WD 2300s

MAINTENANCE MANUAL
WD2300S SERIES
Order Number: 812560-006

Revision: A • Printed in Germany
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 München
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 2005
CROWN Equipment Corporation
TABLE OF CONTENTS
MA- SAFETY PAGE

Symbols Used in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Before Parking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before Working on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warning and Instruction Decals on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ITD- INTRODUCTION PAGE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operator manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M1- LUBRICATION & ADJUSTMENT PAGE

Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting by Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting with another Forklift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Accessing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power unit cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control handle knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Platform and side restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recommended Lubricants and Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cold Store Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Taking the truck out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Returning the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Testing the Operation of the Safety Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive Wheel and Castor Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setting the contact pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WD2300S 09/2005 • Printed in Germany
I
M2- HYDRAULICS PAGE
Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lifting (Main Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lowering (Main Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lifting (Initial Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Lowering (Initial Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Changing the Hydraulic oil and Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor & Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hydraulic lines and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
General Rules for Hydraulic Lines and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacing the relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relief valve test and setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Testing and setting the load-sensing pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Setting the pressure switch points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Pressure switch PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
M3- POWER UNIT PAGE

Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Tools required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Gear Unit Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Preparing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembling the flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pinion Shaft Aassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Adjusting the Bevel Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking the Flank Tooth Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
II
M4- ELECTRICAL SYSTEM PAGE
Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Sundry Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Electrical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Traction Pod (POT, FS, RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fast / Slow Travel Switch (HSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Safety Reverse Switch (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Brake Switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Horn Switch (HNS1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Key Switch (KYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Emergency Disconnect (BD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fuses (FU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Thermo Switch (THS, optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Diode D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Diode Block (DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Platform Logic (PLM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Limit Switch (LMS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Limit Switch (LMS 2, only for masts > 1700mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Limit Switch (LMS3, only for masts > 1700mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Limit Switch LMS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Pressure Switch (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Initial lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hydraulic Control Module (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Raise / Lower Switches (RAS, LOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Control Handle Main PCB (Main PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hydraulic PCB (Hydr. PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Speed Transmitter PCB (R/T PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Heating Option (F/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Battery Discharge Indicator Setting (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Calibration for Wet Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
III
SEM1 Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Precautionary Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Reduced Travel Speed Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Downhill Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Anti Roll Down Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Self-Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Monitored Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Safety Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Incorrect polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wiring Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Protection rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replacing the SEM1 Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Parameter Setting after Replacing the Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Travel Speed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SEM1 Traction Controller Operating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PARAMETER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PROGRAM VACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Menu Structure for Folding Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Parameter Setting, Folding Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TESTER Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Max. speed in relation to the reductionlevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ALARMS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Traction Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Calibrating the Potentiometer, PROGRAM VACC Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
CONFIG Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SET MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SET OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Traction Controller Safety Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
WD2300S Platform Logic Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Platform Logic Controller, Part No. 816050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Checking the Platform Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
IV
Hydraulic Control Module (HCM), Part No. 816177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Calibrating the HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Important Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Traction Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Access to brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Pump Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Access to brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
M5- BRAKE PAGE

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Test and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Air Gap Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Braking Torque Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
M6- STEERING PAGE

Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Control Handle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
V
Control Handle Grip Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Hand Grip Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Upper and lower shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Upper and lower shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Switch Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Hydraulic PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Main board removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Safety Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Hand Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Initial Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
M7- MAST/LIFT MECHANISM PAGE

Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Adjusting the Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fork Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Adjusting the fork height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Lifting Gear Minimum Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Fork Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Fork Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Fork Carriage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Lubricating Roller Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Mast Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Lowering Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Preparatory Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Carrying Out The Vertical Plumb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Lift Limit Cutout / Initial Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Lift Limit Cutout Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
LMS 2-4 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Lift Limit Cutout Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Connecting the Lift Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
VI
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Freedom of Movement of Chain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Chain Anchor and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Worn Connection Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Protruding or Turned Chain Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Chain Lateral Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Uneven Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Misaligned Lift Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Fork Tines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Fork Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Verticality Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fork Blade Warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Measuring the Fork Tip Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fork Tine Height Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fork Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fork Blade Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
M8- CYLINDERS PAGE

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Safety when working on hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
General Instructions for Repairing Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Plunger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Piston Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Single-Acting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Double-Acting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Rod Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Large Rod Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Small Seal Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Rod Seal Assembly, Sealing Lip First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Initial Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Replacing the rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
VII
Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Installing Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Cylinder Bleeding and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Free lift cylinder bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Flushing – Mast Lift Cylinders and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
M9- PLATFORM PAGE

Mechanical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Platform Switch (PLS) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Platform Cushioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Layering the disk springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Side Restraint, Mechanical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
DIA- ELECTRICAL WIRING DIAGRAMS PAGE

Standard Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Traffic Control Logic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Traffic Control Load Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Hydraulic Traffic Modul and Diodes Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Power Unit Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Control Handle Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Platform & Mast Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Platformmodul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Option Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Traffic Control Logic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Traffic Control Load Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Hydraulic Traffic Modul and Diodes Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Power Unit Control Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Control Handle Traffic Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Platform & Mast Traffic circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Platformmodul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Folding platform, all versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Control Handle Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Horn Switch Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
HYD-HYDRAULIC DIAGRAMS PAGE

Hydraulic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
VIII
SAFETY
Printed in Germany
1
Notes:
2
SAFETY
Symbols Used in the Manual
Symbols Used in the Manual

To provide guidance and clearly identify potential Information
hazard points, we have used graphic illustrations in the This symbol is used with
manual:
additional information and
instructions.
Danger
This symbol indicates a danger
to life. Option
You or other people could be This symbol is used with text
seriously or fatally injured if you describing optional equipment.
fail to comply with this This is not included with the
safetyinstruction. standard version.
Warning
This symbol representsa risk of
injury and/or potentially
signficant material damage.
You or other people could be

seriously injured and/or
significant material damage
could occur if you fail to comply
with this safety instruction.
Caution
This symbol represents
potential minor injuries and/or
potential minor material
damage.
You or other people could be

slightly injured and/or minor
material damage could occur if
you fail to comply with this
safety instruction.
WD2300S 09/2005 • Printed in Germany MA-3400
3
SAFETY
General Safety Instructions
General Safety Instructions Maintenance and Repair
1. 1. Always carry out work in accordance with the

Maintenance and Repair test and maintenance schedule enclosed in these
Instructions maintenance instructions and any applicable
service bulletins.
Danger 2. Only qualified and authorised personnel may carry

Observe the safety instructions out work on the truck.
in the maintenance manual and
the truck operator manual. 3. Keep fire protection equipment at hand and do not
use a naked flame to check fluid levels or to test for
Failure to do so could result in
serious or even fatal injuries to leaks.
maintenance and other
personnel. 4. Use groundwater neutral, non-flammable solvents
for cleaning. Always perform cleaning work over an
Motorised trucks can become hazardous if oil separator. Protect the electrical system against
maintenance and servicing work are neglected. For
damp.
this reason maintenance and inspections must be
performed at sufficiently short intervals. There must be
suitably trained personnel and proper guidelines at 5. Keep the work place and battery charging station
your place of work. clean, dry and well ventilated.
Danger 6. Do not allow oils to penetrate the ground or the

drain system. Used oil must be recycled correctly.
Observe all relevant national Oil filters and dehumidifying inserts must be
and local safety regulations for
treated as special waste. Observe the local
maintenance and repair work.
authority regulations.
Failure to do so could result in
serious and even fatal injuries 7. Immediately neutralise and thoroughly rinse any
to maintenance and other spilled battery fluid.
personnel.
8. Keep the truck clean. This will facilitate tracing
loose or faulty components.
9. Maintain the legibility of the data capacity plate and

data plate, warning and instruction decals.
10. Truck modifications and additions may only be

performed with Crown’s prior written approval.
11. The reliability, safety and suitability of Crown

trucks can only be ensured by using original Crown
parts.
MA-3400 WD2300S 09/2005 • Printed in Germany
4
SAFETY
General Safety Instructions
Before Parking the Truck Before Starting the Truck
z Brake until the truck comes to rest. z Test the safety mechanisms.
z Lower the fork carriage fully. z Get into the travel position.
z Apply the parking brake. z Test the lifting mechanism, travel direction switch,
speed control, steering, warning mechanism and
z Switch off the truck and remove the key. brakes.
z When parking on a slope or incline always chock

all wheels. Warning and Instruction Decals on
the Truck
Before Working on the Truck
In the course of periodic maintenance work, check that
the warning and instruction decals on the truck are
z Jack up the truck so that the drive wheel is clear of
complete and legible.
the ground. Apply the Emergency Disconnect and
disconnect the battery.
z Clean any dirty decals.
z Prevent the truck from rolling away and lowering.
z Replace any faulty or missing decals.
z When working on the mast, fork carriage or lifting
A description and the location of the warning and
mast always apply a chock to prevent accidental
instruction decals used on the truck are given in section
lowering.
10.9 of the spare parts manual.
z Allow sufficient room for manoeuvre when testing
the truck, to avoid endangering yourself and other
people.
WD2300S 09/2005 • Printed in Germany MA-3400
5
Notes:
MA-3400 WD2300S 09/2005 • Printed in Germany
6
INTRODUCTION
Printed in Germany
7
Notes:
8
INTRODUCTION
Introduction
Introduction Ordering Spare Parts
The maintenance manual does not cover spare parts.

General These are listed in a separate manual.
The present manual is designed for Customer Service Spare parts can be ordered by quoting:
engineers who wish to familiarise themselves with the
maintenance work required for the various truck z The truck specification number
components.
z The truck model number
It also contains troubleshooting sections which can be
used to identify and remedy truck faults. z The truck serial number
This information can be found on the truck data plate.

Information It is essential to provide this information to ensure
This book is not an operator accurate, fast and efficient order processing.
manual. It is designed solely for
Please refer to the specification sheets for the utilisable
specialist personnel who have loads, technical data and dimensions for this series.
been trained and authorised by Brochures can be obtained from your Crown dealer or
Crown to carry out the work from the following address:
described in the manual.
CROWN Gabelstapler GmbH & Co.KG
This manual therefore contains fewer and less detailed
Moosacher Str.
warnings than the operator’s manual, as the latter is
aimed at persons who have very little or no prior 80809 Munich
experience at all.
Germany
Tel.: +49 (0)89 / 93 002 -0
Operator manual
Fax: +49 (0)89 / 93 002 -175 or 133
This manual contains no operating instructions. An
operator manual is supplied with the vehicle. Additional
copies can be ordered as required.
With the help of this manual you and your personnel

will be able to ensure the long service life, operational
safety and error free functioning of your Crown truck.
Service Training
Crown offers the appropriate truck related training for

service personnel. Details of this training can be
obtained from Crown on request.
WD2300S 09/2005 • Printed in Germany ITD-3400
9
INTRODUCTION
Introduction
Using the Manual
This manual is divided into sections. The following

table shows how the manual is structured.
Maintenance manual structure
Section Description
IDX Index
MA Safety instructions
ITD Introduction
1 Lubrication and Adjustment
2 Hydraulic system maintenance
3 Power unit maintenance
4 Electrical system maintenance
5 Brake system maintenance
6 Steering system maintenance
7 Mast / lift mechanism
maintenance
8 Cylinder maintenance
9 Folding platform
DIA Electrical wiring diagrams
HYD Hydraulic diagrams
ITD-3400 WD2300S 09/2005 • Printed in Germany
10
LUBRICATION & ADJUSTMENT
Printed in Germany
11
Notes:
12
Lifting the Truck
Lifting the Truck Lifting with another Forklift Truck
The WD 2300 S can be raised at an angle using a

Danger forklift truck.
Make sure the crane / truck and
z Position the forks of the truck which is doing the
the lifting gear have the
lifting as shown by the diagram below.
required capacity.
If the crane or lift truck crash or
z Place a chock approx. 90 mm thick between the
if a load falls, fatal injuries could
outriggers of the WD 2300 S and the
result.
corresponding fork of the truck doing the lifting.
Required capacity (WD without battery): 900 kg
z Secure the WS 2300 S firmly to the forks of the
truck doing the lifting (e.g. with straps).
The outriggers must be fully raised and the forks fully
lowered.
Lifting by Crane
Attach lifting gear as shown in the following diagram

and prevent the truck from slipping (see arrow).
90
800
> 800
G_WD-on-forks
G_WD-lift-crane
WD2300S 09/2005 • Printed in Germany M1-3400
13
Jacking up the Truck
Jacking up the Truck z Place a hard wooden block underneath and lower
the truck onto it (4).
Danger
Always support a raised truck
with wooden blocks or other
appropriate equipment to
relieve the jack.
Never reach your hands or other

parts of your body under the
truck before it has been
supported, or when jacking up
the truck.
Improper handling of the truck

or of the auxiliary equipment
can result in fatal accidents. 1
The outriggers must be raised in full in order to jack up

the truck. 3
4
z Place wedges (1) in front of both load wheels.
z Apply a jack with sufficient capacity (>800 kg) to

the centre of the skirting rail and raise the truck to
a maximum of 20 mm (2).
z Place sufficiently sized hard wooden blocks on

both sides underneath the chassis and lower the 3
truck onto the blocks (3).
G_WD-jack-up
z Now raise the outriggers with the jack.
M1-3400 WD2300S 09/2005 • Printed in Germany
14
Towing the Truck
Towing the Truck Pull the truck slowly straight forward (as indicated by
the black arrow).
When the truck is de-energised, the brake (acting on

the drive wheel) is applied. To remove the truck from
an aisle, for example, it can be raised and pulled by a
forklift truck. Capacity required (WD 2300 S unladen):
900 kg . The load wheels remain on the ground when
the truck is towed.
z Position the forks as shown in the diagram.
Take care not to damage the castor wheels on

either side of the truck.
z Raise the truck (at its front) approx. 40 mm.
Caution
The drive wheel must be lifted
from the floor!
Otherwise the truck could be

damaged.
G_WD-tow
15
Accessing the Components
Accessing the Components z Unigage (TT/BDI)
z Key switch (KYS)

The following is a list of covers, panels etc. which must
be removed prior to carrying out repairs and / or z Fuse 3, FU3 (signal system)
servicing in order to access the components. Refer to
the illustrations in this chapter which will help you to z Fuse 4, FU4 (signal system)
locate the parts.
z Platform module (PLM)
Warning
z Pressure switches (PS1, PS2, PS3)
Always remove the battery
connector before carrying out
maintenance work. This applies Control handle
in particular if the connector
and electrical connections have Provides access to:
to be separated.
z Horn switches (HNS1 & HNS2)
Power unit cover z Main Lift – lower switches (LOS1, LOS2)
Provides access to: z Main Lift – lift switch (RAS)
z Traction motor ™ z Fast / Slow Travel Switch (HSS)
z Power unit z Safety Reverse Switch (SAS)
z Brake z Potentiometer (POT), forward travel switch (FS),

reverse travel switch (RS)
z Pump motor (PM), lift contactor (P), lowering valve
(SV1, SV2, SV3) z Lower switch (ILS Lower) initial lift
z Hydraulic oil reservoir z Main switch (ILS Lift) initial lift
z Horn (HN)
Control handle knuckle
z Diode block (DB)
Provides access to:
z Traction control module (TCM)
z Brake switch (BRS)
z Main contactor (line)
z Fuse FU1 (travel power fuse)
z Fuse FU2 (raise)
z Diagnostic LED for TCM (LED)
z Hydraulic control module (HCM)
16
Mast
Provides access to:
z Mast switch:
– Mast 1700 mm: Speed reduction limit switch
(LMS4)
– Mast 2100 mm: Speed reduction limit switches

(LMS4, LMS3, LMS2)
Platform and side restraint
Provides access to:
z Travel mode switches (GCSL, GCSR, PLS)
17
23
1
22
21
4
20
5
6
7
19
9
18 10
16
17 11
15
14 12
13
MS-3400-001
1 Lift chain 13 Castor wheel

2 Mast lift cylinder 14 Pump unit & hydraulics manifold block
3 Safety shield 15 Battery compartment
4 Control handle 16 Outrigger
5 Control handle knuckle 17 Load wheels
6 Side restraint 18 Battery / battery connector
7 Display panel 19 Outer mast
8 Drive unit / brake 20 Fork
9 Controller and contactors 21 Fork carriage
10 Platform 22 Inner mast
11 Castor wheel 23 Mast limit switch
12 Drive wheel
18
Maintenance
Maintenance z Do not park the truck in the open air or in a humid

environment. The ideal place is a dry room where
the temperature and air humidity are reasonably
Recommended Lubricants and Oils constant. If the truck has to be covered, use an air-
permeable material. Do not use plastic sheets.
Otherwise, condensation may form.
Lubricants
z Jack up the truck. Lower the chassis onto suitable
The next page shows typical lubricants used by Crown wooden blocks so that the wheels clear the ground
itself in its facilities. However, you can use any (prevents the wheels from flattening from constant
lubricants provided they meet the same technical pressure).
criteria.
z Every 3 months connect the battery, carry out a
daily inspection and activate all thetruck functions.
Cold Store Trucks Finally, disconnect the battery again.
Special hydraulic oil, lubrication oil and grease must be

used for cold store trucks operating in low temperature
Returning the Truck to Service
conditions (see table on following page). An
anticorrosion fluid (Crown no. 805236-004) must be To return the truck to service, proceed as follows:
applied regularly to all screws, washers, nuts, pins,
retaining rings etc. Carefully protect all electrical z Remove any anti-corrosion film (apart from that
connections and components against corrosion. For provided for cold store use) *.
detailed information, refer to chapter 4.
z Jack up the truck, remove the wooden blocks,
Service intervals must be adapted to the conditions of lower the truck.
use. This means they must be reduced as far as
possible to prevent excessive wear. z Charge the battery or fit a charged battery.
z Connect the battery.

Taking the truck out of service
z Carry out the daily inspection.
z If the truck is to be out of service for 3 months or
more, proceed as follows:
z Disconnect the battery. * Do not apply high pressure cleaning agents and/
or solvents to the truck. Do not use metal brushes!
z De-commission the battery in accordance with the Do not wet clean theelectricalsystem and do not
manufacturer‘s instructions. use flammable solvents.
z Clean the truck*. Carry out lubrication in
accordance with the Maintenance Manual.
z If the truck is to be stored in hostile conditions (e.g.

saline atmosphere) treat the surface of the truck
with a suitable preservative to prevent corrosion.
19
Maintenance
Lubricant Type Product Description Manufacturer Crown Part No. Type
Grease (multi- Aralube HLP2 Aral

purpose) LM-Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
EP2 Maxol 053002-001 B
Mobiluxe EP2 Mobil
Retinax LX Shell
LGWMI SKF
Low temperature Aralube SKL2 Aral 053002-005 BB
grease Unirex Lotemp EP Mobil
Hydraulic oil Vitamin GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
Tellus 32 Shell 053001-003 D
Hydran LZ 32 Finol
B110 Fuchs
Mineralölwerke
GmbH
Low temperature Deutz Oel HVI 32 Klockner 053001-009 DD
hydraulic oil
Transmission oil Hyp 85W90 Aral
GX-D 85W90 Esso
Mobilube HD85W90 Mobil 053002-004 A
Spirax MB90 Shell
Lowtemperature Mobil SHC 624 Mobil 053002-009 AA
transmission oil
Lubricants Product Description Application Crown Part No.
Anti-corrosive agent Tectyl Anti-corrosive agent for cold 805236-004

store trucks.
Clearseal paint 2K clearseal paint Acid-resistant clearseal paint 805236-003
for traction controllers used
in cold stores.
20
Inspection and Maintenance Schedule
Inspection and Maintenance When carrying out maintenance routinely check for
wear, corrosion, damage, component operation and
Schedule safety. If in doubt, replace components.
The following inspection and maintenance schedule

assumes single-shift operation under normal
conditions. The frequency of maintenance intervals
must however be constantly adapted to the prevailing
operating conditions. In dusty or otherwise extreme
operating conditions including cold store application,
the maintenance intervals specified must be reduced.
Exact details should be discussed with a Crown service
engineer.
Daily Operator’s Inspection
Item Location Action

I01 Battery Check battery connector (Emergency Disconnect) and wires for
damage, check contacts for burning.
Check battery compartment for spilled acid.
Battery safety clip and battery terminal support fitted?
Screws tight?
Catch down?
Check/charge battery in accordance with manufacturer’s instructions if
necessary.
I02 Gear unit Check for leaks:
Brown oil at the bottom near the drive wheel?
If leakage is found, take the truck out of service.
I03 Hydraulics Check for leaks:
Traces of light oil on the ground beneath the truck?
If leakage is found, take the truck out of service.
I04 Steering Check operation, ensure there is zero backlash.
I05 Platform Test freedom of movement, automatic return and check for damage.
I06 Side restraint Test freedom of movement and check for any damage.
I07 Forks, outriggers Check for possible damage, cracks and excessive wear.
I08 if applicable: Ensure it is securely fitted and check for damage.
Load backrest
I09 Lift chains, chain Check for possible corrosion, cracks and any other damage.
anchor
I10 Wheels, load wheels Check tyres for wear and foreign bodies. Remove any foreign bodies.
I11 Safety shield Securely attached, not cracked and still visible?
I12 Labels, decals Check that they are all present, clean and legible.
I13 Key switch Switch on and test battery discharge indicator operation.
I14 Outriggers Raise and lower outriggers. Check operation.
21
Daily Operator’s Inspection
I15 Outrigger lifting With the outrigger raised, check for foreign bodies. Remove any foreign
mechanism bodies found with a hook or similar item.
Do not use your hands to reach into the lift mechanism.
I16 Fork carriage Raise and lower forks. Check operation. Check that the chain, inner
mast and mast rollers are running correctly.
I17 Emergency Check operation.
Disconnect
I18 Horn Check operation.
I19 Travel functions Move the truck in both directions, first slowly and then at full speed.
Test rabbit/turtle switch operation (fast / slow)
With the following settings: rider mode, side restraints folded out,
outriggers down, test “rabbit” mode (fast):
Speed reduction for
- fork lift > 880 mm - load > 500 kg
Travel inhibited for

- fork lift > 1700 mm
I20 Brake Test brakes in both directions:
- by changing direction
- by moving the control handle to the braking position (has the stopping
distance increased since the last check?)
The control handle should automatically revert back upright when you
release it from the travel position.
I21 Safety reverse Test operation – see illustrations and description on following pages.
switch
I22 Platform logic Test operation when truck is idle (platform folded up):
- Power up the truck.
- Unfold the LH side restraint

- Apply travel function
- Truck should not move
- Unfold the RH side restraint

- Unfold the LH and RH side restraints

I22 Platform logic Test operation during travel (rider mode):
- Unfold the LH side restraint

- Unfold the RH side restraint

22
I01 , %' 69 &$ .<6 ,

%',
/06 ,
30 ,
&$
, 3/0
+1
,
69/ ,
, 70
,
69 ,
69
, ,
MS-3400-003
I19 I19 I21 I16
MS-3400-002
MS-3400-004
23
+16 6$6 327)656

, +16
&$
&$
5$6
,
/26 ,/6/LIW
/RZHU
&$ &$
&$ &$
&$ &$
MS-3400-005
I09 I08
I11
MS-3400-007
I07
I14
I10
I18
MS-3400-006
MS-3400-008
24
Testing the Operation of the Safety Reverse Switch
Testing the Operation of the

Safety Reverse Switch
Danger
Always test the safety reverse
switch in a secure environment,
free of other people and
sufficiently far from obstacles.
G_WD_ARS_test
z If the test does not work, the fault must be rectified

z Set the control handle straight so that the truck can before using the truck again.
only travel in a forward direction.
The operation can be set (in the configuration menu) to
z Stand to the side with sufficient distance from the either
control handle.
Belly (SAS operation while switch is pressed)
z Slowly move the truck forward with the control
handle (walking ahead in the platform direction).
or
z Make sure no one else is in the environment.
Timed (SAS operation cuts out after 2 seconds)
z Apply the safety reverse switch.
.
The truck should stop immediately and then after a few
seconds or however long the switch is held down for,
move off in the opposite direction (depending on the
truck pre-settings).
25
Inspection and Maintenance

Schedule
Months: 1 3 6 12 24
Item Component Hours: 100 250 500 1000 2000
I01 Travel checks Check operation. Read the error memory x

log.
I02 Castor wheels, load Check the load wheel and castor wheel x
wheels supports for clearance and wear
I03 Clean axles, check for wear and replace if x
necessary
I04 Check tyres for wear. x
I05 Check castor wheels, adjust if necessary x
I06 Outriggers Check for damage and ensure it is x
securely attached.
I07 Hydraulics Check all hoses, lines and connections x
for leaks and damage
I08 Relief valve Test relief valve operation and adjust x
setting if necessary.
I09 Pressure switch Check operation. x
I10 Drive wheel Check wheel nuts are torqued correctly. x
I11 Check drive wheel for wear x
I12 Power unit guide Check the power unit guide for clearance x
and wear
I13 First gearbox oil change after the first x
250 service hours, thereafter every 2000
hours.
I14 Motors/Gear Unit Check pump and traction motor carbon x
brushes for wear, freedom of movement
and contamination.
I15 Check traction and lift motor x
attachments
I16 Check gear unit for noise and leakage x
I17 Check gear unit attachment x
I18 Check lift and traction motor x
commutators for damage and wear,
apply pressurized air to dust.
I19 Check lift motor/pump connection for x
damage and wear; replace if necessary.
26
Months: 1 3 6 12 24
I20 Wiring / switches Check all line connections are secure x

I21 Clean truck, battery and charger x
connector contacts and check contact
springs.
I22 Check wiring, switches & connections x
are secure, check insulation for damage.
I23 Check line connections to traction x
controller, EMERGENCY DISCONNECT
switch and main fuses FU1 & FU2 are
secure
I24 Check power cables from traction and lift x
motors for damage
I25 Check battery cables and connectors for x
damage
I26 Battery Check / service battery as required in x
accordance with battery manufacturer's
service manual.
I27 Check battery condition. x
I28 Check acid density and acid level. x
I29 Contactors Clean and check main contactor tips, x
replace if necessary.
I30 Clean and check pump contactor tips, x
replace if necessary.
I31 Traction controller Check operation. Read the error memory x
log.
I32 Ensure it is securely fixed. x
I33 Brake Blast off abrasion with pressurised air; x
check conical nipple for damage; check
air gap and adjust if necessary.
I34 Check brake lining and friction surfaces x
and replace components as required.
I35 Check air gap and brake lining wear on x
the motor brake; clean brake linings
(apply dry compressed air), and replace if
necessary.
I36 Control handle Test return spring operation. x
I37 Initial lift cylinder Check for leaks, check piston rod for x
wear, make sure attachment is fixed.
I38 Mast connection Check torque. x
27
Months: 1 3 6 12 24
I39 Fork carriage Check for damage. x

I40 Check forks for damage and wear. x
I41 Check slack between forks and fork x
carriage.
I42 Mast Clean bearings and contact surfaces, x
check for wear and replace if necessary;
check mast itself for wear.
I43 Lift chains Clean, check for wear, test elongation. x
I44 Mast column and Check for wear, corrosion and damage. x
free lift cylinder
chains and chain
anchor
I45 Lift chains, chain Check for possible corrosion, cracks and x
anchor any other damage.
I46 Mast section Check for wear. x
I47 Mast rollers Check for wear and clearance. x
I48 Load backrest Check for damage and ensure it is x
securely attached.
I49 Guide pulleys Check for wear. x
I50 Guide pulley yoke Check for damage. x
I51 Mast cylinder Check for leaks, check piston rod for x
wear, make sure attachment is fixed.
I52 Mast switch Check operation. x
UVV testing Germany only; other countries in Annually
accordance with national regulations.
Carry out UVV testing at specified
intervals.
PMT test Test stages in chapter 4 Annually
28
,, ,, , ,

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30 &$ I10
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69 ,, ,,
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MS-3400-009
1 2
I42 I49
I44 I50
I43
I46 I48
I47 I41
I40
I44 I39
I45
MS-3400-012
I51
I07 1 Screw
2 Roller guide
I06 I38
I02
I03
I04
MS-3400-010
29
L7 /06
L11
/06
L9
L10 /06
L5
&$
&$
&$
MS-3400-013
/ /
MS-3400-015
/
/
/ / /
/
MS-3400-014
30
Lubrication Points
Lubrication Points
Item Component Type Quantit 100 250 500 1000 2000

y
L1 Check hydraulic reservoir, top up if D A/R Initial x

necessary inspection
L2 Replace hydraulic oil D A/R First change after 500 service x
hours
L3 Battery cover hinges B A/R x
L4 Control handle return springs B A/R x
L5 Tie rod pintails and all lift mechanism B A/R x
joints.
L6 Lift cylinder attachment B A/R x
L7 Piston rod attachment B A/R x
L8 Change transmission oil A A/R First change after 250 service x
hours
L9 Mast sections B AR x
L10 Mast & fork carriage rollers B AR x
L11 Lift chains G AR x
31
Drive Wheel and Castor Wheels
Drive Wheel and Castor Wheels z Measure the diameter of the castors, obtain a
mean reading and record this.
Setting the contact pressure To calculate the required adjustment:
New drive wheel Ø 230 mm minus current Ø of drive

The castors are located on the left and right hand sides
wheel = reading 1
beneath the truck. They prevent the truck from tipping
over when negotiating bends.
New castor wheel Ø 125 mm minus current Ø of castor
wheel = reading 2
Over time the castors apply a defined force to the
ground as the articulated power unit generally
Reading 1 – reading 2 = Adjustment factor
compensates for the wear of the drive wheel and the
castors. However, the contact pressure of the drive
wheel decreases with increasing tyre wear. This Example:
extends the braking distance and on smooth surfaces
will result in slipping if the truck starts with a heavy You have measured the actual diameter of the drive
load. wheel to be 220 mm. Mean reading for castors
120 mm.
New drive wheels have a 230 mm diameter.
230 mm - 220 mm = 10 mm (reading 1)
If the diameter is only 220 mm the spring pre-
125 mm -120 mm = 5 mm (reading 2)
tension of the power unit must be increased.
Otherwise the drive wheel slipping – and hence the 10 mm -5 mm = 5 mm (adjustment factor)
wear – will increase disproportionately. At the
same time the castor wheels will wear more than The bolts (B) in Fig. MS-3400-018 therefore must be
necessary due to increased contact pressure. screwed in 5 mm.
z Undo both counternuts (A) and turn them up by at

Procedure:
least the adjustment factor calculated above.
z Park the truck (unladen) on a level surface. z Turn in the screws (A) alternately until you reach
the adjustment factor calculated on both screws.
z Disconnect the battery and remove the key.
z Check measurement C: rated measurement
z Prevent the truck from being switched on again. 33 mm (with new wheels)
z Remove the panel.
z Measure and record the diameter of the drive

wheel.
32
z Counterfix bolts (B) with nuts (A).
A B
A
C C
MS-3400-018
33
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.
Information
The torques listed in the
maintenance section always
supersede those shown on next
page.
Screw Grade Marking
Nut Grade Markings
34
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
Umbrako screws and nuts
Grade 10 and 10.8 12 and 12.9

Thread Size Torques (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
Special torques: Screws for mounting the brake to the motor. 3 off M5
screws, torque 6 Nm
Screws for mounting the power unit to the pivot bearing
flange. 4 off M12 screws, torque 86 Nm Screws for mounting the mast to the chassis. 2 off M16
screws, torque 320 Nm
Screws for mounting the knuckle to the pivot bearing
flange. 6 off M10 screws, torque 49 Nm
35
Notes:
36
HYDRAULICS
Printed in Germany
37
Notes:
38
HYDRAULICS
Hydraulic Symbols
Hydraulic Symbols
Symbol Meaning Symbol Meaning
Vented reservoir with Electric motor with

lines above the fluid unidirectional turn and
level speed
Vented reservoir with Hydraulic pump with

lines above the fluid fixed displacement
level and single direction of
turn
Filter or strainer Spring, (bias to normal

de-energised position)
Hydraulic line with full Solenoid single coil or

flow winding
Control line or drainage Assembly housing,

withrestricted flow manifold block
Lines crossing; not Throttle, adjustable

connected
Lines crossing and Throttle, fixed

connected
Plugged port Relief valve,

adjustable
Accumulator gas Check Valve

charged diaphragm
type
39
HYDRAULICS
Hydraulic Symbols
2/2 way valve (2 ways, 2 Hydraulic steer unit

connections)
7 /
3 5
3/2 way valve (3 ways, 2 Torque generator

connections)
3
7
3/2 way valve (3 ways, 2 Shut-off valve, manual

connections);
Spring bias solenoid
control
4/2 way valve (4 ways, 2 Bypass flow control

connections) with controlled flow,
pressure-regulated
4/3 way valve (4 ways, 3 Flow divider/combiner

connections)
4/3 way valve (4 ways, 3 Single counterbalance

connections); valve assembly in
manual activation and manifold
spring centred
Flow meter Electric motor with

unidirectional turn and
0 variable speed
40
HYDRAULICS
Hydraulic Symbols
Valve block with 3 Proportional solenoid

operating units
Shuttle valve Dual solenoid
Relief valve, fixed Solenoid valve, pilot

setting operated
Velocity fuse Hydraulic pilot

operated
Pressure-compensated Manual actuator

flow control with
reverseflow bypass;
fixed.
Pressure-compensated Single-acting cylinder,

flow control with with cushion
reverseflow bypass;
fixed.
Pilot check valve(pilot to Single-acting cylinder

open) ram type
Manual lever actuator Single-acting cylinder

with spring returned
(rod end vented)
41
HYDRAULICS
Hydraulic Symbols
Double-acting cylinder; Thermometer

equal area
Double-acting cylinder; Pressure gauge

unequal area
Pressure switch Hydraulic motor, bi-

directional
42
HYDRAULICS
Hydraulic Unit Removal
Hydraulic Unit Removal
Warning
Depressurise all components
before carrying outwork on the
hydraulic system.
High pressure hydraulic oil can

cause serious injuries.
Whenever a high pressure fluid

enters the skin it must be
treated as an emergency, even if
the skin initially shows no
reaction. Physical effects may
take time to set in.
Tighten all ports before re-

applying system pressure.
Keep hands and body away
from all ports as high pressure
hydraulic oil can emerge.
Use absorbent paper to trace

leaks, never use your hands!
43
HYDRAULICS
Hydraulic System
Hydraulic System Lifting (Initial Lift)
When the “Raise” (ILS Lift) switch is pressed down on

Function the control handle, the pump motor is energised and
starts to drive the pump. The pump initially draws oil
from the reservoir via the suction filter, directing it
Lifting (Main Lift) through the internal check valve and the proportional
valve which opens briefly, and back to the oil reservoir.
While the proportional valve is fully closed, the
When the “Raise” (RAS) switch is pressed down on the
operating pressure builds up on the lift cylinder (soft
control handle, the pump motor is energised and starts
lift). A relief valve in the circuit keeps the pressure to
to drive the pump. The pump initially draws oil from the
the maximum permissible limit. The main lift valve is
reservoir via the suction filter, directing it through the
also opened to allow oil to flow into the initial lift
internal check valve and the proportional valve which
cylinders.
opens briefly, and back to the oil reservoir.
While the proportional valve is fully closed, the

pressure builds up on the lift cylinder (softlift function).
The main lift valve is also opened to allow oil to flow into Lowering (Initial Lift)
the main lift cylinder. A relief valve in the circuit keeps
the pressure to the maximum permissible limit.
If the “Lower” switch (ILS Lower) is pressed down on
the control handle, the shutoff valve opens. The
proportionalvalve opens simultaneously. The main lift
valve is also opened to allow oil to flow from the initial
Lowering (Main Lift) lift cylinder.
The hydraulic oil can now flow from the cylinder(s) via
If one of the two “Lower” switches (LOS1 or LOS2) is
the flow restrictor back to the oil reservoir.
pressed down on the control handle, the shutoff valve
opens. At the same time the proportional valve opens
according to whether LOS1 or LOS2 has switched fully
or partially. The main lift valve is also opened to allow
oil to flow from the main lift cylinder. The hydraulic oil Note:
can now flow from the cylinder(s) via the flow restrictor
back to the oil reservoir. If the proportional valve is The initial lift automatically lowers at a main lift height
partially open, lowering is slow. If the proportional valve of 1700 mm.
is fully open, lowering is fast.
44
Notes:
45
HYDRAULICS
Hydraulic System
MS-3400-019
46
HYDRAULICS
Hydraulic System
1 Suction filter
2 Reservoir ventilation
3 Check valve (CV)
4 Overload valve (RV)
5 Cylinder shutoff valve (SV3)
6 Proportional valve (PV)
7 Pump & motor
8 Main lift cylinder
9 Main lift line break safety device
10 Reservoir
11 Flow restrictor
12 Initial lift cylinder
13 Main lift valve (SV1)
14 Initial lift valve (SV2)
47
HYDRAULICS
Hydraulic System
Hydraulic Reservoir Capacity Changing the Hydraulic oil and

Hydraulic Filter
Fill the hydraulic oil up to the bottom mark of the filler
neck. The cylinders are lowered.
z Fully lower the forks. Retract the mast fully.
The maximum reservoir capacity is 2.0 litres.
z Fully lower the initial lift.
z Turn the key switch OFF. Remove the key.

Disconnect the battery.
z Attach a warning tag to the control handle to advise

others that the truck is being serviced.
z Chock the drive wheel and load wheels.
z Remove the front cover from the power unit to

access the hydraulic reservoir.
z Separate the hydraulic lines from the hydraulic

pump. Seal the hydraulic ports immediately to
minimize oil loss and prevent hydraulic system
contamination.
MS-3400-020
z Disconnect all electrical wiring from the hydraulic
1 Reservoir cap unit. Tag out the wire ends and motor terminals to
2 Motor avoid any confusion when you later connect the
3 Filling level
wires.
z Remove the retaining screws from the hydraulic

unit.
Only start the truck once the reservoir has been filled
with the approved hydraulic oil up to the maximum z The reservoir and motor/pump assembly can now
level. For the correct grade, refer to the lubricant table be moved. Carefully raise the reservoir and pull it
in Chapter 1. forward as far as possible. Remove the reservoir
and the motor/pump assembly from the power unit
The oil level should not deviate by more than frame.
+/- 5 mm from this level.
z Remove the screws securing the motor/pump
assembly to the reservoir flange.
48
HYDRAULICS
Hydraulic System
z Remove the oil from the reservoir and any remains
that have built up in the reservoir. Observe local
disposal regulations.
z Remove the retaining ring of the strainer in the filter

housing of the suction line below the pump.
Replace the filter. Refit the strainer in the filter
housing of the suction line. Attach the strainer and
the retaining ring.
z Fit the motor/pump assembly onto the reservoir.
z Refit the flange and tighten the mounting screw

firmly.
z Fit the reservoir and the motor/pump assembly in

the drive unit frame.
z Refit the mounting screws and tighten them.
z Reconnect the hydraulic supply lines and the

electrical connections. Tighten the ports firmly.
z Fill the reservoir up to the full mark (on top of the

hydraulic reservoirbaffle) via a filter (at least 10
micron) using the correct hydraulic oil grade
according to the operating conditions of the truck
(see Chapter 1, Lubricant table).
z Refit the front cover of the power unit, and tighten

the mounting screws firmly.
z Remove the wedge.
z Connect the battery and remove the warning tag

from the control handle.
z Bleed the hydraulic system (see Chapter 8,

Cylinder Bleeding and Flushing).
49
HYDRAULICS
Motor & Pump Assembly
Motor & Pump Assembly General Rules for Hydraulic Lines and
Connections
Hydraulic lines and fittings z Apply pressurised air to all hoses and lines before
assembling them, to remove any loose particles.
Bent steel or plastic lines will be permanently
Warning damaged. These must be replaced even if the
damage is not externally visible.
De-pressurise all components
before carrying out
z Any hose which bends during operation in its
maintenance work on the
normal assembly position must also be replaced.
hydraulic system. High
pressure hydraulic oil can
z All hoses and lines must have sufficient clearance
from other surfaces or edges that could result in
wear or cuts or where the hoses or lines could get
caught.
z All connections must be tight and without leaks.
Tighten all ports before re-


leaks, never use your hands!
50
HYDRAULICS
Bleeding the Hydraulic System
Bleeding the Hydraulic System Disassembly
Whenever work has been performed on hydraulic

components, the hydraulic system must be flushed and Warning
bled. The procedure for doing this can be found in De-pressurise all components
Chapter 8 under “Cylinder Bleeding and Flushing”. before carrying out
hydraulic system. High
Drift Test pressure hydraulic oil can
Whenever work has been performed on hydraulic
components a drift test must be carried out to ensure Whenever a high pressure fluid
that certain system components are working correctly. enters the skin it must be
The procedure for doing this can be found in Chapter 8 treated as an emergency, even if
under “Drift Test". the skin initially shows no
Proportional function: take time to set in.
Whenever maintenance work has been performed on Tighten all ports before re-
the hydraulic system. applying system pressure.
Ensure that the load can start smoothly when the lift
motor is switched on and that the load can also brake Use absorbent paper to trace
smoothly when lowering is switched off (subjective leaks, never use your hands!
test).
z Fully lower the forks. Retract the mast fully.
z Fully lower the initial lift.

The HCM (hydraulic control module) may have to be
calibrated (see Electrics chapter). z Turn the key switch OFF. Remove the key.
Disconnect the battery.
51
HYDRAULICS
z Attach a warning tag to the control handle to advise Motor
z Chock the drive wheel and load wheels. Refer to Chapter 4, “Electrics”, for pump motor
maintenance and repair instructions.
z Remove the front cover from the power unit to
access the hydraulic components. Pump
z Remove the retaining screws from the hydraulic
unit. The hydraulic pump cannot be serviced and can only
be replaced as a complete assembly. Before fitting a
new pump, make sure that the pump and all its
hydraulic components are clean. Install a new suction
filter (see section on changing the hydraulic oil and
filter).
After replacing the pump:
z Use clean, filtered hydraulic oil (at least 10 micron)

to replenish the reservoir.
z Never run the pump without oil.
z Start the installed pump unladen (pressure side

open) and leave it to pump hydraulic fluid for max.
MS-3400-021
20 seconds. This will ensure the pump is bled and
that there is sufficient lubrication. Close the
1 Reservoir filler cap
pressure side again as soon as the oil emerges
2 Motor without bubbles. Bleed the entire system (see
3 Filling level Chapter 8, Cylinder Bleeding and Flushing).
z If the oil is still foaming after approx. 20 seconds,

the system must be checked.
z Remove the motor/pump assembly from the
reservoir and take it to a suitable work area for z Check the connections again for leaks once the
further dismantling. system has reached operating temperature.
52
HYDRAULICS

3RZHU8QLW

MP-3400-020
53
HYDRAULICS

3RZHU8QLW

MP-3400-022
54
HYDRAULICS
Relief Valve
Relief Valve Relief valve setting
The relief valve (3) protects the hydraulic system and

Replacing the relief valve the lifting mechanism from overloading.
z Remove the locking mechanism (see Fig. MP-

3400-022) and unscrew the relief valve (3),
Warning
Do not let the pump unit run
z Remove the O ring and the strainer from the valve unless it is fixed to the chassis.
seat if they are still in there.
The amount of torque will twist
z Apply a thin coat of hydraulic oil to the new O ring the unit. This can result in short
and place it in the valve seat with the strainer. circuits and damage.
z Apply hydraulic oil to the relief valve (3), insert it

into the valve seat and tighten. Tap in the new
locking mechanism.
z Refit the hydraulic unit and adjust the relief valve

(3).
Model Capacity Minimum test weight Maximum test weight Setting
WD2300S fork lift 1000 kg 1100 kg 1200 kg 180 bar

WD2300S initial lift 2000 kg 2200 kg 2300 kg 180 bar
55
HYDRAULICS
Relief Valve
Relief valve test and setting
z With the truck at operating temperature, lift a test

load on the forks that corresponds to 110% of rated
capacity (= minimum load). It should be easy to
raise the load.
z Now raise a test load that corresponds to 110% of

rated capacity + 100 kg (=maximum load). It
should not be possible to raise this load. (relief
valve opens).
If necessary, adjust the relief valve so that it opens

within the above mentioned tolerance range.
z Hold onto the setscrew and loosen the jam nut (see
Fig. MS-3400-022): Turn the setscrew clockwise to
increase the threshold at which the valve opens, MS-3400-022
turn it anti-clockwise to reduce the threshold.
1 Relief valve setscrew
z Counter-fix the setscrew again with the nut.
56
HYDRAULICS
Relief Valve
Testing and setting the load-sensing

pressure switches
z Power down the truck.
z Remove the panel.
z Remove the connector from the terminal lug of the

load-sensing pressure switch.
z Attach an ohmmeter or a continuity tester to the

terminal lugs of the load-sensing pressure switch.
2
z Power up the truck.
1
z For individual test weights refer to the following
page.
z Raise the test load while observing the test item in

the test menu or the ohmmeter / continuity tester.
If the pressure switch is set correctly, continuity
should be displayed.
z If this is not the case, reset the pressure switch. A

setscrew is located between the terminal lugs of
the pressure switch (2, Fig. MS-3400-023). Turn
this until continuity is displayed.
MS-3400-023
z If it is not possible to make the adjustment, the
pressure switch is faulty and must be replaced. 1 Pressure switch
Lower the load before removing the switch and
2 Setscrew
depressurise the hydraulic system
57
HYDRAULICS
Relief Valve
Setting the pressure switch points Pressure switch PS1
The output signal of the load-sensing pressure switch z Place a load (500 kg) on the forks.
PS1 lies on an input of the platform module. As soon as
the raised load exceeds 500 kg, the signal is used to z Set the switch so that it is activated with load.
control speed reduction.
z Test the switch position by raising and lowering the
load.
The output signal of the load-sensing pressure switch

Pressure switch PS2
PS2 lies on an input of the hydraulic control module.
When the initial lift is raised, this is transmitted to the
hydraulic control module via the switch. z Raise the initial lift without load
z Set the switch so that it is activated (closes) with

initial lift raised.
The output signal of the load-sensing pressure switch
PS3 lies on an input of the platform module. Only when z Set the switch so that it is not activated (open) with
the raised load exceeds 500 kg does the controller the initial lift lowered.
release the 2nd brake level and is used to contribute to
braking. z Test the switch position by raising and lowering the
load.
The signal is also used to control speed reduction.
The correct operation of the pressure switch is Pressure switch PS3

therefore essential for braking with load and for the
other truck functions. It also affects the maximum travel z Place a load (500 kg) on the initial lift.
speed (see chapter 4, Speed Reduction).
z Set the switch so that it is activated with load
(opens).
z Test the switch position by raising and lowering the

load.
DPS1
DPS2-3
58
POWER UNIT
Printed in Germany
59
Notes:
60
POWER UNIT
Gear Unit
Gear Unit z Raise the truck again by approx. 50 mm in order to

be able to loosen the gear unit from the toothing at
a later time.
Preparatory Measures
z Lower the truck onto the wooden blocks/supports.
Raise the truck approx. 500 mm to remove the gear z Raise the device on the jack/pallet truck until it
unit. contacts the gear unit.
Tools required: z Remove the electrical connections from the motor.
z Undo the six gear unit mounting screws (A) and the
z Forklift truck with sufficient capacity, lift height and
three motor mounting screws (B) in Fig. M1564.
fork length for the truck to be raised.
z Safety mechanism for the forks of the lifting truck,

required to hold the raised truck.
z Sufficient number of wooden blocks (surface area

of at least 250 x 250 mm) or suitable supports to
secure the raised truck.

z Device to carry the gear unit onto a jack or pallet
truck.
Disassembly

z Disconnect the battery and remove the key.
z Secure the truck to prevent it from being switched

on again.
z Secure the truck with a second forklift and prevent

it from sliding away.
Danger
Never work underneath a
suspended load.
Fatal injuries could result if the
M1564
truck is suddenly lowered.
A Gear unit mounting screw
z Raise the truck until you can push a jack / pallet
B Motor mounting screw
truck underneath the truck to support it.
z Lower the device together with the gear unit and
pull it out from under the truck.
WD2300S 09/2005 • Printed in Germany M3-XXXX-
61
POWER UNIT
Gear Unit
Servicing General
z All bearings and seals must be replaced.

Warning
z Prior to dismantling, thoroughly clean the gear unit
The gear unit must only be
with a cold cleaning solution and dry with low-
serviced by authorised
pressure pressurised air.
personnel trained by Crown.
Failure to comply with this
z Use assembly equipment and a clean work area.
regulationwill invalidate the
manufacturer’s warranty.
Correcting the flank tooth
bearing and pre-tensioning the
shaft support requires years of
experience with gear units.
Incorrect adjustments and
settings will result in premature
failure of the gear unit.
It is therefore generally
preferable to replace the whole
gear unit.
New gear units are always
supplied without oil.
Before using the gear unit for
the first time, fill oil in
accordance with the "Lubricant
Table".
M3-XXXX- WD2300S 09/2005 • Printed in Germany
62
POWER UNIT
Gear Unit
M1530A
140 Nut 190 Washer

110 Spur wheel 65 Bevel pinion shaft
230 Conical roller bearing 260 Conical roller bearing
440 Shim 70 Bevel pinion shaft
420 Shim 240 Conical roller bearing
360 Screw 160 Spacer ring
290 O-Ring 430 Shim
330 Screw 310 Retaining ring
390 Lock washer 50 Flange shaft
250 Conical roller bearing 150 Wheel bolt
100 Spur pinion 270 Shaft seal ring
130 Live ring bearing 400 Lock washer
30 Lid 350 Hex. socket screw
63
POWER UNIT
Gear Unit Disassembly / Assembly
Gear Unit Disassembly / z Extract the inner ring of the conical roller bearing
(260) from the bevel gear (65).
Assembly
z Push out the flange shaft (50) using a suitable
device.
All item numbers refer to illustration M1530A
unless stated otherwise. z Extract the inner ring of the conical roller bearing
(250) from the flange shaft.
Disassembly z Extract the outer rings of the conical roller bearings
(250, 260) from their seats in the gear unit housing.
z Drain the oil.
z Remove the rotary shaft seal and retaining ring
z Insert the gear unit with the wheel nuts into a (310) from the seat of the housing.
secure device to prevent it from twisting.
z Press the bevel gear (70) down from out of the spur
z Remove screws (330), lock washers (390) and O- wheel (110) and the conical roller bearing (230).
ring and remove lid (30).
z Remove the conical roller bearing (230) and
z Remove the hex. socket screws (350) and the lock shim(s) (440) where applicable.
washers (400).
z Extract the outer ring of the conical roller bearing
z Take off the live ring bearing (130). (240).
z Remove the screw (360) and washer (190). z Extract the inner ring of the conical roller bearing
(240) from the bevel gear.
z Loosen the nut (140) of the bevel gear.
z Thoroughly clean all components and remove the
z Take the gear unit out of the device. remains of the sealant and adhesive.
z Take the bevel gear (65), spacer ring (160) and

adjusting shim(s) (420, 430) where applicable out
of the housing.
64
POWER UNIT
Assembly z Press the rotary shaft seal (270) into the housing
using a suitable tool.
Information Assembling the flange shaft

All bearings and seals must be
replaced. Apply a thin layer of oil to the flange shaft (50) and
carefully fit it in the shaft seal ring (270) and conical
roller bearing (250).
Preparing the gear unit Place the shim (430), spacer ring (160) and pre-
assembled bevel gear (65) onto the flange shaft.
z Press the outer rings of the conical roller bearings
(230, 240, 250 and 260) into their respective
notches in the cleaned housing. Make sure they Information
are positioned level in the housing. Insert the The flange shaft assembly must
retaining ring (310).
be tensioned with a torque
z Press the inner ring of the conical roller bearing wrench.
(260) onto the bevel gear (65).
z Fit the washer (190) and screw (360) and torque
z Screw the wheel bolt (150) into the flange using a the flange shaft assembly to max. 77 Nm.
bolt driver.
z Check the shaft can move freely and make sure
z Bring the housing into its subsequent assembly there is no clearance. If necessary, reduce the
position. torque. Note the final reading. It will be required for
adjustment purposes.
z Insert the inner ring of the conical roller bearing
(250) in the pre-assembled outer ring (blade wheel z Insert the gear unit with the wheel nuts into a
side). secure device to prevent it from twisting.
65
POWER UNIT
Pinion Shaft Aassembly Adjusting the Bevel Wheel Set
z Press the inner ring of the conical roller bearing

(240) onto the bevel gear (70).
Information
Adjust with care. Pre-tensioning
z Insert the pre-assembled bevel gear from the from the bearings and shims will
the inside of the housing into the pre-assembled affect the tooth pattern. Do not
outer rings of the conical roller bearings (230, 240).
set the pre-tension too low. it
z Push the inner ring of the conical roller bearing will automatically reduce during
(230) over the shaft of the bevel gear (70) into the normal operation.
outer ring of the conical roller bearing (230).
The correct setting can be calculated via the tooth
profile pattern.
Information
The spur wheel nut must be Basic Rules:
tightened with a torque wrench.
z Always adjust the bevel wheel set according to the
correct flank position. The tooth ends should not
z Assemble the spur wheel (110) and torque the new form a straight line.
nut (140) to max. 100 Nm.
z The tooth pattern must always align with the inner
z Test the freedom of movement and clearance of tooth end.
the bevel pinion shaft. If necessary, reduce the
torque. Note the final reading. It will be required z The tooth pattern must range from high (top edge
later for adjustment purposes. of the tooth) to low (bottom edge of the tooth).
To adjust, add and/or remove shims (420, 430, 440) or

change the pre-tension of the bearings.
Fig. M1565-1 shows the limits of the permissible tooth

patterns on the bevel pinion and bevel gear.
66
POWER UNIT
Checking the Flank Tooth Bearing Final Assembly
z Colour the tooth profiles of the bevel gear (70) with z Re-assemble the bevel pinion shaft and flange
touch-up past (striking colour). shaft.
z Clean all the components.
z Apply a thin layer of Loctite 307 to the inside of the

bearing inner rings.
z Apply medium strength Loctite 242 (CROWN part

no. 053050-006) to the threads of the nut (140) and
the screw (360 ).
z Re-assemble as described previously.
z Manually turn the gear unit through, while checking

for freedom of movement and ensure it operates
without any clearance.
z Apply a thin layer of Loctite 307 to the flat faces of

the housing lid, insert the O-ring (290) and fit the
lid. Tighten the screws (330) and the lock washers
(390) evenly and crosswise.
M1565-1 z Apply a thin layer of Loctite 307 to the flat face of

the gear unit housing to the live ring bearing. Fit
z Take the gear unit out of the device. the live ring bearing.
z Turn the bevel gear several times in one direction.

The tooth bearing will appear as a bright point Information
(marked black in Fig. M1565-1) on the tooth flanks. Leave the surface and thread
sealants to dry for at least 2
z Check the tooth bearing. Remove and/or add
hours at room temperature.
shims (420, 430, 440) to restore the tooth bearing
to the tolerance limits (Fig. M1565-1). Then fill with oil.
z Set the gear unit in the assembly position.

Warning: Torque the screw (360) and nut (140) to
the previously recorded values. z Replenish with oil up to the bottom marker of the
refill plug – (for the correct oil for the application
Repeat the process until the tooth bearing is within the temperature see the Lubrication and Adjustment
tolerance limits. chapter).
Level: 1.5 l
67
POWER UNIT
Re-Assembly
z Assembly is the reverse of disassembly. Take care

not to damage the toothing of the spur pinion (100)
or the spur wheel (110).
Traction motor
Maintenance and servicing requirements for the

traction motor are described in Chapter 4.
68
ELECTRICAL SYSTEM
Printed in Germany
69
Notes:
70
ELECTRICAL SYSTEM
Wire Colour Code
Wire Colour Code

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 Numbera Function
BLK Black 0** Digital signal

BRN Brown 1** Analog signal
RED Red 2** Positive not allowed
ORG Orange 3** +12 volt DC converter
YEL Yellow 4** Third DC converter
GRN Green 5** Negative not allowed
BLU Blue 6** Insulated negative
VIO Violet 7** +5 volt DC converter
GREY Grey 8** Fourth DC converter
WHT White 9** Various
RED/WHT Red/White 29** Positive connected
GRN/WHT Green/White 59** Negative connected
a. ** Numbers 01 to 99
71
ELECTRICAL SYSTEM
Abbreviations
Abbreviations
Switch Symbol Index of Abbreviationsa
Abbreviation Description Abbreviation Description

K* Relay LMS Limit switch
ACS Travel switch LOS Lower switch
AXS Auxiliary function switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Travel direction switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency Disconnect REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Safety reverse switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS Side lift switch
HSS “Rabbit/Turtle” toggle switch THS Thermo switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk-along / pedestrian mode switch
a. If one of the above abbreviations is used more than once, a number suffix will be used, e.g. SV1, SV2 etc.
72
ELECTRICAL SYSTEM
Abbreviations
Sundry Abbreviations
Sundry Abbreviationsa
Abbreviation Description Abbreviation Description

BV(AK) Battery voltage after the key switch M2(PM) Pump motor
BDI Battery Discharge Indicator MRC Controller
BR Brake OHGD Overhead guard display
BWI Brush wear display P Pump contactor
CA Cable connection PC Plug connection
F Field coil connection 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 block
JC Bushing – counterpart to PC TMM Truck management module
LINE Main contactor TT Hourmeter
M1(TM) Traction motor VMN Motor driver (volt motor negative)
GCSR RH side restraint safety switch GCSL LH side restraint safety switch
PLS Platform switch TCM Traction motor
PS Pressure switch HR Heating
a. If one of the above abbreviations is used more than once, a number suffix will be used, e.g. SV1, SV2 etc.
73
ELECTRICAL SYSTEM
Electrical Wiring Diagrams
Europe USA Description Europe USA Description
Wires joining Switch applied manually
Wires crossing Solenoid valve
Wire connection Throttle / coil
Plug / socket Resistor
Wire strap Capacitor
Terminal board Potentiometer
Fuse Varistor
V
Assembly Thermal protector
Contact, normally Lamp

open
Contact, normally Horn

closed
Selective switch Battery
Contactor / relay Diode
Slow release Breakdown diode

contactor / relay
Time delay contactor LED

/ relay
74
ELECTRICAL SYSTEM
Europe USA Description Europe USA Description
Switch, normally Transistor

open
Push button, MOSFET

mechanically
actuated
Pushbutton, Thyristor
hydraulically
actuated
Emergency Comparator
Disconnect
Motor armature
75
ELECTRICAL SYSTEM
Electrical Components
Electrical Components Brake Switch (BRS)
The brake switch (BRS) is immediately below the

Danger control handle support. The brake switch is activated
as soon as the control handle enters the upper or lower
The truck must be jacked up
braking zone (see Fig. MS-3400-026). The PLM
prior to carrying out repair work
interrupts the power supply to the traction motor (TM)
or troubleshooting the electrical
and the brake (BR) via the traction controller. The
system.
brake coil is switched off. The anchor plate is pressed
against the brake through bias spring force.
Traction Pod (POT, FS, RS)
The traction pod is manually actuated via thumbwheels

on the control handle. The traction pod comprises a
switch (FS) for forward travel, a switch (RS) for reverse C D
travel, and a potentiometer (POT) which governs the
travel speed. The signals are transmitted via drivers on
B
the main PCB.
Fast / Slow Travel Switch (HSS)
The Fast / Slow travel switch (HSS) is activated via a A

rotary switch (Rabbit / Turtle symbol) on the control
handle. The switch signal to the traction controller is
used to change between the high and slow speed
ranges. However, the speed is also dependent on
other factors, see PLM chapter (platform module).
Safety Reverse Switch (SAS) MS-3400-026
The safety reverse switch (SAS) is activated via the

A Lower brake zone
switch cap at the top of the control handle: The PLM
B Travel zone
immediately switches the traction controller from
forward to reverse travel when the SAS is activated. C Upper brake zone
The signal for normal travel to the traction controller is D Neutral / rest zone
simultaneously interrupted. Depending on the traction
controller setting the truck either travels for a given
time, or provided the switch is pressed, travels in
reverse. The SAS function is deactivated in platform
mode.
76
ELECTRICAL SYSTEM
Horn Switch (HNS1 & 2) Diode D4
A buzzer sounds when the horn switch (horn symbol) This freewheel diode on the large brake coil (BR)
is pressed. protects the input on the controller against peak
voltages caused when the large brake coil is switched
off.
Key Switch (KYS)
The key switch directs the battery supply to the traction Diode Block (DB)
controller and the battery discharge indicator (BDI).
The diode block comprises diodes D1 to D3 in a single
component. It acts as a freewheel diode for the small
Emergency Disconnect (BD) brake coil (BR) and guides the pressure switch (PS1)
signal to connect the 2nd brake level.
Pulling the battery connector on the red knob at the top
of the truck completely disconnects the power supply to
the truck. Platform Logic (PLM)
This module detects and analyses the connection

Fuses (FU) status of the platform switch (PLS) and the side
restraint switches (GCSR & GCSL).
The traction control load circuit and the control circuit
are protected by FU2, the control circuit by FU3. Cold Depending on the connection status an output signal is
store trucks have a fuse FU4 for control handle sent to the traction controller which either enables the
heating. The pump load circuit is protected by FU1. higher travel speed or only permits the lower
pedestrian speed.
Thermo Switch (THS, optional) The SAS and BRS signals are also connected via this
module, depending on the platform switch and the side
This switch is an electronic thermostat for cold store restraint switches, as well as the respective function
trucks. Located on the main PCB of the control handle switch.
and applies the heating units at temperatures below 5°
and switches them off from 20°C (switch hysteresis). The RAS signal (main lift) is deactivated from a main lift
height of over 1700 mm plus in platform mode a height
of over 1700 mm.
77
ELECTRICAL SYSTEM
Limit Switch (LMS1) Pressure Switch (PS1)
The limit switch (LMS1) interrupts the initial lift current The pressure switch (PS1) applies when the load
flow when a preset maximum lift height has been raised in the main lift circuit exceeds 500 kg, triggered
reached. The limit switch is under the front panel next by the rise in pressure in the hydraulic system. This
to the control handle support. This switch must be reduces the maximum travel speed in platform mode to
adjusted, see chapter 7, lift mechanism. a safe level. It also applies the 2nd brake level.
Limit Switch (LMS 2, only for masts > Pressure Switch (PS2)
1700mm)
Indicates to the HCM that the initial lift is raised.
Travel stop for lift height of 1700 mm main lift and truck Applied when initial lift circuit is pressurised.
in rider mode. This is controlled by the PLM. This
switch must be adjusted, see chapter 7, lift mechanism. Pressure Switch (PS3)
Limit Switch (LMS3, only for masts > The pressure switch (PS3) applies when the load
raised in the initial lift circuit exceeds 500 kg, triggered
1700mm)
by the rise in pressure in the hydraulic system. This
reduces the maximum travel speed in platform mode to
Automatic lowering of initial lift if the main lift height a safe level. It also applies the 2nd brake level.
exceeds 1700 mm. This is controlled by the HCM.
Initial lift Switch

Limit Switch LMS4
Lifting (ILS Lift-Initial Lift Switch) and lowering (ILS
Speed reduction at a lift height of 880 mm main lift and Lower-Initial Lower Switch).
truck in rider mode. This switch must be adjusted, see
chapter 7, lift mechanism. The lift (ILS Lift) and lower (ILS Lower) switches are
actuated as rocker switches in the lower zone of the
control handle. The lift (RAS) switch activates the
pump contactor (P) which is controlled by the hydraulic
control module (HCM): The pump starts. The lower
(ILS lower) switch applies voltage to the solenoid (SV)
via the hydraulic control module (HCM). The solenoid
opens.
78
ELECTRICAL SYSTEM
Hydraulic Control Module (HCM) Heating Option (F/C)
This module detects and analyses the status of the Fitted to the Main PCB, Hydr. PCB, R/T PCB printed
hydraulic actuation switches (RAS, LOS1, LOS2, ILS circuit boards as well as to an auxiliary board for
Lift, ILS Lower) and some of the limit and pressure traction pod heating.
switches. Depending on the status of the switches, an
output signal is transmitted to the pump contactor or
one of the valves to raise or lower either one of the
main or initial lift circuits.
Raise / Lower Switches (RAS, LOS)

/06
The raise (RAS) and lower (LOS1, LOS2) switches are
activated via rocker switches in the control handle. The /06
rocker switches act on switches assembled on the /06
circuit board of the control handle. The switches are
electrically locked in pairs so that they cannot be
pressed together at the same time. The raise (RAS)
switch activates the pump contactor (P) which is
connected via the hydraulic control module (HCM),
whereby the signal is issued several times via the
platform logic to prevent lifting above 1700 mm in rider
mode: The pump starts. The lower (LOS) switch
applies voltage to the solenoid (SV) via the hydraulic
control module (HCM). The solenoid opens. &$
&$
Control Handle Main PCB (Main PCB)
&$
Support for the drivers of signal transmitters Pot, RS,
FS, HNS1&2, including the THS (option) and the
heating.
Hydraulic PCB (Hydr. PCB)
Support for signal transmitters RAS, LOS1&2, as well

as the heating (option).
MS-3400-027
Speed Transmitter PCB (R/T PCB)
Support for signal transmitter HSS as well as the

heating (option).
79
ELECTRICAL SYSTEM
&$
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%'
69 .<6
/06
30
+1
69/
36
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69 3/0
69 70
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70
&$
36 /('
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MS-3400-017
80
ELECTRICAL SYSTEM
Battery
Battery Replacing the Battery
General Warning
Only use batteries of the
The condition of the battery will affect the performance permitted size, weight and
and driving characteristics of the truck. Optimal specifications for this truck.
maintenance is key to maintaining the performance
and useful life of the battery. An incorrect battery type can
cause damage to the truck.
Warning Incorrect weight and
The battery must be serviced dimensions alter the truck
solely in accordance with the centre of gravity. This can result
battery manufacturer's in fatal accidents.
instructions.
There are several different battery compartment
Incorrect or inadequate models. Refer to the truck operator manual to
maintenance will initially reduce battery replacement instructions.
the performance of the truck
and ultimately result in The operator manual contains the latest safety
premature failure of the battery. instructions and information.
It is essential to adjust the battery discharge indicator

(BDI) correctly to ensure on the one hand that the
battery is not fully discharged and on the other that
there is maximum battery capacity available for the
task in hand.
81
ELECTRICAL SYSTEM
Battery Discharge Indicator (BDI)
Battery Discharge Indicator (BDI) Operation
The upper section of the unigage is a battery discharge The green and yellow LEDs on the battery discharge
indicator with lift cutout, while an hourmeter is located indicator show the degree of discharge on the battery.
in the lower section. A red flashing LED is a warning that the battery will
soon be depleted. If two red LEDs are flashing, the
recorder cuts out lifting. In this event the battery must
be recharged or replaced with a fully charged battery to
restore the truck to service.
MS-3400-028
The purpose of the lift cutout is to monitor and protect MS-3400-029

the battery and the electric components of the truck. To
protect the battery the discharge cycle must not exceed 1 Toggle switch
80% for a full charge (wet cell batteries). 2 Back of recorder
Warning
Greater discharge will result in
permanent battery damage and
can also damage the truck’s
electric components.
82
ELECTRICAL SYSTEM
General If the lift cutout system is activated above 20% of the

battery's residual capacity the battery will not be
damaged, but the truck's maximum operating time
Warning under a single battery charge will not be attained.
The following setting and The lift cutout system should therefore be activated as
calibration instructions for the close to 20% of the battery's residual capacity as
BDI apply only to wet batteries. possible. If at all, it may be slightly above 20%, but
never below.
If maintenance-free batteries
are being used, set the toggle
switch to “P”. No other settings
Information
are required. This applies only For new trucks, adjust the
to batteries approved by Crown. battery discharge indicator after
For other battery types, contact ten discharge and charge
the battery manufacturer.
cycles at the latest.
A battery from the factory will require approx. 5 - 10
charge and discharge cycles to reach its full capacity. Battery Discharge Indicator Setting
A battery is considered to be technically discharged (BDI)
when it has reached 20% residual capacity. For
example, a battery with a 500 amp hour capacity has The acid density is a very reliable indicator of the
an actual available output of 400 amp hours. charge status of a lead acid battery. However, since it
is unrealistic to continually measure the acid density of
In addition, the effective output will depend on the a truck battery to an industrial standard, the battery
discharge speed, which in turn is affected by the voltage is used to determine the charge status over
particular truck application. longer journeys.
The battery discharge indicator must therefore be set To adapt the BDI to the battery used and the truck's
in accordance with the truck's particular application specific application profile, you need the battery
conditions. manufacturer's data sheet. The values you require are
the density of the electrolyte for an 80% discharged
The battery discharge indicator controls the lift cutout battery (20% battery residual capacity) and for a fully
system. The lift cutout system is designed to prevent charged battery (100% battery capacity).
the battery from being operated to the point where is
fully discharged. Finally, via the potentiometer on the back of the BDI the
display is set to the actual discharge terminal voltage of
If the battery is constantly discharged to below 20% of the battery at 20% residual capacity. The factory
residual capacity it will be damaged. default setting of the battery discharge indicator is "N"
(any setting from K to U is possible).
83
ELECTRICAL SYSTEM
Calibration for Wet Batteries z Compare the recorded density with the density
specified by the manufacturer for an 80%
discharged battery (20% residual capacity).
z Fully charge the battery as indicated by the battery
manufacturer in the operating instructions. z If the battery is more than 80% discharged (less
Measure the acid density in accordance with the than 20% residual capacity), set the potentiometer
battery manufacturer's maintenance instructions to on the back of the BDI to direction K.
check if the battery is actually 100% charged.
Faulty battery cells will make calibration z If the battery is more than 80% discharged (less
impossible. than 20% residual capacity), set the potentiometer
on the back of the BDI to direction U.
z Operate the truck as usual under normal operating
conditions until the battery is empty: both LEDs of z Re-charge the battery and check the calibration. If
the BDI will flash and the lift cutout system will be necessary, repeat this process.
triggered.
z Leave the battery for at least 10 to12 hours (one

hour at the very minimum).
z After this interval measure the acid density on at

least three different battery cells. The smallest
recorded value is the one you need.
Setting the discharge terminal voltage in volts/cell
K L M N O P Q R S T U
1.57 1.63 1.68 1.73a 1.78 1.82b 1.84 1.86 1.89 1.91 1.93
a. Wet batteries
b. Maintenance-free batteries
84
ELECTRICAL SYSTEM
Troubleshooting
Connecting terminal 802833
Pin no. Relay option K

8 5
1 No connection
4 1
2 + key switch
3 Relay ARM (+) block
4 Relay N.C. (-) block
5 General (B)
NM P O
L R
T
Q
S
6 Truck service hours
K U
DISCHARGE
7 B+ low (24V)
8 B+ high (48V)
MS-3400-030
Symptoms: Check:
The recorders cannot be reset. Check the battery charge both in terms of voltage and the specific
density. The settings correspond to 2.09 volts/cell. Batteries that have
been charged at a battery acide temperature of 25°C/ 77°F and under
max. charge current up to 1250 SG, will show this voltage. If the
battery cannot be reset, the battery and/or the charger must be
checked.
The truck has to be recharged too quickly Check the specific density of the battery if the red LED on the recorder
is flashing. Do not turn the DISCHARGE setting to K if the specific
density of the battery corresponds to a discharge of more than 80%
(1150 SG for most batteries at a battery acid temperature of 25°/ 77°F
at max. charge current). You can increase the operating time by
turning the DISCHARE setting from N to K, provided the battery does
not indicate a discharge of more than 80%.
85
ELECTRICAL SYSTEM
Contactors
Contactors Inspection
Contacts
The contacts can blacken, swell and roughen during

normal operation. This is normal, and there is no need
to file or polish them. On the contrary: physically re-
worked contacts burn out very rapidly.
Under certain conditions the silver coating of the

contacts can wander from one contact to another and
collect there. This is quite harmless. The contacts must
only be replaced if the silver coating has flaked off to
such an extent that the supporting metal is visible.
Coils
The coil cannot be repaired. In the event of a defect,

replace any coils if no resistance or an endless
resistance can be measured between the connections
M1480 using an ohmmeter.
Springs
Danger
Disconnect the battery before Always replace the springs when fitting new contacts
working on the contactors. and whenever the contacts show signs of corrosion or
discolouring due to overheating.
Important: Only use original Crown contactors as
replacements, or Crown spare parts for repairs. The
contactors are specially made for the truck.
Do not change the place or the angle where they are

positioned, and do not change the wiring.
If dismantling a contactor for inspection or repairs, you

must mark out the position of the contacts with respect
to each other. It is important that contacts that are
already been worked into each other are reassembled
together. Otherwise, excessive wear and premature
failure will result.
86
ELECTRICAL SYSTEM
Contactors
Servicing
This contactor has fixed contacts that are connected to

the cover. As contacts must always be replaced in
pairs, for servicing you need a complete cover, 2
moving contacts and 2 contact springs.
6
Dismantling
All item numbers refer to the illustration unless stated

1
otherwise.
z Unscrew two mounting screws (6) and remove the

upper housing section (5).
5
z Pull out the moving contact (2).
z Unscrew the mounting nuts and take off the fixed 4

contacts (1).
z Clean, check and if necessary replace the

components.
Assembly
2
All item numbers refer to the illustration unless stated
otherwise.
3
Assembly is the reverse order of removal.
z Carefully insert the moving contact into the holes

provided.
z Screw in and tighten the mounting screws with

sealant 053050-006.
MS-3400-031
1 Contact, fixed
2 Contact, moving
3 Coil
5 Housing upper section
6 Mounting screw
87
ELECTRICAL SYSTEM
SEM1 Traction Controller
SEM1 Traction Controller Precautionary Measures
z Do not connect the controller to any battery that

Danger differs from the voltage indicated on the controller
(24 - 26 volts DC). Increasing the battery voltage
The truck must be jacked up
could damage the MOSFETs; while a lower
prior to carrying out repair work
voltage supply would fail to energise the system.
or troubleshooting the electrical
system.
z Only operate the controller with special traction
batteries. Do not connect it to rectifiers or the
General mains network.
z When starting to use the truck, jack it up to prevent

it from moving without the driver in the event of
possible wiring errors.
z When the key switch has been turned off, the filter
capacitors in the controller remain charged for a
few minutes longer. When you work on the
controller at this time, first isolate the controller
from the battery (disconnect the battery). Then
discharge the capacitors by shorting the positive
and negative leads of the power part with each
other over a resistor (10 - 100 Ohm, min. 5 W) for
a few seconds.
Operating Characteristics
M1531
The programmable impulse controller SEM1 provides Speed control

effective control of the truck’s travel performance.
Infinitely variable speed control, programmed via the
The truck is powered by an SEM motor (separate handset, in both traveldirections.
excited motor). With this type of motor there are two
variables for controlling output: field current and
armature voltage.
88
ELECTRICAL SYSTEM
Reduced Travel Speed Zones Anti Roll Down Function
Several independent travel zones with reduced speed This function prevents the truck from rolling down an
are available: incline without the driver. When the key switch is
switched on, the controller monitors the motor speed. If
The corresponding signals are transmitted via switches it detects a rotational movement without a travel
to the platform logic where they are analysed and command being issued, the truck automatically brakes.
transmitted to the controller.
If the truck moves of its own accord on an incline, this
ensures that it automatically brakes to a halt after a
Downhill Speed Control short time. When the truck is stationary the brake force
is removed so that the truck can move again, and again
When the truck travels downhill, the controller monitors braking is activated. If the brake is not applied, the
the motor armature speed, comparing it with the travel truck will therefore move only very slowly down a slope.
signal prescribed by the traction potentiometer. If the
prescribed speed is exceeded, the truck automatically
brakes electrically with energy recovery. Hourmeter
An hourmeter integrated within the traction controller

Regenerative Braking can be optionally set with the help of the programmer
to “KEY ON” (hourmeter activated when key switch is
There are three ways of regenerative braking: on) or “RUNNING” (hourmeter activated only when
truck is travelling).
z Release braking (resetting the accelerator to
neutral)
Self-Diagnostic System
z Inversion braking (setting the accelerator to the
opposite direction) The traction controller self-diagnostic system lists the
five most recent error messages. These error
z Braking through speed restriction on inclines: The messages can be read with the programmer. In
controller constantly governs the motor speed in addition to the error, the error frequency, the respective
accordance with the setpoint prescribed by the number of service hours and the traction controller
accelerator. If the setpoint is exceeded, the truck temperature at the time of the error are logged and
automatically brakes. displayed.
A red LED on the traction controller also indicates the

most recent error via a flashing code. The display is
deleted when the controller is switched off and on
again and if the error was only temporary.
89
ELECTRICAL SYSTEM
Monitored Circuits Safety Mechanisms
The following functions are monitored by the traction

controller microprocessor, depending on the operating Incorrect polarity
mode:
A main contactor controlled by the logic system
z When the truck is switched on: Control logic separates the traction controller from the battery and
(hardware) and program functions (software), field thereby protects the power part from incorrect polarity.
current, VMN, contactor drivers, power up
sequence, travel and lift switch output signals.
Wiring Errors
z Truck on standby (key switch on): VMN, field
current, contactor drivers. All outputs are protected against wiring errors. The
outputs for the main contactor and the magnetic brake
z During operation: control logic (hardware) and can be charged to max. 3 amps and are fitted with an
program functions (software), VMN, field current, overload and short circuit protection.
contactors.
z Permanently monitoring: traction controller

Temperature protection
temperature, battery voltage.
When the power part temperature exceeds 70°C, the
maximum current is restricted in proportion to the rise
in temperature. At 80°C the traction controller
automatically cuts out.
If the temperature drops below -10° the maximum

current is reduced in proportion to the ongoing battery
discharge.
Start sequence
A specific order must be followed for starting up the

truck. Otherwise the main contact will not be activated
and the truck will not operate.
Protection rating
The traction controller is protected against

contamination and spray water (IP 54 protection
rating).
90
ELECTRICAL SYSTEM
Maintenance z Wipe down the traction controller with a clean,

damp cloth.
Maintenance of the SEM1 traction controller is z When everything is dry, reconnect the power cable
restricted to external cleaning and checking the as illustrated in Fig. MS-1723-100.
torques of the nuts securing the power cable
connecting bolts. z Torque the locknut (1, Fig. MS-1723-100)
to 5.5 - 8 Nm.
You should also take this opportunity to check the
errors listed with the help of the programmer.
Important: An incorrect torque can damage the
circuit board and the housing of the controller.
Warning
z Refit the control lines.
The SEM1 traction controller
operates at high currents.
z For cold store versions: Apply a coat of Dow
Particular safety measures are
Corning® 4 Compound, part no. 053051-006, to
therefore required when
the control line connectors. Apply a layer of acid-
handling the controller.
resistant clearseal paint, part no. 805236-003, to
the controller.
Only use specially trained
personnel.
Use non-fatigue goggles. 1
Do not wear loose clothing. 2
Do not wear jewelry. 3
Only use insulated tools. 4
z Disconnect the battery (=EMERGENCY

DISCONNECT). 5
z Jack up the truck.
z Discharge the traction controller capacitors by

connecting the BATT- and BATT+ connections
over a resistance of approx. 10 Ohm, 5 5 W.
z Remove the power cable: Tag out the cable if

necessary. Loosen the bottom nut (1, Fig. MS- MS-1723-100
1723-100).
z Remove any dirt and corrosion from the contact

surfaces.
91
ELECTRICAL SYSTEM
Replacing the SEM1 Traction Controller
Replacing the SEM1 Traction

Controller z Check the contact pattern left behind by the
controller back plate on the heat dissipation sheet.
The controller must lie fully flat on the heat
Warning dissipation sheet. If there are large areas with no
contact to the controller, replace the heat
A WD2300S must only be dissipation sheet to avoid thermal problems.
operated with a SEM1 traction
controller with the correct part z Clean the contact surface of the traction controller
number. on the truck chassis with a lint-free cloth and use
an industry-standard silicon removal agent to
The use of SEM1 traction remove the residue of the heat conducting paste.
controllers with different part
numbers can alter the z Apply a thin and even layer of Dow Corning ® 340
characteristics and result in heat conducting paste, part no. 053051-008 to the
accidents. floorboard (= contact surface of the traction
controller on the truck chassis).
Altered peripherals can also
damage the controller. z Secure the traction controller again with the 4
screws.
When installing a new SEM1 traction controller in a
WD2300S the controller identifies the truck model and z If necessary clean the contact surfaces and refit
automatically loads the correct parameters when it is the power cable (you must follow the instructions in
switched on. the Maintenance section on the previous page)
and refit the connectors for the control lines.
If you have changed and stored the standard
configuration with the programmer, the stored z For cold store versions: Apply a coat of Dow
parameters will be loaded the next time the controller is Corning® 4 Compound, part no. 053051-006, to
started. the control line connectors. Apply a layer of acid-
resistant clearseal paint to the controller.
z Prepare to remove the traction controller as
previously described in the Maintenance section.
Important: After replacing the controller check and
z Remove the 4 mounting screws and remove the adjust the settings. You can adjust the settings to
traction controller. suit the customer’s requirements. Follow the order
described as follows.
z When installing a new traction controller: Using
the part no., check that the new traction controller
is suitable for your truck
92
ELECTRICAL SYSTEM
Parameter Setting after Replacing 5. Test the traction pod starting point at creep speed.
The drive wheel should start when the travel switch
the Traction Controller closes. If necessary increase the value
accordingly. Repeat the test for both travel
Preparatory Measures directions (see PARAMETER CHANGE menu
section).
z Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1). 6. Jack down the truck and bring it to a secure
area where you can perform test runs without
z When the truck is powered down connect the endangering other people.
programmer to the traction controller.
z Power up the truck. Warning

Do not exceed the max.
Adjustment permissible speeds when
making adjustments as
1. If required, change the options for the safety described below.
reverse switch and the internal service hourmeter
of the controller. The standard setting is contained 7. Set the maximum “Forward” (MAX SPEED
in the CONFIG menu table. If you have made FORWARD) and “Reverse” (MAX SPEED BACK)
changes, switch the truck off and on again. This will speeds in pedestrian mode.
activate the changes.
Requirements: No load on forks (PS1), no load on
initial lift (PS3), mast below 880 mm (LMS4), platform
2. Measure the battery voltage directly at the battery up (PLS), side restraints folded in (CSR & GSCL),
and adjust the reading measured and displayed by rabbit/turtle switch set to fast (HSS).
the traction controller (see Config menu section).
Warning: The maximum permissible speed is
3. Using the TEST menu check the wiring and 6 km/h unladen.
operation of the switches (see TEST menu
section). 8. Set the maximum “Forward” (MAX SPEED
FORWARD) and “Reverse” (MAX SPEED BACK)
4. Re-calibrate the traction potentiometer (see speeds in platform mode.
“Traction pod – calibrate potentiometer,
PROGRAM VACC menu). Requirements: No load on forks (PS1), no load on
down (PLS), side restraints folded out (CSR & GSCL),
rabbit/turtle switch set to fast (HSS).

8.5 km/h unladen.
93
ELECTRICAL SYSTEM
9. Set speed level 1 (CTB W C2=0, C3=0 W) in
pedestrian mode.

initial lift (PS3), mast below 880 mm (LMS4), platform 13. Set speed level 3 (CTB W C2=1, C3=0 W) in
up (PLS), side restraints folded in (CSR & GSCL), pedestrian mode.
rabbit/turtle switch set to slow (HSS).
Requirements: More than 500 kg on forks (PS1), no
Warning: The maximum permissible speed is load on initial lift (PS3), mast below 880 mm (LMS4),
6 km/h unladen. platform up (PLS), side restraints folded in (CSR &
GSCL), rabbit/turtle switch set to fast (HSS).
10. Set speed level 1 (CTB W C2=0, C3=0 R) in
platform mode.
2.8 km/h unladen.
rabbit/turtle switch set to slow (HSS). 14. Set speed level 3 (CTB W C2=1, C3=0 R) in
pedestrian mode.
6 km/h unladen. Requirements: More than 500 kg on forks (PS1), no
load on initial lift (PS3), mast below 880 mm (LMS4),
platform down (PLS), side restraints folded out (CSR &
11. Set speed level 2 (CTB W C2=0, C3=1 W) in
GSCL), rabbit/turtle switch set to fast (HSS).
pedestrian mode.
2.8 km/h unladen.
up (PLS), side restraints folded in (CSR & GSCL),
rabbit/turtle switch set to fast (HSS). Warning: Note maximum capacity of truck.
Warning: The maximum permissible speed is Note: The relevant switches are listed in brackets.
3.7 km/h unladen.
15. Set the release brake characteristics: Set the
12. Set speed level 2 (CTB W C2=0, C3=1 R) in unladen truck to maximum speed and release the
platform mode. travel switch. Repeat the test with the maximum
permissible load. If necessary adjust the braking
Requirements: No load on forks (PS1), no load on pattern (RELEASE BRAKING).
rabbit/turtle switch set to fast (HSS).

3.7 km/h unladen.
94
ELECTRICAL SYSTEM
16. Set the braking pattern for changing direction:
Make this setting first in pedestrian mode and then
in platform mode. 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 is
activated 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. Repeat
the process with the maximum permissible load.
Preference should be given to the best setting for
when the truck is unladen.
17. 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.
95
ELECTRICAL SYSTEM
Status LED
Status LED
The status LED is off during normal travel. When an
When the truck is powered up the status LED error occurs it flashes the respective code (see
connected to terminal strip E briefly flashes. This following table) until the error is rectified. The
indicates that the test program is being booted up by programmer can be used to define the error more
the controller. exactly.
Number of Display in Description

flashing codes programmer
1 Logic failure #1 Error in current monitoring system on main contactor

1 Watch dog Error in logic and/or program
1 EEPROM KO Error in EEPROM range
2 INCORRECT STARTS Start sequence error
2 FORW + BACK Both travel directions operated simultaneously
3 CAPACITOR CHARGE Error in power part
3 VMN NOT OK Error during VMN test (armature current circuit)
3 VFIELD NOT OK Error in exciting circuit
4 VACC NOT OK Error in travel potentiometer signal
4 PEDAL WIRE KO Error in traction pod wiring
5 NO FIELD CUR. Error in wiring of exciting circuit or in field signal
measurement
5 HIGH FIELD CUR. Error in wiring of exciting circuit or in field signal
measurement
5 STBY I HIGH Error during armature current detection
5 I = 0 EVER Error during armature current detection
6 CONTACTOR DRIVER Contactor driver error
6 COIL SHORTED Contactor coil shorted
6 CONTACTOR CLOSED Error on contact of main contactor
7 TH. PROTECTION Traction controller temperature too high (> 80°) or too low
(< -10°)
32 BATTERY LOW Battery discharged
96
ELECTRICAL SYSTEM
Travel Speed Test
Travel Speed Test The travel speed can be tested by driving the truck over
a test run of 10 m. The trucks must be operating at
max. speed before they reach the test run and this
Information speed must be maintained over the entire length of the
course. The following table gives the travel speed
The travel speed must be tested values.
when the truck is unladen. The
impulse controller must be set The WD2300S must be tested in both a laden and
precisely before testing the unladen condition.
travel speed. Before starting to
test the travel speed the traction
motor must be at operating
temperature. To reach
operating temperature, drive
the truck at maximum speed
over a distance of 50 m.
Travel speed without load Travel speed with rated load
Rabbit Turtle Rabbit Turtle
Forks and initial lift 5.9 3.8 5.9 3.8

down
Forks above 2.7 2.7 No Drive No Drive
1700 mm (against
overpressure) initial
lift down
97
ELECTRICAL SYSTEM
Programmer
Programmer The programmer is connected to the controller by a

cable, thus powered by the controller.
General Danger
Only connect / disconnect the
The optional programmer enables programming,
programmer to the controller
testing and diagnostics for the controller.
when the truck is switched off.
M0271-new
2
MS-3400-032
1 Display window
z Alphanumeric LCD display
z 2 lines with 16 characters
2 Function keys
98
ELECTRICAL SYSTEM
Programmer
Key description
Key Key reference 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 OUTa Quits a sub-menu or an option. Step by step return to the main menu.
5 PARAM SET UP Increases settings or selects configuration.

6 PARAM SET DOWN Decreases settings or selects configuration.
a. If you have not yet stored the new values you can undo a change by switching the truck on and off.
99
ELECTRICAL SYSTEM
SEM1 Traction Controller Operating Menu
SEM1 Traction Controller ALARMS

Operating Menu In the ALARMS menu error messages generated and
stored during operation can be called up and
processed.
General
When the programmer has been connected a self test

PROGRAM VACC
start routine is performed. The software version of the
controller (e.g. V2.02), the rated voltage and the rated In the PROGRAM VACC menu item the traction
current are now displayed. potentiometer is calibrated. The traction controller
reads and records the potentiometer's minimum and
When it is complete, use the ROLL up/down and maximum output voltage.
ENTER keys to select the required menu.
CONFIG
Menu Functions
The Configuration menu is used to set the operation of
the hourmeter and the safety reverse switch. In
PARAMETER CHANGE addition, the "Adjustments" sub-menu allows for
calibration between the battery voltage measured by
the controller and the actual battery voltage.
In the PARAMETER CHANGE menu the listed truck
parameters can be read and set in real time.
SET MODEL is reserved for future use.
TEST BATTERY ON/OFF must be set to OFF if a Curtis BDI

is used.
In the TESTER menu the listed truck parameters can
be activated, checked and set in real time.
100
ELECTRICAL SYSTEM
Menu Structure for Folding Platform
Menu Structure for Folding

Platform
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
CTB W. C2=0, C3=0 VMN
CTB W. C2=0, C3=1 TEMPERATURE
CTB W. C2=1, C3=0 ACCELERATOR
MAX SPEED FORW W FORWARD SWITCH
MAX SPEED BACK W BACKWARD SWITCH
CTB R. C2=0, C3=0 HANDLE/SEAT SWITCH
CTB R. C2=0, C3=1 QUICK INVERSION
CTB R. C2=1, C3=0 CUTBACK SWITCH
MAX SPEED FRW RU WALKIE SWITCH
MAX SPEED BCK RU BATTERY CHARGE
CREEP SPEED
BATTERY ON/OFF SET MODEL SET OPTIONS ADJUSTMENTS
NOT AVAILABLE HOURS: RUNNING / KEY ON ADJUST BATTERY

QUICK INVERSION: BELLY /
TIMED
QUICK INVERSION ON/OFF
MS-4.4-1723
101
ELECTRICAL SYSTEM
Parameter Setting, Folding Platform
Parameter Setting, Folding

Platform
The settings in this table apply only to traction
controllers with software version SW # 2.01.
Warning
This truck has been supplied
with these values in respect of
Crown safety standards.
These values must not be
increased without express
approval.
Exception:
Tolerance compensation when
installing the controller, see
speed settings.
PARAMETER CHANGE menu, folding platform
Menu item Setting range Recommend Description

ed setting
ACC DELAY 1.15 – 3.00 sec 2 Acceleration delay: The time taken for the traction
controller to increase the output supply to the traction
motors from 0 to 100% (when travel switch suddenly set to
limit).
DEC DELAY 9-0 0 Time taken to reach the new set value when the set value
on the travel switch is changed. Corresponds to the braking
intensity when the transmitter is returned.
RELEASE 0-9 3 Release braking. Activated when the travel switch is
BRAKING released. Time taken for the motor current to fall to zero.
INVERSION 0-9 6 Inversion braking. Activated when travel switch is set to the
BRAKING opposite direction. Time taken for the motor current to fall
to zero.
CTB W. 30 - 100% 9 Maximum current (=speed) for the low speed range
C2=0, C3=0 ACC selected by the fast / slow speed switch (HSS) plus the pre-
set speed reductions (in % of max. current ACC for fast
CTB W. 30 - 100% 4
speed (=normal)) in pedestrian mode. The reduction is a
C2=0, C3=1 ACC
function of inputs C2 & C3 of the controller. CX=0
CTB W. 30 - 100% 1 corresponds to 0 volts, CX=1 corresponds to battery
C2=1, C3=0 ACC positive. Again, the entire mechanical control range of the
transmitter is available. Enables more sensitive travel at
reduced speed.
102
ELECTRICAL SYSTEM
Parameter Setting, Folding Platform
PARAMETER CHANGE menu, folding platform
MAX SPEED FRW 100 - 75% 6 Max. speed in pedestrian mode forward: This reading
W FCN determines the maximum traction current for forward travel.
When the armature voltage has been fully absorbed by the
traction controller, the speed is increased by weakening the
field current. If the value is set to 0 the field current will not
fall below the nominal value (FCN=field current nominal)
when the armature voltage is fully absorbed.
MAX SPEED BCK 100 - 70% 6 Max. speed in pedestrian mode reverse: This reading
W FCN determines the maximum traction current for reverse travel.
CTB R. 30 - 100% 8 Maximum current (=speed) for the low speed range
C2=0, C3=0 ACC selected by the fast / slow speed switch (HSS) plus the pre-
set speed reductions (in % of max. current ACC for fast
CTB R. 30 - 100% 3
speed (=normal)) in platform mode. The reduction is a
C2=0, C3=1 ACC
function of inputs C2 & C3 of thecontroller. CX=0
CTB R. 30 - 100% 0 corresonds to 0 volts, CX=1 corresponds to battery
C2=1, C3=0 ACC positive. Again the entire mechanical control range of the
transmitter is available. Enables more sensitive travel at
reduced speed.
CREEP SPEED 6.5 - 11% 2 Creep speed. Setting for the minimum voltage applied to
Batt. V the traction motor when the travel switch is closed. This
function should be set to one level below the value at which
the truck begins to travel. This ensures that the empty run
of the travel switch is kept to a minimum.
MAX SPEED FRW 100 - 30% 6 Max. speed in platform mode forward: This reading
RU FCN determines the maximum traction current for forward travel.
MAX SPEED BCK 100 - 30% 6 Max. speed in platform mode reverse: This reading
RU FCN determines the maximum traction current for reverse travel.
103
Notes:
104
ELECTRICAL SYSTEM
TESTER Menu
TESTER Menu
The following table describes the various truck
parameters which can be selected and checked in the
TESTER menu.
TESTER Menu
Menu item Description

BATTERY VOLTAGE Battery voltage measured at key switch input.
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
MOTOR CURRENT Current received by motor armature.
FIELD CURRENT Current received by field coil.
VMN Measures the current between VMN (Volt Motor Negativ) and -BATT. The reading
indicates the potential difference over the controller power part.
TEMPERATURE Controller temperature, measured at the aluminium base plate next to the MOSFETs.
ACCELERATOR Displays the nominal signal of the traction potentiometer. The left hand side displays
the voltage reading, the right-hand side the percentage relating to the maximum
operating signal calibrated via PROGRAMM VACC.
FORWARD SWITCH Tests the operation of the “Forward” (FS) switch Displays the open (OFF) and closed
(ON) status.
BACKWARD SWITCH Tests the operation of the “Reverse” (RS) switch. Displays the open (OFF) and closed
(ON) status.
HANDLE/SEAT SWITCH Tests the operation of the brake switch (BRS). Displays the open (OFF) and closed
(ON) status. BRS is connected via PLM, i.e. the controller input is not pulsed in certain
conditions (see PLM chapter).
QUICK INVERSION Tests the operation of the safety reverse switch (SAS). Displays the open (OFF) and
closed (ON) status. SAS is connected via PLM, i.e. the controller input is not pulsed
in certain conditions (see PLM chapter).
CUTBACK SWITCH Speed reduction functional test. The following conditions are displayed
0 –no speed reduction
1 –speed reduction 1 max. 6 Km/h
2 –speed reduction 2 max. 3.7 Km/h
3 –speed reduction 3 max. 2.8 Km/h
The table on the next page shows the platform logic input signals in relation to the
traction controller inputs, and the resulting speeds.
BATTERY CHARGE Displays the battery charge status as a percentage.
105
ELECTRICAL SYSTEM
TESTER Menu
Speed overview
Max. speed in relation to the

reductionlevel
Input PLM Output PLM
PS1 PS3 HSS LMS 4 C2 C3 Speed Max. speed

Pin 18 Pin 20 Pin 6 Pin 19 Pin 15 Pin 16 reduction km/h
Level
+ BV + BV + BV 0V + BV + BV 0 8.5/ 6
+ BV + BV + BV + BV 0V + BV 2 3.7
+ BV + BV 0V 0V 0V + BV 2 3.7
+ BV + BV 0V + BV 0V + BV 2 3.7
+ BV + BV + BV 0V 0V 0V 1 6
+ BV 0V + BV + BV 0V + BV 2 3.7
+ BV 0V 0V + BV 0V + BV 2 3.7
0V 0V + BV 0V 0V 0V 1 6
0V + BV + BV + BV + BV 0V 3 2.8
0V + BV 0V 0V 0V + BV 2 3.7
0V + BV 0V + BV + BV 0V 3 2.8
0V + BV + BV 0V 0V 0V 1 6
0V 0V + BV + BV + BV 0V 3 2.8
0V 0V 0V 0V 0V + BV 2 3.7
0V 0V 0V + BV + BV 0V 3 2.8
+ BV 0V 0V 0V 0V 0V 1 6
106
ELECTRICAL SYSTEM
ALARMS Menu
ALARMS Menu z Error frequency
z Hourmeter status
The traction controller can collect and store operational
faults during operation. The last 5 error messages are z Power part temperature
stored together with the following information:
The ALARMS menu can be used to select and read the
z Type of error respective fault codes.
ALARMS Menu
Error message Description Possible Cause

LOGIC FAILURE #1 Error when testing the main contactordriver Control logic error.
during self-diagnosis when the truck is Replace logic.
powered up.
WATCH DOG Error during self-diagnosis performed when Watchdog circuit (hardware) or program
the truck is powered up, when truck is idle and (software) faulty.
during travel. Replace logic.
EEPROM KO Error in non-volatile memory range. This is Turn key switch off and on again. If the
where the data for the hourmeter, error error persists, replace the logic. If the
messages and truck parameters is stored. error is removed make sure that allthe
stored data has been deleted and reset
to defaults.
INCORRECT START Incorrect starting sequence. The key switch, - Travel switch (FS/RS) or control handle
override switch (move control handle from switch jammed.
neutral to travel position), travel switch (apply - Wiring error
travel switch) sequence must be observed. - Incorrect starting sequence applied by
user.
FORW + BACK The test is performed permanently and checks - Wiring error
if both travel directions are applied - Direction switch jammed
simultaneously. - Incorrect starting sequence applied by
user.
- Control handle main PCB faulty.
CAPACITOR Test during self-diagnosis on power up. If - Armature power cable wiring error.
CHARGE 500 ms after the key switch has been activated - Controller faulty.
the capacitors have not started to charge, an
error message is issued and the main
contactor does not close.
VMN NOT OK Test when truck is idle with main contactor - Motor cable wiring error
closed and during travel. An error message is - Motor losses to earth
issued if VMN - Error in power part
- is below battery voltage when the truck is idle
- does not follow the specification of the driver
during travel
VFIELD NOT OK Test in idle with main contactor open. The error - Motor losses to earth
message is issued if approximately half the - Motor field connections not connected
batttery voltage is not applied to the field or incorrectly connected to the controller.
connections. - Error in field control area of power part.
107
ELECTRICAL SYSTEM
ALARMS Menu
ALARMS Menu
VACC NOT OK Test during self-diagnosis on power up and - Broken wire on potentiometer.
when truck is idle. The error message is issued - Wiring error
if the potentiometer signal deviates from the - Potentiometer faulty.
stored minimum level by more than 2 volts. - Control handle main PCB faulty.
- PROGRAM VACC not / incorrectly
calibrated.
PEDAL WIRE KO The test is performed permanently and - Potentiometer connections not wired or
monitors the travel potentiometer and its interrupted.
wiring. Wire breakage error message. - Potentiometer faulty.
- Control handle main PCB faulty.
STBY I HIGH Test during self-diagnosis on power up and - Current sensor faulty (replace
when truck is idle. The error message is issued controller).
if a current flow is detected. - Error in back-coupling, in logic or in
power part (replace component or entire
controller):
I = 0 EVER The test is performed during travel. The error - No contact with motor (check carbon
message is issued if the traction current does brushes).
not rise above a certain minimum level. - Current sensor faulty (replace
controller).
- Error in back-coupling, in logic or in
power part (replace component or entire
controller):
HIGH FIELD CURR, Test performed permanently and checks the -Error when measuring the field current
NO FIELD CURR field current. (replace controller).
- Field cable not connected.
- Error in power part (replace controller).
CONTACT DRIVER, Test to check the main contactor circuit. - Contactor coil shorted, not / incorrectly
COIL SHORTED connected.
- Contactor driver open or shorted
(replace logic).
- Error in feedback from voltage to
contactor driver (replace logic).
CONTACTOR Test during self-diagnosis on power up. The - Main contactor jammed (check
CLOSED motor field is energised before the main contacts, replace contactor if necessary).
contactor is pulsed. The error message is - Field current circuit faulty (check
issued if the power capacitors do not continuity and connections of field coil
discharge. and field cable).
TH PROTECTION - An error message is issued if the controller - Excessive ambient temperature.
temperature exceeds 70°C. The maximum - Thermostat faulty (replace controller).
current is reduced in proportion to the rise in - Logic faulty (replace logic).
temperature. At 80°C the traction controller - Insufficient heat dissipation (check
automatically cuts out. mounting screws and rest of installation).
- If the temperature drops below -10°C, the
maximum current is reduced to 80%.
- If the error message appears in the normal
temperature range, this indicates an error in
the controller.
108
ELECTRICAL SYSTEM
ALARMS Menu
ALARMS Menu
BATTERY LOW An error message is issued if the battery - Less than 63% of the battery voltage is
voltage drops below 63% of the rated value. applied to input A2 after the key switch.
The current is reduced in proportion to the drop Wiring problem: poor contact, additional
in voltage. The system cuts out at 43% of the consumers, wire too long, small cross
rated voltage. If the error message appears section etc.
when the battery voltage is above 63%, this - Error in microprocessor or when
indicates a fault in the controller or the wiring. measuring the battery voltage (replace
logic).
109
ELECTRICAL SYSTEM
Traction Pod
Traction Pod z Press ENTER. This enables you to select the

calibration routine.
z The display shows the stored minimum and

Calibrating the Potentiometer, maximum voltage of the potentiometer. An arrow in
PROGRAM VACC Menu the display indicates the travel direction to which
the readings are assigned. Arrow up = Forward.
Arrow down = Reverse. If you move the travel
It is always necessary to calibrate the traction pod
switch in the corresponding direction you can
potentiometer when:
change the display accordingly.
z the traction pod potentiometer has been replaced
z Press ENTER to delete the stored values. The
or,
display now shows 0.00 for the minimum and
maximum values.
z the traction controller has been replaced. With the
WD2300S there is no need to physically adjust the
z Pull the control handle towards the travel zone
potentiometer and the travel switch, as is the case
(brake released) and press the travel switch slowly
with the WP2000S.
in the forward direction until it reaches the stop.
Preparatory Measures z The display shows the new minimum and

maximum values and an arrow for the selected
travel direction.
z Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1). z Pull the control handle towards the travel zone
(brake released) and press the travel switch slowly
z Connect the programmer to the traction controller. in the reverse direction until it reaches the stop.
z Power up the truck. z The display shows the new minimum and
maximum values and an arrow for the selected
Calibration travel direction.
z Press OUT when you are ready.

z Press ENTER on the programmer.
z The display asks “Are you sure?”. If you wish to
z Using the ROLL UP and ROLL DOWN keys scroll save the new levels, press ENTER. If not, press
through to the PROGRAM VACC menu. OUT.
110
ELECTRICAL SYSTEM
Traction Pod
z Press OUT to quit the VACC menu.
M1610
111
ELECTRICAL SYSTEM
CONFIG Menu
CONFIG Menu ADJUSTMENTS
The CONFIG menu provides access to the SET In the ADJUST BATTERY menu item you can adapt
OPTIONS, ADJUSTMENTS and SET MODEL sub- the battery voltage measured by the controller to the
menus. actual battery voltage. Using a digital voltmeter
measure the battery voltage directly on the battery.
Adjust the voltage shown in this menu until it matches
SET MODEL the voltage measured directly on the battery.
No function, reserved for future use.
SET OPTIONS
See table below for a description of the parameters.

The standard setting for HOUR COUNTER is
“RUNNING”. For QUICK INVERSION the “BELLY”
setting.
CONFIG menu
Sub-menu Option Description

SET MODEL NOT AVAILABLE This parameter is reserved for future use.
HOUR COUNTER: Determines the operation of the hourmeter contained
SET OPTIONS KEY ON/ RUNNING within the traction controller. The following versions are
available:
- KEY ON: Counts the hours while the truck is switched
on.
- RUNNING: Counts the hours while the traction motor is
activated.
QUICK INVERSION: Determines the operation of the safety reverse switch
BELLY/ TIMED (belly switch):
- BELLY: Truck travels in opposite direction while the
safety reserve switch is pressed.
- TIMED: Truck travels in opposite direction while the
safety reverse switch is pressed, but only for approx. 2
seconds.
QUICK INVERSION: Switch safety reverse switch on or off in platform mode.
ON/ OFF
ADJUSTMENTS ADJUST BATTERY Adapts the battery voltage measured by the controller to
the actual battery voltage. Compensates the drop in
voltage through the wiring and the key switch.
112
ELECTRICAL SYSTEM
Traction Controller Safety Test
Traction Controller Safety Test z Switch off the truck and disconnect the test lead
from VMN (the other end remains connected to -
BATT).
The traction controller safety test takes the form of a
Pulse Monitor Trip Test (PMT). z Attach test lead to F1 (item 2).
In accordance with EU Norm PREN 1175-1 the z Power up the truck. The programmer should
following test must be carried out to check the fuse display VFIELD NOT OK. Activating the traction
circuit. pod should have no effect.
The test requires a test lead of approx. 1 mm2 cross z Switch off the truck and remove the test lead from
section and a 10A fuse. F1 (the other end remains connected to -BATT).
z Switch off the truck and jack it up. z Attach test lead to F2 (item 3).
z Connect one end of the test lead to -BATT. z Power up the truck. The programmer should
display VFIELD NOT OK. Activating the traction
z Connect the other end of the test lead to VMN (see pod should have no effect.
diagram).
z Switch off the truck, remove the test lead
z Connect the programmer to the traction controller. completely, remove the programmer.
z Power up the truck. The programmer should z When the truck is switched on again and the
display CAPACITOR CHARGE. Activating the traction pod activated, the traction motor should
traction pod should have no effect. start.
z If the test proves unsuccessful, replace the traction

controller.
1
FU 10A
2
b 3
+BATT VMN F1 F2 -BATT
A2 F2 F1
A1
TM
Line
M1482
113
ELECTRICAL SYSTEM
WD2300S Platform Logic Box
Platform Logic Controller, Part

No. 816050
Platform Logic Controller, Part No.816050
Total Pins: 20
Used Pins: 18
The truck has THREE modes of operation:
Walkie Mode - Rider Mode - No Drive Mode
Walkie Mode:
1. All three Inputs are low
– Input Pin 2, GCSR is low AND
– Input Pin 3, GCSL is low AND
– Input Pin 4, PLS is low
2. Side restrains are low and PLS is high

– Input Pin 4, PLS is high

Rider Mode:
1. Pin 12 is high when
– Input Pin 2, GCSR is high AND
– Input Pin 3, GCSL is high AND
– Input Pin 4, PLS is high

No Drive Mode:
If the truck is not in Walkie or in Rider Mode, then it is NO DRIVE MODE:
– Pin 12, Rider Mode is low
– Pin 17, BRS output (A5) is low
114
ELECTRICAL SYSTEM
SAS output:
Pin 13 is only high when:
– SAS Input Pin 8 is high AND
– Input Pin 4, PLS is low

BRS output (A5):
Pin 17 is high when:
– BRS Input Pin 5 is high AND
– The truck is in Walkie/ Rider Mode

LLO output (CA221-2):
Pin 14 is high when:
– Input Pin 7, RAS is high
Pin 14 is low when (Low has priority over the high):

– Rider output Pin 12 high AND
– LMS3 Input Pin 9 is high

Speed Control (Controller C2): or
Pin 15 is high when: – Pin 6, HSS is high AND
– Pin 6, HSS is high AND
– Pin 18, PS1 is low AND
– Pin 18, PS1 is high AND
– Pin 19, LMS4 is high AND
– Pin 19, LMS4 is low AND
– Pin 20, PS3 is high
or
– Pin 6, HSS is low AND or – Pin 6, HSS is high AND
– Pin 18, PS1 is low AND – Pin 18, PS1 is low AND
– Pin 19, LMS4 is high AND – Pin 19, LMS4 is high AND
– Pin 20, PS3 is high – Pin 20, PS3 is low

or
– Pin 6, HSS is low AND
– Pin 20, PS3 is low
115
ELECTRICAL SYSTEM
Speed Control (Controller C3): or

Pin 16 is high when: – Pin 6, HSS is high AND
– Pin 6, HSS is high AND
– Pin 18, PS1 ishigh AND
– Pin 19, LMS4 is high AND
or
– Pin 6, HSS is low AND or – Pin 6, HSS is low AND
– Pin 18, PS1 is high AND – Pin 18, PS1 is high AND
– Pin 19, LMS4 is low AND – Pin 19, LMS4 is high AND
– Pin 20, PS3 is high – Pin 20, PS3 is high
or
– Pin 6, HSS is high AND or – Pin 6, HSS is low AND
– Pin 18, PS1 is high AND – Pin 18, PS1 is high AND
– Pin 19, LMS4 is high AND – Pin 19, LMS4 is high AND
– Pin 20, PS3 is low – Pin 20, PS3 is low
or
– Pin 6, HSS is low AND or – Pin 6, HSS is low AND
– Pin 18, PS1 is low AND – Pin 18, PS1 is low AND
– Pin 19, LMS4 is low AND – Pin 19, LMS4 is low AND
– Pin 20, PS3 is high – Pin 20, PS3 is low
Pin 17 (BRS Output) is low when:
– Input Pin 2 AND
– Input Pin 3 AND
– Input Pin 4 are high (Rider Mode) AND
– Input Pin 9, LMS2 is high

+BV (AK):
Pin 1 is connected to +BV (AK)
Batt NEG:
Pin 10 is connected to BATT NEG
116
ELECTRICAL SYSTEM
PLATFORM LOGIC
CA 200
2942 KYS OUT 1 +BV(AK)
2916 JC103-3 GCSR 2 GCSR INPUT
2914 JC101-3 GCSL 3 GCSL INPUT
2915 JC102-3 PLS 4 PLS INPUT
2944 (2956 DIODE BLOCK-2) 5 BRS INPUT
2933 JC202-8 HSS 6 HSS INPUT
2930 PC404-4 BDI 7 RAS INPUT

uC
2932 JC202-11 SAS 8 SAS INPUT
2918 JC107-4 LMS3 9 LMS3 INPUT
505 DIODE BLOCK-1 10 BATT NEG
UNUSED 11 UNUSED
2941 CONTROLLER A-8 12 RIDER OUTPUT
2935 CONTROLLER B-5 13 SAS OUTPUT
2926 PC221-2 HCM 14 LLO OUTPUT
2957 CONTROLLER C-2 15 SPEED OUTPUT
2928 CONTROLLER C-3 16 HSS OUTPUT
2943 CONTROLLER A-5 17 BRS OUTPUT
2901 PS1 18 PS1 INPUT
2917 JC107-3 LMS4 19 LMS4 INPUT
2927 DIODE BLOCK-3 20 PS3 INPUT
MS-3400-033
117
ELECTRICAL SYSTEM
Checking the Platform Logic
Check the platform logic as follows:
In idle
– Power up the truck.
– Unfold the LH side restraint
– Apply travel
– Truck should not move
– Unfold the RH side restraint
– Apply travel
– Unfold the LH and RH side restraints
– Apply travel
During travel (rider mode)

– - Unfold the LH side restraint
– Unfold the RH side restraint
118
ELECTRICAL SYSTEM
Hydraulic Control Module (HCM), Part No. 816177
Hydraulic Control Module (HCM),

Part No. 816177
Initial Lift, Raise:
Operation
Input Initiallift In (CA221-12) to 24V, input LMS Main
The hydraulic control module (HCM) governs the Lift (CA221-14) to 0V:
hydraulic functions ofthe truck as a function of the limit – Output P Out (CA221-12) is active and
switches and the control switches. The HCM outputs
are zero active, i.e. if an output is active zero volts are – Output Initiallift Out (CA221-13) is active and
applied from the module. The proportional valve is
– Output Prop Out (CA221-1) is energised briefly
controlled with fixed defined curves.
(Softlift function).
Main Lift, Raise:
If input LMS Lift Main Lift (CA221-14) is at 24V, there is
no function.
Set Main Lift In input (CA221-2) to 24V: (controlled in
platform logic)
Initial Lift, Lower:
– Output P Out (CA221-12) is active and
– Output Main Lift Out (CA221-6) is active and Set Initial Lift Lower In input (CA221-4) to 24V:
– Output Initiallift Out (CA221-13) is active and
– Output Prop Out (CA221-1) is energised briefly
(Softlift function). – Output Security Lower Valve Output (CA221-8)
is active.
Main Lift, Lower:
– Proportional valve (CA221-1) is active.
Set Main Lower In input (CA221-5) to 24V:

Automatic initial lift lowering:
– Output Main Lift Out (CA221-6) is active and
– Output Security Lower Valve Output (CA221-8) Input Main Lift In (CA221-2) to 24V (controlled via
platform logic) and input LMS Initial Lift In (CA221-9) to
is active and
24V and input LMS Main Lift (CA221-14) to 24V:
– Output Prop Out (CA221-1) is semi-modulated – Raising is terminated (as with quitting RAS)
(slow lowering). and
Also activate input LOS2 In (CA222-3) to 24V: – Initial Lift lower is introduced until the input
LMS Initial Lift In (CA221-9) is not longer
– Output Prop Out (CA221-1) is fully modulated activated, or input LMS Main Lift (CA221-14) is
(fast lowering). not longer activated. If in the meantime input
Main Lift In (CA221-2) is no longer activated,
the current operation is terminated. Otherwise
the Main Lift is automatically raised again after
the Initial Lift has lowered.
119
ELECTRICAL SYSTEM
HCM
CA 221
2907
2921 2953 SVL 5902 1 PROP OUT
2904
2926 PC200-14 LLO OUT 2 MAIN LIFT IN
2925 TCM D-4 3
2906 LMS1 4 INITIAL LIFT IN
2931 JC202-2 MAIN LOWER 5 MAIN LOWER SWITCH IN

2908
SV1 5904 6 MAIN LIFT OUT
2909 PS1
2920 7
2920
2904 2952 SV3 5901 8 SECURITY LOWER VALVE OUTPUT
2903 PS2
2903 LINE 2948 9 LMS INITIAL LIFT IN
2921
2934 JC202-9 INITIAL LOWER 10 INITIAL LOWER IN uC
502 PM BATT NEG 11

2947 LINE
2902 JC103-2 GCSR P 5905 12 P OUT
2908
2907 2954 SV2 5903 13 INITIAL LIFT OUT
2950
2946 JC107-2 LMS2 14 LMS MAIN LIFT
PS3
2950 2951 DB-3 CA 222
UNUSED 1 UNUSED
UNUSED 2
2958 JC202-5 LOS2 3 LOS2 IN
UNUSED 4
MS-3400-034
120
ELECTRICAL SYSTEM
Calibrating the HCM
The system must be re-calibrated every time the wiring

of the HCM module, the proportional valve or the
hydraulic wiring is disconnected. Apply the following
procedure:
z Connect the battery if it is not already connected.
z Turn the key switch ON (lifting and lowering must

be ready for operation).
z Raise the forks to a height of approx. 1 m.
z Disconnect the battery.
z Depress and hold down the “Lower” switch.
z Connect the battery.
z Depress and hold down the “Lower” switch for 5

seconds. The forks should not lower during this
period.
z Release the lowering functions.
z Switch the truck off and on again.
z The procedure is complete. Check all operations in

accordance with the truck’s specifications.
121
ELECTRICAL SYSTEM
Electric Motors
Electric Motors z 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:
General Maintenance Instructions
Oil or grease burns in the brush sparks and leaves
The following instructions apply to all motors. Details behind a highly abrasive oil ash which can very quickly
relating to specific models and designs are provided in destroy the collector and the brushes.
the sub-sections (traction motor, pump motor etc.).
z The brushes must be able to move freely in the
brush support (without spring tension) without
Preparatory Measures tilting. Never modify brushes if one or more
brushes cannot move freely. In this case replace
z Disconnect the battery all brushes as they will probably have been
thermally overloaded. Thermal overloading
z Prevent the truck from rolling away. (temperatures >160 ºC) causes the brushes to
swell up. Brushes which jam in the brush support
produce intense sparking and destroy the
Important Maintenance Instructions
collector.
z Remove all carbon brushes and check for wear. If z The brush edges must not be cracked. Brushes
one or more carbon brushes need to be replaced, with cracking along the long edge of the surface
replace all brushes. In addition to the carbon will have been damaged by a worn collector. If
brushes the pressure springs must also be information is provided in the manual, restore the
replaced to ensure the correct pressure. collector to the specified limits. Otherwise, replace
the armature in full.
The length of the shortest brush determines whether
the brush set needs to be replaced. z Loose brush connections are a clear sign of motor
overload. In this case inspect the collector for
Even if the minimum length has not been reached the burning and repair or replace as necessary.
brushes should be replaced as the remaining useful life
could be much shorter than the time until the next z When fitting the brush take care to place the spring
inspection: gently on the brush. If the contact is too hard the
brush will be damaged.
If a brush is too short the spring will lie on the brush
support. The brush sparks during operation and burns z Make sure that all brushes contact the armature at
the collector with corresponding damage. the same pressure.
z Blast the motor with dry compressed air only. z New brushes must be run in with a medium load in
the first hours. Never fully charge the motor
z Check the armature for unevenness, burning, straight away.
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.
122
ELECTRICAL SYSTEM
Traction Motor Maintenance
Traction Motor Maintenance Maintenance
z Apply dry compressed air to the motor.

Access to brushes
z Remove all carbon brushes and check them with
z Disconnect the battery the armature in accordance with the instructions in
"Important Maintenance Instructions".
z Prevent the truck from rolling away.
z Length of new carbon brushes: 30 mm
z Remove the tensioning belt from the motor.
z Carbon brush wear limit: 23 mm
z Refit the tensioning belt.
MS-3400-036
MS-3400-037
1 Carbon brushes
123
ELECTRICAL SYSTEM
Traction Motor Maintenance
Armature Bearings
z A new armature has a max. diameter of 64.5 mm. z The ball bearings are maintenance-free. They
must always be replaced if removed for repair
z The armature can be overwound provided the work.
diameter is no less than 61.5 mm
z The armature must be replaced if its diameter

is60.5 mm or less.
z After overwinding cut the mica down to 1.5 mm

below the multi-plates without changing the gap
width between the multi-plates.
z The multi-plate edges must be carefully de-burred.
124
ELECTRICAL SYSTEM
Pump Motor Maintenance
Pump Motor Maintenance Maintenance
z Remove the tensioning belt from the pump motor.

Access to brushes
z Apply low pressurised air to remove dust from the
motor.
z Remove all carbon brushes and check them with

the armature in accordance with the instructions in
"Important Maintenance Instructions".
z Fit new springs.
z Fit new brushes.
z Check that the brushes can move freely.
z Check that the contact pressure is the same for all

springs.
z Refit the tensioning belt.
z Reconnect the battery.

1
z Test the pump.
MS-3400-038
z Remove the mechanism for preventing the truck
from rolling away.
1 Pump motor
z Length of new carbon brushes: 25 mm
z Disconnect the battery z Carbon brush wear limit: 14 mm
z Prevent the truck from rolling away. z Remove and discard the brushes.
z Remove and discard the springs.
Armature
z Turn the armature coil and check for signs of

burning or other damage. Replace the armature if
necessary.
z New anchors have a 45 mm diameter. The wear

limit is 44 mm.
z The armature must not be overwound. Instead it

must be replaced when the wear limit has been
reached.
125
Notes:
126
BRAKE
Printed in Germany
127
Notes:
128
BRAKE
Brake
Brake 3 Hex. socket screw

7 Magnetic body
8 Screw
10 Spring
11 Pressure item
12 Spring
13 Bushing
14 Tie plate
15 Hub
16 Rotor
17 Hollow screws
18 Friction plate
20 Electric plug connection
17 17
M1535
3 Hex. socket screw
M0195-1
129
BRAKE
Brake
z Unscrew the friction plate (18) from the motor
flange. A new friction plate (18) is 1.0 mm thick.
Replace if necessary.
Warning
z Remove the screws (8) from their respective nuts.
Do not allow brake components
to come into contact with oil or
z Unscrew the hollow screws (17) from the magnetic
grease.
body (7), (3 off).
z Remove the tie plate (14).

The item numbers in brackets refer to Figure M0195-1.
z Thoroughly clean and de-grease the components.
DISCONNECT). Test and Inspection
z Jack up the truck until the drive wheel is free,
support the truck and prevent it from rolling away. z Check the tie plate (14), friction plate (18) and rotor
(16) for even wear, deep grooves, cracks and
z Remove the front panel. signs of burning. Replace any worn or damaged
components.
z Apply pressurized air to brake dust.
z Check crimp connections of the brake wiring in
z Undo the electrical connection (20) from the brake connector CA 407 for any loose or broken wires.
wiring (CA407). Replace any damaged crimp connectors.
z Unscrew the three hex. socket screws (3). z Test the coils of the magnetic body (7) using an
ohmmeter. To do this, on connector CA407
z Remove the magnetic body (7) from the motor measure between ...
(including everything connected to it).
CA407-1 and CA407-2 (BR/1): 10.5 ± 1 ohm
Dismantling CA407-3 and CA407-4 (BR/2): 33 ± 3 ohm
If the resistance levels of a coil are outside the

z Remove the rotor (16) from the hub (15). Do not
tolerance range, replace the magnetic body (7).
damage the toothing
z Check the insulating compound used to protect
z Measure the thickness of the rotor (16). Replace
and secure the coils in the magnetic body (7) for
the rotor (16) if the lining is less than the minimum
cracks. Replace the magnetic body (7) if cracks
thickness of 6.0 mm (a new rotor (16) is 10 mm
are found.
thick).
130
BRAKE
Brake
Assembly
Warning
Do not allow brake components
to come into contact with oil or
grease.
z Re-insert any pressure items (11) and springs (12)

that may have fallen out of the magnetic body (7).
First the springs (12), then the pressure items (11).
z Insert the spring (10) and bushing (13) in the

magnetic body (7).
z Place the tie plate (14) in the correct position on the

magnetic body (7), while noting the hole pattern.
z Screw the hollow screws (17) into the magnetic

body (7) as far as the stop, using a medium
strength sealant.
z Insert the screws (8) into the tie plate (14) just so
far that a uniform gap of 1 mm remains between
the tie plate (14) and the magnetic body (7).
z Screw the friction plate (18) onto the motor.
z Push the rotor (16) onto the hub (15). Avoid

damaging the toothing.
M1535
3 Hex. socket screw
z Attach the pre-assembled magnetic body (7) with

the hex. socket screws (3) to the motor.
z Refit the electric plug connection (20).
Caution
After assembling, it is important
to set the air gap correctly, test
the braking distance (see
following page) and set the
braking torque if necessary.
131
Air Gap Setting Braking Torque Setting
The operating air gap (A) is measured between the

magnetic body (7) and the tie plate (14) when the
brakes are applied.
The air gap must be set to 0.25 mm (see Fig.

M1467).
z Unscrew the hollow screws (17) until they are in

fixed contact the friction plate (18).
z Torque the hex. socket screws (3) evenly to 9.5 M1535-2

Nm.
a Inner ring
z Check the operating air gap (A) along several
b Outer ring
points using a feeler gauge. The air gap (A) should
be even all the way along. c Safety plate
The braking torque can be set independently for the

z To increase the air gap (A) unscrew the hollow
first and second stages. Turn the outer ring (b) into the
screws (17) slightly. To reduce the air gap (A)
magnetic body (7) to increase the torque of the first
screw the hollow screws (17) into the magnetic
stage (BR/1). Turn the inner ring (a) to increase the
body (7). Now, measure again as described above.
torque of the second stage.
z When the air gap has been correctly set, torque the
The settings are latched due to the retaining
hex. socket screws (3) again to 9.5 Nm.
components (safety plate “c” for the first stage and
safety screw for the second stage). No intermediate
positions are possible, as the retaining components
must work!
For the basic settings refer to the table below (screw

depth A).
M1467
3 Hex. socket screw

17 Hollow screw
A Operating air gap
B Rotor thickness
132
BRAKE
Brake
Brake Test After adjusting the first stage test the brakes with
maximum load.
z Accelerate the empty truck at operating If necessary, remove the safety screw (4, Fig. M0195-
temperature with a fully charged battery on a level, 1) from the inner ring (a) and using the threaded ring
dry and non-skid concrete surface to maximum (6) alter the braking torque until the braking distance
speed. (see table below) with maximum capacity load is within
the tolerance limits.
z Set the control handle to the lower braking range.
Now tighten the inner ring (a) again using the screw (4)
z Measure the braking distances from the time the and washer (5).
brakes are applied to the point where the truck
comes to rest.
If necessary bend up the tappet of the safety plate (c)

and alter the braking torque with the outer ring (b) until
the braking distance for the empty truck is within the
tolerance limit (see table below). Now secure the outer
ring (b) again with the safety plate (c).
Information
If the maximum travel speed is
the same with or without rated
load, the load-sensing pressure
switch is either faulty or
incorrectly set. In this case the
braking distance will be too
long. Check the load-sensing
pressure switch before
adjusting the 2nd brake stage.
(See chapter 2, Hydraulics)
WP 2300 S Rated Braking Distances and Screw Depths
Model Capacity Screw depth A Braking distance (new Braking distance (used
brake) brake)
With rated Without load With rated Without load
load load
2330S 2000 kg Inner ring = 7.4 mm 1.0-1.2 m 1.0-1.1 ma 1.0-1.1 m 0.9-1.0 ma
Outer ring = 7.6 mm 1.6-1.7 mb 1.5-1.6 mb
a. Pedestrian mode
b. Rider mode
133
Notes:
134
STEERING
Printed in Germany
135
Notes:
136
STEERING
Control Handle Return Springs
Control Handle Return Springs z Tilt the control handle (8) fully down.
z If the axle (3) still hasn’t turned, it is obviously rigid

Caution and must be assisted with the aid of the face
wrench. Turn the axle (3), viewed from the LH side,
Pre-tensioned springs! anticlockwise approx. 20° from the fixed position to
Use care when removing them fully discharge the springs (4).
to avoid injuries.
Before carrying out any work on the control handle:

DISCONNECT).
z Prevent the truck from rolling away.
Adjustment
The LH side of the axle (3) is fitted as standard with a

dowel pin (5). If the bias spring force reduces over time,
the pre-tension of the springs (4) can be increased as
follows:
z Unscrew the panel (1) and push it up.
z Leave the control handle (8) in the neutral position

(up).
z Drive out the dowel pin (2) on the LH side.
z Use a face wrench to turn the axle (3) a

corresponding distance. Drive in the dowel pin (2)
on the RH side.
z If the spring tension is now still not sufficient to

keep the control handle (8) up, replace the springs
(4).
Disassembly
M1562
z Unscrew the panel (1) and push it up. 1 Panel

2 Dowel pin
z Bring the control handle (8) up fully and maintain it
in that position. 3 Axle
4 Spring
z Mark the axle (3) position. 5 Dowel pin
8 Control handle
z Drive out the dowel pin (2).
z Drive the axle (3) out to the right so that the two
z The discharged springs (4) should now turn the springs (4) can be removed.
axle (3).
137
STEERING
Control Handle Return Springs
Installation
z Push the springs (4) onto the axle (3). The inner,
angled end should enter the groove of the axle (3)
in the process. It can be useful to attach a belt
around the inner end of the first inserted spring (4),
in order to help line up the other springs (4).
z Drive the axle (3) in fully.
z Tilt the control handle (8) up as far as the stop.
z Drive the dowel pin (2) into the LH side (RH side if
necessary). To do this, turn the axle (3) sufficiently
far. Lubricate the springs (4). Secure the panel (1).
Check the brakes.
138
STEERING
Control Handle Grip
Control Handle Grip
Main Components
This section contains an overview of the main

components and associated terms:
MS518
a Upper shell
b Switch unit
c Hand grip
d Lower shell
e Control handle tube
139
STEERING
Control Handle Grip Components

To access the individual components of the hand grip
you will require:
– Torx® screwdriver set
– a small screwdriver with a flat blade.
Caution
Danger of electric shock
De-energise the truck
(disconnect the battery) and
prevent it from being switched
on again.
Unless otherwise stated, all screws must be torqued to

the standard rating. See chapter 1 of this manual for the
torque table.
MS514
Hand Grip Shells
B Thumb marking
C Thumbwheel
Upper and lower shell removal
z Press the thumb markings (B, Fig. MS514) on the
switch unit or pull on the thumbwheels (C). The
switch unit will slide up out of the bottom shell.
z Disconnect the plug connections from the control

handle wire harness and the horn switches from
the switch unit printed circuit boards (arrow).
MS513
A Torx screw
z Remove the Torx®- screws (A) shown in Fig.

MS513.
140
STEERING
MS501
MS502
A Torx screw
z Using a small flat bladed screwdriver lever off the
cover on each hand grip (see arrow, Fig. MS502). z Remove the inner Torx® screws (A) shown in Fig.
MS501 and pull off the grips.
MS503
z Gently press in the horn switch and pull it out of the

grip (see arrow, Fig. MS503). Disconnect the plug
connection from the switch.
MS517
B Torx screw
C Torx screw
141
STEERING
z Remove the two Torx® screws (B) shown in Fig. z Remove the 4 Torx® screws (A) shown in Fig.
MS517 and the six Torx® screws (C). Lift out the MS513.
shells.
Upper and lower shell assembly
Assembly is the reverse of disassembly. When

assembling, take care not to damage thewiring.
Switch Unit
Disassembly
The switch unit contains the safety reverse switch, the

travel switch, the “rabbit/turtle” switch, the main PC
board and the pump controller PC board.
Replacing any of these components requires the

switch unit to be replaced. MS514a
A Thumb marking
B Thumbwheel
C Side section
z Press the thumb markings (A) shown in Fig.

MS514a on the switch unit or pull on the
thumbwheels (B). The switch unit will slide up out
of the bottom shell.
z Disconnect the plug connections of the control

handle wire harness and the horn from the switch
unit PC boards.
MS513
A Torx screw
142
STEERING
Switch unit assembly
Assembly is always the reverse of disassembly.
Make sure you re-connect the control handle wire

harness and the horn wiring.
Information
The connectors cannot be
interchanged and are protected
against incorrect polarity.
z Guide the switch unit shown in Fig. MS514a over

the two side sections (C) while pushing the switch
unit down and to the front.
z Tighten the mounting screws (A) shown in Fig.

MS513.
z Test all the functions once the battery has been re-
connected.
143
STEERING
“Rabbit/Turtle” Toggle Switch
There are no parts on this switch module that can be z Refit the switch unit (see Switch Unit section in this
repaired. It must be replaced in full. chapter). Test the operation.
This switch module is available in two versions: a

standard and a cold store version. Make sure you
use the right module!
MS504
B Torx screw
Hydraulic PC Board
MS511
There are no parts on this PC board that can be

A Torx screw
repaired. It must be replaced in full.
This PC board is available in two versions: a

Disassembly
use the right PC board!
z Remove the switch unit (see Switch Unit section in
this chapter). Disassembly
z Remove the two inner Torx® screws (A) shown in z Remove the switch unit (see Switch Unit section in
Fig. MS511 and remove the toggle module. this chapter).
Installation z Remove the two Torx® screws (B) (see Fig.

MS504) from the smaller of the two PC boards (the
larger one is the main PC board). Lift out the
z Insert a new toggle module and fix it with 2 Torx®
hydraulic PC board.
screws.
144
STEERING
Installation
z Insert a new hydraulic PC board (make sure it is

the right type, cold store or standard). Fix the board
with 2 Torx® screws (B).
z Refit the switch unit (see Switch Unit section in this

chapter). Test the operation.
Main board removal/installation
This PC board is available in two versions: a

use the right PC board!
Information
Because of its compact design,
it may be difficult to use
this process to reach the
connector on the main PC
board. If you experience
difficulties replacing the PC
board using the above
procedure , remove the
thumbwheel, the lower panel 10682
and the panel of the upper shell
(see “Potentiometer A Torx screw
Installation” in this chapter). X Main PC board
There are no parts on this PC board that can be z Remove the two Torx® screws (A) from the larger
repaired. It must be replaced in full. main PC board (X, the smaller one is the hydraulic
system printed circuit board). Disconnect the wire
z Remove the upper shell (see “Upper Shell” in this connector of the safety reverse switch from the
chapter). main PC board (X) and remove the main PC board
(X).
z Disconnect the potentiometer connector from the
main PC board. z Re-assemble the main PC board (X) in the reverse
order.
145
STEERING
Potentiometer
There are no parts on the potentiometer that can be

repaired. It must be replaced in full.
The potentiometer is available in two versions: a

use the right potentiometer!
MS509
C Torx screw
z Remove the four Torx® screws (C) shown in Fig.

MS509. Remove the switch unit cover.
MS508
A Torx screw
B Torx screw
Disassembly

this chapter).
z Remove the two Torx® screws (A) in Fig. MS508

from the thumbwheels and disconnect the
thumbwheels. Take care not to lose the plastic
slide bearings (washers).
z Remove the two Torx® screws (B) shown in Fig.

MS508 holding the orange lowering switch cap. Lift
MS510
out the switch cap.
D Torx screw
z Remove the 2 Torx® screws (D) shown in Fig.

MS510. Remove the connectors from the PC
boards. Pull the potentiometer off the square axis.
146
STEERING
Installation
Before connecting the cable to the potentiometer:

Fill the potentiometer bushing with grease part no.
053002-005. Do not use any other grease.
Potentiometer assembly is the reverse of disassembly.
Safety Reverse Switch
Disassembly
MS509
C Torx screw
z Remove the two Torx® screws (B) shown in Fig.

MS508 holding the orange lowering switch cap. Lift
out the switch cap.
MS508
A Torx screw
B Torx screw

this chapter).
z Remove the two Torx® screws (A) in Fig. MS508

from the thumbwheels and disconnect the
thumbwheels. Take care not to lose the plastic
slide bearings (washers).
MS500
D Torx screw
E Switch bypass
F Torx screw
147
STEERING
z Remove the four Torx® screws shown in Fig.
MS509. Remove the switch unit cover.
z Remove the Torx® screw (item D, Fig. MS500)

and pull out the switch bypass (item E).
z Remove the two Torx ® screws (item F).

Disconnect the microswitch from the main PC
board.
Installation
z Assemble the safety reverse switch in the reverse

order of disassembly.
Before connecting the microswitch to the main PC

board: Lubricate the microswitch connector with
grease part no. 053002-005. Do not use any other MS502
grease.

chapter) and test the operation.
Information
The thumbwheels cannot be
incorrectly positioned. They will
only fit correctly in one position.
148
STEERING
Horn Switch Hand Grip
Disassembly Disassembly

this chapter).
MS503

this chapter).
z Use a small flat screwdriver to lever off the panel

on the hand grip shown in Fig. MS502.
MS502
grip (see Fig. MS503). Disconnect the plug
connection from the switch.
Installation
Information
The switches on the LH and RH
grips are different. If you fit the
switch on the wrong side the
horn symbol will be upside
down!
Assemble the horn switch in the reverse order of

MS503
disassembly.
z Use a small flat screwdriver to lever off the panel
z Refit the switch unit (see Switch Unit section in this on the hand grip shown in Fig. MS502.
grip.
z Disconnect the plug connection from the switch

(see Fig. MS503).
149
STEERING
z Remove the inner Torx® screw shown in Fig. Assemble the hand grip in the reverse order of
MS501 and pull off the grip. disassembly.

Initial Lift Switch
1 2
MS501
Installation
Information
The switches on the LH and RH
grips are different. If you fit the 126-2681
switch on the wrong side the

1 Initial lift switch
horn symbol will be upside
2 Shell
down!
150
STEERING
Disassembly Installation
z Remove the switch unit (see Switch Unit section in z Assemble the auxiliary switch in the reverse order
this chapter). ofdisassembly.
z Remove the two screws connecting the clip (1) to Make sure the gap between the switch cap (4) and the
the shell. shell (5) is even throughout its circumference. The
switch cap must not jam when applied.
z Remove the screw (2, not visible in the drawing)
connecting the switch to the clip. Lift out the switch z Refit the switch unit (see Switch Unit section in this
block. chapter) and test the operation.
z Remove the two screws (3) to remove the

microswitch.
151
Notes:
152
MAST/LIFT MECHANISM
Printed in Germany
153
Notes:
154
MAST/LIFT MECHANISM
Lift Linkage
Lift Linkage Carry out the measurement on an even surface

(evenness less than or equal to 1 mm).
Adjusting the Fork Height
Note: The item numbers in brackets refer to Fig. M1438

on the following page.
82 ±3mm
82 -3mm
130 ±5mm
MS1723-701
155
MAST/LIFT MECHANISM
Lift Linkage
Fork Adjustment
Adjusting the fork height
z Raise the forks to gain access to the tie rods.
z Loosen the tie rod counternut (Fig. MP-3400-005,

item 17).
z Adjust the tie rod so that the stop of the outrigger

jack have evenly distributed contact to the forks
when the forks are fully lowered. To do this, turn
the tie rod (item 16) on the hex. nut (item A).
z The fork height must be measured directly above

the load wheels. (fork tip height): The rated value
of 82 mm should not be exceeded.
z Measure the fork carriage height from the fork tip

(fork height). The rated value of 95 mm should not
be exceeded.
z Measure the fork height from the back of the fork

shank. (fork shank back height): The rated value of
95 mm should not be exceeded.
z The fork shank back height should be the same or

greater than the fork tip height.
z Tighten the tie rod counternut (Fig. MP-3400-005,

item 17).
156
MAST/LIFT MECHANISM
Lift Linkage
6 7
5
4
3
2 Forke Carriage Frame

1
5
4
Power Unit
10 11
13
14
5
8 11 9 Forke Carriage Frame

5 15
16 A
17
11
12 20 14
9
18
5
9
23
13
26
21
11 25
Forke Carriage 11
Frame 11
25 24
26
22
19 24
23
MP3400-005
157
MAST/LIFT MECHANISM
Mast
Mast Mast Removal
Danger Caution
Risk of trapping and severing Always apply chocks when
limbs! working on a raised mast, even
When carrying out work on the when it is connected to a hoist.
mast and the attachments:
always block the mast stages 1. Position truck under appropriate lifting device.
and attachments to prevent
them from accidentally moving.
2. Lower fork carriage completely. Make certain to
Make sure the wooden blocks
and lifting gear used have remove load, if applicable, from forks.
sufficient capacity.
3. Fully raise the initial lift.
General 4. Jack up the truck: The instruction “Jack up the

truck” always implies that the raised truck is
Torque Requirements lowered onto a secure base.
All screw connections on the mast must be torqued to 5. 2 wooden blocks under the chassis, 2 under the
the standard values. See Chapter 1 for these values. forks. See following illustration
Please note: The mast screw connections must be 6. Turn the key switch OFF. Remove the key and
torqued to 320 Nm. disconnect the battery.
Lifting Gear Minimum Capacity 7. Attach warning tag to control handle to advise
Note the minimum capacity for the lifting gear
whenever carrying out work on the mast.
z Mast without fork carriage: 200 kg
z Fork Carriage: 100 kg
These figures are excluding forks and

attachments.
158
MAST/LIFT MECHANISM
Mast
11. Attach lifting device at top of all sections of the
mast assembly. Then raise lifting device just
enough to eliminate any slack in lifting chains/
slings.
12. Remove mast mounting nuts that secure the outer

mast to the power unit. The nuts should only be
used once and must then be replaced with new
ones of the same type.
13. Remove mast assembly and fork carriage from

truck.
G_WD-jack-up
8. Chock drive tire and load wheels.
9. Disconnect all electrical connections that may

prohibit removal of the mast assembly.
10. Disconnect the hydraulic supply lines to the mast

lift cylinders. Seal connections to minimize oil loss
and prevent hydraulic system contamination.
159
MAST/LIFT MECHANISM
Mast
5. Connect electrical connections between power unit
Installation
and mast assembly.
Warning 6. Remove lifting device from mast assembly.
Wear appropriate safety

7. Remove chocks.
clothing such as safety glasses
and shoes, whenever
performing maintenance work. 8. Connect battery and remove warning tag from the
To avoid injury, do not place control handle.
fingers, hands, arms or feet
through mast and keep them 9. Air that may have entered the system must be bled
away from pinch points.
from the system. Follow the procedure outlined
under "Cylinder Bleeding and Flushing", section
1. Attach lifting device at top of all sections of the
M8, to bleed the hydraulic circuit.
mast assembly.
10. Carry out a lowering plumb test after attaching the

2. Raise mast assembly and move it into position
mast. If the test results are outside the tolerance
against the power unit. When attaching the outer
range, re-adjust the mast and repeat the test.
mast to the drive unit slowly suspend the mast to
avoid damaging it. Place shims between the mast
and the power unit so that the mast is vertical in its
longitudinal section and horizontal in its cross-
section (see first diagram on last page).
3. Secure the mast assembly to the power unit using

new nuts of the same grade. Torque the screws to
320 Nm.
4. Remove any pipe plugs or caps from the hydraulic

lines that were previously used to seal
connections. Then connect all hydraulic lines that
were previously disconnected.
160
MAST/LIFT MECHANISM
Mast
Fork Carriage Removal Fork Carriage Installation
1. Chock drive tire and outrigger load wheels.

Warning
Wear appropriate safety 2. Make certain rollers are in good condition and
clothing such as safety glasses installed on fork carriage. Replace a worn or
and shoes, whenever damaged roller.
performing maintenance work.
To avoid injury, do not place
3. Using a lifting device, raise inner mast, install the
through mast and keep them fork carriage, and lower inner mast to collapsed
away from pinch points. height.
1. Turn the key switch OFF. Remove the key and 4. Attach lifting device to fork carriage and raise
disconnect the battery. carriage enough to allow chains and hydraulic
supply lines, if applicable, to be connected.
2. Attach warning tag to control handle to advise
others that the truck is being serviced. 5. Connect lift chain(s) to chain anchors or tensioner
on fork carriage.
6. Remove any pipe plugs or caps that were
4. Using a lifting device, raise fork carriage until lift previously used to seal connections. Then connect
chains are slack. all hydraulic lines that were previously
disconnected.
5. Disconnect lift chain(s) from chain anchors or
tensioner on fork carriage. Then lower fork 7. Lower fork carriage and remove lifting device.
carriage completely.
8. Check lift chain tension and adjust if necessary.
6. Attach lifting device to top of inner mast. Then raise
inner mast and remove fork carriage. Make certain 9. Remove chocks.
rollers and shims remain in place on fork carriage.
10. Connect battery and remove warning tag from the
7. Lower mast to collapsed height. control handle.
161
MAST/LIFT MECHANISM
Mast
Fork Carriage Adjustment 8. Lower fork carriage completely.
9. If clearances were acceptable, proceed to step 13.

Warning If clearances were not acceptable, proceed to step
Wear appropriate safety 10.
clothing such as safety glasses
and shoes, whenever 10. Remove fork carriage following steps 4 - 8 outlined
performing maintenance work. under "Fork Carriage Removal".
To avoid injury, do not place
11. Add shims, as necessary, to the appropriate roller
through mast and keep them
away from pinch points. locations until clearances are within the acceptable
range. If more than one shim is being added at any
1. Turn the key switch OFF. Remove the key and location, it is recommended that shims be
disconnect the battery. distributed evenly between right and left hand
sides of the fork carriage.
others that the truck is being serviced. 12. Install fork carriage following steps 3 - 8 outlined
under "Fork Carriage Installation."
13. Remove chocks.
4. Using a lifting device, raise fork carriage until the
top two rollers extend above the mast channel and 14. Connect battery and remove warning tag from the
carriage meets the carriage stop. Then lower control handle.
carriage slightly below stop to free carriage.
5. Using a prybar, carefully force the carriage to one

side until its tight against the mast channel. Retain
slight pressure to hold carriage in position against
mast.
6. Using a feeler gage, measure the distance

between top roller and mast and record
measurement. If the distance exceeds 0.5 mm
place more shims on the rollers.
7. Repeat step 6 on the bottom roller.
162
MAST/LIFT MECHANISM
Mast
Mast Maintenance
Lubricating Roller Tracks
1. Lower fork carriage completely.
2. Turn the key switch OFF. Remove the key and


5. Clean roller tracks.
6. Lubricate entire roller path with a lubricant

designed for the truck application (i.e., freezer/
corrosion, etc.). Refer to "Lubricant & Fluid Chart",
section MS-1, for approved lubricants and
recommended suppliers.
7. Remove chocks.
8. Connect battery and remove warning tag from the

control handle.
163
MAST/LIFT MECHANISM
Mast
Mast Shims
Figures in brackets indicate the number of shims

to be positioned.
(2) (1)
(1) (2)
(1) (2)
(2) (1)
(2) (1)
(1) (2)
M0382
M0381
164
MAST/LIFT MECHANISM
Mast
22
Forke Carriage Frame
23
18
B
21
19
20
17
6 19
7 18
14
15
16
12 13
4
5
11
3
1
2
10
8
9
C 15 14
MP-3400-001
A Cross-section C Shims
B Longitudinal section
165
MAST/LIFT MECHANISM
Lowering Plumb Test
Lowering Plumb Test Carrying Out The Vertical Plumb

Test
Always carry out a lowering plumb test if the mast or
fork carriage have been removed.
When the above preparations have been made, extend
the mast fully. Make sure that the mast does not extend
The lowering plumb test must be performed with rated
as far as the stops. The plumb should not be pointing
load (1000 kg).
outside the square when the mast is raised.
Preparatory Measures
z Position the truck for inspection with the above test

load on a level surface. The surface is level if the
height difference at the wheel contact points < is
1mm.
z Now raise the forks 300 mm.
z Attach a plumb to the back of the fork carriage.

Once the plumb has finished oscillating, centre the
middle point of the plumb on the middle point of a
20x50 mm square. The 50 mm long side should
be facing the truck’s longitudinal axis.
166
MAST/LIFT MECHANISM
Lift Limit Cutout / Initial Lift
Lift Limit Cutout / Initial Lift z Check the lift height from the fork tips (see previous
page). If this height is outside the tolerance range,
check the mechanical setting of the lift linkage and
adjust if necessary.
Lift Limit Cutout Setting
z If the mechanical setting of the lift linkage is correct
z Fully lower the truck. and the lift height is still outside the tolerance
range, move the lift limit switch (LMS) into the
z Raise the forks, without rated load, from their slotted holes until the lift limit cutout (pump no
lowest position. longer running) takes place at a height of 130 mm
± 5 mm.
4 3
M1473
1 Upper hole: Limit switch position for max. lift = 150 3 Slotted hole for lift cutout fine-tuning
2 Trail 4 Trip cam
167
MAST/LIFT MECHANISM
LMS 2-4 Limit Switch Adjustment Lift Limit Cutout Setting
The switch console can be adjusted through the slotted z Fully lower the truck.
holes:
z Raise the forks, without rated load, from their
Check the lift height from the fork tips (see previous lowest position.
page). If this height is outside the tolerance range,
check the mechanical setting of the lift linkage and z Check the switch points.
adjust if necessary.
If the lift height is still above the specified levels, move
Mast 1700 mm: the lift limit switch console into the slotted holes until
the switches apply.
*LMS4: 880 mm
Mast 2100 mm:
*LMS4: 880 mm
*LMS3: 1700 mm
*LMS2: 1700 mm
168
MAST/LIFT MECHANISM
MP-3400-019
169
MAST/LIFT MECHANISM
Connecting the Lift Limit Switches
Before the operation of the lift limit switches can be

tested on the mast you must ensure that the switches
are connected correctly. Connect the switches as
follows:
Mast 1700mm:
LMS4: Connect JC601.
Mast 2100mm:
LMS
170
MAST/LIFT MECHANISM
Lift Chains
Lift Chains
Inspection
General
The chain must be inspected every 100 hours for any
Lift chains are a major component of a fork lift truck. signs of faults or damage. If used in a corrosive or
The chain system on this mast is designed to transmit dusty environment, this interval must be reduced to 50
the lift force from the hydraulic cylinder to the fork hours. If this cannot be performed on the truck, the lift
reliably and efficiently. Safe, uninterrupted truck chains must be removed.
operation depends on careful servicing and
maintenance of the lift chains.
Irrespective of the result of the inspection, the lift
Most complaints about the chain performance are due chains, detachable chain anchors and anchor bolts
to lack of maintenance. Highly stressed precision must be replaced every three years.
chains require regular maintenance to ensure a long
useful life. The inspection should include the following:
z Chain wear and elongation.
z Pitting due to rust or corrosion, in particular on the

outer surfaces of the connection plates.
z Pins turning in or extruding from the outside plates.
z Loss of freedom of movement.
z Damage to the anchor bolt attachment
z Wear and corrosion to the anchor bolt and anchor.
z Wear between the bolts and the connection plates.
The following sections cover the above items in detail.
171
MAST/LIFT MECHANISM
Lift Chains
Cleaning Chain wear can be measured with a wear gauge

(Crown No. 106440) or a steel tape measure (see Fig.
2771).
Warning
Before testing the chain elongation it is important to
Never use chemical solvents or tension the lift chain if necessary. For non-detachable
steam to clean the chains. lift chains the weight of the fork carriage or mast is
sufficient. If the lift chain is detached it must be kept
The lubricant applied at the taut during measurement.
factory will be removed from the
inner plate surfaces. The chain slack test must cover at least ten links, over
at least three different points in a section of the chain
The chain surface should be cleaned with paraffin, a which always passes over a pulley during operation.
hard bristle brush and lint-free cloth.
After inspection apply another film of chain spray. The

oil acts both as a lubricant and as an anti-corrosive
protection.
Wear
The chain bends as it passes over the chain rollers.

This leads to a gradual wearing of the joints. 2771
Chain Dimensions (Dimension C in Fig. 2271).

Any slack a chain undergoes during its lifetime is due
to wear to the links and the chain plate eyelet. New: 10 links = 158.75 mm
Danger Wear limit: 10 links = 163.5 mm
When checking for chain wear If the chain has elongated by 3% replace the
be sure to measure a part of the detachable chain anchors, anchor bolts and lift
chain which passes over the
chains.
guide pulleys. Never repair
chains by cutting out the worn
section and replacing it with a Danger
new section. If a chain is worn,
always replace both lift chains. If just one of the faults
mentioned in this chapter is
detected, both chains together
with their chain anchors or bolts
must be immediately replaced.
Never repair damaged chains!
This can result in fatal

accidents!
172
MAST/LIFT MECHANISM
Lift Chains
Freedom of Movement of Chain Chain Tension

Links
When installed, both lift chains should have the same
chain tension to ensure even distribution of the load
Each individual chain link must flex freely. Tight joints over the two chains when lifting.
(Fig. 2775si) increase friction and the chain tension
during lifting. Excessive chain tension in turn When replacing the forks make sure that both forks lie
accelerates material wear. evenly on the surface. If they are not even,
compensate the chain length via the chain anchor so
that both chains have the same chain tension.
After adjusting, tighten the counternuts of the chain

anchor again (for correct torques see Chapter 1,
Torque table).
2775si Chain Anchor and Pulleys
In the course of checking the chain system, the chain

Possible causes of stiff joints are as follows: anchors, chain bolts and pulleys must be checked for
wear.
z Bent pins or plates
On the chain anchor watch out for wear and cracking of
z Rusty joints. the individual fingers. If one of the above problems
occurs replace the chain anchor.
z Peened plate edges.
Pulleys with heavily worn flanges and contact surfaces
Plate edge distortion is caused by: must be replaced. Worn flanges are due to
misalignment. The chain tension and mast roller
z Ruptured chain pinion. setting must be checked.
z Constant overloading of the chain.
z Chain striking the mast components.
Immediately replace any chains with stiff joints.
173
MAST/LIFT MECHANISM
Lift Chains
Worn Connection Plates Protruding or Turned Chain Pins
Danger
Never attempt to repair the
chain by driving pins back into
the chain. This can result in
accidents with severe or even
fatal injuries if the chain tears.
2774si
Fit new chains.
Generally speaking, material wear is the cause of worn

or missing connection plates. The plates near the chain
pin hole (Fig. 2774si) can crack after a large number of
lifting cycles with heavy loads.
Replace both chains immediately if cracking shows or

plates are missing.
2776si
Considerable frictional forces between the connection

plates and the pins occur when lifting heavy loads with
an insufficient or non-existent film of oil. In extreme
cases the frictional torque in the joints can be such that
the pins turn and gradually work out of the chain (Fig.
2776si). This can result in chain failure.
Turned pins can be rapidly identified if the flat ends are

not all pointing in the same direction.
Chains with twisted or protruding pins must be

replaced immediately.
174
MAST/LIFT MECHANISM
Lift Chains
Corrosion Chain Lateral Wear
Wear traces along a stretch of the chain on the pin

heads and the outer plates indicate misalignment. This
can have one of two causes: uneven chain tension or
misalignment between the pulleys and the chain
anchors.
Uneven Chain Tension

2773si
When fitting or adjusting the chains make sure that
The chains used on fork lift trucks are highly stressed they are evenly charged. If for example the fork heel
precision components. It is particularly important to height or the platform height are changed, the chain
maintain the original fatigue strength throughout its anchors must be loosened until both forks touch the
useful life. ground. Both chains must have equal amounts of air or
tension at this point. The lower chain anchor nuts must
Corrosion considerably reduces the capacity of a be tightened by the same number of turns. When the
lift chain. It results in cracking in the side plates. required height has been reached, fix the setting with
the top (chain side) lock nut and its respective lock
Lift chains must therefore be protected from corrosion. washer.
The layer of grease applied in the factory hot dip
galvanizing process is an excellent protection and fully
penetrates the joints. Misaligned Lift Components
Do not remove this initial layer! After commissioning Misalignment of the chain pinion and the chain due to
the chain supplement the factory lubrication through a the wrong number of washers on the mast or a
regular lubrication schedule. damaged mast or cylinder components can also
contribute to wearing of the chain sides.
Rust film on lift chains can be removed and neutralised
by cleaning with chain oil. Always replace heavily To test whether this is the case, proceed as follows:
corroded and rusting chains. The risk of cracking Place the truck on a horizontal surface in the service
as a result of rust is too great. station. Support the fork carriage and detach both ends
of the lift chain from the chain anchor and visually
inspect the alignment with the anchor slots.
175
MAST/LIFT MECHANISM
Lift Chains
Lubrication intervals depend on the operating
Lift Chain Lubrication conditions and the environment. Trucks parked
outdoors, in cold stores or which are subjected to
Lubrication is the most important factor in lift chain extreme weather conditions must be lubricated more
maintenance. It considerably affects the chain's useful frequently.
life.
Dust will gather on oiled chains in dusty environments.
Highly stressed chains under constant use cannot last However, even in these conditions, regular lubrication
sufficiently long if they are not regularly lubricated can considerably reduce wear.
within a planned maintenance schedule.
A paste mixture of oil and dirt will gather on the chain
As with all contact surfaces, the tensiled steel precision joints, but they will not wear as fast as they would if they
moving parts require a durable lubricant film between were left to dry, leaving a metal to metal contact
the contact surfaces to avoid excessive wear. between the pins and plates.
Maintaining a lubricant film on all the chain surfaces Note: A lift chain must never be allowed to dry.
provides the following benefits:
In dusty operating conditions the multi-plate chains can
z Restricts joint wear to a minimum (chain be more efficiently lubricated than roller chains. Multi-
elongation) plate chains consist of several plates. Therefore they
provide several paths for the lubricant to reach the
z Avoids corrosion chain bolt (see Fig. 277si) and allow the oil to penetrate
to the bearing surface on the chain bolt, even when the
z Reduces the risk of chain bolts turning chain is dirty.
z Restricts the danger of chain joints turning in to a In normal operating conditions the chains should be
minimum cleaned and immediately lubricated every 100 service
hours. In extreme conditions this interval must be
z Ensures an even movement of the chains and thus reduced accordingly.
reduces noise levels
z Reduces the chain tension due to less friction in

the chain system
Key factors when considering which lubricant to use

are as follows:
z High degree of penetration in the narrowest of

gaps
z Maximum tolerance of pressure and shearing

forces before the lubricant film comes off.
z Suitability to the operating temperature range,

especially important for cold store trucks.
You will find details of Crown approved chain oils

in the Lubricant table in Chapter 1 of this manual. 2777si
1 Oil film
176
MAST/LIFT MECHANISM
Lift Chains
Separating Lift Chains Separation
Lift chains are supplied by the meter and must be cut

to the required length.
Warning
Tools and Equipment Required Wear protective glasses.
z A secure working plate with a hole slightly larger

than the head diameter of a chain bolt. The hole z Carefully grind the head of the chain bolt. The inner
must be deeper than the chain bolt length. plate surface must not be damaged.
z A bearing ring (washer) with a hole slightly larger z Place the bearing ring onto the hole in the working
than the head diameter of a chain bolt. The bearing plate. The bearing ring prevents the inner plate
ring thickness must be slightlylarger than the surface from being damaged when you drive out
height of the head of a chain bolt. the chain bolt.
z A grinder. z Place the head of the chain bolt to be driven out

into the bearing ring.
z A hole with a diameter slightly shorter than the
chain bolt and a hammer. Or a press with a suitable z Make sure the chain bolt, the bearing ring and the
mandrel. hole are aligned in the working plate and drive the
chain bolt out.
4
1
3 2
MS-7.2
1 Connecting plate 3 Backring

2 Hole in working plate 4 Grinder
177
MAST/LIFT MECHANISM
Fork Tines
Fork Tines Fork Identification
The data plate is on the side of the fork back (Fig. 0345)
General and comprises the following data:
The fork tines (Fig. M0344) must be checked by trained z Capacity

personnel at the specified maintenance intervals (see
chapter 1) for cracks, damage and wear. z Load centre of gravity
If the forks are used to transport abrasive loads the z Manufacturing Data (Month / Year)
inspection must be carried out at shorter intervals.
z Company logo
Terms z Manufacturing site
1 2
1
M0344
M0345
1 Fork blade
1 Fork Identification
2 Fork hanger
3 Fork shank
4 Heel (curved area)
178
MAST/LIFT MECHANISM
Fork Tines
Repairs Fork Inspection
Danger Danger
Never carry out repair welding Forks showing signs of
to surface cracks, damaged or cracking, distortion or wear
worn parts around the heel of beyond the stated tolerance
the fork. levels must be de-
commissioned. They endanger
Fork repairs must only be carried out by the the life of the operator and other
manufacturer / qualified personnel. When repairing people.
supporting members always carry out a load test and
check for signs of cracking. Crack Inspection
Inspect all fork tine surfaces for signs of cracks.
Fatigue cracking tends to occur around the heel of the

forks. Check this area with particular care. If necessary
carry out a non-rupturing crack test (paint penetration
process or Magnaflux).
M0346
1 Cracks
179
MAST/LIFT MECHANISM
Fork Tines
Verticality Test
Check verticality of fork tip (Fig. M0350). If the

tolerance level has been exceeded, de-commission
the fork.
2
1
1
M0347
2 mm
1 Welding seams
For upper and lower fork hangers (Fig. M0347) 250 mm

including their fork back attachments check for cracks
on the welding seam. If any cracking is discovered
which could affect safety remove the relevant fork.
M0350
For the outrigger-overlapping version (Fig. M0348),

1 Ruler
also check for cracks on the welding seam between the
2 Fork tip
fork and fork carriage/fork shank. If any cracking is
discovered which could affect safety remove the
relevant fork.
500 mm
1
max. 6 mm
M0348 M0351
1 Welding seam 1 Ruler
180
MAST/LIFT MECHANISM
Fork Tines
Fork Blade Warping Fork Tine Height Difference
Measure the angle deflection between the top of the Check the height of the fork tines in relation to each
fork blade and the front of the fork shank (Fig. M0353). other (Fig. M0354) if the fork is fixed to the fork
If dimension x is outside the tolerance range, the fork carriage. If the difference is greater than 3% of the fork
must be aligned by a specialist and re-checked. blade length the fork tines must be correctly aligned.
Example: If the length of the fork blade is 1150mm the

500 mm maximum permissable deviation is approx. 35mm.
x - 17 mm However, this would prevent the fork from working. In
x + 8,5 mm practice, forks must be aligned if the deviation is max.
10 mm.
Fork Stop
x
M0353
3
Measuring the Fork Tip Width 1
M0354
M0355 1 1. Fork
2 2. Fork
If the fork tip width S is less than a/6 mm (a = fork back 3 3% of L
width) do not use the fork (Fig. 0355).
Check the stop mechanism (Fig. M0356) on both fork
tines. The mechanism should lock securely, otherwise
the fork must be de-commissioned.
181
MAST/LIFT MECHANISM
Fork Tines
Fork Blade Wear This calliper has 2 opposite tappets. The outer tappet
is used to determine the original fork blade thickness at
a section with no wear. This is the fork shank. This
determines the 100% value. The inner tappets
correspond to 90% of the value previously obtained.
z Scan the thickness of the fork shank using the

outer tappets (Point a = 100% in Fig. MS-2232-
013). Fix the calliper.
z Now use the inner tappets (90%) to scan the fork

blade between the shank and the start of the
curved area. If the calliper fits at any point over the
fork blade, then the fork is worn. Take the fork out
M0356 of service.
1 Stop mechanism
Check the fork blade for wear. The heel is particularly

sensitive to wear. If the width is 90 % or less than the
original value, the fork must be taken out of service. For
the inspection, use the calliper with part no. 107330
(see Fig. 0357). a=100%
90%
2
MS-2232-013
1 Scanning area
2 Wear limit 90%
M0357
182
CYLINDERS
Printed in Germany
183
Notes:
184
CYLINDERS
Cylinders
Cylinders General Instructions for Repairing

Hydraulic Components
General Hydraulic systems are sensitive to dirt.
z Thoroughly clean any hydraulic components that

Safety when working on hydraulic have been removed before dismantling them.
systems
z Always repair hydraulic components in a clean
working environment.
Warning
z Immediately protect cleaned and de-greased
Risk of serious injury from components with a thin coating of hydraulic oil.
pressurized hydraulic oil. Use the same type as is used in the truck.
Pressurized hydraulic oil can
penetrate the skin. This must be z Protect all components from re-contaminating until
treated as an emergency which they are installed again.
requires immediate medical
intervention. z Immediately seal any open hydraulic ports on
The skin will not show any repaired assemblies with filler plugs. This also
obvious initial damage and the applies to the open ports and lines on the truck
physical effects will not be when you remove any hydraulic components.
manifested immediately. Seek
medical assistance if your skin z Do not refinish any cylinder surfaces! Replace any
has been affected by damaged components.
pressurized hydraulic oil.
z When carrying out repairs always replace all
For your personal protection: the seals in the assembly. Never recycle seals
Depressurise the hydraulic which have already been used
system before starting
assembly work on the hydraulic
system. General
After carrying out assembly
work carefully check to see that There are two main types of hydraulic cylinder
all ports are tightened before re-
pressurising the system. z Plunger cylinders
Wear protective clothing, safety
glasses and safety gloves when z Piston Cylinders (Double-Acting Cylinders)
tracing leaks or bleeding the
system. The main difference between the two types of cylinder
Use a piece of absorbent paper lies in their operation as well as the sealing material
to trace leaks, never use your design.
hands.
Follow the hydraulic oil
manufacturer’s safety
instructions when handling
these oils.
185
CYLINDERS
Plunger Cylinders
Plunger Cylinders
The plunger cylinder (see Fig. MS-3400-080) has only

one pressurised rod surface (single acting cylinder).
The piston rod (1) enters the cylinder via one or several
guide rings (3,5). A rod seal (4) in the cylinder head and
a dirt deflector (2) protect the inside of the cylinder and
the piston rod (1) from external contamination. The
piston rod return movement is actuated either by the
net weight of the piston rod (1) or by the force acting on
the piston rod (1) from the load.
MS-3400-080
1 Piston rod
2 Dirt deflector
3 Guide ring
4 Rod seal
5 Guide ring
186
Notes:
187
CYLINDERS
Piston Cylinders
Piston Cylinders
With a piston cylinder both sides (double acting
cylinder) of the piston (8) are pressurized. The piston
rod (1) can therefore be moved in either direction by
the oil flow.
The piston rod (1) can produce different piston areas.

This results in different forces and speeds occurring at
a constant pressure and flow volume levels.
The rod (1) of the piston cylinder has a piston at one

end which enters the cylinder through a guide ring (5)
and whose piston seals (7) protect the two oil-filled
chambers against each other. The cylinder and piston
rod (1) are sealed on the outside by a rod seal (4) in the
cylinder head (9). An additional dirt deflector (2)
protects the rod seal (4) from external contamination.
When a piston cylinder is used as a single-acting

cylinder it offers reduced operating pressure with the
same cylinder tube (6) inside diameter compared with
the plunger cylinder, thanks to the larger piston
surface. However, the operating speed is reduced at
the same flow rate. The de-pressurised side of the
cylinder must be bled.
188
CYLINDERS
Piston Cylinders
Single-Acting Cylinder

MS-3400-081
1 Piston rod 6 Cylinder tube

2 Dirt deflector 7 Piston seal
4 Rod seal 8 Piston
5 Guide ring 9 Cylinder head
Double-Acting Cylinder

MS-3400-082
1 Piston rod 7 Piston seal

2 Dirt deflector 8 Piston
4 Rod seal 9 Cylinder head
5 Guide ring 10 O-Ring
6 Cylinder tube
189
CYLINDERS
Rod Seal Assembly
Rod Seal Assembly
General
All tools and equipment used for rod seals must be

burr-free and not have sharp edges. The tools should
be made either of soft metal (aluminium, brass) or a
suitable plastic.

Do not use hooks to remove seals. The same rule
applies: Burr-free, rounded tips and made of soft metal
to avoid damaging the seal seat. MS-3400-084
1 Insulating tape
2 Self-tapping screw
To do this, a 4 mm self-tapping screw (2) is soldered

onto a screwdriver with a minimum shaft length of
150 mm and a maximum diameter of 4 mm and the
solder joint sanded. The blade of the screwdriver must
then be covered with an insulating tape (1) to avoid
damage.
If the seal has to be pushed over sharp edges, cracks

or nicks, use appropriate protective devices.
MS-3400-083
Screwdrivers or similar tools will damage the seal seats

and the seals. This will result in leaks.
To remove rod seals from lift cylinders and free-lift

cylinders, you will require 2 specially produced tools We will now demonstrate 2 procedures – depending on
(see Figure MS-3400-084). the seal rod diameter – for ensuring safe assembly.
190
CYLINDERS
Rod Seal Assembly
Large Rod Seal Assembly z Now push the tool body into the cylinder cap until
the rod seal is aligned with the seal seat (see Fig.
MS-3400-086).
Tools required:
z Tool body (outer diameter must fit the internal

diameter of the cylinder cap).
z Three pins (1, 2 and 3). Pin (1) is fixed; pins (2) and
(3) are moveable.
Assembly:

z Apply a thin coating of hydraulic oil to the rod seal
and the seal seat in the cylinder cap.
z Place the rod seal over the fixed pin (1).
z Bend the rod seal under pin (2) (see Fig. MS-3400-
085). MS-3400-086
1 Pin
2 Pin
3 Pin
z Pull back pin (3). A section of the rod seal jumps

into the seal seat (Fig. MS-3400-087).
MS-2232-019

1 Pin
2 Pin
z Bend the loop created in this way so far up that pin

(3) can be pushed into the loop.
MS-3400-087
2 Pin
3 Pin
191
CYLINDERS
Rod Seal Assembly
z Now pull back pin (2). The rod seal is now fully Small Seal Rod Assembly
seated in the seal seat.
Tools required:
Groove aligning arbor. The outer diameter must fit the

internal diameter of the cylinder cap. The arbor should
end at the bottom of the seal seat.
Arbor to drive in the seal.
z Apply a thin coating of hydraulic oil to the rod seal

and the seal seat in the cylinder cap.
z Place the cylinder cap onto the groove aligning

arbor.
z Gently squeeze the rod seal together.
MS-3400-088 z Place the rod seal at one point of the seal seat.
z Pull the tool body out of the cylinder cap.
z Press the rod seal and the arbor into the seal seat.
MS-3400-089
192
CYLINDERS
Rod Seal Assembly
Rod Seal Assembly, Sealing Lip

First
The sealing lip is sensitive and must not be damaged.

You therefore require special protective sleeves (1)
when pushing the seal (2) over the thread and holes.
Sealing lip assembly direction: Always to the

pressure side!
MS-3400-090
1 Protective sleeve
2 Seal
193
Notes:
194
CYLINDERS
Initial Lift Cylinder

Operation
The two lift cylinders on the truck are single-acting. The

piston rods are raised by the pressure of the hydraulic
oil and lowered by the weight of the raised load. Figure
MS-3400-080 shows the cross-section of an initial
liftcylinder.

Warning
De-pressurise all components
before carrying out
hydraulicsystem. High pressure
hydraulic oil can cause serious
injuries.

Secure all ports before re-

from any ports as high pressure
MS-3400-080
leaks, never use your hands! 1 Piston rod
2 Dirt deflector
3 Guide ring
4 Rod seal
5 Guide ring
6 Cylinder tube
195
CYLINDERS
Disassembly
z Remove the front panel.
z Extend the piston rod (1) until the attachment of the

LH piston rod (1) is positioned next to the
contactors and the controller in such a way that the
dowel pin can be driven out.
z Support the fork carriage with wooden blocks or

other appropriate and stable components.
1
z Press the “Lower” switch for at least 10 seconds to
depressurise the hydraulic system.
z Initially, drive out the dowel pin from the

attachment of the LH piston rod (1) between the
contactors and the controller only so far as to see
clearly that the dowel pin will not collide against a
contactor or the controller when it is driven out in
full.
z Depressurise the pump motor and prevent it from

beingswitched on again.
z Protect the piston rod (1) from being scratched

where it enters the truck chassis through the hole,
using cardboard or similar material.
z Fully drive out the dowel pin from the attachments

of both piston rods (1).
z Press the “Lower” switch until the piston rods (1)

have been fully lowered into the initial lift cylinders
through their own weight. If necessary, push the
piston rods (1) in manually.
z Undo the hydraulic connection on the initial lift

cylinder. Collect any oil that emerges.
z Remove the brackets (7) at the bottom end of each 7

initial lift cylinder.
z Lift the initial lift cylinders out of the truck chassis.

MS-3400-091
1 Piston rod
7 Clamp
196
CYLINDERS
Inspection Replacing the rod seal
Before commencing repair work carry out a thorough

inspection of the cylinder unit. To do this, extend and
Information
retract the cylinder several times. Check the seal groove and the
piston rod (critical seal
The item numbers refer to Figure MS-3400-080. position) for damage before
fitting a new seal. Otherwise,
z Check the piston rod (1) for scratches, nicks and
other surface damage. leakage will re-occur after the
new seal has been fitted.
z Check the dirt deflectors (2) for wear and unusual
leakage. When fitting rod seals (6) use assembly equipment and
tools made of soft metal or plastic without sharp edges.
z If excess hydraulic oil emerges from the piston rod Do not use a screwdriver or similar tools as these will
(1) from at the cylinder head it may be due to a damage the seal edges.
damaged rod seal (4). Replace the rod seal (4) and
make sure that the seal seat is clean and intact. If the new rod seal (4) has to be pushed over sharp
edges, cracks or nicks, use appropriate protective
z When repairing the cylinder check the condition of mechanisms.
the guide rings (3). Always replace all the seals
when carrying out repairs.
z Minor irregularities on the cylinder tube (6) surface

or on the piston rod can be removed with an
aluminium oxide cleaning cloth or a honing tool.
Heavily worn components must be replaced.
z When all the parts have been checked clean the

cylinder components in a high-grade solvent and
dry with low-pressure pressurised air.
z Before assembling, apply a thin layer of hydraulic

oil to the cleaned components and replacement
parts.
197
CYLINDERS
Free Lift Cylinder
Free Lift Cylinder z Attach warning tag to control handle to advise

z Chock drive wheel and outrigger load wheels.

Seal Replacement
z Remove forks.
When excessive hydraulic oil is evident on the cylinder,
where the piston rod exits the cap, one or more of the z Using a lifting device, raise fork carriage until lift
seals are bad and need replaced. It is advisable to chains are slack. Then place wood blocks under
replace all the seals in the cylinder whenever the each side of carriage and lower carriage onto
cylinder is removed and disassembled for seal blocks.
replacement. Follow the procedure outlined below to
remove cylinder and replace seals. z Disconnect hydraulic line to fork carriage cylinder.
Seal connections to minimize oil loss and prevent
z Turn the key switch OFF. Remove the key and hydraulic system contamination.
z Disconnect lift chain from tensioner on fork
carriage and pull chain through yoke assembly.

z Remove screws that secure the free lift cylinder to
inner mast and carefully remove the cylinder. Make
certain to save shims that were between mast and
free lift cylinder.

MS-3400-092
1 Seal
2 Bleed screw
3 Cylinder tube
4 Piston rod
5 O-Ring
6 Backring
7 Cap
8 Guide
9 Seal
10 Dirt deflector
198
CYLINDERS
Free Lift Cylinder
z Remove the retaining rings (12, 13) and piston (11)
z Remove retaining ring used to secure yoke from the piston rod (4). Discard the piston (11).
assembly to the free lift cylinder piston rod. Then
remove yoke assembly. z Inspect contact surfaces on the piston rod (4) and
cylinder cap (7). If slight scoring is present, sand
z Remove cap from cylinder tube. with fine emery paper until all high surfaces have
been removed. Heavily scored components must
z Remove bleed screw from cap. Then remove seal be replaced. After all parts have been
from bleed screw and discard seal. disassembled and inspected, thoroughly wash all
metal parts and blow dry with clean compressed
z Remove deflector (10), seal (9), guide (8), backring air.
(6) and O-ring (5) from cap (7) and discard.
z Apply a light coating of hydraulic oil (Crown P/N
z Carefully remove piston rod (4) from cylinder tube. 063001-001) to all seals being installed.
Do not allow the piston rod to come in contact with
any sharp edges. z Attach the retaining ring (13) to the piston rod (4).
Mount a new piston (11) to the bottom of the piston
rod (4) and fix with the retaining ring (12).
z Install piston rod (4) in cylinder tube (3). Use care
when installing piston rod (4) to avoid contact with
sharp edges. Make sure the piston rod (4) is
positioned correctly in the cylinder tube (3).
z Install new deflector (10), seal (9), guide (8),

backring (6)and O-ring (5) in cap. Use care when
installing to avoid nicking the components.
MS-3400-093 z Mount a new seal (1) on the bleedscrew. Now

screw the bleedscrew (2) into the cap (7) and
4 Piston rod tighten it.
11 Piston
12 Retaining ring z Install the cap (7) on the cylinder tube (3) and
tighten securely. Take care not to damage the new
13 Retaining ring
seals.
199
CYLINDERS
Free Lift Cylinder
Installing Carriage Cylinder
z Install free lift cylinder and secure it to inner mast

using screws and shims previously removed.
Tighten screws securely.
z Install yoke assembly on piston rod and secure it

with retaining ring previously removed.
z Insert lifting chain through yoke assembly and

connect chain to tensioner in fork carriage. Make
certain chain is not twisted.
z Connect hydraulic supply line to free lift cylinder

and tighten connections securely.
z Using lifting device, raise fork carriage and remove

blocks from under carriage. Then lower carriage
completely and remove lifting device.
z Install forks.
z Remove chocks.
z Connect battery and remove warning tag from the

control handle.
z Bleed the hydraulic system. See section: Cylinder

Bleeding and Flushing
z Carry out a drift test. See section: Drift Test
200
CYLINDERS
Free Lift Cylinder
Cylinder Bleeding and Flushing Flushing – Mast Lift Cylinders and Free
Lift Cylinders
Hydraulic circuits need to be flushed after repair of lift
cylinders and bled of all air. Before bleeding and z Actuate control valve to raise carriage through free
flushing, all hydraulic ports must be checked for leaks. and stage lift and stop to hold in position.
In addition you must ensure that all filters, where
applicable, are fitted and that there is sufficient z When the fork carriage is raised visually inspect for
hydraulic fluid in the reservoir for flushing and bleeding. leaks.
Hydraulic system must be pressurized during the
flushing and bleeding procedures. z Actuate control valve to lower carriage through
stage and free lift while visually checking operation
and staging.
Free lift cylinder bleeding
z Raise and lower carriage rapidly for a minimum of
Always stay away from the 10 cycles to flush system.
Danger!
operatingarea of the fork
carriage while bleeding is
taking place.
Drift Test
The fork carriage can
automatically lower and result Danger! Never stand or work under a
in fatal injuries. suspended load
z Slowly extend the fork carriage to free lift. The free If a raised load drops, fatal
lift is approx. 1220 mm. injuries can result.
z Slowly open fork carriage cylinder bleed screw and All drift tests should be conducted with a capacity load
bleed air from cylinder until a solid stream of (refer to capacity plate for the rated capacity of your
hydraulic fluid flows out of bleed screw hole. truck). The material used for the test load must be
evenly distributed within a 1.2 m x 0.8 m pallet and
z Tighten bleed screw securely. must be attached to the fork carriage. Fully extend the
mast with maximum rated load. The load may not drift
z Flush cylinder following procedure outlined below. down more than 50 mm within 5 minutes.
Occasionally internal leaks in the cylinder may cause
the fork assembly to lower slowly. However, this may
also be due to leaks in the check valves, pilot valves
etc. In this case flush the system by raising and
lowering the fork carriage several times to remove any
foreign bodies from the valve seats. Now repeat the
drift test.
201
Notes:
202
PLATFORM
Printed in Germany
203
Notes:
Printed in Germany
204
PLATFORM
Mechanical Adjustment
M1550
1 Platform 11 Brake arm

3 Adjusting ring 12 Brake lining
4 Screw 21 Platform switch
10 Shaft 23 Panel
WD2300S 09/2005 • Printed in Germany M9--XXXX-
205
PLATFORM
Warning!
Safety-critical setting The
platform should always fold up
when the driver exits. The
platform switch is actuated and
the maximum travel speed
reduced.
All item numbers relate to diagram M1550.
z Remove the panel (23).
z The brake arm (11) and the brake lining (12) brake
the platform (1) when it folds up. Turn screw (14) in
to increase the friction, turn it out to reduce it.
z Adjust the braking pattern so that the platform will

automatically fold up from any position, but still
cushioned. The critical point is at a platform angle
of approx. 45° above the horizontal.
M9--XXXX- WD2300S 09/2005 • Printed in Germany
206
PLATFORM
Platform Switch (PLS) Adjustment
Platform Switch (PLS)

Adjustment
This switch transmits a signal to the traction controller.
The traction controller switches to a higher, maximum
speed for platform mode if the platform is tilted down.
All item numbers relate to diagram M1550.
The control lever of the platform switch (21) is actuated

by the adjusting ring (3). A screw (4) secures the
adjusting ring to the shaft (10) to prevent it from
twisting.
Warning!
Safety-critical setting
The platform should always fold
up when the driver exits. The
PLS should apply within 10°.
z Loosen the screw (4).
z With the platform lowered, turn the adjusting ring

(3) until the switch is actuated. Actuation of the
switch should take place between 0° (fully lowered
platform) and max. 10° raised platform. The switch
should not be actuated above 10°. Now tighten the
screw (4) and check the setting again.
207
PLATFORM
Platform Cushioning
Platform Cushioning
Layering the disk springs
You can ensure maximum operational lift and spring

qualities of the platform by layering the disk springs in
6 packets of 3 springs and one of 2 springs.
MS1720-101
M9--XXXX- WD2300S 09/2005 • Printed in Germany
208
PLATFORM
Side Restraint, Mechanical Adjustment
Side Restraint, Mechanical z The brake (5) setting determines the manual force
required to fold the side restraint in and out. Turn
Adjustment screw (12) in to increase the force, turn it out to
reduce it.
z Adjust the brake so that the restraint can be moved
with medium manual force.
M1546
5 Brake
10 Panel
12 Screw
209
Notes:
Printed in Germany
210
ELECTRICAL WIRING
DIAGRAMS
Printed in Germany
211
Notes:
212
Notes:
213
ELECTRICAL WIRING DIAGRAMS
Standard Diagrams
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DIA-3400 WD2300S 09/2005 • Printed in Germany
214
Standard Diagrams
1 Diagnostic LED or panel 10 PS2: Reduced initial lift speed (0 bar = open, >0 Kg)
2 Curtic 803, unigage 11 PS3: Reduced initial lift speed (0 bar = closed, >500 Kg)
3 LMS1: Max. initial lift 12 Pedestrian mode: GCSR open & GCSL open & PLS open or
GCSR open & GCSL open & PLS closed
4 LMS2: Max. main lift 13 Diode block
5 LMS3: lift stop > 1500 mm 14 Fan
6 LMS4: Reduced travel speed > 880 mm 15 Hydraulic control module (HCM)
7 Reduced travel speed: HSS and/or LMS4/PS1 open 16 Platform logic
8 Active: RAS, BRS, SAS, HNS, LOS1, LOS2, ILS closed 17 Fan, HCM, DB, BDI connected to battery neg.
9 PS1: Main lift load switch 500 Kg (0 bar = closed)
WD2300S 09/2005 • Printed in Germany DIA-3400
215
Standard Diagrams
Traffic Control Logic Circle
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Standard Diagrams
Power Unit Control Circle
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Platform & Mast Control Circle

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Standard Diagrams
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222
Notes:
223
Option Wiring Diagrams

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224
1 Diagnostic LED or panel 10 PS2: Reduced initial lift speed (0 bar = open, >0 Kg)
2 Unigage 11 PS3: Reduced initial lift speed (0 bar = closed, >500 Kg)
3 LMS1: Max. initial lift 12 Pedestrian mode: GCSR open & GCSL open & PLS open or
GCSR open & GCSL open & PLS closed
4 LMS2: Max. main lift 13 Diode block
5 LMS3: lift stop > 1500 mm 14 Fan
6 LMS4: Reduced travel speed > 880 mm 15 Hydraulic Control Module (HCM)
7 Reduced travel speed: HSS and/or LMS4, PS1 open 16 Platform logic
8 Active: RAS, BRS, SAS, HNS, LOS1, LOS2, ILS closed 17 Fan, HCM, DB, BDI connected to battery neg.
9 PS1: Main lift load switch 500 Kg (0 bar = closed) 18 F/C package: Active below 5°C
225
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232
Notes:
233
Power Cables
Power Cables
9
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234
Power Cables
Legend
Item no. Part no. mm2 Remarks
1 052051-018 25 SBE 160 Standard

052051-061 25 DIN 160 Optional
2 052065-001 16
3 052065-058 16
4 052065-014 16
5 052051-020 25 SBE 160 Standard
052051-060 25 DIN 160 Optional
6 052065-024 16
7 052065-059 16
8 052065-039 16
9 807636-002 4
10 807636-001 4
11 052065-001 16
12 812284 *
* Busbar
235
236
DIA-3400
3/0 %', .< 6 '%
30 ' 3& 3& 287 ,1 SLQ SLQ SLQ SLQ SLQ
D D D

Main Wire Harness
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Main Wire Harness

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237
DIA-3400
813865_2f
Horn Switch Wire Harness
Horn Switch Wire Harness
3&

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811931_2e
Item no. Part no.

Housing Part no.
2 803450-024
PC 413 803450-021
PC 417 803450-023
PC 419 803450-023
Item no. Part no.
1 803450-022
238
HYDRAULIC DIAGRAMS
Printed in Germany
239
Notes:
240
Notes:
241
HYDRAULIC DIAGRAMS
Hydraulic Diagrams
Hydraulic Diagrams
MS-3400-019
HYD-3400 WD2300S 09/2005 • Printed in Germany
242
HYDRAULIC DIAGRAMS
Hydraulic Diagrams
1 Suction filter
2 Reservoir ventilation
3 Check valve (CV)
4 Overload valve (RV)
5 Cylinder shutoff valve (SV3)
6 Proportional valve (PV)
7 Pump & motor
8 Main lift cylinder
9 Main lift
10 Reservoir
11 Flow restrictor
12 Initial lift cylinder
13 Main lift valve (SV1)
14 Initial lift valve (SV2)
WD2300S 09/2005 • Printed in Germany HYD-3400
243
Notes:
244

WD 2300s

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MAINTENANCE MANUAL

Order Number: 812560-006

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

MA- SAFETY PAGE

ITD- INTRODUCTION PAGE

M1- LUBRICATION & ADJUSTMENT PAGE

WD2300S 09/2005 • Printed in Germany

M3- POWER UNIT PAGE

WD2300S 09/2005 • Printed in Germany

WD2300S 09/2005 • Printed in Germany

WD2300S 09/2005 • Printed in Germany

M5- BRAKE PAGE

M6- STEERING PAGE

WD2300S 09/2005 • Printed in Germany

M7- MAST/LIFT MECHANISM PAGE

WD2300S 09/2005 • Printed in Germany

M8- CYLINDERS PAGE

WD2300S 09/2005 • Printed in Germany

M9- PLATFORM PAGE

DIA- ELECTRICAL WIRING DIAGRAMS PAGE

HYD-HYDRAULIC DIAGRAMS PAGE

WD2300S 09/2005 • Printed in Germany

WD2300S 09/2005 • Printed in Germany

Symbols Used in the Manual

You or other people could be

You or other people could be

WD2300S 09/2005 • Printed in Germany MA-3400

General Safety Instructions Maintenance and Repair

1. 1. Always carry out work in accordance with the

Danger 2. Only qualified and authorised personnel may carry

Danger 6. Do not allow oils to penetrate the ground or the

9. Maintain the legibility of the data capacity plate and

10. Truck modifications and additions may only be

11. The reliability, safety and suitability of Crown

MA-3400 WD2300S 09/2005 • Printed in Germany

Before Parking the Truck Before Starting the Truck

z When parking on a slope or incline always chock

WD2300S 09/2005 • Printed in Germany MA-3400

MA-3400 WD2300S 09/2005 • Printed in Germany

WD2300S 09/2005 • Printed in Germany

Introduction Ordering Spare Parts

The maintenance manual does not cover spare parts.

This information can be found on the truck data plate.

With the help of this manual you and your personnel

Crown offers the appropriate truck related training for

WD2300S 09/2005 • Printed in Germany ITD-3400

Using the Manual

This manual is divided into sections. The following

Maintenance manual structure

ITD-3400 WD2300S 09/2005 • Printed in Germany

WD2300S 09/2005 • Printed in Germany

Lifting the Truck Lifting with another Forklift Truck

The WD 2300 S can be raised at an angle using a

Attach lifting gear as shown in the following diagram

WD2300S 09/2005 • Printed in Germany M1-3400

Never reach your hands or other

Improper handling of the truck

The outriggers must be raised in full in order to jack up

z Apply a jack with sufficient capacity (>800 kg) to

z Place sufficiently sized hard wooden blocks on

M1-3400 WD2300S 09/2005 • Printed in Germany

I01 , %' 69 &$ .<6 ,

+16 6$6 327)656

,, ,, , ,