Crown Forklift WP2300S Series Maintenance Manual 812529-006

Maintenance Manual

WP2300S Series MS-WP2300S 05/03 • Printed in Germany Order Number: 812529-006

This master maintenance manual is subject to continual updates.

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

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

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

Copyright 2002 CROWN Equipment Corporation

REVISION Overview of Revisions: Page 3

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

Reference to authorised service personnel added.

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TABLE OF CONTENT

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TABLE OF CONTENT Table of Content ITD – INTRODUCTION

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

M1 – LUBRICATION AND ADJUSTMENT

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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 Testing and Setting the LoadDependent Pressure Switch ............................................. 47

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TABLE OF CONTENT 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 Brake Switch (BRS) .......................................................... 63 Raise/Lower Switch (RAS, LOS) ...................................... 63 Pressure Switch (PS) ....................................................... 63 Platform Control Switches (GCSR, GCSL, PLS) .............. 64 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 Battery .................................................................................. 67 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 MS-WP2300S-GB 05/03 • Printed in Germany

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TABLE OF CONTENT M4 – ELECTRICS

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Start Sequence ........................................................... 70 Safety Class ................................................................ 70 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, 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 Electric Motors .................................................................... 89 General Maintenance Instructions ................................... 89 Preparation ................................................................. 89 Important Maintenance Instructions ............................ 89 Traction Motor Maintenance ............................................... 90 Access to Brushes ........................................................... 90 Maintenance .................................................................... 90 Armature ..................................................................... 90 Bearings ...................................................................... 90 Pump Motor Maintenance ................................................... 91 Access to brushes ............................................................ 91 Maintenance .................................................................... 91 Armature ..................................................................... 91

M5 – BRAKE

PAGE

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

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TABLE OF CONTENT M6 – STEERING

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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 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

PAGE

Lift Linkage .......................................................................... 115 Fork Height Setting .......................................................... 115 Lift Limit Cutout ................................................................... 117 Lift Limit Cutout Setting .................................................... 117

M8 – CYLINDERS

PAGE

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 ..................................................................... 131 Replacing the Deadman Switch ....................................... 131

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TABLE OF CONTENT DIA – ELECTRICAL DIAGRAMS

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Overall Wiring Diagram, Standard, Folded Platform ......... 135 Overall Wiring Diagram, Folded Platform with Options ... 136 Overall Wiring Diagram, Standard, Fixed Platform ........... 137 Overall Wiring Diagram, Fixed Platform with Options ...... 138 Wire harness overview, folded platform, all versions .......................................................................... 139 Wire harness overview, fixed platform, all versions .......................................................................... 140 Power Cables ....................................................................... 141

HYD – HYDRAULIC SCHEMATIC

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Hydraulic Schematic ........................................................... 145

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SAFETY

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SAFETY Safety Symbols used in the Manual

General Maintenance and Repair Safety Notes

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

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

DANGER

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

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

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

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

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

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

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

CAUTION

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.

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INTRODUCTION

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

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

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

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

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

Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address:

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

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

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

Additional copies can be ordered as required.

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

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

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

These are listed in a separate manual.

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

Sections Maintenance Section

Description

IDX

Table of Content

MA

Safety

ITD

Introduction

M1

Lubrication and Adjustment

M2

Hydraulics

M3

Drive Unit

M4

Electrical

M5

Brake

Spare parts can be ordered by quoting: ●

The truck specification number

M6

Steering

●

The truck model number

M7

Mast / Lifting Mechanism

●

The truck serial number

M8

Cylinder

DIA

Electrical Diagrams

HYD

Hydraulic Schematic A01M-gb

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

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

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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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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

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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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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

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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

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Drive wheel

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

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

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

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

●

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

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

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

●

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

●

Charge the battery or install a charged battery.

●

Connect the battery.

●

Carry out the daily check.

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

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

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

Disconnect the battery.

●

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

●

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

●

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

●

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

●

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

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LUBRICATION AND ADJUSTMENT Lubricant Type

Product Description

Manufacturer CROWN-Part-No.

Grease (multi purpose)

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

Aral Castrol Century Esso Maxol Mobil Shell SKF

053002-001

B

Low temperature grease

Aralube SKL2 Unirex Lotemp EP

Aral Mobil

053002-005

BB

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

Aral Castrol Esso Mobil Shell Finol Fuchs Minralölwerke GmbH

053001-003

D

Low temperature hydraulic oil

Deutz Oel HVI 32

Klockner

053001-009

DD

Transmission oil

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

Aral Esso Mobil Shell

053002-004

A

Low temperature transmission oil

Mobil SHC 624

Mobil

053002-009

AA

Hydraulic oil

Type

L01_lubricants_wp-GB

Product

Product Name

Application

Crown Part No.

Anti-corrosive agent

Tectyl

Anti-corrosive agent for cold store trucks.

805236-004

2K Klarlack

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

805236-003

Transparent coating

L01_adjuvants_WPS-GB

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

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

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

Daily or every 8 service hours No.

Item

Action

1

Battery

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

2

Battery Connector ( = Emergency Stop )

Check operation

3

Horn

Check operation

4

Lift / Lower rocker switch

Check operation

5

Travel switch

Check operation (both directions)

6

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

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LUBRICATION AND ADJUSTMENT

8 2 7

1

10 11

12

MS1723-200

9

3 10

6

4 3

5, 8

7 MS1723-004

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

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

●

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

●

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

●

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

●

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

●

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

●

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

WP 2000

●

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LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours No.

Item

Action

1

Battery

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

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LUBRICATION AND ADJUSTMENT

2 6

5 1

4

7 3 11 8

MS1723-200

10

MS1723-013

9

9

MS1723-011

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

Item

Action

1

Truck, battery and charger connectors/plugs

Clean contacts and check contact springs

2

Carbon brushes Pump and drive motor

Check for wear, ease of motion and contamination

3

Connecting rods

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

4

Forks

Check height setting, adjust if necessary

5

Gear unit

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

L04-gb

Every six months or 500 service hours No.

Item

Action

6

Tiller

Check operation and grease flat coil springs for return function

7

Brake

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

8

Lift cylinder

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

9

Lift mechanism

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

10

Load wheel and castor axles

Clean, check for wear, replace if necessary, grease

11

Hydraulic system

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

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

Page intentionally left blank

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

Page intentionally left blank

Printed in Germany

48

DRIVE UNIT

Printed in Germany

49

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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.

MS-WP2300S-GB 05/03 • 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

MS-WP2300S-GB 05/03 • 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).

MS-WP2300S-GB 05/03 • 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. ●

High

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

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.

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.

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

●

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

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

●

To assemble, proceed as described previously.

●

●

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).

MS-3.1-1723

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

MS-WP2300S-GB 05/03 • Printed in Germany

DRIVE UNIT ●

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

●

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.

MS-WP2300S-GB 05/03 • Printed in Germany

M-1.0-0000-00055 M1.0-0000-00055 55

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ELECTRICS

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57

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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

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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.

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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 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.

Electrical Components DANGER Jack up the truck before carrying out repairs or troubleshooting the electrical system.

Raise/Lower Switch (RAS, LOS)

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.

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.

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 lower (LOS) switch supplies the solenoid (SV) with current, causing the solenoid to open.

Pressure Switch (PS) 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.

Brake Switch (BRS) The brake switch (BRS) is located directly below the control handle suspension. As soon as the control

Upper brake zone Neutral / Idle Position

C

Travel zone

B

Lower brake zone

A

M1559-2

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

MS-4.2-1723

M1.0-0000-00063 63

ELECTRICS Platform Control Switches (GCSR, GCSL, PLS) Only available with folding platforms. These three switches are in series. The chain controls the position of the gate and the platform. If all the switches are closed, the traction controller changes to the higher platform speed.

Lift Limit Switch (LMS) 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.

Key Switch (KYS) 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

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.

MS-4.2-MS-1723

64M1.0-0000-00064

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

ELECTRICS 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

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-WP2300-GB 04/03 • Printed in Germany

MS-4.2-1723

M1.0-0000-00065 65

ELECTRICS 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

HSS (R/T) RAS/LOS HNS POT,FS,RS

FU3 (Option F/C)

BB (SAS)

BD

LMS

P LINE BUSBAR PC/JC 101 MS-4.2-1723

66M1.0-0000-00066

FTS

MS-WP2300-GB 04/03 •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

M1.0-0000-00067 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

68M1.0-0000-00068

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-GB 05/03 • 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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M1.0-0000-00069 69

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.

MS-4.3-1723

70M1.0-0000-00070

MS-WP2300S-GB 05/03 •Printed in Germany

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-GB 05/03 • Printed in Germany

MS-4.3-1723

M1.0-0000-00071 71

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. ●

●

●

●

Parameter Setting after Replacing the Traction Controller Preparatory Measures ●

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

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.

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.

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.

72M1.0-0000-00072

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.

MS-4.3-1723

Setting

MS-WP2300S-GB 05/03 •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.

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MS-4.3-1723

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

No of Flashes

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

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

Console Display

Notes

1

Logic failure #1:

Line contactor voltage control error

1

Watch dog:

Logic or software error

1

EEPROM KO:

EEPROM error

2

INCORRECT STARTS:

Star ting sequence for travel not correct

2

FORW + BACK:

Forward and backward simultaneously requested

3

CAPACITOR CHARGE

Problem with power block

3

VMN NOT OK

Problem with chopper; armature voltage not correct

3

VFIELD NOT OK

Field voltage not correct

4

VACC NOT OK

Signal from traction potentiometer not correct

4

PEDAL WIRE KO

Traction pod wiring not correct

5

NO FIELD CUR.

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

5

HIGH FIELD CUR.

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

5

STBY I HIGH

High current: Armature current sensor error

5

I = 0 EVER

No current: Armature current sensor error

6

CONTACTOR DRIVER

Contactor driver error

6

COIL SHORTED

Contactor coil shor ted

6

CONTACTOR CLOSED

Line contactor contact faulty

7

TH. PROTECTION

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

32

BATTERY LOW

Battery voltage too low E04-gb

MS-4.4-1723

74M1.0-0000-00074

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-WP2300S-GB 05/03 • Printed in Germany

MS-4.4-1723

M1.0-0000-00075 75

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.

MS-4.4-1723

76M1.0-0000-00076

MS-WP2300S-GB 05/03 •Printed in Germany

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-GB 05/03 • 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

MS-4.4-1723

M1.0-0000-00077 77

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

MS-4.5-1723

78M1.0-0000-00078

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-GB 05/03 •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-GB 05/03 • Printed in Germany

MS-4.5-1723

M1.0-0000-00079 79

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

MS-4.5-1723

80M1.0-0000-00080

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-4.5-1723

M1.0-0000-00081 81

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

MS-4.5-1723

82M1.0-0000-00082

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-WP2300S-GB 05/03 • Printed in Germany

MS-4.4-1723

M1.0-0000-00083 83

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

MS-4.5-1723

84M1.0-0000-00084

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-WP2300S-GB 05/03 • Printed in Germany

MS-4.5-1723

M1.0-0000-00085 85

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

MS-4.6-1723

86M1.0-0000-00086

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-WP2300S-GB 05/03 • Printed in Germany

MS-4.5-1723

M1.0-0000-00087 87

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

MS-4.6-1723

88M1.0-0000-00088

MS-WP2300S-GB 05/03 •Printed in Germany

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

MS-WP2300S-GB 05/03 • Printed in Germany

MS-4.10-1723

M1.0-0000-00089 89

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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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-F 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).

MS-5.0-1723

M1.0-0000-00095 95

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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96M1.0-0000-00096

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-F 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

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.

Inner ring

M0195-1

Outer ring

WP2300S Nominal Braking Distances and Screw Depth Model

Capacity

Screw Depth A

Tab washer 2330 2335

2.000 kg

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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M1.0-0000-000100 100 M1.0-0000-000100

STEERING Multitask Handle - Springs for Return Function 1

CAUTION Pre-tensioned springs!

When removing, take care to avoid injury.

8 2

Before carrying out any work on the tiller: ●

Remove the battery connector (EMERGENCY STOP).

●

Block the truck.

3

7

4

Adjustment

5

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

Unscrew the panel (1) and push it up.

●

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

●

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

●

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

●

6

M1562

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

Removal ●

Unscrew the panel (1) and push it up.

●

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

●

Mark the position of the axle (3).

●

Drive out the tensioning pin (2).

The relieved springs should now turn the axle.

●

Tilt the tiller down to its lowest position.

●

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

20° anticlockwise from the fixed position.

MS-WP2300-GB 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 Tiller Handle Main Components This is an overview of the main components and their associated terms:

Upper Shell

Tiller Tube

Switch Unit

Handle MS518

Lower Shell

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STEERING Tiller Handle Component Removal / Installation

Tiller Handle Shells Removing the Upper and Lower Shells

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

CAUTION Danger of short circuiting!

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

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

A ●

MS513

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

B

MS503

A

MS514

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●

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

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

●

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

MS-WP2300S-GB 05/03 • Printed in Germany

STEERING

MS501

●

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

MS502

●

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

M8

M8 MS503

●

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

MS517

M5 ●

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

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

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STEERING ●

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

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

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

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

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

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

Tighten the mounting screws (M5).

After re-connecting the battery test all functions.

A

●

MS513

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

B

C

A

MS514

●

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

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

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STEERING "Fast/Slow" Toggle Switch

Hydraulic Board

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

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

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

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

Removal Removal ●

●

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

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

MS504

● MS511 ●

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

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

Installation Installation ●

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

●

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

MS-WP2300S-GB 05/03 • Printed in Germany

●

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

●

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

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

Removal ●

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

MS510

MS508

●

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

●

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

●

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

Remove the potentiometer from the square axle.

Installation ●

●

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

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

Installation of the potentiometer is the reverse of removal.

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

MS509

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STEERING Safety Reverse Switch Removal ●

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

A

B C MS500

MS508

●

●

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

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

●

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

●

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

Remove the microswitch connector from the main board.

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

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

Do not use any other grease.

●

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

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

MS509

●

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

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STEERING Installation

Horn Switch Removal ●

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

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

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

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

MS502

●

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

MS503

●

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

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STEERING Handle Removal ●

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

MS501

●

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

Installation

MS502

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

Fit the horn switch in the reverse order of removal.

●

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

●

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

MS503

●

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

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LIFTING MECHANISM

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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

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LIFTING MECHANISM

Loadwheel, tandem

M1438 MS-7.1-1723

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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 MS-WP2300S-GB 05/03 • Printed in Germany

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CYLINDERS

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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.

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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

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

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

●

Check the scraper rings for wear and unusual leakage.

●

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

●

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

●

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

●

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

●

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

MS-WP2300S-GB 05/03 • Printed in Germany

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

Failure to do so will otherwise result in repeated leakage.

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

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

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PLATFORM

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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.

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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.

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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

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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

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PLATFORM Fixed Platform Replacing the Deadman Switch ●

Remove screw (A).

●

Raise the upper section of the platform (B) and remove the deadman switch plug connection.

●

Remove the upper section of the platform.

Remove the deadman switch (C).

C

B

MS-1723-901

B MS-1723-900

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132

ELECTRICAL DIAGRAMS

Printed in Germany

133

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Printed in Germany

134

DIAGRAMS Overall Wiring Diagram, Standard, Folded Platform

Key:

201

202 KYS COMM +BV

1 = Diagnostics LED. Remove to connect the programmer.

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

203 JC404-7 BDI +BV

FU2 10A

2901 PC404-2 BDI +BV (AK)

TCM SEM1

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

5

+BATT

A1

6 7

BD:1

8

2916 PC404-3 RAS SIG

CA 202

LMS 2917

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

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

010 PC410-7 POT SIG

2

011 PC410-8 POT LOW

3

009 PC410-5 POT HIGH

4

007 PC410-4 RS SIG

5

005 PC410-2 SAS SIG

6

008 PC410-3 FS SIG

PS

F1

C

2908 JC202-3 +BV (AK)

1

2909

2

2921 PS SIG

3

006 PC414-3 R/T (HSS) SIG

+

RED

-

LINE

2910

PM

505 P-

POT CIRCUIT & DRIVER

5903

VMN

2909

24V BATTERY

A2

2911 PS SIG

B

FAN

BD:2

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

1

RED

002 A7 +BV (AK)

2

BLK

001 A5 BRS SIG

3

WHT

UNUSED

4

UNUSED

P

+ -

+

SV

-

CA 407 2928 DIODE BLOCK (2) BRS SIG

1

CA 410

2962 PC410-9 +BV(AK)

1

013 PC202-6 BATT NEG

1

001 PC202-3 +BV(AK)

2

005 B-5 SAS SIG

2

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

UNUSED

1

POT

2 3

008 B-6 FS SIG

3

002 PC202-1 RAS SIG

4

003 PC202-2 LOS SIG

5

RAS

LOS

+

BR/1

+

BR/2

BR

-

007 B-4 RS SIG

4

009 B-3 POT HIGH

5

UNUSED

FS

5

6

5961 PC415-8 NOT USED

6

7

010 B-1 POT SIG

7

5961 PC410-6 NOT USED

8

011 B-2 POT LOW

8

2962 PC415-1 +BV(AK)

9

004 PC202-4 HNS SIG

10

CA 414

261 PC415-6 NOT USED

11

2963 PC415-3 +BV(AK)

1

5962 PC414-4 NOT USED

12

UNUSED

2

006 C-3 R/T (HSS) SIG

3

5962 PC410-12 NOT USED

4

CA 412 3

BLK GRAY

1

BLU

2

SAS

2

4 5 6

MAIN PCB PN 812941

2

BLK

2903

3

WHT

4

UNUSED

GCSL

UNUSED

1

RED

2920 A8 PL SIG

2

BLK

2906 PL SIG

3

WHT

UNUSED

4

UNUSED

PLS

CA 417

1

2

HSS

SAS PN 811935

CA 413

3

2906

CA 102

7

012 PC202-5 NOT USED

RED

RS

6

2

1

ACS PN 813533

4

3

261 PC410-11 NOT USED

HYDRAULIC PCB PN 812942-001

BLK

CA 101 CA 411

2963 PC414-1 +BV(AK)

1

503 2919 JC202-2 LOS SIG

CA 415

BRS

2904

HNS1 PN 811932-001

2903 2902 2901

CA 103

HNS1

1

CA 419 2 1

HNS2 HNS2 PN 811932-002

UNUSED

1

RED

2904 A7 +BV (AK)

2

BLK

2903 PL SIG

3

WHT

UNUSED

4

UNUSED

GCSR

813202-Standard_complete_Variant-2 R/T SWITCH 811941

MS-DIA-1723

MS-WP2300S-GB 05/03 • Printed in Germany

135

135

DIAGRAMS Key:

205 +BV F/C HR 202 KYS COMM +BV FU3 2A FU2 10A

202 KYS COMM +BV c

FU1 160A

+BATT

BD:1

2916 PC404-3 RAS SIG

1

5900 PC404-1 TT

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 2920 JC102-2 PL SIG

6 7 8

LMS

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

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

2925

KYS

2926

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

2901 PC404-2 BDI +BV (AK)

TCM SEM1 A

A1

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

1 = Diagnostics LED. Remove to connect the programmer.

203 JC404-7 BDI +BV

201

204

Overall Wiring Diagram, Folded Platform with Options

CA 202 1

002 PC415-4 RAS SIG

2919 LOS SIG

2917

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

+

1

010 PC410-7 POT SIG

2

011 PC410-8 POT LOW

3

009 PC410-5 POT HIGH

4

007 PC410-4 RS SIG

5

005 PC410-2 SAS SIG

6

008 PC410-3 FS SIG

PS 2910

-

+

2908 JC202-3 +BV (AK)

1

2909

2

2921 PS SIG

3

006 PC414-3 R/T (HSS) SIG

RED

PM

LINE

F1

C

505 P-

POT CIRCUIT & DRIVER

5903

VMN

2909

24V BATTERY

A2

2911 PS SIG

B

BD:2

FAN

P

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

+

-

003 PC202-2 LOS SIG

4

RAS

16 x //R

HR POT F/C

002 PC202-1 RAS SIG

3 LOS

005 B-5 SAS SIG 008 B-6 FS SIG

1

002 A7 +BV (AK)

2

6

010 B-1 POT SIG

7

5961 PC410-6 COMM F/C HR

8

2

011 B-2 POT LOW

8

2962 PC415-1 +BV(AK)

9

004 PC202-4 HNS SIG

10

15 x //R

BLK

001 A5 BRS SIG

3

WHT

UNUSED

4

UNUSED

2

CA 412 3

BLK GRAY

1

BLU

SAS

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

+

BR/1

+

BR/2

BR

-

11

2

5962 PC414-4 COMM F/C HR

12

15 x //R

4 5 6

HSS

1

RED

2906

2

BLK

2903

3

WHT

4

UNUSED

GCSL

UNUSED

1

RED

2920 A8 PL SIG

2

BLK

2906 PL SIG

3

WHT

UNUSED

4

UNUSED

PLS

CA 417

1

2

261 PC415-6 +BV HR

SAS PN 811935

CA 413

3

CA 414

BRS

CA 102

2

HYDRAULIC PCB F/C PN 812273-001

RED

RS

6

5

009 B-3 POT HIGH 5961 PC415-8 LOW HR

4

UNUSED

UNUSED

FS

5

4

007 B-4 RS SIG

1

5962 PC410-12 COMM F/C HR

UNUSED

ACS PN 813534

4

3

CA 416

3

8

POT

2

2

7

006 C-3 R/T (HSS) SIG

BDI

UNUSED

UNUSED

1

1

6

2

UNUSED

7

CA 101

012 PC202-5 +BV F/C HR

UNUSED

6

203 KYS COMM

CA 407

1

261 PC410-11 +BV F/C HR

1

UNUSED

7

5

2963 PC415-3 +BV(AK)

BATT NEG

3

BLK

2963 PC414-1 +BV(AK)

4

5

503

013 PC202-6 BATT NEG

2

4

500 A6 BATT NEG

-

CA 410

RED

001 PC202-3 +BV(AK)

2915 RAS SIG

2919 JC202-2 LOS SIG

CA 415

1

3

P

CA 411

2962 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

HNS PN 811933-001

2903 2902 2901

CA 103

HNS1

1

CA 419 2 1

HNS2 HNS PN 811933-002

MAIN PCB F/C PN 812272

813201-complete-_Opt RED

UNUSED

1

2904 A7 +BV (AK)

2

BLK

2903 PL SIG

3

WHT

UNUSED

4

UNUSED

GCSR

3 2 x //R

813202-Options_Folded

R/T PCB F/C PN 812877

MS-DIA-1723

136

MS-WP2300S-GB 05/03 • Printed in Germany

136

DIAGRAMS Key:

Overall Wiring Diagram, Standard, Fixed Platform 201

202 KYS COMM +BV

1 = Diagnostics LED. Remove to connect the programmer.

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

203 JC404-7 BDI +BV

FU2 10A

2901 PC404-2 BDI +BV (AK)

TCM SEM1

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

5

+BATT

A1

6 7

BD:1

8

2916 PC404-3 RAS SIG

CA 202

LMS 2917

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

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

010 PC410-7 POT SIG

2

011 PC410-8 POT LOW

3

009 PC410-5 POT HIGH

4

007 PC410-4 RS SIG

5

005 PC410-2 SAS SIG

6

008 PC410-3 FS SIG

PS

F1

C

2908 JC202-3 +BV (AK)

1

2909

2

2921 PS SIG

3

006 PC414-3 R/T (HSS) SIG

+

RED

-

LINE

2910

PM

505 P-

POT CIRCUIT & DRIVER

5903

VMN

2909

24V BATTERY

A2

2911 PS SIG

B

FAN

BD:2 UNUSED

2

2912 HNS SIG

3

501 BATT NEG

4

2914 RAS SIG

5

502 BATT NEG

6

2918 LOS SIG

1

504 JC202-6

2

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

+

-

-

2915 PC404-4 RAS SIG

+ RXD NEG + TXD

4

TXD NEG

5

BATT NEG

6

+ BV (AK)

7

UNUSED

8

UNUSED

UNUSED

1

RED

002 A7 +BV (AK)

2

BLK

001 A5 BRS SIG

3

WHT

UNUSED

4

UNUSED

+ -

+

SV

-

BRS

P

+ RXD

3

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

CA 407 2928 DIODE BLOCK (2) BRS SIG

1

BLK

5902 DIODE BLOCK (4) BATT NEG

2

BLU

503 2919 JC202-2 LOS SIG

1

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 415 2962 PC410-9 +BV(AK)

CA 410 013 PC202-6 BATT NEG

1

1

POT

2

1

3

001 PC202-3 +BV(AK)

2

005 B-5 SAS SIG

2

2963 PC414-1 +BV(AK)

3

008 B-6 FS SIG

3

002 PC202-1 RAS SIG

4

007 B-4 RS SIG

4

003 PC202-2 LOS SIG

RAS

LOS

FS

5

RS

6

CA 102

7

009 B-3 POT HIGH

5

ACS PN 813533

4

5

261 PC410-11 NOT USED

6

5961 PC415-8 NOT USED

6

012 PC202-5 NOT USED

7

010 B-1 POT SIG

7

5961 PC410-6 NOT USED

8

011 B-2 POT LOW

8

2

CA 412 3

GRAY

1

BLU

2

HYDRAULIC PCB PN 812942-001

2962 PC415-1 +BV(AK)

9

004 PC202-4 HNS SIG

10

2963 PC415-3 +BV(AK)

1

UNUSED

2

006 C-3 R/T (HSS) SIG

3

5962 PC410-12 NOT USED

4

SAS

1 2

11

5962 PC414-4 NOT USED

4

12

5 6

HSS

MAIN PCB PN 812941

1

RED

2903 A8 FTS SIG

2

BLK

2904 A7 +BV (AK)

3

WHT

UNUSED

4

UNUSED

FTS

CA 417 2

261 PC415-6 NOT USED

SAS PN 811935

CA 413

3

CA 414

BLK

UNUSED

2904

HNS1 PN 811932-001

2903 2902 2901

HNS1

1

CA 419 2 1

HNS2 HNS2 PN 811932-002

R/T SWITCH 811941

MS-DIA-1723

MS-WP2300S-GB 05/03 • Printed in Germany

137

137

DIAGRAMS Key:

205 +BV F/C HR 202 KYS COMM +BV FU3 2A FU2 10A

c

FU1 160A

A 1

5900 PC404-1 TT

2

2902 +BV (AK)

3

5903 BATT NEG

4

5904 BATT NEG

5

+BATT

6

BD:1

7 8

LMS 4 = HR POT F/C is part of the ACS module

2925

KYS

2926

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

2901 PC404-2 BDI +BV (AK)

TCM SEM1 202 KYS COMM +BV

A1

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

1 = Diagnostics LED. Remove to connect the programmer.

203 JC404-7 BDI +BV

201

204

Overall Wiring Diagram, Fixed Platform with Options

2916 PC404-3 RAS SIG 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

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

+

010 PC410-7 POT SIG

2

011 PC410-8 POT LOW

3

009 PC410-5 POT HIGH

4

007 PC410-4 RS SIG

5

005 PC410-2 SAS SIG

6

008 PC410-3 FS SIG

PS

F1

C

2908 JC202-3 +BV (AK)

1

2909

2

2921 PS SIG

3

006 PC414-3 R/T (HSS) SIG

+

RED

-

LINE

2910

PM

505 P-

1

POT CIRCUIT & DRIVER

5903

VMN

2909

24V BATTERY

A2

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

1

RED

002 A7 +BV (AK)

2

BLK

001 A5 BRS SIG

3

WHT

UNUSED

4

UNUSED

P

+ -

SV

+

-

BRS

CA 407 2928 DIODE BLOCK (2) BRS SIG

1

BLK

5902 DIODE BLOCK (4) BATT NEG

2

BLU

503 2919 JC202-2 LOS SIG

1

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

4

RAS

LOS

6

012 PC202-5 +BV F/C HR

7

5961 PC410-6 COMM F/C HR

8

005 B-5 SAS SIG

2

4

008 B-6 FS SIG

3

5

007 B-4 RS SIG

4

5961 PC415-8 LOW HR

6

010 B-1 POT SIG

7

2

011 B-2 POT LOW

8

2

CA 412 3

2962 PC415-1 +BV(AK)

9

004 PC202-4 HNS SIG

10

2

4

006 C-3 R/T (HSS) SIG

3

5962 PC410-12 COMM F/C HR

4

12

5 6

HSS

UNUSED

1

RED

2903 A8 PL SIG

2

BLK

2904 A7 +BV (AK)

3

WHT

UNUSED

4

UNUSED

FTS

CA 417

1

11

5962 PC414-4 COMM F/C HR

SAS PN 811935

CA 413

15 x //R

2

BLU

SAS

2

261 PC415-6 +BV HR

CA 414

BLK GRAY

1

3

1

CA 102

2

HYDRAULIC PCB F/C PN 812273-001

UNUSED

RS

6

5

009 B-3 POT HIGH

1

CA 416 15 x //R

2963 PC415-3 +BV(AK)

ACS PN 813534 FS

7

5

201 PC410-11 +BV F/C HR

HR POT F/C

3

002 PC202-1 RAS SIG

16 x //R

2963 PC414-1 +BV(AK)

003 PC202-2 LOS SIG

4

2

POT

2

1

3

BLK

001 PC202-3 +BV(AK)

013 PC202-6 BATT NEG

1

RED

2962 PC410-9 +BV(AK)

1

2904

HNS PN 811933-001

2903 2902 2901

MAIN PCB F/C PN 812272

HNS1

1

CA 419 2 1

HNS2 HNS PN 811933-002

3 2 x //R R/T PCB F/C PN 812877

MS-DIA-1723

138

MS-WP2300S-GB 05/03 • Printed in Germany

138

2927

11

2922

(pin 3) 10

7+8

6+4

7+8

6+4

LMS 6+4

FU2 6+4

FU3 6+4

9

9

2925

2926

2926

2916

2925

2917

201

202

204

205

505

2914

HANDLE MAIN PCB 2915

2

502

2

503

2

5+4

2

504

2

8

203

2

500

7

2915

5 6

2916

4

1 2

3

4

5 6

1010 1010

2924 2922 5904 5902 2921

(pin 4) 10

P

P-

3

5900

PC404

2

2901

7+8

2901 2927

2902

7+8

202

4

(pin 5) 10

4

BDI 1

PC413

2904 2903 2902 2901

5

KYS

203

Wire harness overview, folded platform, all versions

6+4

DIAGRAMS

1

2911 2928

(pin 2) 10

2923

2909

506 (pin 1) 10

PC202

1

505

002BLK

1

2

001BLK

1

3

JC202

LINE

6+4 6+4

JC406

201

2910

5+4 FU1

204

5903

3

4

2

2 1

2919

001

2

3

3 1

2908

004

2

4

4 1

2913

012

2

5

5 1

205

2 2 2 2 1 2 3 4

013

2

6

6 1

504

BR

PS

BRS

506

1 1

2

2924

1

003

5902

2

2917

2928

002

6+4 6+4

2910 2911

2918

PC407

SV

6+4 6+4

2919 503

1 Main wire harness 813257

2913

2

2903

1

3

GCSR

3 3 Horn switch wire harness 811931

4

5 Diode Assembly (D4) 813368

D 1 3 3

501

4 3

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

Terminal Type Par t No. 4 5 6 7 8 9 10

500 002BLK 2904

062007-021 803678-006 803448-003 062007-043 803448-002 062007-068 062007-005

B 1 3

010

2 3

011

3 3

009

4 3

007

5 3

005

6 3

008

013 005 008 007 009 5961 010 011 2962 004

E100-GB

261 5962

2920

2962

3 3 2 3 1

3

2

2

3

2

4

2

5

2

6

2

7

2

8

2

9

2

10

2

11

2

12

Housing

PC415 1

2

2

2

3

002

2

4

003

2

5

2

6

2

7

2

8

2963

261

C

1

2

2

001

012

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

5961

006

PC414

2961 2963

2908 2909

JC101

GCSL 4

2

1 2

006 5962

11 11

11 11

PC417 2 1 2

JC102

1

2

1

2

1

PC419

HNS HNS

PC410 2

2

Key:

4

PLS

2 2

3 4

HANDLE R/T PCB

TCM SEM1

A

1 1 1 2 3

HANDLE HYDRAULIC PCB

2912

HANDLE MAIN PCB

2 3

1 1 1 2 3

2906

2920

4 Diode Block 102232

JC103

2902 2901

6+4

1

2904 2903

2912

HN

2 2 Tiller wire harness 812960

1 2904

2903

501

2906

6+4

JC101 JC102 JC103 JC202 PC202 PC404 JC406 PC407 PC410 PC413 P C4 1 4 PC415 PC417 PC419 A B C D

Par t No. 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

Contact Type 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 MS-DIA-1723

MS-WP2300S-GB 05/03 • Printed in Germany

139

139

2927

11

2922

(pin 4) 10

(pin 3) 10

7+8

7+8

6+4

6+4

LMS

6+4

6+4

6+4

9

FU2

2926

2925

2926

2916

2925

2917

201

202

204

205

2914

505

1 2

3

4

5 6

1010 1010

2924 2922 5902 5904 2921

(pin 5) 10

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

PC413

2904 2903 2902 2901

4

P

P-

3

2916

7+8

PC404

2

2901

2902

BDI 1

5900

5

4

202

203

7+8

KYS

2901 2927

Wire harness overview, fixed platform, all versions

6+4

DIAGRAMS

1

2911 2928

(pin 2) 10

2923

2909

506 (pin 1) 10

PC202

1

505

002 BLK

1

2

001 BLK

1

3

JC202

LINE

6+4 6+4

JC406

201

2910

5+4 FU1

204

5903

3

4

2

2 1

2919

001

2

3

3 1

2908

004

2

4

4 1

2913

012

2

5

5 1

205

2 2 2 2 1 2 3 4

013

2

6

6 1

504

BR

PS

BRS

506

1 1

2

2924

1

003

5902

2

2917

2928

002

6+4 6+4

2910 2911

2918

PC407

SV

6+4 6+4

2919 503

1 Main wire harness 813258 2 2 Tiller wire harness 812960

501 2912

6+4

3 3 Horn switch wire harness 811931

2913

5 Diode Assembly (D4) 813368

D

3 3

501

4 3

2914

5 3

502

6 3

2918

TCM SEM1

1 3

5900

2 3

2902

3 3

5903

4 3

5904 001 BLK 2923

5 3 6 3 7 3 8 3

1 1 1 2 3

Terminal Type Par t No. 4 5 6 7 8 9 10

500 002 BLK 2903

062007-021 803678-006 803448-003 062007-043 803448-002 062007-068 062007-005

B 1 3

010

2 3

011

3 3

009

4 3

007

5 3

005

6 3

008

013 005 008 007 009 5961 010 011 2962 004

E100-GB

261 5962

2904

11 11

2962

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

1

2

2

2

3

002

2

4

003

2

5

2

6

2

7

2

8

001 2963

261

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

012 5961

C

3

006

PC414

2961 2908 2909

2963

2

1 2

006 5962

MS-DIA-1723

2 2

3 4

HANDLE R/T PCB

3 3 2 3

JC101

1

2

1

2

1

PC419

HNS HNS

PC410 2

2

Key:

4

FTS

HANDLE MAIN PCB

2912

HANDLE HYDRAULIC PCB

2 3

A

140

11 11

PC417 2 1 2

1

1

2904

2903

4 Diode Block 102232

2902 2901

HN

2904 2903

6+4

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 116858 116858 803450-024 803450-024 803450-019 803450-019 803450-019 803450-019 E101-GB

Harness_Complete-WPS-Fixed.

MS-WP2300S-GB 05/03 • Printed in Germany

140

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

MS-WP2300S-F 02/03 • Printed in Germany

MS-DIA-1723

M1.0-0000-000141 141

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

142

HYDRAULIC SCHEMATIC

Printed in Germany

143

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Printed in Germany

M1.0-0000-000144 144 M1.0-0000-000144

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

MS-WP2300S-GB 05/03 • Printed in Germany

M1457-2

MS-HYD-1723

M1.0-0000-000145 145

Page intentionally left blank

146