Maintenance Manual: Series
Maintenance Manual: Series
Maintenance Manual: Series
WP2300S Series
Printed in Germany ● Revision Level B
Order Number: 812529-006
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
Overview of Revisions:
Page A Rev.1 04/00 General corrections and additions to the text.
Reference to authorised service personnel added.
Page 64 Rev.2 05/05 Additions to Platform Control Switches (GCSR, GCSL, PLS)
Used from serial no. 5A336576, except for 5A337937.
Page 80_A Rev.2 05/05 Parameter setting for trucks with folded platform.
Parameter setting for trucks with fixed platform.
from page 102 Rev.2 05/05 General text corrections. Updates and additions: Control handle grip,
up to page 112 Switch unit, fast/slow toggle switch, hydraulic PCB, main PCB removal/
installation, potentiometer, safety reverse switch, horn switch, hand grip.
from page 131 Rev.2 05/05 Corrections to diagrams and WP2340S addition.
from page 136 Rev.2 05/05 Wiring diagram updates. WP2340S addition.
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TABLE OF CONTENT
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M1.0-0000-000II
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TABLE OF CONTENT
Table of Content
III
TABLE OF CONTENT
Testing and Setting the Load-
Dependent Pressure Switch ............................................. 47
IV
TABLE OF CONTENT
General ............................................................................ 67
Replacing the battery ....................................................... 67
Battery Discharge Indicator (BDI) ...................................... 67
General ............................................................................ 67
Battery Discharge Indicator Setting (BDI) ........................ 68
Calibration ................................................................... 68
SEM1 Traction Controller .................................................... 69
General ................................................................................. 69
Precautionary Measures ............................................. 69
Operational Features ....................................................... 69
Speed Control ............................................................. 69
Reduced Speed Ranges ............................................. 69
Downhill Speed Control ............................................... 69
Regenerative Braking .................................................. 69
Anti - Roll Down Function ............................................ 69
Hourmeter ................................................................... 70
Self Test ...................................................................... 70
Monitored Circuits ....................................................... 70
Protective Devices ............................................................ 70
Polarity Protection ....................................................... 70
Wiring Errors ............................................................... 70
Temperature ................................................................ 70
Start Sequence ........................................................... 71
Safety Class ................................................................ 71
Maintenance .................................................................... 71
Replacing the SEM1 Traction Controller ........................... 72
Parameter Setting after Replacing the Traction Controller 72
Preparatory Measures ................................................ 72
Setting ......................................................................... 72
Status LED .................................................................. 74
Programmer ......................................................................... 75
General ............................................................................ 75
Operating SEM1 Controller Menu .................................... 76
General ....................................................................... 76
Menu Functions .......................................................... 76
PARAMETER CHANGE .............................................. 76
Menu Structure for Folded Platform ............................ 77
Menu Structure for Fixed Platform .............................. 78
Parameter Setting, Folded Platform ................................... 79
Parameter Setting, Folded Platform ................................... 80
Parameter Setting, Folded or Fixed Platform .................... 80_A .................................................... Rev.2 05/2005
Parameter Setting, Fixed Platform ..................................... 80
TESTER Menu ................................................................. 82
ALARMS Menu ................................................................ 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu .................................................. 86
Preparatory Measures ................................................ 86
Calibration ................................................................... 86
CONFIG Menu ...................................................................... 87
SET MODEL .................................................................... 87
SET OPTIONS ................................................................. 87
Adjustments ..................................................................... 87
Traction Controller Safety Test .......................................... 88
Troubleshooting Platform Logic, Controller PN 815144 .... 88_A ..................................................... Rev.2 05/2005
Electric Motors .................................................................... 89
General Maintenance Instructions ................................... 89
Preparation ................................................................. 89
Important Maintenance Instructions ............................ 89
Traction Motor Maintenance ............................................... 90
Access to Brushes ........................................................... 90
WP2300S 05/2005 • Printed in Germany
V
TABLE OF CONTENT
Maintenance .................................................................... 90
Armature ..................................................................... 90
Bearings ...................................................................... 90
Pump Motor Maintenance ................................................... 91
Access to brushes ............................................................ 91
Maintenance .................................................................... 91
Armature ..................................................................... 91
VI
TABLE OF CONTENT
M8 – CYLINDERS PAGE SER-NR. CUT REV.
Lift Cylinders ....................................................................... 121
Operation ......................................................................... 121
Removal ........................................................................... 121
Inspection ......................................................................... 123
Replacing the Piston Seal ................................................ 123
VII
TABLE OF CONTENT
SCHEMATIC DIAGRAM ................................................... 155 ....................................................... Rev.2 05/2005
TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 155 ....................................................... Rev.2 05/2005
POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 156 ....................................................... Rev.2 05/2005
PLATFORM CIRCUIT ...................................................... 156 ....................................................... Rev.2 05/2005
POWER UNIT CIRCUIT ................................................... 157 ....................................................... Rev.2 05/2005
CONTROL HANDLE CIRCUIT ......................................... 157 ....................................................... Rev.2 05/2005
Wire harness overview, folded platform,
WP2330S all versions ......................................................... 158 ....................................................... Rev.2 05/2005
Main Harness, Folded Platform, WP2330S, All Versions .. 159 ....................................................... Rev.2 05/2005
Control Handle - Wire Harness Folded Platform,
WP2330S, All Versions ........................................................ 160 ....................................................... Rev.2 05/2005
Horn Switch - Wire Harness, Folded Platform,
WP2330S, All Versions ........................................................ 161 ....................................................... Rev.2 05/2005
Wire harness overview, Fixed Platform,
WP2340S, All Versions ....................................................... 162 ....................................................... Rev.2 05/2005
Wire harness overview, Fixed Platform,
WP2340S, All Versions ....................................................... 163 ....................................................... Rev.2 05/2005
Control Handle - Wire Harness FFixed Platform,
WP2340S, All Versions ........................................................ 164 ....................................................... Rev.2 05/2005
Horn Switch - Wire Harness Fixed Platform,
WP2340S, All Versions ........................................................ 165 ....................................................... Rev.2 05/2005
Cables, Platform, Fixed Platform, WP2340S,
All Versions .......................................................................... 166 ....................................................... Rev.2 05/2005
Power Cables ....................................................................... 167
VIII
SAFETY
Printed in Germany
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SAFETY
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INTRODUCTION
Operating Instructions
Section Description
This manual contains no operating instructions. An
operating instructions manual is supplied with the vehicle. IDX Table of Content
Additional copies can be ordered as required.
With the help of this manual you and your personnel will MA Safety
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle. ITD Introduction
A01M-gb
M1.0-0000-0007
7
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
2.0 WP 2335S – 3 – 2 – S
Model Description
Fork Length
WP = Electric Pedestrian Pallet Truck
Dash mm inch
1 36
2 995
Platform Type
3 42
2335 = Fixed Platform
4 1125
2330 = Folded Platform
5 46
6 1210 48
7 54
8 60
I02a-gb
Fork Spread
Dash mm inch
1 18
2 520 20
3 540 22
4 670 27
I03a-gb
88
M1.0-0000-0008
LUBRICATION AND ADJUSTMENT
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9
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10M1.0-0000-00010
LUBRICATION AND ADJUSTMENT
Jack up Points
MS1723-100
M1458-a
M-1.0-0000-00011
11
LUBRICATION AND ADJUSTMENT
Folding Platform
Fit the chains or lifting slings as shown in the diagram:
or
S
H
R L
L R
MS-1723-101
12M-1.0-0000-00012
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
M-1.0-0000-00013
13
LUBRICATION AND ADJUSTMENT
600
> 800
WP
2300
MS-1723-103
14M-1.0-0000-00014
LUBRICATION AND ADJUSTMENT
Battery connector
(EMERGENCY
DISCONNECT)
FU1
FU2 - FU3 F/C
Fan
Magnetic brake
Traction
controller
Pump contactor
Lift cylinder (LH)
Pump motor
Pressure switch
PS
Lowering
MS-1723-120
valve SV
M-1.0-0000-00015
15
LUBRICATION AND ADJUSTMENT
Fast / Slow Travel Switch
Button, Horn
Travel Switch
16M-1.0-0000-00016
LUBRICATION AND ADJUSTMENT
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M-1.0-0000-00017
17
LUBRICATION AND ADJUSTMENT
Cold Store Trucks ● Jack up the truck, remove the wooden blocks and
lower the truck.
Special hydraulic oil, lubricant oils and grease for low
temperature applications must be used for cold store ● Charge the battery or install a charged battery.
trucks (see table on following page). All screws, wash-
ers, nuts, pins, retaining rings etc. must be treated ● Connect the battery.
regularly with an anti-corrosion solution CROWN no.
805236-004. Electrical connections and components ● Carry out the daily check.
must be carefully protected against corrosion. For more
details refer to chapter 4. *) Do not use high pressure cleaners and/or
solvents on the truck. Do not use metal brushes.
Maintenance intervals must be adapted to the condi- Do not wet-clean the electrical system and do not
tions of use. They should be as frequent as possible to use flammable cleaning solutions.
prevent excess wear.
Truck Decommissioning
When taking the truck out of service for more than 3
months, proceed as follows:
● Disconnect the battery.
18M-1.0-0000-00018
LUBRICATION AND ADJUSTMENT
Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
Hydraulic oil Tellus 32 Shell 053001-003 D
Hydran LZ 32 Finol
B110 Fuchs
Minralölwerke
GmbH
Low temperature
Deutz Oel HVI 32 Klockner 053001-009 DD
hydraulic oil
Low temperature
Mobil SHC 624 Mobil 053002-009 AA
transmission oil
L01_lubricants_wp-GB
M-1.0-0000-00019
19
LUBRICATION AND ADJUSTMENT
Check and Maintenance Schedule
The following check and maintenance schedule as- When performing maintenance work always check for
sumes single-shift operation under normal operating wear, corrosion and damage and ensure that the parts
conditions. The length of maintenance intervals will are operating correctly and are secure. If in doubt,
however depend on the particular operating conditions. replace them.
Battery Connector
2 Check operation
( = Emergency Stop )
10 Wheels / Load wheels Check tyres for wear, nails, metal splints etc.
11 Hydraulic lines and connections Check for leaks, tighten connections if necessary
L02-S-GB
20M-1.0-0000-00020
LUBRICATION AND ADJUSTMENT
2
7
1
10
11
12 MS1723-200 9
3
10 6
5, 8
7
MS1723-004
M-1.0-0000-00021
21
LUBRICATION AND ADJUSTMENT
22M-1.0-0000-00022
LUBRICATION AND ADJUSTMENT
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M-1.0-0000-00023
23
LUBRICATION AND ADJUSTMENT
9 Load wheels and castor bearings Check for play, replace bearings if necessary
11 Drive unit guide Check for play, replace rails if necessary. Lubricate.
L03-S-GB
24M-1.0-0000-00024
LUBRICATION AND ADJUSTMENT
6 5
7
3
11
MS1723-200
10
MS1723-013
9
9
MS1723-011
M-1.0-0000-00025
25
LUBRICATION AND ADJUSTMENT
Carbon brushes
2 Check for wear, ease of motion and contamination
Pump and drive motor
L04-gb
10 Load wheel and castor axles Clean, check for wear, replace if necessary, grease
L05-gb
26M-1.0-0000-00026
LUBRICATION AND ADJUSTMENT
1
7
11
9
10 9 3
4
MS1723-011
MS1723-011
M-1.0-0000-00027
27
LUBRICATION AND ADJUSTMENT
No Item Action
1 Pump and drive motor Check commutator for damage and wear; blast dust with air
L06-gb
L07-gb
28M-1.0-0000-00028
LUBRICATION AND ADJUSTMENT
MS1723-200
M-1.0-0000-00029
29
LUBRICATION AND ADJUSTMENT
Grease items and grease intervals
9 Change gearbox oil A A/R Initial change after 250 hoursof operation X
L08-S-gb
A/R = As required
30M-1.0-0000-00030
LUBRICATION AND ADJUSTMENT
4
3
1,2
MS1723-011
M-1.0-0000-00031
31
LUBRICATION AND ADJUSTMENT
The castor wheels are on the left and right hand sides 230 mm - 220 mm = 10 mm (A)
below the truck. They prevent the truck from tipping 125 mm - 120 mm = 5 mm (B)
over when travelling around bends. 10 mm - 5 mm = 5 mm (Adjustment)
The castors apply a certain supporting force to the Therefore, the screws (B) in Fig. M1519 should be
ground over long periods of time, as the drive unit on tightened by 5 mm.
the slide generally compensates the drive wheel and
castor wheel wear. However, the greater the tyre wear, ● Loosen both jam nuts (A) and turn them upward
the less the drive wheel contact pressure. This by at least the calculated adjusting measurement.
increases the braking distance and when travelling with
heavy loads the truck can skid on smooth surfaces. ● Tighten screws (A) in turn until the calculated
adjusting measurement is obtained for both
New drive wheels have a 230 mm diameter. screws.
If the diameter is only 220 mm, the drive unit spring ● Check dimension C: nominal measurement
pre-tension must be increased. Otherwise the drive = 33 mm (with wheels)
wheel will skid excessively, thereby also increasing
the wear. The castor wheels will also wear out ● Jam the screws (B) with nuts (A).
prematurely due to excess contact pressure.
Procedure:
A - B = Adjustment required
M1519
32M-1.0-0000-00032
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
8 .8
8 .8 8
1 2 .9
1 2 .9
M-1.0-0000-00033
33
LUBRICATION AND ADJUSTMENT
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
T02-gb
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
T03-gb
34M-1.0-0000-00034
HYDRAULICS
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36M1.0-0000-00036
HYDRAULICS
Hydraulic Symbols
Vented reservoir
with lines above the fluid level Electric motor
M
with unidirectional turn and speed
Vented reservoir
with lines below the fluid level
Electric motor
M with unidirectional turn
and variable speed
Filter or strainer
Hydraulic pump
with fixed displacement
Hydraulic line with full flow
and single direction of turn
(tubing or hose)
Pressure gauge
Thermometer
M3559
M-1.0-0000-00037
M1.0-0000-00037
37
HYDRAULICS
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
Single-acting cylinder,
with cushion
Dual solenoid
Assembly housing,
manifold block
Proportional solenoid
M3560
38M1.0-0000-00038
M-1.0-0000-00038
HYDRAULICS
Throttle, adjustable
Pressure-compensated
flow control with reverse
flow bypass; fixed.
Flow divider/combiner
Velocity fuse
Bypass flow control
with controlled flow,
pressure-regulated
P
Torque generator
Relief valve, adjustable T
M3561
M-1.0-0000-00039
M1.0-0000-00039
39
HYDRAULICS
M3562
40M1.0-0000-00040
M-1.0-0000-00040
HYDRAULICS
Hydraulic System
Lift cylinder
Pressure-Switch
Lowering valve
Filter
Filter
Non-return valve
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
M-1.0-0000-00041
M1.0-0000-00041
41
HYDRAULICS
Removing the Hydraulic Unit
WARNING ● Unplug the battery connector
(= Emergency Disconnect).
De-pressurise all components before
carrying out maintenance work on the ● Secure the truck from rolling away.
hydraulic system.
● High pressure hydraulic oil can cause ● Before commencing maintenance work place a
serious injuries. flat container or (if necessary) a large cardboard
box underneath the work surface.
● Whenever a high pressure fluid penetrates
the skin it must be treated as an ● Disconnect the wire connections (see Fig.
emergency, even if the skin shows no M1522).
initial reaction. Physical effects set in later.
● Secure all connections before re-applying ● Unscrew the power connections to the pump
system pressure. Keep hands and body motor (see Fig. M1522).
away from any ports as high pressure
hydraulic oil can emerge. ● Unscrew the pressure connection.
● Use absorbent paper to track leaks, never ● Obtain a suitable support on which to rest the
use your hands! hydraulic unit, e.g. a heavy iron ring.
Connecting
Cable
Screws fastening
hydraulic unit to
chassis
Reservoir flange
M1522
42M1.0-0000-00042
M-1.0-0000-00042
HYDRAULICS
Replacing the Hydraulic Pump ● To refit the hydraulic unit proceed in the reverse
order of Removal. Note torques!
NOTE Both motor connecting cables: 4±0.5 Nm.
The hydraulic pump should not be
replaced on site. Commissioning and Bleeding the
The pump is replaced as a complete as- System
sembly.
The seals of any disassembled parts and ● Check that the system is clean and properly
filters must always be replaced! assembled. In particular, the pressure ports must
be tightly secured.
Removal
● Initially, fill the hydraulic oil only up to half
● Remove the hydraulic unit as described in the the reservoir height (see lubricant table) using
previous section. a filter with a 10 µm minimum retention rate.
In the following instructions all item numbers refer ● Never operate the pump without oil.
to Figure M1442 on next page:
● All components, in particular the hydraulic ports,
● Drain the oil via the filler neck. must be completely clean and dry prior to
commissioning. Otherwise it is impossible to
● Loosen the four screws (item 1). check whether the system is sealed.
● Lift up the motor while ensuring that it does not ● Operate the lifting functions for approx. 30
fall apart. seconds to bleed the system. The oil in the
reservoir will foam considerably.
● Remove the four screws (item 26) from the
reservoir flange and remove the reservoir. ● Check the pressure port and surrounding
hydraulic components for leaks.
● Loosen the four screws (M6 x 50, hex. head) from
the engine side of the hydraulic unit and remove ● Park the truck and leave it to stand for approx. 20
the pump. 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. ● When there is no more foam in the reservoir
replenish with oil up to half the max. filling height
● Clean all components (except the motor) with a and bleed again until no more foam is visible.
clean degreasing agent; remove the old seals
and blow dry. ● Lower the forks fully.
M-1.0-0000-00043
M1.0-0000-00043
43
HYDRAULICS
M1442
44M1.0-0000-00044
M-1.0-0000-00044
HYDRAULICS
Pump Motor
For maintenance and repair work to the pump motor see
chapter 4.
Filters
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.
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 (=
● Remove the hydraulic unit as described in the maximum load). It should not be possible to raise
previous section "Removing the Hydraulic Unit". this load (safety valve opens).
● Remove the locking mechanism (4, Fig. MS1723- lf necessary adjust the safety valve so that it opens
007) and unscrew the safety valve (3), within the above-mentioned tolerance range:
● Remove the O-ring and the filter from the valve ● Remove the hydraulic unit as described in the
seat if they are still located there. previous section "Removing the Hydraulic Unit".
● Apply a thin coat of hydraulic oil to the new O- ● Using a large screwdriver hold the setscrew
ring and position it together with the filter in the securely (1, Fig. MS1723-007) and with a fork
valve seat. wrench undo the jam nut (2, Fig. MS1723-007):
Turn the setscrew clockwise to increase the limit
● Apply a thin coat of hydraulic oil to the safety at which the valve opens, turn it anticlockwise to
valve and screw it in securely to the valve seat. reduce the limit.
Insert the new locking mechanism.
Note: 1/8 turn ~ 200 kg
● Re-fit the hydraulic unit and adjust the safety
valve. ● Fix the setscrew (1) again using the nut (2).
Safety Valve Setting ● Refit the hydraulic unit and repeat the test.
Repeat the setting until the safety valve opens
The safety valve (15, Fig. M1542 previous page and 1 within the tolerance range.
to 3, Fig. MS1723-007 ) protects the hydraulic system
and the lifting mechanisms against overloading.
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
3
adjustments.
2
Safety Valve Test and Setting
MS1723-007
● With the truck at operating temperature raise a 1
test load positioned in the centre of the forks 4
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.
H01-GB
46M1.0-0000-00046
M-1.0-0000-00046
HYDRAULICS
Testing and Setting the Load-
Dependent 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
2
is then also used for braking.
M-1.0-0000-00047
M1.0-0000-00047
47
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DRIVE UNIT
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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:
Removal Lower the mechanism with the gear unit and remove it
from underneath the truck.
Remove the battery connector and key.
Maintenance
Make sure that the truck cannot be switched on.
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
DANGER AND AUTHORISED BY CROWN. FAILURE TO
COMPLY WILL INVALIDATE THE
NEVER WORK UNDERNEATH A SUSPENDED MANUFACTURER'S WARRANTY.
LOAD.
SEVERE INJURIES CAN RESULT IF THE To adjust the flank tooth bearing and pre-
TRUCK SUDDENLY FALLS. tension the shaft bearing requires years of
experience in gear units. Faulty settings will
Raise the truck until a jack / lift truck with a support for result in the premature failure of the gear unit.
the gear unit can be pushed underneath the truck. Therefore it is generally preferable to replace
Lift the truck by approximately another 50 mm to the gear in full.
release the gear unit from the gear teeth. New gear units are always supplied without oil!
Lower the truck onto the wooden blocks / supports. Prior to commissioning fill with oil in
accordance with the "Lubricant table".
Raise the mechanism onto the jack / lift truck until it
contacts the gear unit.
General
● All bearings and seals must be replaced.
Remove the electrical connections from the motor.
● Prior to disassembly thoroughly clean the gear
Loosen the six gear unit fastening screws (A) and the unit with a cold-cleaning solution and blast dry
three motor fastening screws (B) in Fig. M1564. with weak compressed air.
M-1.0-0000-00051
M1.0-0000-00051
51
DRIVE UNIT
70
M1530A
52M1.0-0000-00052
M-1.0-0000-00052
DRIVE UNIT
Gear Unit Disassembly / Assembly ● Remove the bearing inner ring (240) from the
bevel pinion shaft.
All item numbers refer to Figure M1530A unless
otherwise stated. ● Thoroughly clean all components and remove
any sealant and adhesive residue.
Disassembly
Assembly
● Drain the oil.
NOTE
● Place the gear unit with the wheel studs in a
device which prevents it from twisting. ALL SEALS AND BEARINGS MUST BE
REPLACED.
● Remove the screws (390), lock washers (330)
and O ring (290) and lift off the cover (30). Preparing the Gear Unit
● Remove the Allen screws (350) and spring lock ● Fit the outer rings of the conical roller bearings
washers (190). (230, 240, 250 and (260) in the respective
grooves of the clean gearbox. Make sure they sit
● Remove live ring bearing (130). evenly in the gearbox. Fit the lock washer (310).
● Remove screw (360) and spacer (190). ● Push the inner ring (260) of the conical roller
bearing (260) onto the bevel wheel (65).
● Loosen bevel wheel nut (140).
● Screw the wheel stud (150) into the flange using
● Remove the gear unit from the device. a dynametric key.
● Pull out the bearing outer rings (250, 260) from NOTE
their seats in the gearbox.
THE FLANGE SHAFT ASSEMBLY MUST BE
● Remove the rotary shaft seal and the lock washer TENSIONED WITH A TORQUE WRENCH.
(310) from its gearbox seat.
● Arrange the shim (190) and screw (360) and
torque the flange shaft assembly to max. 77 Nm.
● Press the bevel pinion shaft (70) down and out of
the drive pinion (110) and the bearing (230). ● Check freedom of movement and play of the
shaft. If necessary, reduce the torque.
● Remove the bearing (230) and shim(s) (440) if Record the final reading. It will be required during
necessary. calibration.
● Remove the bearing outer ring (240). ● Insert the gear unit with wheel studs in a device
which prevents it from twisting.
M-1.0-0000-00053
M1.0-0000-00053
53
DRIVE UNIT
Pinion Shaft Assembly Checking the Flank Tooth Bearing
● The tooth bearing must always rest on the inner ● Clean the components.
tooth end.
● Coat the inside of the bearing inner rings with a
● The tooth bearing must lead from high (tooth thin layer of Loctite 307.
upper edge) to low (tooth lower edge).
● Apply medium strength nut locking solution
To adjust, add and/or remove compensating spacers Loctite 242 (Crown part no. 053050-006) to the
(420, 430, 440), and/or change the bearing pre- threads of the nut (140) and screw (360).
tension.
● To assemble, proceed as described previously.
Figure M1565-1 shows the permissible tooth bearing
limits on the bevel pinion and bevel gear. ● Manually turn the gear unit while checking for
freedom of movement and the absence of play
during operation.
54M1.0-0000-00054
M-1.0-0000-00054
DRIVE UNIT
● Coat the surfaces of the gearbox cover with a thin
layer of Loctite 307 surface sealant , insert the
O ring (290) and fit the lid.
Evenly tighten the screws (390) and spring
washers (330) crossways.
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.
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.
M-1.0-0000-00055
M1.0-0000-00055
55
Blank Page
Printed in Germany
56
ELECTRICS
Printed in Germany
57
Blank Page
Printed in Germany
58M1.0-0000-00058
M1.0-0000-00058
ELECTRICS
Electrics - General
** Numbers 01 to 99 E01-gb
M1.0-0000-00059
59
ELECTRICS
Abbreviations
* If one of the above abbreviations is used more than once, a number extension
E02-gb
will be used, e.g . SV1, SV2 etc.
60M1.0-0000-00060
ELECTRICS
Sundry Abbreviations *
* If one of the above abbreviations is used more than once, a number extension
will be used, e.g . SV1, SV2etc. E03-gb
M1.0-0000-00061
61
ELECTRICS
Other Abbreviations*
GCSR Gate Closed Switch Right GCSL Gate Closed Switch Left
* 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 USA DESCRIPTION EUROPE USA DESCRIPTION
Hand operated
Wires joining maintained contact
Wires crossing Solenoid valve
c
Mechanically actuated MOSFET
c
Emergency disconnect Comparator
Motor armature
.
M0056-gb
62M1.0-0000-00062
ELECTRICS
M1559-2
63
ELECTRICS
Raise/Lower Switch (RAS, LOS) Key Switch (KYS)
The raise (RAS) and lower (LOS) switches are activated The key switch activates the power supply to the traction
by cams in the control handle cap. The cams act on controller and the battery discharge indicator (BDI).
switches mounted on the hydraulic PCB of the control
handle. The switches are mutually and mechanically Emergency Disconnect (BD)
locked so that they cannot be pressed at the same time.
Pull the battery connector on the red handle at the top
The raise (RAS) switch activates the pump contactor of the truck to fully disconnect the truck's power supply.
(P), causing the pump to start.
Fuses (FU)
The lower (LOS) switch supplies the solenoid (SV) with
current, causing the solenoid to open. The entire truck circuit is protected by the FU1 fuse
and the control circuit is protected by FU2. Cold store
Pressure Switch (PS) trucks have an additional fuse, FU3, for control
OPTION
handle heating.
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 maxi-
OPTION
Thermal Switch (THS)
mum travel speed in rider mode to a safe level. This is an electronic thermostat for cold store trucks. It
is located on the main PCB of the control handle and
Platform Control Switches applies the heating units when the temperature falls
below 0°C.
(GCSR, GCSL, PLS)
Filter (WP2340S only)
Folded platform only. These three switches are ar-
ranged in series. The chain controls the position of the When jolts are caused by travelling on uneven sur-
gate and the platform. When all the switches are faces, switches FPS1 & FPS2 – actuated by the side
closed, the traction controllers changes to the higher entry bars – can briefly open and inhibit travel. The
platform speed. filter delays the signal to inhibit travel by approx. 1s.
This avoids accidental travel cut-out.
Platform Control Switches
(GCSR, GCSL, PLS) Diode D4
Used from serial no. 5A336576, This freewheel diode on the large brake coil (BR) protects
except for 5A337937. the input on the controller against peak voltages caused
when the large brake coil is switched off.
Folded platform only. These three switches are signal
transmitters for the platform logic and enable slow / fast Diode block (DB)
travel. When all the switches are closed, the traction
controller changes to the higher platform speed. The diode block comprises diodes D1 to D3 in a single
component. It acts as a freewheel diode for the small
Lift Limit Switch (LMS) brake coil (BR) and guides the pressure switch (PS)
signal to connect the 2nd brake level.
The limit switch (LMS) cuts out the pump contactor
circuit when the preset maximum height is reached.
The limit switch is located under the front panel next to
the knuckle.
This switch must be adjusted, see Chapter 7, LIFTING
MECHANISM.
The SAS and BRS signals are also connected via this
module, depending on the platform switch and the side
gate switch, as well as the respective function switch.
64_A
ELECTRICS
WP2330S PC/JC 415
PC/JC 414
PC/JC 413
PC/JC 412
BATTERY TRAY PC/JC 411 HSS (R/T)
PC/JC 410
FU3 (Option F/C) RAS/LOS
HNS
POT,FS,RS
BD
BB (SAS)
LMS
PC/JC 203
813507
P
LINE CA 419 (HNS2)
HANDLE HARNESS
BUSBAR
PC/JC 101 CA 417 (HNS1) PC/JC 406
GCSL BRS
PC/JC 407
BR
INSTRUMENT
PC/JC 404
KYS
MAIN HARNESS
FU2
DB
FU1 PC/JC 202
A,B,C,D AND E
PM
TCM
SV
PS HN
PLS
PC/JC 102
TM
PC/JC 103
GCSR
65
ELECTRICS
WP2330S PC / JC 415
PC / JC 414
PC / JC 413
PC / JC 412
BATT PC / JC 411 HSS (R/ T)
PC / JC 410
FU3 AND RAS / LOS
FU3 HOLDER
OPT. HNS
POT, FS, RS
BD
BB (SAS)
PLM
PC / JC 200
PC / JC 416
LMS
LINE
813507_2B
BUSBAR
PC / JC 101
GCSL
FAN
CA 419 (RHS)
HANDLE HARNESS
CA 417 (LHS) PC / JC 4065
BRS
PC / JC 407
BR
INSTRUMENT
PC / JC 404
KYS
MAIN HARNESS
FU2 AND FU2
HOLDER DB
FU1 AND FU1
PC / JC 202
HOLDER
A, B, C, D AND E
PM
SV TCM
PS HN
PLS
PC / JC 102
TM
PC / JC 103
GCSR
PM
SV
PS
TM
PC/JC 415
PC/JC 414 813508
PC/JC 413
PC/JC 412
PC/JC 411 HSS (R/T)
BATTERY TRAY PC/JC 410
RAS/LOS
HNS
POT,FS,RS
FU3 (Option F/C) BB (SAS)
BD
LMS
P
LINE
BUSBAR
FTS
PC/JC 101
66
ELECTRICS
WP2340S
CA 419 (RHS)
CA 417 (LHS) HANDLE HARNESS
PC/JC 406
FU2 AND
BRS
FU2 HOLDER
PC/JC 407
BR
INSTRUMENT
PC/JC 404
KYS
DB
PM MAIN HARNESS
PC/JC 202
FU1 AND A, B, C, D AND E
FU1
TCM
HOLDER
SV HN
PS
TM
FPS
FILTER 813509
FU3 AND
FU3 HOLDER
OPT.
BD
POT,
FS, RS
BB (SAS)
LMS
P
LINE
BUSBAR
PC / JC 101 FTS
66_B
ELECTRICS
NOTE
For new trucks the battery discharge
indicator should be set at the latest after
ten discharge and charge cycles.
67
ELECTRICS
Battery Discharge Indicator Setting to check if the battery is actually 100% charged.
Faulty battery cells will make calibration impos-
(BDI) sible.
The acid density is a very reliable indicator of the ● Operate the truck as usual under normal
charge status of a lead acid battery. However, since it operating conditions until the battery is empty:
is unrealistic to continually measure the acid density of both LEDs of the BDI will flash and the lift cutout
a truck battery to an industrial standard, the battery system will be triggered.
voltage is used to determine the charge status over
longer journeys. ● Leave the battery for at least 10 to12 hours (one
hour at the very minimum!).
To adapt the BDI to the battery used and the truck's
specific application profile, you need the battery ● After this interval measure the acid density on at
manufacturer's data sheet. The values you require are least three different battery cells. The smallest
the density of the electrolyte for an 80% discharged recorded value is the one you need.
battery (20% battery residual capacity) and for a fully
charged battery (100% battery capacity). ● Compare the recorded density with the density
specified by the manufacturer for an 80%
Finally, via the potentiometer on the back of the BDI discharged battery (20% residual capacity).
the display is set to the actual discharge terminal
voltage of the battery at 20% residual capacity. ● If the battery is more than 80% discharged (less
than 20% residual capacity), set the
The factory default setting of the battery discharge potentiometer on the back of the BDI to direction
indicator is "N" (any setting from K to U is possible). K.
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
68
ELECTRICS
Regenerative Braking
M1531
Three forms of regenerative braking are available:
The programmable SEM1 impulse controller provides
effective control over the driving behaviour of the truck. ● Release braking (travel switch or multitask handle
return to neutral)
The truck is powered by a separate excited motor
(SEM). This version has two variables for governing the ● Inversion braking (travel switch set in opposite
motor output: field and armature current. direction)
69
ELECTRICS
Hourmeter Temperature
An hourmeter is integrated within the traction controller From a power part temperature of 70°C upwards the
which can be set via the programmer either to "KEY maximum current is limited in proportion to the rise in
ON" (hourmeter activated when key switch on) or temperature. At 80°C the traction controller automati-
"RUNNING" (hourmeter activated only during travel). cally cuts out.
Monitored Circuits
The following functions are monitored by the traction
controller microprocessor depending on the operating
mode:
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.
70
ELECTRICS
Maintenance ● Wipe the traction controller with a clean, damp
cloth.
Maintenance of the SEM1 controller is confined to
external cleaning. When carrying out maintenance work, ● When everything is dry, re-connect the power
check the listed errors using the programmer. cable as indicated in Fig. MS-1723-100.
MS-1723-100
71
ELECTRICS
Replacing the SEM1 Traction ● If necessary clean the contact surfaces and refit
the power cable (you must follow the
Controller instructions in the Maintenance section on the
previous page) and refit the connectors for the
WARNING control lines.
A WP2300S must only be operated with a ● For cold store versions: coat the control line
SEM1 traction controller, part no 81309x- connectors with Dow Corning® 4 Compound, part
xxx. no. 053051-006. Paint the controller with an acid-
resistant clearseal paint.
● Using the SEM1 traction controllers from
the WP2000S series (with different part Important: After replacing the controller check and
numbers) can change the operating adjust the settings. You can adjust the settings to
characteristics and hence result in suit the customer’s requirements. Follow the order
accidents. described as follows.
When you fit a new SEM1 traction controller with part
no. 81309x-xxx in a WP2300S the controller identifies Parameter Setting after Replacing the
the truck model and automatically loads the correct Traction Controller
settings when the truck is switched on.
If you have changed and stored the standard configura- Preparatory Measures
tion with the programmer, the stored parameters will be
loaded the next time the controller is started. ● 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.
● Check the contact pattern left behind by the 2. Measure the battery voltage directly at the battery
controller back plate on the heat dissipation sheet. and adjust the reading measured and displayed by
The controller must lie fully flat on the heat the traction controller (see CONFIG MENU
dissipation sheet. section).
If there are large areas with no contact to the
controller, replace the heat dissipation sheet to 3. Using the TEST menu check the wiring and
avoid thermal problems. operation of the switches (see TEST menu
section).
● Clean the contact surface of the traction controller
on the truck chassis with a lint-free cloth and use 4. Re-calibrate the traction potentiometer (see
an industry-standard silicon removal agent to “Traction pod – calibrate potentiometer, PRO-
remove the residue of the heat conducting paste. GRAM VACC menu).
● Apply a thin and even layer of Dow Corning® 340 5. Test the traction pod starting point at creep speed.
heat conducting paste, part no. 053051-008 to the The drive wheel should start when the travel
floorboard (= contact surface of the traction switch closes. If necessary increase the value
controller on the truck chassis). accordingly. Repeat the test for both travel
directions (see PARAMETER CHANGE menu
● Secure the traction controller again with the 4 section).
screws.
72
ELECTRICS
WARNING Both parameters, INVERSION BRAKING and
AUX TIME DELAY affect the “feel” of the delay
Do not exceed the maximum permissible when changing direction.
speeds when carrying out the following
adjustments as described below. Important: Power down the truck before
disconnecting the programmer. Now reconnect the
LEDs.
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).
73
ELECTRICS
Status LED The status LED is off during normal travel. When an
error occurs it flashes the respective code (see follow-
When the truck is powered up the status LED connected ing table) until the error is rectified.
to terminal strip E briefly flashes. This indicates that the
test program is being booted up by the controller. The programmer can be used to define the error more
exactly.
E04-gb
74
ELECTRICS
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
● Alpha-numeric LCD display
● 2 lines @ 16 characters
1 P A R A M . I M A X B .R E V E R S E
B R A K IN G C O M P E N S :
A C C E L . R .B R A K E
2 T E S T E R
M A X S P . S P E E D I
S .P .I S P E E D II
3 S A V E S .P .II S P E E D III
B Y P A S S F IE L D W E A K ..
4 R E S T O R E
I M O T V .P O T .
T E M P . V .B A T T .
5 A L A R M S V . M O T V M N .M O T .
M .S W .T E S T
6 A C C E L E R A T O R
7 M O T O R D A T A
1 3 5
R O L L E N T E R P A R A M
R O L L O U T S E T Operating Keys
2 4 6
M0274d
75
ELECTRICS
Description of Keys
4 OUT * Quits a sub-menu or an option. Step by step return to the main menu.
* 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
76
ELECTRICS
Menu Structure for Folded Platform
STARTROUTINE
77
ELECTRICS
Menu Structure for Fixed Platform
STARTROUTINE
78
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
Time taken to reach the new set value when the set value on the
DECELER DELAY 9-0 0 transmitter is changed. Corresponds to the braking intensity when
the transmitter is returned.
Maximum current (= speed) for the low speed range selected by the
fast / slow speed switch (HSS) (in % of max. current ACC for fast
30 - 100 %
CUTBACK SPEED 2 speed (= normal)) in walkie mode. Again, the entire mechanical
ACC
control range of the transmitter is available. Enables more sensitive
travelling at reduced speed.
Maximum current (= speed) for the low speed range selected by the
fast / slow speed switch (HSS) (in % of max. current ACC for fast
30 - 100 %
CUTBACK SPEED 1 8 speed (= normal)) in rider mode. Again, the entire mechanical
ACC
control range of the transmitter is available. Enables more sensitive
travelling at reduced speed.
E06-1-GB
79
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
E06-2-GB
Recom-
Setting
Menu item mended Description
range
setting
Time taken to reach the new set value when the set value on the
DECELER DELAY 9-0 0 transmitter is changed. Corresponds to the braking intensity when
the transmitter is returned.
E06-3-GB
80
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
E06-2-GB
Recom-
Setting
Menu item mended Description
range
setting
Time taken to reach the new set value when the set value on the
DECELER DELAY 9-0 0 transmitter is changed. Corresponds to the braking intensity when
the transmitter is returned.
E06-3-GB
Printed in Germany
80_B
ELECTRICS
Recom-
Setting
Menu item mended Description
range
setting
Release braking with foot safety switch: activated when the foot
safety switch is released. Time taken for the motor voltage to drop to
FTS BRAKING 0-9 8
zero. A setting of 9 achieves the maximum motor braking effect and
the mechanical brake is also applied with a shorter time delay.
Maximum current (= speed) for the low speed range selected by the
fast / slow speed switch (HSS) (in % of max. current ACC for fast
30 - 100 %
CUTBACK SPEED 1 8 speed (= normal)). Again, the entire mechanical control range of the
ACC
transmitter is available. Enables more sensitive travelling at reduced
speed.
Creep speed. Setting for the minimum voltage applied to the traction
motor when the travel switch is closed.
6.7 - 11 %V This function should be set to one level below the value at which the
CREEP SPEED 3
Batt. truck begins to travel.
This ensures that the empty run of the transmitter (butterfly switch)
is kept to a minimum.
E06-4-GB
81
ELECTRICS
TESTER Menu
The following table describes the various truck param-
eters which can be selected and checked in the
TESTER menu.
TESTER Menu
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
Measures the current between VMN (Volt Motor Negativ) and -BATT.
VMN
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.
Displays the nominal signal of the traction potentiometer. The left hand side displays
ACCELERATOR the voltage reading, the right-hand side the percentage relating to the maximum
operating signal calibrated via PROGRAM VACC.
Tests the operation of the load dependent "Pressure" (PS) switch). Displays the open
PRESSURE SWITCH
(OFF, load < 1.2to) and closed (ON, load > 1.2to).
Tests the operation of the "series connection" of (GCSR, GCSL, PLS) switches.
WALKIE SWITCH Displays the open (OFF) and closed (ON) status of this circuit. Only available with
folded platform!
E07-GB
82
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
ALARMS Menu
Main contactor drive test error during auto- Control logic error.
LOGIC FAILURE #1
diagnostic function on truck power-up. Replace logic system.
Star t sequence incorrect. The following sequence - Travel direction switch (FS/RS) or
must be maintained: Override switch (by moving multitask handle switch jammed.
INCORRECT START the multitask handle from idle to travel position), - Wiring error.
followed by travel switch (by pressing the butterfly - Incorrect star t sequence entered
switch). by user.
- Wiring error.
- Travel direction switch jammed.
Test is performed constantly and checks whether
FORW + BACK - Incorrect star t sequence entered
both travel directions are applied simultaneously.
by user.
- Tiller main board faulty.
83
ELECTRICS
Test performed constantly and monitors the -Potentiometer connections not wired or
PEDAL WIRE KO traction potentiometer and its wiring. Error interrupted.
message appears for broken wires. - Tiller main board faulty.
84
ELECTRICS
85
ELECTRICS
Calibrating the Traction Pod ● The display shows the new minimum and
maximum value and an arrow for the selected
Potentiometer, PROGRAM VACC travel direction.
menu
● Press OUT when you are ready.
It is always necessary to calibrate the traction pod
potentiometer when: ● The display asks “Are you sure?” If you wish to
store the new readings, press ENTER. If not,
● the traction pod potentiometer has been replaced press OUT.
or,
● Press OUT to quit the VACC menu.
● the traction controller has been replaced.
Preparatory Measures
● Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1).
Calibration
● Press ENTER on the programmer.
86
ELECTRICS
CONFIG Menu
SET MODEL NOT AVAILABLE This parameter is reserved for future use.
QUICK INVERSION
Safety reverse switch in platform mode switched on or off.
ON/OFF
Must be set to OFF if a Cur tis BDI (standard for all trucks) is
BATTERY CHECK ON/OFF
used.
E11-GB
87
ELECTRICS
● Connect one end of the test lead to -BATT. ● Switch off the truck, remove the test lead com-
pletely, 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
● Connect the programmer to the traction controller. start.
Test lead
1
FU 10A
2
3
Traction Controller
A2 F2 F1
A1
TM
Line
+ -
P
PM
FU1
125A
BD:1 24V BATT. BD:2
805980_6
88
ELECTRICS
Troubleshooting CA 200
PLATFORM LOGIC
UNUSED 11 UNUSED
814990-7_2A
Rider Mode:
1 – Pin 12 is high when:
a – Input Pin 2, GCSR is high AND
b – Input Pin 3, GCSL is high AND
c – Input Pin4, PLS is high
No Drive Mode:
If the truck is not in Walkie or in rider mode, then it is
NO DRIVE MODE:
a – Pin 12, Rider mode, is low
b – Pin 17, BRS output (A5) is low
SAS output:
Pin 13 is only high when:
a – SAS Input Pin 8 is high AND
b – Input Pin 2, GCSR is low AND
c – Input Pin 3, GCSL is low AND
d – Input Pin4, PLS is low
Code:
Pin 20 is connected to BATT NEG
+BV (AK)
Pin 1 is connected to +BV (AK)
BATT NEG
Pin 10 is connected to BATT NEG
Printed in Germany
M1.0-0000-00094
88_B
ELECTRICS
probably have been thermally overloaded. Ther-
Electric Motors mal overloading (temperatures >160 ºC) causes
the brushes to swell up.
General Maintenance Instructions Brushes which jam in the brush support produce
intense sparking and destroy the collector.
The following instructions apply to all motors. Details
relating to specific models and designs are provided in ● The brush edges must not be cracked. Brushes
the sub-sections (traction motor, pump motor etc.). with cracking along the long edge of the surface
will have been damaged by a worn collector.
Preparation If information is provided in the manual, restore
the collector to the specified limits. Otherwise,
● Disconnect the battery (= EMERGENCY replace the armature in full.
DISCONNECT).
● Loose brush connections are a clear sign of
● Secure the truck from rolling away. motor overload. In this case inspect the collector
for burning and repair or replace as necessary.
Important Maintenance Instructions
● When fitting the brush take care to place the
● Remove all carbon brushes and check for wear.
spring gently on the brush. If the contact is too
If one or more carbon brushes need to be
hard the brush will be damaged.
replaced, replace all brushes. In addition to the
carbon brushes the pressure springs must also
● Make sure that all brushes contact the armature
be replaced to ensure the correct pressure.
at the same pressure.
The length of the shortest brush determines
whether the brush set needs to be replaced. ● New brushes must be run in with a medium load
in the first hours. Never fully charge the motor
Even if the minimum length has not been straight away.
reached the brushes should be replaced as the
remaining useful life could be much shorter than
the time until the next inspection:
89
ELECTRICS
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.
Bearings
M1569 ● The ball bearings are maintenance-free. They
must always be replaced if removed for repair
Access to Brushes work.
● Disconnect the battery
Maintenance
● Apply dry compressed air to the motor.
90
ELECTRICS
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.
M1522
91
Blank Page
Printed in Germany
92
BRAKE
Printed in Germany
93
Blank Page
Printed in Germany
M1.0-0000-000100
94M1.0-0000-000100
BRAKE
Brake
Brake fastening screws on the drive motor
(3 off)
M1462
Removal
CAUTION
Do not bring brake components into con-
tact with oil or grease.
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).
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.
● Remove the magnetic body (7) from the motor
(including everything connected to it). ● Insert the spring (10) and bushing (13) into the
magnetic body (7).
Disassembly
● Position the armature plate (14) correctly on the
● Remove the rotor (16) from the hub (15). magnetic body, while noting carefully the hole
Take care not to damage the gear teeth. pattern.
96
BRAKE
● Using a medium strength screw sealant screw Air Gap Setting
the banjo bolts (17) into the magnetic body (7) as
far as the stop. The operating air gap is measured between the mag-
netic body and the armature plate when the truck is
● Insert the screws (8) into the armature plate so braked. Set the air gap to 0.25 mm (see Fig. M1467).
far that a gap of at least 1mm remains all around
between the armature plate and the magnetic ● Unscrew the banjo bolts (3) as far as the fixed
body. 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 ● Test the working air gap at several points around
the gear teeth are not damaged in the process. 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
● Re-fit the electrical connector (20). bolts (17) into the magnetic body (7). Then re-
measure as described above.
Assembly
● When the air gap has been correctly set, torque
Re-assemble the brake in the reverse order of re- the Allen screws (3) again to 9.5 Nm.
moval.
CAUTION
Fastening screw
Banjo bolt
Rotor thickness
97
BRAKE
Brake Moment Setting 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
Inner ring truck is empty (see Table B0 1S-GB) .Now fix the outer
Outer ring ring again using the retaining sheet.
NOTE
Laden Laden
(nominal Unladen (nominal Unladen
load) load)
98
STEERING
Printed in Germany
99
Blank page
Printed in Germany
100
STEERING
Pre-tensioned springs!
8
When removing, take care to avoid injury.
Removal ● Drive the axle (3) as far out to the right hand side
so that the 2 springs (4) can be removed.
● Unscrew the panel (1) and push it up.
● Bring the tiller (8) to its highest position and keep Assembly
it there.
● Push the springs (4) onto the axle (3). The inner,
offset end must insert into the axle (3) groove. A
● Mark the position of the axle (3).
strap wrapped around the inner end of the first
spring to be inserted can prove useful when
● Drive out the tensioning pin (2).
inserting the other springs.
The relieved springs should now turn the axle.
● Drive the axle (3) into position.
● Tilt the tiller down to its lowest position.
● Set the tiller (8) to the upper limit.
● If the axle (3) has still not turned, it is clearly fixed
in its position and must be moved with the aid of
● Drive in the tensioning pin on the left-hand side
a face spanner. To fully relieve the springs, rotate
(if necessary on the right). Turn the axle as far as
the axle (3), seen from the left hand side, approx.
necessary. Grease the springs. Fasten the panel.
20° anticlockwise from the fixed position.
Check the brakes.
M1.0-0000-000107
101
Blank Page
Printed in Germany
102
STEERING
Control Handle Grip
Main Components
This section contains an overview of the main compo-
nents and associated terms:
Upper shell
Switch unit
Grip
MS518
Lower shell
CAUTION
MS514
A
MS501
● Remove the inner Torx® screws (A) and pull off
the grips (see Fig. MS501).
MS502
MS503
MS517
B
Replacing any of these components requires the switch Make sure you re-connect the control handle wire har-
unit to be replaced. ness and the horn wiring. The connectors cannot be in-
terchanged and are protected against incorrect polarity.
Guide the switch unit over the two side parts (C, Fig.
MS514) and push the switch unit down and forward.
Test all the functions once the battery has been re-con-
nected.
A
MS513
MS514
There are no parts on this switch module that can be ● Insert a new toggle module and fix it with 2 Torx®
repaired. It must be replaced in full. screws.
This switch module is available in two versions: a ● Refit the switch unit (see SWITCH UNIT section in
standard and a cold store version. Make sure you use this chapter). Test the operation.
the right module!
MS504
Hydraulic PC board
A
There are no parts on this PC board that can be repaired.
MS511 It must be replaced in full.
Assembly
Printed in Germany
107_A
STEERING
Main PC Board Removal/Installation ● Remove the two (A) Torx® screws from the
larger, main PC board (the smaller one is the
This PC board is available in two versions: a standard hydraulic PC board). Disconnect safety reversing
and a cold store version. Make sure you use the right PC switch lead connector from main PC board and
board! remove board.
Main A
PC Board
10682
A MS509
B MS508
Disassembly
● Remove the two Torx® screws (B) holding the ● Remove the two Torx® screws (D) shown in Fig.
orange lowering switch cap. Lift out the switch MS510. Remove the connectors from the PC
cap. boards. Pull the potentiometer off the square
axis.
Assembly
E
F
MS500
B MS508
● Remove the four Torx® screws shown in Fig.
● Remove the switch unit (see SWITCH UNIT section MS509. Remove the switch unit cover.
in this chapter).
INFORMATION
● Remove the two Torx® screws (A) (see Fig.
MS508) from the thumbwheels and disconnect The thumbwheels cannot be incorrectly
the thumbwheels. Take care not to lose the positioned. They will only fit correctly in
plastic slide bearings (washers). one position.
Assembly
MS509
MS502
Horn switch
Disassembly
MS503
MS501
Assembly
INFORMATION
MS503
112
LIFTING MECHANISM
Printed in Germany
113
Blank Page
Printed in Germany
114
LIFTING MECHANISM
WARNING
Lift 130 mm ± 5 mm
+3
85-3 mm 85 -3 mm
MS1723-701
M1.0-0000-000123
115
LIFTING MECHANISM
Loadwheel, tandem
M1438
116
LIFTING MECHANISM
Limit switch fitted for lift Upper hole: Limit switch location for
cut-out at 130 mm max. lift = 150 mm
Trip cam
Track
M1473
M1.0-0000-000125
117
Blank Page
118
CYLINDERS
Printed in Germany
119
Blank Page
Printed in Germany
M1.0-0000-000128
120
M1.0-0000-000128
CYLINDERS
Lift Cylinders
Operation
The two lift cylinders are single-acting. The piston rods
are raised by the hydraulic oil pressure and lowered by
the weight of the raised load. Fig. M1475 shows a
cylinder cross-section. Piston Rod
Removal Scraper
● Remove the front panel.
Guide Ring
● 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 Seal
out.
Cylinder Tube
WARNING
M1.0-0000-000129
121
CYLINDERS
● First drive out the dowel from the left-hand piston
rod attachment between the contactors and
controller so far as to be able to check whether
the pin collides with the contactor or controller
when it is fully driven out.
M1474
Bracket
M1.0-0000-000130
122
CYLINDERS
Inspection Replacing the Piston Seal
Carefully examine the cylinder unit prior to carrying out NOTE
repair work. To do this, extend and retract the cylinder
several times. Check the seal groove and piston rod
(critical seal location) for damage before
● Check the piston rods for signs of nicks, fitting a new seal.
scratches or other damage to the surface. Failure to do so will otherwise result in
repeated leakage.
● Check the scraper rings for wear and unusual
leakage.
Use burr-free assembly tools and equipment made of
● If any excess hydraulic oil is leaking from the soft metal or a suitable plastic without sharp edges to
piston rod this may be due to a damaged rod replace piston seals. Do not use a screw driver or
seal. Replace the rod seal and make sure that similar tools as these could damage the seal edges.
the seal seat is clean and intact.
If a new seal must be inserted over sharp edges, slots
● When repairing the cylinder check the condition or corners, take appropriate protective measures.
of the guide rings. Ideally, all seal components
should be replaced, not just worn or damaged
seals.
M1.0-0000-000131
123
Blank Page
124
PLATFORM
Printed in Germany
125
Blank Page
Printed in Germany
126
M1.0-0000-000134
M1.0-0000-000134
PLATFORM
This is a critical setting. The platform must ● Adjust the braking effect so that the platform can
always swing up whenever the driver swing up by itself, with the damping effect, from
leaves the truck. The platform switch is any position. The critical point is a platform angle
actuated and the maximum travel speed of approx. 45 degrees above the horizontal
reduced. position.
M1550
M1.0-0000-000135
127
PLATFORM
Platform Switch Setting (PLS) ● Remove the panel (23).
The switch sends a signal to the traction controller. This ● Loosen the screw (4).
causes the traction controller to switch to a higher max.
travel speed for platform mode when the platform folds ● With the platform lowered twist the adjusting ring
down. (3) so that the switch is activated. Actuation must
occur between 0 degrees (fully lowered platform)
The switch lever for the platform switch (21) is activated and max. 10 degrees for the raised platform. The
via the adjusting ring (3). A screw (4) on the shaft (10) switch must not be activated above 10 degrees.
prevents the adjusting ring from twisting. Now tighten the screw (4) again and check the
setting.
WARNING
This is a critical setting. The platform must
always swing up whenever the driver
leaves the truck. The PLS must then be
actuated within 10 degrees.
M1550
M1.0-0000-000136
128
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
M1.0-0000-000137
129
PLATFORM
Side Gates, Mechanical Setting
● Remove the panel (10)
M1546
M1.0-0000-000138
130
PLATFORM
MS-1723-901
B
MS-1723-900
8
5
3
4 6 4
3
7
8
9
1
10
12
18
17 B
11 19
15 =A C
35
14 34
36
35
38
13
24
24 24 43
26 24
34 39
C 16 27 45
35 25 44
43 40 41 31
44 23 28
45 42
38 24 24 20
31
26
24 27 21 22
25
41 28
37 42 30
24 23 33 FPS 1 & FPS 2 (29)
20
31 32
Entry Bar (34) 21 29 MS-1723-003
22
8
5
3
4 6 4
3
7
8
9
1
10
12
18
17 B
11 19
15 =A C
35
14 34
36
35
38
13
24
24 24 43
26 24
34 39
16 27 45
C 35 25 44
43 40 41 31
44 23 28
45 42
38 24 24 20
31
26
24 27 21 22
25
41 28
37 42 30
33
24 23
20
FPS 1 & FPS 2 (29)
31 32
21 29 MS-1723-003
Entry Bar (34) 22
132_B
ELECTRICAL DIAGRAMS
Printed in Germany
133
Blank Page
Printed in Germany
134
Blank Page
Printed in Germany
135
DIAGRAMS
Notes to overall wiring diagram,
standard version, folded platform,
WP2330S
Key:
1 Walkie mode
GCSR &/ or PLS &/or GCSL open
201
KYS
202 KYS COMM +BV 2 CA 202
c LMS
A 2916 PC404-3 RAS SIG
2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
2 2902 +BV (AK) 2927 D4 5905 2919 LOS SIG 2 003 PC415-5 LOS SIG
160A
2911 PS SIG
BRN (010) PC410-7 POT SIG
5903
A2 1
VMN POT CIRCUIT
505 P-
2 BLU (011) PC410-8 POT LOW 2901 BDI +BV (AK) 2 KYS
& DRIVER
BATTERY
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
1 2909 UNUSED 8 UNUSED
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T (HSS) SIG
FAN +
BD:2
2913 JC 202-4 HNS SIG CA 406
D
1 UNUSED HN
F2 + - - UNUSED 1 RED
F2 2 2912 HNS SIG 2927 D4
002 A7 +BV (AK) 2 BLK BRS
3 501 BATT NEG
5
4 2914 RAS SIG 001 A5 BRS SIG 3 WHT
2915 PC404-4 RAS SIG
BLK
5 502 BATT NEG UNUSED UNUSED
4
6 2918 LOS SIG
E + -
-BATT P CA 407
1 + RXD
+ BR/1
504 JC202-6 2928 DIODE BLOCK (2) BRS SIG 1 BLK
2 RXD NEG + -
505 DB(1) SV 503 -
3 + TXD 5902 DIODE BLOCK (4) BATT NEG 2 BLU
4 TXD NEG - + 2919 JC202-2 LOS SIG BR
+ BR/2
2924 DIODE BLOCK (5) BRS / PS SIG 3 BLK
5 BATT NEG
-
6 + BV (AK) 7 506 DIODE BLOCK (1) BATT NEG 4 BLK
7 UNUSED
8 UNUSED CA 101
CA 411 UNUSED 1 RED
CA 415 CA 410 1
POT 2906 2 BLK GCSL
2
2961 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1 1
3 2903 3 WHT
WHT (001) PC202-3 +BV(AK) 2 GREY/PINK (005) B-5 SAS SIG 2 4
ACS
UNUSED 4 UNUSED
FS
2961 PC414-1 +BV(AK) 3 YEL (008) B-6 FS SIG 3 5
6
RS
VIO (002) PC202-1 RAS SIG 4 BLK (007) B-4 RS SIG 4 CA 102
RAS 5 LOS 7
PINK (003) PC202-2 LOS SIG 5 RED/BLU (009) B-3 POT HIGH 5 UNUSED 1 RED
6 CA 412
BLK
261 PC410-11 NOT USED 6 5961 PC415-8 NOT USED 6 3 2920 A8 PL SIG 2 BLK PLS
GRAY 1
1 SAS
RED (012) PC202-5 NOT USED 7 BRN (010) B-1 POT SIG 7 SAS 2906 PL SIG 3 WHT
2
BLU 5
1
5961 PC410-6 NOT USED 8 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB CA 103
2 5
1
2 HNS1
GRAY (004) PC202-4 HNS SIG 10 1 UNUSED 1 RED
3
2904
CA 414 261 PC415-6 NOT USED 11 2903 HNS1
4 2904 A7 +BV (AK) 2 BLK GCSR
CA 419
2902 1
2961 PC415-3 +BV(AK) 1 5962 PC414-4 NOT USED 12 5 2 2903 PL SIG 3 WHT
HNS2 5
1
6
2901 1
UNUSED 2 4 UNUSED 4
HNS2 UNUSED
HSS MAIN PCB
WHT/GRN (006) C-3 R/T (HSS) SIG 3
POT
D4
c
9
DIODE BLOCK BRS 5 5
3
1 5900 PC404-1 BDI KYS 200 PC404-7 BDI
5
HNS 1
HNS 2
SAS
2
2 2902 203 FU2 OUT +BV
BR SMALL COIL 5
5 3 5904
BR LARGE COIL
1
RAS LOS
4 4 5902 DIODE BLOCK (4)
HYDR. PCB
HSS
8 5 2918 PC200-17
LINE
R/T PCB
MAIN PCB
6 UNUSED
INSTRUMENT 2932 JC406-2 BRS
CURTIS 803 "COMBI" 2 7
c
LINE
2919 JC103-2 GCSR
TT 1 LMS
2920 PC200-12
8
2921
2930
KYS 2 8
3
4
BATT NEG 5 8
GCSR
UNUSED 6
7
BDI 1
B PS
UNUSED 8
GCSL
HN
1
4 BLK (007) PC410-4 RS
5 2933 PC210-2
10 5 2 3 4
20 6 YEL (008) PC410-3 FS
1 8 P SV
10
17 13
12
9
C 2914 JC202-3 +BV (AK)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
1 2921
C
D
A
TCM (SEM 1)
FAN
+BATT
-BATT
VMN
E
F1
F2
2
3
4
5
6
7
8
1
814990-1_2A.pdf 814990-2_2A.pdf
201
1
FU1 LINE 2929 PC200-3 3 WHT
160A KYS +BV IN TO THE LOGIC 2
LINE CONTACTOR LOW 3 4 UNUSED
BRAKE LOW (large coil) 4
BRS INPUT 5 CA 102
BATTERY NEG 6
1 RED
BATTERY POS (AK) 7 PLS
WALKIE/RIDER MODE 8 2927 2 BLK
A1 +BATT WHT
B 2928 PC200-4 3
BD:1 POT WIPER 1
4 UNUSED
POT LOW 2
POT HIGH 3 CA 103
RS - REVERSE SWITCH IN 4
SAS SAFETY SWITCH IN 5 2926 1 RED
GCSR
FS - FORWARD SWITCH IN 6
2919 CONTROLLER A7 +BV (AK) 2 BLK
A2
VMN
C 2925 PC200-2 3 WHT
BATTERY POS (AK) 1
24V PERF.CUT 2
4 UNUSED
BATTERY TM
PERF. 1/2,HSS (R/T) INPUT 3 NOTE:
GCSL, PLS & GCSR are shown in walkie mode.
F2
+ F1
D DIODE BLOCK
UNUSED 1
HN - HORN HIGH 2
HN - HORN LOW 3 501 PC407-4 BR LOW D1
502 P CONTACTOR CONTACTS 1
P - PUMP CONTACTOR HIGH 4
503 PC200-10
BD:2
- P&SV-P CONTACTOR LOW 5
D2
PM SV - LOWERING VALVE HIGH 6 2911 PC407-1 BRAKE
2
2912 PC200-5
F1
F2 E
2909 CONTROLLER C-2 D3
POSITIVE SERIAL RECEPTION 1 3
2910 PS
NEGATIVE SERIAL RECEPTION 2
P 5902 CONTROLLER A-4
POSITIVE SERIAL TRANSMISSION 3
5903 PC407-2 4
NEGATIVE SERIAL TRANSMISSION 4
5901
BATT NEG 5
BATTERY POS (AK) 6 2908 PC 407-3 5
D4
UNUSED 7
UNUSED 8
-BATT 2904 JC406-3 BRS-5
502 DIODE BLOCK (1) 504 JC202-6
500 PC404-5 814990-3_2A.pdf 814990-4_2A.pdf
NOTE:
1- Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND Used from S/No. 5A336576 on, but not on S/No. 5A337937
CA 407 UNUSED 2
HSS
LARGE COIL WHT/GRN (006) CONTROLLER C-3 3
2911 DIODE BLOCK (2) 1 BLK
5962 PC410-12 NOT USED 4
5903 DIODE BLOCK (4) 2 BLU
SMALL COIL BR R/T PCB
2908 DIODE BLOCK (5) 3 BLK
PLATFORM LOGIC
CA 200
2901 +BV 1 +BV(AK)
UNUSED 7 UNUSED
uC
2922 SAS 8 SAS INPUT
UNUSED 9 UNUSED
UNUSED 11 UNUSED
UNUSED 14 UNUSED
UNUSED 15 UNUSED
UNUSED 16 UNUSED
UNUSED 19 UNUSED
814990-7_2A.pdf
Key:
1 Walkie-mode
GCSR &/ or PLS &/or GCSL open
204
LMS
10A TCM SEM1
201
KYS
2926
2925
202 KYS COMM +BV CA 202
c
A 2916 PC404-3 RAS SIG 2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
2 2902 +BV (AK) 2927 D4 5905 2919 LOS SIG 2 003 PC415-5 LOS SIG
160A
FU1
2911 PS SIG
A2 BRN (010) PC410-7 POT SIG
5903
VMN 1
POT CIRCUIT
505 P-
2 BLU (011) PC410-8 POT LOW 2901 BDI +BV (AK) 2 KYS
BATTERY
& DRIVER
3 RED/BLU (009) PC410-5 POT HIGH
24V
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
1 2909 UNUSED 8 UNUSED
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T (HSS) SIG
BD:2 FAN +
2913 JC 202-4 HNS SIG
D CA 406
1 UNUSED HN
F2 + - UNUSED 1 RED
F2
2912 HNS SIG
- 2927 D4
2
P 3 501 BATT NEG
002 A7 +BV (AK) 2 BLK BRS
5
4 2914 RAS SIG 001 A5 BRS SIG 3 WHT
2915 PC404-4 RAS SIG
BLK
5 502 BATT NEG UNUSED UNUSED
4
6 2918 LOS SIG
E + -
-BATT P
1 + RXD CA 407
+ BR/1
504 JC202-6
2 RXD NEG + 2928 DIODE BLOCK (2) BRS SIG 1 BLK
-
505 DB(1) SV 503 -
3 + TXD 5902 DIODE BLOCK (4) BATT NEG 2 BLU
4 TXD NEG - + 2919 JC202-2 LOS SIG BR
5
+ BR/2
2924 DIODE BLOCK (5) BRS / PS SIG 3 BLK
5 BATT NEG
-
6 + BV (AK) 8 506 DIODE BLOCK (1) BATT NEG 4 BLK
7 UNUSED
8 UNUSED CA 101
CA 411 UNUSED 1 RED
CA 415 CA 410 1
POT 2906 2 BLK GCSL
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1 1
3 2903 3 WHT
16 x //R
WHT (001) PC202-3 +BV(AK) 10 GRAY/PINK (005) B-5 SAS SIG ACS
HR POT F/C
2 2 4
UNUSED 4 UNUSED
FS
2961 PC414-1 +BV(AK) 3 YEL (008) B-6 FS SIG 3 5
6
RS
VIO (002) PC202-1 RAS SIG 4 BLK (007) B-4 RS SIG 4 CA 102
RAS 5 LOS 7
PINK (003) PC202-2 LOS SIG 5 RED/BLU (009) B-3 POT HIGH 5 UNUSED 1 RED
7
RED
CA 412
BLK
POT
D4
c
9
DIODE BLOCK BRS
1 5900 PC404-1 BDI KYS 200 PC404-7 BDI
5 5
5 2 2902 203 FU2 OUT +BV
HNS 1
HNS 2
SAS
BR SMALL COIL
3 5904
5
5902 DIODE BLOCK (4)
BR LARGE COIL
4
RAS LOS
4
HYDR. PCB
F/C 5 2918 PC200-17
8
HSS 11 LINE
F/C
11
F/C
11
6 UNUSED
MAIN PCB
R/T PCB
INSTRUMENT 7
2919 JC103-2 GCSR
CURTIS 803 "COMBI" 2
c
LINE
8 2920 PC200-12
2921
2930
TT 1 LMS
KYS 2 8
3
4
BATT 5 8
GCSR
6
UNUSED PS
BDI 7
1
B
UNUSED 8 1 BRN (010) PC410-7 POT WIPER
GCSL
HN
4 BLK (007) PC410-4 RS
1
5 2933 PC210-2
10 5 2 3 4 6 YEL (008) PC410-3 FS
20
1 8 P SV
10
17 13
12
9 C 2914 JC202-3 +BV (AK)
1 2921
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
D
A
TCM (SEM 1)
FAN
+BATT
-BATT
VMN
E
F1
F2
HN
D 2915 JC 202-4
7
KYS A2 F2 F1 1 UNUSED
A1 2 2916
TM NOTE: 3 505
8
FU2 FU2 LINE
1- Walkie Mode: GCSR + GCSL + PLS open. 4 2907 P
2A 10A
or GCSR + GCSL open + PLS closed.
5 506
+ - 2- Forks lower than 130mm: LMS closed.
6 2917 SV 507
P
3- Load is less than 1000kg: PS closed, 2/3 brake.
FU1 PM 4- Reduce speed: HSS is open. 2913 JC202-2
160A
BD:1 24V BATT BD:2
5- Active: RAS, BRS, SAS, HNS & LOS are closed.
8- Diode Block Pin 1, BDI (BATT NEG), Main PCB (Earth contact),
connected to Pump Contactor Contacts.
9- Diode Block Pin 3 connected to Controller C-2.
11- F/C Package: Below 5°C active.
814991-1_2A.pdf 814991-2_2A.pdf
201
HOUR METER OUTPUT 1
FU1 LINE 2927 2 BLK
160A KYS +BV IN TO THE LOGIC 2
LINE CONTACTOR LOW 3 2929 PC200-3 3 WHT
BRAKE LOW (large coil) 4
4 UNUSED
BRS INPUT 5
BATTERY NEG 6
CA 102
BATTERY POS (AK) 7
WALKIE/RIDER MODE 8 1 RED
PLS
A1 +BATT
B 2927 2 BLK
BD:1 POT WIPER 1
2928 PC200-4 3 WHT
POT LOW 2
POT HIGH 3 4 UNUSED
RS - REVERSE SWITCH IN 4
CA 103
SAS SAFETY SWITCH IN 5
FS - FORWARD SWITCH IN 6
2926 1 RED
A2 GCSR
VMN
C 2919 CONTROLLER A7 +BV (AK) 2 BLK
BATTERY POS (AK) 1
24V PERF.CUT 2925 PC200-2 3 WHT
2
BATTERY TM
PERF. 1/2,HSS (R/T) INPUT 3 4 UNUSED
F2 NOTE:
+ F1 GCSL, PLS & GCSR are shown in walkie mode.
D
UNUSED 1
HN - HORN HIGH 2 DIODE BLOCK
HN - HORN LOW 3
P - PUMP CONTACTOR HIGH 4 501 PC407-4 BR LOW D1
BD:2
- P&SV-P CONTACTOR LOW 5 502 P CONTACTOR CONTACTS 1
PM SV - LOWERING VALVE HIGH 6 503 PC200-10
2911 PC407-1 BRAKE D2
F1 2
F2 E
2912 PC200-5
POSITIVE SERIAL RECEPTION 1
NEGATIVE SERIAL RECEPTION 2 2909 CONTROLLER C-2 D3
3
P POSITIVE SERIAL TRANSMISSION 3 2910 PS
NEGATIVE SERIAL TRANSMISSION 4 5902 CONTROLLER A-4
BATT NEG 5 5903 PC407-2 4
BATTERY POS (AK) 6 5901
UNUSED 7
UNUSED 8 2908 PC 407-3 5
D4
-BATT
502 DIODE BLOCK (1) 504 JC202-6
500 PC404-5 814991-3_2A.pdf 2904 JC406-3 BRS-5 814991-4_2A.pdf
NOTE:
1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND. Used from S/No. 5A336576 on, but not on S/No. 5A337937
2914 CONTROLLER C1 3 WHT (001) PC415-2 +BV(AK) GRAY/PINK (005) B-5 SAS 2 4
POT P
FS
YEL (008) B-6 FORWARD 3 5
2915 HN HIGH 4 GRAY (004) PC410-10 HN RS
6
BLK (007)B-4 REVERSE 4
204 +BV FU3 OUT 5 RED (012) CA415-7 +BV F/C 7
RED/BLU (009) B-3 POT HIGH 5
CA 412
504 P CONTACTOR CONTACTS 6 GRN (013) CA410-1 BATT NEG BLK
5961 PC415-8 GND F/C 6 3
GRAY
1 SAS
BRN (010) B- POT SIGN 7 SAS
2
BLU
CA 404 INSTRUMENT BLU (011) B-2 POT LOW 8
CA 413
CA 417
2962 PC415-1 +BV(AK) 9 1
CURTIS 803 "COMBI" 2
2 HNS1
GRAY (004) PC202-4 HN 10 1
5900 CONTROLLER A1 TT 1 TT 3 2904 HNS
261 PC415-6 +BV F/C 11 4 2903
2900 KYS NO + BV(AK) 2 KYS 15 x //R CA 419
5962 PC414-4 GND F/C 12 5 2902 2
HNS2
2905 LMS OUT NC +BV 3 6 2901 1
HNS
2906 P CONTACTOR COIL 4 MAIN PCB
UNUSED 4 UNUSED
CA 414
CA 407 UNUSED 2
HSS
LARGE COIL WHT/GRN (006) CONTROLLER C-3 3
2911 DIODE BLOCK (2) 1 BLK
5962 PC410-12 GND F/C 4
5903 DIODE BLOCK (4) 2 BLU 2 x //R
SMALL COIL BR R/T PCB F/C
2908 DIODE BLOCK (5) 3 BLK
PLATFORM LOGIC
CA 200
2901 +BV 1 +BV(AK)
UNUSED 7 UNUSED
uC
2922 SAS 8 SAS INPUT
UNUSED 9 UNUSED
UNUSED 11 UNUSED
UNUSED 14 UNUSED
UNUSED 15 UNUSED
UNUSED 16 UNUSED
UNUSED 19 UNUSED
814990-5_2A.pdf
Key:
1 No drive:
FTS open
201
KYS
202 KYS COMM +BV 2 CA 202
c LMS
A 2916 PC404-3 RAS SIG
2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
2 2902 +BV (AK) 2927 D4 5905 2919 LOS SIG 2 003 PC415-5 LOS SIG
160A
2911 PS SIG
5903
A2 1 BRN (010) PC410-7 POT SIG
VMN POT CIRCUIT
505 P-
2 BLU (011) PC410-8 POT LOW 2901 BDI +BV (AK) 2 KYS
& DRIVER
BATTERY
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
1 2909 UNUSED 8 UNUSED
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T
FAN +
BD:2
2913 JC 202-4 HNS SIG CA 406
D
1 UNUSED HN
F2 + - - UNUSED 1 RED
F2 2 2912 HNS SIG 2927 D4
002 A7 +BV (AK) 2 BLK BRS
3 501 BATT NEG
5
4 2914 RAS SIG 001 A5 BRS SIG 3 WHT
2915 PC404-4 RAS SIG
BLK
5 502 BATT NEG UNUSED UNUSED
4
6 2918 LOS SIG
E + -
-BATT P CA 407
1 + RXD
+ BR/1
504 JC202-6 2928 DIODE BLOCK (2) BRS SIG 1 BLK
2 RXD NEG + -
505 DB(1) SV 503 -
3 + TXD 5902 DIODE BLOCK (4) BATT NEG 2 BLU
4 TXD NEG - + 2919 JC202-2 LOS SIG BR
+ BR/2
2924 DIODE BLOCK (5) BRS / PS SIG 3 BLK
5 BATT NEG
-
6 + BV (AK) 7 506 DIODE BLOCK (1) BATT NEG 4 BLK
7 UNUSED
8 UNUSED
CA 411
CA 415 CA 410 1
POT
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1
3
WHT (001) PC202-3 +BV(AK) 2 GRAY/PINK (005) B-5 SAS SIG 2 4
ACS
FS
2961 PC414-1 +BV(AK) 3 YEL (008) B-6 FS SIG 3 5
6
RS
VIO (002) PC202-1 RAS SIG 4 BLK (007) B-4 RS SIG 4 CA 102
RAS 5 LOS 7
PINK (003) PC202-2 LOS SIG 5 RED/BLU (009) B-3 POT HIGH 5 UNUSED 1 RED
6 CA 412
BLK
261 PC410-11 NOT USED 6 5961 PC415-8 NOT USE 6 3 2903 A8 FTS SIG 2 BLK FTS
GRAY 1
1 SAS 2904 A7 +BV (AK)
RED (012) PC202-5 +BV F/C HR 7 BRN (010) B-1 POT SIG 7 SAS 3 WHT
2
BLU 5
5961 PC410-6 NOT USED 8 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB 2
2 HNS1 5
GRAY (004) PC202-4 HNS SIG 10 1
3
2904
CA 414 261 PC415-6 NOT USED 11 2903 HNS1
4
CA 419
2902
2961 PC415-3 +BV(AK) 1 5962 PC414-4 NOT USED 12 5 2 5
2901 HNS2
UNUSED 2 4 6 1
HNS2
HSS MAIN PCB
WHT/GRN (006) C-3 R/T (HSS) SIG 3
204
LMS
10A TCM SEM1
201
KYS
2926
2925
202 KYS COMM +BV CA 202
c
A 2916 PC404-3 RAS SIG 2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
2 2902 +BV (AK) 2927 D4 5905 2919 LOS SIG 2 003 PC415-5 LOS SIG
160A
FU1
2911 PS SIG
A2 BRN (010) PC410-7 POT SIG
5903
VMN 1
POT CIRCUIT
505 P-
2 BLU (011) PC410-8 POT LOW 2901 BDI +BV (AK) 2 KYS
BATTERY
& DRIVER
3 RED/BLU (009) PC410-5 POT HIGH
24V
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
1 2909 UNUSED 8 UNUSED
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T (HSS) SIG
BD:2 FAN +
2913 JC 202-4 HNS SIG
D CA 406
1 UNUSED HN
F2 + - UNUSED 1 RED
F2
2912 HNS SIG
- 2927 D4
2
P 3 501 BATT NEG
002 A7 +BV (AK) 2 BLK BRS
5
4 2914 RAS SIG 001 A5 BRS SIG 3 WHT
2915 PC404-4 RAS SIG
BLK
5 502 BATT NEG UNUSED UNUSED
4
6 2918 LOS SIG
E + -
-BATT P
1 + RXD CA 407
+ BR/1
504 JC202-6
2 RXD NEG + 2928 DIODE BLOCK (2) BRS SIG 1 BLK
-
505 DB(1) SV 503 -
3 + TXD 5902 DIODE BLOCK (4) BATT NEG 2 BLU
4 TXD NEG - + 2919 JC202-2 LOS SIG BR
+ BR/2
2924 DIODE BLOCK (5) BRS / PS SIG 3 BLK
5 BATT NEG
-
6 + BV (AK) 8 506 DIODE BLOCK (1) BATT NEG 4 BLK
7 UNUSED
8 UNUSED
CA 411
CA 415 CA 410 1
POT
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1
3
16 x //R
WHT (001) PC202-3 +BV(AK) 10 GRAY/PINK (005) B-5 SAS SIG ACS
HR POT F/C
2 2 4
FS
2961 PC414-1 +BV(AK) 3 YEL (008) B-6 FS SIG 3 5
6
RS
VIO (002) PC202-1 RAS SIG 4 BLK (007) B-4 RS SIG 4 CA 102
RAS 5 LOS 7
PINK (003) PC202-2 LOS SIG 5 RED/BLU (009) B-3 POT HIGH 5 UNUSED 1 RED
RED
CA 412
BLK
7
BLK 2903 A8 PL SIG
201 PC410-11 +BV F/C HR 6 CA 416 5961 PC415-8 LOW HR 6 3 2 BLK FTS
GRAY 1
1 SAS WHT
RED (012) PC202-5 +BV F/C HR 7 15 x //R 1 BRN (010) B-1 POT SIG 7 SAS 2904 A7 +BV (AK) 3
2
BLU 5
5961 PC410-6 COMM F/C HR 8 2 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB F/C 2
2 HNS1 5
GRAY (004) PC202-4 HNS SIG 10 1
3
2904
CA 414 261 PC415-6 +BV HR 11 2903 HNS
4
15 x //R CA 419
2902
2961 PC415-3 +BV(AK) 1 5962 PC414-4 COMM F/C HR 12 5 2 5
2901 HNS2
6 1
UNUSED 2 4
HNS
HSS MAIN PCB F/C
WHT/GRN (006) C-3 R/T (HSS) SIG 3 6
5
RS
A 2901 PC404-2 BDI
BRS FPS1
To C-2 1 5 5
1 5900 PC404-1 BDI KYS 203 JC404-7 BDI
DIODE BLOCK
D4 SAS
2 2902 202 FU2 OUT +BV
HNS 1
HNS 2
3
2
BR SMALL COIL 5 4 5 3 5903
RAS LOS
HSS
1 4 5904 DIODE BLOCK (4)
2923 DIODE BLOCK (2)
BR LARGE COIL 5
10 9 001 BLK (2 core) JC 406-3 BRS LINE
INSTRUMENT R/T PCB HYDR. PCB 6 500 PC 404-5 BATT NEG
CURTIS 803 "COMBI" 2903 JC101-2 +BV (AK) FTS
1
LMS
7
LINE MAIN PCB 2
002 BLK (2 core) PC 406-2 BRS
2
8 2904 JC103-1 FPS2
3
2909
2910
4
5 1
6
FAN
7
FPS2
8 HN
PS
8 P SV
B
INPUT FILTER
+BV
+BV (AK) 1 BRN (010) PC410-7 POT WIPER
OUT NO
POT CIRCUIT
To DB 3
2 BLU (011) PC410-8 POT LOW
BATT
NEG & DRIVER
RED/BLU (009) PC410-5 POT HIGH
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
D
A
TCM (SEM 1)
-BATT
E
F1
F2
1 2909
2
3
4
5
6
7
8
1
LINE
FU2
10A
+ - 2915 PC404-4 +BV
9 NOTE:
HN
FU1 PM
P
1- No Drive: FTS, FPS1 & FPS2 open. D 2913 JC 202-4
160A
2- Forks lower than 130mm: LMS closed. 1 UNUSED
BD:1 24V BATT BD:2
3- Load is less than 1000kg: PS closed, 2/3 brake. 2 2912
Speed Unladen 10Km/h.
3 501
4- Reduce speed: HSS is open.
5- Active: RAS, BRS, SAS, HNS & LOS are closed. 4 2914 P
9- Diode Block Pin 1 connected to P (contactor contacts). 5 502
10- Input Filter Batt Neg connected to Diode Block Pin 1 6 2918 SV 503
2919 JC202-2
815513-1_2B.pdf 815513-2_2B.pdf
201
HOUR METER OUTPUT 1
FU1 LINE 2972 2 BLK FTS
160A KYS +BV IN TO THE LOGIC 2
LINE CONTACTOR LOW 3 2904 CONTROLLER A8 3 WHT
BRAKE LOW (large coil) 4
UNUSED 4 UNUSED
BRS INPUT 5
BATTERY NEG 6
BATTERY POS (AK) 7
CA 102
WALKIE/RIDER MODE 8 2971 1 RED
A1 +BATT FPS1
B 2970 2 BLK
BD:1 POT WIPER 1
UNUSED 3 WHT
POT LOW 2
POT HIGH 3 UNUSED 4 UNUSED
RS - REVERSE SWITCH IN 4
SAS SAFETY SWITCH IN 5 CA 103
FS - FORWARD SWITCH IN 6
2970 1 RED
A2
VMN
C FPS2
2903 CONTROLLER A7 2 BLK
BATTERY POS (AK) 1
24V PERF.CUT 2 UNUSED 3 WHT
BATTERY
TM PERF. 1/2,HSS (R/T) INPUT 3
UNUSED 4 UNUSED
F2 +BV(AK)
INPUT FILTER
+ F1
D
OUT NO
UNUSED 1
HN - HORN HIGH 2 BATT NEG
HN - HORN LOW 3
570 D1 +BV
P - PUMP CONTACTOR HIGH 4
506 PC 407-4 BRK SMALL 1
NOTE:
1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND. 815513-3_2B.pdf 815513-4_2B.pdf
6
RS
2913 HN HIGH 4 GRAY (004) PC410-10 HN DRIVER BLK (007) B-4 REVERSE 4
7
205 FU3 OUT NOT USED 5 RED (012) CA415-7 NOT USED RED/BLU (009) B-3 POT HIGH 5
CA 412
BLK
504 P CONTACTOR 6 GRN (013) CA410-1 BATT NEG 5961 PC415-8 NOT USED 6 3
GRAY
1 SAS
BRN (010) B-1 POT WIPER 7 SAS
2
BLU
BLU (011) B-2 POT LOW 8
CA 404 INSTRUMENT CA 413
CA 417
2962 PC415-1 +BV(AK) 9 1
2
CURTIS 803 "COMBI" HNS1
2
GRAY (004) PC202-4 HN 10 1
5900 CONTROLLER A1 1 TT 3
2904
HNS
261 PC415-6 NOT USED 11 4
2903
2901 KYS OUT 2 KYS CA 419
2902
5962 PC414-4 NOT USED 12 5 2
2916 LMS 3 2901 HNS2
6 1
UNUSED 4 UNUSED
HYDRAULIC PCB
CA 407 CA 414
LARGE COIL
2928 DIODE BLOCK (2) 1 BLK 2961 PC415-3 +BV(AK) 1
6 TCM SEM1
POT PCB F/C
PS 3 FS
RS
5 1
A 2901 PC404-2 BDI
POT
To C-2 BRS FPS1
5 5 1 5900 PC404-1 BDI KYS 203 JC404-7 BDI
DIODE BLOCK
SAS
3
2 2902 202 FU2 OUT +BV
HNS 1
HNS 2
D4
2
BR SMALL COIL 5903
5 3
1
4 RAS
5
LOS 4 5904 DIODE BLOCK (4)
F/C F/C
HSS
6 2923 DIODE BLOCK (2)
BR LARGE COIL 6 5
11 10 F/C
001 BLK (2 core) JC 406-3 BRS LINE
6 HYDR. PCB
INSTRUMENT R/T PCB 6 500 PC 404-5 BATT NEG
CURTIS 803 "COMBI"
MAIN PCB LMS 2903 JC101-2 +BV (AK) FTS
TT 1 7
LINE
2 002 BLK (2 core) PC 406-2 BRS
KYS 2
3
8 2904 JC103-1 FPS2
2909
2909
4
BATT NEG 5 1
UNUSED 6
FPS2 FAN
BDI 7
UNUSED 8 9 HN
PS
P SV
B
INPUT FILTER
+BV
+BV (AK)
OUT NO 1 BRN (010) PC410-7 POT WIPER
BATT POT CIRCUIT
NEG
2 BLU (011) PC410-8 POT LOW
To DB 3
& DRIVER
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
5 GRAY/PINK (005) PC410-2 SAS
D
A
TCM (SEM 1)
6 YEL (008) PC410-3 FS
+BATT
-BATT
E
F1
F2
2909
2
3
4
5
6
7
8
1
1
2 2921 DIODE BLOCK (3)
KYS A2F2F1 8
3 WHT/GRN (006) CA414-3 PERF. 1/2 (R/T)
A1
TM FAN
LINE
FU2 FU2
10A 10A
+-
10 2915 PC404-4 +BV
P HN
FU1 PM D 2913 JC 202-4
160A
1 UNUSED
24V BATT
BD:1 BD:2
2 2912
3 501
NOTE: 4 2914 P
1- No Drive: FTS, FPS1 & FPS2 open.
5 502
2- Forks lower than 130mm: LMS closed.
3- Load is less than 1000kg: PS closed, 2/3 brake, Speed Unladen 10Km/h. 6 2918 SV 503
4- Reduce speed: HSS is open. 2919 JC202-2
5- Active: RAS, BRS, SAS, HNS & LOS are closed.
6- F/C Package: Below 5°C active.
10- Diode Block Pin 1 connected to P (contactor contacts).
11- Input Filter Batt Neg connected to Diode Block Pin 1 815514-1_2B.pdf 815514-2_2B.pdf
201
FU1 LINE
160A KYS +BV IN TO THE LOGIC 2 2904 CONTROLLER A8 3 WHT
LINE CONTACTOR LOW 3
UNUSED 4 UNUSED
BRAKE LOW (large coil) 4
BRS INPUT 5
BATTERY NEG
CA 102
6
BATTERY POS (AK) 7 2971 1 RED
WALKIE/RIDER MODE 8 FPS1
2970 2 BLK
A1 +BATT
B
UNUSED 3 WHT
BD:1 POT WIPER 1
POT LOW 2 UNUSED 4 UNUSED
POT HIGH 3
RS - REVERSE SWITCH IN 4 CA 103
SAS SAFETY SWITCH IN 5
2970 1 RED
FS - FORWARD SWITCH IN 6
A2 2903 CONTROLLER A7 2 BLK FPS2
VMN
C
BATTERY POS (AK) 1 UNUSED 3 WHT
24V PERF.CUT 2
BATTERY TM UNUSED 4 UNUSED
PERF. 1/2,HSS (R/T) INPUT 3
+BV(AK)
INPUT FILTER
F2
+ F1 OUT NO
D
UNUSED 1 BATT NEG
HN - HORN HIGH 2
570 D1 +BV
HN - HORN LOW 3
506 PC 407-4 BRK SMALL 1
P - PUMP CONTACTOR HIGH 4
505 P- CONTACTOR CONTACTS
BD:2 - P&SV-P CONTACTOR LOW 5
2928 PC407-1 BRK LARGE D2
PM SV - LOWERING VALVE HIGH 6 2
2923 CONTROLLER A5
F1 F2 E D3
2911 PS NO
POSITIVE SERIAL RECEPTION 1 3
2921 CONTROLLER C2
NEGATIVE SERIAL RECEPTION 2
P POSITIVE SERIAL TRANSMISSION 3 5904 CONTROLLER A4
NEGATIVE SERIAL TRANSMISSION 4
5902 PC407-2 BRK LARGE 4
5905
BATT NEG 5
BATTERY POS (AK) 6
2924 PC 407-3 BRK SMALL 5
UNUSED 7 D4
UNUSED 8
-BATT 2974 2927 JC406-2
DIODE BLOCK
505 DIODE BLOCK (1) 504 JC202-6 2973
NOTE:
1) Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND 815514-3_2B.pdf 815514-4_2B.pdf
CA 407
CA 414
LARGE COIL
2928 DIODE BLOCK (2) 1 BLK 2961 PC415-3 +BV(AK) 1
[7+8] 6+4
[7+8] 6+4
BDI
folded platform, PC404 1 2 3 4 5 6 7 8
P- P FU3 FU2 LMS
5+4
6+4
6+4
6+4
6+4
6+4
6+4
7+8
7+8
2 2 2 2 2 2
WP2330S all versions
9
2902
2901
203
202
HANDLE MAIN PCB
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
6+4 2927 1 2 3 4 5 6
5 1010 1010
12+11 5905 PC413
2904
2903
2902
2901
(pin 5)
2924
10
5905 1
(pin 4) 10
5904
5902
2921
4 (pin 3) 10 2911
2928
(pin 2) 10 2923 2909 201
506 2927 6+4 2910
(pin 1) 10 505
1 LINE 5+4 FU1
002BLK 1 5903 204
2 6+4
001BLK 1 3
JC406 3
PC202 JC202 4
(002) VIO 2 1 1 1 2917 6+4
2910
PS
2928
5902
2924
BRS
506
(003) PINK 2 2 2 1 2919 6+4
2911
(001) WHT 2 3 3 1 2908
(004) GREY 2 4 4 1 2913 2 2 2 2 2918
(012) RED 2 5 5 1 205 1 2 3 4 PC407 6+4 2919
(013) GRN 504
SV
2 6 6 1 BR 6+4
503
2906
2903
2904
2903
2902
2901
4
4 Diode block 131011
JC103 1 1
11 11 11 11
1 2 3 4 JC101
2920
2906
5 Diode (D4) 813368 PC417 2 1 2 1 PC419
D GCSL
1 Terminal Type Part No. 1 1
2 1 2 1
2 3 2912
4 062007-021 1 2 3 4 JC102
3 3 501 HNS HNS
PLS
4 3 2914 5 803678-006
5 3 502 PC410
2918
6 803448-003 (013) GRN Housing Par t No. Contact Type Par t No.
6 3 2 1
7 062007-043 (005) GRAY / PINK
2 2
JC101 803450-002 1 803450-010
(008) YEL
A 2 3
1 3 5900 8 803448-002 (007) BLK JC102 803450-002 1 803450-010
2 4
MAIN PCB
2902 9 062007-068 (009) RED / BLU
HANDLE
2 3 2 5
5903 5961 JC103 803450-002 1 803450-010
3 3 2 6
5904 10 062007-005 (010) BRN JC202 803450-003 1 803450-010
4 3 2 7
001BLK
11 813409-003 (011) BLU
TCM SEM1
5 3 2 8
2923
2962 PC202 803450-007 2 116858
6 3 2 9
500 12 813409-001 (004) GRAY PC404 803450-008 2 116858
7 3 002BLK 2 10
2904 E100_Rev2B-GB 261
8 3 2 11
2920 5962 JC406 803450-002 1 803450-010
2 12
B 2 PC407 803450-006 2 116858
1 3 (010) BRN
2 3 (011) BLU
PC415 P C4 1 0 803450-015 2 116858
2962
HYDRAULIC PCB
2 1
3 3 (009) RED/BLU (001) WHT PC413 803450-021 10 803450-022
(007) BLK 2 2
4 3 Key:
HANDLE
2961
5 3 (005) GREY/PINK
2 3 P C4 1 4 803450-020 2 116858
(002) VIO 4
(008)YEL 2
6 3 (003) PINK PC415 803450-008 2 116858
R/T PCB = “Fast/Slow” changeover 261
2 5
R/T PCB
1 3 2 1
2909
(006) WHT/GRN
2 D 803450-017 3 803450-019
2 3
E99-GB
( ) Colours correspond to old revision pre-August 2003 5962
2 4
2900
2900
2902
2901
2903
200
2934
2905
2906
2907
5900
2905
2906
203
201
204
202
500
502
504
506
507
500
203
200
5901 2904
11+12 6+4
DIODE BLOCK
(pin 1) (pin 2) (pin 3) (pin 4) (pin 5)
10 10 10 10 10
JC406
501
502
503
2911
2912
2909
2910
5901
5902
5903
2908
2904
1
BRAKE 2 1
2932
2921 SWITCH 3 1
2931
201
6+4
JC 202
2930 4 2934
FU1 5+4 202 LINE 1 1
5904
6+4 2913 HANDLE
2911
5903
2908
1 2
HARNESS
501
2914
1 3
PC200 2 2 2 2
2915
1 4
2901 204
2 1 +BV 1 2 3 4 PC407 1 5
2925 504
2 2 GCSR 1 6
2929 JC103 BRAKE
2 3 GCSL 505
2928 1 2919 6+4
2930
6+4
2 4 PLS GCSR 2 1 2926 2915 HN
2931
2910 6+4
PS 2 5 BRS
3 1
2925 2916 6+4
2912
6
4 D
7
2913 2922 PC210 JC210 1
2917 6+4 2 8 SAS GRAY/PINK (005)
2922 2916
3 2
TCM
from Handle Harness 1 1 1
507 SV 9
2933 2923 505
3 3
6+4 503 to Controller B-5 3 2 2 2 1
2 10 Batt Neg 2907
3 4
11 815179_2C, 506
2920 3 5
2 12 Rider (A8) C 2914 see Note 4 2917
2923 3 6
2 13 SAS (OUT) (B5) 2921
1 3
14 TCM 2 3
2909
5900
2902
5904
5902
2918
2932
2919
2920
15 3
16
2918 BRS (A-5) 3 3 3 3 3 3 3
2 17
18
1 2 3 4 5 6 7 8 A
815179-1_2C
19 TCM
2903
2 20 +BV (Control)
2927
2928
PC 200 1 803450-010
1 1 1 1
JC 202 803450-003 2 116858
1 2 3 4 JC101 1 2 3 4 JC102
PC 210 803450-005 3 803450-013
GCSL PLS
JC 210 803450-001 4 62007-021
PC 404 803450-008 5 803678-006
JC 406 803450-002 6 803448-003
PC 407 803450-006 7 62007-043
JC 101 803450-002 8 803448-002
JC 102 803450-002 9 62007-068
JC 103 803450-002 10 62007-005
A 803450-018 11 813409-003
C 803450-016 12 813409-001
D 803450-017 13 803678-012 Used from serial no. 5A336576, except for 5A337937
C 803450-016 815179_2-GB
815179_1-GB Connections by April 2005
PC 410
GRN (013)
2 1
WHT/GRN (006)
TCM C-3 3 GRAY/PINK (005)
2 2
YEL (008)
2 3
BLK (007)
GRAY/PINK (005) 2 4
TCM B-5 2
RED/BLU (009)
2 5
B 5961
2 6
BRN (010) BRN (010)
1 3 2 7
BLU (011) BLU (011)
2 3 2 8
RED/BLU (009) 2962
3 3 2 9
BLK (007) GRAY (004)
4 3 2 10
261
5 2 11
YEL (008) 5962
6 3 2 12
PC 202 PC 415
VIO (002) 2962
1 2 2 1
PINK (003) WHT (001)
2 2 2 2
WHT (001) 2961
3 2 2 3
GRAY (004) VIO (002)
4 2 2 4
RED (012) PINK (003)
5 2 2 5
GRN (013) 261
6 2 2 6
RED (012)
2 7
5961
2 8
PC 414
2961
2 1
2
WHT/GRN (006)
2 3
5962
2 4
815180_2B
HOUSING Part No. TYPE Part No.
PC 202 803450-007 2 116858
PC 410 803450-015 3 803450-190
PC 414 803450-020 815180_2-GB
PC 415 803450-008
B 803450-017
815180_1-GB
PC419
2901
PC413 2 1
2902
6 1 2901 2 2
2902
5 1
2903
4 1 PC417
2904
3 1 2903
2 1
2 2904
2 2
1
811931-1_2C
[7+8] 6+4
[7+8] 6+4
BDI
Fixed platform, PC404 1 2 3 4 5 6 7 8
P- P FU3 FU2 LMS
5+4
6+4
6+4
6+4
6+4
6+4
6+4
7+8
7+8
All versions 2 2 2 2 2 2
9
2902
2901
203
202
HANDLE MAIN PCB
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
6+4 2927 1 2 3 4 5 6
5 1010 1010
12+11 5905 PC413
2924
2904
2903
2902
2901
(pin 5) 10
5905 1
(pin 4) 10
5902
5904
2921
(pin 3) 10 2911
4
2928
(pin 2) 10 2923 2909 201
506 6+4 2910
2927 1 FU1
(pin 1) 10 505 LINE 5+4
002 BLK 1 5903 204
2 6+4
001 BLK 1 3
JC406
3
PC202 JC202 4
(002) VIO 2 1 1 1 2917 6+4
2910
PS
2928
5902
2924
BRS
506
(003) PINK 2 2 2 1 2919 6+4
2911
(001) WHT 2 3 3 1 2908
(004) GREY 2 4 4 1 2913 2 2 2 2 2918
(012) RED 2 5 5 1 205 1 2 3 4 PC407 6+4 2919
(013) GRN 504
SV
2 6 6 1 BR 6+4
503
501
2 Tiller wire harness 812960
6+4
HN 2912
6+4 2913 3 Horn switch wire harness 811931
2904
2903
2902
2901
4 Diode Block 102232
11 11 11 11
2903
2904
5 Diode Assembly (D4) 813368 PC417 2 1 2 1 PC419
D 2 1 2 1
1 1 1
2912
2 3 Terminal Type Part No. 1 2 3 4 JC101
3 3 501 HNS HNS
2914 4 062007-021 FTS
4 3
502 PC410
5 3 5 803678-006 (013) GRN
6 3 2918 2 1
6 803448-003 (005) GRAY / PINK
2 2
(008) YEL Housing Par t No. Contact Type Par t No.
A 7 062007-043 2 3
1 3 5900 (007) BLK 4
2
8 803448-002 JC101 803450-002 1 803450-010
MAIN PCB
2902 (009) RED / BLU
HANDLE
2 3 2 5
9 062007-068 5961
3 3 5903
2 6 JC202 803450-003 1 803450-010
4 3 5904 (010) BRN 7
2
001 BLK 10 062007-005 (011) BLU PC202 803450-007 2 116858
TCM SEM1
5 3 2923 2 8
6 3 500
11 813409-003 2962
2 9 PC404 803450-008 2 116858
(004) GRAY
7 3 002 BLK
2903
12 813409-001 261
2 10
JC406 803450-002 1 803450-010
8 3 2 11
E100_Rev2B-GB 5962
2904
2 12 P C4 0 7 803450-006 2 116858
B 22
1 3 (010) BRN PC410 803450-015 2 116858
2 3 (011) BLU
PC415
2962 PC413 803450-021 10 803450-022
HYDRAULIC PCB
2 1
3 3 (009) RED/BLU (001) WHT
4 3 (007) BLK Key: 2 2 PC414 803450-020 2 11685 8
HANDLE
2961 3
(005) GREY/PINK 2
5 3
(002) VIO 2 4 PC415 803450-008 2 116858
6 3 (008)YEL
R/T PCB = "Fast/Slow" changeover (003) PINK 2 5 P C4 1 7 803450-023 11 803450-024
261 6
module (012) RED
2
P C4 1 9 803450-023 11 803450-024
2 7
(all PCBs/modules are located in the 5961
2 8 A 803450-018 3 803450-019
C tiller)
(006) WHT GRN
B 803450-017 3 803450-019
3 3
2 3 2921 PC414 C 803450-016 3 803450-019
2961
HANDLE
2908
R/T PCB
1 3 2 1
2909
D 803450-017 3 803450-019
2
(006) WHT/GRN
2 3
E101-GB
( ) Colours correspond to old revision pre-August 2003 5962
2 4
Connections by April 2005 Harness_Complete-WPS-Fixed_Rev2B
6+4
P- P LMS
PC404 1 2 3 4 5 6 7 8
6+4
6+4
6+4
6+4
5+4
6+4
6+4
7+8
7+8
2 2 2 2 2 2
9
2902
2901
203
202
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
2927
6+4
(pin 4)10
5904
11+12 PC 404 803450-008 2 116858
2921 JC 406 803450-002 3 803450-013
(pin 3)10 2911
2928
PC 407 803450-006 4 62007-021
(pin 2)10 2923 2909
JC 101 803450-002 5 803678-006
201
506
(pin 1)10
2927 1 LINE
6+4 2910
5+4 FU1 A 803450-018 6 803448-003
505 002BLK(2) 5903 204
1 2
001BLK(2) JC406
6+4 D 803450-017 7 62007-043
1 3
4 C 803450-016 8 803448-002
HANDLE HARNESS
1 1 2917 2910
PS 6+4 E103_1-GB 9 62007-068
2928
5902
2924
2919 506 BRAKE SWITCH 2911
2 1 6+4
3 1 2908 10 62007-005
2913 2 2 2 2
4 1 2918 11 813409-003
5 1 205 1 2 3 4 PC407 6+4 2919
504 BRAKE SV 12 813409-001
6 1 6+4
503
E103_2-GB
JC202
6+4
501
HN 2912
6+4 2913
2903
2904
2908
D C
1 2909 3 1 1 1
2 3 2912 2921 3 2 TCM 1 2 3 4 JC101
3 3 501 3
TCM 2914 FTS
4 3
5 3 502
6 3 2918
001BLK(2)
002BLK(2)
5900
2902
5903
5904
2923
2903
2904
500
3 3 3 3 3 3 3 3
1 2 3 4 5 6 7 8 A
TCM 813258-1_2D
PC 410
GRN (013)
2 1
GRAY/PINK (005)
2 2
YEL (008)
WHT/GRN (006) 2 3
TCM C-3 3
BLK (007)
2 4
RED/BLU (009)
2 5
5961
2 6
BRN (010)
2 7
B BLU (011)
BRN (010) 2 8
1 3 2962
BLU (011) 2 9
2 3 GRAY (004)
RED/BLU (009) 2 10
3 3 261
BLK (007) 2 11
4 3 5962
GRAY/PINK (005) 2 12
5 3
YEL (008)
6 3
PC 415
2962
2 1
WHT (001)
PC 202 2 2
VIO (002) 2963 (2961)
1 2 2 3
PINK (003) VIO (002)
2 2 2 4
WHT (001) PINK (003)
3 2 2 5
GRAY (004) 261
4 2 2 6
RED (012) RED (012)
5 2 2 7
GRN (013) 5961
6 2 2 8
PC 414
2963 (2961)
2 1
2
WHT/GRN (006)
2 3
5962 4
2
812960-1_2G
PC419
2901
PC413 2 1
2902
6 1 2901 2 2
2902
5 1
2903
4 1 PC417
2904
3 1 2903
2 1
2 2904
2 2
1
811931-1_2C
Batt Neg
+BV(AK)
OUT NO
+BV
DISCONNECT 2903 / 2904 6+4 6+4 6+4 6+4
FROM JC101 MAIN HARNESS
2972
2971
2973
570
JC 103 JC 101
4 3 2 1 1 2 3 4
1 1
2903
2970
2972
2904
Connect with Wire 2927 14+15 2974 JC 102
2974 4
Connect with Diode Inline Wire 2927 4 2973 3
2970
1 2
2971
1
570
Connect with Diode Block Pin1 10
Power Cables
BD:2
7 052065-024 16
A * Busbar
E102-GB
1
5
160 A
FU1
6 7 P
+ PM -
4
2
Line
11 8
A1 A2
TM
3
10 F1 F2 9
+ BATT F1 F2 VMN
TCM SEM1
807473-2C
A = Battery disconnect
M1.0-0000-000177
167
Blank Page
Printed in Germany
168
HYDRAULIC SCHEMATIC
Printed in Germany
169
Blank Page
Printed in Germany
M1.0-0000-000180
170
M1.0-0000-000180
HYDRAULIC CIRCUIT
Lift cylinder
Pressure-Switch
Lowering valve
Filter
Filter
Non-return valve
150 bar
to 170 bar*
Motor
Vent cap
Pump
Filter Filter
Reservoir
171
Blank Page
172