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WF 3000-1.2
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Crown WF 3000-1.0, WF 3000-1.2 Service Manual

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Page 1
Service Manual
WF3000 Series
Printed in
Germany ● Revision Level A
Order Number: 812556-006
Page 2
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.
- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0)89 93 00 2 - 0
Fax +49 (0)89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement.
CROWN Equipment Corporation
Copyright 2005
Page 3
Overview of Revisions:

REVISION

WF3000 09/2005 • Printed in Germany MS-REV-3300
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TABLE OF CONTENTS
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TABLE OF CONTENTS
Table of Contents
MA – SAFETY PAGE SER-NO. CUT.................. REV.
Safety Symbols used in the Manual...................................... 3
ITD – INTRODUCTION PA GE SER-N0. CUT REV.
General Maintenance and Repair Safety Notes ................... 3
Maintenance and Repair ................................................ 3
Before Leaving the Truck ................................................ 4
Before Carrying out Work on the Truck.......................... 4
Before Operating the Tr uck ............................................. 4
Warnings and Labels on the Truck........................................ 4
General..................................................................................... 7
Operating Instructions .................................................... 7
Service Training .............................................................. 7
Ordering Spare Parts...................................................... 7
Using the Manual............................................................ 7
Model-Number ......................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0. CUT .................. REV.
Raising And T owing The Truck ............................................... 11
Raising With Another Forklift Truck................................ 11
Lifting by Crane............................................................... 12
Towing the Truck ............................................................. 13
Component Access ................................................................ 14
Maintenance ............................................................................ 16
Recommended Lubricants and Oils .............................. 16
Lubricants ................................................................... 1 6
Cold Store Trucks........................................................ 16
Taking the tr uck out of service ....................................... 16
Bringing the truck back into service .............................. 16
Lubricant T able ........................................................................ 17
Adjuvants T able ....................................................................... 18
T ruck Tilt Settings ................................................................... 22
Testing and Adjusting the Lateral Inclination ................ 22
Lowering Plumb Test ....................................................... 22
M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV.
Hydraulic Symbols.................................................................. 27
Hydraulics................................................................................ 31
Hydraulic Reservoir Capacity ......................................... 31
Changing the Hydraulic oil and
Hydraulic Filter................................................................ 31
Hydraulic system ............................................................ 33
Function........................................................................... 33
Lifting (see diagram) ................................................... 33
Lowering (see diagram) .............................................. 34
MOTOR AND PUMP ASSEMBLY................................... 35
Hydraulic Lines and Fittings ....................................... 35
General Rules for Hydraulic Lines and Connections.. 35
Bleeding the Hydraulic System................................... 35
Drift T est...................................................................... 35
Proportional function:................................................ 35
REMOVAL ....................................................................... 35
MOTOR............................................................................ 3 6
PUMP .............................................................................. 36
After replacing the pump: ......................................... 36
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TABLE OF CONTENTS
M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV.
Replacing the relief valve....................................................... 37
Relief valve test and setting................................................... 37
Hydraulic System Troubleshooting ................................. 38
M3 – DRIVE UNIT PAGE SER-N0. CUT .................. REV .
Gear Unit.................................................................................. 41
Drive unit, general................................................................... 42
Drive unit removal........................................................... 42
Drive motor removal ....................................................... 42
Motor disassembly.......................................................... 43
Motor assembly ............................................................... 43
Drive motor assembly..................................................... 45
Gear unit disassembly.................................................... 46
General ....................................................................... 46
Preparation ................................................................. 46
Draining the oil............................................................ 46
Drive unit removal....................................................... 46
Gear unit cover removal.............................................. 46
Gear unit disassembly ................................................ 47
Gear unit assembly..................................................... 47
Gear unit cover installation ......................................... 49
Adding Oil ................................................................... 49
Drive unit installation ...................................................... 49
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
Electrics - General .................................................................. 53
Wire Colour Codes ......................................................... 53
Abbreviations .................................................................. 54
Electrical Symbols .......................................................... 57
Electrical Components ........................................................... 58
Traction Pod (POT, FS, RS)............................................ 58
Fast / Slow Travel Switch (HSS)..................................... 58
Safety Reverse Switch (SAS)......................................... 58
Brake Switch (BRS) ........................................................ 58
Override Switch (ORS)................................................... 58
Raise / Lower Switches (RAS, LOS) ............................. 59
Limit Switch (LMS).......................................................... 59
Horn Switch (HNS) ......................................................... 59
Key Switch (KYS)............................................................ 59
Emergency Disconnect (BD).......................................... 59
Fuses (FU) ...................................................................... 59
OPTION
Thermal Switch (THS) ......................................... 59
Thermal switch (THS2)................................................... 5 9
Hydraulic Control Module (HCM)................................... 59
Unigage (BDI) ................................................................. 59
Integrated Charger .......................................................... 59
Plug Holder (PC)............................................................. 5 9
Drive motor (M1)............................................................. 59
Hydraulic Motor (M2) ...................................................... 60
Main Contactor (Line/LC) ............................................... 60
Lift Contactor (P/P1+P2) ................................................ 60
Electromagnetic Brake (BRK) ........................................ 60
Ter minal Board (TB) ....................................................... 60
Travel Alarm Driver (DR) ................................................ 60
Aux. Hydraulic Switch (SLS/SRS).................................. 60
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TABLE OF CONTENTS
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
Remote Control Toggle Switch (ECS)............................ 60
Aux. Hydraulic Valves (SVA1/SVA2) .............................. 60
Horn (HN) ........................................................................ 60
Main Circuit Board (MAIN PCB)..................................... 60
Hydraulic Circuit Board (HYD PCB) ............................... 60
Travel Alarm (ALM) ......................................................... 60
Receiver .......................................................................... 60
Transmitter....................................................................... 6 0
SEM0 T raction Controller........................................................ 64
General............................................................................ 64
Precautionary Measures............................................. 64
Functional Characteristics.............................................. 64
Speed control.............................................................. 64
Reduced speed ranges .............................................. 64
Downhill speed control................................................ 64
Regenerative braking.................................................. 64
Anti Roll Down Function ............................................. 65
Hourmeter................................................................... 65
Self-Diagnostic System ............................................... 65
Monitored Circuits....................................................... 65
Safety Mechanisms......................................................... 65
Incorrect polarity ......................................................... 65
Wiring Errors............................................................... 65
Temperature protection............................................... 65
Start sequence ........................................................... 65
Protection rating.......................................................... 65
Maintenance.................................................................... 66
Replacing the SEM0 Traction Controller............................... 67
Parameter Setting after Replacing
the Traction Controller .................................................... 6 7
Preparatory Measures ................................................ 67
Adjustment.................................................................. 67
Status LED ...................................................................... 69
Programmer............................................................................. 70
General............................................................................ 70
Crown Handset P/N 793548 (Includes Cord) ........... 70
Operating SEM0 Controller Menu.......................................... 71
General............................................................................ 71
Menu structure............................................................ 71
Menu Functions .............................................................. 72
PARAMETER CHANGE.............................................. 72
TEST........................................................................... 72
ALARMS ..................................................................... 7 2
PROGRAM VACC ....................................................... 72
CONFIG ...................................................................... 72
Functions Menu, general................................................ 73
Parameter Change Menus ............................................. 74
Settings and Error Messages......................................... 75
Tester Menu..................................................................... 80
TESTER Menu ................................................................ 81
Alar m s M en u ................................................................... 8 2
ALARMS Menu ................................................................ 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu................................................. 86
Preparatory Measures ................................................ 86
Calibration................................................................... 86
Conf ig . Menu ................................................................... 8 7
CONFIG Menu ................................................................ 88
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TABLE OF CONTENTS
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
SET MODEL ............................................................... 88
SET OPTIONS............................................................ 88
ADJUSTMENTS ......................................................... 88
On Board Charger ................................................................... 89
General............................................................................ 89
Battery Charging Phases ............................................... 89
First Phase (I1) ........................................................... 89
Second Phase (P)....................................................... 89
Third Phase (U) .......................................................... 8 9
Fourth Phase (I2)........................................................ 89
End of Normal Charging ............................................. 90
Special Charging Phases............................................... 90
Compensating Charge................................................ 90
Float Charge ............................................................... 90
Partial Charging .......................................................... 90
Charging Errors ............................................................... 91
Green LED is not lit..................................................... 91
Possible Causes: ...................................................... 91
Green LED flashing .................................................... 91
Important Technical Data................................................ 92
Replacing the Charger ................................................... 92
Removal / Installation.................................................. 92
Electric Motors ........................................................................ 93
General Maintenance Instructions ........................................ 93
Preparation...................................................................... 93
Important Maintenance Instructions ........................... 93
Traction Motor Maintenance (WF 1.0 t) ................................. 94
Access to brushes .......................................................... 94
Maintenance.................................................................... 94
Armature ..................................................................... 94
Bearings...................................................................... 94
Traction Motor Maintenance (WF 1.2 t) ................................. 95
Access to brushes .......................................................... 95
Maintenance.................................................................... 95
Armature ..................................................................... 95
Bearings...................................................................... 95
Pump Motor Maintenance ...................................................... 96
Access to brushes .......................................................... 96
Maintenance.................................................................... 96
Armature.......................................................................... 96
Contactors ............................................................................... 97
Inspection........................................................................ 97
Contacts...................................................................... 97
Coils ............................................................................ 97
Springs........................................................................ 97
Servicing ......................................................................... 98
Dismantling ................................................................. 98
Assembly .................................................................... 98
Hydraulic Control Module (HCM)........................................... 99
Battery Discharge Indicator (BDI) ......................................... 100
OPERATION.................................................................... 100
General............................................................................ 101
Battery Discharge Indicator Setting (BDI) ..................... 101
Calibration for wet batteries ........................................... 1 02
TROUBLESHOOTING.................................................... 103
Traction Controller Safety Test ....................................... 104
VIII
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TABLE OF CONTENTS
M5 – BRAKE PAGE SER-N0. CUT .................. REV .
Brake ........................................................................................ 107
Function........................................................................... 107
Disassembly.................................................................... 107
Assembly......................................................................... 109
Air gap setting ................................................................. 109
Brake moment setting ..................................................... 110
Brake test ........................................................................ 110
Definition of run-in/new rotor ...................................... 110
General Notes............................................................. 110
M6 – STEERING PAGE SER-N0. CUT .................. REV.
Steering.................................................................................... 11 5
Live ring bearing ............................................................. 115
Disassembly ............................................................... 115
Installation................................................................... 115
Control handle return springs ............................................... 116
Adjustment ...................................................................... 116
Disassembly.................................................................... 116
Installation ....................................................................... 116
Steering Chain......................................................................... 117
Permissible Elongation................................................... 11 7
Chain Tension Adjustment.............................................. 117
Tiller Handle ............................................................................ 119
Main Components........................................................... 119
Tiller Handle Component Removal / Installation ................. 120
Tiller Handle Shells......................................................... 120
Removing the Upper and Lower Shells ...................... 120
Fitting the Upper and Lower Shells ............................. 121
Switch Unit ...................................................................... 122
Removal...................................................................... 122
Switch Unit Installation................................................ 122
"Fast/Slo w" Toggle Switch .............................................. 123
Removal...................................................................... 123
Installation................................................................... 123
Hydraulic Board .............................................................. 123
Removal...................................................................... 123
Installation................................................................... 123
Potentiometer.................................................................. 124
Removal...................................................................... 124
Installation................................................................... 124
Safety Reverse Switch.................................................... 125
Removal...................................................................... 125
Installation................................................................... 125
Horn Switch..................................................................... 126
Removal...................................................................... 126
Installation................................................................... 126
Handle ............................................................................. 127
Removal...................................................................... 127
Installation................................................................... 127
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TABLE OF CONTENTS
M7 – MAST PAGE SER-N0. CUT .................. REV .
Mast.......................................................................................... 131
General............................................................................ 131
Torque Requirements ................................................. 131
Lifting Gear Minimum Capacity................................... 131
Mast Removal ................................................................. 131
Installation ....................................................................... 132
Fork Carriage Removal .................................................. 132
Fork Carriage Installation............................................... 132
Fork Carriage Adjustment .............................................. 133
Mast Maintenance .......................................................... 134
Lubricating Roller Tracks............................................. 134
Lowering Plumb Test .............................................................. 135
Preparatory measures.................................................... 135
Carrying out the vertical plumb test............................... 135
Lift chains ................................................................................ 136
General............................................................................ 136
Inspection........................................................................ 136
Cleaning...................................................................... 136
Wear ........................................................................... 136
Freedom of Movement of Chain Links ........................ 137
Chain Tension ............................................................. 137
Chain Anchor and Pulleys .......................................... 138
Worn Connection Plates ............................................. 138
Protruding or Turned Chain Pins................................. 138
Corrosion .................................................................... 138
Chain Lateral Wear ..................................................... 13 9
Uneven Chain Tension .............................................. 139
Misaligned Lift Components ..................................... 139
Lift Chain Lubrication...................................................... 140
Separating Lift Chains .................................................... 14 1
Tools and Equipment Required ...................................... 141
Detachment..................................................................... 141
Fork Tines ................................................................................ 142
General............................................................................ 142
Terms .......................................................................... 142
Fork Identification ....................................................... 142
Repairs ............................................................................ 142
Fork Inspection ............................................................... 142
Crack Inspection ......................................................... 142
V erticality Test ............................................................. 143
Fork Blade Warping .................................................... 143
Measuring the Fork Tip Width........................................ 143
Fork Tine Height Difference ........................................... 143
Fork Stop......................................................................... 143
Fork Blade Wear ............................................................. 144
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TABLE OF CONTENTS
M8 – CYLINDERS PAGE SER-N0. CUT .................. REV .
Cylinders.................................................................................. 147
General............................................................................ 147
Safety when working on hydraulic systems ................ 147
General Instructions for Repairing Hydraulic
Components ............................................................... 147
Rod Seal Assembly................................................................. 148
General............................................................................ 148
Large Rod Seal Assembly.............................................. 148
Small Seal Rod Assembly .............................................. 149
Rod Seal Assembly, Sealing Lip First............................ 150
Cylinders.................................................................................. 151
TL Mast Lift Cylinder....................................................... 151
Seal Replacement ...................................................... 151
Installing TL Mast Lift Cylinders.................................. 152
TF Mast Lift Cylinders .................................................... 154
Removing the TF Mast Lift Cylinders.......................... 154
Seal Replacement ...................................................... 154
Installing TF Mast Lift Cylinders.................................. 155
Free Lift Cylinder TF and Mono Mast ............................ 156
Seal Replacement ...................................................... 156
Installing Free Lift Cylinder............................................. 157
Cylinder Bleeding and Flushing ..................................... 157
Bleeding — Mast Lift Cylinders................................... 157
Bleeding — Free Lift Cylinder (if applicable) .............. 1 57
Flushing – Mast Lift Cylinders
and Free Lift Cylinders (if applicable) ......................... 158
Drift T est...................................................................... 15 8
Cylinder Shimming .......................................................... 158
Lift Cylinder Shims...................................................... 158
Free Lift Cylinder Shims .............................................. 15 8
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
WF 3000-10 Standard.............................................................. 163
Overview.......................................................................... 163
WF3000-10 Standard,
Traction Controller - SEM0 Logic ................................... 164
WF3000-10 Standard,
Traction Controller - SEM0 Power Circuit...................... 165
WF3000-10 Standard,
Power Unit Control Circuit .............................................. 166
WF3000-10 Standard,
Control Handle - Control Circuit..................................... 167
WF3000-10 Standard,
Hydraulic Control Module (HCM)................................... 168
WF3000-10 with Options ........................................................ 169
Overview.......................................................................... 169
WF3000-10 with Options,
Traction Controller - SEM0 Logic ................................... 170
WF3000-10 with Options,
Traction Controller - SEM0 Power Circuit...................... 171
WF3000-10 with Options,
Power Unit - Control Circuit............................................ 172
WF3000-10 with Options,
Control Handle - Control Circuit..................................... 1 73
WF3000-10 with Options,Hydraulic Control Module (HCM)
- Travel Alarm and Flashing Beacon.............................. 174
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TABLE OF CONTENTS
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0. CUT .................. REV.
WF 3000-12 Standard.............................................................. 175
Overview.......................................................................... 175
WF3000-12 Standard,
Traction Controller - SEM0 Logic ................................... 176
WF3000-12 Standard,
Traction Controller - SEM0 Power Circuit...................... 177
WF3000-12 Standard,
Power Unit Control Circuit .............................................. 178
WF3000-12 Standard,
Control Handle - Control Circuit..................................... 179
WF3000-12 Standard,
Hydraulic Control Module (HCM)................................... 180
WF3000-12 with Options ........................................................ 181
Overview.......................................................................... 181
WF3000-12 Swith Options,
Traction Controller - SEM0 Logic ................................... 182
WF3000-12 with Options,
Traction Controller - SEM0 Power Circuit...................... 183
WF3000-12 with Options,
Power Unit - Control Circuit............................................ 184
WF3000-12 with Options,
Control Handle - Control Circuit..................................... 1 85
WF3000-12 with Options, Hydraulic Control Module (HCM)
- Travel Alarm and Flashing Beacon.............................. 186
Wire Harness ........................................................................... 187
Control Handle Wiring .................................................... 188
Power Cab les .................................................................. 18 9
HYD – HYDRAULIC SCHEMATICS PAGE SER-N0. CUT .................. REV .
Hydraulik Schematic Standard Lift ....................................... 193
Hydraulik Schematic Soft Lift ................................................ 194
XII
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SAFETY
1
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SAFETY

Safety Symbols used in the Manual

T o help guide you through the man ual and to highlight parti­cular danger areas, we have used graphic illustrations:
DANGER
This symbol indicates life-threatening
risks
● Failure to comply with this notice may result in fatal injuries to yourself or other people.
WARNING
This symbol indicates the risk of serious injury and/or serious material damage.
● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.
CAUTION
This symbol indicates the risk of minor injury and/or minor material damage.
General Maintenance and Repair Safety Notes
DANGER
Read the safety notices in the truck Maintenance and Operator's Manuals.
● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.
Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guide­lines.
DANGER
Follow all national/local safety regula­tions applicable for maintenance work, e.g. for work on higher levels.
● Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.
● Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage.
INFORMATION
Contains additional information with supplementary notes and hints.
OPTION
These items relate to optional features not supplied with the standard version.

Maintenance and Repair

1. Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices.
2. Only qualified and authorised personnel may carry out work on the truck.
3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame.
4. To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness.
5. Keep the service area clean, dry and well­ventilated.
6. Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.
7. Neutralise and thoroughly rinse any spilled battery fluid immediately.
8. Keep the truck clean. This will facilitate the location of loose or faulty components.
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Page 18
SAFETY
9. Make sure that capacity and data plates, warnings and labels are legible at all times.
10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown.
11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck.
Before Leaving the Truck
● Stop the truck.
● Lower the fork carriage fully.
● Apply the parking brake.
● Turn off the truck and remove the key.
● Block all wheels when parking on an uneven
surface.
Before Carrying out Work on the Truck
● Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.

Warnings and Labels on the Truck

During regular maintenance check that the warnings and labels on the truck are complete and legible.
● Clean any illegible labels.
● Replace any faulty or missing labels.
The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual.
● Prevent the truck from rolling away.
● Before carrying out work on the hoist frame, the
lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.
● Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.
Before Operating the Truck
● Check the safety devices.
● Get into the driver's seat.
● Check the operation of the lifting device, travel
direction switch, speed control, steering, warning devices and brakes.
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INTRODUCTION
5
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Page 21

INTRODUCTION

General

The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck com­ponents.
It also contains troubleshooting sections which can be used to identify and remedy truck faults.
INFORMATION
This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual.
This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.
This information can be found on the truck's data plate. Only if this information is provided can the order be processed quickly, correctly and reliably.
Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from y our CROWN dealer or from the following address:
CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
80809 Munich
GERMANY
Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 or133
Using the Manual
The manual is divided into sections. The following table shows how the manual is structured.
ecnanetniaMsnoitceS
Operating Instructions
This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required.
With the help of this manual you and your personnel will be able to ensure the long service life, operational saf ety and error free functioning of your CROWN vehicle.
Service T raining
CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.
Ordering Spare Parts
The maintenance manual does not cover spare parts. These are listed in a separate manual.
Spare parts can be ordered by quoting:
● The truck specification number
noitceS noitpircseD
XDItnetnoCfoelbaT
AMytefaS
DTInoitcudortnI
1MtnemtsujdAdnanoitacirbuL
2MsciluardyH
3MtinUevirD
4MlacirtcelE
5MekarB
6MgnireetS
● The truck model number
● The truck serial number
WF3000 09/2005 • Printed in Germany MS-ITD 3300
7MmsinahceMgnitfiL/tsaM
8MrednilyC
AIDsmargaiDlacirtcelE
DYHcitamehcSciluardyH
A01M-gb
7M1.0-0000-00077
Page 22
INTRODUCTION

Model-Number

This manual describes the maintenance and repairs for the following truck versions:
WF 3000-1.0 WF 3000-1.2
WF3000 09/2005 • Printed in GermanyMS-ITD-3300
8M1.0-0000-00088
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LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT

Raising And T owing The T ruck

Raising With Another Forklift Truck
DANGER
Failure to read the instructions can cause the truck to tip over or fall from the forks. Fatal accidents could result.
● Position the forks of the truck which is doing the
lifting as shown by the diagram below.
● The centre of gravity of the WF 3000 with and
without the battery is near the battery compart­ment. It should always be between the forks of the truck doing the lifting.
● Secure the WF 3000 firmly to the forks of the
truck which is doing the lifting (e.g. with appropri­ate straps).
Schwerpunkt
> 850
> 650
MO-3300-014
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LUBRICATION AND ADJUSTMENT
Lifting by Crane
DANGER
Make sure the crane / fork lift and the lifting equipment have sufficient capac­ity.
If the crane / lift truck crash or a load falls, fatal injuries can result.
Capacity required: 900 kg
Attach lifting gear as shown in the following diagram and prevent the truck from slipping.
12
MO-3300-013
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LUBRICATION AND ADJUSTMENT
Towing the Truck
DANGER
Tipovers can result in fatal accidents. If the towing truck negotiates a bend, a
fork will slip under the truck that is being towed. This can cause the towed truck to tip over and result in fatal injuries.
Only travel straight ahead when towing.
When the truck is de-energised, the brake (acting on the drive wheel) is applied. To remove the truck from an aisle, for example , it can be raised and pulled by a f orklift truck. The required capacity (WF unladen, with battery , 800 kg): 1100 kg. The load wheels remain on the ground when the truck is towed.
CAUTION
Risk of damage to the drive system. If the drive wheel is still touching the
ground, the drive system will be dam­aged when the truck is towed.
Only raise the truck so far that the drive wheel is not touching the ground.
● Position the forks as shown in the diagram.
● Raise the truck (at its front) approx. 20 mm, but
no higher than necessary as otherwise the bottom of the WF’s fork tips will scratch the ground.
MO-3300-015
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LUBRICATION AND ADJUSTMENT

Component Access

Undo the 3 screws securing the dashboard. Lift off the dashboard and panel to gain access to the components beneath the panel.
Note: The illustration shows the model with the TT mast.
Mast
Fork
Load wheel
Safety Screen
Control handle
Free lift cylinder
Dashboard
Control handle knuckle
Controller and contactors
Traction and pump motors
Caster wheel
14
Battery and battery connector
Drive wheel
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LUBRICATION AND ADJUSTMENT
After disassembling the top panel you will be able to access the:
● Diagnostic LED on the TCM
● Fuse FU1 (travel power fuse)
● Fuse FUS (raise power fuse)
● Combination instrument
● Fuse FU3 (signal)
● Fuse FU4 (cold store versions only)
After lifting off the bottom panel you will be able to access the:
● Traction motor
● Power unit
● Brake
● Pump motor
The control handle knuckle contains the:
● BRS (brake switch)
● ORS (brake override zone switch)
The mast contains the:
● FLS (flashing light)
● LMS (lift limit switch)
● Hydraulic unit
● Horn
● Alarm transmitter
● Diode block
● Main contactor
● Relay K2
● Alarm filter block
● TCM (traction control module)
● HCM (hydraulic control module)
The hand grip contains:
● HNS1 & HNS2 (horn switches)
● LOS1 & LOS2 (fork lower switches)
● RAS (raise switch)
● HSS (fast / slow travel switch)
● SAS (safety reverse switch)
● FS, RS, POT (travel switch unit and
potentiometer)
WF3000 09/2005 • Printed in Germany MS-1.0-3300
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LUBRICATION AND ADJUSTMENT

Maintenance

Recommended Lubricants and Oils

Lubricants
The next page shows typical lubricants used by Crown itself in its factories. Howe ver , you can use any lubricants provided they meet the same technical criteria.
Cold Store Trucks
Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table on following page). An anticorrosion fluid (Crown no. 805236-004) must be applied to all screws, washers, nuts, pins, retaining rings etc. Care­fully protect all electrical connections and components against corrosion. F or detailed information, refer to chap­ter 4.
Service intervals must be adapted to the conditions of use. This means they must be reduced as far as possi­ble to prevent excessive wear.
Taking the truck out of service
● Every 3 months connect the battery, carry out a
daily inspection and activate all the truck func­tions. Now disconnect the battery again.
Bringing the truck back into service
● If you wish to bring the truck back into service,
proceed as follows:
● Remove any anti-corrosion agents which have
been additionally applied (apart from the cold store agents)*.
● Jack up the truck, remove the wooden blocks and
lower the truck.
● Charge the battery or fit a charged battery.
● Connect the battery.
● Carry out the daily inspection.
* Do not apply high pressure cleaning agents and/or solvents to the truck. Do not use metallic brushes. Do not wet clean the electrical system and do not use flamma­ble solvents.
If you wish to take the truck out of service for more than 3 months, proceed as follows:
● Disconnect the battery from the truck.
● Decommission the battery in accordance with the
manufacturer’s instructions.
● Clean the truck*). Lubricate in accordance with
the maintenance manual.
● If the truck is to be stored in harsh conditions
(e.g. saline atmosphere) treat the surface of the truck with a suitable preservative to prevent corrosion.
● Do not park the truck in the open air or in a
humid environment. The ideal place is a dry room where the temperature and air humidity are as constant as possible. If the truck has to be covered, use an air-permeable material. Do not use plastic sheets. Otherwise, condensation may form.
● Jack up the truck. Lower the chassis onto suit-
able wooden blocks so that the wheels clear the ground (prevents the wheels from flattening from constant pressure).
16
WF3000 09/2005 • Printed in GermanyMS-1.0-3300
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Page 31

Lubricant T able

LUBRICATION AND ADJUSTMENT
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WF3000 09/2005 • Printed in Germany MS-1.0-3300
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Page 32
LUBRICATION AND ADJUSTMENT

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18
WF3000 09/2005 • Printed in GermanyMS-1.0-3300
Page 33
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LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT
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WF3000 09/2005 • Printed in GermanyMS-1.0-3300
20
L05_WF-GB
Page 35
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LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT

T ruck Tilt Settings

DANGER
Truck tipovers can result in fatal injuries. The risk of a tipover is greatly increased
by setting the truck tilt angle beyond the tolerance level.
Adjust the truck tilt angle regularly and with care.
The stability of the truck requires the tilt angle to be kept as low as possible.
Maximum stability is achieved by measuring the lateral inclination and carrying out a lowering plumb test on the mast with appropriate adjustment.
The inclination of the truck and therefore the mast changes as the drive wheel and / or the caster wheel increasingly wear.
● Fix the caster wheel again. Repeat the measure­ment to check the adjustment.
● If necessary, repeat the adjustment until the difference in height on the two sides is within the tolerance lev el.
● Now carry out the lowering plumb test.

Lowering Plumb Test

Test the lateral inclination before carrying out the lowering plumb test.
The truck must be parked on a flat, level surface. The max. permissible deviation from the evenness and levelness of the 4 contact points on the truck (the two load wheels, caster wheel and drive wheel) must be less than 1 mm.
● Attach a test load (the maximum weight at maxi­mum lift height and with the correct load centre of gravity - see capacity plate).
The inclination of the truck must be checked and if nec­essary adjusted in the following cases:
● Lateral inclination and lowering plumb test at the intervals given in the maintenance schedule.
● Replacing the drive wheel
● Replacing the caster wheel
● Replacing the mast
Testing and adjustment take place in 2 stages:
Testing and Adjusting the Lateral Incli­nation
The truck must be parked on a flat, level surface. The max. permissible deviation from the evenness and levelness of the 4 contact points on the truck (the two load wheels, caster wheel and drive wheel) m ust be less than 1 mm.
● Measure the skir t height off the ground (at the separating joint) on the left and right hand sides. The difference between the left and right hand sides should not exceed +/- 1mm.
● Adjust the height of the caster wheel to correct the lateral inclination of the chassis. To do this, undo the locking screw (3, Fig. MP-3300-007) and adjust the height via the setscrew (1).
● Raise the test load approx. 300 mm.
● Attach a lowering plumb to the back of the fork
carriage.
● Prepare a paper rectangle: 50 mm long and 20 mm wide. Mark out the middle of the rectangle.
● Wait until the plumb has finished oscillating and stick the previously prepared paper rectangle onto the ground below the plumb. The centre should lie underneath the tip of the plumb. The long side of the rectangle (50 mm) should be perpendicular to the truck’s longitudinal axis.
● Now extend the mast as far as the stop and then lower it a few millimetres. It is important that the mast is not tensioned at the limit positions.
● Check the position of the lowering plumb. The plumb should not now be pointing outside the rectangle.
● If the plumb is pointing outside the rectangle in the lateral direction, the lateral mast inclination must be compensated using shims 813875-001/-
002. The shims are positioned between the base of the outer mast and the truck base (RH or LH) and screwed to the rear panel of the battery.
22
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LUBRICATION AND ADJUSTMENT
● If the plumb is pointing outside the rectangle in the longitudinal direction, either the drive and caster wheels or the load rollers are heavily worn. In this case, check the wheels and rollers for wear and replace any worn wheels and rollers. Now repeat the lateral inclination setting and the vertical plumb test.
1
2
3
4
5
6
14
13
12
9
7
11
10
8
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9
MP-3300-007
10
23
Page 38
Blank page
24
Printed in Germany
Page 39
Printed in Germany
HYDRAULICS
25
Page 40
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26
Printed in Germany
Page 41

Hydraulic Symbols

Vented reservoir with lines above the fluid level
Vented reservoir with lines below the fluid level
Filter or strainer
M
M

HYDRAULICS

Electric motor with unidirectional turn and speed
Electric motor with unidirectional turn and variable speed
Hydraulic line with full flow (tubing or hose)
Pilot or drain line or drainage with limited flow
Lines crossing; not connected
Lines crossing and connected
Hydraulic pump with fixed displacement and single direction of turn
Hydraulic motor, bi-directional
Pressure gauge
Thermometer
Plugged port (test por t )
Flow meter
M3559
WF3000 09/2005 • Printed in Germany
Accumulator gas charged diaphragm type
MS-2.0-0000
M1.0-0000-00027M-1.0-0000-0002727
Page 42
HYDRAULICS
Pressure switch
Double-acting cylinder; unequal area
Double-acting cylinder; equal area
Single-acting cylinder with spring returned (rod end vented)
Single-acting cylinder ram type
Manual actuator
Spring, (bias to normal de­energised position)
Solenoid single coil or winding
Hydraulic pilot operated
Single-acting cylinder, with cushion
Assembly housing, manifold block
Manual lever actuator
Solenoid valve, pilot operated
Dual solenoid
Proportional solenoid
Pilot check valve (pilot to open)
M3560
MS-2.0-0000
M1.0-0000-00028M-1.0-0000-0002828
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HYDRAULICS
Throttle, fixed
Throttle, adjustable
Pressure-compensated flow control, fixed
Pressure-compensated flow control with reverse flow bypass; fixed.
Shuttle valve
Single counterbalance valve assembly in manifold
Flow divider/combiner
Velocity fuse
Relief valve, fixed setting
Relief valve, adjustable
Check valve
Bypass flow control with controlled flow, pressure-regulated
Shut-off valve, manual
P T
T P
L R
Torque generator
Hydraulic steer unit
M3561
WF3000 09/2005 • Printed in Germany
MS-2.0-0000
M1.0-0000-00029M-1.0-0000-0002929
Page 44
HYDRAULICS
2/2 way valve (two way, two switch positions)
3/2 way valve (three way, two switch positions)
4/2 way valve (four way, two switch positions)
Valve block with 3 operating units
4/3 way valve (four way, two switch positions)
4/3 way valve (four way, two switch positions); manual activation and spring centered
3/2 way valve (three way, two switch positions); Spring bias solenoid control
M3562
MS-2.0-0000
M1.0-0000-00030M-1.0-0000-0003030
WF3000 09/2005 • Printed in Germany
Page 45

HYDRAULICS

Hydraulics

Hydraulic Reservoir Capacity

The hydraulic reservoir has a capacity of 5.4 litres up to the max. oil le vel mark. The marking on the hydraulic res­ervoir serves to indicate the maximum capacity. When checking the hydr aulic oil lev el, mak e sure that the cylin­ders are fully retracted and that the entire hydraulic sys­tem is fully bled.
Only start the truck once the reservoir has been filled with the approved hydraulic oil up to the maximum level. For the correct grade, ref er to the lubricant table in Chap­ter 1.
The hydraulic oil is filled up to the marking on the hy­draulic reservoir. The oil le vel should not de viate by more than +/-3 mm from this level.

Changing the Hydraulic oil and Hydraulic Filter

WARNING
De-pressurise all components before carrying out maintenance work on the hydraulic system.
High pressure hydraulic oil can cause serious injuries.
Whenever a high pressure fluid enters the skin it must be treated as an emer­gency, even if the skin initially shows no reaction.
Physical effects may take time to set in. Secure all connections before re-apply-
ing system pressure. Keep hands and body away from any ports as high pres­sure hydraulic oil can emerge.
MS-3300-001
Use absorbent paper to trace leaks, never use your hands!
● Fully lower the forks. Retract the mast fully.
● Turn the key switch OFF. Remove the key. Dis-
connect the battery.
● Attach a warning tag to the control handle to advise others that the truck is being serviced.
● Chock the drive wheel and load wheels.
● Remove the front cover from the drive unit to
access the hydraulic reservoir.
● Remove the knuckle cover and the two-part centre cover of the control handle. Rotate the control handle 90° (towards the hydraulic reser­voir). This will give you better access to the hydraulic system components.
● Undo the retaining strap which secures the motor to the chassis. Push the strap up to loosen it from the chassis.
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HYDRAULICS
● Separate the hydraulic lines from the hydraulic pump. Seal the hydraulic ports immediately to minimize oil loss and prevent hydraulic system contamination.
● Disconnect all electrical wiring from the hydraulic unit. Insulate the wire ends to prevent sparking. Tag out the wire ends and motor ter minals to avoid any confusion when you later connect the wires.
● The reservoir and motor/pump assembly can now be moved. Carefully raise the reservoir and pull it forward as far as possible. Remove the reservoir and the motor/pump assembly from the drive unit frame.
● Remove the screw from the clamp securing the motor/pump assembly to the reservoir flange. Open the clamp until it drops off the flange and rests on the top of the reservoir.
● Lift the motor/pump assembly from the reservoir.
● Remove the oil from the reservoir and any re-
mains that have built up in the reservoir. Observe local disposal regulations.
● Fill the reservoir up to the full mark via a filter (at least 10 micron) using the correct hydraulic oil grade according to the operating conditions of the truck (see Chapter 1, Lubricant table).
● Refit the covers of the control handle, and tighten the mounting screws firmly.
● Refit the front cover of the drive unit, and tighten the mounting screws firmly.
● Remove the wedge.
● Connect the battery and remove the warning tag
from the control handle.
● Bleed the hydraulic system (see Chapter 8, Cylinder Bleeding and Flushing).
● Remove the retaining ring of the strainer in the filter housing of the suction line below the pump. Replace the filter. Refit the strainer in the filter housing of the suction line. Attach the strainer and the retaining ring.
● Fit the motor/pump assembly onto the reservoir. Centre the pump flange with the flange on the reservoir.
● Refit the clamp and tighten the mounting screw firmly.
● Fit the reservoir and the motor/pump assembly in the drive unit frame.
● Connect the power cables to the pump motor and tighten the connections securely.
● Reconnect the hydraulic supply lines and the electrical connections. Tighten the connections firmly.
● Make sure that the reservoir and motor/pump assembly are against the frame. Now tighten the holding strap to secure the motor/pump assembly to the drive unit frame.
32
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HYDRAULICS
Hydraulic system Function
Lifting (see diagram)
If the “Raise” switch is pressed down on the control han­dle, the pump motor is energised and starts to drive the pump. The pump initially draws oil from the reservoir via the suction filter, directing it through the internal check valve and the proportional valve which opens briefly, and back to the oil reservoir. While the propor tional valve is fully closed, the operating pressure builds up on the lift cylinder (soft lift). A relief valve in the circuit keeps the pressure to the maximum permissible limit.
1 Suction filter 2 Reservoir ventilation 3 Check valve (CV) 4 Overload valve (RV) 5 Cylinder shutoff valve (SVCL) 6 Proportional valve (PV) 7 Pump & motor 8 Line break safety device (LH lift cylinder, opposite
the fork direction) 9 Free lift cylinder line break safety device 10 Reservoir 11 Flow restrictor 12 Line break safety device (RH lift cylinder, opposite
the fork direction)
12
A
Suction line Pressure line
NT mast Lift - Hydraulics
TL mast Lift - Hydraulics
8
A
12
SVCL
M
9
5 3
CV
TF mast Lift - Hydraulics
8
A
6
PV
11
4
RV
230 bar
A
2
8
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7 1 10
M3435a
33
Page 48
HYDRAULICS
Lowering (see diagram)
If one of the two “Lower” switches (LOS1 or LOS2) is pressed down on the control handle, the shutoff valve opens. At the same time the proportional valve opens according to whether LOS1 or LOS2 has switched fully or partially. The hydraulic oil can now flow from the cylinder(s) via the flow restrictor back to the oil reservoir. If the proportional valve is partially open, lowering is slow. If the proportional valve is fully open, lowering is fast.
TL mast Lift - Hydraulics
1 Suction filter 2 Reservoir ventilation 3 Check valve (CV) 4 Overload valve (RV) 5 Cylinder shutoff valve (SVCL) 6 Proportional valve (PV) 7 Pump & motor 8 Line break safety device (LH lift cylinder, opposite
the fork direction) 9 Free lift cylinder line break safety device 10 Reservoir 11 Flow restrictor 12 Line break safety device (RH lift cylinder, opposite
the fork direction)
12
TF mast Lift - Hydraulics
A
Return
NT mast Lift - Hydraulics
A
9
12
8
A
8
5 3 6
A
PV
SVCL
CV
RV
M
SX: 205 bar ST: 175 bar
8
11
4
2
34
7 1 10
M3565a
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HYDRAULICS

MOTOR AND PUMP ASSEMBLY

Hydraulic Lines and Fittings
WARNING
De-pressurise all components before carrying out maintenance work on the hydraulic system. High pressure hydrau­lic oil can cause serious injuries.
Whenever a high pressure fluid enters the skin it must be treated as an emer­gency, even if the skin initially shows no reaction.
Physical effects may take time to set in. Secure all connections before re-apply-
ing system pressure. Keep hands and body away from any ports as high pres­sure hydraulic oil can emerge.
Use absorbent paper to trace leaks, never use your hands!
General Rules for Hydraulic Lines and Con­nections
● Apply pressurised air to all hoses and lines before assembling them, to remove any loose particles. Bent steel or plastic lines will be perma­nently damaged. These must be replaced even if the damage is not externally visible.
● Any hose which bends during operation in its normal assembly position must also be replaced.
Drift Test
Whenever work has been performed on hydraulic com­ponents a drift test must be carried out to ensure that certain system components are working correctly. The procedure for doing this can be f ound in Chapter 8 under “Drift T est”.
Proportional function:
Whenever maintenance work has been perf ormed on the hydraulic system.
Ensure that the load can start smoothly when the lift motor is switched on and that the load can also brake smoothly when lowering is switched off (subjective test).
The HCM (hydraulic control module) ma y have to be cali­brated (see Electrics chapter).

REMOVAL

WARNING
De-pressurise all components before carrying out maintenance work on the hydraulic system.
High pressure hydraulic oil can cause serious injuries.
Whenever a high pressure fluid enters the skin it must be treated as an emer­gency, even if the skin initially shows no reaction.
Physical effects may take time to set in.
● All hoses and lines must have sufficient clear­ance from other surfaces or edges that could result in wear or cuts or where the hoses or lines could get caught.
● All connections must be tight and without leaks.
Bleeding the Hydraulic System
Whenever work has been performed on hydraulic com­ponents, the hydraulic system must be flushed and b led. The procedure for doing this can be found in Chapter 8 under “Cylinder Bleeding and Flushing”.
WF3000 09/2005 • Printed in Germany MS-2.1-3300
Secure all connections before re-apply­ing system pressure. Keep hands and body away from any ports as high pres­sure hydraulic oil can emerge.
Use absorbent paper to trace leaks, never use your hands!
● Fully lower the forks. Retract the mast fully.
● Turn the key switch OFF. Remove the key. Dis-
connect the battery.
35
Page 50
HYDRAULICS
● Attach a warning tag to the control handle to advise others that the truck is being serviced.
● Chock the drive wheel and load wheels.
● Remove the front cover from the drive unit to
access the hydraulic components.
● Disconnect the power cables from the pump motor. Insulate the wire ends to prevent sparking.
● Disconnect all the hydraulic supply lines and/or electrical connections that obstruct you when removing the motor/pump unit.
● Remove the strap (and where applicable the spacer) which fixes the pump motor to the chas­sis. Undo the clamp that fixes the motor/pump assembly to the reservoir.
● Remove the motor/pump assembly from the reservoir and take it to a suitable work area for further dismantling.
● Check the connections again for leaks once the system has reached operating temperature.

MOTOR

Refer to Chapter 4, “Electrics”, for pump motor mainte­nance and repair instructions.

PUMP

The hydraulic pump cannot be serviced and can only be replaced as a complete assembly. Before fitting a new pump, make sure that the pump and all its h ydraulic com­ponents are clean. Install a new suction filter (see sec­tion on changing the hydraulic oil and filter).
After replacing the pump:
● Use clean, filtered hydraulic oil (at least 10 micron) to replenish the reservoir.
● Never run the pump without oil.
● Star t the installed pump unladen (pressure side
open) and leave it to pump hydraulic fluid for max. 20 seconds. This will ensure the pump is bled and that there is sufficient lubrication. Close the pressure side again as soon as the oil emerges without bubbles. Bleed the entire sys­tem (see Chapter 8, Cylinder Bleeding and Flushing).
● If the oil is still foaming after approx. 20 seconds, the system must be checked (see “Hydraulic System Troubleshooting Table” on following page).
36
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Replacing the relief valve

● Remove the locking mechanism (4) and unscrew
the relief valve (3),
● Remove the O ring and the strainer from the
valve seat if they are still in there.
● Apply a thin coat of hydraulic oil to the new O ring
and place it in the valve seat with the strainer.
● Apply hydraulic oil to the relief valve, insert it into
the valve seat and tighten. Tap in the new locking mechanism.
● Refit the hydraulic unit and adjust the relief valve.

Relief valve test and setting

The relief valve protects the hydraulic system and the lifting mechanism from overloading.
HYDRAULICS
Repeat the test. Repeat the setting until the relief
●
valve opens within the tolerance range.
WARNING
Do not let the pump unit run unless it is fixed to the chassis.
The amount of torque will twist the unit. This can result in short circuits and damage.
ledoM
0.1-0003FWt0,1gk001,1gk002,1
2.1-0003FWt2,1gk023,1gk024,1
● With the truck at operating temperature, raise a
detaR
yticapac
muminiM
daol
daol
H01_GB
test load on the forks that corresponds to 110% of rated capacity (= minimum load). It should be easy to raise the load.
● Now raise a test load that corresponds to 110%
of rated capacity + 100 kg (=maximum load). It should not be possible to raise this load. (relief valve opens).
3
2
1
MS1723-007
4
mumixaM
lIf necessary, adjust the relief v alve so that it opens within the above mentioned tolerance range.
● Hold onto the setscrew (1) and loosen the jam
nut (2): Tur n the setscrew clockwise to increase the limit until the valve opens, turn it anti-clock­wise to reduce the limit
● Counter-fix the setscrew (1) again with the nut
(2).
WF3000 09/2005 • Printed in Germany MS-2.1-3300
Rev. 01/03
37
Page 52
HYDRAULICS

Hydraulic System Troubleshooting

motpmyS esuaCelbaborP ydemeR
pmuPysioNlevelliowoL•
liociluardyhgnimaoFmetsysniriA•
gnitaehrevolioropmuP liodradnats.g.e(ytisocsivliotcerrocnI•
wolfwoLmetsysniriA•
.hsinelper,levelliokcehC
liodradnats.g.e(ytisocsivliotcerrocnI•
)erotsdlocnidesu
pmup(kaelnoitcennocesohtelnI•
)riasnoitcus
retlifesohnoitcusdekcolbyllaitraP•
lioniretaW•
)erotsdlocnidesu
retawhtiwdetanimatnocliO•
metsysniriA•
nepoyltnenamrepevlavfeilererusserP•
evlav
woloottesrognikaelevlavfeileR•
tohootliO•
.noitacilppa
.pmup
retlifecalpeR
levelliokcehC
pmup
ecalperdnariovresernaelC
.liociluardyh
.lionaelc
levelliokcehC
)"liOgnimaoF"ees(pmup
."liognimaoF"eeS
ytluaffiecalper,evlav
ehtrofliociluardyhtcerrocehtesU
ehtotnoitcennocenilnoitcuskcehC
ehtotnoitcennocenilnoitcuskcehC
htiwllifdnanaelc,niardylluF
.noitacilppaehtroflioelbatius
ddadnariovresernaelc,niardylluF
otnoitcennocenilnoitcuskcehC
feilerfonoitarepodnagnitteskcehC
"gnitaehrevOliOropmuP"eeS
feilerfonoitarepodnagnitteskcehC
erusserpdliuboteruliaFevlavfeilerevitcefeD•
,evlavfeilerfonoitarepokcehC
levelliowoL•
lioddA
.ytluaffiecalper
H02-GB
38
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Printed in Germany
DRIVE UNIT
39
Page 54
Blank page
40
Printed in Germany
Page 55
Gear Unit

DRIVE UNIT

Drive unit attached to flange of control handle support
Discharge filter
Drive motor with drive pinion removed
MS-3230-100
Drive wheel
Gear unit cover
Pinion shaft and gearwheel
Oil refill plug (6 Nm)
Oil level
Driven shaft and gearwheel
M1472
Drain plug (6 Nm)
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Page 56
DRIVE UNIT

Drive unit, general

The drive unit consists of the gear unit and the drive motor . The drive motor can be removed without removing the
drive unit or dismantling the gear unit. For a v ertical drive system it is not necessary to drain the oil.
WARNING
The drive unit is heavy. Use a suitable device to prevent the drive
unit from tipping over on removal. The easiest method is to lift the truck
away from the loosened drive unit using a crane.
If you have to jack up the truck in order to release the drive unit, firmly secure the truck underneath.

Drive unit removal

● Disconnect the battery and prevent the truck from being switched on again.
● Prevent the drive unit from tipping over and remove the 4 mounting screws (1, Fig. MS1723-
031) which secure the drive unit to the flange of the control handle support.
● Either jack up the truck so that the drive unit can be removed from underneath it, or raise the truck using a crane with sufficient capacity (see chap­ter 1 for instructions and safety notes).
● Position the drive unit in a secure device.

Drive motor removal

NOTE
If you are removing the drive motor with the drive unit installed, you must ensure that the motor does not get caught in the bearing cage of the drive unit when it is removed.
Tilt the drive unit so that the motor can be freely removed.
● Disconnect the battery and prevent the truck from being switched on again.
● Disconnect the electric wiring from the motor.
● Disconnect the electric wiring from the motor.
1
● Unscrew the mounting screws (A, Fig. MS1723-
021) approx. 5 mm from out of the housing.
A
42
MS1723-031
MS1723-021
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DRIVE UNIT
C
B
MS1723-024

Motor disassembly

NOTE
All item numbers in the following sec­tions refer to Figure MS-1723-027-A on
MS1723-022
the following page unless another figure number is indicated.
● Unscrew both screws (B, Fig. MS1723-022).
● Screw 2 M8 bolts into the thread (B, Fig.
MS1723-022) with a minimum length of 35 mm and tighten them on alternate sides until the motor is removed from the centering shoulder.
● Prevent the motor from falling out! Unscrew both screws (A, Fig. MS1723-021). Attention:
Take care not to damage the toothing (C, Fig. MS1723-024) and D, Fig. MS1723-023)
D
● Remove the motor as described in the previous section.
● Disassemble the brake (see “Brake” chapter).
● Remove the retaining ring (40).
● Remove the pinion (1) via the bushing (11) using
an extractor .
● Remove the conical nipple (29).
● Press out the shaft seal (32).
● Extract the bearing (20) and the inner ring (12).

Motor assembly

● Press the bearing (20) onto the rotor shaft. At the same time hold the opposite shaft end securely.
● Seal the inner ring (12) with Loctite® 601.
● Place the conical nipple (29) in the bushing (11)
and press in the shaft seal (32). Now insert the ball bearing shim (33) into the bushing (11).
● Fit the complete bushing onto the motor arma­ture.
● Inser t the feather key (50) and the pinion (1).
MS1723-023
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Page 58
DRIVE UNIT
58
5 59
29
33
11
32
1
40
50 12
20
6
70
31
7
3
24
21
30
22
51
61
62
2
45
48/49
4
44
43
60
44
23
9
MS1723-027A
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Page 59
● Fit the retaining ring (40).
● Attach the brake (see “Brake” chapter).
● Fit the motor as described below.

Drive motor assembly

Tools required: 2 off M6 threaded rods, approx. 100 mm long.
● To aid the assembly, screw 2 off M6 threaded rods, approx. 100 mm long, into two opposite threaded holes of the motor (E, MS1723-023)
DRIVE UNIT
A
E
MS1723-023
● Push the motor into the gear unit with the mount­ing aids ahead, and push it into the locating edge.
Take care not to damage the toothing in the process.
● Insert the two mounting screws of the motor (A, Fig. MS1723-021) back onto the gear unit. Alter­nately tighten the two screws in small increments. This will pull the motor completely into the centering shoulder and prevent it from twisting in the centering shoulder.
● Refit the screws (B, Fig. MS1723-022).
MS1723-021
B
● Torque screws A, Fig. MS1723-021 and B, Fig. MS1723-022 to 10 Nm.
● Refit electrical connections to the motor and the brake.
● Carry out an operational test.
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MS1723-021
45
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DRIVE UNIT

Gear unit disassembly

General
NOTE
It is not necessary to remove the motor is you are dismantling the gear unit and re-assembling it.
If you are dismantling the gear unit, you must replace all bearings and seals. Used bearings and seals will result in premature failure of the unit.
Preparation
● Disconnect the battery and prevent the truck from being switched on again.
● If necessar y, remove the motor as described in the previous section.
● Unscrew and remove the drive wheel.
Draining the oil
● Place a tray underneath the drain plug (G, Fig. MS1723-029) of the gear unit and drain the oil. Unscrew the control plug (F) to allow the oil to drain faster.
Drive unit removal
● Now remove the drive unit for disassembly. Refer to the “Drive unit removal” section at the start of this chapter.
● Remove both screws (58, Fig. MS1723-027) and the 10 screws (6) which secure the housing lid.
Gear unit cover removal
WARNING
Do not damage the contact surfaces of the gear unit housing and the gear unit cover.
Do not use a thick tool (screwdriver or similar). This will damage the contact surfaces.
● Tap a burr-free, thin tool along the circumference of the seal gap until the housing cover can be gently removed (see Fig. MS1723-030).
F
G
MS1723-029
● Using a scraper carefully remove the sealant remains from the contact surfaces of the gear unit housing and the gear unit cover. Now thor­oughly clean the contact surfaces with a suitable solvent (e.g. Loctite® 7063 Cleaner).
46
MS1723-028
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DRIVE UNIT
Gear unit disassembly
NOTE
All item numbers in the following sec­tions refer to Figure MS-1723-0027-A on the following page unless another figure number is indicated.
● Remove the retaining ring (61, Fig. MS1723­027A) and the supporting ring (62).
● Using a suitable extractor pull off the wheel (2).
● Remove the retaining ring (45) and the two shims
(48, 49).
● Press off the driven shaft (7) in the direction of the drive wheel. This will inevitably damage the
bearing (23).
● Remove the retaining ring (44) and extract the bearing (23). The bearing can no longer be
used.
● Remove the retaining ring (43) and extract the bearing (24) via the outer ring.
● Press the shaft seal (31) from the outside into the seat on the gear unit housing.
● Fit the outer ring of the roller bearing (24) and insert the retaining ring (43).
● Place the bushing (9) onto the rollers of the bearing (24) and press the bearing (23) into the gear unit housing and insert the retaining ring (44).
● Place the wheel (4) in position and guide the drive shaft carefully into the shaft seal. Align the bushing in the process.
● Align the wheel (4) with the tooth shaft profile of the drive shaft (7).
● Suppor t the wheel (4) with suitable bushing and press the drive shaft (7) into the wheel (4).
● Using an appropriate number of shims (49), distance the drive shaft (7) between the two shims (48) so that there is no slack and insert the retaining ring (45).
● Press the bearing (22) onto the pinion shaft (3).
● Now press out the shaft seal (31).
● Remove the retaining ring (42) and the sealing
cover (30).
● Press off the pinion shaft (3) in the direction of the gear unit cover (6). Both bearings (21 and 22) will remain on the pinion shaft.
● Remove the two bearings (21 and 22) from the pinion shaft (3).
NOTE
The output gear is part of the motor. The procedure for removing the pinion and the bearings is described in the Drive Motor section on the previous pages.

Gear unit assembly

Replace all bearings and seals. Used bearings and seals will result in premature failure of the unit.
● Hold against the inner ring of the bearing (21) and fit the pinion shaft (3). Press in the retaining ring (42).
● The contact surfaces of the cover and gear unit housing must be clean and oil-free. If necessary, clean the surfaces as described in the Gear Unit Cover Removal section.
● Apply a layer of Dirko® sealant (part no. see chapter one, lubricants) all around the contact surfaces of the gear unit cover.
● Inser t the feather key (51) into the pinion shaft (3).
● Hold against the inner ring of the bearing (21) and fit the wheel (2) onto the pinion shaft (3).
● Thread the suppor ting r ing (62) onto the pinion shaft (3) and insert the retaining ring (61).
● Press the sealing cover (30) into the housing.
● Press the bearing (21) into the housing via the
outer ring.
● Press the inner ring of the roller bearing (24) onto the drive shaft (7).
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Page 62
DRIVE UNIT
58
5 59
29
33
11
32
1
40
50 12
20
6
70
31
7
30
3
24
21
22
51
61
62
2
45
48/49
4
48
43
60
44
23
9
MS1723-027A
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DRIVE UNIT
Gear unit cover installation
● Place the gear unit cover onto the housing and press on it gently.
● Insert all 10 mounting screws (M8x16 Tuflock A) of the cover and torque them evenly and cross­wise to 25 Nm.
● If you have removed the motor, install it again as described in the Drive Motor Assembly section.

Adding Oil

You will require approx. 0.7 litres of gear oil (see Lubri­cant table in chapter 1 to select an oil appropriate to your operating conditions).
● Unscrew the discharge filter (A, Fig. MS1723-
026) and remove the control screw (B). New gear units are fitted with a filler plug instead of a discharge filter. This prevents from escaping during transport. Ensure that a discharge filter is fitted (A, Fig. MS1723-026) if the gear unit is being installed in a truck.
● With the drive unit vertical, fill the specified amount of gear oil up to the bottom edge of the control screw (B) through the hole for the dis­charge filter (A).
● Screw the discharge filter (A) and the control screw (B) back on once you have reached the correct oil level. The tightening torque for the filter and the control screw is 6 Nm.

Drive unit installation

● Install the drive unit in the reverse order of disassembly (see Drive Unit Removal section in the present chapter).
● Carry out an operational test of the truck and then check the gear unit for leaks.
A
B
MS1723-026
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ELECTRICS
51
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52
Printed in Germany
Page 67

Electrics - General

Wire Colour Codes

The wires used in the truck are colour-coded and num­bered according to their function. The first digit or the first two digits indicate the wire colour while the last two digits are counter numbers.
Exceptions to this can be component leads supplied by vendors. Each wire is identified by a number on a wiring pictorial (refer to section DIA).
NOITAIVERBBA RUOLOC REBMUN NOITCNUF
KLB kcalB **0 langislatigiD

ELECTRICS

NRB nworB **1 langisgolanA
DER deR **2 detcennoctonevitisoP
GRO egnarO **3 retrevnocCDV21+
LEY wolleY **4 retrevnocCDdrihT
NRG neerG **5 detcennoctonevitageN
ULB eulB **6 evitagendetalusnI
OIV teloiV **7 retrevnocCDV5+
YERG yerG **8 retrevnocCDhtruoF
THW etihW **9 suoiraV
THW/DER etihW/deR **92 detcennocevitisoP
THW/NRG etihW/neerG **95 detcennocevitageN
99ot10srebmuN**
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M1.0-0000-0005353
E01-GB
Page 68
ELECTRICS

Abbreviations

*tsiLnoitaiverbbAlobmyShctiwS
noitaiverbbA tnenopmoC noitaiverbbA tnenopmoC
*K yaleR SML hctiwstimiL
SCAhctiwsladeprotareleccA
SXAhctiwsnoitcnufyrailixuASROhctiwsedirrevO
SRBhctiwsekarBTOPretemoitnetoP
SIDhctiwslortnocnoitceriDARretemoitnetopesiaR
SRDhctiwsrooDSARhctiwsesiaR
SDEhctiwStcennocsiDycnegremEAERretemoitnetophcaeR
MEeludomredocnESRhctiwsesreveR
CNEredocnESAShctiwsytefasesreveR
SFhctiwsdrawroFSDShctiwstratS
SOL hctiwsrewoL
SBHhctiwsekarbdnaHSEShctiwstaeS
SSHhctiwslevarTwolS/tsaFSSShctiwsretfihsediS
SNHhctiwsnroHSHThctiwsomrehT
SYKhctiwsyeKTLThctiwstliT
SGLhctiwsthgiLSAWhctiwsgnolaklaW
.cte2VS,1VS.g.e,desueblliw
M1.0-0000-0005454
noisnetxerebmuna,ecnonahteromdesusisnoitaiverbbaevobaehtfoenofI*
WF3000 09/2005 • Printed in GermanyMS-4.0-0000
E02-gb
Page 69
*snoitaiverbbAyrdnuS
noitaiverbbA noitpircseD noitaiverbbA noitpircseD
)KA(VB yekretfaegatloVyrettaB )MP(2M rotompmuP
IDB rotacidniegrahcsidyrettaB CRM rellortnoC
ELECTRICS
RBekarB
IWBrotacidniraewhsurBProtcatnocpmuP
ACnoitcennocelbaCCP)CJgnittif(rotcennocgulP
FsliocdleifnoitcennoCBCPdraobtiucricdetnirP
NAFnaFFSdleiftnuhS
UFesuFITSrotacidnileehwgnireetS
NHnroHVSevlavdioneloS
DFIyalpsidnoitamrofnIBTdraoblanimreT
CJ)CPgnittif(rotcennockcaJMMTeludomtnemeganamkcurT
DGHO yalpsiddraugdaehrevO
ENILrotcatnoceniLTTretemruoH
)MT(1MrotomnoitcarTNMV)rotomegatlovevitageN(reppohC
noisnetxerebmuna,ecnonahteromdesusisnoitaiverbbaevobaehtfoenofI*
.cte2VS,1VS.g.e,desueblliw
WF3000 09/2005 • Printed in Germany MS-4.0-0000
M1.0-0000-0005555
E03-gb
Page 70
ELECTRICS
*snoitaiverbbarehtO
noitaiverbbA noitangiseD noitaiverbbA noitangiseD
RSCG thgirhctiwsdesolcetaG LSCG tfelhctiwsdesolcetaG
SLPhctiwsmroftalP
SPhctiwserusserPRHretaeH
MCHeludomlortnocciluardyHMLAmralalevarT
REVIECERrevieceR
IDBtnemurtsniibmoCREGRAHCregrahcdetargetnI
KRBekarbcitengamortcelERDrevirD
SLStfelhctiwstfihsediSSRSthgirhctiwstfihsediS
SCEhctiwSlortnoCnoitavelE
.cte,2VS,1VS.g.e,desueblliw
MCT rotomnoitcarT
-SNART
RETTIM
rettimsnarT
noisnetxerebmuna,ecnonahteromdesusisnoitaiverbbaevobaehtfoenofI*
E12-S1-GB
WF3000 09/2005 • Printed in GermanyMS-4.0-0000
M1.0-0000-0005656
Page 71

Electrical Symbols

ELECTRICS
EUROPE USA
123456
123456
c
NO
DESCRIPTION
Wires joining
Wires crossing
Wire connection Plug / socket Wire strap Terminal board Fuse
Assembled unit Contact, normally open
Contact, normally closed
Contact double throw
Operating device Operating devices,
slow releasing Operating device, slow operating Hand operated push button
Mechanically actuated
EUROPE USA DESCRIPTION
Hand operated maintained contact
Solenoid valve Inductor Resistor Capacitor Potentiometer
U
J
Varistor Thermal protector
T
Lamp Horn Battery Diode Breakdown diode LED Transistor MOSFET
.
c
c
Hydraulically actuated Emergency disconnect
Thyristor Comparator
Motor armature
.
M0056-gb
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M1.0-0000-0005757
Page 72
ELECTRICS

Electrical Components

DANGER
Jack up the truck before carrying out repair work or troubleshooting the elec­trical system.
Traction Pod (POT, FS, RS)
The travel switches are activated via the thumbswitches on the control handle. The traction pod comprises a s witch (FS) for forward travel, a switch (RS) for reverse travel, and a potentiometer (POT) which governs the travel speed. For cold store versions the potentiometer is heated.
Fast / Slow Travel Switch (HSS)
The fast / slow travel switch (HSS) is activated via a ro­tary switch (rabbit / turtle symbol) on the control handle. The switch signal to the traction controller is used to change between the high and slow speed ranges.
The switch is connected in series to the limit switch (LMS).
Safety Reverse Switch (SAS)
The safety rev erse switch (SAS) is activated via the s witch cap at the top of the control handle: the traction control­ler immediately changes from forward to reverse travel when the SAS is activated. The signal for normal travel to the traction controller is simultaneously interrupted. Depending on the traction controller setting the truck ei­ther travels for a given time, or provided the switch is pressed, travels in reverse.
Brake Switch (BRS)
The brake switch (BRS) is immediately belo w the control handle knuckle. As soon as the control handle reaches the upper or lower braking zone (see Fig. M1476) the brake switch is activ ated. The traction controller interrupts the power supply to the traction motor (TM) and the brak e (BR). The brake magnet releases the anchor disk which in turn, spring powered, brakes the truck.
Override Switch (ORS)
The override switch (ORS) is immediately belo w the con­trol handle knuckle. As soon as the control handle enters the brake override zone (see Fig. M1476) the override switch (ORS) sends a signal to the traction controller with the resulting slow travel option (by pressing the traction pod). This provides better shunt operation in restricted conditions.
Neutral / rest position
Reverse
Upper brake zone
Brake override
Drive
Lower brake zone
Forward
M1476
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ELECTRICS
Raise / Lower Switches (RAS, LOS)
The raise (RAS) and lower (LOS1, LOS2) switches are activated via rocker switches in the control handle. The rocker switches act on switches assembled on the hy­draulic circuit board of the control handle. The switches are electrically locked in pairs so that they cannot both be pressed at the same time.
The raise (RAS) switch activ ates the pump contactor (P) which is controlled by the hydraulic control module (HCM): The pump starts.
The lower (LOS) switch applies voltage to the solenoid (SV) via the hydraulic control module (HCM). The sole­noid opens.
Limit Switch (LMS)
On reaching a preset height, approx. 0.5m + the free lift range, the limit switch (LMS) interrupts a signal to the traction controller. The switch signal to the traction con­troller is used to change between the high and slow speed ranges. The switch is connected in series to the Fast/ Slow Travel (HSS) switch.

Thermal Switch (THS)
This switch is an electronic thermostat for cold store trucks. It is located on the main circuit board of the con­trol handle and switches the heaters on when the tem­perature falls below 0°C.
Thermal switch (THS2)
This thermal switch is located in the pump motor. When the pump motor temperature reaches 170°C, it discon­nects the pump.
After cooling down to 140 °C +/- 15 °C it switches the pump back on.
Hydraulic Control Module (HCM)
Controls the lift contactor P and the valves SVCL & PV as a function of the raise/lower switches RAS /LOS1/ LOS2. A curve is internally stored.
Warning: Make sure you order the correct spare part to avoid damaging system components.
Horn Switch (HNS)
A buzzer sounds when the horn button is pressed.
Key Switch (KYS)
The key switch directs the battery supply to the traction controller and the battery discharge indicator (BDI).
Emergency Disconnect (BD)
Pulling the battery connector on the red knob at the top of the truck completely disconnects the power supply to the truck.
Fuses (FU)
The entire truck circuit is protected by fuses FU1 & FU2, the control circuit by fuse FU3. Cold store trucks have a fuse FU4 for control handle heating.
● FU1 for the traction circuit and the control lines.
● FU2 for the pump circuit.
● FU3 control circuit and options.
Unigage (BDI)
Contains an adjustable battery discharge indicator with a specific algorithm, an hourmeter and a lift cutout sys­tem.
For a detailed description of its operation and adjustment, refer to the appropriate chapter. Standard with some models, otherwise optional.
Integrated Charger
Intelligent charger which disconnects the truck’s control circuit when connected to the mains. (See electrical dia­grams)
Plug Holder (PC)
To accommodate the mains plug while the truck is in

operation. No electrical function.
Drive motor (M1)
Drive motor for the truck (separately e xcited motor), gov­erned by the traction controller.
● FU4 heaters.
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Hydraulic Motor (M2)
Drives the hydraulic pump (compound motor), indirectly via the hydraulic control module, directly via the pump contactor.
Main Contactor (Line/LC)
Activated by the key switch (positive voltage). Connects the positive power supply to the load circuit of the trac­tion circuitry.
Can be deactivated by the traction controller (output A3).
Lift Contactor (P/P1+P2)
Connects the positive power supply to the lift motor of the truck. Governed by the hydraulic control module.
With the remote control option this is a contactor with 2 contacts (in series).
Electromagnetic Brake (BRK)
Activated by the ov erride switch or the brake s witch (posi­tive voltage).
Aux. Hydraulic Valves (SVA1/SVA2)
Controls the auxiliary hydraulics as a function of the aux. hydraulic switch.
Horn (HN)
Horn: Activated via horn switches HNS1 or HNS2 via the drivers on the main circuit board.
Main Circuit Board (MAIN PCB)
Contains driver connections for switches SAS/FS/RS/ POT/HNS1 and HNS2, including the thermostat which switches on the control handle heating on cold store trucks.
Hydraulic Circuit Board (HYD PCB)
Carrier for the raise / lower switches, also acts as a dis­tributor for the positive pow er supply to the heating unit / thermostat resistors.
Equipped with heating resistors for cold store trucks.
Travel Alarm (ALM)
Can be deactivated by the traction controller (output A4).
Terminal Board (TB)
This is where the hydraulic control connections are made; lift cutout, pump contactor etc. (see electrical diagrams).
Travel Alarm Driver (DR)
Activates the trav el alarm as a function of the tra v el con­trol signal issued to the traction controller.
See electrical diagrams (travel alarm option).
Aux. Hydraulic Switch (SLS/SRS)
Enables the auxiliary hydraulics to be controlled from the control handle (optional, cannot be combined with re­mote control).
Remote Control Toggle Switch (ECS)
Switch to activate lift remote control, deactivates travel when activated (optional, cannot be combined with aux. hydraulics).
Alarm transmitter, activated by the driver circuitry and indirectly via the travel switches.
Receiver
Input / output device for the remote control option. Allows lift/lower to be operated in remote control mode,
deactivates travel. Connected to the transmitter via a cable.
Transmitter
Manual device for the remote control option. Allows lift/lower to be operated in remote control mode,
deactivates trav el. Connected to the receiv er via a cable.
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ELECTRICS
MS-3300-033
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ELECTRICS
MS-3300-030
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ELECTRICS
Bracket for mains connector
Dashboard
Mains connector
MS-3300-032
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ELECTRICS

SEM0 T raction Controller

DANGER
The truck must be jacked up prior to carrying out repair work or troubleshoot­ing the electrical system.
General
● When the key switch has been turned off, the filter capacitors in the controller remain charged for a few minutes longer. When you work on the controller at this time, first isolate the controller from the battery (disconnect the batter y). Then discharge the capacitors by shorting the positive and negative leads of the power part with each other over a resistor (10 - 100 Ohm, min. 5 W) for a few seconds.
Functional Characteristics
Speed control
Infinitely variable speed control in both directions, pro­grammable via the handset.
Reduced speed ranges
There are two travel ranges with reduced speed avail­able. Slow travel (via a rotary switch HSS integrated in the control handle grip) and the brake override zone (de­pending on the control handle position, activated via a microswitch ORS integrated within the control handle).
M1478
The programmable SEM 0 impulse controller provides effective control of the truck’s travel characteristics.
The truck is powered by an SEM motor (Separate Ex­cited Motor). With this type of motor there are two vari­ables for controlling output: field current and armature voltage.
Precautionary Measures
● Do not connect the controller to any battery that differs from the voltage indicated on the controller (24 - 26 volts DC). Increasing the battery voltage could damage the MOSFETs; while a lower voltage supply would fail to energise the system.
● Only operate the controller with special traction batteries. Do not connect it to rectifiers or the mains network.
● When star ting to use the truck, jack it up to prevent it from moving without the driver in the event of possible wiring errors.
In addition, slow travel can be activated and fast travel deactivated by pressing the mast switch.
Downhill speed control
When the truck travels downhill, the controller monitors the motor armature speed, comparing it with the travel signal prescribed by the traction potentiometer. If the pre­scribed speed is exceeded, the truck automatically brakes electrically with energy recovery.
Regenerative braking
There are three ways of regenerative braking:
● Release braking (resetting the accelerator to neutral)
● Inversion braking (setting the accelerator to the opposite direction)
● Braking through speed restriction on inclines: The controller constantly governs the motor speed in accordance with the nominal value prescribed by the accelerator. If the nominal value is exceeded, the truck automatically brakes.
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Anti Roll Down Function
This function prevents the truck from rolling down an in­cline without the driver. When the key switch is switched on, the controller monitors the motor speed. If it detects a rotational movement without a travel command being issued, the truck automatically brakes.
If the truck moves of its own accord on an incline, this ensures that it automatically brakes to a halt after a short time. When the truck is stationary the brake force is re­moved so that the truck can mov e again, and again brak­ing is activated. If the brake is not applied, the truck will therefore move only very slowly down a slope.
Hourmeter
An hourmeter integrated within the traction controller can be optionally set with the help of the programmer to “KEY ON” (hourmeter activated when ke y switch is on) or “R UN­NING” (hourmeter activated only when truck is tra velling).
Self-Diagnostic System
The traction controller self-diagnostic system lists the five most recent error messages. These error messages can be read with the programmer . In addition to the error , the error frequency, the respective number of service hours and the traction controller temperature at the time of the error are logged and displayed.
A red LED on the traction controller also indicates the most recent error via a flashing code. The display is de­leted when the controller is switched off and on again and if the error was only temporary.
Monitored Circuits
Safety Mechanisms
Incorrect polarity
A main contactor controlled by the logic system sepa­rates the traction controller from the battery and thereby protects the power part from incorrect polarity.
Wiring Errors
All outputs are protected against wiring errors. The out­puts for the main contactor and the magnetic brake can be charged to max. 3 amps and are fitted with an over­load and short circuit protection.
T emperature pr otection
When the power part temperature exceeds 80°C, the maximum current is restricted in proportion to the rise in temperature. At 90°C the traction controller automatically cuts out.
If the temperature drops below -10° the maximum cur­rent is reduced in proportion to the ongoing batter y dis­charge.
Start sequence
A specific order must be follow ed for starting up the truck. Otherwise the main contact will not be activated and the truck will not operate.
Protection rating
The traction controller is protected against contamina­tion and spray water (IP 54 protection rating).
The following functions are monitored b y the traction con­troller microprocessor, depending on the oper ating mode:
● When the truck is switched on: Control logic (hardware) and program functions (software), field current, VMN, contactor drivers, power up sequence, travel and lift switch output signals.
● Truck on standby (key switch on): VMN, field current, contactor drivers.
● During operation: control logic (hardware) and program functions (software), VMN, field current, contactors.
● Permanently monitoring: traction controller temperature, battery voltage.
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ELECTRICS

Maintenance

Maintenance of the SEM0 traction controller is restricted to external cleaning and checking the torques of the nuts securing the power cable connecting bolts.
You should also take this opportunity to check the errors listed with the help of the programmer.
WARNING
The SEM 0 traction controller operates at high currents. Particular safety measures are therefore required when handling the controller.
- Only use specially trained personnel.
- Use non-fatigue goggles.
- Do not wear loose clothing.
- Do not wear jewelry.
- Only use insulated tools.
● Disconnect the battery (=EMERGENCY DIS­CONNECT).
● Jack up the truck.
● Discharge the traction controller capacitors by
connecting the BATT- and BATT+ connections over a resistance of approx. 10 Ohm, 5 W.
● Remove the power cable: label the cable if necessary. Secure the bottom nuts (2, Fig. MS519) with a fork wrench. Undo the top nut (1, Fig. MS519).
Note:
The bottom nut secures the connecting bolt to the power part circuit board and the plastic housing. If this nuts is under-tightened (torque less than 6 Nm), high transition resistances will occur between the circuit board and the bolt. The heat generated can damage the controller and melt the cover near the connecting bolts.
If the bolt is over-tightened (torque greater than 7 Nm), this can result in physical damage to the power part cir­cuit board and the housing.
● Check the torque for the locknuts (2, Fig. MS519) of the connecting bolt with a torque wrench: It should be 6 - 7 Nm.
Important: An incorrect torque can damage the circuit board and the housing of the controller.
● Remove any dirt and corrosion from the contact surfaces.
● Wipe down the traction controller with a clean, damp cloth.
● When everything is dry, re-connect the power cables. To do this, secure the bottom nut (2, Fig. MS519) with a fork wrench and tighten only the top nut (1, Fig. MS519). Fit the control lines.
● For cold store versions: Apply a coat of Dow Corning® 4 Compound, par t no. 053051-006, to the control line connectors.
MS-4.2-3300
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1
2
MS519
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ELECTRICS

Replacing the SEM0 Traction Controller

WARNING
Make sure you are operating the truck with the correct controller.
The use of SEM0 traction controllers with different part numbers can change the characteristics and result in accidents.
When fitting a new SEM0 traction controller in a truck you must select the right truck model through the appro­priate selection in the configuration menu.
If you have changed and stored the standard configura-
tion with the programmer, the stored parameters will be loaded the next time the controller is started.
● Prepare to remove the traction controller as previously described in the Maintenance section.
● Remove the 4 mounting screws and remove the traction controller.
● Check the contact pattern left behind by the controller back plate on the heat dissipation sheet. The controller must lie fully flat on the heat dissipation sheet.If there are large areas with no contact to the controller, replace the heat dissipa­tion sheet to avoid thermal problems.
● Clean the contact surface of the traction control­ler on the truck chassis with a lint-free cloth and use an industry-standard silicon removal agent to remove the residue of the heat conducting paste.
● Apply a thin and even layer of Dow Corning heat conducting paste, part no. 053051-008 to the floorboard (= contact surface of the traction controller on the truck chassis).
®
the control line connectors. Apply a layer of acid­resistant clearseal paint to the controller.
Important: After replacing the controller check and ad­just the settings. You can adjust the settings to suit the customer’s requirements. Follow the order described as follows.

Parameter Setting after Replacing the Traction Controller

Preparatory Measures
● Power down the truck and jack it up so that
the drive wheel is free (see Chapter 1).
340
● When the truck is programmer to the traction controller.
● Power up the truck.
powered down
Adjustment
1. If required, change the options for the safety reverse switch and the internal ser vice hour meter of the controller. The standard setting is con­tained in Table 11-GB. If you have made changes, switch the truck off and on again. This will acti­vate the changes.
2. Measure the battery voltage directly at the battery and adjust the reading measured and displayed by the traction controller (see CONFIG MENU section).
3. Using the TEST menu check the wiring and operation of the switches (see TEST menu section).
4. Re-calibrate the traction potentiometer (see “Traction pod – calibrate potentiometer, PRO­GRAM V ACC menu).
connect the
● Secure the traction controller again with the 4 screws.
● If necessary clean the contact surfaces and refit the power cable (you must follow the instruc-
tions in the Maintenance section on the previous page) and refit the connectors for the
control lines.
● For cold store versions: Apply a coat of Dow Corning® 4 Compound, part no. 053051-006, to
WF3000 09/2005 • Printed in Germany
5. Test the traction pod starting point at creep speed. The drive wheel should start when the travel switch closes. If necessary increase the value accordingly. Repeat the test for both travel directions (see PARAMETER CHANGE menu section).
6. Jack down the truck and bring it to a secure
area where you can perform test runs without endangering other people.
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7. Set the maximum speed to slow travel if neces­sary (CUTBACK SPEED). Repeat the test with maximum load (see PARAMETER CHANGE menu).
8. Set the maximum speed to the special range if necessary (OVERRIDE). Repeat the test with maximum load (see PARAMETER CHANGE menu).
9. Set the maximum speed “Forward” (MAX SPEED FORWARD) and “Reverse” (MAX SPEED BACK).
Warning: The maximum permissible speed is 6 km/h unladen.
Set the maximum speed to mast stage slow travel if necessary (CUTBACK 2). Repeat the test with maximum load.
10. Set the release brake characteristics: Set the unladen truck to maximum speed and release the travel switch. Repeat the test with the maximum permissible load. If necessary adjust the braking pattern (RE­LEASE BRAKING).
11. Set the braking pattern for changing direction: Set the unladen truck to approx. 25% of maxi­mum speed and move the travel switch in the opposite direction until it reaches the stop. Set the braking pattern so that the delay sets in gently (INVERSION BRAKING). Now repeat the test at maximum permissible speed. Adjust the setting until the delay sets in gently in both speed ranges and the effect is ideal. Preference should be given to the best setting for when the truck is unladen. Repeat the process with the maximum permissi­ble load.
12. Adjust, where necessary, the time taken to change direction. To do this change the AUX TIME DELAY parameter. Both parameters, INVERSION BRAKING and AUX TIME DELAY affect the “feel” of the delay when changing direction.
Important: Po wer down the truck before disconnect­ing the programmer. Now reconnect the LEDs.
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ELECTRICS

Status LED

When the truck is powered up the status LED connected to terminal strip E briefly flashes. This indicates that the test program is being booted up by the controller.
o
N
sehsalFfo yalpsiDelosnoC setoN
1 :1#eruliafcigoL rorrelortnocegatlovrotcatnoceniL
1:godhctaW
1:OKMORPEErorreMORPEE
2:STRATSTCERROCNItcerroctonlevartrofecneuqesgnitratS
2:KCAB+WROF detseuqerylsuoenatlumisdrawkcabdnadrawroF
The status LED is off during normal travel. When an er­ror occurs it flashes the respective code (see following table) until the error is rectified.
The programmer can be used to define the error more exactly.
rorreerawtfosrocigoL
3EGRAHCROTICAPACkcolbrewophtiwmelborP
3KOTONNMV tcerroctonegatloverutamra;reppohchtiwmelborP
3KOTONDLEIFVtcerroctonegatlovdleiF
4KOTONCCAV tcerroctonretemoitnetopnoitcartmorflangiS
4OKERIWLADEPtcerroctongniriwdopnoitcarT
5.RUCDLEIFON
5 .RUCDLEIFHGIH
5 HGIHIYBTS rorrerosnestnerrucerutamrA:tnerruchgiH
5 REVE0=I rorrerosnestnerrucerutamrA:tnerrucoN
6 REVIRDROTCATNOCrorrerevirdrotcatnoC
tcerroctongniriwdleiF:tnerrucdleifoN
rorrerosnestnerrucdleifro
tcerroctongniriwdleiF:tnerrucdleifhgiH
rorrerosnestnerrucdleifro
6 DETROHSLIOCdetrohsliocrotcatnoC
6 DESOLCROTCATNOCytluaftcatnocrotcatnoceniL
7 NOITCETORP.HT
23 WOLYRETTABwolootegatlovyrettaB
WF3000 09/2005 • Printed in Germany
)C°08>(hgihoottinulortnocfoerutarepmeT
)C°01-<(wolootro
E04-GB
MS-4.2-3300
M1.0-0000-0006969
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ELECTRICS

Programmer

General
The optional programmer, Crown P/N 793548, enables programming, testing and diagnostics for the controller.
Crown Handset P/N 793548 (Includes Cord)
Connects To "E" Port On Controller
Display
Forward Back
The programmer is connected to the controller by a ca­ble, thus powered by the controller.
1 3 5
Roll Roll
ENT E R
OUT
PARAM.
SET
642
Operating Keys
8084
syeKfonoitpircseD
yeK noitangiseD noitanalpxE
1puLLOR.noitponarounem-bustxenehtstceleS
2nwodLLOR.noitponarounem-bussuoiverpehtstceleS
3RETNE .noitarugifnocnipehtserotS.unemniamehtsretnE
4*TUO .unemniamehtotnruterpetsybpetS.noitponarounem-busastiuQ
5PUTESMARAP .noitarugifnocstcelesroseulavgnittessesaercnI
6NWODTESMARAP .noitarugifnocstcelesroseulavgnittessesaerceD
,seulavtuptuoehtottesereblliwrellortnocehT.niaganodnaffokcurtehtgnihctiwsybegnahcaodnunacuoY*
.erofebsgnittesehtdefastonevahuoysagnolsa
E05-GB
MS-4.2-3300
M1.0-0000-0007070
WF3000 09/2005 •Printed in Germany
Page 85

Operating SEM0 Controller Menu

General
When the programmer has been connected a self test start routine is performed. The software version of the controller (e.g. V2.02), the rated voltage and the rated current are now displayed.
When it is complete, use the ROLL up/down and ENTER keys to select the required menu.
Menu structure
STARTROUTINE
ELECTRICS
PARAMETER
CHANGE
ACCELER DELAY DECELER DELAY
RELEASE BRAKING
INVERSION BRAKING
AUX TIME DELAY
CUTBACK SPEED
OVERRIDE
MAX SPEED FORW
MAX SPEED BACK
CREEP SPEED
TEST ALARMS PROGRAM V A C C CONFIG
BATTERY VOLTAGE
MOTOR VOLTAGE
MOTOR CURRENT
FIELD CURRENT
VMN TEMPERATURE ACCELERATOR
FORWARD SWITCH
BACKWARD SWITCH
HANDLE/SEAT
SWITCH
QUICK INVERSION
CUTBACK SWITCH
BRS SWITCH
BATTERY CHARGE
SET MODEL SET OPTIONS ADJUSTMENTS
CODE
H, N°, °C
VACC SETTING
WF3000 09/2005 • Printed in Germany
SX 3000-30
ON/OFF
HOURS: RUNNING / KEY ON QUICK INVERSION: BELLY / TIMED BATTERY CHECK: ON/OFF
ADJUST BATTERY
MS-4.2-3300
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ELECTRICS

Menu Functions

PARAMETER CHANGE
In the PARAMETER CHANGE menu the listed truck pa­rameters can be read and set in real time.
TEST
In the TEST menu the listed truck parameters can be activated, checked and set in real time.
ALARMS
In the ALARMS menu error messages generated and stored during operation can be called up and processed.
PROGRAM V A CC
In the PROGRAM VACC menu item the traction potentiometer is calibrated. The traction controller reads and records the potentiometer’s minimum and maxim um output voltage.
CONFIG
The Configuration menu is used to set the operation of the hourmeter and the safety reverse s witch. In addition, the "Adjustments" sub-menu allows for calibration be­tween the battery voltage measured by the controller and the actual battery voltage.
The SX parameter in the SET MODEL submenu is de­signed to select the truck, for the SX3000 it must be set to ON, for the ST3000 it must be set to OFF, for the WP2300 it should always be OFF.
The BATTERY CHECK parameter must be set OFF with these systems, otherwise with the ON setting and incor­rect BATTERY ADJUST setting, it will result in travel f ail­ure.
MS-4.2-3300
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WF3000 09/2005 •Printed in Germany
Page 87

Functions Menu, general

SEM0 CROWN X.XX Power Up Menu
24 V 200A 00000
1
3
ENTER
ROLL ROLL
OUT
2
4 6
MAIN MENU
PARAMETER CHANGE
5
PARAM.
SET
Press “Enter” to go to
first menu.
ELECTRICS
Use “roll up” or “roll
down” key to scroll
through menus.
ROLL ROLL
1
3
ENTER
OUT
2
4 6
5
PARAM.
SET
PARAMETER CHANGE
ALARMS
TESTER
CONFIG MENU Menu Listing
PROGRAM VACC
When desired menu
appears on display,
press “Enter” to go to
ROLL ROLL
1
3
ENTER
OUT
2
4 6
5
PARAM.
SET
that particular menu.
See chapter Parameter Change Menu. See chapter Alarms Menu. See chapter for the Tester Menu. See chapter for the Config Menu. See chapter for the Program VACC Menu.
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Parameter Change Menus

In this menu the parameters can be read and adjusted. Parameters can be monitored during truck operation with the handset. Refer to the tune-up section for a complete listing and description of each parameter.
MAIN MENU
PARAMETER CHANGE
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
ACCELER. DELAY
LEVEL = 0
Press “Enter” key to
display first parameter.
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
LEVEL = 9
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
LEVEL = 8
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
ARE YOU SURE?
YES = ENTER NO = OUT
Use “roll up” or “roll down”
keys to scroll through
controller parameters.
When desired parameter is
displayed, press
“parameter set up” or
"parameter set down” key
to change parameter value.
When desired parameter
value is displayed, press
“out” key.
123
ROLL ROLL
ENTER
OUT
4 6
PARAM.
5
SET
ROLL ROLL
MAIN MENU
PARAMETER CHANGE
MS-4.2-3300
M1.0-0000-0007474
123
ENTER
OUT
4 6
PARA M.
5
SET
Press “Enter" key to
accept the new value
and to exit the menu or
press "Out" to exit the menue without saving
the new parameter.
WF3000 09/2005 •Printed in Germany
Page 89

Settings and Error Messages

ELECTRICS
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.desaelersihctiwslevartehtnehwdetavitcA.gnikarbesaeleR
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E06-01-GB
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ELECTRICS
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llaftonlliwtnerrucdleifeht0ottessieulavehtfI.tnerruc
nehw)lanimontnerrucdleif=NCF(eulavlanimonehtwoleb
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mumixamehtsenimretedeulavsihT:tnerrucesrever.xaM
ehtnehW.levartesrevergnirudtnerrucrotomnoitcart
noitcartehtybdebrosbayllufneebsahegatloverutamra
dleifehtgninekaewybdesaercnisideepseht,rellortnoc
llaftonlliwtnerrucdleifeht0ottessieulavehtfI.tnerruc
nehw)lanimontnerrucdleif=NCF(eulavlanimonehtwoleb
.debrosbayllufsiegatloverutamraeht
ehtotdeilppaegatlovmuminimehtrofgnitteS.deepspeerC noitcnufsihT.desolcsihctiwslevartehtnehwrotomnoitcart
kcurtehthcihwtaeulavehtwoleblevelenoottesebdluohs
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MS-4.2-3300
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Page 91
ELECTRICS
)t0.1FWrofylnodilav(unemEGNAHCretemaraP
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YALEDCCA
YALEDCED0-90
GNIKARBESAELER9-01
NOISREVNI
GNIKARB
YALEDEMITXUA9-03
1DEEPSKCABTUC
gnitteS
egnar
00.3-51.1
ces
9-09
%001-03
CCA
-moceR
dednem
gnittes
0
5
noitpircseD
otrellortnocnoitcartehtrofnekatemitehT:yalednoitareleccA
ot0morfsrotomnoitcartehtotylppustuptuoehtesaercni
.)timilottesylneddushctiwslevartnehW(.%001
noeulavtesehtnehweulavteswenehthcaerotnekatemiT
gnikarbehtotsdnopserroC.degnahcsihctiwslevarteht
.denrutersirettimsnartehtnehwytisnetni
.desaelersihctiwslevartehtnehwdetavitcA.gnikarbesaeleR
.orezotllafottnerrucrotomehtrofnekatemiT
ehtottessihctiwslevartnehwdetavitcA.gnikarbnoisrevnI
.noitceridetisoppo
otgnikarbnoisrevnirofnekatemitehtsecudereulavrewolA
etisoppoehtotnoitceridenomorfgnignahcnehwetavitca
.noitcerid
ybdetcelesegnardeepswolehtrof)deeps=(tnerrucmumixaM
CCAtnerruc.xamfo%ni()SSH(hctiwsdeepswols/tsafeht
lortnoclacinahcemeritneeht,niagA.))lamron=(deepstsafrof
evitisneseromselbanE.elbaliavasirettimsnartehtfoegnar
.deepsdecudertalevart
ehtotegnahcuoynehwelbaliava)deeps=(tnerruclevart.xaM
2DEEPSKCABTUC
%001-03
CCA
3
.deepsdecudertalevartevitisnes
levart.xamfo%ni(SMLhctiwstsamhtiwegnardeepswol
lacinahcemeritneeht,niagA.)lamron=(tsafrofCCAtnerruc
eromselbanE.elbaliavasirettimsnartehtfoegnarlortnoc
E06-03-GB
WF3000 09/2005 • Printed in Germany
MS-4.2-3300
M1.0-0000-0007777
Page 92
ELECTRICS
)t0.1FWrofylnodilav(unemEGNAHCretemaraP
metiuneM
EDIRREVO
WROFDEEPSXAM
KCABDEEPSXAM
DEEPSPEERC
gnitteS
egnar
%05-01
CCA
%07-001
NCF
%07-001
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%11-7,6 .ttaBV
-moceR
dednem
gnittes
6
9
9
2
noitpircseD
ees(enozedirrevoekarbni)deeps=(tnerruclevart.xaM
)2.4Mnoitces
mumixamehtsenimretedeulavsihT:deepsdrawrof.xaM
ehtnehW.levartdrawrofgnirudtnerrucrotomnoitcart
noitcartehtybdebrosbayllufneebsahegatloverutamra
dleifehtgninekaewybdesaercnisideepseht,rellortnoc
llaftonlliwtnerrucdleifeht0ottessieulavehtfI.tnerruc
nehw)lanimontnerrucdleif=NCF(eulavlanimonehtwoleb
.debrosbayllufsiegatloverutamraeht
mumixamehtsenimretedeulavsihT:tnerrucesrever.xaM
ehtnehW.levartesrevergnirudtnerrucrotomnoitcart
noitcartehtybdebrosbayllufneebsahegatloverutamra
dleifehtgninekaewybdesaercnisideepseht,rellortnoc
llaftonlliwtnerrucdleifeht0ottessieulavehtfI.tnerruc
nehw)lanimontnerrucdleif=NCF(eulavlanimonehtwoleb
.debrosbayllufsiegatloverutamraeht
ehtotdeilppaegatlovmuminimehtrofgnitteS.deepspeerC noitcnufsihT.desolcsihctiwslevartehtnehwrotomnoitcart
kcurtehthcihwtaeulavehtwoleblevelenoottesebdluohs
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muminimaottpeksihctiws
E06-03-GB
MS-4.2-3300
M1.0-0000-0007878
WF3000 09/2005 •Printed in Germany
Page 93
Blank page
Printed in Germany
79
Page 94
ELECTRICS

Tester Menu

In this menu the handset acts as a multimeter reading voltages, current, temperature and switch state.
Listed are the output or input signals that can be meas­ured while in the “Tester” mode. These measurements are to be used for reference as each truck, due to the age of components, may vary slightly.
It should be noted that no parameter changes can be
made in “Tester”.
MAIN MENU
TESTER
1
3
5
PARAM.
ENTER
ROLL ROLL
SET
OUT
2
4 6
Press “Enter” key to display
first item to be tested.
BATTERY VOLTAGE
27.8 Volts
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
MOTOR VOLTAGE
0.0 Volts
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
MAIN MENU
TESTER
Use “roll up” or “roll down”
keys to display items
to be tested.
Press “out” key
when finished.
MS-4.2-3300
M1.0-0000-0008080
WF3000 09/2005 •Printed in Germany
Page 95
ELECTRICS
TESTER Menu
The following table describes the v arious truck parameters which can be selected and check ed in the TESTER menu.
unemRETSET
metiuneM noitpircseD
EGATLOVYRETTAB .tupnihctiwsyektaderusaemegatlovyrettaB
EGATLOVrotoM .NMVdnaTTAB+neewtebderusaem,erutamraotdeilppatnerruC
TNERRUCROTOM.erutamrarotomybdeviecertnerruC
TNERRUCDLEIF
ERUTAREPMET
ROTARELECCA
HCTIWSDRAWROF
HCTIWSDRAWKCAB
HCTIWSTAES/ELDNAH
NOISREVNIKCIUQ
1HCTIWSKCABTUC
.sTEFSOM
hctiws)SF("drawroF"ehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
.hctiws)SR("esreveR"ehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
hctiws)SRO("edirrevO"ehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
.noitcennocseires)SML(
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
.hctiws)SHS("wolS/tsaF"ehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
.traprewoprellortnocehtrevoecnereffidlaitnetopehtsetacidni
ehtottxenetalpesabmuinimulaehttaderusaem,erutarepmetrellortnoC
CCAVMMARGORPaivdetarbilaclangisgnitarepomumixam
gnidaerehT.TTAB-dna)vitageNrotoMtloV(NMVneewtebtnerrucehtserusaeM
edisdnahtfelehT.retemoitnetopnoitcartehtfolangislanimonehtsyalpsiD
ehtotgnitaleregatnecrepehtedisdnah-thgireht,gnidaeregatlovehtsyalpsid
hctiwstsamehtdnahctiws)SF("esreveRytefaS"ehtfonoitarepoehtstseT
2HCTIWSKCABTUC
HCTIWSSRB
EGRAHCYRETTAB .egatnecrepasasutatsegrahcyrettabehtsyalpsiD
WF3000 09/2005 • Printed in Germany
.)SML(hctiwstsamehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
.)SRB(hctiwsekarbehtfonoitarepoehtstseT
.sutats)NO(desolcdna)FFO(nepoehtsyalpsiD
E07-GB
MS-4.2-3300
M1.0-0000-0008181
Page 96
ELECTRICS

Alarms Menu

In this menu the traction controller microprocessor re­members the last 5 alarms that have occurred. Items re­membered that are associated with each alarm are; the event code , the hour meter reading, the number of times that particular alarm occurred, and the controller tem­perature.
MAIN MENU
ALARMS
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
CODE
00005h #02 20St
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
CODE
00007h #03 18St
1
3
5
PARAM.
ENTER
ROLL ROLL
2
OUT
4 6
SET
CLEAR LOGBOOK?
YES = ENTER NO = OUT
123
ROLL ROLL
ENTER
OUT
4 6
PARAM.
5
SET
123
ROLL ROLL
ENTER
OUT
4 6
PARA M.
5
SET
Press “Enter” key to
display the most recent
event code.
Use “roll up” to display
previous event codes.
NOTE: Traction controller
will store up to 5 event
codes. Use “roll down” to
return to most recent event
code.
When desired parameter
value is displayed, press
“out” key.
ARE YOU SURE?
YES = ENTER NO = OUT
ROLL ROLL
1
2
3
ENTER
OUT
4 6
5
PARAM.
SET
LOGBOOK CLEARED
(PRESS OUT)
MAIN MENU
ALARM
MS-4.2-3300
M1.0-0000-0008282
Using the Alarms (event
codes) found here, refer to
the tables "ALARMS
Menue" for troubleshooting
guidelines.
WF3000 09/2005 •Printed in Germany
Page 97

ALARMS Menu

The traction controller can collect and store operational faults during operation. The last 5 error messages are stored together with the following information:
● Type of error
● Error frequency
● Hourmeter status
● Power part temperature
The ALARMS menu can be used to call up and read the respective fault codes.
uneMSMRALA
ELECTRICS
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.levartgniruddnadekrapnehw,pu-rewopkcurt
erehwaerayromemelitalov-nonnirorrE
retemarapkcurtdnaegassemrorre,retemruoh
gnivomyb(hctiwsedirrevO:deniatniamebtsum
,)noitisoplevartoteldimorfeldnahksatitlumeht
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gniruddemrofrepnoitcnufcitsongaid-otuanirorrE
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ecneuqesgniwollofehT.tcerrocniecneuqestratS
.rorregniriW-
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ecalpeR.ytluaf)erawtfos(margorp
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deretneecneuqestratstcerrocnI-
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EGRAHCROTICAPAC
WF3000 09/2005 • Printed in Germany
.pu-rewopnonoitcnufcitsongaid-otuagnirudtseT sm005egrahcotdetratstonevahsroticapacehtfI
egassemrorrena,hctiwsyekehtgninrutretfa
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MS-4.2-3300
M1.0-0000-0008383
rorregniriwelbacrewoperutamrA-
E08-GB
Page 98
ELECTRICS
egasseMrorrE noitpircseD esuaCelbissoP
KOTONNMV
).dtnoC(uneMSMRALA
niamehthtiwedomeldinidemrofreptseT
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eldisikcurtnehwegatlovyrettabehtwolebsi-
sikcurtnehwrewophtiwylpmoctonseod-
gnillevart
.rorretraprewoP-
.rorregniriwelbacrotoM-
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niamdnaeldisikcurtnehwdemrofreptseT
KOTONDLEIFV
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KOTONCCAV
.eulavmuminim
OKERIWLADEP
.seriwnekorbrofsraeppaegassem
HGIHIYBTS
REVE0=I
.eulavmuminimnevigadeecxeton
fisraeppaegassemrorreehT.neporotcatnoc
tonsiegatlovyrettabehtfo%05.xorppa
.egnar
noitcnufcitsongaid-otuagniruddemrofreptseT
rorreehT.eldisikcurtnehwdnapu-rewopno langisretemoitnetopehtfisraeppaegassem derotsehtmorfstlov2nahteromybsetaived
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rorrE.gniriwstidnaretemoitnetopnoitcart
noitcnufcitsongaid-otuagniruddemrofreptseT
rorreehT.eldisikcurtnehwdnapu-rewopno
.detcetedsiwolftnerrucafisraeppaegassem
rorreehT.gnillevartgniruddemrofreptseT
seodtnerrucnoitcartehtfisraeppaegassem
.rorregniriW-
.detpurretni
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.htraeotssolrotoM-
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.rellortnocotdetcennocyltcerrocniro
rellortnocdleiftraprewopnirorrE-
.elbacretemoitnetopnekorB-
.ytluafretemoitnetoP-
.ytluafdraobniamrelliT-
rodemrofreptonCCAVMARGORP-
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roderiwtonsnoitcennocretemoitnetoP-
.ytluafdraobniamrelliT-
rosnestnerrucytluaF-
.)rellortnocecalper(
rewoprometsyscigol,gnilpuockcaB­eritnerotnenopmocecalper(rorretrap
kcehc(tcatnocrotomtneiciffusnI-
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MS-4.2-3300
M1.0-0000-0008484
E09-GB
WF3000 09/2005 •Printed in Germany
Page 99
).dtnoc(uneMSMRALA
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ELECTRICS
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DESOLCROTCATNOC
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E10-GB
WF3000 09/2005 • Printed in Germany
MS-4.2-3300
M1.0-0000-0008585
Page 100
ELECTRICS
Calibrating the Traction Pod Potentiometer, PROGRAM VACC menu
It is always necessary to calibrate the traction pod potentiometer when:
● the traction pod potentiometer has been replaced or,
● the traction controller has been replaced.
There is no need to physically adjust the potentiometer and the travel switch.
Preparatory Measures
● Power down the truck and jack it up so that the drive wheel is free (see Chapter 1).
● Connect the programmer to the traction control­ler.
● Power up the truck.
● The display shows the new minimum and maxi-
mum value and an arrow for the selected travel direction.
● Press OUT when you are ready.
● The display asks “Are you sure?”. If you wish to
save the new levels, press ENTER. If not, press OUT.
● Press OUT to quit the VACC menu.
Calibration
● Press ENTER on the programmer.
● Using the ROLL UP and ROLL DOWN keys scroll
through to the PROGRAM VACC menu.
● Press ENTER. This enables you to select the calibration routine.
● The display shows the stored minimum and maximum voltage of the potentiometer. An arrow in the display indicates the travel direction to which the values are assigned. Arrow up = Forward. Arrow down = Reverse. If you move the travel switch in the corresponding direction you can change the display accordingly.
● Press ENTER to delete the stored values. The display now shows 0.00 for the minimum and maximum values.
● Pull the tiller to the travel range (brake released) and press the travel switch slowly in the forward direction until it reaches the stop.
● The display shows the new minimum and maxi­mum value and an arrow for the selected travel direction.
● Pull the tiller to the travel range (brake released) and press the travel switch slowly in the reverse direction until it reaches the stop.
MS-4.2-3300
M1.0-0000-0008686
M1610
WF3000 09/2005 •Printed in Germany
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