special traction batteries. Do not connect to a rectifier or mains components.
●
When commissioning jack up the truck to prevent it from starting suddenly if there is a wiring error.
●
When the key switch has been turned off the filter capacitors in the controller remain charged for a few minutes. If work is performed on the controller during this time it must be disconnected from the battery (disconnect battery). Finally, to discharge the capacitors short-circuit the positive and negative terminals of the power part together over a resistance (10 - 100 Ohm, min. 5 W) for a few seconds.
MS-WP2300S 05/05 • Printed in Germany
●
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.
Anti - Roll Down Function 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. 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.
Temperature From a power part temperature of 70°C upwards the maximum current is limited in proportion to the rise in temperature. At 80°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 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.
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.
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ELECTRICS ●
Wipe the traction controller with a clean, damp cloth.
Maintenance of the SEM1 controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.
●
When everything is dry, re-connect the power cable as indicated in Fig. MS-1723-100.
WARNING
●
Torque the mounting nut (1, Fig. MS-1723-100) to 5.5 - 8 Nm.
Maintenance
The SEM1controller operates with high current. Special safety measures are therefore required.
Important: An incorrect torque can damage the board and the controller housing.
● Only properly trained personnel must carry out maintenance work.
●
Re-connect the control lines.
● Wear safety glasses.
●
For cold store versions: coat the control line connectors with Dow Corning® 4 Compound, part no. 053051-006. Apply an acid-resistant transparent lacquer, part no. 805236-003, to the controller.
● 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. Undo the lower nut (1, Fig. MS-1723100).
1 2 3 4 5
MS-1723-100
MS-WP2300S 05/05 • Printed in Germany
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ELECTRICS Replacing the SEM1 Traction Controller
●
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.
●
For cold store versions: coat the control line connectors with Dow Corning® 4 Compound, part no. 053051-006. Paint the controller with an acidresistant clearseal paint.
WARNING A WP2300S must only be operated with a SEM1 traction controller, part no 81309xxxx. ● Using the SEM1 traction controllers from the WP2000S series (with different part numbers) can change the operating characteristics and hence result in accidents. When you fit a new SEM1 traction controller with part no. 81309x-xxx in a WP2300S the controller identifies the truck model and automatically loads the correct settings when the truck is switched on. 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. ●
●
●
●
Preparatory Measures Power down the truck and jack it up so that the drive wheel is free (see Chapter 1).
Prepare to remove the traction controller as previously described in the Maintenance section.
●
When the truck is powered down connect the programmer to the traction controller.
Remove the 4 mounting screws and remove the traction controller.
●
Power up the truck.
When installing a new traction controller: Check the part no. to make sure the new traction controller is the right one for this truck.
Setting 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 E11-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).
WP2300S, fixed platform WP2300S, fixed platform, F/C WP2300S, folding platform WP2300S, folding platform, F/C
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 Corning® 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.
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Parameter Setting after Replacing the Traction Controller
●
813195-001 813195-002 813196-001 813196-002 ●
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.
MS-WP2300S 05/05 • Printed in Germany
ELECTRICS WARNING Do not exceed the maximum permissible speeds when carrying out the following adjustments as described below.
7.
With the truck unladen, set the maximum slow travel speed in walkie mode (CUTBACK SPEED) (folded platform only). Now set the maximum slow travel speed for rider mode (CUTBACK SPEED 1).
8.
With the truck unladen, set the maximum "Forward" (MAX SPEED FRW W ) and "Reverse" (MAX SPEED BCK W) speeds in walkie mode (folding platform only). Note: The maximum permissible speed is 6 km/h unladen.
9.
With the truck unladen, set the maximum "Forward" (MAX SPEED FRW RU) and "Reverse" (MAX SPEED BCK RU) speeds for rider mode. Note: The maximum permissible speed is 10 km/h unladen.
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.
10. Apply the maximum load to the truck. Now record the maximum speed in walkie mode again (folding platform only) and then in rider mode. The maximum permissible speed with the maximum load in walkie mode is 6 km/h, in rider mode max. 7 km/h. 11. Release Brake Pattern Setting: Drive the unladen truck at maximum speed and release the travel switch. Repeat the test with the maximum permissible load. If necessary adjust the braking pattern (RELEASE BRAKING). 12. Adjusting the braking pattern when reversing direction: Carry out this setting first in walkie mode and then in rider mode. Drive the unladen truck at approx. 25% of maximum speed and apply the travel switch in the opposite travel direction until it reaches the stop. Adjust the braking pattern so that the delay effect is gentle (INVERSION BRAKING). Now repeat the test at maximum speed. Adjust the setting until the delay effect is gentle in both speed ranges and the optimum effect is achieved. Repeat the process in both operating modes with the maximum permissible load. Preference should be given to the optimum setting with the truck unladen. 13. Adjust, where necessary, the time taken to change direction. To do this change the AUX TIME DELAY parameter. MS-WP2300S 05/05 • Printed in Germany
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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
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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 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
I M A X B R A K IN G A C C E L . M A X S P . S .P .I S .P .II B Y P A S S
P A R A M . 2
T E S T E R 3
S A V E
4
R E S T O R E 5
B .R E V E R S E C O M P E N S : R .B R A K E S P E E D I S P E E D II S P E E D III F IE L D W E A K ..
V .P O T . I M O T V .B A T T . T E M P . V . M O T V M N .M O T . M .S W .T E S T
A L A R M S 6
7
Alpha-numeric LCD display 2 lines @ 16 characters
A C C E L E R A T O R M O T O R D A T A
1 3
5
R O L L R O L L
E N T E R O U T
P A R A M S E T
2 4
6
Operating Keys
M0274d
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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 SEM1 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.
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.
Menu Functions CONFIG 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.
The Configuration menu is used to set the operation of the hourmeter and the safety reverse switch. In addition, the "Adjustments" sub-menu allows for calibration between the battery voltage measured by the controller and the actual battery voltage.
SET MODEL sub-menu is reserved for future use. BATTERY ON/OFF must be OFF , if a Curtis BDI is used.
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ELECTRICS Menu Structure for Folded Platform STARTROUTINE
PARAMETER CHANGE
TEST
ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERSION BRAKING CUTBACK SPEED MAX SPEED FORW W MAX SPEED BACK W CUT BACK SPEED 1 MAX SPEED FRW RU MAX SPEED BCK RU CREEP SPEED
BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT VMN TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH HANDLE/SEAT SWITCH QUICK INVERSION PRESSURE SWITCH CUTBACK SWITCH WALKIE SWITCH BATTERY CHARGE
BATTERY ON/OFF
MS-WP2300S 05/05 • Printed in Germany
ALARMS
PROGRAM VACC
CODE H, N°, °C
VACC SETTING
CONFIG
SET MODEL
SET OPTIONS
ADJUSTMENTS
NOT AVAILABLE
HOURS: RUNNING / KEY ON QUICK INVERSION: BELLY / TIMED QUICK INVERSION ON/OFF
ADJUST BATTERY
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ELECTRICS Menu Structure for Fixed Platform STARTROUTINE
PARAMETER CHANGE
TEST
ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERSION BRAKING FTS BRAKING CUT BACK SPEED 1 MAX SPEED FRW RU MAX SPEED BCK RU CREEP SPEED
BATTERY VOLTAGE MOTOR VOLTAGE MOTOR CURRENT FIELD CURRENT VMN TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH HANDLE/SEAT SWITCH QUICK INVERSION PRESSURE SWITCH CUTBACK SWITCH WALKIE SWITCH BATTERY CHARGE
BATTERY ON/OFF
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ALARMS
PROGRAM VACC
CODE H, N°, °C
VACC SETTING
CONFIG
SET MODEL
SET OPTIONS
ADJUSTMENTS
NOT AVAILABLE
HOURS: RUNNING / KEY ON QUICK INVERSION: BELLY / TIMED QUICK INVERSION ON/OFF
ADJUST BATTERY
MS-WP2300S 05/05 • Printed in Germany
ELECTRICS Parameter Setting, Folded Platform The settings in this table apply only to traction controllers with part nos. 813196-xxx and software version SW#006B.
PARAMETER CHANGE Menu, folded platform, SW#006B Menu item
Setting range
Recommended setting
ACCELER DELAY
1.15 - 3.00 sec
2
Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when 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
6
Inversion braking. Activated when transmitter (butterfly switch) is set to the opposite direction. Time taken for the motor current to fall to zero.
2
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)) in walkie mode. Again, the entire mechanical control range of the transmitter is available. Enables more sensitive travelling at reduced speed.
6
Max. forward speedin walkie mode: 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 speedin walkie mode: 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.
8
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)) in rider mode. Again, the entire mechanical control range of the transmitter is available. Enables more sensitive travelling at reduced speed.
CUTBACK SPEED
MAX SPEED FRW W
MAX SPEED BCK W
CUTBACK SPEED 1
30 - 100 % ACC
100 - 75 % FCN
100 - 75 % FCN
30 - 100 % ACC
Description
E06-1-GB
MS-WP2300S 05/05 • Printed in Germany
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ELECTRICS Parameter Setting, Folded Platform The settings in this table apply only to traction controllers with part nos. 813196-xxx and software version SW#006B.
PARAMETER CHANGE Menu, folded platform, SW#006B Menu item
CREEP SPEED
MAX SPEED FRW RU
MAX SPEED BCK RU
Setting range
6.5 - 11 % V Batt.
100 - 30 % FCN
100 - 30 % FCN
Recommended setting
Description
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.
8
Max. forward speedin rider mode: 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.
8
Max. reverse speed in rider mode: 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. E06-2-GB
Parameter Setting, Fixed Platform The settings in this table apply only to traction controllers with part nos. 813195-xxx and software version SW#105
PARAMETER CHANGE Menu, fixed platform, SW#0105 Menu item
Setting range
Recommended setting
ACCELER DELAY
1.15 - 3.00 sec
2
Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when 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.
Description
E06-3-GB
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ELECTRICS Parameter Setting, for Trucks with a Folded Platform The settings in this table apply only to traction controllers with part nos. 813196-xxx and software version SW#006B. Valid for WP2335S and WP2340S.
PARAMETER CHANGE Menu, folded platform, SW#006B Menu item
CREEP SPEED
MAX SPEED FRW RU
MAX SPEED BCK RU
Setting range
6.5 - 11 % V Batt.
100 - 30 % FCN
100 - 30 % FCN
Recommended setting
Description
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.
8
Max. forward speedin rider mode: 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.
8
Max. reverse speed in rider mode: 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. E06-2-GB
Parameter Setting, for Trucks with a Fixed Platform The settings in this table apply only to traction controllers with part nos. 813195-xxx and software version SW#105 Valid for WP2335S and WP2340S.
PARAMETER CHANGE Menu, fixed platform, SW#0105 Menu item
Setting range
Recommended setting
ACCELER DELAY
1.15 - 3.00 sec
2
Acceleration delay. The time taken for the traction controller to increase the output supply to the traction motors from 0 to 100% (when 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.
Description
E06-3-GB
MS-WP2300S-GB 05/03 • Printed in Germany
MS-4.5-1723
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Blank Page
Printed in Germany
80_B
ELECTRICS PARAMETER CHANGE Menu, fixed platform, SW#105 Menu item
Setting range
Recommended setting
INVERSE BRAKING
0-9
6
Inversion braking. Activated when transmitter (butterfly switch) is set to the opposite direction. Time taken for the motor current to fall to zero.
8
Release braking with foot safety switch: activated when the foot safety switch is released. Time taken for the motor voltage to drop to zero. A setting of 9 achieves the maximum motor braking effect and the mechanical brake is also applied with a shorter time delay.
8
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.
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 speed: 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.
FTS BRAKING
CUTBACK SPEED 1
MAX SPEED FRW RU
MAX SPEED BCK RU
CREEP SPEED
0-9
30 - 100 % ACC
100 - 75 % FCN
100 - 75 % FCN
6.7 - 11 %V Batt.
Description
E06-4-GB
MS-WP2300S-GB 05/03 • Printed in Germany
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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 "Brake" (BRS) 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.
PRESSURE SWITCH
Tests the operation of the load dependent "Pressure" (PS) switch). Displays the open (OFF, load < 1.2to) and closed (ON, load > 1.2to).
CUTBACK SWITCH
Tests the operation of the "Fast / Slow" (FS) switch. Displays the open (OFF) and closed (ON) status.
WALKIE SWITCH
Tests the operation of the "series connection" of (GCSR, GCSL, PLS) switches. Displays the open (OFF) and closed (ON) status of this circuit. Only available with folded platform!
BATTERY CHARGE
Displays the battery charge status as a percentage. E07-GB
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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
Star t 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 star t 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 star t sequence entered by user. - Tiller main board faulty.
CAPACITOR CHARGE
Test during auto-diagnostic function on power-up. If the capacitors have not star ted 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
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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 EV ER
E09-GB
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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 70°C. The maximum current is reduced in propor tion to the rise in temperature. At 80°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
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ELECTRICS Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu It is always necessary to calibrate the traction pod potentiometer when: ●
the traction pod potentiometer has been replaced or,
●
the traction controller has been replaced.
●
The display shows the new minimum and maximum value and an arrow for the selected travel direction.
●
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.
With the WP2300S there is no need to physically adjust the potentiometer and the travel switch as is the case with the WP2000S.
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. M1610
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ELECTRICS ADJUSTMENTS
CONFIG Menu The CONFIG menu provides access to the SET OPTIONS, ADJUSTMENTS and SET MODEL sub-menus.
SET MODEL
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 parameter is reserved for future use.
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 NOT AVAILABLE
Description This parameter is reserved for future use.
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.
QUICK INVERSION ON/OFF
Safety reverse switch in platform mode switched on or off.
ADJUSTMENTS
ADJUST BATTERY
Battery voltage recorded by the controller is adjusted to the actual battery voltage. Compensates the voltage drop via the wiring and the key switch.
BATTERY CHECK
ON/OFF
Must be set to OFF if a Cur tis BDI (standard for all trucks) is used.
SET OPTIONS
E11-GB
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ELECTRICS Traction Controller Safety Test
●
Power up the truck. The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.
●
Switch off the truck and remove the test lead from F1 (the other end remains connected to -BATT).
●
Attach test lead to F2 (item 3).
●
Power up the truck. The programmer should display VFIELD NOT OK. Activating the transmitter should have no effect.
The traction controller safety test takes the form of a Pulse Monitor Trip Test (PMT). In accordance with EU Norm PREN 1175-1 the following test must be carried out to check the fuse circuit. The test requires a test lead of approx. 1 mm2 diameter and a 10A fuse. ●
Switch off the truck and jack it up.
●
Connect one end of the test lead to -BATT.
●
Switch off the truck, remove the test lead completely, remove the programmer.
●
Connect the other end of the test lead to VMN (item 1 in Fig. 805980_6).
●
When the truck is switched on again and the transmitter activated, the traction motor should start.
●
If the test proves unsuccessful, replace the traction controller.
●
Connect the programmer to the traction controller.
●
Power up the truck. The programmer should display CAPACITOR CHARGE. Activating the transmitter should have no effect.
●
Switch off the truck and disconnect the test lead from VMN (the other end remains connected to -BATT).
●
Attach test lead to F1 (item 2).
Test lead 1
FU 10A 2
3
Traction Controller +BATT
F1
VMN F2
A2
F2
-BATT
F1
A1 TM Line +
PM
FU1 125A BD:1
24V BATT.
P
BD:2 805980_6
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ELECTRICS Troubleshooting
CA 200
Platform Logic Controller PN 815144 WP2300S Platform Logic Box, M502 Total Pins: 20 Used Pins: 11 The Truck has THREE modes of operation: 1 – Walkie Mode 2 – Rider Mode 3 – No Drive Mode
PLATFORM LOGIC
2901 +BV
1
+BV(AK)
2925 GCSR
2
GCSR INPUT
2929 GCSL
3
GCSL INPUT
2928 PLS
4
PLS INPUT
2933 BRS 2912 DIODE BLOCK-2 UNUSED
5
BRS INPUT
6
UNUSED
UNUSED
7
UNUSED
2922 SAS
8
SAS INPUT
UNUSED
9
UNUSED
503 DIODE BLOCK-1
10
BATT NEG
UNUSED
11
UNUSED
2920 CONTROLLER A-8
12
RIDER OUTPUT
2932 CONTROLLER B-5
13
SAS OUTPUT
UNUSED
14
UNUSED
UNUSED
15
UNUSED
UNUSED
16
UNUSED
2919 CONTROLLER A-5
17
BRS OUTPUT
UNUSED
18
PS1 INPUT
UNUSED
19
UNUSED
2903 +BV (CONTROL)
20
CODE: +BV
uC
Walkie Mode: 1 – All three Inputs are low a – Input Pin 2, GCSR is low AND b – Input Pin 3, GCSL is low AND c – Input Pin4, PLS is low 2 – Side restrains are low and PLS is high a – Input Pin 2, GCSR is low AND b – Input Pin 3, GCSL is low AND c – Input Pin4, PLS is high
814990-7_2A
Rider Mode: 1 – Pin 12 is high when: a – Input Pin 2, GCSR is high AND b – Input Pin 3, GCSL is high AND c – Input Pin4, PLS is high No Drive Mode: If the truck is not in Walkie or in rider mode, then it is NO DRIVE MODE: a – Pin 12, Rider mode, is low b – Pin 17, BRS output (A5) is low SAS output: Pin 13 is only high when: a – SAS Input Pin 8 is high AND b – Input Pin 2, GCSR is low AND c – Input Pin 3, GCSL is low AND d – Input Pin4, PLS is low BRS output (A5): Pin 17 is high when BRS Input Pin 5 high AND The truck is in Walkie / Rider Mode Code: Pin 20 is connected to BATT NEG +BV (AK) Pin 1 is connected to +BV (AK) BATT NEG Pin 10 is connected to BATT NEG
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M1.0-0000-00094 88_B
ELECTRICS probably have been thermally overloaded. Thermal overloading (temperatures >160 ºC) causes the brushes to swell up. Brushes which jam in the brush support produce intense sparking and destroy the collector.
Electric Motors General Maintenance Instructions The following instructions apply to all motors. Details relating to specific models and designs are provided in the sub-sections (traction motor, pump motor etc.).
●
The brush edges must not be cracked. Brushes with cracking along the long edge of the surface will have been damaged by a worn collector. If information is provided in the manual, restore the collector to the specified limits. Otherwise, replace the armature in full.
●
Loose brush connections are a clear sign of motor overload. In this case inspect the collector for burning and repair or replace as necessary.
●
When fitting the brush take care to place the spring gently on the brush. If the contact is too hard the brush will be damaged.
●
Make sure that all brushes contact the armature at the same pressure.
●
New brushes must be run in with a medium load in the first hours. Never fully charge the motor straight away.
Preparation ●
Disconnect the battery (= EMERGENCY DISCONNECT).
●
Secure the truck from rolling away.
Important Maintenance Instructions ●
Remove all carbon brushes and check for wear. If one or more carbon brushes need to be replaced, replace all brushes. In addition to the carbon brushes the pressure springs must also be replaced to ensure the correct pressure. The length of the shortest brush determines whether the brush set needs to be replaced. Even if the minimum length has not been reached the brushes should be replaced as the remaining useful life could be much shorter than the time until the next inspection: If a brush is too short the spring will lie on the brush support. The brush sparks during operation and burns the collector with corresponding damage.
●
Blast the motor with dry compressed air only.
●
Check the armature for uneveness, burning, grooves and cracking of the multi-plate edges. Turn the armature if necessary. A non-oily, evenly distributed layer on the brush surfaces is normal.
●
If oil or grease is found in the motor collector compartment (usually a paste consisting of oil, oil vapour, dust and carbon particles), immediately remove the cause and clean the motor thoroughly: Oil or grease burns in the brush sparks and leaves behind a highly abrasive oil ash which can very quickly destroy the collector and the brushes.
●
The brushes must be able to move freely in the brush support (without spring tension) without tilting. Never modify brushes if one or more brushes cannot move freely. In this case replace all brushes as they will
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ELECTRICS Traction Motor Maintenance
M1570
Carbon brush
Armature ●
A new armature has a max. diameter of 64.5 mm.
●
The armature can be overwound provided the remaining diameter is no less than 61.5mm.
●
The armature must be replaced if the diameter is 60.5mm or less.
●
After overwinding cut the mica down to a depth of 0.5 mm without changing the gap width between the multi-plates.
●
The multi-plate edges must be carefully deburred.
Bearings M1569
Access to Brushes ●
Disconnect the battery
●
Prevent the truck from rolling away.
●
Remove the tensioning belt from the motor.
●
The ball bearings are maintenance-free. They must always be replaced if removed for repair work.
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.
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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
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.
M1522
●
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.
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BRAKE
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M1.0-0000-000100 94 M1.0-0000-000100
BRAKE Brake Brake fastening screws on the drive motor (3 off)
M1462
Removal CAUTION Do not bring brake components into contact with oil or grease. 17
17
M0195-1
MS-WP2300 04/03 • Printed in Germany
Reference numbers in brackets refer to Figure M01951. ●
Disconnect the battery (EMERGENCY DISCONNECT).
●
Jack up the truck until the drive wheel is free. Support the truck and prevent it from rolling away.
●
Remove the front panel.
●
Blow away any brake dust.
●
Undo the electrical connection (CA407) for the brake wiring (20).
●
Unscrew the three Allen screws (3).
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BRAKE ●
Measure the thickness of the rotor (16). Replace the rotor if it is less than the minimum permissible thickness of 6.0 mm (new rotors are 10 mm thick).
●
Unscrew the friction plate (18) from the motor flange. New friction plates are 1.0 mm thick. Replace if necessary.
●
Unscrew the screws (8) from their respective nuts.
●
Remove the banjo bolts (17) from the magnetic body (3 off).
●
Remove the armature plate (14).
●
Thoroughly clean and de-grease the parts.
Test and Inspection
17
Remove the magnetic body (7) from the motor (including everything connected to it).
Disassembly ●
Remove the rotor (16) from the hub (15). Take care not to damage the gear teeth.
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Check the armature plate (14), friction plate (18) and rotor (16) for signs of even wear, deep grooving, cracking and burning. Replace any worn or damaged components.
●
Check the crimp connections of the brake wiring in connector CA407 for loose or broken wires. Replace any damaged crimp connections.
●
Check the coils of the magnetic body (7) with an ohmmeter. To do this, on connector CA407 measure between ... CA407-1 and CA407-2 (BR/1): 10,5 ± 1 Ohm CA407-3 and CA407-4 (BR/2): 33 ± 3 Ohm Replace the magnetic body if the resistance recordings of a coil lie outside the tolerance range.
●
Check the sealing compound (insulating compound) which secure the coils in the magnetic body for cracks. Replace the magnetic body in the event of cracking.
17
M0195-1
●
●
Assembly ●
If the pressure parts (11) and springs (12) have fallen out of the magnetic body (7), insert them again: first the springs, then the pressure parts.
●
Insert the spring (10) and bushing (13) into the magnetic body (7).
●
Position the armature plate (14) correctly on the magnetic body, while noting carefully the hole pattern.
MS-WP2300 04/03 • Printed in Germany
BRAKE ●
●
Using a medium strength screw sealant screw the banjo bolts (17) into the magnetic body (7) as far as the stop. Insert the screws (8) into the armature plate so far that a gap of at least 1mm remains all around between the armature plate and the magnetic body.
Air Gap Setting The operating air gap is measured between the magnetic body and the armature plate when the truck is braked. Set the air gap to 0.25 mm (see Fig. M1467). ●
Unscrew the banjo bolts (3) as far as the fixed stop on the friction plate (18).
●
Screw the friction plate (18) onto the motor.
●
Torque the Allen screws (3) evenly to 9.5 Nm.
●
Push the rotor (16) onto the hub (15). Ensure that the gear teeth are not damaged in the process.
●
Test the working air gap at several points around the circumference using a feeler gauge. The air gap must be the same all the way around.
●
Fasten the pre-assembled magnetic body (7) to the motor with the Allen screws (3).
●
To increase the air gap slightly unscrew the banjo bolts (17). To reduce the air gap screw the banjo bolts (17) into the magnetic body (7). Then remeasure as described above.
●
When the air gap has been correctly set, torque the Allen screws (3) again to 9.5 Nm.
●
Re-fit the electrical connector (20).
Assembly Re-assemble the brake in the reverse order of removal.
CAUTION After assembly it is essential to set the air gap correctly, test the braking distance (see following page) and if necessary set the brake moment.
Fastening screw Banjo bolt Operating air gap Rotor thickness
M1467
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De-energised brake
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BRAKE If necessary turn up the nose of the retaining sheet and change the brake moment using the outer ring until the braking distance is within tolerance when the truck is empty (see Table B0 1S-GB) .Now fix the outer ring again using the retaining sheet.
Brake Moment Setting Inner ring
Outer ring
NOTE If the max. travel speed is the same with or without nominal load, the load-dependent pressure switch is either faulty or incorrectly set. The braking distance will also be much too long. In this case check the load-dependent pressure switch before adjusting the 2nd brake stage (See Chapter 2, HYDRAULICS)
Retaining Sheet M1535
The brake moment can be set separately for the first and second stages. Screw the outer ring into the magnetic body to increase the moment of the first stage (BR/1). Screw in the inner ring to increase that of the second stage. The settings are pre-set, determined by the retaining elements (retaining sheet for first stage and retaining screw for the second stage). Intermediate settings are not possible, as the retaining elements must remain effective.
After setting the 1st stage test the brakes with maximum load. If necessary, remove the retaining screw (4, Fig. M0195-1) from the inner ring and using the threaded ring (6) change the brake moment until the braking distance (see Table B0 1S-GB) is within the tolerance range with maximum load. Now secure the inner ring again using the screw (4) and washer (5).
The default settings can be found in table B0 1S-GB (screw depth A).
Testing the Brakes ●
On a level, dry concrete surface with sufficient grip accelerate the unladen truck, at operating temperature with a fully charged battery, up to maximum speed.
●
Set the control handle to the lower brake zone.
●
Record the braking distance from the point of brake activation to the time when the truck comes to rest.
M0195-1
WP2300S Nominal Braking Distances and Screw Depth Model
2330 2335
Capacity
2.000 kg
Screw Depth A
Inner ring = 6.6 mm Outer ring = 6.4 mm
Braking Distance (new brake)
Braking Distance (used brake)
Laden (nominal load)
Unladen
Laden (nominal load)
Unladen
1.95 - 2.05 m
1.85 - 1.95 m
1.85 - 1.95 m
1.75 - 1.85 m B01-S-GB
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STEERING
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STEERING Multitask Handle - Springs for Return Function 1
CAUTION Pre-tensioned springs! When removing, take care to avoid injury.
8 2
Before carrying out any work on the tiller: ●
Remove the battery connector (EMERGENCY STOP).
●
Block the truck.
3
7
Adjustment
4 5
The axle (4) is fitted as standard on the left hand side with a tensioning pin (5). If the spring pressure reduces over time the spring pre-tension (2) can be increased as follows: ●
Unscrew the panel (1) and push it up.
●
Leave the tiller (8) in the rest position (up).
●
Drive out the tensioning pin (2) on the left-hand side.
●
Using a face spanner (3) turn the axle (3) as far as necessary. Drive in the tensioning pin (2) on the right-hand side.
●
6
M1562
If the spring tension is still not sufficient to keep the tiller up, replace the springs.
Removal ●
Unscrew the panel (1) and push it up.
●
Bring the tiller (8) to its highest position and keep it there.
●
Mark the position of the axle (3).
●
Drive out the tensioning pin (2). The relieved springs should now turn the axle.
●
Tilt the tiller down to its lowest position.
●
If the axle (3) has still not turned, it is clearly fixed in its position and must be moved with the aid of a face spanner. To fully relieve the springs, rotate the axle (3), seen from the left hand side, approx. 20° anticlockwise from the fixed position.
MS-WP2300 04/03 • Printed in Germany
●
Drive the axle (3) as far out to the right hand side so that the 2 springs (4) can be removed.
Assembly ●
Push the springs (4) onto the axle (3). The inner, offset end must insert into the axle (3) groove. A strap wrapped around the inner end of the first spring to be inserted can prove useful when inserting the other springs.
●
Drive the axle (3) into position.
●
Set the tiller (8) to the upper limit.
●
Drive in the tensioning pin on the left-hand side (if necessary on the right). Turn the axle as far as necessary. Grease the springs. Fasten the panel. Check the brakes.
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STEERING Control Handle Grip Main Components This section contains an overview of the main components and associated terms:
Upper shell
Control handle tube
Switch unit
Grip MS518
Lower shell
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STEERING Hand grip component removal and assembly
Hand Grip Shells Upper and lower shell removal
To access the individual components of the hand grip you will require: Torx® screwdriver set and a small flat bladed screwdriver.
CAUTION Short circuit danger! De-energise the truck (disconnect the battery) and prevent it from being switched on again. Unless otherwise stated, all screws must be torqued to the standard rating. See chapter 1 of this manual for the torque table.
A ●
MS513
Remove the four Torx® screws (A, Fig. MS513).
C
B
MS514
●
Press the thumb markings (B, Fig. MS514) on the switch unit or pull on the thumbwheels (C). The switch unit will slide up out of the lower shell.
●
Disconnect the plug connections from the control handle wire harness and the horn switches from the switch unit printed circuit boards.
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STEERING
A MS501
●
Remove the inner Torx® screws (A) and pull off the grips (see Fig. MS501).
MS502
●
Using a small flat bladed screwdriver lever off the cover on each hand grip (see Fig. MS502). C
C MS503
●
Gently press in the horn switch until pull it out of the grip (see Fig. MS503). Disconnect the plug connection from the switch. MS517
B
●
Remove the two Torx® screws (B) and the six Torx® screws (C) (see Fig. MS517). Lift out the shells.
Upper and lower shell assembly Assembly is the reverse of disassembly. When assembling, take care not to damage the wiring.
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STEERING ●
Switch Unit Disassembly The switch unit contains the safety reverse switch, the travel switch, the “rabbit/turtle” switch, the main PC board and the pump controller PC board. Replacing any of these components requires the switch unit to be replaced.
Disconnect the plug connections of the control handle wire harness and the horn from the switch unit PC boards.
Switch unit assembly Assembly is always the reverse of disassembly. Make sure you re-connect the control handle wire harness and the horn wiring. The connectors cannot be interchanged and are protected against incorrect polarity. Guide the switch unit over the two side parts (C, Fig. MS514) and push the switch unit down and forward. Tighten the mounting screws (A, Fig. MS513). Test all the functions once the battery has been re-connected.
A ●
MS513
Remove the 4 Torx® screws (A, Fig. MS513). B
C
A
MS514
●
Press the thumb markings (B, Fig. MS514) on the switch unit or pull on the thumbwheels (B). The switch unit will slide up out of the bottom shell.
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STEERING Assembly
“Rabbit/Turtle” toggle switch There are no parts on this switch module that can be repaired. It must be replaced in full.
●
Insert a new toggle module and fix it with 2 Torx® screws.
This switch module is available in two versions: a standard and a cold store version. Make sure you use the right module!
●
Refit the switch unit (see SWITCH UNIT section in this chapter). Test the operation.
B MS504
Hydraulic PC board A MS511
Disassembly ●
●
Remove the switch unit (see SWITCH UNIT section in this chapter). Remove the two Torx® screws (A) (see Fig. MS511) and remove the toggle module.
There are no parts on this PC board that can be repaired. It must be replaced in full. This PC board is available in two versions: a standard and a cold store version. Make sure you use the right circuit board!
Disassembly ●
Remove the switch unit (see SWITCH UNIT section in this chapter).
●
Remove the two Torx® screws (B) (see Fig. MS504) from the smaller of the two PC boards (the larger one is the main PC board). Lift out the hydraulic PC board.
Assembly ●
Insert a new hydraulic PC board (make sure it is the right type, cold store or standard). Fix the board with 2 Torx® screws (B).
●
Refit the switch unit (see SWITCH UNIT section in this chapter). Test the operation.
WP2300S 05/2005 • Printed in Germany
MS-6.2-1723
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107
Blank page
Printed in Germany
107_A
STEERING ●
Main PC Board Removal/Installation This PC board is available in two versions: a standard and a cold store version. Make sure you use the right PC board!
INFORMATION
Remove the two (A) Torx® screws from the larger, main PC board (the smaller one is the hydraulic PC board). Disconnect safety reversing switch lead connector from main PC board and remove board.
To install, reverse removal procedures.
Because of the compact design, it may be somewhat difficult to access the connector on the main PC board through this process. If you experience difficulties replacing the board using above procedures, remove thumb wheels, lower cover and control handle cap cover (see Traction Potentiometer Assembly in this section). There are no parts on this board that can be repaired. It must be replaced in full. ●
Remove control handle cap (see Control Handle Cap in this section).
●
Disconnect potentiometer connector from main PC board.
Main PC Board
A
10682
WP2300S 05/2005 • Printed in Germany
MS-6.2-1723
02 Rev. 05/05
107_B
STEERING Potentiometer
C
There are no parts on the potentiometer that can be repaired. It must be replaced in full. The potentiometer is available in two versions: a standard and a cold store version. Make sure you use the right potentiometer!
A
MS509
C ●
B
Remove the four Torx® screws (C) shown in Fig. MS509. Remove the switch unit cover.
MS508
D
Disassembly ●
Remove the switch unit (see SWITCH UNIT section in this chapter).
●
Remove the two Torx® screws (A) (see Fig. MS508) from the thumbwheels and disconnect the thumbwheels. Take care not to lose the plastic slide bearings (washers).
●
Remove the two Torx® screws (B) holding the orange lowering switch cap. Lift out the switch cap.
MS510
●
Remove the two Torx® screws (D) shown in Fig. MS510. Remove the connectors from the PC boards. Pull the potentiometer off the square axis.
Assembly ●
Before connecting the cable to the potentiometer: Fill the potentiometer bushing with grease part no. 053002-005. Do not use any other grease.
Potentiometer assembly is the reverse of disassembly.
MS-6.2-1723
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02 Rev. 05/05
108
STEERING ●
Safety Reverse Switch Disassembly
Remove the two Torx® screws (B) holding the orange lowering switch cap. Lift out the switch cap.
D
A
E F MS500 MS508
B ●
Remove the switch unit (see SWITCH UNIT section in this chapter).
●
Remove the two Torx® screws (A) (see Fig. MS508) from the thumbwheels and disconnect the thumbwheels. Take care not to lose the plastic slide bearings (washers).
●
Remove the four Torx® screws shown in Fig. MS509. Remove the switch unit cover.
INFORMATION The thumbwheels cannot be incorrectly positioned. They will only fit correctly in one position. ●
Remove the Torx® screw (item D, Fig. MS500) and pull out the switch bypass (item E).
●
Remove the two Torx® screws item F). Disconnect the microswitch from the main PC board.
C
Assembly ●
Assemble the safety reverse switch in the reverse order of disassembly.
●
Before connecting the microswitch to the main PC board: Lubricate the microswitch connector with grease part no. 053002-005. Do not use any other grease.
●
Refit the switch unit (see SWITCH UNIT section in this chapter) and test the operation.
MS509
C
WP2300S 05/2005 • Printed in Germany
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02 Rev. 05/05
109
STEERING Assembly
INFORMATION The thumbwheels cannot be incorrectly positioned. They will only fit correctly in one position.
INFORMATION The switches on the LH and RH grips are different. If you fit the switch on the wrong side the horn symbol will be upside down! Assemble the horn switch in the reverse order of disassembly. ●
Refit the switch unit (see SWITCH UNIT section in this chapter) and test the operation.
MS502
Horn switch Disassembly
MS503
●
Remove the switch unit (see SWITCH UNIT section in this chapter).
●
Using a small flat bladed screwdriver lever off the hand grip cover (see Fig. MS502).
●
Gently press in the horn switch until pull it out of the grip (see Fig. MS503). Disconnect the plug connection from the switch.
MS-6.2-1723
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02 Rev. 05/05
110
STEERING Hand Grip Disassembly ●
Remove the switch unit (see SWITCH UNIT section in this chapter).
MS501
Assembly INFORMATION The switches on the LH and RH grips are different. If you fit the switch on the wrong side the horn symbol will be upside down! Assemble the hand grip in the reverse order of disassembly. ●
MS502
Refit the switch unit (see SWITCH UNIT section in this chapter) and test the operation.
MS503
●
Using a small flat bladed screwdriver lever off the hand grip cover (see Fig. MS502).
●
Gently press in the horn switch until pull it out of the grip. Disconnect the plug connection from the switch (see Fig. MS503).
●
Unscrew the inner Torx® screw (see Fig. MS501) and pull the hand grip off.
WP2300S 05/2005 • Printed in Germany
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02 Rev. 05/05
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MS-6.2-1723
112
WP2300S 05/05 • Printed in Germany
LIFTING MECHANISM
Printed in Germany
113
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Printed in Germany
114
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 ± 5 mm 85-3 mm
+3
85 -3 mm
MS1723-701 WP2300S 05/2005 • Printed in Germany
MS-7.1-1723
M1.0-0000-000123 115
LIFTING MECHANISM
Loadwheel, tandem
M1438 MS-7.1-1723
116
WP2300S 05/2005 • Printed in Germany
LIFTING MECHANISM Lift Limit Cutout Lift Limit Cutout Setting ●
Fully lower the forks.
●
Raise the forks from this postion without rated load.
●
Check the lift height at the fork tip (see previous page). If the lift height lies outside the tolerance range, check the mechanical setting of the lift linkage and adjust if necessary.
●
If the mechanical setting of the lift linkage is correct and the lift height is still outside the tolerance range, move the lift limit switch (LMS) into the elongated holes until the lift limit cutout (pump no longer operates) takes place at a lift height of 130 mm ± 5 mm.
Limit switch fitted for lift cut-out at 130 mm
Upper hole: Limit switch location for max. lift = 150 mm
Trip cam
Track
M1473
Elongated hole for fine adjustment of lift cut-out point WP2300S 05/2005 • Printed in Germany
MS-7.1-1723
M1.0-0000-000125 117
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118
CYLINDERS
Printed in Germany
119
Blank Page
Printed in Germany
M1.0-0000-000128 120 M1.0-0000-000128
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.
WP2300S 05/2005 • Printed in Germany
MS-8.1-1723
M1.0-0000-000129 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
M1.0-0000-000130 122
WP2300S 05/2005 • 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.
WP2300S 05/2005 • 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
M1.0-0000-000131 123
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124
PLATFORM
Printed in Germany
125
Blank Page
Printed in Germany
126 M1.0-0000-000134 M1.0-0000-000134
PLATFORM Folding Platform
●
Remove the panel (23).
●
The brake arm (11) and the brake lining (12) brake the platform (1) when it swings up. Turn in the screw (14) to increase the friction, turn it out to reduce it.
●
Adjust the braking effect so that the platform can swing up by itself, with the damping effect, from any position. The critical point is a platform angle of approx. 45 degrees above the horizontal position.
Mechanical Setting WARNING This is a critical setting. The platform must always swing up whenever the driver leaves the truck. The platform switch is actuated and the maximum travel speed reduced.
M1550 MS-WP2300S 05/03 • Printed in Germany
MS-9.0-1723
M1.0-0000-000135 127
PLATFORM Platform Switch Setting (PLS) The switch sends a signal to the traction controller. This causes the traction controller to switch to a higher max. travel speed for platform mode when the platform folds down. The switch lever for the platform switch (21) is activated via the adjusting ring (3). A screw (4) on the shaft (10) prevents the adjusting ring from twisting.
●
Remove the panel (23).
●
Loosen the screw (4).
●
With the platform lowered twist the adjusting ring (3) so that the switch is activated. Actuation must occur between 0 degrees (fully lowered platform) and max. 10 degrees for the raised platform. The switch must not be activated above 10 degrees. Now tighten the screw (4) again and check the setting.
WARNING This is a critical setting. The platform must always swing up whenever the driver leaves the truck. The PLS must then be actuated within 10 degrees.
M1550 MS-9.0-1723
M1.0-0000-000136 128
MS-WP2300S 05/03 • Printed in Germany
PLATFORM Platform Suspension Plate Spring Layers To achieve optimal lifespan and spring quality of the platform, layer the plate springs with 6 sets of 3 springs and one set of 2 springs.
MS1720-101
MS-WP2300S 05/03 • Printed in Germany
MS-9.0-1723
M1.0-0000-000137 129
PLATFORM Side Gates, Mechanical Setting ●
Remove the panel (10)
●
The setting of the brake (5) determines the manual force required to fold the side gates in or out. Turn in the screw (12) to increase the force, turn out to reduce it.
●
Adjust the brake so that the gates can be handled with medium manual force.
M1546
MS-9.0-1723
M1.0-0000-000138 130
MS-WP2300S 05/03 • Printed in Germany
PLATFORM Fixed Platform WP2335S Replacing the Safety Switch ●
Remove screw (A).
●
Raise the upper section of the platform (B) and remove the safety switch plug connection.
●
Remove the upper section of the platform. Remove the safety switch (C).
C
B
MS-1723-901
A
B MS-1723-900
WP2300S 05/2005 • Printed in Germany
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PLATFORM Fixed Platform WP2340S Replacing the Safety Switch ●
Remove screw (A=15).
●
Raise the upper section of the platform (B) and remove the Safety Switch plug connection.
●
Remove the upper section of the platform. Remove the Safety Switch (29).
3 4 7 2
6 8
5
3 3
4
4
6
6 7 8
9
1
10 12
18
B
17 11
19
C
15 =A 14
35 34
36
35
38 13
24 24 26
34
C
16
35 43
23
44
45
31
24
Entry Bar (34)
23
21
25
41 42
28
33 32 22
21
29
MS-9.0-1723
45
44 31
41 42
22
FPS 1 & FPS 2 (29) MS-1723-003 WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 M1.0-0000-000140 131_A
39
30
20 31
24
20
27
24
28
24 26
24
43
25
40
38
37
27
24
PLATFORM Fixed Platform WP2340S Replacing Switches below the Entry Bars (FPS 1 & FPS 2)
3
●
Remove screws (A=15).
●
Raise upper platform section (B) and disconnect the plug connection to the platform switches.
●
Remove the upper platform section. Remove the switch (44).
When assembling, ensure that the switch is not damaged by the mechanical elements.
4 7 2
6 8
5
3 3
4
4
6
6 7 8
9
1
10 12
18
B
17 11
19
C
15 =A 14
35 34
36
35
38 13
24 24 26
34
C
16
35 43
23
44
38
31
24
24
23
28
45
44 31
41 42
21
22
30 33
20
FPS 1 & FPS 2 (29)
32
31
Entry Bar (34)
39
20 26 25
27
24
28
24
41 42
43 24
25
40 45
37
27
24
22
21
29
MS-1723-003
WP2300S 05/2005 • Printed in Germany
MS-9.0-1723
02 Rev. 05/05 M1.0-0000-000141 132_A
Blank Page
132_B
ELECTRICAL DIAGRAMS
Printed in Germany
133
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Printed in Germany
134
Blank Page
Printed in Germany
135
DIAGRAMS Notes to overall wiring diagram, standard version, folded platform, WP2330S Key: 1
Walkie mode GCSR &/ or PLS &/or GCSL open
2
Forks above 130 mm; LMS open
3
Load < 1000 kg; PS closed, 2/3 brake force
4
Reduce speed: HSS open
5
Active: RAS, BRS, SAS, HNS & LOS closed
6
An SAS signal is required to produce a travel signal from the FS and RS drivers.
7
Diagnostic LED. Remove to connect programmer.
8
Voltage between B1 and B2 (traction controller) 10 v = Full speed 0 v = No command
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 136
146
DIAGRAMS Overall Wiring Diagram, Standard, Folded Platform, WP2330S
( ) Colours in brackets correspond to the old revision pre-August 2003
201
202 KYS COMM +BV
203 JC404-7 BDI +BV
FU2 10A
2901 PC404-2 BDI +BV (AK)
TCM SEM1
KYS 2
202 KYS COMM +BV c
FU1 160A
A 1
5900 PC404-1 TT
2
2902 +BV (AK)
3
5903 BATT NEG
4
5904 BATT NEG
6 7
BD:1
8
CA 202
LMS 2917
2927
5905
D4
5902 PC407-2 BATT NEG
2923 PC407-1 BRS SIG 001 JC 406-3 BRS SIG 500 PC 404-5 BATT NEG 2904 JC103-2 +BV (AK) 002 PC 406-2 +BV (AK) BRS 2920 JC102-2 PL SIG
5
+BATT
A1
2916 PC404-3 RAS SIG
2928 PC407-1 BRS SIG 2
2921 2911
D2
4
D1
D3
506 PC 407-4 BATT NEG
1
3
1
002 PC415-4 RAS SIG
2919 LOS SIG
2
003 PC415-5 LOS SIG
2908 C1 +BV (AK)
3
001 PC415-2 +BV(AK)
2913 HNS SIG
4
004 PC410-10 HNS SIG
2922 NOT USED
5
012 PC415-7 NOT USED
504 P- BATT NEG
6
013 PC410-1 BATT NEG
5
5
CA 404
2924 PC407-3 BRS / PS SIG
CURTIS 803 "COMBI"
TM F1
+
1
BRN (010) PC410-7 POT SIG
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS SIG
5
GREY/PINK (005) PC410-2 SAS SIG
6
YEL (008) PC410-3 FS SIG
PS
F1
C
2908 JC202-3 +BV (AK)
1
2909
2
2921 PS SIG
3
WHT/GRN (006) PC414-3 R/T (HSS) SIG
+
RED
-
LINE
3 2910
PM
505 P-
POT CIRCUIT & DRIVER
5903
VMN
2909
24V BATTERY
A2
8 2911 PS SIG
B
FAN
BD:2
504 JC202-6 505 DB(1)
UNUSED
2
2912 HNS SIG
3
501 BATT NEG
4
2914 RAS SIG
5
502 BATT NEG
6
2918 LOS SIG
+
-
-
2915 PC404-4 RAS SIG
+
1
+ RXD
2
RXD NEG
3
+ TXD
4
TXD NEG
5
BATT NEG
6
+ BV (AK)
7
UNUSED
8
UNUSED
+ -
SV
+
2915 RAS SIG
4
500 A6 BATT NEG
5
BATT NEG
UNUSED
6
UNUSED
203 KYS COMM
7
BDI
UNUSED
8
UNUSED
UNUSED 2927 D4 002 A7 +BV (AK)
1
RED
2
BLK
001 A5 BRS SIG
3
WHT
UNUSED
4
UNUSED
-
CA 407 2928 DIODE BLOCK (2) BRS SIG
2
BLU
2924 DIODE BLOCK (5) BRS / PS SIG
3
BLK
506 DIODE BLOCK (1) BATT NEG
4
BLK
2961 PC414-1 +BV(AK) VIO (002) PC202-1 RAS SIG PINK (003) PC202-2 LOS SIG
GREY/PINK (005) B-5 SAS SIG YEL (008) B-6 FS SIG
3 4
RAS
5
LOS
BLK (007) B-4 RS SIG
1
POT
2
1 2 3
UNUSED
FS
5
BR/2
BR
-
5
6
5961 PC415-8 NOT USED
6
RED (012) PC202-5 NOT USED
7
BRN (010) B-1 POT SIG
7
5961 PC410-6 NOT USED
8
BLU (011) B-2 POT LOW
8 9
GRAY (004) PC202-4 HNS SIG
10
3
BLK GRAY
1
BLU
SAS
261 PC415-6 NOT USED
11
2961 PC415-3 +BV(AK)
1
5962 PC414-4 NOT USED
12
1 2
UNUSED
2
WHT/GRN (006) C-3 R/T (HSS) SIG
3
5962 PC410-12 NOT USED
4
4 5 6
4
BLK
2903
3
WHT
4
UNUSED
GCSL 1
UNUSED
1
RED
2920 A8 PL SIG
2
BLK
2906 PL SIG
3
WHT
UNUSED
4
UNUSED
PLS 1
CA 417 2
CA 414
SAS 5 1
CA 413
3
RED
2
CA 102
CA 412
2
2962 PC415-1 +BV(AK)
1
RS
6
4
261 PC410-11 NOT USED
HSS
+
ACS
4
6
HYDRAULIC PCB
BR/1
-
2906
UNUSED
7
RED/BLU (009) B-3 POT HIGH
5
+
CA 101 CA 410
2
BLK
5902 DIODE BLOCK (4) BATT NEG
3
WHT (001) PC202-3 +BV(AK)
1
503
7
GRN (013) PC202-6 BATT NEG
BRS 5
-
2919 JC202-2 LOS SIG
CA 415 1
3
P
CA 411
2961 PC410-9 +BV(AK)
KYS
2916 RAS SIG
CA 406
HN
1
E
-BATT
TT
2
+
BLK
F2
1
2901 BDI +BV (AK)
2913 JC 202-4 HNS SIG
D F2
5900 A1 TT
2904
HNS1
2903 2902 2901
MAIN PCB
CA 103
5 1
HNS1
1
CA 419 2 1
HNS2 HNS2
5 1
UNUSED
1
RED
2904 A7 +BV (AK)
2
BLK
2903 PL SIG
3
WHT
UNUSED
4
UNUSED
GCSR 1
813202-Standard_Folded_Rev2B R/T SWITCH
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 137
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT
WP2330S STANDARD, FOLDED PLATFORM SCHEMATIC DIAGRAM
TCM SEM1
2903 PC200-20
FS
2901 PC200-1 BDI
3
5
5
SAS
2 5
5
BR LARGE COIL LINE
TT 1 KYS 2
A
2900 PC404-2 BDI
1
5900 PC404-1 BDI
2
2902
3
5904
4
5902 DIODE BLOCK (4)
5
2918 PC200-17
6
UNUSED 2932 JC406-2 BRS 2919 JC103-2 GCSR 2920 PC200-12
7
2
c
INSTRUMENT CURTIS 803 "COMBI"
LOS
HSS
MAIN PCB
8
RAS
4
HYDR. PCB
1
R/T PCB
BR SMALL COIL
5
LMS
8
8
KYS
200 PC404-7 BDI 203 FU2 OUT +BV
LINE
3
2930
BRS
HNS 1
DIODE BLOCK
HNS 2
D4
c
9
POT
RS
2921
PS 3
4
BDI
7
UNUSED
8
8
FAN
POT CIRCUIT & DRIVER
PLS
1 HN
1
10 5
2
3
4
20 1
8
10
17
PS
B
1
P
1
BRN (010) PC410-7 POT WIPER
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS
5
2933 PC210-2
6
YEL (008) PC410-3 FS
C
2914 JC202-3 +BV (AK)
1
2921
2
2909 DIODE BLOCK (3)
3
WHT/GRN (006) PC414-3 HSS
2910 DIODE BLOCK (3)
6
GCSR
5
UNUSED
GCSL
BATT NEG
SV
13
12
6
5
4
3 D
2
1
3
2 C
1
6
8
7
6
5
E 4
3
2
-BATT
1
5
3
4
TCM (SEM 1)
FAN
F2
VMN
F1
B
2
1
8
7
6
5
4
3
+BATT
A
2
1
9
2906 PC404-4 +BV 7 F2
A2
KYS
F1
D
2915 JC 202-4
1
UNUSED
2
2916
3
505
4
2907
5
506
HN
A1 TM 8 FU2 10A
LINE
+
P PM
FU1 160A BD:1
24V BATT
BD:2
NOTE: 1- Walkie Mode: GCSR&/or PLS &/or GCSL open. 2- Forks lower than 130mm: LMS closed. 3- Load is less than 1000kg: PS closed, 2/3 brake. 4- Reduce speed: HSS is open. 5- Active: RAS, BRS, SAS, HNS & LOS are closed. 8- Diode Block Pin 1, BDI (BATT NEG), Main PCB (Earth contact), connected to Pump Contactor Contacts. 9- Diode Block Pin 3 connected to Controller C-2.
6
2917
P SV
507
2913 JC202-2
814990-1_2A.pdf
814990-2_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 138
148
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM PLATFORM CIRCUIT
WP2330S STANDARD, FOLDED PLATFORM TRACTION CONTROLLER - SEM1 POWER CIRCUIT
CA 101 203 KYS IN
204 JC202-5 NOT USED
201
FU1 160A
TCM SEM1
FU2 10A
202
FU3 not mounted
RED
2927
2
BLK
2929 PC200-3
3
WHT
4
UNUSED
BD:1
A2
KYS +BV IN TO THE LOGIC
2
LINE CONTACTOR LOW
3
BRAKE LOW (large coil)
4
BRS INPUT
5
BATTERY NEG
6
BATTERY POS (AK)
7
WALKIE/RIDER MODE
8
POT WIPER
B 1
POT LOW
2
POT HIGH
3
RS - REVERSE SWITCH IN
4
SAS SAFETY SWITCH IN
5
2926
1
RED
FS - FORWARD SWITCH IN
6
2919 CONTROLLER A7 +BV (AK)
2
BLK
C 1
2925 PC200-2
3
WHT
BATTERY POS (AK) PERF.CUT
2
4
UNUSED
PERF. 1/2,HSS (R/T) INPUT
3
VMN
TM F2
+
HOUR METER OUTPUT
A 1
+BATT
A1
BD:2
1
GCSL LINE
24V BATTERY
2926
CA 102 1
RED
2927
2
BLK
2928 PC200-4
3
WHT
4
UNUSED
PLS
CA 103
GCSR
NOTE: GCSL, PLS & GCSR are shown in walkie mode.
F1 D
PM
UNUSED
1
HN - HORN HIGH
2
HN - HORN LOW
3
P - PUMP CONTACTOR HIGH
4
P&SV-P CONTACTOR LOW
5
SV - LOWERING VALVE HIGH
6
DIODE BLOCK
501 PC407-4 BR LOW 502 P CONTACTOR CONTACTS 503 PC200-10 2911 PC407-1 BRAKE
D1 1
D2 2
2912 PC200-5 F1
P
F2
E
POSITIVE SERIAL RECEPTION
1
NEGATIVE SERIAL RECEPTION
2
POSITIVE SERIAL TRANSMISSION
3
NEGATIVE SERIAL TRANSMISSION
4
BATT NEG
5
BATTERY POS (AK)
6
UNUSED
7
UNUSED
8
2910 PS
D4
504 JC202-6 500 PC404-5
NOTE: 1- Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND
3
5902 CONTROLLER A-4 5903 PC407-2 5901
4
2908 PC 407-3
5
2904 JC406-3 BRS-5
-BATT 502 DIODE BLOCK (1)
D3
2909 CONTROLLER C-2
814990-3_2A.pdf
814990-4_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 139
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM CONTROL HANDLE CIRCUIT
WP2330S STANDARD, FOLDED PLATFORM POWER UNIT CIRCUIT CA 202 2905 PC404-3 BDI
2934
CA 411 CA 410
VIO (002) PC415-4 RAS
1
LMS 2913 SV HIGH
1
GRAY/PINK (005) B-5 SAS
2
3
WHT (001) PC415-2 +BV(AK)
3
POT
2
PINK (003) PC415-5 LOS
2
2914 CONTROLLER C1
GRN (013) PC202-6
1
YEL (008) B-6 FORWARD
3
BLK (007)B-4 REVERSE
4
2915 HN HIGH
4
GRAY (004) PC410-10 HN
204 +BV FU3 OUT
5
RED (012) CA415-7 +BV F/C
RED/BLU (009) B-3 POT HIGH
5
504 P CONTACTOR CONTACTS
6
GRN (013) CA410-1 BATT NEG
5961 PC415-8 NOT USED
6
BRN (010) B- POT SIGN
7
POT
4
FS
5
RS
6 7
CA 412 3
GRAY
1
BLU
2
CA 404
INSTRUMENT
BLU (011) B-2 POT LOW
8
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HN
10
261 PC415-6 NOT USED
11
5962 PC414-4 NOT USED
12
CA 413 1
CURTIS 803 "COMBI" 5900 CONTROLLER A1 TT
1
TT
2900 KYS NO + BV(AK)
2
KYS
2905 LMS OUT NC +BV
BLK
CA 417 2
2
3
SAS
SAS
HNS1
1
3
2904
4
2903
5
2902
2
6
2901
1
HNS CA 419 HNS2 HNS
MAIN PCB
2906 P CONTACTOR COIL
4
500 P CONTACTOR CONTACTS
5
BATT NEG
UNUSED
6
UNUSED
2962 PC410-9 +BV(AK)
1
200 KYS +BV
7
BDI
WHT (001) PC202-3 +BV(AK)
2
UNUSED
8
UNUSED
2961 PC414-1 +BV(AK)
3
VIO (002) PC202-1 LMS
4
PINK (003) PC202-2 SV HIGH
5
261 CA410-11 NOT USED
6
RED (012) CA202-5 NOT USED
7
5961 PC410-6 NOT USED
8
CA 415
CA 406 UNUSED
1
RED
2904 DIODE D4 2932 CONTROLLER A-7
2
BLK
2931 PC200-5
3
WHT
UNUSED
4
UNUSED
HYDRAULIC PCB
CA 414
LARGE COIL
1
BLK
5903 DIODE BLOCK (4)
2
BLU
2908 DIODE BLOCK (5)
3
BLK
501 DIODE BLOCK (1)
4
BLK
LOS
BRS
CA 407 2911 DIODE BLOCK (2)
RAS
SMALL COIL
2961 PC415-3 +BV(AK)
1
UNUSED
2
WHT/GRN (006) CONTROLLER C-3
3
5962 PC410-12 NOT USED
4
BR
HSS
R/T PCB 814990-5_2A.pdf
814990-6_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 140
150
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM PLATFORM LOGIC CA 200
PLATFORM LOGIC
2901 +BV
1
+BV(AK)
2925 GCSR
2
GCSR INPUT
2929 GCSL
3
GCSL INPUT
2928 PLS
4
PLS INPUT
2933 BRS 2912 DIODE BLOCK-2 UNUSED
5
BRS INPUT
6
UNUSED
UNUSED
7
UNUSED uC
2922 SAS
8
SAS INPUT
UNUSED
9
UNUSED
503 DIODE BLOCK-1
10
BATT NEG
UNUSED
11
UNUSED
2920 CONTROLLER A-8
12
RIDER OUTPUT
2932 CONTROLLER B-5
13
SAS OUTPUT
UNUSED
14
UNUSED
UNUSED
15
UNUSED
UNUSED
16
UNUSED
2919 CONTROLLER A-5
17
BRS OUTPUT
UNUSED
18
PS1 INPUT
UNUSED
19
UNUSED
2903 +BV (CONTROL)
20
CODE: +BV
814990-7_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 141
DIAGRAMS Notes to overall wiring diagram, standard version, fixed platform WP2330S Key:
MS-DIA-1723
Walkie-mode GCSR &/ or PLS &/or GCSL open
2
Forks above 130 mm, LMS open
3
Load < 1000 kg PS closed, 2/3 brake
4
Reduce speed: HSS open
5
Active: RAS, BRS, SAS, HNS & LOS closed
6
Electronic thermal switch, applies earth for F/C HR when temperature < +5°C.
7
An SAS signal is required for a travel signal from the FS and RS drivers.
8
Diagnostic LED. Remove to connect the programmer.
9
Voltage between B1 and B2 (traction controller) 10 v = Full speed 0 v = No command
10
Heating for travel switch module
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 142
1
152
DIAGRAMS Overall Wiring Diagram, Folded Platform with Options WP2330S
( ) Colours in brackets correspond to the old revision pre-August 2003
205 +BV F/C HR 202 KYS COMM +BV
203 JC404-7 BDI +BV 2
2901 PC404-2 BDI +BV (AK)
TCM SEM1
LMS
KYS 202 KYS COMM +BV c
FU1 160A
A 1
5900 PC404-1 TT
2
2902 +BV (AK)
3
5903 BATT NEG
4
5904 BATT NEG
6
BD:1
2916 PC404-3 RAS SIG 2927
5905
D4
5902 PC407-2 BATT NEG
2923 PC407-1 BRS SIG 001 JC 406-3 BRS SIG 500 PC 404-5 BATT NEG 2904 JC103-2 +BV (AK) 002 PC 406-2 +BV (AK) BRS 2920 JC102-2 PL SIG
5
+BATT
A1
7 8
2925
FU2 10A
2926
201
204
FU3 2A
2928 PC407-1 BRS SIG 2
2921 2911
D2
4
D1
D3 3
506 PC 407-4 BATT NEG
1
CA 202 2917
1
002 PC415-4 RAS SIG
2919 LOS SIG
2
003 PC415-5 LOS SIG
2908 C1 +BV (AK)
3
001 PC415-2 +BV(AK)
2913 HNS SIG
4
004 PC410-10 HNS SIG
205 +BV F/C HR
5
012 PC415-7 +BV F/C HR
504 P- BATT NEG
6
013 PC410-1 BATT NEG
5
5
CA 404
2924 PC407-3 BRS / PS SIG
CURTIS 803 "COMBI"
TM F1
+
BRN (010) PC410-7 POT SIG
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS SIG
5
GRAY/PINK (005) PC410-2 SAS SIG
6
YEL (008) PC410-3 FS SIG
3
PS 2910
-
+
2908 JC202-3 +BV (AK)
1
2909
2
2921 PS SIG
3
WHT/GRN (006) PC414-3 R/T (HSS) SIG
RED
PM
LINE
F1
C
505 P-
1
POT CIRCUIT & DRIVER
5903
VMN
2909
24V BATTERY
A2
9 2911 PS SIG
B
BD:2 UNUSED
2
2912 HNS SIG
3
501 BATT NEG
4
2914 RAS SIG
5
502 BATT NEG
6
2918 LOS SIG
+
-
-
2915 PC404-4 RAS SIG
+
E
-BATT 504 JC202-6 505 DB(1)
1
+ RXD
2
RXD NEG
3
+ TXD
4
TXD NEG
5
BATT NEG
6
+ BV (AK)
7
UNUSED
8
UNUSED
+ -
SV
+
-
4
RAS
5
LOS
5
261 PC410-11 +BV F/C HR
6
CA 416
RED (012) PC202-5 +BV F/C HR
7
1
15 x //R
2
8
8
1
3
5962 PC410-12 COMM F/C HR
4
BDI
UNUSED
8
UNUSED
UNUSED 2927 D4 002 A7 +BV (AK)
1 2
BLK
001 A5 BRS SIG
3
WHT
UNUSED
4
UNUSED
GRAY/PINK (005) B-5 SAS SIG
2
4
YEL (008) B-6 FS SIG
3
5
BLK (007) B-4 RS SIG
4
BRS 5
1
BLK
5902 DIODE BLOCK (4) BATT NEG
2
BLU
2924 DIODE BLOCK (5) BRS / PS SIG
3
BLK
506 DIODE BLOCK (1) BATT NEG
4
BLK
+
BR/1
+
BR/2
5
BR
-
RED/BLU (009) B-3 POT HIGH
5
5961 PC415-8 LOW HR
6
BRN (010) B-1 POT SIG
7
7
BLU (011) B-2 POT LOW
8
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HNS SIG
10
261 PC415-6 +BV HR
11
5962 PC414-4 COMM F/C HR
12
UNUSED
BLK GRAY
1
BLU
SAS
6
SAS 5
CA 413 2
MAIN PCB F/C
2 x //R
2
BLK
2903
3
WHT
4
UNUSED
GCSL 1
UNUSED
1
RED
2920 A8 PL SIG
2
BLK
2906 PL SIG
3
WHT
UNUSED
4
UNUSED
PLS 1
1
CA 417
1
6
2906
CA 102
3
5
RED
RS
CA 412
4
1
ACS FS
6
4
HSS
RED
2928 DIODE BLOCK (2) BRS SIG
POT
2
1
15 x //R 1 2
UNUSED
7
CA 101
3
WHT/GRN (006) C-3 R/T (HSS) SIG
6
203 KYS COMM
UNUSED
2
CA 414
UNUSED
UNUSED
2919 JC202-2 LOS SIG
2
HYDRAULIC PCB F/C
2961 PC415-3 +BV(AK)
BATT NEG
7
PINK (003) PC202-2 LOS SIG
5961 PC410-6 COMM F/C HR
HR POT F/C
VIO (002) PC202-1 RAS SIG
10
5
3
16 x //R
3
4
500 A6 BATT NEG
503
GRN (013) PC202-6 BATT NEG
BLK
2
2961 PC414-1 +BV(AK)
3
2915 RAS SIG
CA 407
CA 410
RED
WHT (001) PC202-3 +BV(AK)
2916 RAS SIG
P
CA 415 1
KYS
-
CA 411
2962 PC410-9 +BV(AK)
2
CA 406
HN
1
BLK
P
TT
2901 BDI +BV (AK)
+
FAN
F2
1
2913 JC 202-4 HNS SIG
D F2
5900 A1 TT
2904
HNS
2903 2902 2901
CA 103
5
HNS1
1
CA 419 2 1
HNS2 HNS
5
UNUSED
1
RED
2904 A7 +BV (AK)
2
BLK
2903 PL SIG
3
WHT
UNUSED
4
UNUSED
GCSR 1
1
813202-Options_Folded_Rev2B
R/T PCB F/C 1
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 143
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT
WP2330S OPTIONS, FOLDED PLATFORM SCHEMATIC DIAGRAM
TCM SEM1
11
2903 PC200-20
POT PCB F/C
2901 PC200-1 BDI
FS
5
5
SAS
5
BR SMALL COIL BR LARGE COIL
5 LOS
11
11
TT 1 KYS 2
F/C
2900 PC404-2 BDI
1
5900 PC404-1 BDI
2
2902
3
5904
4
5902 DIODE BLOCK (4)
5
2918 PC200-17
6
UNUSED 2932 JC406-2 BRS 2919 JC103-2 GCSR 2920 PC200-12
KYS
200 PC404-7 BDI 203 FU2 OUT +BV
LINE
11
7
2
c
LINE
HYDR. PCB
HSS F/C
R/T PCB
INSTRUMENT CURTIS 803 "COMBI"
F/C
MAIN PCB
8
RAS
4
A
8
LMS
8
2930
BRS
HNS 1
DIODE BLOCK
HNS 2
D4
c
9
POT
RS
2921
PS 3
3 4
7
UNUSED
8
1
BRN (010) PC410-7 POT WIPER
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS
5
2933 PC210-2
6
YEL (008) PC410-3 FS
9
C
2914 JC202-3 +BV (AK)
1
2921
POT CIRCUIT & DRIVER
FAN
PLS
1 HN
1
10 5
PS
B
1
2 3
4
2910 DIODE BLOCK (3)
BDI
8
2
6
GCSL
UNUSED
GCSR
5
BATT
20 1
8
10
17
P
SV
13
6
5
4
3 D
2
1
3
C
1
6
TM 8 FU2 10A
LINE
+
P PM
FU1 160A BD:1
24V BATT
BD:2
WHT/GRN (006) PC414-3 HSS
8
7
6
5
E 4
3
2
-BATT
1
5
3
4
TCM (SEM 1)
F1
A1
FU2 2A
2909 DIODE BLOCK (3)
3
2906 PC404-4 +BV
7 F2
A2
KYS
2
FAN
F2
VMN
F1
B
2
1
8
7
6
5
4
3
+BATT
A
2
1
12
NOTE: 1- Walkie Mode: GCSR + GCSL + PLS open. or GCSR + GCSL open + PLS closed. 2- Forks lower than 130mm: LMS closed. 3- Load is less than 1000kg: PS closed, 2/3 brake. 4- Reduce speed: HSS is open. 5- Active: RAS, BRS, SAS, HNS & LOS are closed. 8- Diode Block Pin 1, BDI (BATT NEG), Main PCB (Earth contact), connected to Pump Contactor Contacts. 9- Diode Block Pin 3 connected to Controller C-2. 11- F/C Package: Below 5°C active.
D
2915 JC 202-4
1
UNUSED
2
2916
3
505
4
2907
5
506
6
2917
HN
P SV
507
2913 JC202-2
814991-1_2A.pdf
814991-2_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 144
154
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM PLATFORM CIRCUIT
WP2330S STANDARD, FOLDED PLATFORM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT 204 JC202-5 +BV F/C
FU1 160A
HOUR METER OUTPUT LINE
BD:1
A2
F2
+
BD:2
2
LINE CONTACTOR LOW
3
BRAKE LOW (large coil)
4
BRS INPUT
5
BATTERY NEG
6
BATTERY POS (AK)
7
WALKIE/RIDER MODE
8
POT WIPER
B 1
POT LOW
2
POT HIGH
3
RS - REVERSE SWITCH IN
4
SAS SAFETY SWITCH IN
5
FS - FORWARD SWITCH IN
6
BATTERY POS (AK)
C 1
PERF.CUT
2
PERF. 1/2,HSS (R/T) INPUT
3
VMN
TM
A 1
KYS +BV IN TO THE LOGIC
+BATT
A1
24V BATTERY
CA 101
TCM SEM1
FU2 10A
201
FU3 2A
202
F/C
203 KYS IN
PM F1
P
HN - HORN HIGH
2
HN - HORN LOW
3
P - PUMP CONTACTOR HIGH
4
P&SV-P CONTACTOR LOW
5
SV - LOWERING VALVE HIGH
6
RED
2927
2
BLK
2929 PC200-3
3
WHT
4
UNUSED
CA 102 1
RED
2927
2
BLK
2928 PC200-4
3
WHT
4
UNUSED
2926
1
RED
2919 CONTROLLER A7 +BV (AK)
2
BLK
2925 PC200-2
3
WHT
4
UNUSED
DIODE BLOCK
501 PC407-4 BR LOW 502 P CONTACTOR CONTACTS 503 PC200-10 2911 PC407-1 BRAKE
D1 1
D2 2
E
POSITIVE SERIAL RECEPTION
1
NEGATIVE SERIAL RECEPTION
2
2909 CONTROLLER C-2
POSITIVE SERIAL TRANSMISSION
3
2910 PS
NEGATIVE SERIAL TRANSMISSION
4
5902 CONTROLLER A-4 5903 PC407-2 5901
4
2908 PC 407-3
5
5
BATTERY POS (AK)
6
UNUSED
7
UNUSED
8
GCSR
NOTE: GCSL, PLS & GCSR are shown in walkie mode.
F2
BATT NEG
PLS
CA 103
D 1
1
GCSL
F1 UNUSED
2926
2912 PC200-5
D4
D3 3
-BATT 502 DIODE BLOCK (1)
504 JC202-6 500 PC404-5
NOTE: 1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND.
814991-3_2A.pdf
2904 JC406-3 BRS-5
814991-4_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 145
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM CONTROL HANDLE CIRCUIT
WP2330S OPTIONS, FOLDED PLATFORM POWER UNIT CIRCUIT CA 202
CA 411
2905 PC404-3 BDI
2934
1
VIO (002) PC415-4 RAS
2913 SV HIGH
2
PINK (003) PC415-5 LOS
GRN (013) PC202-6
1
2914 CONTROLLER C1
3
WHT (001) PC415-2 +BV(AK)
GRAY/PINK (005) B-5 SAS
2
4
2915 HN HIGH
4
GRAY (004) PC410-10 HN
YEL (008) B-6 FORWARD
3
5
BLK (007)B-4 REVERSE
4
RED/BLU (009) B-3 POT HIGH
5
5961 PC415-8 GND F/C
6
BRN (010) B- POT SIGN
7
CA 410
1
LMS
POT
2 3
204 +BV FU3 OUT
RED (012) CA415-7 +BV F/C
5
504 P CONTACTOR CONTACTS
FS RS
6 7
GRN (013) CA410-1 BATT NEG
6
POT P
CA 412 3
GRAY
1
BLU
2
CA 404
5900 CONTROLLER A1 TT 2900 KYS NO + BV(AK)
1 2
INSTRUMENT
BLU (011) B-2 POT LOW
8
CURTIS 803 "COMBI"
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HN
10
261 PC415-6 +BV F/C
11
5962 PC414-4 GND F/C
12
TT KYS
3
2906 P CONTACTOR COIL
4
500 P CONTACTOR CONTACTS
5
BATT NEG
UNUSED
6
UNUSED
2962 PC410-9 +BV(AK)
1
200 KYS +BV
7
BDI
WHT (001) PC202-3 +BV(AK)
2
UNUSED
8
UNUSED
2961 PC414-1 +BV(AK)
3
VIO (002) PC202-1 LMS
4
PINK (003) PC202-2 SV HIGH
5
261 CA410-11 +BV F/C
6
RED (012) CA202-5 +BV F/C
7
5961 PC410-6 GND F/C
8
SAS
SAS
CA 413
CA 417
1
2
2
15 x //R
2905 LMS OUT NC +BV
BLK
HNS1
1
3
2904
HNS
4
2903
5
2902
2
6
2901
1
CA 419 HNS2 HNS
MAIN PCB
CA 415
CA 406 UNUSED
1
RED
2904 DIODE D4 2932 CONTROLLER A-7
2
BLK
2931 PC200-5
3
WHT
UNUSED
4
UNUSED
BRS
BLK
5903 DIODE BLOCK (4)
2
BLU
2908 DIODE BLOCK (5)
3
BLK
501 DIODE BLOCK (1)
4
BLK
CA416 1
0R
2
RED BLK
16 x //R POT PCB F/C
HYDRAULIC PCB F/C
CA 414
LARGE COIL
1
LOS
15 x //R
CA 407 2911 DIODE BLOCK (2)
RAS
2961 PC415-3 +BV(AK)
1
UNUSED
2
WHT/GRN (006) CONTROLLER C-3
3
5962 PC410-12 GND F/C
4
HSS
2 x //R SMALL COIL
BR
R/T PCB F/C
814991-5_2A.pdf
814991-6_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 146
156
DIAGRAMS WP2330S STANDARD, FOLDED PLATFORM PLATFORM LOGIC
CA 200
PLATFORM LOGIC
2901 +BV
1
+BV(AK)
2925 GCSR
2
GCSR INPUT
2929 GCSL
3
GCSL INPUT
2928 PLS
4
PLS INPUT
2933 BRS 2912 DIODE BLOCK-2 UNUSED
5
BRS INPUT
6
UNUSED
UNUSED
7
UNUSED
2922 SAS
8
SAS INPUT
UNUSED
9
UNUSED
503 DIODE BLOCK-1
10
BATT NEG
UNUSED
11
UNUSED
2920 CONTROLLER A-8
12
RIDER OUTPUT
2932 CONTROLLER B-5
13
SAS OUTPUT
UNUSED
14
UNUSED
UNUSED
15
UNUSED
UNUSED
16
UNUSED
2919 CONTROLLER A-5
17
BRS OUTPUT
UNUSED
18
PS1 INPUT
UNUSED
19
UNUSED
2903 +BV (CONTROL)
20
CODE: +BV
uC
814990-5_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937 WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 147
DIAGRAMS Notes to overall wiring diagram, Standard Version, Fixed platform WP2335S Key:
MS-DIA-1723
No drive: FTS open
2
Forks above 130 mm, LMS open
3
Load < 1000 kg PS closed, 2/3 brake
4
Reduce speed: HSS open
5
Active: RAS, BRS, SAS, HNS & LOS closed
6
An SAS signal is required for a travel signal from the FS and RS drivers.
7
Diagnostic LED. Remove to connect the programmer.
8
Voltage between B1 and B2 (traction controller) 10 v = Full speed 0 v = No command
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 148
1
158
DIAGRAMS Overall Wiring Diagram, Standard, Fixed Platform WP2335S
( ) Colours in brackets correspond to the old revision pre-August 2003
201
202 KYS COMM +BV
203 JC404-7 BDI +BV
FU2 10A
2901 PC404-2 BDI +BV (AK)
TCM SEM1
KYS 2
202 KYS COMM +BV c
FU1 160A
A
+BATT
A1
1 2
2902 +BV (AK)
3
5903 BATT NEG
4
5904 BATT NEG
5
2923 PC407-1 BRS SIG 001 JC 406-3 BRS SIG 500 PC 404-5 BATT NEG 2904 JC103-2 +BV (AK) 002 PC 406-2 +BV (AK) BRS 2903 JC102-2 FTS SIG
7
BD:1
8
CA 202
LMS 2917
5900 PC404-1 TT
6
2916 PC404-3 RAS SIG 2927
5905
D4
5902 PC407-2 BATT NEG 2928 PC407-1 BRS SIG 2
2921 2911
D2
4
D1
D3 3
506 PC 407-4 BATT NEG
1
1
002 PC415-4 RAS SIG
2919 LOS SIG
2
003 PC415-5 LOS SIG
2908 C1 +BV (AK)
3
001 PC415-2 +BV(AK)
2913 HNS SIG
4
004 PC410-10 HNS SIG
2922 NOT USED
5
012 PC415-7 NOT USED
504 P- BATT NEG
6
013 PC410-1 BATT NEG
5
5
CA 404
2924 PC407-3 BRS / PS SIG
CURTIS 803 "COMBI"
TM F1
+
1
BRN (010) PC410-7 POT SIG
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS SIG
5
GRAY/PINK (005) PC410-2 SAS SIG
6
YEL (008) PC410-3 FS SIG
3
PS 2910
-
+
2908 JC202-3 +BV (AK)
1
2909
2
2921 PS SIG
3
WHT/GRN (006) PC414-3 R/T
RED
PM
LINE
F1
C
505 P-
POT CIRCUIT & DRIVER
5903
VMN
2909
24V BATTERY
A2
8 2911 PS SIG
B
FAN
BD:2 UNUSED
2
2912 HNS SIG
+
-
-
501 BATT NEG
4
2914 RAS SIG
5
502 BATT NEG
6
2918 LOS SIG
2915 PC404-4 RAS SIG
+
E
-BATT 504 JC202-6 505 DB(1)
KYS
2916 RAS SIG
3
2915 RAS SIG
4
500 A6 BATT NEG
5
BATT NEG
UNUSED
6
UNUSED
203 KYS COMM
7
BDI
UNUSED
8
UNUSED
CA 406
HN
1 3
TT
2
+
BLK
F2
1
2901 BDI +BV (AK)
2913 JC 202-4 HNS SIG
D F2
5900 A1 TT
1
+ RXD
2
RXD NEG
3
+ TXD
4
TXD NEG
5
BATT NEG
6
+ BV (AK)
7
UNUSED
8
UNUSED
UNUSED 2927 D4 002 A7 +BV (AK)
1
RED
2
BLK
001 A5 BRS SIG
3
WHT
UNUSED
4
UNUSED
P
+ -
SV
+
-
BRS 5
CA 407 2928 DIODE BLOCK (2) BRS SIG
1
BLK
5902 DIODE BLOCK (4) BATT NEG
2
BLU
2924 DIODE BLOCK (5) BRS / PS SIG
3
BLK
506 DIODE BLOCK (1) BATT NEG
4
BLK
503 2919 JC202-2 LOS SIG
7
+
BR/1
+
BR/2
BR
-
CA 411 CA 415
CA 410
2962 PC410-9 +BV(AK)
1
GRN (013) PC202-6 BATT NEG
1
WHT (001) PC202-3 +BV(AK)
2
GRAY/PINK (005) B-5 SAS SIG
2
1
POT
2 3
2961 PC414-1 +BV(AK)
3
YEL (008) B-6 FS SIG
3
VIO (002) PC202-1 RAS SIG
4
BLK (007) B-4 RS SIG
4
PINK (003) PC202-2 LOS SIG
5
RED/BLU (009) B-3 POT HIGH
5
RAS
LOS
5
ACS
4
FS
5
RS
6
CA 102
7
6 261 PC410-11 NOT USED
6
5961 PC415-8 NOT USE
6
RED (012) PC202-5 +BV F/C HR
7
BRN (010) B-1 POT SIG
7
5961 PC410-6 NOT USED
8
BLU (011) B-2 POT LOW
8
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HNS SIG
10
CA 412 3
GRAY
1
BLU
2
HYDRAULIC PCB
2961 PC415-3 +BV(AK)
2
5962 PC414-4 NOT USED
UNUSED
2
WHT/GRN (006) C-3 R/T (HSS) SIG
3
5962 PC410-12 NOT USED
4
11
4
12
5
4
6
HSS
MAIN PCB
1
RED
2903 A8 FTS SIG
2
BLK
2904 A7 +BV (AK)
3
WHT
UNUSED
4
UNUSED
FTS 1
CA 417
1
2
261 PC415-6 NOT USED
1
SAS
SAS 5
CA 413
3
CA 414
BLK
UNUSED
2904
HNS1
2903 2902 2901
5
HNS1
1
CA 419 2 1
HNS2
5
HNS2
813202-Standard_Fixed_Rev2B R/T SWITCH
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 149
DIAGRAMS Notes to overall wiring diagram, with options, fixed platform WP2335S Key:
MS-DIA-1723
No drive: FTS open
2
Forks above 130 mm, LMS open
3
Load < 1000 kg PS closed, 2/3 brake
4
Reduce speed: HSS open
5
Active: RAS, BRS, SAS, HNS & LOS closed
6
Electronic thermal switch, applies earth for F/C HR when temperature < +5°C
7
An SAS signal is required for a travel signal from the FS and RS drivers.
8
Diagnostic LED. Remove to connect the programmer.
9
Voltage between B1 and B2 (traction controller) 10 v = Full speed 0 v = No command
10
Heating for travel switch module
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 150
1
160
DIAGRAMS Overall Wiring Diagram, Fixed Platform with Options WP2335S
( ) Colours in brackets correspond to the old revision pre-August 2003
205 +BV F/C HR 202 KYS COMM +BV
203 JC404-7 BDI +BV 2
2901 PC404-2 BDI +BV (AK)
TCM SEM1
LMS
KYS 202 KYS COMM +BV c
FU1 160A
A 1
5900 PC404-1 TT
2
2902 +BV (AK)
3
5903 BATT NEG
4
5904 BATT NEG
6
BD:1
2916 PC404-3 RAS SIG 2927
5905
D4
5902 PC407-2 BATT NEG
2923 PC407-1 BRS SIG 001 JC 406-3 BRS SIG 500 PC 404-5 BATT NEG 2904 JC103-2 +BV (AK) 002 PC 406-2 +BV (AK) BRS 2903 JC102-2 FTS SIG
5
+BATT
A1
7 8
2925
FU2 10A
2926
201
204
FU3 2A
2928 PC407-1 BRS SIG 2
2921 2911
D2
4
D1
D3 3
506 PC 407-4 BATT NEG
1
CA 202 2917
1
002 PC415-4 RAS SIG
2919 LOS SIG
2
003 PC415-5 LOS SIG
2908 C1 +BV (AK)
3
001 PC415-2 +BV(AK)
2913 HNS SIG
4
004 PC410-10 HNS SIG
205 +BV F/C HR
5
012 PC415-7 +BV F/C HR
504 P- BATT NEG
6
013 PC410-1 BATT NEG
5
5
CA 404
2924 PC407-3 BRS / PS SIG
CURTIS 803 "COMBI"
TM
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS SIG
5
GRAY/PINK (005) PC410-2 SAS SIG
6
F1
+
BRN (010) PC410-7 POT SIG
3
YEL (008) PC410-3 FS SIG
PS
F1
C
2908 JC202-3 +BV (AK)
1
2909
2
2921 PS SIG
3
WHT/GRN (006) PC414-3 R/T (HSS) SIG
+
RED
-
LINE
2910
PM
505 P-
1
POT CIRCUIT & DRIVER
5903
VMN
2909
24V BATTERY
A2
9 2911 PS SIG
B
BD:2
FAN
P
504 JC202-6 505 DB(1)
2
KYS
2916 RAS SIG
3
2915 RAS SIG
4
500 A6 BATT NEG
5
BATT NEG
UNUSED
6
UNUSED
203 KYS COMM
7
BDI
UNUSED
8
UNUSED
UNUSED
2
2912 HNS SIG
3
501 BATT NEG
4
2914 RAS SIG
5
502 BATT NEG
6
2918 LOS SIG
+
-
-
2915 PC404-4 RAS SIG
+
1
+ RXD
2
RXD NEG
3
+ TXD
4
TXD NEG
5
BATT NEG
6
+ BV (AK)
7
UNUSED
8
UNUSED
CA 406
HN
1
E
-BATT
TT
2901 BDI +BV (AK)
+
BLK
F2
1
2913 JC 202-4 HNS SIG
D F2
5900 A1 TT
UNUSED 2927 D4 002 A7 +BV (AK)
1
RED
2
BLK
001 A5 BRS SIG
3
WHT
UNUSED
4
UNUSED
P
+ -
SV
+
-
BRS 5
CA 407 2928 DIODE BLOCK (2) BRS SIG
1
BLK
5902 DIODE BLOCK (4) BATT NEG
2
BLU
503 2919 JC202-2 LOS SIG
8
2924 DIODE BLOCK (5) BRS / PS SIG
3
BLK
506 DIODE BLOCK (1) BATT NEG
4
BLK
+
BR/1
+
BR/2
BR
-
CA 411 CA 410
CA 415
RAS
5
LOS
6
RED (012) PC202-5 +BV F/C HR
7
5961 PC410-6 COMM F/C HR
8
GRAY/PINK (005) B-5 SAS SIG
2
4
YEL (008) B-6 FS SIG
3
5
BLK (007) B-4 RS SIG
4
5961 PC415-8 LOW HR
6
BRN (010) B-1 POT SIG
7
2
BLU (011) B-2 POT LOW
8
7
CA 412 3
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HNS SIG
10
2
3
5962 PC410-12 COMM F/C HR
4
12
5962 PC414-4 COMM F/C HR
4 5 6
4
HSS
6
MAIN PCB F/C
UNUSED
1
RED
2903 A8 PL SIG
2
BLK
2904 A7 +BV (AK)
3
WHT
UNUSED
4
UNUSED
FTS 1
CA 417
1
11
261 PC415-6 +BV HR
SAS 5
CA 413
15 x //R
WHT/GRN (006) C-3 R/T (HSS) SIG
BLU
SAS
2
CA 414
2
BLK GRAY
1
3
1
CA 102
2
HYDRAULIC PCB F/C
UNUSED
RS
6
5
RED/BLU (009) B-3 POT HIGH
1
CA 416 15 x //R
2961 PC415-3 +BV(AK)
ACS FS
7
5
201 PC410-11 +BV F/C HR
HR POT F/C
4
16 x //R
3
VIO (002) PC202-1 RAS SIG PINK (003) PC202-2 LOS SIG
10
2
2961 PC414-1 +BV(AK)
POT
2
1
3
BLK
WHT (001) PC202-3 +BV(AK)
GRN (013) PC202-6 BATT NEG
1
RED
2962 PC410-9 +BV(AK)
1
2904
HNS
2903 2902 2901
5
HNS1
1
CA 419 2 1
HNS2
5
HNS
813202-Options_Fixed_Rev2B
2 x //R R/T PCB F/C
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 151
DIAGRAMS WP 2340S STANDARD TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT
WP 2340S STANDARD, FIXED PLATFORM SCHEMATIC DIAGRAM
TCM SEM1 FS RS
5 FPS1
1
DIODE BLOCK
5
D4
3
5
SAS
HNS 1
To C-2
2
BR SMALL COIL
HNS 2
BRS
4
5
RAS
5
LOS
HSS 1
A
2901 PC404-2 BDI
1
5900 PC404-1 BDI
2
2902
3
5903
4
5904 DIODE BLOCK (4) 2923 DIODE BLOCK (2) 001 BLK (2 core) JC 406-3 BRS 500 PC 404-5 BATT NEG 2903 JC101-2 +BV (AK) FTS 002 BLK (2 core) PC 406-2 BRS 2904 JC103-1 FPS2
5
BR LARGE COIL
10 9 INSTRUMENT
R/T PCB
6
HYDR. PCB
CURTIS 803 "COMBI"
7
LMS
1 MAIN PCB
LINE
2
2
8
202 FU2 OUT +BV
4 5
203 JC404-7 BDI
LINE
2909
3
KYS
1
2910
PS 3
6 FAN FPS2
HN P
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS
5
GRAY/PINK (005) PC410-2 SAS
6
YEL (008) PC410-3 FS
E
F2
C
2908 JC202-3 +BV (AK)
1
2909
2
2921 DIODE BLOCK (3)
3
WHT/GRN (006) CA414-3 HSS
6
5
4
3
8
6
5
D
2
1 3
2
1
-BATT
C
1
6
5
4
3 B
F2
F1
VMN A2
TCM (SEM 1)
1
8
7
6
5
4
3
2
10
A
2
1
+BATT KYS
BRN (010) PC410-7 POT WIPER
2
4
FTS
1
1
To DB 3
BATT NEG
PS
B
SV
POT CIRCUIT & DRIVER
3
+BV (AK) OUT NO
2
+BV
INPUT FILTER
8
7
8
2911 DIODE BLOCK (3)
7
7
F1
A1 FAN LINE FU2 10A
+
9 P PM
FU1 160A
BD:1
24V BATT
BD:2
2915 PC404-4 +BV
NOTE: 1- No Drive: FTS, FPS1 & FPS2 open. 2- Forks lower than 130mm: LMS closed. 3- Load is less than 1000kg: PS closed, 2/3 brake. Speed Unladen 10Km/h. 4- Reduce speed: HSS is open. 5- Active: RAS, BRS, SAS, HNS & LOS are closed. 9- Diode Block Pin 1 connected to P (contactor contacts). 10- Input Filter Batt Neg connected to Diode Block Pin 1
D
2913 JC 202-4
1
UNUSED
2
2912
3
501
4
2914
5
502
6
2918
HN
P SV
503
2919 JC202-2
815513-1_2B.pdf
815513-2_2B.pdf
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 152
162
DIAGRAMS WP 2340S STANDARD, FIXED PLATFORM PLATFORM CIRCUIT
WP 2340S STANDARD POWER CIRCUIT - TRACTION & PUMP MOTOR
201
FU1 160A
TCM SEM1
FU2 10A
204
FU3 2A (not mounted)
202 KYS COMM
LINE
BD:1
A2
24V BATTERY
RED
2972
2
BLK
2904 CONTROLLER A8
3
WHT
UNUSED
4
UNUSED
KYS +BV IN TO THE LOGIC
2
LINE CONTACTOR LOW
3
BRAKE LOW (large coil)
4
BRS INPUT
5
BATTERY NEG
6
BATTERY POS (AK)
7
WALKIE/RIDER MODE
8
2971
1
RED
B 1
2970
2
BLK
POT WIPER POT LOW
2
UNUSED
3
WHT
POT HIGH
3
UNUSED
4
UNUSED
RS - REVERSE SWITCH IN
4
SAS SAFETY SWITCH IN
5
FS - FORWARD SWITCH IN
6
FTS
CA 102
FPS1
CA 103 2970
1
RED
BATTERY POS (AK)
C 1
2903 CONTROLLER A7
2
BLK
PERF.CUT
2
UNUSED
3
WHT
PERF. 1/2,HSS (R/T) INPUT
3
UNUSED
4
UNUSED
F2
+
BD:2
1
A 1
VMN
TM
UNUSED
HOUR METER OUTPUT
+BATT
A1
CA 101
FPS2
+BV(AK)
F1
PM
D 1
OUT NO
UNUSED HN - HORN HIGH
2
BATT NEG
HN - HORN LOW
3
P - PUMP CONTACTOR HIGH
4
P&SV-P CONTACTOR LOW
5
SV - LOWERING VALVE HIGH
6
570
D1
506 PC 407-4 BRK SMALL
P
F2
E
POSITIVE SERIAL RECEPTION
1
NEGATIVE SERIAL RECEPTION
2
POSITIVE SERIAL TRANSMISSION
3
NEGATIVE SERIAL TRANSMISSION
4
BATT NEG
5
BATTERY POS (AK)
6
UNUSED
7
UNUSED
8
1
505 P CONTACTOR CONTACTS 2928 PC407-1 BRK LARGE
F1
+BV
INPUT FILTER
205 CA202-5 NOT USED
D2 2
2923 CONTROLLER A5 D3
2911 PS NO 2921 CONTROLLER C2
D4
3
5904 CONTROLLER A4 5902 PC407-2 BRK LARGE 5905
4
2924 PC 407-3 BRK SMALL
5
2974 2973
DIODE BLOCK
-BATT 505 Diode Block (1)
504 JC202-6
NOTE: 1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND.
815513-3_2B.pdf
WP2300S 05/2005 • Printed in Germany
2927 JC406-2
815513-4_2B.pdf
MS-DIA-1723
02 Rev. 05/05 153
DIAGRAMS WP 2340S STANDARD, FIXED PLATFORM CONTROL HANDLE CIRCUIT
WP 2340S STANDARD, FIXED PLATFORM POWER UNIT CIRCUIT 2925 LMS1 Opt.
CA 411
2926 LMS1 Opt.
CA 410
CA 202
2916 PC404-3 BDI
2917
1
VIO (002) PC415-4 RAS
GRN (013) CA202-6 BATT NEG
1 2
2919 SV HIGH
2
PINK (003) PC415-5 LOS
GRAY/PINK (005) B-5 SAS
2908 CONTROLLER C1
3
WHT (001) PC415-2 +BV(AK)
YEL (008) B-6 FORWARD
3
GRAY (004) PC410-10 HN DRIVER
BLK (007) B-4 REVERSE
4 5
4
POT
2 3
LMS
2913 HN HIGH
1
POT
4
FS
5
RS
6 7
205 FU3 OUT NOT USED
5
RED (012) CA415-7 NOT USED
RED/BLU (009) B-3 POT HIGH
504 P CONTACTOR
6
GRN (013) CA410-1 BATT NEG
5961 PC415-8 NOT USED
6
BRN (010) B-1 POT WIPER
7
BLU (011) B-2 POT LOW
8
2962 PC415-1 +BV(AK)
9
GRAY (004) PC202-4 HN
10
261 PC415-6 NOT USED
11
5962 PC414-4 NOT USED
12
CA 412 3
GRAY
1
BLU
2
CA 404
CA 413
INSTRUMENT
2901 KYS OUT
1 2
3
3
2915 P HIGH
4
500 CONTROLLER A6
5
BATT NEG
UNUSED
6
UNUSED
203 KYS IN
7
BDI
2962 PC410-9 +BV(AK)
1
UNUSED
8
UNUSED
WHT (001) PC202-3 +BV(AK)
2
2961 PC414-1 +BV(AK)
3
VIO (002) PC202-1 LMS COMM
4
PINK (003) PC202-2 SV HIGH
5
261 CA410-11 NOT USED
6
RED (012) CA202-5 NOT USED
7
5961 PC410-6 NOT USED
8
5 6
2904
HNS
2903 2902 2901
HNS1
1
CA 419 2
HNS2
1
HNS
MAIN PCB
CA 415
CA 406 UNUSED
1
RED
2927 D4 002 BLK(2) CONTROLLER A7
2
BLK
001 BLK(2) CONTROLLER A5
3
WHT
UNUSED
4
UNUSED
BRS
RAS
LOS
HYDRAULIC PCB
CA 407
CA 414 LARGE COIL
2928 DIODE BLOCK (2)
1
BLK
5902 DIODE BLOCK (4)
2
BLU
2924 DIODE BLOCK (5)
3
BLK
506 DIODE BLOCK (1)
4
BLK
SMALL COIL
BR
815513-5_2B.pdf
2961 PC415-3 +BV(AK)
1
UNUSED
2
WHT/GRN (006) CONTROLLER C-3
3
5962 PC410-12 NOT USED
4
HSS
R/T PCB
MS-DIA-1723
815513-6_2B.pdf
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 154
4
KYS
2916 LMS
2
2
TT
SAS
SAS
CA 417
1
CURTIS 803 "COMBI" 5900 CONTROLLER A1
BLK
164
DIAGRAMS WP 2340S OPTIONS, FIXED PLATFORM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT
WP 2340S OPTIONS, FIXED PLATFORM SCHEMATIC DIAGRAM
TCM SEM1
6 POT PCB F/C FS
FPS1
5
5
SAS
3
D4 BR SMALL COIL
2
HNS 2
DIODE BLOCK
BRS
HNS 1
To C-2
1
POT
RS
5
5 1
4 HSS BR LARGE COIL
RAS
F/C
5
LOS
6
CURTIS 803 "COMBI"
R/T PCB
MAIN PCB
TT 1 KYS 2
2901 PC404-2 BDI
1
5900 PC404-1 BDI
2
2902
3
5903
4
5904 DIODE BLOCK (4) 2923 DIODE BLOCK (2) 001 BLK (2 core) JC 406-3 BRS 500 PC 404-5 BATT NEG 2903 JC101-2 +BV (AK) FTS 002 BLK (2 core) PC 406-2 BRS 2904 JC103-1 FPS2
F/C
6
F/C
11 10 INSTRUMENT
A
6
5
HYDR. PCB
6
LMS
LINE
7
2
8
202 FU2 OUT +BV
4 6
BDI
7
UNUSED
8
1 FAN
FPS2
9 +BV +BV (AK) OUT NO BATT NEG FTS
HN P
11
POT CIRCUIT & DRIVER
1
BRN (010) PC410-7 POT WIPER
2
BLU (011) PC410-8 POT LOW
3
RED/BLU (009) PC410-5 POT HIGH
4
BLK (007) PC410-4 RS
5
GRAY/PINK (005) PC410-2 SAS
6
YEL (008) PC410-3 FS
C
2908 JC202-3 +BV (AK)
1
2909
2
2921 DIODE BLOCK (3)
3
WHT/GRN (006) CA414-3 PERF. 1/2 (R/T)
6
5
4
3 D
2
1
3
2
8
7
6
5
4
3
2
1
E
-BATT
C
1
6
5
3
4
TCM (SEM 1)
F2
VMN
F1
B
2
1
8
7
6
5
4
3
+BATT
A
2
1
1
8
A2F2F1
KYS
PS
B
SV
To DB 3
5
UNUSED
INPUT FILTER
BATT NEG
LINE
2909
3
203 JC404-7 BDI
KYS
2909
3
2911 DIODE BLOCK (3)
PS
A1 FAN
TM LINE FU2 10A
FU2 10A
+-
2915 PC404-4 +BV
10 P PM
FU1 160A
BD:1
24V BATT
NOTE: 1- No Drive: FTS, FPS1 & FPS2 open. 2- Forks lower than 130mm: LMS closed. 3- Load is less than 1000kg: PS closed, 2/3 brake, Speed Unladen 10Km/h. 4- Reduce speed: HSS is open. 5- Active: RAS, BRS, SAS, HNS & LOS are closed. 6- F/C Package: Below 5°C active. 10- Diode Block Pin 1 connected to P (contactor contacts). 11- Input Filter Batt Neg connected to Diode Block Pin 1
BD:2
D
2913 JC 202-4
1
UNUSED
2
2912
3
501
4
2914
5
502
6
2918
HN
P SV
503
2919 JC202-2
815514-1_2B.pdf
WP2300S 05/2005 • Printed in Germany
815514-2_2B.pdf
MS-DIA-1723
02 Rev. 05/05 155
DIAGRAMS WP 2340S OPTIONS, FIXED PLATFORM PLATFORM CIRCUIT
WP 2340S OPTIONS, FIXED PLATFORM POWER CIRCUIT - TRACTION & PUMP MOTOR
CA 101
202 KYS COMM
FU1 160A
201
FU2 10A 204
FU3 2A
TCM SEM1
LINE
A1
A2
24V BATTERY
RED
A 1
2972
2
BLK
KYS +BV IN TO THE LOGIC
2
2904 CONTROLLER A8
3
WHT
LINE CONTACTOR LOW
3
BRAKE LOW (large coil)
4
UNUSED
4
UNUSED
BRS INPUT
5
BATTERY NEG
6
BATTERY POS (AK)
7
WALKIE/RIDER MODE
8
FTS
CA 102 2971
1
RED
2970
2
BLK
POT WIPER
B 1
UNUSED
3
WHT
POT LOW
2
UNUSED
4
UNUSED
POT HIGH
3
RS - REVERSE SWITCH IN
4
SAS SAFETY SWITCH IN
5
FS - FORWARD SWITCH IN
6
BATTERY POS (AK)
C 1
PERF.CUT
2
PERF. 1/2,HSS (R/T) INPUT
3
VMN
TM
1
HOUR METER OUTPUT
+BATT
BD:1
UNUSED
FPS1
CA 103 2970
1
RED
2903 CONTROLLER A7
2
BLK
UNUSED
3
WHT
UNUSED
4
UNUSED
FPS2
+BV(AK)
F2
+
BD:2
PM
F1
-
OUT NO
UNUSED
D 1
HN - HORN HIGH
2
HN - HORN LOW
3
P - PUMP CONTACTOR HIGH
4
P&SV-P CONTACTOR LOW
5
SV - LOWERING VALVE HIGH
6
BATT NEG
570 506 PC 407-4 BRK SMALL 505 P- CONTACTOR CONTACTS 2928 PC407-1 BRK LARGE
D1
+BV
INPUT FILTER
205 CA202-5 +BV F/C
1
D2 2
2923 CONTROLLER A5 F1
P
F2
E
POSITIVE SERIAL RECEPTION
1
NEGATIVE SERIAL RECEPTION
2
POSITIVE SERIAL TRANSMISSION
3
NEGATIVE SERIAL TRANSMISSION
4
BATT NEG
5
BATTERY POS (AK)
6
UNUSED
7
UNUSED
8
2921 CONTROLLER C2
D4
-BATT 505 DIODE BLOCK (1)
815514-3_2B.pdf
4
2924 PC 407-3 BRK SMALL
5
2927 JC406-2
DIODE BLOCK
815514-4_2B.pdf
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 156
3
5904 CONTROLLER A4 5902 PC407-2 BRK LARGE 5905
2974 2973
504 JC202-6
NOTE: 1) Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND
D3
2911 PS NO
166
DIAGRAMS WP 2340S OPTIONS, FIXED PLATFORM CONTROL HANDLE CIRCUIT
WP 2340S OPTIONS, FIXED PLATFORM POWER UNIT CIRCUIT 2926 UNUSED
2925 LMS1
CA 411
CA 202
CA 410 2916 PC404-3 BDI
Not Mounted
2917
2919 SV HIGH 2908 CONTROLLER C1
3
001 BLK PC415-2 +BV(AK)
2913 HN HIGH
4
004 BLK PC410-10 HN DRIVER
1
GRAY/PINK (005) B-5 SAS
2
3
YEL (008) B-6 FORWARD
3
BLK (007) B-4 REVERSE
4
RED/BLU (009) B-3 POT HIGH
5
5961 PC415-8 GND F/C
6
BRN (010) B-1 POT WIPER
7
POT
4
FS
5
RS
6 7
CA 412
013 BLK CA410-1 BATT NEG
6
POT
2
012 BLK CA415-7 +BV F/C
5
504 P CONTACTOR CONTACTS
GRN (013) CA202-6 BATT NEG 003 BLK PC415-5 LOS
2
205 FU3 OUT
1
002 BLK PC415-4 RAS
1
3
GRAY
1
BLU
2
CA 404
INSTRUMENT
BLU (011) B-2 POT LOW
8
CURTIS 803 "COMBI"
2962 PC415-1 +BV(AK)
9 10 11
1
TT
2901 KYS OUT
2
KYS
261 PC415-6 +BV
2916 LMS
3
CA 417
1 2 3 4
15 x //R 5962 PC414-4 GND F/C
SAS
CA 413
12
5 6
2915 P HIGH
SAS
2
GRAY (004) PC202-4 HN
5900 CONTROLLER A1
BLK
2904
HNS
2903 2902 2901
HNS1
1
CA 419 2 1
4
HNS2 HNS
MAIN PCB F/C 500 CONTROLLER A6
5
BATT NEG
UNUSED
6
UNUSED
203 KYS IN
7
BDI
2962 PC410-9 +BV(AK)
1
UNUSED
8
UNUSED
WHT (001) PC202-3 +BV(AK)
2
2961 PC414-1 +BV(AK)
3
VIO (002) PC202-1 LMS COMM
4
PINK (003) PC202-2 SV HIGH
5
CA 416
261 CA410-11 +BV
6
1
RED (012) CA202-5 FU3 OUT
7
5961 PC410-6 GND F/C
8
CA 415
CA 406 UNUSED
1
RED
2927 D4 002 BLK(2) CONTROLLER A7
2
BLK
001 BLK(2) CONTROLLER A5
3
WHT
UNUSED
4
UNUSED
BRS
RAS
LOS
0R 2
RED BLK
16 x //R
15 x //R POT PCB F/C HYDRAULIC PCB F/C
CA 407
CA 414 LARGE COIL
2928 DIODE BLOCK (2)
1
BLK
5902 DIODE BLOCK (4)
2
BLU
2924 DIODE BLOCK (5)
3
BLK
506 DIODE BLOCK (1)
4
BLK
SMALL COIL
2961 PC415-3 +BV(AK)
1
UNUSED
2
WHT/GRN (006) CONTROLLER C-3
3
5962 PC410-12 GND F/C
4
BRK
815514-5_2B.pdf
HSS
2 x //R
815514-6_2B.pdf
R/T PCB F/C
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 157
DIAGRAMS
4
2927 5905
(pin 5)
10
(pin 4)
10
(pin 3)
10
(pin 2)
10
7+8
7+8
6+4
6+4
6+4
LMS
6+4
6+4
6+4
FU2
2925
2926
2926
2916
2925
2917
201
202
204
205
2914
505
1 2
3
4
5 6
1010 1010
2924 5905 5904 5902 2921
PC413
2904 2903 2902 2901
6+4 12+11
FU3
HANDLE MAIN PCB 2915
2
9
2
502
2
503
2
5+4
2
504
2
8
203
7
500
5 6
2915
4
2916
3
5900 5
P
P-
2
2901
PC404
1
9
BDI
2901
2902
[7+8] 6+4
202
203
[7+8] 6+4
KYS
Wire harness overview, folded platform, WP2330S all versions
1
2911 2928 2923
2909
506 10
505
PC202
JC202
(002) VIO
2
1
1 1
2917
(003) PINK
2
2
2 1
2919
(001) WHT
2
3
3 1
2908
(004) GREY
2
4
4 1
2913
(012) RED
2
5
5 1
205
2 2 2 2 1 2 3 4
(013) GRN
2
6
6 1
504
BR
1
2
001BLK
1
3
506
D 1
2914
5 3
502
6 3
2918
1 3
5900
2 3
2902
3 3
5903
4 3
5904 001BLK 2923
5 3 6 3 7 3 8 3
500 002BLK 2904
1
Main wire harness 813258
2
Control handle - wire harness 812960
3
Horn switch - wire harness 811931
4
Diode block 131011
5
Diode (D4) 813368
Terminal Type
Part No.
4 5 6 7 8 9 10 11 12
062007-021 803678-006 803448-003 062007-043 803448-002 062007-068 062007-005 813409-003 813409-001 E100_Rev2B-GB
1 1 1 2 3
(013) GRN (005) GRAY / PINK (008) YEL (007) BLK (009) RED / BLU 5961 (010) BRN (011) BLU 2962 (004) GRAY 261
PC410 2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
2
10
2
11
2
12
1 3 (010) BRN 2962
5 3 (005) GREY/PINK 6 3
3 3 2 3 1
3
2
2
3
(002) VIO
2
4
(003) PINK
2
5
2
6
2
7
2
8
2961
(008)YEL
R/T PCB = “Fast/Slow” changeover module (All PCBs/modules located in control handle)
C
1
2
(001) WHT
Key:
PC415 2
261 (012) RED 5961
HANDLE HYDRAULIC PCB
4 3
(006) WHT GRN
PC414
2921 2961
2908 2909
2
1 2
(006) WHT/GRN
( ) Colours correspond to old revision pre-August 2003 Connections by April 2005
JC101
4
5962
2 2
3 4
11 11
2
JC102
JC101 JC102 JC103 JC202 PC202 PC404 JC406 PC407 P C4 1 0 PC413 P C4 1 4 PC415 PC417 PC419 A B C D
11 11
PC417 2 1
GCSL
Housing
2
(007) BLK
4
1
2
1
2
1
PC419
HNS HNS
PLS
5962
3 3 (009) RED/BLU
1 1 1 2 3
2902 2901
GCSR
503
2904 2903
3
2919
2903
2
1
2911
2906
1
2903
2920
B
6+4 6+4
2904
2910
2918
2 3 (011) BLU
Par t No.
Contact Type
803450-002 803450-002 803450-002 803450-003 803450-007 803450-008 803450-002 803450-006 803450-015 803450-021 803450-020 803450-008 803450-023 803450-023 803450-018 803450-017 803450-016 803450-017
1 1 1 1 2 2 1 2 2 10 2 2 11 11 3 3 3 3
Par t No. 803450-010 803450-010 803450-010 803450-010 116858 116858 803450-010 116858 116858 803450-022 116858 116858 803450-024 803450-024 803450-019 803450-019 803450-019 803450-019 E99-GB
Harness_Complete-WPS-Folded_Rev2B
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 158
6+4
HANDLE R/T PCB
TCM SEM1
A
6+4
2906
2924
5902
2928
2913
PS
SV
JC103
4 3
5+4 FU1
204
5903
3
PC407
4
3 3
JC406
201
2910
2920
6+4
501
6+4 6+4
BRS
1
501 2912
HN
2912
LINE
4
6+4
2 3
1
HANDLE MAIN PCB
(pin 1)
2927 002BLK
168
DIAGRAMS Main Harness, Folded Platform, WP2330S, All Versions
11+12
14 *7+8+13
2903
200
6+4 *7+8
2901
500
5901
OUT
6+4 *7+8
2902
2
2900
2
IN 203
2 2906
5900
2 2 2900
2
2905
9
2907
2906
202
9
507
204
COIL
5+4
506
201
CONTACTS 504
6+4
502
6+4
500
6+4
203
FU3
6+4
2905
FU2
7+8
2934
LMS 7+8
KYS
COMBI INSTRUMENT 1 2 3 4 5 6 7 8 PC404
200
P CONTACTOR
2904
6+4
6+4
2910
2928 6+4 6+4
PS
507
2
2
GCSR
2
3
GCSL
2
4
PLS
2
5
BRS
2912
6
2922 6+4
SV 6+4
2
8
SAS
2 10
1
GCSR 2 1 3 1
Batt Neg
to Controller B-5 3
1 2933
2
1 1 2 1
2
2916
2923
505
815179_2C, see Note 4
C TCM
1 3 2 3
2914 2921 2909
3
3 3 3 3 3 1 2 3 4 5 6
BRS (A-5)
2927 2926
2929
2927
2928
1 3
1
GCSL
4
JC101
1
PLS
JC102
5903
5902
2910
2908 6+4
HN 6+4
2907 506 2917
3
2
3
3
3
4
3
5
3
6
TCM
A
815179-1_2C
+BV (Control)
HOUSING
4
3 3 7 8
TCM
19
1 2
5902
SAS (OUT) (B5)
18
1 3
5901
1
2922
16
1 2
6
D PC210 JC210 GRAY/PINK (005)
5904
Rider (A8)
2 13
2 20
5
1
2916
15
2903
4
1
505
2902
2 12
2 17
3
1
2925
14
2918
1
HANDLE HARNESS
2915
5900
2923
2
2919 2926
11 2920
2909
504
BRAKE
from Handle Harness
9 503
JC103
204
PC407
1
1
4
7
2913 2917
2931
+BV
2915
2 2 2 2 1 2 3 4
1
2920
2929
1
2914
2919
2925
2
2913
2932
2901
2912
2934
PC200
2930
2911
JC 202
4
LINE
2918
5904
2931
501
202
6+4
2908
2930
5903
2921
(pin 4) (pin 5) 10 10
2932
2911
FU1 5+4
BRAKE 2 1 SWITCH 3 1
503
2904
1
201
501
JC406
(pin 2) (pin 3) 10 10
502
DIODE BLOCK (pin 1) 10
PC 200 JC 202 PC 210 JC 210 PC 404 JC 406 PC 407 JC 101 JC 102 JC 103 A C D C
Part No. 803450-003 803450-005 803450-001 803450-008 803450-002 803450-006 803450-002 803450-002 803450-002 803450-018 803450-016 803450-017 803450-016
TYPE
Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13
803450-010 116858 803450-013 62007-021 803678-006 803448-003 62007-043 803448-002 62007-068 62007-005 813409-003 813409-001 803678-012
Used from serial no. 5A336576, except for 5A337937
815179_2-GB
815179_1-GB
WP2300S 05/2005 • Printed in Germany
Connections by April 2005
MS-DIA-1723
02 Rev. 05/05 159
DIAGRAMS Control Handle - Wire Harness Folded Platform, WP2330S All Versions
Note: Only for use on trucks with PLM
PC 410 GRN (013)
TCM C-3 3
WHT/GRN (006)
GRAY/PINK (005) YEL (008)
TCM B-5 2
BLK (007)
GRAY/PINK (005)
RED/BLU (009)
B
5961
1
3
2
3
3
3
4
3
BRN (010)
BRN (010)
BLU (011)
BLU (011)
RED/BLU (009)
2962
BLK (007)
GRAY (004) 261
5 6
3
YEL (008)
5962
2 2 2 2 2 2 2 2 2 2 2 2
PC 202
1 2 3 4 5 6 7 8 9 10 11 12
PC 415
1
2
VIO (002)
2962
2
2
PINK (003)
WHT (001)
3
2
WHT (001)
2961
4
2
GRAY (004)
VIO (002)
5
2
RED (012)
PINK (003)
6
2
GRN (013)
261 RED (012) 5961
2 2 2 2 2 2 2 2
1 2 3 4 5 6 7 8
PC 414 2961
2
1 2
WHT/GRN (006) 5962
2 2
3 4
815180_2B
HOUSING
Part No.
TYPE
Part No.
PC 202 PC 410 PC 414 PC 415 B
803450-007 803450-015 803450-020 803450-008 803450-017
2 3
116858 803450-190 815180_2-GB
815180_1-GB
Used from serial number 5A336576, except for 5A337937 ( ) Colours correspond to old revision pre-August 2003
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 160
170
DIAGRAMS Horn Switch - Wire Harness Folded Platform, WP2330S All Versions
PC419 2901
PC413 6 5 4 3
1 1 1 1
2902
2901
2 2
1 2
2902 2903
PC417
2904
2903
2
2904
1
2 2
1 2
811931-1_2C
HOUSING
Part No.
TYPE
Part No.
PC 413 PC 417 PC 419
803450-021 803450-023 803450-023
1 2
803450-022 803450-024 811931_2-GB
811931_1-GB
Used from serial number 5A336576, except for 5A337937
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 161
DIAGRAMS Wire Harness Overview, Fixed platform, All versions 6+4
2927
12+11
5905
(pin 5)
10
(pin 4)
10
(pin 3)
10
(pin 2)
10
2923
7+8
7+8
6+4
6+4
6+4
6+4
6+4
2926
2925
2926
2916
2925
2917
201
202
204
205
2909
10
2927 002 BLK
505
1 1
2
1
3
JC202
LINE
6+4 6+4
JC406
5+4 FU1
204
5903
3
3
3 1
2908
(004) GREY
2
4
4 1
2913
(012) RED
2
5
5 1
205
2 2 2 2 1 2 3 4
(013) GRN
2
6
6 1
504
BR
501 2912
HN 6+4
2913
2911
2918
PC407
SV
6+4 6+4
1
Main wire harness 813258
2
Tiller wire harness 812960
3
Horn switch wire harness 811931
4
Diode Block 102232
5
D
6+4
2919 503
Diode Assembly (D4) 813368
2902 2901
2
6+4
2904 2903
(001) WHT
PS
BRS
2910
2904
2919
11 11
11 11
PC417 2 1 2
1
2914
5 3
502
6 3
2918
1 3
5900
2 3
2902
3 3
5903
4 3
5904 001 BLK 2923
5 3 6 3 7 3 8 3
500 002 BLK 2903
E100_Rev2B-GB
2904
B 1 3
062007-021 803678-006 803448-003 062007-043 803448-002 062007-068 062007-005 813409-003 813409-001
5 3
(005) GREY/PINK
6 3 (008)YEL
C 3 3 2 3 3
(008) YEL (007) BLK (009) RED / BLU 5961 (010) BRN (011) BLU 2962 (004) GRAY 261 5962
2962
3 3 (009) RED/BLU 4 3 (007) BLK
(005) GRAY / PINK
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
2
10
2
11
2
12
Housing
PC415
2 3 (011) BLU
2
1
2
2
2
3
(002) VIO
2
4
(003) PINK
2
5
2
6
2
7
2
8
(001) WHT
Key:
2961
R/T PCB = "Fast/Slow" changeover module (all PCBs/modules are located in the tiller)
261 (012) RED 5961
(006) WHT GRN
PC414
2921 2961
2908 2909
2
1 2
(006) WHT/GRN
( ) Colours correspond to old revision pre-August 2003 Connections by April 2005
JC101
1
2
1
2
1
PC419
HNS HNS
PC410 (013) GRN
22
(010) BRN
4
FTS
5962
2 2
3 4
HANDLE R/T PCB
A
4 5 6 7 8 9 10 11 12
1 1 1 2 3
Part No.
HANDLE HYDRAULIC PCB
4 3
Terminal Type
HANDLE MAIN PCB
501
PC413
201
2910
2903
2 1
506
2
2924
1 1
2
5902
1
(003) PINK
2928
2
2917
3 3
5 6
4
(002) VIO
2912
4
2911
6+4
TCM SEM1
6+4
9
2914
2915
505
2915
1
001 BLK
2 3
3
1010 1010
2928
(pin 1)
JC101 JC202 PC202 PC404 JC406 P C4 0 7 PC410 PC413 PC414 PC415 P C4 1 7 P C4 1 9 A B C D
Par t No. 803450-002 803450-003 803450-007 803450-008 803450-002 803450-006 803450-015 803450-021 803450-020 803450-008 803450-023 803450-023 803450-018 803450-017 803450-016 803450-017
Contact Type 1 1 2 2 1 2 2 10 2 2 11 11 3 3 3 3
Par t No. 803450-010 803450-010 116858 116858 803450-010 116858 116858 803450-022 11685 8 116858 803450-024 803450-024 803450-019 803450-019 803450-019 803450-019 E101-GB Harness_Complete-WPS-Fixed_Rev2B
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 162
LMS
1 2
506
1
FU2
HANDLE MAIN PCB
2924 5905 5902 5904 2921
4
PC202
FU3
2904 2903 2902 2901
5
9
2
502
2
503
2
5+4
2
504
2
8
203
7
500
5 6
2916
3 4
5900
2
2
P
P-
1
2901
[7+8] 6+4
BDI PC404
2901
2902
202
203
[7+8] 6+4
KYS
172
DIAGRAMS Wire Harness Overview, Fixed Platform, WP2340S, All Versions
6+4
7+8
7+8
2926
2925
2926
2916
6+4
2925
6+4
2917
6+4
201
203
202
500
6+4
2915
6+4
2916
6+4
204
2
205
2
LMS 9
2
P
2914
2
P-
8
2915
2
2901
7
9
2
5900
2927
6
503
5
5+4
4
504
3
505
2
2901
2902
202
203
PC404
1
502
COMBI INSTRUMENT
6+4
6+4
KYS
2924
(pin 5)10
DIODE BLOCK
5905 5902
(pin 4)10
5904 2921 (pin 3)10
2911 2928
(pin 2)10
2923
2909
506 (pin 1)10
2927
505
LINE
1
002BLK(2)
1
2
001BLK(2)
1
3
6+4 6+4
JC406
201
2910
5+4
204
5903
FU1
4
3 1
2908
4 1
2913
5 1
205
2 2 2 2 1 2 3 4
6 1
504
BRAKE
BRAKE SWITCH
506
2 1
2919
2924
2917
5902
1 1
2928
HANDLE HARNESS
5905
11+12
PS
6+4 6+4
PC407
2910
6+4 6+4
2919 503
TYPE
Part No.
JC 202 PC 404 JC 406 PC 407 JC 101 A D C
803450-003 803450-008 803450-002 803450-006 803450-002 803450-018 803450-017 803450-016
1 2 3 4 5 6 7 8 9 10 11 12
803450-010 116858 803450-013 62007-021 803678-006 803448-003 62007-043 803448-002 62007-068 62007-005 813409-003 813409-001 E103_2-GB
JC202
6+4
Part No.
E103_1-GB
2911
2918
SV
HOUSING
501 2912 2913
2908
D 1
2918
3
2
2904
502
6 3
1
2921
500 002BLK(2) 2903
2914
5 3
5904 001BLK(2) 2923
4 3
3
TCM
1
3
3 3 3 3 3 3 3 3 1 2 3 4 5 6 7 8
A
5903
3 3
501
2902
2912
5900
TCM
2 3
C
2909
2904
6+4
2903
HN
1 1 2 3
4
JC101
FTS
TCM
813258-1_2D
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 163
DIAGRAMS Control Handle - Wire Harness Fixed Platform, WP2340S, All Versions
PC 410 GRN (013) GRAY/PINK (005)
TCM C-3
3
YEL (008)
WHT/GRN (006)
BLK (007) RED/BLU (009) 5961 BRN (010)
B 1
BLU (011)
3
BRN (010) 2962 BLU (011)
2
3
3
3
RED/BLU (009)
4
3
BLK (007)
3
GRAY/PINK (005)
3
YEL (008)
5 6
GRAY (004) 261 5962
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
2
10
2
11
2
12
PC 415 2962 WHT (001)
PC 202 1
2
2
2
3
2
4
2
5 6
2 2
VIO (002)
2963 (2961)
PINK (003)
VIO (002)
WHT (001)
PINK (003)
GRAY (004)
261
RED (012)
RED (012)
GRN (013)
5961
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
PC 414 2963 (2961)
2
1 2
WHT/GRN (006) 5962
2 2
3 4
812960-1_2G
HOUSING
Part No.
Pos. Nr.
Teile-Nr.
PC 202 PC 410 PC 414 PC 415 B
803450-007 803450-015 803450-020 803450-007 803450-017
2 3
116858 803450-019 812960_2-DE
812960_1-GB
( ) Colours correspond to old revision pre-August 2003
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 164
174
DIAGRAMS Horn Switch - Wire Harness Fixed Platform, WP2340S, All Versions
PC419 2901
PC413 6 5 4 3
1 1 1 1
2902
2901
2 2
1 2
2902 2903
PC417
2904
2903
2
2904
1
2 2
1 2
811931-1_2C
HOUSING
Part No.
TYPE
Part No.
PC 413 PC 417 PC 419
803450-021 803450-023 803450-023
1 2
803450-022 803450-024 811931_2-GB
811931_1-GB
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
02 Rev. 05/05 165
DIAGRAMS Cables, Platform Fixed Platform, WP2340S, All Versions
JC 101
4
1
1
1
3
+BV(AK)
+BV
Batt Neg
6+4
6+4
6+4
6+4
2971
2973
570
4
2904
2974
2
2972
2 1
2970
3
2903
Connect with Wire 2927 14+15
JC 103
OUT NO
DISCONNECT 2903 / 2904 FROM JC101 MAIN HARNESS
2972
Connect to Input Filter
JC 102 4
2974
Connect with Diode Inline Wire 2927 4
3
2973 2970 2971
Connect with Diode Block Pin1 10
1
2 1
570
HOUSING
Part No.
TYPE
Part No.
JC 101 JC 102 JC 103
803450-002 803450-002 803450-002
1 4 6 10 14 15
803450-010 062007-021 803448-003 062007-005 803448-004 803448-005
815281_1-GB
815281_2-GB
MS-DIA-1723
WP2300S 05/2005 • Printed in Germany
02 Rev. 05/05 166
176
DIAGRAMS Power Cables
-
24V
BD:2
BD:1
+
A
Index
Part No.
(mm2)
Index
Part No.
(mm2)
1 2 3 4 5 6 7 * Busbar
052051-010 052065-040 052065-031 045250 052051-008 052065-023 052065-024
25 16 16 * 25 16 16
8 9 10 11
052065-039 807636-002 807636-001 052065-001
16 4 4 16
E102-GB
1
FU1 160 A
5
6
7
+
PM
P
-
4
2
Line 11
A1
8
A2
TM F1
10
3
+ BATT
F2
F1
9
F2
VMN
TCM SEM1 807473-2C
A = Battery disconnect
WP2300S 05/2005 • Printed in Germany
MS-DIA-1723
M1.0-0000-000177 167
Blank Page
Printed in Germany
168
HYDRAULIC SCHEMATIC
Printed in Germany
169
Blank Page
Printed in Germany
M1.0-0000-000180 170 M1.0-0000-000180
HYDRAULIC CIRCUIT
Lift cylinder
Pressure-Switch
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
WP2300S 05/2005 • Printed in Germany
M1457-2
MS-HYD-1723
171
Blank Page
172