Wp2300 Series

Maintenance Manual
WP2300 Series
MS-WP2300 04/03 • Printed in Germany
Order Number: 812528-006
This master maintenance manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2002
CROWN Equipment Corporation
REVISION
Overview of Revisions:
Page 3 Rev.1 04/00 General corrections and additions to the text.
Reference to authorised service personnel added.
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TABLE OF CONTENT
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TABLE OF CONTENT
Table of Content
ITD – INTRODUCTION PAGE SER-NR. CUT REV.

Safety Symbols used in the Manual .................................. 3 ............................................................... Rev.1 04/00
General Maintenance and Repair Safety Notes ................ 3
Maintenance and Repair .................................................. 3 ............................................................... Rev.1 04/00
Before Leaving the Truck .................................................. 4
Before Carrying out Work on the Truck ............................ 4
Before Operating the Truck ............................................... 4
Warnings and Labels on the Truck ..................................... 4
General ................................................................................. 7
Operating Instructions ...................................................... 7
Service Training ................................................................ 7
Ordering Spare Parts ....................................................... 7
Using the Manual ............................................................. 7
Model-Number ..................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV.

Component Access ............................................................. 11
Jacking up the Truck ........................................................... 11
Lifting by Crane ................................................................... 11
Lifting by Truck ................................................................. 12
Components ........................................................................ 13
Maintenance ........................................................................ 16
Recommended Lubricants and Oils ................................. 16
Lubricants ................................................................... 16
Cold Store Trucks ........................................................ 16
Truck Decommissioning ..................................................... 16
Restoring the Truck to Service ........................................... 16
Check and Maintenance Schedule ..................................... 18
Safety Reverse Switch – Functional Test .......................... 20
Grease items and grease intervals .................................... 28
Castors ................................................................................. 30
Torques ................................................................................ 31
M2 – HYDRAULICS PAGE SER-NR. CUT REV.

Hydraulic Symbols .............................................................. 35
Hydraulic System ................................................................ 39
Operation ......................................................................... 39
Removing the Hydraulic Unit ............................................ 40
Replacing the Hydraulic Pump ......................................... 41
Removal ...................................................................... 41
Installation ................................................................... 41
Commissioning and Bleeding the System ........................ 41
Filters ............................................................................... 43
Replacing the Pressure Filter ...................................... 43
Replacing the Suction and Return Filters .................... 43
Oil Change ....................................................................... 43
Replacing the Safety Valve ............................................... 44
Safety Valve Setting ......................................................... 44
Safety Valve Test and Setting ...................................... 44
M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

Gear Unit .............................................................................. 47
Drive Unit, General .............................................................. 48
Removing the Drive Unit ..................................................... 48
MS-WP2300-GB 04/03 • Printed in Germany
III
TABLE OF CONTENT
M3 – DRIVE UNIT PAGE SER-NR. CUT REV.
Traction Motor Removal ................................................... 48
Dismantling the Motor ...................................................... 49
Assembling the Motor ...................................................... 49
Traction Motor Assembly .................................................. 51
Gear Unit Disassembly .................................................... 52
General ....................................................................... 52
Preparation ................................................................. 52
Draining the oil ............................................................ 52
Removing the drive unit .............................................. 52
Dismantling the gear unit lid ........................................ 52
Dismantling the gear unit ............................................ 53
Gear Unit Assembly .................................................... 53
Installing the gear unit lid ............................................ 55
Adding Oil ................................................................... 55
Installing the drive unit ..................................................... 55
M4 – ELECTRICS PAGE SER-NR. CUT REV.

Electrics - General ............................................................... 59
Wire Colour Codes ........................................................... 59
Abbreviations ................................................................... 60
Electrical Symbols ............................................................ 62
Electrical Components ....................................................... 63
Transmitter (POT, FS, RS) ................................................ 63
Fast / Slow Travel Switch (HSS) ....................................... 63
Reverse Safety Switch (SAS) ........................................... 63
Brake Switch (BRS).......................................................... 63
Override Switch (ORS) ..................................................... 63
Raise / Lower Switch (RAS, LOS) .................................... 64
Limit Switch (LMS) ........................................................... 64
Horn Switch (HNS) ........................................................... 64
Key Switch (KYS) ............................................................. 64
Emergency Disconnect .................................................... 64
Fuses (FU) ....................................................................... 64
OPTION
Thermal Switch (THS) ........................................... 65
Battery .................................................................................. 67
General ............................................................................ 67
Replacing the battery ....................................................... 67
Battery Discharge Indicator (BDI) ...................................... 67
General ............................................................................ 67
Battery Discharge Indicator Setting (BDI) ........................ 68
Calibration ........................................................................ 68
SEM0 Traction Controller .................................................... 67
General ............................................................................ 67
Precautionary Measures ............................................. 67
Operational Features ....................................................... 67
Speed Control ............................................................. 67
Reduced Speed Ranges ............................................. 67
Downhill Speed Control ............................................... 67
Regenerative Braking .................................................. 67
Anti - Roll Down Function ............................................ 67
Hourmeter ................................................................... 68
Self Test ...................................................................... 68
Monitored Circuits ....................................................... 68
Protective Devices ............................................................ 68
Polarity Protection ....................................................... 68
Wiring Errors ............................................................... 68
Temperature ................................................................ 68
Start Sequence ........................................................... 68
IV
TABLE OF CONTENT
M4 – ELECTRICS PAGE SER-NR. CUT REV.
Safety Class ................................................................ 68
Maintenance .................................................................... 69
Replacing the SEM0 Traction Controller........................... 70
Parameter Setting
after Replacing the Traction Controller ............................. 70
Preparatory Measures ................................................ 70
Setting ......................................................................... 70
Status LED .................................................................. 72
Programmer ......................................................................... 73
General ............................................................................ 73
Operating SEM0 Controller Menu .................................... 74
General ....................................................................... 74
Operating Menu - Overview ........................................ 75
Menu Functions .......................................................... 75
PARAMETER CHANGE .............................................. 75
Settings and Alarms............................................................ 76
TESTER Menu ................................................................. 77
ALARMS Menu ................................................................ 78
PROGRAM VACC Menu .................................................. 79
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu .................................................. 81
Preparatory Measures ................................................ 81
Calibration ................................................................... 81
CONFIG Menu ...................................................................... 82
SET MODEL .................................................................... 82
SET OPTIONS ................................................................. 82
Adjustments ..................................................................... 82
Traction Controller Safety Test ........................................... 83
Battery .................................................................................. 85
General ............................................................................ 85
Replacing the battery ....................................................... 85
Battery Discharge Indicator (BDI) ...................................... 85
General ............................................................................ 85
Battery Discharge Indicator Setting (BDI) ........................ 86
Calibration ........................................................................ 86
On Board Charger ............................................................... 87
General ............................................................................ 87
Battery Charging Phases ............................................ 87
Special Charging Phases ............................................ 87
Charging Errors ................................................................ 88
Green LED is not lit ..................................................... 88
Green LED flashing ..................................................... 88
Important Technical Data ................................................. 89
Replacing the Charger ..................................................... 89
Removal / Installation .................................................. 89
Electric Motors .................................................................... 91
General Maintenance Instructions ................................... 91
Preparation ................................................................. 91
Important Maintenance Instructions ............................ 91
Traction Motor Maintenance ............................................... 92
Access to Brushes ........................................................... 92
Maintenance .................................................................... 92
Armature ..................................................................... 92
Bearings ...................................................................... 92
Pump Motor Maintenance ................................................... 93
Access to brushes ............................................................ 93
Maintenance .................................................................... 93
Armature ..................................................................... 93
V
TABLE OF CONTENT
M5 – BRAKE PAGE SER-NR. CUT REV.
Brake .................................................................................... 97
Operation ......................................................................... 97
Removal ........................................................................... 97
Assembly .......................................................................... 99
Air Gap Setting ................................................................. 99
Brake Moment Setting ...................................................... 99
Testing the Brakes ............................................................ 99
M6 – STEERING PAGE SER-NR. CUT REV.

Live Ring Bearing ................................................................ 103
Disassembly ..................................................................... 103
Installation ........................................................................ 103
Multitask Handle - Springs for Return Function ............... 104
Adjustment ....................................................................... 104
Removal ........................................................................... 104
Assembly .......................................................................... 104
Tiller Handle ......................................................................... 105
Main Components ............................................................ 105
Tiller Handle Component Removal / Installation .............. 106
Tiller Handle Shells .......................................................... 106
Removing the Upper and Lower Shells ....................... 106
Fitting the Upper and Lower Shells ............................. 107
Switch Unit ....................................................................... 108
Removal ...................................................................... 108
Switch Unit Installation ................................................ 108
"Fast/Slow" Toggle Switch ................................................ 109
Removal ...................................................................... 109
Installation ................................................................... 109
Hydraulic Board ................................................................ 109
Removal ...................................................................... 109
Installation ................................................................... 109
Potentiometer ................................................................... 110
Removal ...................................................................... 110
Installation ................................................................... 110
Safety Reverse Switch ..................................................... 111
Removal ...................................................................... 111
Installation ................................................................... 111
Horn Switch ...................................................................... 112
Removal ...................................................................... 112
Installation ................................................................... 112
Handle .............................................................................. 113
Removal ...................................................................... 113
Installation ................................................................... 113
M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

Lift Linkage .......................................................................... 117
Fork Height Setting .......................................................... 117
M8 – CYLINDERS PAGE SER-NR. CUT REV.

Lift Cylinders ....................................................................... 121
Operation ......................................................................... 121
Removal ........................................................................... 121
Inspection ......................................................................... 123
Replacing the Piston Seal ................................................ 123
VI
TABLE OF CONTENT
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.
Overall Wiring Diagram, Standard Version ........................ 127
Overall Wiring Diagram with Options ................................ 128
Wire harness overview, all versions .................................. 129
HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

Hydraulic Schematic ........................................................... 133
VII
Printed in Germany
VIII
SAFETY
Printed in Germany
1
Printed in Germany
2 M1.0-0000-0002
SAFETY
Safety Symbols used in the General Maintenance and Repair

Manual Safety Notes
To help guide you through the manual and to highlight DANGER
particular danger areas, we have used graphic illustra-
tions: Read the safety notices in the truck Mainte-
nance and Operator's Manuals.
DANGER
● Failure to do so could result in severe or
This symbol indicates life-threatening risks fatal injuries to maintenance personnel
and/or other persons.
● Failure to comply with this notice may
result in severe or fatal injuries to yourself
or other people. Motorised vehicles can be dangerous if maintenance
and service are neglected. For this reason maintenance
and inspections must be carried out at regular short
intervals by trained personnel working to approved
WARNING
company guidelines.
This symbol indicates the risk of serious DANGER
injury and/or serious material damage.
Follow all national/local safety regulations
● Failure to comply with this notice may applicable for maintenance work, e.g. for
result in severe injuries to yourself or other work on higher levels.
people and/or serious material damage.
● Failure to do so could result in severe or
fatal injuries to maintenance personnel
and/or other persons.
CAUTION
Maintenance and Repair
This symbol indicates the risk of minor
injury and/or minor material damage. 1. Maintenance work must only be carried out in
accordance with the test and maintenance pro-
● Failure to comply with this notice may
gram contained in the present Maintenance
result in minor injuries to yourself or other
Manual and any applicable service notices.
people and/or minor material damage.
2. Only qualified and authorised personnel may
carry out work on the truck.
INFORMATION
3. Always keep fire extinguishers in good working
Contains additional information with condition. Do not approach fluid levels or leaks
supplementary notes and hints. with a naked flame.
4. To clean, use a non flammable, non combustible

OPTION cleaning solution which is groundwater-neutral.
Only carry out cleaning with an oil separator.
OPTION
These items relate to optional features not Protect the electrical system from dampness.
supplied with the standard version.
5. Keep the service area clean, dry and well-venti-
lated.
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.
MS-WP2000-GB 04/03 • Printed in Germany MP/MS-0000-MA

REV. 1 4/00
3
SAFETY
8. Keep the truck clean. This will facilitate the loca- Warnings and Labels on the Truck
tion of loose or faulty components.
During regular maintenance check that the warnings
9. Make sure that capacity and data plates, warn- and labels on the truck are complete and legible.
ings and labels are legible at all times.
● Clean any illegible labels.
10. Alterations or modifications by the owner or
operator are not permitted without the express ● Replace any faulty or missing labels.
written authorisation from Crown.
The order and meaning of the warnings and labels on
11. Only use original Crown spare parts to ensure the the truck are described in section 10.9 of the parts
reliability, safety and suitability of the Crown truck. manual.
Before Leaving the Truck

● Stop the truck.
● Lower the fork carriage fully.
● Apply the parking brake.
● Turn off the truck and remove the key.
● Block all wheels when parking on an uneven

surface.
Before Carrying out Work on the Truck

● Raise the truck to free the drive wheel. Press the
emergency Stop button and disconnect the
battery.
● Prevent the truck from rolling away.
● Before carrying out work on the hoist frame, the

lift mast or on the fork carriage: Block these parts
according to maintenance instructions in order to
prevent them from dropping.
● Only carry out operational testing when there is

sufficient room to manoeuvre, to avoid the risk of
injury to yourself and others.
Before Operating the Truck

● Check the safety devices.
● Get into the driver's seat.
● Check the operation of the lifting device, travel

direction switch, speed control, steering, warning
devices and brakes.
MP/MS-0000-MA MS-WP2000-GB 04/03 • Printed in Germany

REV. 1 4/00
44
INTRODUCTION
Printed in Germany
5
Printed in Germany
M1.0-0000-0006
6 M1.0-0000-0006
INTRODUCTION
General This information can be found on the truck's data plate.

Only if this information is provided can the order be
The present manual is designed for Customer Service processed quickly, correctly and reliably.
engineers who wish to familiarise themselves with the
maintenance work required for the various truck com- Please refer to the Technical Specifications Sheet for the
ponents. utilisable loads, technical data and dimensions for
thisseries. Brochures can be obtained from your CROWN
It also contains troubleshooting sections which can be dealer or from the following address:
used to identify and remedy truck faults.
INFORMATION CROWN Gabelstapler GmbH & Co.KG

Moosacher Str. 52
This book is not an operating manual. It is 80809 Munich
designed solely for specialist personnel GERMANY
who have been trained and authorised to Tel.: +49 (0)89 / 93 002 -0
carry out the work described in the Fax: +49 (0)89 / 93 002 -175 oder 133
manual.
Using the Manual
This manual therefore contains fewer and less detailed The manual is divided into sections. The following table
warnings than the Operator's Manual, as the latter is shows how the manual is structured.
aimed at persons who have very little or no prior
experience at all.
Sections Maintenance
Operating Instructions
Section Description
This manual contains no operating instructions. An
operating instructions manual is supplied with the vehicle. IDX Table of Content
Additional copies can be ordered as required.
With the help of this manual you and your personnel will MA Safety
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle. ITD Introduction
Service Training M1 Lubrication and Adjustment
CROWN offers the appropriate vehicle related training

for service personnel. Details on this training can be M2 Hydraulics
obtained from CROWN on request.
M3 Drive Unit
Ordering Spare Parts
The maintenance manual does not cover spare parts. M4 Electrical
These are listed in a separate manual.
M5 Brake
Spare parts can be ordered by quoting:
M6 Steering
● The truck specification number
● The truck model number M7 Mast / Lifting Mechanism
● The truck serial number

M8 Cylinder
DIA Electrical Diagrams
HYD Hydraulic Schematic
A01M-gb
MS-WP2300-GB 04/03 • Printed in Germany MS-ITD-1723
M1.0-0000-0007
7
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
1.6 WP 2015 – 3 – 2 – S
Capacity Load Wheels
1.6 = 1600 kg S = Single

2.0 = 2000 kg T = Tandem
Model Description
Fork Length
WP = Electric Pedestrian Pallet Truck
Dash mm inch
1 36
2 995
Battery Box Size (l x w x h)
3 42
2315 = 150 Ah (146 x 660 x 604)
2320 = 240 Ah (212 x 624 x 627) 4 1125
5 46
6 1210 48
7 54
8 60
I02a-gb
Fork Spread
Dash mm inch
1 18
2 520 20
3 540 22
4 670 27
I03a-gb
MS-ITD-1723 MS-WP2300-GB 04/03 • Printed in Germany
88
M1.0-0000-0008
LUBRICATION AND ADJUSTMENT
Printed in Germany
9
Printed in Germany
10M1.0-0000-00010
Component Access Lifting by Crane

Lifting off the panel will provide access to the drive unit, Attach the straps to the hitch points as shown and
hydraulic system, contactors, traction controller etc. prevent them from sliding off.
The panel is fixed to the chassis via two screws.
By removing the screws you can lift up the panel from
the lower lugs, tilt and lift it out over the tiller.
Jacking up the Truck

CAUTION
Always support a raised truck with wooden
blocks or other suitable equipment,
thereby relieving the jack.
Please follow the instruction "Jack up the truck" in this

manual by jacking up the truck and supporting it with
wooden blocks.
MS1723-005
Jacking Points
M1458-a
MS-WP2300-GB 04/03 • Printed in Germany MS-1.0-1723
M-1.0-0000-00011
11
Lifting by Truck
DANGER
Use a forklift with sufficient capacity and
prevent the truck from sliding off the forks.
● Raise the forks to their maximum height.
● Drive the forklift sideways underneath the truck

(see diagram).
● Place hard wooden blocks under the truck.
● Secure the truck to prevent it from sliding off the

forks.
● Raise the truck.
90
600
> 800
WP
2000
MS-1723-002
MS-1.0-1723 MS-WP2300-GB 04/03 • Printed in Germany
12M-1.0-0000-00012
Components
Battery Connector Control fuse

(Emergency Disconnect)
FU3 F/C (Power) Fuse
Traction Controller
Lift Cylinder Main Contactor

RH
Pump Contactor
Lift Cylinder LH
Pump Motor
Lowering Valve
Hydraulic Reservoir
with Integrated Pump
Horn
Magnetic Brake
Drive Motor Drive Wheel
M1454-new
M-1.0-0000-00013
13
Fast / Slow Travel Switch
Button, Horn
Travel Switch
Reverse Safety Switch MS1723-004

Lift / Lower Switch
Socket for storing Charger Plug Battery Monitor Displays
Key Switch
Hourmeter and Battery Discharge Display
MS1723-009
14M-1.0-0000-00014
Seite absichtlich freigelassen
M-1.0-0000-00015
15
Maintenance ● Every 3 months connect the battery, carry out a

daily check and test the truck functions. Then
disconnect the battery again.
Recommended Lubricants and Oils
Restoring the Truck to Service
Lubricants
When restoring the truck to service, proceed as
The following page lists typical lubricants which are follows:
also used by Crown in the factory. However, any
lubricants with the same technical specifications can ● Remove any addition corrosion protection applied
be used. (except for cold store protection)*.
Cold Store Trucks ● Jack up the truck, remove the wooden blocks and
lower the truck.
Special hydraulic oil, lubricant oils and grease for low
temperature applications must be used for cold store ● Charge the battery or install a charged battery.
trucks (see table on following page). All screws, wash-
ers, nuts, pins, retaining rings etc. must be treated ● Connect the battery.
regularly with an anti-corrosion solution CROWN no.
805236-004. Electrical connections and components ● Carry out the daily check.
must be carefully protected against corrosion. For more
details refer to chapter 4. * Do not use high pressure cleaners and/or
solvents on the truck. Do not use metal brushes.
Maintenance intervals must be adapted to the condi- Do not wet-clean the electrical system and do not
tions of use. They should be as frequent as possible to use flammable cleaning solutions.
prevent excess wear.
Truck Decommissioning
When taking the truck out of service for more than 3
months, proceed as follows:
● Disconnect the battery.
● Decommission the battery in accordance with the

manufacturer's instructions.
● Clean the truck*). Wipe off any grease in

accordance with the maintenance manual.
● If the truck is to be stored in hostile ambient

conditions (e.g. saline atmosphere) treat the
surfaces of the truck with a suitable solution to
prevent corrosion.
● Do not park the truck in the open air or in a

humid environment. The ideal location is a dry
room with as constant a temperature and air
humidity as possible. If the truck has to be
covered, use material through which air can
permeate rather than plastic sheets. Otherwise
condensation water may form.
● Jack up the truck. Lower the chassis onto suitable

wooden blocks in order to clear the wheels from
the ground (this prevents the wheels from
flattening under constant pressure).
16M-1.0-0000-00016
Lubricant Type Product Description Manufacturer CROWN-Part-No. Type
Aralube HLP2 Aral

LM-Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
Grease (multi purpose) 053002-001 B
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
LGWMI SKF
Aralube SKL2 Aral

Low temperature grease 053002-005 BB
Unirex Lotemp EP Mobil
Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
Hydraulic oil Tellus 32 Shell 053001-003 D
Hydran LZ 32 Finol
B110 Fuchs
Minralölwerke
GmbH
Low temperature
Deutz Oel HVI 32 Klockner 053001-009 DD
hydraulic oil
Hyp 85W90 Aral

GX - D 85W90 Esso
Transmission oil 053002-004 A
Mobilube HD85/90 Mobil
Spirax MB90 Shell
Low temperature
Mobil SHC 624 Mobil 053002-009 AA
transmission oil
L01_lubricants_wp-GB
Product Product Name Application Crown Part No.
Anti-corrosive agent for

Anti-corrosive agent Tectyl 805236-004
cold store trucks
Acid resistant transparent
coating for traction
Transparent coating 2K transparent coating 805236-003
controllers for cold store
applications.
310 ml cartridge:
Jointing compound for 805236-002
Jointing compound Elring Dirko
gear unit lid (liquid seal). 100 g Tube:
805236-001
L01_adjuvants_WP-GB
M-1.0-0000-00017
17
Check and Maintenance Schedule
The following check and maintenance schedule as- When performing maintenance work always check for
sumes single-shift operation under normal operating wear, corrosion and damage and ensure that the parts
conditions. The length of maintenance intervals will are operating correctly and are secure. If in doubt,
however depend on the particular operating conditions. replace them.
In dusty or otherwise extreme environments, including

cold stores, the specified maintenance intervals should
be reduced. The exact periods should be established
after consultation with Crown service personnel.
Daily or every 8 service hours
No. Item Action
Re-charge a discharged battery. Check electrolyte level and

1 Battery
replenish if necessary.
Battery Connector
2 Check operation
( = Emergency Stop )
3 Horn Check operation
4 Lift / Lower rocker switch Check operation
5 Travel switch Check operation (both directions)
6 Fast / Slow travel switch Check operation
7 Reverse safety switch Check operation
Check operation (both directions, both normal braking with the

8 Brake
multi-task handle and inverse braking)
9 Steering Check play
10 Fork Check for visible signs of cracks and deformation
11 Wheels / Load wheels Check tyres for wear, nails, metal splints etc.
12 Hydraulic lines and connections Check for leaks, tighten connections if necessary
L02-gb
18M-1.0-0000-00018
8
2 1
MS1723-011
9
10
11
12
MS1723-012
MS1723-014
5, 8
7
MS1723-004
M-1.0-0000-00019
19
Safety Reverse Switch –

Functional Test
DANGER
The safety reversing switch must only be

tested in a safe environment, without
bystanders and sufficiently far from
obstacles.
● Set the tiller straight (for straight-ahead travel).
● The truck must be ready for operation, i.e.

switched on.
● Position yourself at a sufficient distance to the

side of the tiller.
● Using the tiller, slowly move the truck forward

(you walk ahead of the truck).
● Check again for any obstacles and press the

safety reversing switch.
● The truck should stop immediately and then move

back a few feet in the opposite direction.
● If the test is not successful, the fault must be

rectified before the truck can be operated again.
WP
2000
20M-1.0-0000-00020
M-1.0-0000-00021
21
Monthly or every 100 service hours
No. Item Action
1 Battery According to instructions of battery fabricant
2 Contactors Clean; check, replace if necessary
3 Lift limit switch Check operation
Check wires, switches and connections are secure, check

4 Electrical system
insulation for damage
5 Controller Check operation
6 Brake Blast off corrosion; check seal for damage; check air gap
7 Lift cylinder Ensure seal is tight
8 Hydraulic oil tank Check oil level, replenish if necessary
9 Load wheels and castor bearings Check for play, replace bearings if necessary
10 Drive wheel Ensure wheel nuts are correctly torqued.
L03-gb
22M-1.0-0000-00022
4
3 2
8
6
MS1723-016
10
MS1723-015
MS1723-013
9
9
MS1723-011
M-1.0-0000-00023
23
Every 3 months or 250 service hours
No. Item Action
Truck, battery and charger

1 Clean contacts and check contact springs
connectors/plugs
Carbon brushes
2 Check for wear, ease of motion and contamination
Pump and drive motor
Check for wear, ensure attachment is secure, tighten if

3 Connecting rods
necessary or replace connecting rods.
4 Forks Check height setting, adjust if necessary
Initial change of gear oil after 250 hours of operation,

5 Gear unit
thereafter every 2000 hours.
L04-gb
Every six months or 500 service hours
No. Item Action
Check operation and grease flat coil springs for return

6 Tiller
function
Check brake lining and contact surfaces for wear,

7 Brake
replace par ts if necessary.
Clean attachments of cylinder (bottom) and piston rods (top),

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

9 Lift mechanism
check for wear, replace if necessary, grease
10 Load wheel and castor axles Clean, check for wear, replace if necessary, grease
Change suction and return filters initially after 500 service

11 Hydraulic system
hours, thereafter every 2000 service hours.
L05-gb
24M-1.0-0000-00024
11
7
MS1723-016 2
9
10 9 3
4
MS1723-011
MS1723-011
M-1.0-0000-00025
25
Annually or every 1000 service hours
No Item Action
1 Pump and drive motor Check commutator for damage and wear; blast dust with air
2 Gear unit Check gear oil level, replenish if necessary
Check brake lining and contact surfaces for wear, replace

3 Brake
par ts if necessary
4 Carry out UVV test
L06-gb
Every 2 years or 2000 service hours
No. Item Action
Change hydraulic oil; replace filter

(initial replacement after 500 hours);
5 Hydraulic system
Clean lines and connections,
check tightness and sealing, tighten if necessary
6 Gear unit Change gear oil
L07-gb
26M-1.0-0000-00026
MS1723-016
2, 6
1
M-1.0-0000-00027
27
Grease items and grease intervals
Grease Items / Grease Intervals
100 250 500 1000 2000

Item Component Type Total
hours hours hours hours hours
Check hydraulic reservoir,

1 D A/R X
replenish if necessary
2 Change hydraulic oil D A/R X
3 Battery comp. lid hinges B A/R X
4 Battery comp. lid latch B A/R X
Tiller: flat coil springs

5 B A/R X
for return function
Connecting rod pins and

6 B A/R X
all lifting mechanism joints
7 Lift cylinder attachment B A/R X
8 Piston rod attachment B A/R X
9 Change gearbox oil A A/R Initial change after 250 hoursof operation X
L08-gb
28M-1.0-0000-00028
3
3
7 8
1, 2
MS1723-016
MS1723-011
M-1.0-0000-00029
29
Castors
The castors are on the left and right-hand sides under ● Manually screw in the adjusting screw on both
the truck. They prevent the truck from tilting when castors as far as possible. Now continue to screw
travelling around bends. The supporting force can be half a turn using a wrench.
adjusted with a adjusting screw. This screw pushes the
wheel bracket down around the bracket rotary axle via ● Completely unscrew the adjusting screw on both
a plate and two spring units. castors again.
If the truck wheels are heavily worn or if they have ● Again, manually screw in the adjusting screw on
been replaced, both castors must be adjusted. both castors as far as possible. Now continue to
screw three quarters of a turn using a wrench.
● Park truck (unladen) on an even surface.
● Set the adjustment with a jam nut.
● Remove battery connection (=Emergency Stop).
The supporting force of each castor should now be
● Remove the jam nut on both castors. 500 N, the equivalent of a 50 kg load.
● Completely unscrew the adjusting screw on both

castors.
Jam nut
Adjusting screw
Rotary axle bracket
M1470
Plate Wheel Wheel bracket
30M-1.0-0000-00030
Torques
The screw and nut strengths shown below are used in
the manufacture of Crown trucks. The information on
the page is designed to help determine the correct
torque for maintenance work.
NOTE
The torques listed in the maintenance

section always supersede those shown
on next page.
Screw grade marking Nut grade marking
8 .8
8 .8 8
1 2 .9
1 2 .9
graphics: m0340_1...5 T01-gb
M-1.0-0000-00031
31
Standard Screws and Nuts
Grade 8 and 8.8 10 and 10.9 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100
T02-gb
Umbrako Screws and Nuts
Grade 10 and 10.8 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717
T03-gb
32M-1.0-0000-00032
HYDRAULICS
Printed in Germany
33
Printed in Germany
34M1.0-0000-00034
HYDRAULICS
Hydraulic Symbols
Vented reservoir
with lines above the fluid level Electric motor
M
with unidirectional turn and speed
Vented reservoir
with lines below the fluid level
Electric motor
M with unidirectional turn
and variable speed
Filter or strainer
Hydraulic pump
with fixed displacement
Hydraulic line with full flow
and single direction of turn
(tubing or hose)
Pilot or drain line or drainage

Hydraulic motor,
with limited flow
bi-directional
Lines crossing; not connected
Pressure gauge
Lines crossing and connected
Thermometer
Plugged port (test port)
Accumulator gas charged

diaphragm type
Flow meter
M3559
M-1.0-0000-00035
M1.0-0000-00035
35
HYDRAULICS
Pressure switch Manual actuator
Double-acting cylinder; Spring, (bias to normal de-

unequal area energised position)
Double-acting cylinder;
equal area
Solenoid single coil or winding
Single-acting cylinder
with spring returned
(rod end vented)
Hydraulic pilot operated
Single-acting cylinder
ram type
Solenoid valve, pilot operated
Single-acting cylinder,
with cushion
Dual solenoid
Assembly housing,
manifold block
Proportional solenoid
Manual lever actuator Pilot check valve (pilot to open)
M3560
36M1.0-0000-00036
M-1.0-0000-00036
HYDRAULICS
Throttle, fixed Shuttle valve
Throttle, adjustable
Single counterbalance valve

assembly in manifold
Pressure-compensated
flow control, fixed
Pressure-compensated
flow control with reverse
flow bypass; fixed.
Flow divider/combiner
Velocity fuse
Bypass flow control
with controlled flow,
pressure-regulated
Relief valve, fixed setting Shut-off valve, manual
P
Torque generator
Relief valve, adjustable T
T L Hydraulic steer unit

Check valve
P R
M3561
M-1.0-0000-00037
M1.0-0000-00037
37
HYDRAULICS
2/2 way valve

(two way, two switch positions) Valve block with
3 operating units
3/2 way valve

(three way, two switch positions)
4/2 way valve

(four way, two switch positions)
4/3 way valve

(four way, two switch positions)
4/3 way valve

(four way, two switch positions);
manual activation and spring centered
3/2 way valve

(three way, two switch positions);
Spring bias solenoid control
M3562
38M1.0-0000-00038
M-1.0-0000-00038
HYDRAULICS
Hydraulic System
Operation Lifting: The pump delivers oil from the reservoir to

the two lift cylinders.
The hydraulic unit is installed next to the left hand lift The lowering valve remains closed.
cylinder and comprises the motor, pump, reservoir and
all filters and valves. Lowering: The lowering valve opens. The oil flow
returns from the two lift cylinders to the
reservoir.
Lift cylinder
Lowering valve
Filter
Filter
Non-return valve
Pressure relief valve Flow reducer
150 bar
bis 170 bar*
Motor
Vent cap
Pump
Filter Filter
Reservoir
* abhängig von Modell und Einstellung des Sicherheitsventills M1457-1
M-1.0-0000-00039
M1.0-0000-00039
39
HYDRAULICS
Removing the Hydraulic Unit
WARNING ● Unplug the battery connector
(= Emergency Disconnect).
De-pressurise all components before
carrying out maintenance work on the ● Secure the truck from rolling away.
hydraulic system.
● High pressure hydraulic oil can cause ● Before commencing maintenance work place a
serious injuries. flat container or (if necessary) a large cardboard
box underneath the work surface.
● Whenever a high pressure fluid penetrates
the skin it must be treated as an ● Disconnect the wire plug connection on the
emergency, even if the skin shows no lowering valve magnet (see Fig. M1523).
initial reaction. Physical effects set in later.
● Secure all connections before re-applying ● Unscrew the power connections to the pump
system pressure. Keep hands and body motor (see Fig. M1522).
away from any ports as high pressure
hydraulic oil can emerge. ● Unscrew the pressure connection
(see Fig. M1522).
● Use absorbent paper to track leaks, never
use your hands! ● Obtain a suitable support on which to rest the
hydraulic unit, e.g. a heavy iron ring.
● Remove the hydraulic unit by removing the two

fastening screws (see Fig. 1522) from the
chassis.
Safety pressure relief

valve (rear view)
Connecting
Cable
Pressure switch (load-

sensitive travel speed
Pump motor reduction)
Screws fastening
hydraulic unit to
chassis
Reservoir flange
M1522
40M1.0-0000-00040
M-1.0-0000-00040
HYDRAULICS
Pressure port,
non-return valve
Filler neck and

vent cap
Lowering valve and

actuating magnet
M1523
Replacing the Hydraulic Pump ● Remove the four screws (item 26) from the
reservoir flange and remove the reservoir.
NOTE
● Loosen the four screws (M6 x 50, hex. head)
The hydraulic pump should not be re- from the engine side of the hydraulic unit and
placed on site. remove the pump.
The pump is replaced as a complete as-
sembly. ● Loosen the filter clamps (25) and (22) and
The seals of any disassembled parts and remove the filter.
filters must always be replaced!
● Clean all components (except the motor) with a
Removal clean degreasing agent; remove the old seals
and blow dry.
● Remove the hydraulic unit as described in the
previous section. Installation
In the following instructions all item numbers refer ● Attach the new filter parts to the pump.
to Figure M1442,.
● Apply a thin coat of oil to the seal (24) and insert
● Drain the oil via the filler neck. seal.
● Loosen the four screws (item 1). ● Fit pump (note alignment! See Figure M1442)
and fix with 4 M6 x 50 screws. Torque crossways
● Lift up the motor while ensuring that it does not to 18 ±2.5 Nm.
fall apart.
M-1.0-0000-00041
M1.0-0000-00041
41
HYDRAULICS
● Fit the reservoir with a new lightly oiled seal (26) ● Now fill with hydraulic oil up to the lower mark of
and torque the flange ring with four hex. head the filler neck.
screws (M6 x 10) to 8 ±1.2 Nm.
Pump Motor
● Fit the motor on the hydraulic block so that the
drive shaft carrier fits into the pump shaft recess. For maintenance and repair work to the pump motor see
Align the motor and torque with the four screws chapter 4.
(1) to 8 ±1.2 Nm.
Filters
● To refit the hydraulic unit proceed in the reverse
order of Removal. Note torques! Replacing the Pressure Filter
Both motor connecting cables: 4±0.5 Nm.
● The pressure filter (150 µ) is integrated within the
pressure connection (20). When unscrewing the
Commissioning and Bleeding the Sys- pressure port make sure that the ball of the non-
return valve (21) is not lost.
tem
Replacing the Suction and Return Filters
● Check that the system is clean and properly
assembled. In particular, the pressure ports must ● To access the suction (25) and return filter (22),
be tightly secured. the reservoir (26) must be disconnected from the
pump connection plate (14). To do this, remove
● Initially, fill the hydraulic oil only up to half the 4 screws (26) from the flange (26).
the reservoir height (see lubricant table) using
a filter with a 10 µm minimum retention rate. ● The filters (450 µ) are integrated within the
hopper-shaped end piece (nozzle) of the suction
● Never operate the pump without oil. (25) and return (22) lines. To disassemble,
release the clamps.
● All components, in particular the hydraulic ports,
must be completely clean and dry prior to Oil Change
commissioning. Otherwise it is impossible to
check whether the system is sealed. The oil reservoir (capacity 0.75 litres) does not have an
oil drain plug. The used oil must therefore be
● Operate the lifting functions for approx. 30 suctionned off or drained from the oil reservoir.
seconds to bleed the system. The oil in the
reservoir will foam considerably. Dispose of used oil via approved disposal methods
only.
● Check the pressure port and surrounding
hydraulic components for leaks.
● Park the truck and leave it to stand for approx. 20

minutes. During this interval the air will separate
from the oil in the container.
● When there is no more foam in the reservoir

replenish with oil up to half the max. filling height
and bleed again until no more foam is visible.
● Lower the forks fully.
42M1.0-0000-00042
M-1.0-0000-00042
HYDRAULICS
M-1.0-0000-00043
M1.0-0000-00043
43
HYDRAULICS
Replacing the Safety Valve ● Now raise a test load which corresponds to
110% of the rated capacity + 100 kg (=
● Remove the hydraulic unit as described in the maximum load). It should not be possible to raise
previous section "Removing the Hydraulic Unit". this load (safety valve opens).
● Remove the locking mechanism (4, Fig. MS1723- lf necessary adjust the safety valve so that it opens
007) and unscrew the safety valve (3), within the above-mentioned tolerance range:
● Remove the O-ring and the filter from the valve ● Remove the hydraulic unit as described in the
seat if they are still located there. previous section "Removing the Hydraulic Unit".
● Apply a thin coat of hydraulic oil to the new O- ● Using a large screwdriver hold the setscrew
ring and position it together with the filter in the securely (1, Fig. MS1723-007) and with a fork
valve seat. wrench undo the jam nut (2, Fig. MS1723-007):
Turn the setscrew clockwise to increase the limit
● Apply a thin coat of hydraulic oil to the safety at which the valve opens, turn it anticlockwise to
valve and screw it in securely to the valve seat. reduce the limit.
Insert the new locking mechanism.
Note: 1/8 turn ~ 200 kg
● Re-fit the hydraulic unit and adjust the safety
valve. ● Fix the setscrew (1) again using the nut (2).
Safety Valve Setting ● Refit the hydraulic unit and repeat the test.
Repeat the setting until the safety valve opens
The safety valve (15, Fig. M1542 previous page and 1 within the tolerance range.
to 3, Fig. MS1723-007 ) protects the hydraulic system
and the lifting mechanisms against overloading.
WARNING
Do not run the pump unit unless it is fixed
to the chassis
● The torque is so great that the unit will
twist. This may result in short circuits and
cause damage.
The safety valve is not accessible when the pump unit
is installed. First remove the pump unit before making
adjustments.
Safety Valve Test and Setting

3
● With the truck at operating temperature raise a 2
test load positioned in the centre of the forks
which corresponds to 110% of the rated capacity
(= minimum load). It should be possible to raise MS1723-007
1
this load safely. 4
Rated Minimum Maximum

Model
Capacity Load Load
WP2315 1,600 kg 1,760 kg 1,860 kg
WP2320 2,000 kg 2,200 kg 2,300 kg
H01-GB
44M1.0-0000-00044
M-1.0-0000-00044
DRIVE UNIT
Printed in Germany
45
Printed in Germany
46M1.0-0000-00046
DRIVE UNIT
Gear Unit
Drive unit attachment

to knuckle flange
Vent filter
Drive wheel
Drive motor (drive pinion disassembled)
M1471
Gear unit lid
Pinion shaft and gear wheel
Oil filler plug (6 Nm)
Oil level
Driven shaft and gear wheel
Oil drain plug (6 Nm) M1472
M-1.0-0000-00047
M1.0-0000-00047
47
DRIVE UNIT
Drive Unit, General ● Prevent the drive unit from tipping and remove
the 4 mounting screws (1, Fig. MS1723-031)
The drive unit comprises the gear unit and the traction connecting the drive unit to the knuckle.
motor.
● Either jack up the truck so that the drive unit can
The traction motor can be removed without having to be removed from under it or raise the truck using
remove the drive unit or the gear unit. It is not neces- a crane with sufficient capacity (see Chapter 1 for
sary to drain the oil when the drive is upright. instructions and safety guidelines),
WARNING ● Place the drive unit in a secure device.
The drive unit is heavy.

Traction Motor Removal
● When removing the drive unit use an Note: If you are removing the traction motor with
appropriate mechanism to prevent it from the drive unit still installed, ensure that the motor
tipping. does not get caught in the bearing cage of the
● It is easiest to lift the truck away from the drive unit when removed.
drive unit using a crane.
Set the drive unit at an angle so that the motor can be
● If you need to jack up the truck to release freely removed.
the drive unit, secure the truck using
secure supports. ● Disconnect the battery and prevent the truck from
being switched on again.
Removing the Drive Unit
● Disconnect the electrical wiring from the motor.
● Disconnect the battery and prevent the truck from
being switched on again. ● Remove the two mounting screws connecting the
motor (A, Fig. MS1723-021) to the gear unit.
● Disconnect the electrical wiring from the motor.
MS1723-031
MS1723-021
48M1.0-0000-00048
M-1.0-0000-00048
DRIVE UNIT
MS1723-024
● Remove the motor as described in the previous
section.
● Dismantle the brake (see “BRAKE” chapter)

MS1723-022
● Remove the retaining ring (40).
● Unscrew both screws (B, Fig. MS1723-022) by
approx. 2 turns. ● Using an extractor, remove the pinion (1) via the
bushing (11).
● Using a plastic hammer tap alternately on the
screw heads (B) to drive the motor from the ● Remove the seal (29).
centering flange. Do not damage the screws.
● Force out the rotary shaft seal (32).
● Fully remove the screws (B) and take out the
motor. Note: Do not damage the gear teeth in ● Remove the bearing (20) and the inner raceway
the process (C, Fig. MS1723-024) and D, Fig. (12).
MS1723-023)
Assembling the Motor
Dismantling the Motor
● Press the bearing (20) onto the rotor shaft while
Note: If no other figure number is indicated, all holding up the opposite shaft end.
reference numbers in the following sections refer
to Figure MS-1723-027-A on the next page. ● Apply Loctite® 601 to the inner raceway (12).
● Insert the seal (29) into the bushing (11) and

press the rotary shaft seal (32) in. Now insert the
ball bearing compensating shim (33) into the
bushing (11).
D ● Fit the complete bushing onto the motor rotor.
● Insert the key (50) and press on the pinion (1).
● Put the retaining ring (40) in position.

B
● Attach the brake (see “BRAKE” chapter)
● Attach the motor as described below.
MS1723-023
M-1.0-0000-00049
M1.0-0000-00049
49
DRIVE UNIT
5
59
29 11
33 32
1
40
50
12
58
20
6
22
21
70
30
51
3
24
61
62
31
45
48/49
60
43 9 23 44
MS1723-027A
50M1.0-0000-00050
M-1.0-0000-00050
DRIVE UNIT
Traction Motor Assembly
A
Auxiliary Tools Required: 2 x M6 threaded rods,
approx. 100 mm long.
● To aid assembly screw 2 M6 threaded rods,

approx. 100 mm long, into two opposite threaded
holes on the motor (E, MS1723-023)
● Slide the motor into the gear unit with the

mounting aids facing forward and slide it into
position. Do not damage the gear teeth in the
process.
MS1723-021
MS1723-023
B
● Re-insert the two mounting screws for the motor
(A, Fig. MS1723-021) on the gear unit. Tighten
the two screws alternately in small increments.
This will bring the motor fully into alignment and
will prevent it from tipping in this position.
● Re-insert the screws (B, Fig. MS1723-022).
● Torque the screws A, Fig. MS1723-021 and B,

Fig. MS1723-022 to 10 Nm.
● Refit the electrical connections to the motor and

brake.
● Test the operation of the motor.
MS1723-022
M-1.0-0000-00051
M1.0-0000-00051
51
DRIVE UNIT
Gear Unit Disassembly Draining the oil
General ● Place a container underneath the drain plug (G,
Fig. MS1723-029) of the gear unit and drain the
Note: It is not necessary to dismantle the motor if you oil. Unscrew the control plug (F) to drain the oil
are disassembling the gear unit and then reassembling more quickly.
it.
Removing the drive unit
Always replace all the bearings and seals when
dismantling the gear unit. Worn seals and bearings ● Now remove the drive unit for disassembly. Refer
will result in premature failure of the unit. to the “REMOVING THE DRIVE UNIT” section at the
beginning of this chapter.
Preparation
● Remove both screws (58, Fig. MS1723-027)
● Disconnect the battery and prevent the truck from together with the 10 screws (60) securing the
being switched on again. housing lid.
● If necessary, remove the motor as described in Dismantling the gear unit lid
the previous section.
WARNING
● Unscrew and remove the drive wheel.
Do not damage the contact surfaces of the
gear unit housing and the gear unit lid.
● Do not use a thick tool (screwdriver or
similar). This will damage the contact
surfaces.
● Tap a burr-free, thin tool around the circum-

ference of the sealing gap until the housing lid
can be easily lifted off (see Fig. MS1723-030).
MS1723-029
● Using a scraper carefully remove the sealant

compound residue from the contact surfaces of
MS1723-028
the gear unit housing and the gear unit lid. Now
thoroughly clean the contact surfaces with a
52M1.0-0000-00052
M-1.0-0000-00052
DRIVE UNIT
suitable cleaning agent (e.g. Loctite® 7063 Clea- ● Place the bushing (9) onto the rollers of the
ner). bearing (24) and press the bearing (23) into the
gear unit housing and insert the retaining ring
Dismantling the gear unit (44).
Note: If no other figure number is indicated, all ● Place the wheel (4) in position and guide the
reference numbers in the following sections refer driven shaft carefully into the shaft seal, threading
to Figure MS-1723-0027-A on the next page. in the bushing in the process.
● Remove the retaining ring (61, Fig. MS1723- ● Thread the wheel (4) onto the external spline of
027A) and the supporting ring (62). the driven shaft (7).
● Remove the wheel (2) using a suitable extractor. ● Support the wheel (4) with a suitable bushing and
press the driven shaft (7) into the wheel (4).
● Remove the retaining ring (45) and the two shims
(48, 49). ● Using a suitable number of shims (49) between
the two shims (48) separate the driven shaft (7)
● Press out the driven shaft (7) towards the drive so that it is free of play and insert the retaining
wheel. This will damage the bearing (23). ring (45).
● Remove the retaining ring (44) and pull out the ● Press the bearing (22) onto the pinion shaft (3).
bearing (23). The bearing is no longer useable.
● Hold up the inner raceway of the bearing (21)
● Remove the retaining ring (43) and pull the and fit the pinion shaft (3). Insert the retaining
bearing (24) out via the outer ring. ring (42).
● Now press out the rotary shaft seal (31). ● The contact surfaces on the lid and the gear unit
housing must be clean and free of oil.
● Remove the retaining ring (42) and the locking lid If necessary clean the surfaces as described in
(30). DISMANTLING THE GEAR UNIT LID.
● Press out the pinion shaft (3) towards the gear ● Apply Dirko® sealant paste around the contact
unit lid (6). Both bearings (21 and 22) will remain surface of the gear unit lid (see chapter 1, table
on the pinion shaft. adjuvants).
● Pull both bearings (21 and 22) off the pinion shaft ● Place the key (51) in the pinion shaft (3).
(3).
● Hold up the inner raceway of the bearing (21)
Note: The driven pinion is a component of the motor. and press the wheel (2) onto the pinion shaft (3).
The pinion and bearing removal process is described
above in the TRACTION MOTOR section. ● Thread the supporting ring (62) into the pinion
shaft (3) and insert the retaining ring (61).
Gear Unit Assembly
● Press the locking lid (30) into the housing.
Always replace all the bearings and seals when
dismantling the gear unit. Worn seals and bearings
will result in premature failure of the unit.
● Press the bearing (21) into the housing via the

outer ring.
● Press the inner raceway of the roller bearing (24)

onto the driven shaft (7).
● Press the shaft seal (31) from the outside into the
gear unit housing seat.
● Fit the outer ring of the roller bearing (24) and

insert the retaining ring (43).
M-1.0-0000-00053
M1.0-0000-00053
53
DRIVE UNIT
5
59
29 11
33 32
1
40
50
12
58
20
6
22
21
70
30
51
3
24
61
62
31
45
48/49
60
43 9 23 44
MS1723-027A
54M1.0-0000-00054
M-1.0-0000-00054
DRIVE UNIT
Installing the gear unit lid ● With the drive unit vertical, fill the specified
amount of gear oil up to the bottom mark of the
● Place the gear unit lid onto the housing and control screw (B) via the hole for the vent filter
gently press against it. (A).
● Insert all 10 mounting screws (M8x16 Tuflock A) ● Screw in the vent filter (A) and the control screw
of the lid and torque them evenly and alternately (B) again once the correct oil level is reached.
to 25 Nm. The torque for the filter and the control screw is 6
Nm.
● If you have removed the motor, install it again as
described in TRACTION MOTOR ASSEMBLY. Installing the drive unit
Adding Oil ● Fit the drive unit in the reverse order of removal
(see DRIVE UNIT REMOVAL in this chapter.
You require approx. 0.7 litres of gear oil (see LUBRICANT TABLE
IN CHAPTER1 to make a selection which is appropriate to ● Test the truck’s operation and then check the
your conditions of use). gear unit for leaks.
● Unscrew the vent filter (A, Fig. MS1723-026) and

remove the control screw (B). New gear units are
supplied with a lock screw instead of a vent filter.
This prevents oil from spilling during transport.
Make sure a vent filter is fitted (A, Fig. MS1723-
026) if the gear unit is fitted in the truck.
MS1723-026
M-1.0-0000-00055
M1.0-0000-00055
55
56
ELECTRICS
Printed in Germany
57
Printed in Germany
58M1.0-0000-00058
M1.0-0000-00058
ELECTRICS
Electrics - General
Wire Colour Codes

The wires used in the truck are colour-coded and
numbered according to their function. The first digit or
the first two digits indicate the wire colour while the last
two digits are counter numbers.
ABBREVIATION COLOUR NUMBER FUNCTION
BLK Black 0 ** Digital signal
BRN Brown 1 ** Analog signal
RED Red 2 ** Positive not connected
ORG Orange 3 ** +12 V DC conver ter
YEL Yellow 4 ** Third DC conver ter
GRN Green 5 ** Negative not connected
BLU Blue 6 ** Insulated negative
VIO Violet 7 ** +5 V DC conver ter
GREY Grey 8 ** Four th DC conver ter
WHT White 9 ** Various
RED/WHT Red/White 29 ** Positive connected
GRN/WHT Green/White 59 ** Negative connected
** Numbers 01 to 99 E01-gb
M1.0-0000-00059
59
ELECTRICS
Abbreviations
Switch Symbol Abbreviation List *
Abbreviation Component Abbreviation Component
K* Relay LMS Limit switch
ACS Accelerator pedal switch LOS Lower switch
AXS Auxiliary function switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Direction control switch RA Raise potentiometer
DRS Door switch RAS Raise switch
E DS Emergency Disconnect Switch REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Reverse safety switch
FS Forward switch SDS Star t switch
HBS Handbrake switch SES Seat switch
HSS Fast / Slow Travel switch SSS Sideshifter switch
HNS Horn switch THS Thermo switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk along switch
* If one of the above abbreviations is used more than once, a number extension
E02-gb
will be used, e.g . SV1, SV2 etc.
60M1.0-0000-00060
ELECTRICS
Sundry Abbreviations *
Abbreviation Description Abbreviation Description
BV(AK) Battery Voltage after key M2 (PM) Pump motor
BDI Battery discharge indicator MRC Controller
BR Brake OHGD Overhead guard display
BWI Brush wear indicator P Pump contactor
CA Cable connection PC Plug connector (fitting JC)
F Connection field coils PCB Printed circuit board
FAN Fan SF Shunt field
FU Fuse STI Steering wheel indicator
HN Horn SV Solenoid valve
IFD Information display TB Terminal board
JC Jack connector (fitting PC) TMM Truck management module
LINE Line contactor TT Hourmeter
M1 (TM) Traction motor VMN Chopper (Negative voltage motor)
* If one of the above abbreviations is used more than once, a number extension
will be used, e.g . SV1, SV2etc. E03-gb
M1.0-0000-00061
61
ELECTRICS
Other Abbreviations*
Abréviation Désignation Abréviation Désignation
GCSR Gate Closed Switch Right GCSL Gate Closed Switch Left
PLS Platformswitch TCM Traction Motor
PS Pressure Switch HR Heater
* If an abbreviation is used more than one time, a index number is added. E.g.PLS1, PLS2 etc.
E12-S-GB
Electrical Symbols
EUROPE USA DESCRIPTION EUROPE USA DESCRIPTION
Hand operated
Wires joining maintained contact
Wires crossing Solenoid valve
Wire connection Inductor
Plug / socket Resistor
Wire strap Capacitor

1 2 3 4 5 6 1 2 3 4 5 6 Terminal board Potentiometer .
Fuse U Varistor
Assembled unit J T Thermal protector
Contact, normally open Lamp
Contact, normally closed Horn
Contact double throw Battery
Operating device Diode

Operating devices,
slow releasing Breakdown diode
Operating device,
slow operating LED
Hand operated
NO push button Transistor
c
Mechanically actuated MOSFET
c Hydraulically actuated Thyristor
c
Emergency disconnect Comparator
Motor armature
.
M0056-gb
62M1.0-0000-00062
ELECTRICS
Electrical Components Reverse Safety Switch (SAS)

The safety reverse switch (SAS) is activated via the
DANGER switch cap at the end of the tiller head: the traction
controller immediately changes from forward to reverse
Jack up the truck before carrying out
travel when the SAS is activated. The signal for normal
repair work or troubleshooting the
travel to the traction controller is simultaneously inter-
electrical system.
rupted. Depending on the traction controller setting the
truck either travels for a given time, or provided the
switch is pressed, travels in reverse.
Transmitter (POT, FS, RS)
Brake Switch (BRS)
The travel switches are activated via the butterfly
switches on the tiller. The transmitter comprises a The brake switch (BRS) is immediately below the
switch (FS) for forward travel, a switch (RS) for reverse multitask handle attachment. As soon as the multitask
travel, and a potentiometer (POT) which governs the handle reaches the upper or lower braking zone (see
travel speed. For cold store versions the potentiometer Fig. M1476) the brake switch is activated. The traction
is heated. controller interrupts the power supply to the traction
motor (TM) and the brake (BR). The brake magnet
Fast / Slow Travel Switch (HSS) releases the anchor disk which in turn, spring powered,
brakes the truck.
The Fast / Slow travel switch (HSS) is activated via a
toggle switch (Rabbit / Turtle symbol) on the multitask Override Switch (ORS)
handle head. The switch signal to the traction controller
is used to change between the high and slow speed The override switch (ORS) is immediately below the
ranges. multitask handle attachment. As soon as the multitask
handle reaches the special travel zone (see Fig.
M1476) the override switch (ORS) sends a signal to
the traction controller with the resulting slow travel
option (by pressing the travel switch). This provides
better shunt operation in restricted conditions.
Upper brake zone
Special
travel zone
Travel zone
Neutral / Idle Position
Lower brake
zone
Reverse Forward
M1476
M1.0-0000-00063
63
ELECTRICS
Raise / Lower Switch (RAS, LOS) Fig. 1473 shows the position of the limit switch after lift
cut-out.
The raise (RAS) and lower (LOS) switches are
activated via rocker switches in the tiller head. The Horn Switch (HNS)
rocker switches act on switches fitted on the tiller
hydraulic PCB. The switches are physically locked in A buzzer sounds when the horn button is pressed.
pairs so that they cannot be pressed together at the
same time. Key Switch (KYS)
The raise (RAS) switch activates the pump contactor The key switch directs the battery supply to the traction
(P), which cause the pump to start. controller and the battery discharge indicator (BDI).
The lower (LOS) switch applies voltage to the solenoid Emergency Disconnect
(SV) which causes the solenoid to open.
Pulling the battery connector on the red knob at the top
Limit Switch (LMS) of the truck completely disconnects the power supply
to the truck.
The limit switch (LMS) interrupts the pump contactor
current flow when a preset maximum lift height has Fuses (FU)
been reached. The limit switch is under the front panel
next to the multitask handle support.
Limit switch fitted for lift Upper hole: Limit switch location for
cut-out at 130 mm max. lift = 150 mm
Trip cam
Track
M1473
Elongated hole for fine adjustment of lift cut-out point
MS-4.3-1723 MS-WP2300-GB 04/03 •Printed in Germany
64M1.0-0000-00064
ELECTRICS
The entire truck circuit is protected by fuse FU1, the SAS
control circuit by fuse FU2. Cold store trucks have
OPTION CA 419 (RHS)
a fuse FU3 for multitask handle heating. POT, FS, RS
HNS
OPTION
Thermal Switch (THS) CA 417 (LHS)
This switch is an electronic thermostat for cold store HNS

trucks. It is located on the main tiller PCB and switches
the heating units on when the temperature falls below
0°C.
RAS / LOS
HSS
CA 410
CA 414
CA 411
CA 415
CA 412
CA 413
CA 404 ORS
FU3
KYS
BDI BRS FU2
FU1
CA 403
CA A, B, C, D, and E
BD TCM
LMS/LMS1 Main Harness
CA 402 P
Onboard Line
Charger
PM
SV
HN Handle Harness
BR Plug Holder
TM CA 202
BATT
CA 406
M1.0-0000-00065
65
Printed in Germany
66
ELECTRICS
SEM0 Traction Controller short-circuit the positive and negative terminals

of the power part together over a resistance (10 -
100 Ohm, min. 5 W) for a few seconds.
DANGER
Jack up the truck before carrying out any Operational Features
repair work or troubleshooting the
electrical system. Speed Control
Stepless, handset programmable speed control in both
directions.
General
Reduced Speed Ranges
Two reduced speed ranges are available: slow travel
(via a HSS rotary switch contained in the tiller handle)
and the special travel range (dependent on the tiller
position, activated via a ORS microswitch contained in
the tiller).
Downhill Speed Control

When travelling downhill the controller monitors the
motor anchor speed via the drive signal from the
traction potentiometer. When the set speed is
exceeded, electrical braking with energy retention is
introduced.
M1478
Regenerative Braking
The programmable SEM0 impulse controller provides
effective control over the driving behaviour of the truck. Three forms of regenerative braking are available:
The truck is powered by a separate excited motor ● Release braking (travel switch or multitask handle
(SEM). This version has two variables for governing the return to neutral)
motor output: field and armature current.
● Inversion braking (travel switch set in opposite
Precautionary Measures direction)
● Do not attach the controller to a battery with a ● Braking by reducing speed on a slope: the
different rated voltage to that of the controller controller constantly regulates the engine speed
(24 - 36 VDC). according to the set value prescribed by the
A higher battery voltage may destroy the travel switch. Braking is automatically activated
MOSFETs, while a lower power supply will result when the set value is exceeded.
in system failure.
Anti - Roll Down Function
● Only operate the controller with special traction
batteries. Do not connect to a rectifier or mains This function prevents the truck from accidentally
components. rolling down a slope. When the key switch is on the
controller monitors the engine speed. If it detects a
● When commissioning jack up the truck to prevent turning movement without a travel command, braking is
it from starting suddenly if there is a wiring error. automatically activated.
● When the key switch has been turned off the filter If the truck automatically starts to move on a slope, it
capacitors in the controller remain charged for a therefore brakes after a short period. When the truck
few minutes. If work is performed on the stops braking is released causing the truck to move
controller during this time it must be again, followed by further braking. If the brake is not
disconnected from the battery (disconnect applied the truck will therefore move down the slope
battery). Finally, to discharge the capacitors very slowly.
M1.0-0000-00067
67
ELECTRICS
Hourmeter Temperature
An hourmeter is integrated within the traction controller From a power part temperature of 80°C upwards the
which can be set via the programmer either to "KEY maximum current is limited in proportion to the rise in
ON" (hourmeter activated when key switch on) or temperature. At 90°C the traction controller
"RUNNING" (hourmeter activated only during travel). automatically cuts out.
Self Test At temperatures below -10°C the maximum current is

reduced in proportion to the ongoing battery discharge.
The traction controller self-diagnostic system lists the
five most recent error messages. These error Start Sequence
messages can be called up via the programmer. As
well as the error, the system stores and displays the To start the truck there is a specific start sequence
error frequency, the respective number of service which must be observed. Otherwise the general
hours and the temperature of the traction controller at protection will not be activated and the truck will not
the time the error was recorded. function.
In addition a red LED on the traction controller Safety Class

indicates the last recorded error via a flashing code.
The display is deleted when the controller is switched The traction controller is protected against dust and spray
off and on again, and if the error was only temporary. water (IP54).
Monitored Circuits
The following functions are monitored by the traction
controller microprocessor depending on the operating
mode:
● Starting the truck: control logic system

(hardware) and program functions (software),
field current, VMN, contactor drivers, switch order
sequence, traction and lift switch output signal.
● Standby mode (key switch on): VMN, field

current, contactor drivers.
● During travel: control logic system (hardware)

and program functions (software), field current,
VMN, contactors.
● Continual monitoring: Traction controller

temperature, battery voltage.
Protective Devices
Polarity Protection
A general protection controlled by the logic system
separates the traction controller from the battery and
thus protects the power part from incorrect polarity.
Wiring Errors
All outputs are protected against wiring errors. The
outputs for the general protection and the magnetic
brake can be charged with max. 3 A and are fitted with
both an overload and a short circuit protection.
68M1.0-0000-00068
ELECTRICS
Maintenance Note:
The lower nut secures the connection bolt to the
Maintenance of the SEM0 controller is confined to power part board and the plastic housing. If this
external cleaning. When carrying out maintenance nut is insufficiently torqued (less than 6 Nm),
work, check the listed errors using the programmer. excessive transition resistances will occur
between the board and the bolt. The resultant
WARNING heat may damage the controller and melt the
cover around the connection bolts.
The SEM0controller operates with high If the torque is too high (more than 7 Nm) the
current. Special safety measures are power part board and the housing may suffer
therefore required. physical damage.
● Only properly trained personnel must ● Using a torque wrench check the torque for
carry out maintenance work. the fastening nut (2, Fig. MS519) of the
● Wear safety glasses. connection bolt. The rated value is 6 – 7 Nm.
● Do not wear any loose clothing. Important: An incorrect torque may damage
the controller board and housing.
● Do not wear any jewelry.
● Remove any dirt and corroded material from the
● Use insulated tools only. contact surfaces.
● Wipe the traction controller with a clean, damp

● Disconnect the battery (= emergency cloth.
disconnect).
● When everything is dry connect the power cable
● Jack up the truck. again. To do so, secure the lower nut (2, Fig.
MS519) with a fork wrench and only tighten the
● Discharge the controller capacitors by connecting for upper nut (1, Fig. MS519). Connect the control
a short time BATT- and BATT+ of the controller via a lines.
cable including a resistor of about 10 Ohm, 5 W.
● For cold store versions: coat the control line
● Remove the power cable: mark the cable if connectors with Dow Corningâ 4 Compound, part
necessary. Secure the lower nut (2, Fig. MS519) no. 053051-006.
with a fork wrench. Undo the upper nut (1, Fig.
MS519).
MS519
M1.0-0000-00069
69
ELECTRICS
Replacing the SEM0 Traction no. 053051-006. Paint the controller with an acid-
resistant clearseal paint.
Controller
Important: After replacing the controller check and
WARNING adjust the settings. You can adjust the settings to
suit the customer’s requirements. Follow the order
The WP2300 must only be operated with the described as follows.
SEM0 traction controller (Part No. 813096-
001). Parameter Setting after Replacing the
● The use of SEM0 traction controllers with Traction Controller
different part numbers can change the
characteristics and result in accidents. Preparatory Measures
When fitting a new SEM0 traction controller with part
● Power down the truck and jack it up so that
no. 813096-001 on a WP2300, the controller
the drive wheel is free (see Chapter 1).
recognises the truck model and automatically loads the
standard parameters for the WP2300 when it is
● When the truck is powered down connect the
powered up.
programmer to the traction controller.
If you have changed and stored the standard configu-
ration with the programmer, the stored parameters will ● Power up the truck.
be loaded the next time the controller is started.
Setting
● Prepare to remove the traction controller as
previously described in the Maintenance section. 1. If required, change the options for the safety
reverse switch and the internal service hourmeter
● Remove the 4 mounting screws and remove the of the controller. The standard setting is
traction controller. contained in Table 11-GB. When you have made
the changes, switch the truck off and on again to
● Check the contact pattern left behind by the activate the changes.
controller back plate on the heat dissipation
sheet. The controller must lie fully flat on the heat 2. Measure the battery voltage directly at the
dissipation sheet. battery and adjust the reading measured and
If there are large areas with no contact to the displayed by the traction controller (see CONFIG
controller, replace the heat dissipation sheet to MENU section).
avoid thermal problems.
3. Using the TEST menu check the wiring and
● Clean the contact surface of the traction operation of the switches (see TEST menu
controller on the truck chassis with a lint-free section).
cloth and use an industry-standard silicon rem-
oval agent to remove the residue of the heat 4. Re-calibrate the traction potentiometer (see
conducting paste. “Traction pod – calibrate potentiometer, PRO-
GRAM VACC menu).
● Apply a thin and even layer of Dow Corningâ
340 heat conducting paste, part no. 053051-008 5. Test the traction pod starting point at creep
to the floorboard (= contact surface of the traction speed. The drive wheel should start when the
controller on the truck chassis). travel switch closes. If necessary increase the
value accordingly. Repeat the test for both travel
● Secure the traction controller again with the 4 directions (see PARAMETER CHANGE menu
screws. section).
● If necessary clean the contact surfaces and refit 6. Jack down the truck and bring it to a secure area
the power cable (you must follow the where you can perform test runs without endan-
instructions in the Maintenance section on gering other people.
the previous page) and refit the connectors for
the control lines. 7. Set the maximum speed to slow travel if
necessary (CUTBACK SPEED). Repeat the test
● For cold store versions: coat the control line with maximum load (see PARAMETER CHANGE
connectors with Dow Corningâ 4 Compound, part menu section).
70M1.0-0000-00070
ELECTRICS
8. Set the maximum speed to the special range if
necessary (OVERRIDE). Repeat the test with
maximum load (see PARAMETER CHANGE
menu).
9. Set the maximum speed “Forward” (MAX SPEED

FORWARD) and “Reverse” (MAX SPEED BACK).
Warning: The maximum permissible speed is 6
km/h unladen.
10. Set the release brake characteristics:

Set the unladen truck to maximum speed and
release the travel switch. Repeat the test with the
maximum permissible load. If necessary adjust
the braking pattern (RELEASE BRAKING).
11. Set the braking pattern for changing direction:

Set the unladen truck to approx. 25% of
maximum speed and move the travel switch in
the opposite direction until it reaches the stop.
Set the braking pattern so that the delay sets in
gently (INVERSION BRAKING).
Now repeat the test at maximum permissible
speed. Adjust the setting until the delay sets in
gently in both speed ranges and the effect is
ideal. Preference should be given to the best
setting for when the truck is unladen.
Repeat the process with the maximum
permissible load.
12. Adjust, where necessary, the time taken to

change direction. To do this change the AUX
TIME DELAY parameter.
Both parameters, INVERSION BRAKING and
AUX TIME DELAY affect the “feel” of the delay
when changing direction.
Important: Power down the truck before

disconnecting the programmer. Now reconnect the
LEDs.
M1.0-0000-00071
71
ELECTRICS
Status LED The status LED is off during normal travel. When an
error occurs it flashes the respective code (see follow-
When the truck is powered up the status LED con- ing table) until the error is rectified.
nected to terminal strip E briefly flashes. This indicates
that the test program is being booted up by the control- The programmer can be used to define the error more
ler. exactly.
No of Flashes Console Display Notes
1 Logic failure #1: Line contactor voltage control error
1 Watch dog: Logic or software error
1 EEPROM KO: EEPROM error
2 INCORRECT STARTS: Star ting sequence for travel not correct
2 FORW + BACK: Forward and backward simultaneously requested
3 CAPACITOR CHARGE Problem with power block
3 VMN NOT OK Problem with chopper; armature voltage not correct
3 VFIELD NOT OK Field voltage not correct
4 VACC NOT OK Signal from traction potentiometer not correct
4 PEDAL WIRE KO Traction pod wiring not correct
No field current: Field wiring not correct

5 NO FIELD CUR.
or field current sensor error
High field current: Field wiring not correct

5 HIGH FIELD CUR.
or field current sensor error
5 STBY I HIGH High current: Armature current sensor error
5 I = 0 EVER No current: Armature current sensor error
6 CONTACTOR DRIVER Contactor driver error
6 COIL SHORTED Contactor coil shor ted
6 CONTACTOR CLOSED Line contactor contact faulty
Temperature of control unit too high (> 80°C)

7 TH. PROTECTION
or too low (< -10°C)
32 BATTERY LOW Battery voltage too low
E04-gb
72M1.0-0000-00072
ELECTRICS
Programmer The programmer is connected to the controller by a

cable, thus powered by the controller.
General
CAUTION
The optional programmer, Crown P/N 793548, enables
programming, testing and diagnostics for the controller. Only connect / disconnect the programmer
to the controller when the truck is switched
off.
M0271-neu
Display Window
● Alpha-numeric LCD display
● 2 lines @ 16 characters
1 3 5
ROLL ENTER PARAM
ROLL OUT SET Operating Keys
2 4 6
M0274-neu
M1.0-0000-00073
73
ELECTRICS
Description of Keys
Key Designation Explanation
1 ROLL up Selects the next sub-menu or an option.
2 ROLL down Selects the previous sub-menu or an option.
3 ENTER Enters the main menu. Stores the pin configuration.
4 OUT * Quits a sub-menu or an option. Step by step return to the main menu.
5 PARAM SET UP Increases setting values or selects configuration.
6 PARAM SET DOWN Decreases setting values or selects configuration.
* You can undo a change by switching the truck off and on again. The controller will be reset to the output values,
as long as you have not safed the settings before.
E05-GB
Operating SEM0 Controller Menu

General
When the programmer has been connected a self test
start routine is performed. The software version of the
controller (e.g. V2.02), the rated voltage and the rated
current are now displayed.
When it is complette, use the ROLL up/down and

ENTER keys to select the required menu.
74M1.0-0000-00074
ELECTRICS
Operating Menu - Overview
STARTROUTINE
PARAMETER TEST ALARMS PROGRAM VACC CONFIG

CHANGE
ACCELER DELAY BATTERY VOLTAGE

CODE VACC SETTING
DECELER DELAY MOTOR VOLTAGE
H, N°, °C
RELEASE BRAKING MOTOR CURRENT
INVERSION BRAKING FIELD CURRENT
CUTBACK SPEED VMN
OVERRIDE TEMPERATURE
MAX SPEED FORW ACCELERATOR
MAX SPEED BACK FORWARD SWITCH
CREEP SPEED BACKWARD SWITCH
HANDLE/SEAT
SWITCH
QUICK INVERSION
LOW PERF. SWITCH
CUTBACK SWITCH
BRS SWITCH
BATTERY CHARGE
SET MODEL SET OPTIONS ADJUSTMENTS
SX YES/NO HOURS: RUNNING / KEY ON ADJUST BATTERY

QUICK INVERSION: BELLY /
TIMED
Menu Functions
PARAMETER CHANGE PROGRAM VACC

In the PARAMETER CHANGE menu the listed truck In the PROGRAM VACC menu item the traction
parameters can be read and set in real time. potentiometer is calibrated. The traction controller
reads and records the potentiometer's minimum
TEST and maximum output voltage.
In the TEST menu the listed truck parameters CONFIG

can be activated, checked and set in real time.
The Configuration menu is used to set the operation
ALARMS of the hourmeter and the safety reverse switch.
In the ALARMS menu error messages generated In addition, the "Adjustments" sub-menu allows for
and stored during operation can be called up and calibration between the battery voltage measured
processed. by the controller and the actual battery voltage.
The SX parameter in the SET MODEL sub-menu is

reserved for future use and must remain set on SX =
NO.
M1.0-0000-00075
75
ELECTRICS
Settings and Alarms
PARAMETER CHANGE Menu
Recom-
Setting
Menu item mended Description
range
setting
Acceleration delay. The time taken for the traction controller to

1.15 - 3.00
ACCELER DELAY 0 increase the output supply to the traction motors from 0 to 100%
sec
(when transmitter (butterfly switch) suddenly set to limit).
Time taken to reach the new set value when the set value on the
DECELER DELAY 9-0 0 transmitter is changed. Corresponds to the braking intensity when
the transmitter is returned.
Release braking. Activated when the accelerator pedal is released

RELEASE BRAKING 0-9 3 or when it returns to neutral. Time taken for the motor current to
fall to zero.
Inversion braking. Activated when transmitter (butterfly switch) is

INVERSE BRAKING 0-9 9 set to the opposite direction. Time taken for the motor current to
fall to zero.
A lower value reduces the time taken for inverse braking to
AUX TIME DELAY 0-9 1 activate when changing from one direction to the opposite
direction.
Maximum current (= speed) for the low speed range selected by the
fast / slow speed switch (HSS) (in % of max. current ACC for fast
30 - 100
CUTBACK SPEED 7 speed (= normal)). Again, the entire mechanical control range of the
% ACC
transmitter is available. Enables more sensitive travelling at reduced
speed.
10 - 50 Max. travel current (= speed) in special travel zone (see section

OVERRIDE 2
% ACC M4.2).
Max. forward speed: this value determines the maximum traction

motor current during forward travel.
When the armature voltage has been fully absorbed by the
100 - 58
MAX SPEED FORW 6 controller, the speed is increased by weakening the field current.
% FCN
If the value is set to 0 the field current will not fall below the
nominal value (FCN = field current nominal) when the armature
voltage is fully absorbed.
Max. reverse current: this value determines the maximum traction

motor current during reverse travel.
When the armature voltage has been fully absorbed by the
100 - 58
MAX SPEED BACK 6 controller, the speed is increased by weakening the field current.
% FCN
If the value is set to 0 the field current will not fall below the
nominal value (FCN = field current nominal) when the armature
voltage is fully absorbed.
Creep speed. Setting for the minimum voltage applied to the

traction motor when the travel switch is closed.
5 - 14 This function should be set to one level below the value at which
CREEP SPEED 3
% V Batt. the truck begins to travel.
This ensures that the empty run of the transmitter (butterfly switch)
is kept to a minimum.
E06-GB
76M1.0-0000-00076
ELECTRICS
TESTER Menu
The following table describes the various truck param-
eters which can be selected and checked in the
TESTER menu.
TESTER Menu
Menu Item Description
BATTERY VOLTAGE Battery voltage measured at key switch input.
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
MOTOR CURRENT Current received by motor armature.
FIELD CURRENT Current received by field coil.
Measures the current between VMN (Volt Motor Negativ) and -BATT.
VMN
The reading indicates the potential difference over the controller power par t.
TEMPERATURE Controller temperature, measured at the aluminium base plate next to the MOSFETs.
Displays the nominal signal of the traction potentiometer. The left hand side displays
ACCELERATOR the voltage reading, the right-hand side the percentage relating to the maximum
operating signal calibrated via PROGRAM VACC.
Tests the operation of the "Forward" (FS) switch.

FORWARD SWITCH
Displays the open (OFF) and closed (ON) status.
Tests the operation of the "Reverse" (RS) switch.

BACKWARD SWITCH
Tests the operation of the "Override" (ORS) switch.

HANDLE/SEAT SWITCH
Tests the operation of the "Safety Reverse" (FS) switch.

QUICK INVERSION
Zero function, as the switch is not present on the truck.

LOW PERF. SWITCH
Control logic input is bridged.
Tests the operation of the "Fast / Slow" (FS) switch.

CUTBACK SWITCH
Tests the operation of the "Brake" (BRS) switch.

BRS SWITCH
BATTERY CHARGE Displays the battery charge status as a percentage.
E07-GB
M1.0-0000-00077
77
ELECTRICS
ALARMS Menu
The traction controller can collect and store operational
faults during operation. The last 5 error messages are
stored together with the following information:
● Type of error
● Error frequency
● Hourmeter status
● Power part temperature
The ALARMS menu can be used to call up and read

the respective fault codes.
ALARMS Menu
Error Message Description Possible Cause
Main contactor drive test error during auto- Control logic error.
LOGIC FAILURE #1
diagnostic function on truck power-up. Replace logic system.
Watchdog circuit (hardware) or

Error in auto-diagnostic function performed during
WATCH-DOG program (software) faulty. Replace
truck power-up, when parked and during travel.
logic system.
Turn key switch off and on again. If

Error in non-volatile memory area where the error persists, replace the logic
EEPROM KO hourmeter, error message and truck parameter system. If the error is removed,
data is stored. make sure that all the stored data is
deleted and reset to a default value.
Start sequence incorrect. The following sequence - Travel direction switch (FS/RS) or
must be maintained: Override switch (by moving multitask handle switch jammed.
INCORRECT START the multitask handle from idle to travel position), - Wiring error.
followed by travel switch (by pressing the butterfly - Incorrect start sequence entered
switch). by user.
- Wiring error.
- Travel direction switch jammed.
Test is performed constantly and checks whether
FORW + BACK - Incorrect start sequence entered
both travel directions are applied simultaneously.
by user.
- Tiller main board faulty.
Test during auto-diagnostic function on power-up. If

the capacitors have not started to charge 500
- Armature power cable wiring error
CAPACITOR CHARGE metres after turning the key switch, an error
- Faulty controller.
message appears and the main contactor does not
close.
E08-GB
78M1.0-0000-00078
ELECTRICS
ALARMS Menu (Contd.)
Test performed in idle mode with the main

contactor closed and during travel.
- Motor cable wiring error.
The error message appears when VMN
VMN NOT OK - Motor loss to ear th.
- is below the battery voltage when truck is idle
- Power par t error.
- does not comply with power when truck is
travelling
- Motor loss to ear th.

Test performed when truck is idle and main
- Motor field connections not connected
contactor open. The error message appears if
VFIELD NOT OK or incorrectly connected to controller.
approx. 50% of the battery voltage is not
- Error in power par t field controller
applied to the field connections.
range.
- Broken potentiometer cable.

Test performed during auto-diagnostic function
- Wiring error.
on power-up and when truck is idle. The error
- Potentiometer faulty.
VACC NOT OK message appears if the potentiometer signal
- Tiller main board faulty.
deviates by more than 2 volts from the stored
- PROGRAM VACC not performed or
minimum value.
incorrectly performed.
Test performed constantly and monitors the -Potentiometer connections not wired or
PEDAL WIRE KO traction potentiometer and its wiring. Error interrupted.
message appears for broken wires. - Tiller main board faulty.
- Faulty current sensor

Test performed during auto-diagnostic function (replace controller).
STBY I HIGH on power-up and when truck is idle. The error - Back coupling, logic system or power
message appears if a current flow is detected. par t error (replace component or entire
controller).
- Insufficient motor contact (check

carbon brushes).
Test performed during travelling. The error - Faulty current sensor
I = 0 EVER message appears if the traction current does (replace controller).
not exceed a given minimum value. - Back coupling, logic system or power
par t error (replace component or entire
controller).
E09-GB
PROGRAM VACC Menu
The PROGRAM VACC sub-menu enables each
traction potentiometer to be calibrated individually for
each truck by taking and storing the minimum and
maximum output voltages of the traction potentiometer.
The minimum output voltage is read as the travel

switch is closed, the maximum output voltage when the
travel switch is fully applied (rocket switch at limit). This
ensures that the full physical path of the potentiometer
is used.
Approx. 14V is applied to the travel switch via the

traction controller. The signal range used by the
potentiometer is from 0V (minimum speed) to 10V
(maximum speed).
M1.0-0000-00079
79
ELECTRICS
ALARMS Menu (contd.)
- Main contactor jammed (check

Test performed during auto-diagnostic function on
contacts, if necessary replace
power-up.
contactor).
CONTACTOR CLOSED The motor field is energised before the main
- Faulty field circuit (check field coil
contactor is applied. The error message appears
and field cable operation and
if the power capacitors do not discharge.
connections).
- An error message appears if the controller

temperatue exceeds 80°C. The maximum current
- Excessive ambient temperature.
is reduced in propor tion to the rise in
- Temperature sensor faulty (replace
temperature. At 90°C the system automatically
controller).
cuts out.
TH PROTECTION - Faulty logic (replace logic system.)
- If the temperature falls below -10°C, the
- Insufficient heat transfer (check
maximum current is reduced to 80%.
mounting bolts and the rest of the
- If the error message appears in the normal
system).
temperature range, this indicates an error in the
controller.
- Less than 63 % of the battery

An error message appears if thebattery voltage
voltage is applied to input A2 after the
falls below 63% of the nominal value.The
key switch is applied.
ccurrent is reduced in propor tion to the potential
Wiring problem: poor contact,
difference. At 43% of the nominal value the
BATTERY LOW additional consumer, cable too long,
system automatically cuts out.
small diameter etc.
- If the error message appears at a battery
- Microprocessor error or battery
voltage above 63%, this indicates an error in the
current measurement error (replace
controller or the wiring.
logic system).
- Field current measuring error

(replace controller).
HIGH FIELD CURR, Test performed constantly and checks the field
- Field cable not connected.
NO FIELD CURR current.
- Power par t error (replace
component or entire controller).
- Contactor coil shor t-circuited, not

connected or incorrectly connected
CONTACTOR DRIVER; - Contactor drive opened or shor t-
Tests the main contactor circuit.
COIL SHORTED circuited (replace logic system).
- Voltage feedback error to contactor
driver (replace logic system).
E10-GB
80M1.0-0000-00080
ELECTRICS
Calibrating the Traction Pod ● The display shows the new minimum and
maximum value and an arrow for the selected
Potentiometer, PROGRAM VACC menu travel direction.
It is always necessary to calibrate the traction pod ● Press OUT when you are ready.
potentiometer when:
● The display asks “Are you sure?” If you wish to
● the traction pod potentiometer has been replaced store the new readings, press ENTER. If not,
or, press OUT.
● the traction controller has been replaced. ● Press OUT to quit the VACC menu.
With the WP2300 there is no need to physically adjust

the potentiometer and the travel switch as is the case
with the WP2000.
Preparatory Measures
● Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1).
● Connect the programmer to the traction

controller.
● Power up the truck.
Calibration
● Press ENTER on the programmer.
● Using the ROLL UP and ROLL DOWN keys scroll

through to the PROGRAM VACC menu.
● Press ENTER to select the calibration routine.
● The display shows the stored minimum and

maximum voltage of the potentiometer. An arrow
in the display indicates the travel direction to
which the values are assigned. Arrow up =
Forward. Arrow down = Reverse.
If you move the travel switch in the corresponding
direction you can change the display accordingly.
● Press ENTER to delete the stored values. The

display now shows 0.00 for the minimum and
maximum values.
● Pull the tiller to the travel range (brake released)

and press the travel switch slowly in the forward
direction until it reaches the stop.
● The display shows the new minimum and M1610

maximum values and an arrow for the selected
travel direction.
● Pull the tiller to the travel range (brake released)

and press the travel switch slowly in the reverse
direction until it reaches the stop.
M1.0-0000-00081
81
ELECTRICS
CONFIG Menu ADJUSTMENTS

The CONFIG menu provides access to the SET OP- In the menu item ADJUST BATTERY you can adjust
TIONS, ADJUSTMENTS and SET MODEL sub-menus. the battery voltage measured by the controller to give
the actual battery voltage.
SET MODEL
Using a digital voltmeter measure the battery voltage
WARNING directly at the battery. Adjust the voltage shown in this
menu until it matches the voltage measured directly at
This menu item provides options for future the battery.
use. Do not change the default settings (SX
= NO).
● This would result in incorrect standard
settings being loaded. This would change
the truck operating characteristics and
could cause accidents.
SET OPTIONS
See Table E11-GB for a description of the parameters.
The standard setting for HOUR COUNTER is “RUN-
NING”. For QUICK INVERSION the “BELLY” setting.
CONFIG Menu
Sub-Menu Option Description
This parameter is reserved for future use. Do not change this

SET MODEL SX YES/NO
parameter. SX = NO must be set.
Determines the operation of the hourmeter in the traction

HOUR COUNTER: controller. The following options are available:
KEY ON / RUNNING - KEY ON: Counts the hours while the truck is switched on
- RUNNING: Counts the hours while the traction motor is applied
SET OPTIONS
Determines the operation of the reverse safety switch (belly
switch):
QUICK INVERSION: - BELLY: Truck travels in opposite direction while the safety
BELLY / TIMED reverse switch is applied.
- TIMED: Truck travels in opposite direction while the safety
reverse switch is applied, however, only for 2 seconds.
Adjusts the battery current measured by the controller to the

ADJUSTMENTS ADJUST BATTERY actual battery current. This can be necessary for example in the
event of a relatively high voltage potential on the key switch.
E11-GB
82M1.0-0000-00082
ELECTRICS
Traction Controller Safety Test ● Attach test lead to F1 (item 2).
The traction controller safety test takes the form of a ● Power up the truck.
Pulse Monitor Trip Test (PMT). The programmer should display VFIELD NOT OK.
Activating the transmitter should have no effect.
In accordance with EU Norm PREN 1175-1 the
following test must be carried out to check the fuse ● Switch off the truck and remove the test lead
circuit. from F1 (the other end remains connected to -
BATT).
The test requires a test lead of approx. 1 mm2
diameter and a 10A fuse. ● Attach test lead to F2 (item 3).
● Switch off the truck and jack it up. ● Power up the truck.
The programmer should display VFIELD NOT OK.
● Connect one end of the test lead to -BATT. Activating the transmitter should have no effect.
● Connect the other end of the test lead to VMN ● Switch off the truck, remove the test lead com-
(item 1 in Fig. 805980_6). pletely, remove the programmer.
● Connect the programmer to the traction control- ● When the truck is switched on again and the
ler. transmitter activated, the traction motor should
start.
● Power up the truck.
The programmer should display CAPACITOR ● If the test proves unsuccessful, replace the
CHARGE. Activating the transmitter should have traction controller.
no effect.
● Switch off the truck and disconnect the test lead

from VMN (the other end remains connected to
-BATT).
Test lead
1
FU 10A
2
3
Traction Controller
+BATT VMN F1 F2 -BATT
A2 F2 F1
A1
TM
Line
+ -
P
PM
FU1
125A
BD:1 24V BATT. BD:2
805980_6
M4.20-1720-001 M1.0-0000-00083
83
84
ELECTRICS
Battery Battery Discharge Indicator (BDI)

WARNING
General The following setting and calibration
The battery condition has a considerable impact on the instructions for the BDI apply only to wet
performance of the truck. Effective maintenance will batteries.
maintain the performance levels and lifespan of the ● For maintenance-free batteries follow the
battery. manufacturer's instructions regarding the
discharge terminal voltage.
WARNING
General
The battery must be serviced solely in
accordance with the battery A battery from the factory will require approx. 5 - 10
manufacturer's instructions. charge and discharge cycles to reach its full capacity.
● Incorrect or inadequate maintenance will
initially reduce the performance of the A battery is considered to be technically discharged
truck and ultimately result in premature when it has reached 20% residual capacity. For
failure of the battery. example, a battery with a 500 amp hour capacity has
an actual available output of 400 amp hours.
It is essential to adjust the battery discharge indicator
(BDI) correctly to ensure on the one hand that the In addition, the effective output will depend on the
battery is not fully discharged and on the other that discharge speed, which in turn is affected by the
there is maximum battery capacity available for the particular truck application.
task in hand.
The battery discharge indicator must therefore be set
Replacing the battery in accordance with the truck's particular application
conditions.
WARNING
The battery discharge indicator controls the lift cutout
Only use batteries of the permitted size, system. The lift cutout system is designed to prevent
weight and specifications for this truck. the battery from being operated to the point where is
● An incorrect battery type can cause fully discharged.
damage to the truck.
If the battery is constantly discharged to below 20% of
● An incorrect weight and size will alter the residual capacity it will be damaged.
centre of gravity of the truck, potentially
resulting in accidents. If the lift cutout system is activated above 20% of the
battery's residual capacity the battery will not be
There are several different battery compartment damaged, but the truck's maximum operating time
versions. Refer to the truck operator manual to under a single battery charge will not be attained.
battery replacement instructions.
The operator manual contains the latest safety The lift cutout system should therefore be activated as
instructions and information. close to 20% of the battery's residual capacity as
possible. If at all, it may be slightly above 20%, but
never below.
NOTE
For new trucks the battery discharge
indicator should be set at the latest after
ten discharge and charge cycles.
M1.0-0000-00085
85
ELECTRICS
Battery Discharge Indicator Setting to check if the battery is actually 100% charged.
Faulty battery cells will make calibration impos-
(BDI) sible.
The acid density is a very reliable indicator of the ● Operate the truck as usual under normal
charge status of a lead acid battery. However, since it operating conditions until the battery is empty:
is unrealistic to continually measure the acid density of both LEDs of the BDI will flash and the lift cutout
a truck battery to an industrial standard, the battery system will be triggered.
voltage is used to determine the charge status over
longer journeys. ● Leave the battery for at least 10 to12 hours (one
hour at the very minimum!).
To adapt the BDI to the battery used and the truck's
specific application profile, you need the battery ● After this interval measure the acid density on at
manufacturer's data sheet. The values you require are least three different battery cells. The smallest
the density of the electrolyte for an 80% discharged recorded value is the one you need.
battery (20% battery residual capacity) and for a fully
charged battery (100% battery capacity). ● Compare the recorded density with the density
specified by the manufacturer for an 80%
Finally, via the potentiometer on the back of the BDI discharged battery (20% residual capacity).
the display is set to the actual discharge terminal
voltage of the battery at 20% residual capacity. ● If the battery is more than 80% discharged (less
than 20% residual capacity), set the
The factory default setting of the battery discharge potentiometer on the back of the BDI to direction
indicator is "N" (any setting from K to U is possible). K.
Calibration ● If the battery is less than 80% discharged (more

than 20% residual capacity), set the
● Fully charge the battery as indicated by the potentiometer on the back of the BDI to direction
battery manufacturer in the operating instructions. U.
Measure the acid density in accordance with the
battery manufacturer's maintenance instructions ● Charge the battery again and then check the
calibration.
Discharge Terminal Voltage Setting in Volts/Cell
K L M N O P Q R S T U
1.57 1.63 1.68 1.73 1.78 1.82 1.84 1.86 1.89 1.91 1.93
E20-GB
86M1.0-0000-00086
ELECTRICS
Third Phase (U)
On Board Charger
Note: This charger is intended solely for use with In the third phase (U) the charging current is kept
open lead acid batteries (wet batteries). constant. The output voltage of the charger is restricted
to 29 volts. During this phase the charging current
WARNING drops increasingly. (The yellow LED flashes rapidly.)
Fourth Phase (I2)

The charger cannot be repaired in the field.
Attempting to make repairs can result in
The fourth and for normal charges last phase (I2) is
accidents caused by electric shock and
again a charge with constant current until the gassing
fire.
voltage stage is reached. The amount of constant
● Replace the charger where necessary current used to charge is calculated from the charge
with an original Crown replacement consumed by the battery during the first two phases (I1
charger. and P).
General The duration of this phase is set to reach 17% of

Please read this paragraph carefully. It contains capacity (= Boost - factor 1.15) consumed by the
important information on the operation of the battery during the first three phases (I1, P and U). The
charger. You must understand how the charger charging voltage is restricted to 34 volts. (The yellow
operates in order to correctly assess any problems LED flashes slowly.)
which may occur when charging the battery.
End of Normal Charging
This charger is an "intelligent" device. A
microprocessor controls the charging by taking into Normal charging is completed at the end of the fourth
account the charge status of the battery. phase. (The yellow LED is off)
A complete charge cycle consists of several phases, The battery is now fully charged and the total battery
indicated by a yellow LED. A green LED indicates the capacity can be used.
presence of the mains supply.
Special Charging Phases
Both LEDs are located on the instrument panel next to
the socket to protect the mains lead. Compensating Charge
For instructions on compensating charging, in

Battery Charging Phases
particular charging intervals, please refer to the
The charge cycle begins with connection to the mains battery manufacturer's documentation
supply. The green LED is permanently lit.
If the charger remains connected to the mains at the
First Phase (I1) end of a normal charge, 15 minutes after Phase I2 a
compensating charge will begin with half the constant
The first phase (I1) is a charge with constant current used during phase I2. (The yellow LED flashes
(maximum possible) current. This phase lasts until the either regularly or intermittently.)
battery voltage > 24 volts. (The yellow LED is
permanently lit.) The compensating charge reduces the problem of
sulphating and the cell voltage of the 12 battery cells is
Second Phase (P) compensated to 2 volts / cell.
In the second phase (P) the charging capacity (product This phase ends when the battery voltage is stable, i.e.
of charging current and charging voltage) is kept changes by less than 60 mV/h.
constant. In addition the charging current is reduced in
proportion to the increasing battery voltage. This phase
ends when the battery voltage reaches a certain level.
(The yellow LED is permanently lit.)
M1.0-0000-00087
87
ELECTRICS
Float Charge Charging Errors
If the charger remains connected to the mains after the Green LED is not lit
compensating charge, 48 hours later the charge
recommences with the first phase (I1). As the battery Possible Causes:
however is still full, the individual charging cycles are Socket does not conduct mains voltage
severely reduced, and the first phase (I1) is even Check whether the socket conducts voltage by
bypassed if the battery voltage has not fallen below 24 plugging in an item of equipment (e.g. lamp etc.) which
volts. you know is working.
The float charge ensures that the battery can be used Faulty mains lead to charger
even after long periods of inactivity. (The yellow LED Temporarily replace the mains lead to the charger with
flashes regularly or intermittently.) one which you know is ok. When you finally replace the
mains lead avoid damaging the lead when fitting the
Partial Charging clamp.
The charger is designed to adapt to all discharge Faulty Charger

conditions of the battery and all typical partial charge Replace the charger.
cycles. It uses an "occasional charging" feature. The
electronic system takes into account these partial
charges and adjusts the current in the fourth phase (I2) Green LED flashing
accordingly.
In this case an error has occurred during charging. The
If charging is interrupted by the user (mains connector charging time in phase I1 or P is too long (time limit
removed) and if the mains connector is re-inserted exceeded).
within 13 minutes, it then continues at the point at
which it was interrupted. Possible Causes:
The charger stores the capacity charged into the One or more battery cells faulty
battery up to the interruption for 13 minutes and Repair the battery in accordance with the battery
calculates a correction value which ensures that the manufacturer's instructions.
capacity subsequently removed from the battery is re-
charged. The ambient temperature is too high. The charger
automatically reduces the output capacity in order to
If the mains interruption lasts for more than 13 minutes, avoid a thermal overload. When the ambient
the charging process will start again with phase 1. temperature is too high the charging current is
reduced, which can lead to time limits being exceeded.
Also check whether the fan starts up when the mains
lead is connected. The air inlet and outlet of the
charger must not be covered.
Error in charger microprocessor. Reset the

microprocessor as follows:
Charging Phases
Tstop= Compensat- Tstop= Float
Phases I1 and P U1 I2 U2
15 Min ing Charge 48 h Charge
Error Stop
Disconnec-
Mains Mains plug connected
ted
Fan On Off On Off On Undefined Off
Green
Permanently on Flashes Off
LED
Yellow Permanen- Intermittent As for I2
Rapid flash Slow flash Off Off Undefined Off
LED tly on flash and U2
E21-GB
88M1.0-0000-00088
ELECTRICS
● Remove the mains plug and disconnect the Charger safety class: IP20
battery.
Ambient temperature: 0 °C to +40 °C
● Disconnect the charger connections to the earth
contact or the pump contactor and fuse F1 and Air humidity: 90% relative, not condensing
short-circuit the two leads of the charger.
Alternatively, wait 10 minutes. Then re-connect Replacing the Charger
the charger lead to the battery.
WARNING
● Re-connect the mains plug.
Do not reverse the battery connection
● Check that the green LED is permanently lit and wires
the charger fan is running.
● If you reverse connect the charger wires to
● If the green LED is not lit and/or the fan is not a battery, the minimum damage you will
running, replace the charger. incur is a blown internal fuse.
This fuse can only be replaced by the
Important: Before replacing a charger, always manufacturer. Replace the charger where
check whether the malfunction is due to a necessary with an original Crown
temperature problem or the battery. replacement charger.
Faulty battery cells of poorly serviced batteries or Removal / Installation

charger ambient temperatures above 40 °C are
typical causes of faults. ● Remove the mains plug and disconnect the
battery.
Take into account the fact that the charger emits
heat (the temperature of the airflow extracted by ● Undo the mains supply lock on the charger and
the on-board fan is 20 °C above ambient remove the connector.
temperature). This heat loss also heats up the
environment if the ventilation is inadequate. ● Disconnect the charger connections to the earth
contact of the pump contactor and fuse F1.
If the temperature and battery can both be safely
ruled out as possible causes, reset the ● Disconnect the plug connection of the 3 wire lead
microprocessor and check if it is possible to to the LEDs.
charge.
● Remove the 4 screws which attach the charger to
Important Technical Data the retaining plate and remove the charger.
Mains voltage: 230 V +10% / -15% ● Installation is the reverse order of removal.
Mains frequency: 50 - 60 Hz + /-1%
Output capacity: 720 W + /-3%
● Can be used for open lead acid batteries with 12

cells and a cell voltage of 2 volts (24 volt battery)
● Minimum battery capacity 160 Ah
● Maximum battery capacity 300 Ah
The maximum charging time at room temperature for

an 80% discharged battery is:
● 15 h for a 300 Ah battery
M1.0-0000-00089
89
Printed in Germany
90
ELECTRICS
In this case replace all brushes as they will
Electric Motors probably have been thermally overloaded.
Thermal overloading (temperatures >160 ºC)
General Maintenance Instructions causes the brushes to swell up.
Brushes which jam in the brush support produce
The following instructions apply to all motors. Details intense sparking and destroy the collector.
relating to specific models and designs are provided in
the sub-sections (traction motor, pump motor etc.). ● The brush edges must not be cracked. Brushes
with cracking along the long edge of the surface
Preparation will have been damaged by a worn collector.
If information is provided in the manual, restore
● Disconnect the battery (= EMERGENCY the collector to the specified limits. Otherwise,
DISCONNECT). replace the armature in full.
● Secure the truck from rolling away. ● Loose brush connections are a clear sign of
motor overload. In this case inspect the collector
Important Maintenance Instructions for burning and repair or replace as necessary.
● Remove all carbon brushes and check for wear.
● When fitting the brush take care to place the
If one or more carbon brushes need to be
spring gently on the brush. If the contact is too
replaced, replace all brushes. In addition to the
hard the brush will be damaged.
carbon brushes the pressure springs must also
be replaced to ensure the correct pressure.
● Make sure that all brushes contact the armature
The length of the shortest brush determines at the same pressure.
whether the brush set needs to be replaced.
● New brushes must be run in with a medium load
Even if the minimum length has not been in the first hours. Never fully charge the motor
reached the brushes should be replaced as the straight away.
remaining useful life could be much shorter than
the time until the next inspection:
If a brush is too short the spring will lie on the

brush support. The brush sparks during
operation and burns the collector with
corresponding damage.
● Blast the motor with dry compressed air only.
● Check the armature for uneveness, burning,

grooves and cracking of the multi-plate edges.
Turn the armature if necessary. A non-oily,
evenly distributed layer on the brush surfaces is
normal.
● If oil or grease is found in the motor collector

compartment (usually a paste consisting of oil,
oil vapour, dust and carbon particles),
immediately remove the cause and clean the
motor thoroughly:
Oil or grease burns in the brush sparks and

leaves behind a highly abrasive oil ash which
can very quickly destroy the collector and the
brushes.
● The brushes must be able to move freely in the

brush support (without spring tension) without
tilting. Never modify brushes if one or more
brushes cannot move freely.
M1.0-0000-00091
91
ELECTRICS
Traction Motor Maintenance
Access to Brushes
Battery connector
M1460
Carbon brush
Armature
● A new armature has a max. diameter of 53.3 mm.
MS1723-016 ● The armature can be overwound provided the

diameter is no less than 51.8 mm.
Traction Motor ● The armature must be replaced if the diameter is

Tensioning Belt 49.5 mm or less.
● Disconnect the battery ● After overwinding cut the mica down to at least
0.5 mm below the multi-plates without changing
● Prevent the truck from rolling away. the gap width between the multi-plates.
● Remove the tensioning belt from the motor. ● The multi-plate edges must be carefully de-
burred.
Maintenance
Bearings
● Apply dry compressed air to the motor.
● The ball bearings are maintenance-free. They
● Remove all carbon brushes and check them with must always be replaced if removed for repair
the armature in accordance with the instructions work.
in "Key Maintenance Instructions".
● A new carbon brush is 28 mm long
● Carbon brush wear limit: 15 mm
● Refit the tensioning belt.
92M1.0-0000-00092
ELECTRICS
Pump Motor Maintenance Maintenance

● Apply dry compressed air to the motor.
Access to brushes
● Remove all carbon brushes and check them with
the armature in accordance with the instructions
Battery Connector
in "Key Maintenance Instructions".
● A new carbon brush is 20 mm long
● Carbon brush wear limit: 10 mm
Armature
● A new armature has a diameter of 40 mm. The
wear limit is 38.3 mm.
● The armature must not be overwound. Instead it
must be replaced when the wear limit is reached.
Refit the hydraulic unit as described in CHAPTER 2.
MS1723-016
Pump motor
commutator bearing lid
Hydraulic unit
attachment
● Disconnect the battery
● Prevent the truck from rolling away.
● Remove the hydraulic unit as described in

CHAPTER 2.
● Unscrew the commutator bearing lid and remove

the insulating protective cap.
M1.0-0000-00093
93
Printed in Germany
94
BRAKE
Printed in Germany
95
Printed in Germany
M1.0-0000-00096
96M1.0-0000-00096
BRAKE
Brake
Operation
The drive motor contains the drive wheel brake in the
form of a disk brake.
The assembly is shown on page 5.6-1720-001 in the
spare parts manual.
The brake interlocks with the motor shaft. When the

truck is de-energised the brake is applied. If the truck
must be moved in this case the brake can be mechani-
cally released by turning the two cheese head screws.
However, afterwards you must always return them to
their original position! Before operating the truck again,
make sure that it cannot be moved.
The brake is electro-magnetically released. The axial M1462

force generated by compression springs acts on the Mounting screws Screws for mechanical re-
moving anchor disk. The rotor has a friction lining on (hex. head) leasing of brake
both sides and also moves axially. The force acting on
(cheese head screws)
the anchor disk jams the rotor between the anchor disk
and the friction plate. When DC voltage is applied to
the coil a magnetic force acts on the anchor disk. The
anchor disk is pulled against the compression springs.
The rotor is no longer jammed, i.e. the brake is
released. ● Remove magnetic body (3) from motor (including
everything connected to it).
Removal
● Remove rotor (7) from hub (5) while taking care
The item numbers in brackets refer to Figure M1441 not to damage the toothing.
on the next page.
● Measure the thickness of the rotor. Replace the
● Unplug the battery connector (=Emergency rotor if the minimum thickness of 5.5 mm is
Disconnect). exceeded.
● Secure the truck to prevent it from rolling away. ● Remove the friction plate (9).
● Remove the front panel. ● Unscrew the chees head screws (see Fig.
M1462) from their nuts.
● Remove the rubber cover ring (8) from the groove
in the magnetic body. ● Unscrew banjo bolts (2) from the magnetic body
(3 off).
● Remove any abrasion dust.
● Remove anchor disk (6).
● Unplug the electric connections from the mag-
netic body (3). ● Thoroughly clean components.
● Loosen the three mounting screws ● Check anchor disk (6), friction plate (9) and rotor
(see Fig. M1462). (7) for even wear, grooves, cracks and burning, if
necessary replace components.
CAUTION
Do not allow the striking surfaces to come

into contact with grease or oil.
MS-WP2300-F 04/03 • Printed in Germany MS-5.0-1723
M1.0-0000-00097
97
BRAKE
M1441
MS-5.0-1723 MS-WP2300-F 04/03 •Printed in Germany
98M1.0-0000-00098
BRAKE
Assembly throughout.
To assemble, proceed in the reverse order. ● To increase the air gap slightly unscrew the hex.
bolts. To reduce the air gap slightly screw the
● If any thrust members (for the three internal banjo bolts into the magnetic body. Then proceed
compression springs) have fallen out of the as described above.
magnetic body, insert them correctly with the end
face facing the spring. ● When the air gap has been correctly set, torque
the hex. bolts to 6 Nm using a torque wrench.
● Place the anchor disk correctly on the magnetic
body: thefriction plate must lie on the side facing Brake Moment Setting
away from the magnetic body.
The brake moment can be increased by screwing the
● Screw the banjo bolts into the magnetic body as adjusting ring (1) into the magnetic body. The setting is
far as the stop. notched.
● Screw the cylinder bolts into their nuts so that Testing the Brakes
there is a gap of at least 1mm between the
anchor disk and the magnetic body. ● Accelerate the unladen truck with completely
loaded battery at operating temperature on an
● Place the friction plate on the motor. even, dry concrete surface until it reaches
maximum speed.
● Push the rotor onto the hub while taking care not
to damage the toothing. ● Set multi-task handle to lower brake zone.
● Attach the magnetic body and everything con- ● Measure the braking distance from the time of
nected to it to the motor with the hex. bolts. application of the brakes to the time the truck
halts.
Air Gap Setting Nominal Braking Distance (unladen)
The working air gap is measured between the magnetic
body and the anchor disk while the brake is applied. Used (braked)
Model New Rotor
It should be set to 0.2 mm. Rotor
The max. permissible setting is 0.55 mm.
2320 0.6 to 0.7 m 0.5 to 0.6 m
● Unscrew the banjo bolts as far as the fixed stop
on the friction plate.
2315 0.5 to 0.6 m 0.45 to 0.55 m
● Tighten the hex. bolts evenly.
B01-gb
● Using a feeler gauge measure the working air
gap at several points. It must be uniform
Mounting screw
Banjo bolt
Working air gap
Rotor thickness
Brake de-energized M1467
MS-WP2300-F 04/03 • Printed in Germany MS-5.0-1723
M1.0-0000-00099
99
100
STEERING
Printed in Germany
101
Printed in Germany
M1.0-0000-000102
102
M1.0-0000-000102
STEERING
Live Ring Bearing ● Using a rubber hammer gently knock the flange
(17) and the drive unit down out of the chassis.
The multitask handle is connected to the drive unit via The lower conical roller bearing together with the
the knuckle and a flange. The live ring bearing is inner ring and the seal (14) remain on the flange.
located between the flange and the truck chassis and
acts as a twin conical roller bearing. It is maintenance- ● Remove the lower conical roller bearing to-gether
free and contains lubricant for lifetime. Fig. M1477 with the inner ring and the seal (14) from the
shows a cross-section of the live ring bearing with the flange.
drive unit disassembled.
● Lift out the upper conical roller bearing together
Disassembly with the inner ring and the seal (14).
The item numbers in brackets refer to the graphics of ● Drive out the outer rings (16) of both bearings
the knuckle in section 3.3 of the spare parts manual. from the chassis.
● Disconnect the battery (emergency disconnect). Installation

● Jack up the truck. ● Prior to installation make sure that the surfaces
are clean and burr-free.
● Remove the front panel and knuckle panels.
● Refit all wire connections without twisting them.
● Remove all 6 mounting screws (12) of the
knuckle (6) and remove the multitask handle and ● Torque the knuckle mounting screws (12) to
its support. Make sure that no wires are damaged 49 Nm.
in the process.
● Disconnect the drive unit wires.
Multitask
Screws (12) Handle
Knuckle (6)
Upper Conical
Roller Bearing Seal (14)
Conical Rollers
with Inner Ring
Outer Ring (16)
Lower Conical
Roller Bearing Flange (17) Truck Chassis
M1477
M1.0-0000-000103
103
STEERING
Multitask Handle - Springs for Adjustment

Return Function The axle (4) is fixed on the left hand side as standard
with a roll pin (5). If the spring pressure reduces with
The 3 springs for return function are located on the time, the springs (2) can be re-tensioned as follows:
rotary axle of the multitask handle. The inner, offset
end of the springs fits in the longitudinal slot of the ● Set multitask handle (1) to zero/rest position (1).
axle.
The external end which is also offset exerts upward ● Drive out the dowel pin on the left hand side.
pressure on the multitask handle.
The springs can be easily accessed for lubrication by ● Drive in the dowel pin on the right hand side by
removing the panel from the knuckle. rotating the axle as far as possible using a face
spanner.
CAUTION
Removal
Do not place your hands inside the multi-
task handle near the rotary axle while the ● Multitask handle (1) in zero position.
springs are tensioned.
● Record the position of the axle.
To prevent injury caused by the vehicle suddenly ● Drive out the roll pin.
moving, in particular when working on the multitask The de-pressurised springs should rotate the
handle support: axle.
● Disconnect the battery (emergency disconnect). ● Set the multitask handle to the lowest position.
● Secure the truck to prevent it from rolling away. ● If the axle has still not turned, it is clearly fixed in
its position and must be moved with the aid of a
The item numbers in brackets refer to the graphic face spanner. Rotate the axle, seen from the left
M1491. hand side, approx. 20° anticlockwise from the
fixed position.
Roll Pin (5) ● Drive the axle as far out to the right hand side so
that the 3 springs can be removed.
R.H.
Side L.H.
Side
Assembly
● Push the 3 springs onto the axle. The inner, offset
end must insert into the axle groove. A strap
Knuckle (6) wrapped around the inner end of the first spring
to be inserted can prove useful when inserting
the other springs.
● Drive the axle into position.
● Set the multitask handle to the upper limit.

Axle (4)
● Using a roll pin fix the axle to the left hand side
(right hand side if necessary). To do this, rotate
the axle as far as necessary.
Control
Handle (1)
Springs (2) M1491
104
M1.0-0000-000104
STEERING
Tiller Handle
Main Components
This is an overview of the main components and their
associated terms:
Upper Shell
Tiller Tube
Switch Unit
Handle
MS518
Lower Shell
M 1 . 0 - 0 0 0 0 - 0 0 0 1 0 105
5
STEERING
Tiller Handle Component Tiller Handle Shells

Removal / Installation Removing the Upper and Lower Shells
To access the various components of the tiller handle
you will need:
A 2, 3, 5, 8 mm Torx® screwdriver and a small

screwdriver with a flat blade.
CAUTION
Danger of short circuiting!
De-energise the truck (disconnect the

battery) and prevent it from being switched
on again.
Unless otherwise stated, all screws must be tightened
with a standard torque. A torque table can be found in
chapter 1 of this manual. A MS513
● Remove the four M5 Torx® screws (A, Fig.

MS513).
B
MS503
MS514
● Press on the thumb markings (A, Fig. MS514) of

the switch unit or pull on the butterfly switches (B).
The switch unit will slide up out of the lower shell.
● Remove the plug connector of the tiller wire

harness and the horn switch from the switch unit
boards.
M
106 1 . 0 - 0 0 0 0 - 0 0 0 1 0 6
STEERING
MS501
● Remove the internal M5 Torx® screws and pull the

handles off (see Fig. MS501).
MS502
● Using a small flat screwdriver lever out the

protective cap from each tiller handle (see Fig.
MS502).
M8
M8
MS503
● Gently press the horn switch inward and pull it out

of the handle (see Fig. MS503). Disonnect the plug
connector from the switch.
MS517
M5
● Remove the two M5 Torx® screws and the six M8

Torx® screws (see Fig. MS517). Remove the
shells.
Fitting the Upper and Lower Shells

Installation is the reverse of removal. When installing,
take care not to damage the wiring.
M 1 . 0 - 0 0 0 0 - 0 0 0 1 0 107
7
STEERING
Switch Unit ● Remove the plug connector of the tiller wire
harness and the horn switch from the switch unit
Removal boards.
The switch unit contains the safety reverse switch, the Switch Unit Installation
travel switch, the "Fast/Slow" toggle switch, the main
board and the pump controller board. Installation is essentially the reverse order of removal.
To replace any one of these components you have to Ensure you re-connect the tiller wire harness and the
disassemble the entire switch unit. horn wiring. The connectors cannot be interchanged and
are reverse battery protected.
Guide the switch unit over the two side sections (C, Fig.
MS514), pushing the switch unit downward and forward
in the process.
Tighten the mounting screws (M5).
After re-connecting the battery test all functions.
A MS513
● Remove the 4 M5 Torx® screws (A, Fig. MS513).

B
MS514
● Press on the thumb markings (A, Fig. MS514) of

the switch unit or pull on the butterfly switches (B).
The switch unit will slide up out of the lower shell.
M
108 1 . 0 - 0 0 0 0 - 0 0 0 1 0 8
STEERING
"Fast/Slow" Toggle Switch Hydraulic Board
There are no parts in this switch module which can be There a no parts in this board which can be repaired. It
repaired. The entire module must be replaced. must be replaced in full.
The switch module comes in two variants: a The board comes in two variants: a standard version
standard version (812943-001) and a cold store and a cold store version. Make sure you use the
version (812274-001). Make sure you use the right right board!
module!
Removal
Removal
● Remove the switch unit (see SWITCH UNIT section in
● Remove the switch unit (see SWITCH UNIT section in this chapter).
this chapter).
MS504
● Remove the two M3 Torx® screws (see Fig.

MS511 MS504) from the smaller of the two boards (the
larger one is the main board). Remove the
● Remove the two M3 Torx® screws (see Fig. hydraulic board.
MS511) and remove the toggle module.
Installation
Installation
● Fit a new hydraulic board (ensuring it is the right
● Fit the new toggle module and fix it with two M3 version, cold store or standard!) and fix it with two
Torx® screws. M3 Torx® screws.
● Re-install the switch unit (see SWITCH UNIT section ● Re-install the switch unit (see SWITCH UNIT section
in this chapter).Carry out a functional test. in this chapter).Carry out a functional test.
M 1 . 0 - 0 0 0 0 - 0 0 0 1 0 109
9
STEERING
Potentiometer
There are no parts in the potentiometer which can be
repaired. It must be replaced in full. The potentiometer
comes in two variants: a standard version and a
cold store version. Make sure you use the right
potentiometer!
Removal
● Remove the switch unit (see SWITCH UNIT section
in this chapter).
MS510
● Remove the two M3 Torx® screws which secure

the orange lower switch cap. Remove the switch
cap.
● Remove the four M5 Torx® screws shown in Fig.

MS509. Remove the switch unit cover.
● Remove the two M3 Torx® screws shown in Fig.

MS510. Remove the connectors from the boards.
Remove the potentiometer from the square axle.
MS508 Installation
● Before connecting the wire to the
potentiometer, pack the potentiometer bush-
● Remove the two M3 Torx® screws (see Fig. ing with grease (part no. 053002-005). Do not
MS508) from the butterfly switches and pull the use any other grease.
butterfly switches off. Take care not to lose the
plastic slide bearings (washers). Installation of the potentiometer is the reverse of
removal.
Note: The butterfly switches cannot be fitted

incorrectly. They will only fit properly in a single
position.
MS509
110
M1.0-0000-000110
STEERING
Safety Reverse Switch
Removal
in this chapter). A
B
C
MS500
● Remove the M3 Torx® screw (item A, Fig. MS500)

and pull out the switch jumper (item B).
MS508
● Remove the two M2 Torx® screws (item C).
Remove the microswitch connector from the main
board.
● Remove the two M3 Torx® screws (see Fig.
MS508) from the butterfly switches and pull the
Installation
butterfly switches off. Take care not to lose the Installation of the safety reverse switch is the reverse of
plastic slide bearings (washers). removal.
● Remove the two M3 Torx® screws which secure ● Before connecting the microswitch to the
the orange lower switch cap. Remove the switch main board, lubricate the microswitch
cap. connector with grease (part no. 053002-005).
Do not use any other grease.
● Re-install the switch unit (see SWITCH UNIT section

in this chapter) and carry out a functional test.
Note: The butterfly switches cannot be fitted

incorrectly. They will only fit properly in a single
position.
MS509
● Remove the four M5 Torx® screws shown in Fig.

MS509. Remove the switch unit cover.
M1.0-0000-000111
111
STEERING
Horn Switch Installation
Removal Note: The switches for the left and right handles are
different. If you fit the switch on the wrong side the
● Remove the switch unit (see SWITCH UNIT section horn symbol will be upside down!
in this chapter).
Fit the horn switch in the reverse order of removal.

MS502

handle protective cap (see Fig. MS502)
MS503
● Simply press the horn switch inward and pull it

out of the handle (see Fig. MS503). Disconnect
the plug connector from the switch.
112
M1.0-0000-000112
STEERING
Handle
Removal
in this chapter).
MS501
● Unscrew the internal M5 Torx® screw (see Fig.

MS501) and pull off the handle.
Installation
Note: The switches for the left and right handles are
different. If you fit the switch on the wrong side the
horn symbol will be upside down!
MS502
Fit the horn switch in the reverse order of removal.

handle protective cap (see Fig. MS502)
MS503
● Simply press the horn switch inward and pull it

out of the handle (see Fig. MS503). Disconnect
the plug connector from the switch (see Fig.
MS503).
M1.0-0000-000113
113
Printed in Germany
114
LIFTING MECHANISM
Printed in Germany
115
Printed in Germany
MM
116 11 . . 00 -- 00 00 00 00 -- 00 00 00 11 1 6
LIFTING MECHANISM
Lift Linkage ● Repeat procedure on second fork tine.
● Measure the fork height above the lift joint pivot

Fork Height Setting point (left hand measuring point in Fig. M1465).
The height should not exceed 83mm.
Note: The item numbers in brackets refer to Figure
M1438 on the following page. ● Measure the fork height at the fork carriage rear
wall (right and measuring point in Fig. M1465).
Carry out the measurement on a level surface (level to The height should not exceed 89mm.
1mm). The measurement on the fork carriage rear wall
must be equal to or greater than that at the fork
● Lower the fork fully. The lifting joint (25) stop tip.
should match the fork tines (see Fig. M1468).
If not, adjust fork height as desribed:
● Raise lifting equipment.
WARNING
The forks must be supported with wooden

blocks or other suitable devices before
carrying out work on or below raised forks.
● Unscrew counternuts (14) from connecting rod.
● Turn connecting rod (13) on hex. head.
● Lower lifting equipment and check lifting joint

stop.
● Repeat the above steps until the stop setting is M1468

right when the fork is lowered.
Lift joint stop Stop points
● Tighten counternuts (14). (both sides)
Lift 130 mm
+3
85-3 mm 85 -3 mm
M1465
M1.0-0000-000117
117
LIFTING MECHANISM
Loadwheel, tandem
M1438
118
M1.0-0000-000118
CYLINDERS
Printed in Germany
119
Printed in Germany
M1.0-0000-000120
120
M1.0-0000-000120
CYLINDERS
Lift Cylinders
Operation
The two lift cylinders are single-acting. The piston rods
are raised by the hydraulic oil pressure and lowered by
the weight of the raised load. Fig. M1475 shows a
cylinder cross-section. Piston Rod
Removal Scraper
● Remove the front panel.
Guide Ring
● Extend the piston rods until the left piston rod
attachment comes to rest next to the contactors
and controller so that the dowel pin can be driven Seal
out.
● Support the fork carriage with wooden blocks or Guide Ring

other suitable parts.
Oil
● Press the "Lower" switch for at least 10 seconds
to de-pressurise the hydraulic system.
Cylinder Tube
WARNING
De-pressurise all hydraulic system compo-

nents before carrying out maintenance
work.
● If pressurised hydraulic oil escapes from
the system it can result in serious injuries.
● If any high-pressure fluid penetrates the
skin it should be treated as an emergency
M1475
even if there are no markings to the skin at
first. Pain will set in later. Damage to the
tissue may result.
● Tighten all connections before re-pressu-

rising the system. Keep hands and feet
away from screw holes as high-pressure
fluids can emerge at these points.
● Use paper or cardboard to trace leaks.
Do not use your hands.
M1.0-0000-000121
121
CYLINDERS
● First drive out the dowel from the left-hand piston
rod attachment between the contactors and
controller so far as to be able to check whether
the pin collides with the contactor or controller
when it is fully driven out.
● De-energise the pump motor and prevent it from

being switched on again.
● Protect the piston rods from scratches where

they have been introduced into the chassis
through the hole by using cardboard or similar
material.
● Drive out the dowel pins from the attachments of

both piston rods.
● Keep pressing on the "Lower" switch until the

piston rods have been lowered into the lift cylin-
ders by their own weight.
● Unscrew the hydraulic connection to the lift

cylinder, collecting any spilled oil.
● Remove the brackets at the lower end of the lift

cylinders.
● Lift out the lift cylinders from the chassis.
M1474
Bracket
122
M1.0-0000-000122
CYLINDERS
Inspection Replacing the Piston Seal
Carefully examine the cylinder unit prior to carrying out NOTE
repair work. To do this, extend and retract the cylinder
several times. Check the seal groove and piston rod
(critical seal location) for damage before
● Check the piston rods for signs of nicks, fitting a new seal.
scratches or other damage to the surface. Failure to do so will otherwise result in
repeated leakage.
● Check the scraper rings for wear and unusual
leakage.
Use burr-free assembly tools and equipment made of
● If any excess hydraulic oil is leaking from the soft metal or a suitable plastic without sharp edges to
piston rod this may be due to a damaged rod replace piston seals. Do not use a screw driver or
seal. Replace the rod seal and make sure that similar tools as these could damage the seal edges.
the seal seat is clean and intact.
If a new seal must be inserted over sharp edges, slots
● When repairing the cylinder check the condition or corners, take appropriate protective measures.
of the guide rings. Ideally, all seal components
should be replaced, not just worn or damaged
seals.
● Minor irregularities on the cylinder tube surface

or the piston rod can be removed with an
aluminium oxide cloth or a honing tool.
● After inspection, clean all cylinder components in

a high grade solvent and dry with a weak stream
of compressed air.
● Gently oil the clean parts and replacement parts

with hydraulic oil before fitting them.
M1.0-0000-000123
123
124
ELECTRICAL DIAGRAMS
Printed in Germany
125
Printed in Germany
126
DIAGRAMS
Overall Wiring Diagram, Standard Version 2913 PC404-3 RAS SIG
LMS
2912
CA 202
1 002 PC415-4 RAS SIG
2914 LOS SIG 2 003 PC415-5 LOS SIG
2902 PC404-2 +BV (AK)
2910 +BV (AK) 3 004 PC415-2 +BV (AK)
A 203 JC404-7 BDI +BV 2906 HNS SIG 4 005 PC410-10 HNS SIGN
1 5900 PC404-1 NOT USED KYS
C
2 2901+BV (AK) 202 KYS COMM +BV UNUSED 5 013 PC415-7 NOT USED
3 101 UNUSED 6 UNUSED
- BR +
202 KYS COMM +BV 4 5901 BATT NEG
-
5 103 JC406-3 ORS SIG
FU2 102 +BV(AK) LINE
10A 6
501 PC404-5 BATT NEG + CA 404
201
7 2907 +BV(AK) CURTIS 900R "BDI"

FU1 LINE 8 2908 JC406-1 +BV (AK) 5900 NOT USED 1 UNUSED
125A 2909 JC406-2 BRS SIG
2902 +BV (AK) 2 2901 4 KYS
2 2910 PC 202-3 +BV (AK)
2913 RAS SIG 3 701
B 2915 RAS SIG 4 2 UNUSED
1 006 PC410-7 POT SIG
POT CIRCUIT 501 A6 BATT NEG 5 501 3 BATT NEG
& 2 007 PC410-8 POT LOW
DRIVER UNUSED 6 UNUSED
3 008 PC410-5 POT HIGH
A1 +BATT
4 009 PC410-4 RS SIG 203 KYS COMM +BV 7 201 1 +BV
BD:1
5 010 PC410-2 SAS SIG
UNUSED 8 UNUSED
6 011 PC410-3 FS SIG
TM
C
+BV (AK)
1 CA 406 RED (unused)
A2
VMN 2 2908 A7 +BV (AK) BLK BRS
1
3 012 PC414-3 R/T (HSS) SIG
2909 A8 BRS SIG 2 WHT
24V
BATTERY 103 A5 ORS SIG 3 WHT
2906 JC 202-4 HNS SIG
TCM SEM0 2911+BV (AK)
+
4 BLK ORS
F2 2915 PC404-4 RAS SIG
F1 RED (unused)
D + -
1 UNUSED
HN CA 411
2 2903 HNS SIG 1
PM CA 410
POT
3 502 BATT NEG 2
+ 001 BATT NEG 1
4 2904 RAS SIG -
P 3
5 503 BATT NEG 010 B-5 SAS SIG 2 4
ACS PN 813533
BD:2 + FS
6 2905 LOS SIG SV - 504 011 B-6 FS SIG 3 5
-
2914 JC202-2 LOS SIG 6

RS
F1 009 B-4 RS SIG 4
F2 7
008 B-3 POT HIGH 5
3 CA 412
BLK
5961 PC415-8 NOT USED 6 3
P GRAY
E 006 B-1 POT SIG 7
1 SAS PN 811935
BLU SAS
1 + RXD 2
2 RXD NEG 007 B-2 POT LOW 8
CA 413
3 + TXD 2962 PC415-1 +BV(AK) 9 CA 417
1
TXD NEG - + 2
4 2 HNS1
005 PC202-4 R/T (HNS) SIG 10 1
5 BATT NEG 3
2904
261 PC415-6 NOT USED 11 2903 HNS1 PN 811932-001
-BATT
6 +BV (AK) 1 4
CA 419
7 UNUSED 2902
5962 PC414-4 NOT USED 12 5 2
2901 HNS2
8 UNUSED 6 1
HNS2 PN 811932-002
MAIN PCB PN 812941
Key:
1 = Diagnostics LED. Remove to CA 415
connect the programmer. 2962 PC410-9 +BV(AK) 1
004 PC202-3 +BV(AK) 2
CA 414
2 = The BRS signal to release the 2963 PC414-1 +BV(AK) 3
2963 PC415-3 +BV(AK) 1
brake is transmitted via a diode in the
002 PC202-1 RAS SIG 4
RAS LOS
traction controller. UNUSED 2
HSS 003 PC202-2 LOS SIG 5
012 C-3 R/T (HSS) SIG 3
261 PC410-11 NOT USED 6
3 = An SAS signal is required for a 5962 PC410-12 NOT USED 4
013 PC202-5 NOT USED 7
travel signal from the FS and RS R/T SWITCH PN 811941
drivers. 5961 PC410-6 NOT USED 8
HYDRAULIC PCB PN 812942-001
813200-complete
MS-WP2300-GB 04/03 • Printed in Germany MS-DIA-1723
1 2 7 127
DIAGRAMS
Overall Wiring Diagram 2916
LMS1
2902 PC404-2 +BV (AK) 2918 CA 202
UNUSED
with Options A 6
203 JC404-7 BDI +BV 2913 PC404-3 RAS SIG 2912 1 002 PC415-4 RAS SIG
205 +BV F/C HR 1 5900 PC404-1 TT KYS
C 2914 LOS SIG 2 003 PC415-5 LOS SIG
2 2901+BV (AK) 202 KYS COMM +BV
3 101 2910 +BV (AK) 3 004 PC415-2 +BV (AK)
202 KYS COMM +BV - BR +
4 5901 BATT NEG 2906 HNS SIG 4 005 PC410-10 HNS SIG
FU3 FU2 -
2A 10A 5 103 JC406-3 ORS SIG
102 +BV(AK) LINE 205 +BV F/C HR 5 013 CA415-7 +BV F/C HR
6
201
204
501 PC404-5 BATT NEG +

FU1 LINE 7 UNUSED 6 UNUSED
125A 2907 +BV(AK)
8 2908 JC406-1 +BV (AK)
2909 JC406-2 BRS SIG
2 2910 PC 202-3 +BV (AK)
CA 404 CURTIS 803 "COMBI"
B 5900 A1 TT 1 TT
1 006 PC410-7 POT SIG
POT CIRCUIT
& 2 007 PC410-8 POT LOW 2902 +BV (AK) 2 +BV (AK)
A1 +BATT
DRIVER
3 008 PC410-5 POT HIGH 2913 RAS SIG 3
BD:1
4 009 PC410-4 RS SIG
2915 RAS SIG 4
5 010 PC410-2 SAS SIG
6 011 PC410-3 FS SIG 501 A6 BATT NEG 5 BATT NEG
TM
UNUSED 6 UNUSED
203 KYS COMM +BV 7 BDI +BV
C
A2 +BV (AK) UNUSED 8 UNUSED
VMN 1
2
24V 3 012 PC414-3 R/T (HSS) SIG
BATTERY
2906 JC 202-4 HNS SIG
F2
F1
TCM SEM0 CA 406 RED (unused)
2915 PC404-4 RAS SIG BRS
2908 A7 +BV (AK) 1 BLK
D
+
+ - 2909 A8 BRS SIG 2 WHT

1 UNUSED
HN 103 A5 ORS SIG 3 WHT
2 2903 HNS SIG
3 502 BATT NEG 2911 +BV (AK)
PM 4 BLK ORS
+ -
4 2904 RAS SIG P
BD:2 RED (unused)
5 503 BATT NEG
_ +
6 2905 LOS SIG SV - 504
F1 F2 2914 JC202-2 LOS SIG CA 411
CA 410 1
P POT
2
001 P BATT NEG 1
3
010 B-5 SAS SIG 2 ACS PN 8135334
E 4
FS
1 + RXD 011 B-6 FS SIG 3 5
RS
2 RXD NEG 6
009 B-4 RS SIG 4
3 + TXD 7
TXD NEG - + 008 B-3 POT HIGH 5
4 CA 412
3 BLK
-BATT 5 BATT NEG 5961 PC415-8 COMM F/C HR 6 3
GRAY
6 +BV (AK) 1 006 B-1 POT SIGN 7
1
SAS
SAS PN 811935
2
BLU
7 UNUSED
007 B-2 POT LOW 8
8 UNUSED CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
+ _ 2
2 HNS1
005 PC202-4 HNS SIG 10 1
3
2904
261 PC415-6 +BV F/C HR 11 2903 HNS PN 811933
5 Key: 5962 PC414-4 COMM F/C HR 12
15 x //R
4
5
2902
CA 419
2
2901 HNS2
6 1
1 = Diagnostics LED. Remove to connect the programmer. MAIN PCB F/C PN 812272
HNS PN 811933
4
2 = The BRS signal to release the brake is transmitted via a diode in the traction controller. CA 415
2962 PC410-9 +BV(AK) 1
3 = An SAS signal is required for a travel signal from the FS and RS drivers. 004 PC202-3 +BV(AK) 2
2963 PC414-1 +BV(AK) 3
813201-complete-_Opt
4 = Electronic thermo switch, 002 PC202-1 RAS SIG 4
RAS LOS 7
switches ground for F/C HR at ambient temperature < +5 °C. CA 414
003 PC202-2 LOS SIG 5
2963 PC415-3 +BV(AK) 1
261 PC410-11 +BV F/C HR 6 CA 416
5 = "Charger installed" option. UNUSED 2 RED
013 CA202-5 +BV F/C HR 7 15 x //R 1
HSS
012 C-3 R/T (HSS) SIG 3 16 x //R
BLK
5961 PC410-6 COMM F/C HR 8 2
6 = Mains plug socket, for "installed charger" option only 5962 PC410-12 GND F/C 4
2 x //R HYDRAULIC PCB F/C PN 812273-001 HR POT F/C
7 = HR POT F/C is part of the ACS module R/T PCB F/C PN 812877 PN 812315
MS-DIA-1723 MS-WP2300-GB 04/03 • Printed in Germany
128 1 2 8
DIAGRAMS
Wire harness overview, all versions
PC 404
5900 D
2 1
202 2902 1
7+8 2 2 2903
2
FU3
203 2913 3
2 3 502 HANDLE MAIN PCB 6+4 6+4
KYS 2915 3 3
2 4
205
204
BDI 2904
4
2901 501 3
2902 2 5 503
7+8 3 5 1 2 3 4 5 6
6 2905
203 3 6 1010 1010 PC413
2 7
2904
2903
2902
2901
201
6+4 8
FU2 202
6+4 A
5900
3 1
2901
3 2
101 4
3 3
201 5901
FU1 5+4 3 4
103 3 5
102
3 6
501
3 7
2907
3 8 3
1 Main wire harness 808276 2908
204
2909 FU1 2
2913
2912
2 2 Tiller wire harness 811953
102
TCM SEM0
4
BR 4 5901
3 3 Horn switch wire harness 811931
10+11 6+4
10+11 6+4
1
2914 6+4
2905
SV
JC406 2911 504
2908 6+4
1 1
RED/WHT
RED/WHT
2909
BRS 2 1 5
ORS 3 103
1
4 1 2911
2906
6+4
2903
2904
2903
2902
2901
HN
2915
2904
503
502
504
6+4 11 11 11 11
205
2907
2910
101
PC417 2 1 2 1 PC419
7+8
7+8
6+4
6+4
2 1 2 1
P 1
6+4
6+4
B LMS
LINE 006 HNS HNS JC 202-5
3 1
007
3 2
PC 410 008
3 3
001
1 2 009
3 4
4 F/C auxiliary wire harness 812961-001
010
2 2
HANDLE MAIN PCB

010
011 3 5
3 2
009 2
011
3 6 5 F/C adapter wiring LMS 812961-002
2913
2912
2912
2914
2910
2906
4 2
008
5 2
6 2 5961 C Housing Part No. Contact Type Part No.
6+4
6+4
1 1 1 1 2961
7 2 006 3 1
1 2 3 4 5 6 JC 202 2961
LMS 8 2 007 3 2 JC202 803450-003 1 803450-010
012 3
2 2962 3
9 PC202 803450-007 2 116858
1 2 3 4 5 6 PC 202 10 2
005
2 2 2 2 2 11 2
261 001
PC404 803450-008 2 116858
9 P-
Terminal Type Par t No. 5962
JC406 803450-002 1 803450-010
002
003
004
005
013
12 2
4 062007-021 PC410 803450-015 2 116858
5 803678-006 PC413 803450-021 10 803450-022
6 803448-003 PC414 803450-020 2 116858
7 062007-043 Key: PC415 803450-008 2 116858
5962
5961
2963
2962
2963
261
013
012
002
003
004
8 803448-002 PC417 803450-023 11 803450-024
R/T PCB = "Fast/Slow" changeover module 2 2 2 2 2 2 2 2 2 2 2
9 062007-054 PC 414 PC 415
PC419 803450-023 11 803450-024
4 3 2 1 1 2 3 4 5 6 7 8
(all PCBs/modules are located in the tiller) A 803450-018 3 803450-019
10 803448-004 HANDLE R/T PCB HANDLE HYDRAULIC PCB
11 803448-005 B 803450-017 3 803450-019
E100-GB C 803450-016 3 803450-019
D 803450-017 3 803450-019
E99-GB
Harness_Complete
MS-WP2300-GB 04/03 • Printed in Germany MS-DIA-1723
1 2 9 129
130
HYDRAULIC SCHEMATIC
Printed in Germany
131
Printed in Germany
MM
132 11 . . 00 -- 00 00 00 00 -- 00 00 00 11 3 2
HYDRAULIC CIRCUIT
Lift cylinder
Lowering valve
Filter
Filter
Non-return valve
Pressure relief valve Flow reducer
150 bar
to 170 bar*
Motor
Vent cap
Pump
Filter Filter
Reservoir
* depending on model and setting of the pressure relef walve M1457-1
MS-WP2300-GB 04/03 • Printed in Germany MS-HYD-1723
M1.0-0000-000133
133
134

Wp2300 Series

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Maintenance Manual

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

MS-WP2300-GB 04/03 • Printed in Germany MS-REV-1723

ITD – INTRODUCTION PAGE SER-NR. CUT REV.

M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR. CUT REV.

M2 – HYDRAULICS PAGE SER-NR. CUT REV.

M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

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

M4 – ELECTRICS PAGE SER-NR. CUT REV.

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

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

M6 – STEERING PAGE SER-NR. CUT REV.

M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

M8 – CYLINDERS PAGE SER-NR. CUT REV.

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

HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

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

Safety Symbols used in the General Maintenance and Repair

4. To clean, use a non flammable, non combustible

6. Do not allow oil to penetrate the ground or enter

7. Neutralise and thoroughly rinse any spilled

MS-WP2000-GB 04/03 • Printed in Germany MP/MS-0000-MA

Before Leaving 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

Before Carrying out Work on the Truck

● Prevent the truck from rolling away.

● Before carrying out work on the hoist frame, the

● Only carry out operational testing when there is

Before Operating the Truck

● Get into the driver's seat.

● Check the operation of the lifting device, travel

MP/MS-0000-MA MS-WP2000-GB 04/03 • Printed in Germany

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

INFORMATION CROWN Gabelstapler GmbH & Co.KG

Service Training M1 Lubrication and Adjustment

CROWN offers the appropriate vehicle related training

● The truck model number M7 Mast / Lifting Mechanism

● The truck serial number

DIA Electrical Diagrams

HYD Hydraulic Schematic

MS-WP2300-GB 04/03 • Printed in Germany MS-ITD-1723

Capacity Load Wheels

1.6 = 1600 kg S = Single

MS-ITD-1723 MS-WP2300-GB 04/03 • Printed in Germany

Component Access Lifting by Crane

Jacking up the Truck

Please follow the instruction "Jack up the truck" in this

MS-WP2300-GB 04/03 • Printed in Germany MS-1.0-1723

● Drive the forklift sideways underneath the truck

● Place hard wooden blocks under the truck.

● Secure the truck to prevent it from sliding off the

● Raise the truck.

MS-1.0-1723 MS-WP2300-GB 04/03 • Printed in Germany

Battery Connector Control fuse

Lift Cylinder Main Contactor

MS-WP2300-GB 04/03 • Printed in Germany MS-1.0-1723

Reverse Safety Switch MS1723-004

Socket for storing Charger Plug Battery Monitor Displays

MS-1.0-1723 MS-WP2300-GB 04/03 • Printed in Germany